beRobox introduced its 3D Dynamic Safety module for the PALTZ robotic palletizer series at PACK EXPO 2026 in Chicago (October 18–21). The module integrates Sonair’s ADAR One, the world’s first SIL 2 / Pl d safety-certified 3D ultrasonic sensor, directly onto the robot arm (demonstrated with a Universal Robots UR20). Unlike conventional fixed-zone safety systems that stop the entire cell when an operator enters a predefined area, this approach creates a dynamic protective zone that travels with the robot.
The system continuously combines the robot’s real-time position with 3D ultrasonic presence detection of people and objects. This enables selective responses: an operator can safely perform a pallet changeover at one station while the robot continues stacking at another, without a full cell stop. Continuous detection also prevents unintended restarts if a person remains in the protected volume.
The ultrasonic technology operates reliably in real production conditions—dust, variable lighting, reflective surfaces, bright industrial lights, or near-dark areas—where vision- or laser-based sensors can degrade. David Demers, CEO of beRobox, noted the goal was to match how palletizing actually works on the floor (operators interact with the system, pallets change, and the robot is in constant motion). Knut Sandven, CEO of Sonair, highlighted that true human-robot coexistence requires reliable 3D perception under any factory condition, enabling machines and people to share tight spaces without halting production.
Max Walsh, robotic safety engineer at beRobox, emphasized the flexibility gained by combining robot position data with real-time 3D detection. For warehouse and distribution operators, the technology reduces downtime associated with safety interventions, supports higher throughput in mixed or high-volume palletizing lines, and improves ergonomics and injury risk by allowing safer, more natural human interaction. It is particularly relevant for 3PLs, e-commerce fulfillment, and manufacturing end-of-line operations handling variable case sizes and frequent pallet exchanges.
The solution reflects broader industry movement toward more adaptive, software-defined safety architectures that increase the usable uptime of collaborative and industrial robotic cells without compromising required safety performance levels.