Automatic mixing, stacking and packaging system

Abstract

The invention relates to the technical field of freight stacking and packaging, in particular to an automatic mixing, stacking and packaging system which comprises a cargo conveying unit, a stacking unit, a stacking unit and a packaging unit. The cargo identification system is used for acquiring cargo information on the cargo conveying unit, constructing a three-dimensional model according to the cargo information and constructing a virtual stacking scheme according to the three-dimensional model; the intelligent circulating identifying and sorting unit comprises a circulating type conveying unit, and the input end of the circulating type conveying unit is connected with a goods conveying unit; the sorting unit is used for identifying the to-be-stacked goods on the circulating conveying unit and adjusting the placing sequence and direction of the to-be-stacked goods according to the virtual stacking scheme; the stacking and packaging subsystem is arranged at the output end of the circulating type conveying unit and used for stacking, shaping, shaping and packaging the goods; the whole set of system can achieve full-automatic mixed stacking and packaging of cargos of various specifications, and the operation efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of freight palletizing and packaging, and in particular to an automated mixed palletizing and packaging system. Background Art

[0002] Palletizing is widely used in freight, warehousing, and logistics. In air cargo, palletizing and packing (often referred to as "palletizing") is a crucial process, requiring cargo to be precisely stacked onto air pallets to maximize space utilization and ensure safe transportation.

[0003] Currently, palletizing for air cargo is primarily done manually. Workers first check the cargo information, then rely on their experience to determine the placement method, manually stacking the cargo onto pallets one by one, and finally securing them. While this traditional manual palletizing and packaging method offers a certain degree of flexibility, it suffers from serious technical drawbacks: Low efficiency: Manual palletizing usually takes 2-4 hours to complete the palletizing of a standard container, which is far from meeting the high efficiency requirements of modern air cargo transportation. Inconsistent quality: The quality of manual palletizing depends entirely on the worker's experience. The results of different workers may vary significantly, affecting space utilization and transportation safety. High labor intensity: Plate making operations require long hours of heavy physical labor, which easily fatigues workers. This not only affects work quality but also poses safety risks. Furthermore, labor shortages and costs continue to rise. Lack of standardization: The lack of unified operating standards and quality control systems makes it difficult to establish standardized operating procedures; Limited optimization capabilities: It is difficult for humans to consider numerous constraints simultaneously and find the globally optimal palletizing solution, resulting in low space utilization.

[0004] To improve the automation level of palletizing and packaging operations, the industry has developed a number of automated equipment and systems. Existing automated palletizing systems can handle standardized cargo, but these systems are primarily suitable for a single type of cargo with regular shapes and standard sizes. They lack the ability to effectively handle the diverse and unusually shaped cargo commonly found in air cargo. Summary of the Invention

[0005] The present invention provides an automated mixed palletizing and packaging system, which can realize fully automatic mixed palletizing and packaging of goods of various specifications, thereby improving operation efficiency.

[0006] In the first aspect, an embodiment of the present invention provides an automated mixed palletizing and packaging system, comprising: a cargo conveying unit; a cargo identification system for acquiring cargo information on the cargo conveying unit, constructing a three-dimensional model based on the cargo information, and constructing a virtual palletizing scheme based on the three-dimensional model; an intelligent circular identification and sorting unit, comprising: a circular conveying unit, the input end of the circular conveying unit being connected to the cargo conveying unit; a sorting unit for identifying cargo to be palletized on the circular conveying unit, and adjusting the placement order and direction of the cargo to be palletized according to the virtual palletizing scheme; a palletizing and packaging subsystem, arranged at the output end of the circular conveying unit, for palletizing, shaping, solidifying, and packaging the cargo; a cargo carrier conveying unit, connected to the palletizing and packaging subsystem, for conveying the carrier to the palletizing and packaging subsystem.

[0007] In one possible implementation, the sorting unit is also used to review the goods to be palletized on the circulating conveying unit and form a layer-by-layer physical palletizing plan based on a single target pallet type; wherein the palletizing and packaging subsystem automatically palletizes and packages the goods according to the physical palletizing plan.

[0008] In a possible implementation, the cargo information acquired by the cargo identification system includes at least one of size, weight, shape, and cargo identification information.

[0009] In one possible implementation, a virtual palletizing solution is generated by calculation based on a three-dimensional model of the goods, and includes a theoretical solution for the combination form, stacking sequence, stacking direction, and stacking position of the goods.

[0010] In one possible implementation, the palletizing and packaging subsystem includes: a palletizing temporary storage position for temporarily storing goods to be palletized from the intelligent cycle identification and sorting unit; a palletizing and packaging position for carrying a carrier and placing goods on it; and a transport mechanism for transporting the goods from the palletizing temporary storage position to the palletizing and packaging position and performing layered palletizing.

[0011] In a possible implementation, the stacking and packaging position can be raised and lowered to cooperate with the transport mechanism to perform layered stacking operations.

[0012] In a possible implementation, the palletizing and packaging subsystem further includes a shaping enclosure device, which is disposed around the palletizing and packaging position and is used to control the palletizing boundary according to the target pallet shape.

[0013] In a possible implementation, the palletizing and packaging subsystem further includes a fixing device for fixing the goods layer by layer during the palletizing process.

[0014] In a possible implementation, the cargo carrier conveying unit includes a first conveying unit and a second conveying unit, the output end of the first conveying unit is connected to the palletizing and packaging subsystem, and the input end of the second conveying unit is connected to the palletizing and packaging subsystem.

[0015] In a possible implementation, it further includes: an acceptance system for inspecting the goods on the second conveying unit; and a loading system, provided at the output end of the second conveying unit, for loading and processing the goods.

[0016] In a possible implementation, the cargo conveying unit includes a regular cargo inlet and an irregular cargo inlet.

[0017] In a possible implementation, the transport mechanism includes: a truss structure; and a plurality of lifting claws disposed on the truss structure, capable of automatically selecting a corresponding lifting claw according to characteristics of the cargo.

[0018] In a possible implementation, the transport mechanism is a mobile robotic arm device.

[0019] In a possible implementation, the fixing device is a film wrapping device, which cooperates with the descending action of the stacking and packaging position to achieve spiral layer-by-layer fixing.

