Wooden pallet condition can directly affect automated fork entry, load stability and warehouse safety. A cracked board, missing bottom deck board or unusual fork-entry opening may prevent an autonomous forklift from safely handling the load. However, not every Chinese AGV uses the same pallet inspection technology. Buyers should distinguish between systems that detect pallet geometry, systems that use cameras to inspect pallet condition and systems that rely on predefined pallet specifications and weight or position feedback.

Quick Answer

A Chinese automated forklift may detect pallet problems through 2D or 3D vision, fork-position sensors, load sensors, laser scanners or predefined pallet-profile checks. But a standard AGV should not automatically be assumed to identify every cracked or structurally weak wooden pallet. During procurement, ask the manufacturer exactly which pallet defects the vehicle can detect and whether the detection function has been validated with your actual pallet types.

How Can an AGV Detect a Broken or Cracked Lower Pallet Board?

The first challenge is that a damaged pallet board may be underneath the load and partially hidden from the vehicle's sensors. For this reason, pallet-integrity detection is not simply a matter of installing one sensor on the front of the AGV.

Depending on the vehicle design, an automated forklift may use cameras, laser scanners, depth sensors or fork-position feedback to identify abnormal pallet geometry during the approach and fork-entry process.

Vision Camera

Can inspect visible pallet boards, openings and unusual geometry when the relevant areas are within the camera's field of view.

3D / Depth Sensor

Can provide dimensional information about pallet geometry and the available fork-entry space.

Fork Position Feedback

Can help identify abnormal resistance or positioning during fork insertion, although it does not by itself prove that a pallet board is cracked.

Important Limitation

A pallet can be structurally damaged without showing an obvious visual defect. Automated detection should therefore be treated as a risk-control function rather than a guarantee that every hidden crack will be identified.

Will an AGV Reject Pallets With Missing or Improperly Spaced Bottom Boards?

Potentially, yes, if the vehicle has been configured to recognize the pallet geometry and the defect falls within the system's detection capability. This is particularly relevant when the AGV relies on known fork-entry openings and predefined pallet dimensions.

A pallet with missing boards may change the visible geometry of the fork-entry area. However, whether the AGV stops, rejects the pallet or simply reports an abnormal condition depends on the manufacturer's software and safety configuration.

Typical Automated Response Options

1

Continue Handling

2

Slow Down

3

Stop and Recheck

4

Reject / Escalate

For procurement, do not simply ask whether the AGV “supports pallet detection.” Ask the supplier to demonstrate specific conditions such as missing bottom boards, broken boards, incorrect board spacing and pallets with dimensions outside the approved profile.

How Does Vision Intelligence Handle Non-Standard Pallet Fork Entries?

Different pallet designs can have substantially different bottom-board arrangements and fork-entry openings. A vision-enabled AGV can potentially compare the observed pallet structure with a configured pallet profile before attempting full fork insertion.

For a warehouse using multiple pallet standards, the software may need separate pallet profiles rather than treating every pallet as identical.

Standard Pallet

Known dimensions and fork-entry geometry can simplify automated handling.

Non-Standard Pallet

May require an additional pallet profile, wider tolerance or special handling rules.

Damaged Pallet

May require inspection, rejection or manual intervention depending on the detected condition.

Can I Configure a Weight Variance Limit for Unevenly Loaded Pallets?

Some automated forklift systems can use load-weight information as part of their handling logic. A configured weight threshold can help identify a load that differs significantly from the expected pallet weight.

However, weight variance alone cannot determine whether a wooden pallet is structurally sound. A pallet may weigh exactly as expected while still having a cracked board or damaged structural member.

Use Weight Detection as a Secondary Check

• Compare actual load weight against expected SKU or pallet weight.

• Flag unusually high or low weights.

• Combine weight information with pallet-position and fork-entry data.

• Use vision or other sensing technologies when physical pallet inspection is required.

What Pallet Defects Should I Test Before Purchasing a Chinese AGV?

A useful factory acceptance test should use the same pallet problems that operators encounter in the target warehouse. Testing only a new, clean pallet provides limited information about real-world performance.

How Should Pallet Detection Be Integrated Into AGV Operations?

Pallet inspection should ideally be connected to the warehouse operating process. When an abnormal pallet is detected, the system needs a defined workflow instead of simply stopping the vehicle.

Example Exception Workflow

1

Pallet Approaches

2

Geometry Checked

3

Abnormal Condition Detected

4

AGV Stops or Escalates

5

Operator Inspects Pallet

What Technical Questions Should I Ask a Chinese AGV Manufacturer?

• Which pallet dimensions and bottom-board configurations does the AGV support?

• Can the vehicle detect missing or incorrectly positioned bottom boards?

• Can the vision system identify visible cracks or damaged fork-entry areas?

• What sensor technology is used for pallet-profile recognition?

• Can multiple pallet profiles be configured in the fleet-management software?

• Can weight thresholds be configured for different SKU or pallet categories?

• What does the AGV do when a pallet fails the configured inspection criteria?

• Are pallet inspection events recorded in the fleet-management system?

• Can the manufacturer demonstrate these functions using our actual pallet samples before shipment?

Test With Your Real Pallets Before Importing the Fleet

For a Chinese AGV project, pallet compatibility should be treated as an engineering validation item rather than a simple product specification. Provide the manufacturer with representative pallets, including damaged, non-standard and unevenly loaded examples, and require the supplier to demonstrate detection, fork-entry and exception-handling behavior. This gives your engineering team a much clearer basis for approving the automated forklift before shipment.