[0020] In one possible implementation, the variable cross-section setting of the shaping enclosure device can adapt to different stacking requirements by adjusting the enclosure shape.

[0021] In one possible implementation, the stacking and packaging position is fixed, and the shaping enclosure device and the fixing device can be raised and lowered.

[0022] In one possible implementation, the palletizing and packaging subsystem implements palletizing and packaging according to a cyclic process of enclosure positioning, layered palletizing, platform lowering, and layer-by-layer fixing.

[0023] The automated mixed palletizing and packaging system provided by the present invention uses a cargo conveying unit to transport the processed cargo to a cargo identification system for information collection. The cargo identification system uses multiple sensors to obtain key information such as the cargo's size, weight, and shape, and uses this information to construct a three-dimensional digital model of the cargo. The circulating conveying unit within the intelligent circular identification and sorting unit provides multiple opportunities for cargo adjustment. The sorting unit can identify the actual state of the cargo on the circulating conveying unit and accurately adjust the order and orientation of the cargo according to a virtual palletizing scheme. The palletizing and packaging subsystem receives the sorted and adjusted cargo and performs the actual palletizing and packaging operations according to the optimized scheme. The cargo carrier conveying unit is responsible for the transportation of the carriers and, together with other conveying units, ensures smooth logistics integration throughout the entire system. Through the system integration of the cargo conveying unit, cargo identification system, intelligent circular identification and sorting unit, palletizing and packaging subsystem, and cargo carrier conveying unit, automated packaging of the entire freight process is achieved, improving operational efficiency. Furthermore, the system uses a virtual palletizing scheme to guide the actual palletizing operation, fundamentally solving the technical problems of low efficiency and unstable quality of traditional manual palletizing. The entire system uses 3D modeling technology to construct a digital representation of the goods, then generates a theoretically optimal virtual palletizing solution based on the digital information, and finally converts the theoretical solution into executable practical operation instructions through intelligent sorting units, realizing a complete technical chain from information collection to automated execution. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the technical solutions in the present invention or the prior art, a brief introduction is given below to the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0025] Figure 1 The figure is a schematic top view of the structure of an automated mixed palletizing and packaging system provided by the present invention.

[0026] Figure 2 It is a structural schematic diagram of the connection between a palletizing and packaging subsystem, a circulating conveying unit and a cargo carrier conveying unit provided by the present invention.

[0027] Figure 3 It is a schematic planar structural diagram of the connection between a palletizing and packaging subsystem and a cargo carrier conveying unit provided by the present invention.

[0028] Reference numerals: 1. Cargo conveying unit; 11. Regular cargo entrance; 12. Special-shaped cargo entrance; 2. Cargo identification system; 3. Intelligent cycle identification and sorting unit; 31. Circular conveying unit; 32. Sorting unit; 4. Palletizing and packing subsystem; 41. Palletizing temporary storage location; 42. Palletizing and packing location; 43. Handling mechanism; 431. Truss structure; 432. Lifting claw; 44. Shaping enclosure device; 45. Fixing device; 5. Cargo carrier conveying unit; 51. First conveying unit; 52. Second conveying unit; 53. Carrier; 6. Acceptance system; 7. Install the system. DETAILED DESCRIPTION

[0029] To make the objectives, technical solutions, and advantages of the present invention more clear, the technical solutions of the present invention will be clearly and completely described below in conjunction with the accompanying drawings. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts shall fall within the scope of protection of the present invention.

[0030] The following combination Figure 1-3 Description: An embodiment of the present invention provides an automated mixed palletizing and packaging system, comprising: a cargo conveying unit 1, a cargo identification system 2, an intelligent cycle identification and sorting unit 3, a palletizing and packaging subsystem 4, and a cargo carrier conveying unit 5, wherein: The cargo identification system 2 is used to obtain cargo information on the cargo conveying unit 1; construct a three-dimensional model based on the cargo information; and construct a virtual palletizing solution based on the three-dimensional model.

[0031] The intelligent circulation identification and sorting unit 3 includes: a circulation conveying unit 31, the input end of which is connected to the goods conveying unit 1; a sorting unit 32, which is used to identify the goods to be stacked on the circulation conveying unit 31 and adjust the placement order and direction of the goods to be stacked according to the virtual stacking plan.

[0032] The palletizing and packing subsystem 4 is provided at the output end of the circulating conveying unit 31 and is used for palletizing and packing goods.

[0033] The cargo carrier conveying unit 5 is connected to the palletizing and packaging subsystem 4 and is used to convey the carrier 53 to the palletizing and packaging subsystem 4 .

[0034] The present invention achieves the beneficial effect of fully automated palletizing for air cargo through the system integration of a cargo conveying unit 1, a cargo identification system 2, an intelligent cycle identification and sorting unit 3, a palletizing and packaging subsystem 4, and a cargo carrier conveying unit 5. This system employs a virtual palletizing scheme to guide actual palletizing operations, fundamentally addressing the inefficiency and inconsistent quality of traditional manual palletizing. The entire system constructs a digital representation of the cargo using 3D modeling technology, then generates a theoretically optimal virtual palletizing scheme based on this digital information. Finally, the intelligent sorting unit converts this theoretical scheme into executable, practical instructions, completing a complete technical chain from information collection to automated execution.

[0035] Specifically, the cargo conveying unit 1 is responsible for conveying the cargo to be processed to the cargo identification system 2 for information collection. The cargo identification system 2 obtains key information such as the size, weight, and shape of the cargo through a variety of sensors, and uses this information to build a three-dimensional digital model of the cargo. The circulating conveying unit 31 in the intelligent circulating identification sorting unit 3 provides multiple opportunities for adjustment of the cargo. The sorting unit 32 can identify the actual cargo status on the circulating conveying unit and accurately adjust the order and direction of the cargo according to the virtual palletizing plan. The palletizing and packaging subsystem 4 receives the sorted and adjusted cargo and performs the actual palletizing and packaging operations according to the optimized plan. The cargo carrier conveying unit 5 is responsible for the transportation of the carrier 53, and together with other conveying units, ensures smooth logistics connection of the entire system.

[0036] In a specific embodiment, when processing mixed cargo in air freight that includes bags of different sizes, special-shaped goods, and standard pallets, the traditional manual palletizing method requires experienced workers to adjust the placement of the goods one by one according to the characteristics of the goods. Not only does the operation take several hours, but the quality of the palletizing is completely dependent on the workers' level of experience, and is prone to problems such as low space utilization and uneven center of gravity distribution. However, after adopting the automated mixed palletizing and packaging system of the present invention, the cargo identification system 2 can complete the information collection and three-dimensional modeling of all goods within a few seconds, and the generation of the virtual palletizing scheme only takes a few minutes. The intelligent cycle identification and sorting unit 3 can adjust the goods to the optimal state through multiple rounds of cycle adjustment. The entire palletizing and packaging process can be completed within 30 minutes, which is 4-6 times more efficient than manual operation. More importantly, the palletizing scheme generated by the automated system has reached the theoretical optimal level in terms of space utilization and center of gravity distribution, and the consistency and stability of the palletizing quality far exceeds that of manual operation.

[0037] Among related technologies, traditional air cargo palletizing relies primarily on manual labor. Workers need to estimate the physical characteristics of the cargo, such as size and weight, based on their personal experience, and then use this experience to determine how to arrange the cargo to achieve optimal space utilization and load distribution. While this method has a certain degree of flexibility and can handle a variety of special-shaped cargo and special situations, it has obvious technical flaws: First, the operation efficiency is extremely low. Manual palletizing of a standard container typically takes 2-4 hours. Second, the quality is unstable. The difference in the experience level of different workers leads to uneven palletizing quality. Third, the labor intensity is high. Long periods of heavy physical labor can easily lead to worker fatigue, which in turn affects the quality and safety of the work. Fourth, standardization cannot be achieved. There is a lack of unified operating standards and quality control systems.

[0038] In the embodiment of the present invention, the traditional operation mode is completely changed by constructing a complete automated mixed palletizing and packaging system. The application of the cargo identification system 2 makes the acquisition of cargo information fast, accurate and standardized, and the three-dimensional modeling technology provides a reliable data basis for the subsequent generation of palletizing solutions. The introduction of the virtual palletizing solution realizes the transformation from experience dependence to scientific calculation, and the theoretically optimal palletizing solution can be obtained through algorithm optimization. The design of the intelligent cycle identification and sorting unit 3 solves the conversion problem between theoretical solutions and actual execution, and ensures the executability of the solution through the cycle adjustment mechanism. The automated execution capability of the palletizing and packaging subsystem 4 eliminates the unstable factors of manual operation and realizes efficient, accurate and consistent palletizing operations. The integrated design of the entire system not only greatly improves the operating efficiency, but more importantly, establishes a standardized operating process, laying a technical foundation for the modernization of air cargo palletizing operations.

[0039] In some embodiments, the sorting unit 32 is also used to review the goods to be palletized on the circulating conveying unit 31, and form a layer-by-layer physical palletizing plan based on a single target pallet type; wherein the palletizing and packaging subsystem 4 performs automatic palletizing and packaging of the goods according to the physical palletizing plan.

[0040] In this invention, the review function of the sorting unit 32 and the generation of a physical palletizing plan achieve the beneficial effect of transforming a theoretical virtual plan into a practical, executable plan. The sorting unit 32 not only adjusts the position and orientation of the goods but, more importantly, performs plan verification and optimization. By reviewing the goods to be palletized on the circulating conveyor unit 31, it can detect and correct any deviations between the virtual palletizing plan and the actual situation, ensuring that the resulting physical palletizing plan is highly operational and reliable. This dual-plan mechanism fundamentally resolves the contradiction between theoretical optimality and practical feasibility, achieving a perfect combination of intelligent decision-making and practical execution.

[0041] Specifically, the review function of the sorting unit 32 verifies whether the goods have been adjusted in place according to the requirements of the virtual palletizing plan by re-identifying and confirming the status of the goods on the circulating conveyor unit 31. During the review process, the system will check whether the actual position, direction, and status of the goods are consistent with the information in the virtual plan. If any deviation is found, the sorting unit 32 will alarm and make secondary adjustments. The generation of the physical palletizing plan is based on the virtual palletizing plan, and is further optimized based on factors such as the actual cargo status, equipment capabilities, and environmental conditions. The palletizing operation sequence is organized on a layer-by-layer basis based on a single target pallet type. After receiving the physical palletizing plan, the palletizing and packaging subsystem 4 can execute the automated palletizing and packaging operations according to a clear instruction sequence, avoiding uncertainty during the execution process.

[0042] Existing automated palletizing systems typically employ a single palletizing solution generation mechanism, directly generating and executing palletizing instructions based on cargo information. While simple and efficient, this approach suffers from significant technical drawbacks. First, there's a lack of solution verification. If there are errors in cargo identification or cargo shifts during transport, simply following the original solution can lead to palletizing failures. Second, there's a lack of adaptability, making it unable to cope with dynamic changes in cargo status. Third, there's poor error handling, forcing the system to shut down and await manual intervention if an anomaly occurs.

[0043] In the embodiment of the present invention, a dual guarantee system is established by introducing the review function of the sorting unit 32 and the generation mechanism of the physical palletizing plan. The review function of the sorting unit 32 is equivalent to adding a quality checkpoint before palletizing is executed. By reconfirming the actual status of the goods, the accuracy and feasibility of the palletizing plan are ensured. The generation of the physical palletizing plan is optimized for practicality based on the virtual plan, which not only maintains the guiding role of the theoretical optimality but also fully considers the constraints of actual execution. The layer-by-layer organization method based on a single target pallet type makes the palletizing operation more orderly and controllable, and reduces the complexity and error rate during the execution process. This design not only improves the reliability of the system, but more importantly, enhances the system's adaptability to various abnormal situations, providing technical support for the realization of truly stable and reliable automated palletizing operations.

[0044] In some embodiments, the cargo information acquired by the cargo identification system 2 includes but is not limited to size, weight, shape, and cargo identification information.

[0045] In this invention, the cargo identification system 2 acquires multi-dimensional cargo information, including size, weight, shape, and cargo identification information, achieving the beneficial effect of comprehensive and accurate digital representation of cargo. This multi-dimensional information acquisition mechanism provides a rich and reliable data foundation for subsequent 3D modeling and virtual palletizing plan generation, ensuring that the entire automated mixed palletizing and packaging system can accurately understand and process various types of cargo. By acquiring multiple cargo attribute information, the system can build a more accurate cargo model, thereby generating more reasonable and feasible palletizing plans.

[0046] Specifically, dimensional information includes geometric parameters such as the length, width, and height of the goods, which form the basis for space planning and palletizing arrangements. Weight information reflects the quality characteristics of the goods and is crucial for load distribution and palletizing stability. Morphological information describes the geometric shape characteristics of the goods, including whether they are regular, the presence of protrusions, surface flatness, and packaging type, which affect the palletizing and stability of the goods. Cargo identification information includes business information such as the cargo number, category, attributes, special requirements, place of shipment, destination, and time, helping the system make more intelligent palletizing decisions. By integrating multiple sensors and recognition technologies, the Cargo Identification System 2 can simultaneously acquire information from these different dimensions, creating a complete digital archive for the goods.

[0047] In one specific embodiment, while processing mixed cargo in a batch of air freight, the cargo identification system 2 encountered a variety of cargo types, including standard cartons, cylindrical cargo, irregular packaging bags, and palletized cargo. For standard cartons, the system primarily acquired precise dimensions and weight information. For cylindrical cargo, in addition to acquiring basic dimensions, the system also specifically identified its circular cross-sectional features to account for rolling protection during palletizing. For irregular packaging bags, the system determined their flexibility through morphological recognition, arranging them in a relatively stable position during palletizing. For palletized cargo, the system identified its special requirements through cargo identification information, ensuring appropriate protection and positioning during palletizing. By acquiring this multi-dimensional information, the system generated a virtual palletizing solution that fully considered the characteristics of each cargo type, ultimately achieving safe, stable, and efficient palletizing.

[0048] In related technologies, traditional cargo identification systems often focus solely on basic cargo identification information, lacking comprehensive information on other dimensions such as size, weight, and shape. This single-dimensional approach to information acquisition presents significant limitations: first, incomplete information; relying solely on cargo identification information cannot fully capture the specific physical characteristics of a cargo; second, insufficient decision-making basis and lack of sufficient information support make it difficult to generate an optimal palletizing solution; third, poor adaptability, making it ineffective for handling cargo with various special shapes and requirements; and fourth, safety risks, as insufficient consideration of key factors such as weight distribution and stability can lead to potential safety hazards in palletizing.

[0049] In the embodiment of the present invention, by establishing a multi-dimensional information acquisition mechanism, the comprehensiveness and accuracy of cargo identification are greatly improved. The acquisition of size information provides precise geometric constraints for space planning; the acquisition of weight information enables the system to reasonably plan the load distribution to avoid problems such as top-heavy or local overload; the acquisition of shape information enables the system to identify and process cargo of various special shapes, improving the adaptability of the system; the acquisition of cargo identification information enables the system to understand the business attributes and special requirements of the cargo, and achieve more intelligent processing. This multi-dimensional information acquisition mechanism not only improves the accuracy of cargo identification, but more importantly, provides rich data support for subsequent intelligent decision-making, enabling the entire automated mixed palletizing and packaging system to cope with more complex and diverse cargo handling needs, laying a solid technical foundation for the realization of truly intelligent air cargo automated packaging.

[0050] In some embodiments, the virtual palletizing plan is generated by calculation based on a three-dimensional model of the goods, and includes a theoretical plan for the combination form, stacking sequence, stacking direction, and stacking position of the goods.

[0051] In this invention, the cargo identification system includes an algorithmic system that, based on a three-dimensional cargo model, generates a theoretical virtual palletizing plan that includes the cargo configuration, stacking order, stacking direction, and stacking location. This system achieves the beneficial effect of scientific and standardized palletizing planning. The virtual palletizing plan generation process utilizes computer algorithm optimization technology, which can rapidly calculate the theoretically optimal palletizing configuration based on multiple factors, such as spatial constraints, weight distribution, and stability requirements. This computational approach to plan generation revolutionizes the traditional palletizing planning model that relies on empirical judgment, achieving a shift from subjective experience to objective science.

[0052] Specifically, the virtual palletizing solution generation process begins with a spatial analysis based on the three-dimensional model of the goods. Computer geometry algorithms are then used to determine the spatial relationships and possible combinations between different goods. Determining the cargo combination involves effectively combining goods of varying sizes and shapes to achieve optimal space utilization. Planning the stacking sequence requires consideration of factors such as the weight, stability, and fragility of the goods, ensuring that heavy goods are positioned at the bottom and light goods at the top, with stable goods serving as the foundation and unstable goods receiving appropriate support. Determining the stacking position requires precise calculation of the coordinates of each item in three-dimensional space to ensure no interference between goods while maintaining the stability of the overall structure. The entire solution generation process is based entirely on mathematical calculations and logical reasoning, making it highly scientific and repeatable.

[0053] In one specific example, when palletizing an aviation pallet, the system needs to handle 15 items of varying sizes, including five large cartons, six medium-sized packages, and four small precision equipment packages. Traditional manual planning can require experienced workers to spend one to two hours trialing and adjusting the placement, and plans can vary significantly between workers. However, generating a digital palletizing plan takes only tens of seconds. Through 3D model analysis, the system determines the optimal cargo combination: five large cartons form the bottom layer, six medium-sized packages are placed in the middle layer, and four small precision equipment packages are placed on the top layer. The stacking order is arranged from heaviest to lightest and from largest to smallest. Precisely calculated stacking positions ensure a centered center of gravity and structural stability. The resulting virtual palletizing plan achieves theoretically optimal levels in terms of space utilization, center of gravity distribution, and structural stability, providing scientific and reliable guidance for subsequent actual palletizing.

[0054] Traditional palletizing scheme planning relies heavily on manual experience, with workers making subjective judgments and placing items based on the physical characteristics and personal experience of the goods. This approach has significant technical limitations: First, it is highly subjective, with varying levels of experience and judgment among workers, leading to varying solution quality. Second, it is inefficient, as manual planning requires significant time for deliberation and trial and error. Third, it suffers from limited optimization, as the sheer volume of goods in a single order makes it difficult for workers to simultaneously consider all constraints and find the global optimal solution. Fourth, it suffers from a low level of standardization, lacking unified planning standards and evaluation systems.

[0055] In the embodiment of the present invention, by introducing a calculation and generation mechanism based on a three-dimensional model, the scientific and standardized planning of the palletizing scheme is achieved. The analysis based on the three-dimensional model ensures the geometric accuracy of the scheme and avoids the errors that may be caused by manual estimation; the calculation and generation method makes the scheme planning fast and efficient, greatly shortening the planning time; the complete information including the combination form of goods, stacking order and stacking position makes the scheme highly operational; the positioning of the theoretical scheme enables this scheme to provide scientific guidance for subsequent actual adjustments. More importantly, this calculation and generation method is highly consistent and repeatable. The same goods input will inevitably produce the same optimal solution, laying the foundation for the standardization of palletizing operations. The introduction of the virtual palletizing scheme not only improves the efficiency and quality of palletizing planning, but more importantly, it establishes a scientific decision-making mechanism, providing key technical support for the realization of a truly intelligent automatic palletizing system.

[0056] In some embodiments, the palletizing and packing subsystem 4 includes: a palletizing temporary storage position 41, which is used to temporarily store the goods to be palletized from the intelligent cycle identification and sorting unit 3; a palletizing and packing position 42, which is used to carry the carrier; and a transport mechanism 43, which is used to transport the goods from the temporary storage position to the palletizing and packing position 42 and perform layered palletizing.

[0057] The present invention achieves the beneficial effects of efficient coordination and flexible operation of the palletizing and packaging subsystem 4 by providing a functional modular configuration of the palletizing and packaging temporary storage position 41, the palletizing and packaging position 42, and the handling mechanism 43. This modular design breaks down the complex palletizing and packaging process into mutually coordinated but functionally independent operating units, improving not only the system's operational efficiency but also its maintainability and scalability. The buffering effect of the palletizing temporary storage position 41 solves the speed matching problem between the upstream sorting unit and the downstream palletizing system; the dedicated palletizing and packaging position 42 provides a stable palletizing platform for the carrier; and the precise operation of the handling mechanism 43 enables high-precision transfer of goods from temporary storage to final palletizing.

[0058] Specifically, the palletizing temporary storage position 41 serves as a temporary storage area for goods from the intelligent circulation identification and sorting unit 3. It can accommodate goods to be palletized after sorting and adjustment, and provide a stable supply of goods for subsequent palletizing operations. The palletizing and packaging position 42 is specifically used to carry cargo carriers and provide a stable working platform for palletizing operations. Its design needs to take into account the size specifications and load-bearing requirements of the carriers. The transport mechanism 43, as a key device connecting the temporary storage position and the palletizing and packaging position 42, is responsible for accurately transporting the goods from the temporary storage position to the designated position of the palletizing and packaging position 42, and performing layered palletizing operations according to the actual palletizing plan. The three functional modules coordinate and cooperate to form a complete palletizing and packaging operation process. Each module focuses on a specific function, which not only ensures the professionalism of the operation, but also achieves overall efficiency.

[0059] In one specific embodiment, when processing a batch of cargo to be palletized onto an air pallet, the intelligent loop recognition sorting unit 3 adjusts the cargo and delivers it to the palletizing temporary storage 41 at a rate of six pieces per minute. Palletizing temporary storage 41 can accommodate up to twelve pieces of cargo simultaneously, providing ample buffer for the handling mechanism 43. Following the instructions for the actual palletizing plan, the handling mechanism 43 moves the cargo from the palletizing temporary storage 41 to the palletizing and packaging position 42 for precise placement. Due to speed differences, without the buffer provided by palletizing temporary storage 41, the sorting unit 32 might need to wait frequently, or the handling mechanism 43 might face insufficient cargo supply. However, with the palletizing temporary storage 41, the system effectively balances these speed differences. The sorting unit 32 can continuously deliver cargo to the temporary storage, and the handling mechanism 43 can continuously retrieve cargo from the temporary storage for palletizing, significantly improving the overall system's operational efficiency.

[0060] Traditional palletizing systems often employ a direct docking approach, whereby goods are transferred directly from the conveyor system to the palletizing location. While this approach may appear simple, it suffers from significant technical drawbacks. First, there's the lack of a buffer mechanism, resulting in speed mismatches between upstream and downstream equipment, which can easily lead to system bottlenecks. Second, operational flexibility is limited, as handling equipment must perform complex operations within a limited space, making interference more likely. Third, reliability is low, as problems in any link can impact the operation of the entire system. Fourth, maintenance is difficult due to the high degree of functional coupling, requiring the entire system to be shut down for maintenance.

[0061] In the embodiment of the present invention, the technical problems of the traditional method are effectively solved by adopting a modular design concept. The setting of the palletizing temporary storage position 41 provides an important buffering function, which not only solves the speed matching problem, but also provides the system with a time window for exception handling; the special setting of the palletizing and packaging position 42 ensures that the carrier has a stable working platform, improving the accuracy and quality of palletizing; the independent design of the transport mechanism 43 enables it to focus on cargo handling and precise placement, improving work efficiency and accuracy. More importantly, this modular design greatly improves the maintainability of the system. Each module can be maintained and upgraded independently without affecting the normal operation of other modules. The operation process of transporting from the temporary storage position to the palletizing and packaging position 42 and performing layered palletizing not only ensures the orderliness of the operation, but also achieves the accuracy of the operation, providing a reliable technical guarantee for achieving high-quality automated palletizing and packaging.

[0062] In some embodiments, the stacking and packaging position 42 can be raised and lowered to cooperate with the transport mechanism 43 to perform layered stacking operations.

[0063] In this invention, the coordinated operation of the liftable stacking and packaging station 42 and the transport mechanism 43 achieves the beneficial effect of efficient and precise layered palletizing. The design of the liftable stacking and packaging station 42 cleverly solves the operating height issue during multi-layer palletizing. By dynamically adjusting the height of the work platform, the transport mechanism 43 consistently performs palletizing at the optimal height, ensuring operational accuracy and improving efficiency. This lifting mechanism also facilitates subsequent layer-by-layer solidification operations and is a key technical feature for achieving automated palletizing and packaging.

[0064] Specifically, the height of the palletizing and packing station 42 can be automatically adjusted according to the progress of the palletizing operation through a precise lifting mechanism. At the beginning of palletizing, the packing station is in the highest position, making it convenient for the handling mechanism 43 to place the first layer of goods. After the first layer of palletizing is completed, the packing station is lowered to a preset height, so that the palletizing height of the second layer of goods remains the same as the height at the completion of the first layer of palletizing. The handling mechanism 43 can continue the palletizing operation of the second layer without adjusting its operating height. And so on, until the palletizing of the entire stack is completed. This design ensures that the operating height of the handling mechanism 43 remains constant, avoiding frequent height adjustments and improving work efficiency and accuracy. At the same time, the liftable setting also coordinates with the rhythm of the layered palletizing operation, providing a stable working platform for each layer of palletizing.

[0065] In a specific embodiment, when stacking an aviation cargo stack with a height of 3.0 meters, it is necessary to divide it into 5 layers for stacking, and the height of each layer is about 60 centimeters. The traditional fixed-height stacking method requires the conveying mechanism 43 to have a wide range of height adjustment capabilities. From the first layer on the ground to the fifth layer at a height of 3.0 meters, the conveying mechanism 43 needs to constantly adjust its gripping and placement height, which not only increases the overall size of the equipment, but also reduces the operation accuracy and efficiency. After adopting the design of the liftable stacking and packaging position 42, the operating height of the conveying mechanism 43 is always maintained at a fixed height of about 60 centimeters from the packaging position surface. After each layer of stacking is completed, the packaging position automatically drops 60 centimeters to prepare for the next layer of stacking. This method not only simplifies the control algorithm of the conveying mechanism 43, but also greatly improves the stacking accuracy. The placement error of each layer of goods is controlled within ±5 mm, far exceeding the accuracy level of traditional methods.

[0066] In related technologies, traditional palletizing systems usually use a fixed-height palletizing platform, and the handling equipment needs to continuously adjust its operating height according to the increase in the number of palletizing layers. This method has obvious technical limitations: first, the overall height of the equipment is high, and the handling equipment needs to have a wide range of height adjustment capabilities, which increases the complexity and cost of the mechanical structure; second, accuracy is difficult to guarantee. Due to the fixed-height palletizing platform, the initial position of the first layer of palletizing is often the maximum travel of the equipment, resulting in the maximum accuracy error when palletizing the base layer. Only as the palletizing height increases, the positioning accuracy of the handling equipment will improve as the rigidity of the handling equipment increases; third, the operating efficiency is low, and frequent height adjustments increase operating time; fourth, there is a stability risk, and working at height increases equipment failure and safety risks.

[0067] In the embodiment of the present invention, the technical problems of the traditional method are effectively solved by introducing the innovative design of the liftable stacking and packaging position 42. The liftable setting transfers the complexity of the palletizing operation from the transport mechanism 43 to the packaging position, and the lifting mechanism is simpler and more reliable than the complex adjustment of the robotic arm; the design of the layered palletizing operation in conjunction with the transport mechanism 43 ensures that the palletizing of each layer is carried out under the same operating conditions, ensuring consistent operating accuracy and quality; the transport mechanism 43 does not need to be adjusted in height over a large range, which simplifies its mechanical structure and control system, and improves the reliability and maintainability of the equipment. More importantly, this design lays the foundation for the subsequent layer-by-layer solidification operation. The descending action of the liftable stacking and packaging position 42 can perfectly match the working rhythm of the solidification device 45, realizing the synchronous palletizing and solidification, and greatly improving the operating efficiency of the entire packaging system.

[0068] In some embodiments, the palletizing and packaging subsystem 4 further includes a shaping enclosure device 44 , which is disposed around the palletizing and packaging position 42 and is configured to adjust enclosure dimensions according to a target pallet shape to control a palletizing boundary.

[0069] In this invention, the palletizing boundary is controlled by positioning a shaping enclosure device 44 around the palletizing and packaging station 42 and adjusting the enclosure size according to the target pallet shape, thereby achieving the beneficial effects of precise pallet shape control and palletizing quality assurance. As a boundary control mechanism during the palletizing process, the shaping enclosure device 44 not only provides clear spatial constraints for the palletizing operation, but also dynamically adjusts to the dimensional requirements of different pallet shapes, ensuring that the final palletizing results meet the preset shape and size specifications. This active boundary control mechanism significantly improves the accuracy and consistency of automated palletizing and is a key technical feature for achieving high-quality palletizing and packaging.

[0070] The enclosed space of the shaping enclosure device 44 can be of a fixed size to ensure the consistency of the stack shape and size and to guarantee the quality of the stacking.

[0071] Optionally, the enclosed space of the shaping enclosure device 44 can also be set to be variable. The shaping enclosure device 44 forms an adjustable three-dimensional boundary frame by surrounding the stacking and packaging position 42. The frame can be dynamically adjusted according to the specific size requirements of the target stack type. Before the stacking operation begins, the shaping enclosure device 44 automatically adjusts the initial size of its internal space according to the stack size determined by the target stack type, and sets precise boundary constraints for the upcoming stacking operation. During the stacking process, the shaping enclosure device 44 provides a clear placement boundary guide for the transport mechanism 43. The goods must be placed within the space limited by the shaping enclosure device 44. Any placement beyond the boundary will be mechanically guided, discovered and corrected in time. The shaping enclosure device 44 also has a certain supporting function, especially for goods at the edge position, it can provide necessary lateral support to prevent the goods from shifting or tipping over during the stacking process.

[0072] In a specific embodiment, when stacking an aviation cargo stack with a size of 318cm×244cm (122cm)×192cm (300cm), the shaping enclosure device 44 first adjusts its internal dimensions to a bottom area of ​​318cm×244cm and a height of 192cm according to the target stack. During the stacking process, the handling mechanism 43 places the cargo layer by layer according to the actual stacking plan, and the shaping enclosure device 44 ensures that each piece of cargo is accurately placed within the specified boundary. When a piece of cargo may exceed the boundary due to size error or placement deviation, the boundary constraint of the shaping enclosure device 44 immediately takes effect to prevent the cargo from exceeding the predetermined range. For cargo placed at the edge of the stack, the shaping enclosure device 44 provides reliable lateral support to prevent the cargo from shifting during the stacking process. At a height of more than 192 cm, the shaping enclosure device 44 gradually reduces the internal dimensions to the limit size of 318 cm × 122 cm by adjusting the enclosure width. The final stack size is precisely controlled within the variable cross-section stack size, and the boundary error is controlled within ±5 mm, fully meeting the strict requirements of air transportation for cargo stacking accuracy.

[0073] Traditional automated palletizing systems often lack effective boundary control mechanisms, relying primarily on the positioning accuracy of handling equipment to ensure palletizing quality. This approach has significant technical drawbacks: First, accuracy is difficult to guarantee; relying solely on the positioning accuracy of handling equipment can easily lead to cumulative errors; second, stability is insufficient, and the lack of boundary constraints makes it easy for goods to shift during the palletizing process; third, adaptability is poor, making it impossible to adjust to the requirements of different pallet types, especially the boundary dimensions during the palletizing process; and fourth, quality control is difficult, lacking real-time boundary monitoring and error correction mechanisms.

[0074] In the embodiment of the present invention, an active boundary control mechanism is established by providing a special shaping enclosure device 44. The setting around the stacking and packaging position 42 ensures that the shaping enclosure device 44 can perform all-round boundary control of the entire stacking area; the ability to adjust the enclosure size according to the target stacking type enables the system to adapt to various different stacking requirements; the function of controlling the stacking boundary not only provides spatial constraints, but also realizes real-time quality monitoring. More importantly, the setting of the shaping enclosure device 44 provides physical protection for the stacking operation. Even if there is a slight positioning error in the conveying mechanism 43, the shaping enclosure device 44 can guide and correct it in time to prevent the expansion and propagation of the error. This design not only improves the stacking accuracy, but also enhances the fault tolerance of the system, providing important technical support for the realization of stable and reliable automated stacking. The application of the shaping enclosure device 44 enables the automated stacking system to completely surpass the accuracy level of manual stacking, laying a solid foundation for the practical application of automated packaging for air cargo.

[0075] In some embodiments, the palletizing and packaging subsystem 4 further includes a fixing device 45 for fixing the goods layer by layer during the palletizing process.

[0076] In the present invention, the goods are fixed layer by layer during the stacking process by the fixing device 45, achieving the beneficial effect of significantly improving the stability and structural integrity of the stacking. The layer-by-layer fixing mechanism of the fixing device 45 changes the traditional overall fixing method. By performing small-pitch segmented fixing immediately after each layer of stacking is completed, it ensures that each layer of goods has at least two circles of fixed clamping, ensuring the stability of stacking and shaping, and preventing the deformation or displacement of the lower layer of goods due to the pressure of the upper layer. This small-pitch layer-by-layer fixing method not only improves the overall stability of the stacking structure, but also provides technical support for handling mixed goods of different weights and shapes. It is the core technical feature for achieving high-quality automated stacking and packaging.

[0077] Specifically, the small-pitch layer-by-layer fixing process of the fixing device 45 is carried out synchronously with the palletizing operation. When the transport mechanism 43 completes the palletizing of a layer of goods, the fixing device 45 immediately fixes the layer of goods, that is, after each layer of palletizing is completed, the lifting platform of the palletizing and packaging position 42 is lowered by no more than one layer, and the shaping enclosure device 44 still effectively supports to keep the stack shape unchanged, and the fixing device 45 quickly wraps the film and tape for reinforcement. The fixing process usually uses wrapping film, strapping tape or other fixing materials to stabilize all the goods in the layer into a whole to form a stable structural unit. This layer-by-layer fixing method ensures that each layer of goods has formed a stable structure before bearing the weight of the upper layer, avoiding structural deformation caused by weight pressure. At the same time, layer-by-layer fixing can also effectively connect different layers to form an overall three-dimensional structure, which greatly improves the structural strength and stability of the entire stack.

[0078] In one specific embodiment, when stacking a mixed cargo stack containing light and heavy goods, 20 heavy-duty cartons weighing 50 kg are placed on the bottom layer, 40 medium-duty cartons weighing 30 kg are placed in the middle layer, and 20 light-duty cartons weighing 15 kg are placed on the top layer. If a traditional overall securing method is used, securing the stack after stacking is complete, the heavy-duty cartons on the bottom layer may deform under the weight of the upper layers, totaling approximately 1,500 kg. In particular, the paper packaging may suffer compression deformation, resulting in reduced stability of the entire stack. However, with a layer-by-layer securing method, once the 20 heavy-duty cartons on the bottom layer are placed, the securing device 45 immediately wraps them with film to secure them, forming a stable bottom layer structure. The middle layer of cargo is then placed and secured again, and finally the top layer of cargo is placed and secured. This method ensures that each layer of cargo possesses sufficient structural strength to withstand the weight of the upper layers. The resulting stack maintains good structural stability at a total height of 1.8 meters, fully meeting air transportation safety requirements.

[0079] In related technologies, traditional palletizing usually adopts an overall fixation method, that is, after all goods are palletized, the entire stack is uniformly fixed. Although this method is relatively simple to operate, it has obvious technical defects: first, the structural stability is insufficient. The bottom cargo needs to bear the weight of the entire stack, and without side support, it is very easy to deform or damage; second, it has poor adaptability and is not effective for handling goods of mixed weights; third, it has high safety risks. Before fixation, the stability of the entire stack depends entirely on the stacking of the goods themselves, which poses a risk of collapse; fourth, the fixing effect is limited. The overall fixation can often only be processed on the surface, and the connection strength of the internal structure is insufficient.

[0080] In the embodiment of the present invention, the technical problems of the traditional method are effectively solved by introducing an innovative mechanism of fine-pitch layer-by-layer shaping and fixing. The design of fixing during the palletizing process organically combines the fixing operation with the palletizing operation, thereby improving the overall operating efficiency; the method of fine-pitch layer-by-layer fixing ensures that each layer of goods has independent structural strength, and even if a problem occurs in a certain layer, it will not affect the stability of other layers; the treatment of fixing the goods includes not only surface fixation, but also structural connection, forming a truly integrated structure. More importantly, this fine-pitch layer-by-layer fixing mechanism provides technical possibilities for handling various complex combinations of goods. Whether it is a mixture of light and heavy, large and small, or goods of various shapes, a stable and reliable palletizing structure can be obtained by fixing them layer by layer. The application of the solid device 45 not only improves the quality of palletizing, but also greatly enhances the safety of the palletizing structure during transportation, providing a key technical guarantee for the realization of a truly practical automated palletizing and packaging subsystem 4.

[0081] In some embodiments, the cargo carrier conveying unit 5 includes a first conveying unit 51 and a second conveying unit 52 . The output end of the first conveying unit 51 is connected to the palletizing and packaging subsystem 4 , and the input end of the second conveying unit 52 is connected to the palletizing and packaging subsystem 4 .

[0082] In the present invention, the bidirectional conveying configuration of the cargo carrier conveying unit 5, comprising a first conveying unit 51 and a second conveying unit 52, achieves the beneficial effects of efficient bidirectional flow of carriers and cargo and system logistics integration. The first conveying unit 51 is responsible for conveying empty carriers to the palletizing and packaging subsystem 4, while the second conveying unit 52 is responsible for conveying loaded cargo out of the system. This bidirectional separation design avoids interference between carriers and cargo in the same channel, improving the system's traffic efficiency and operational safety. The bidirectional conveying configuration also creates conditions for continuous system operation, enabling the parallel processing of carrier supply and cargo output.

[0083] Specifically, the output end of the first conveying unit 51 is connected to the palletizing and packaging subsystem 4, which is specifically responsible for conveying empty carriers, such as aviation pallets, pallets and other carrier platforms, to the palletizing and packaging position 42. The design of the first conveying unit 51 needs to take into account the size specifications, weight characteristics and conveying speed requirements of the carrier to ensure that the carrier can reach the palletizing and packaging position 42 accurately and in a timely manner. The input end of the second conveying unit 52 is connected to the palletizing and packaging subsystem 4, which is specifically responsible for conveying the palletized and packaged goods from the palletizing and packaging position 42 to the subsequent acceptance, inspection or installation links. The design of the second conveying unit 52 needs to take into account the total weight after loading, the stacking size and the transportation stability requirements to ensure that the loaded goods can be transported safely and stably.

[0084] In one specific embodiment, when handling continuous palletizing of air cargo, the first conveyor unit 51 delivers empty pallets to the palletizing and packaging subsystem 4 at a rate of one every 10 minutes. The palletizing and packaging subsystem 4 takes approximately 25 minutes to complete the palletizing and packaging process. The second conveyor unit 52 then transports the completed pallets to the inspection area for quality inspection. If a single conveyor channel is used, both the input and output of empty pallets must occur within the same channel, which not only causes channel congestion but also can lead to waiting for carriers and cargo. However, with a bidirectional, separate conveyor configuration, the first conveyor unit 51 continuously delivers empty pallets to the system. A suitable buffer area is provided at the palletizing and packaging station 42, capable of temporarily storing two to three empty pallets. The second conveyor unit 52 continuously transports completed pallets out of the system without interfering with incoming empty pallets. This configuration enables continuous operation of the entire system, significantly improving its processing capacity and efficiency.

[0085] In some embodiments, it further includes: an acceptance system 6 for inspecting the goods on the second conveying unit 52; and an installation system 7, which is provided at the output end of the second conveying unit 52 and is used for loading and processing the goods.

[0086] In this invention, the inspection system 6 inspects the goods on the second conveyor unit 52, and the loading system 7 loads the goods, achieving the beneficial effects of packaging quality control and connecting with subsequent processes. As a key link in quality control, the inspection system 6 ensures that all palletized and packaged goods meet preset quality standards and transportation requirements, promptly identifying and addressing quality issues and preventing unqualified products from entering subsequent processes. As a key link in process integration, the loading system 7 transfers qualified goods to the loading process in a standardized manner, achieving a seamless transition from automated packaging to practical application.

[0087] In some embodiments, the cargo conveying unit 1 includes a regular cargo inlet 11 and an irregular cargo inlet 12 .

[0088] In this invention, the cargo conveying unit 1, comprising a regular cargo inlet 11 and a special-shaped cargo inlet 12, achieves specialized handling of cargo of varying shapes and enhances system adaptability. The separate design of the regular cargo inlet 11 and the special-shaped cargo inlet 12 takes into account the diverse nature of cargo shapes, providing the most appropriate conveying channels and handling methods for cargo with different characteristics. This not only improves cargo conveying efficiency but also facilitates subsequent identification and processing. This categorized conveying design demonstrates the system's in-depth understanding of and technical response to the complex cargo handling requirements.

[0089] Specifically, the regular cargo entrance 11 is specially used to handle cargo with standard geometric shapes, such as rectangular cartons, cylindrical barreled cargo, standard pallet cargo, etc. This type of cargo is characterized by regular appearance, relatively standard size, and easy automated processing. The design of the regular cargo entrance 11 is optimized for these characteristics, including standardized conveying equipment, standardized placement requirements, and efficient identification processes. The special-shaped cargo entrance 12 is specially used to handle cargo with irregular shapes, special sizes, or non-standard packaging, such as soft packaging bags, special-shaped containers, oversized or undersized cargo, fragile items, etc. This type of cargo requires special handling methods and more flexible identification means. The design of the special-shaped cargo entrance 12 takes these special requirements into consideration, providing a more flexible conveying method and a more sophisticated processing flow.

[0090] In a specific example, a batch of air freight orders containing multiple types of cargo included 15 standard cartons, 8 cylindrical containers, 5 flexible packaging bags, 3 precision equipment in irregular packaging, and 2 oversized specialty items. If a single entry design were used, all items would need to be processed in the same lane, which would not only reduce conveying efficiency but also potentially make handling difficult due to the varying characteristics of the goods. However, with a categorized entry design, the 15 standard cartons and 8 cylindrical containers entered the system through the regular cargo entry 11. Due to their regular shapes and sizes, these items could be conveyed and identified at a high speed, with each item processed in approximately 30 seconds. Five flexible packaging bags, 3 pieces of precision equipment in irregular packaging, and 2 oversized items entered the system through the irregular cargo entry 12. Although these items required more meticulous handling, the specialized process allowed for a processing time of approximately 90 seconds per item, saving approximately 40% compared to processing in the regular cargo lane. Overall, the categorized entry design improved the system's average processing efficiency by 25%.

[0091] In some embodiments, the transport mechanism 43 includes: a truss structure 431; and a plurality of lifting claws 432 disposed on the truss structure 431, capable of automatically selecting a corresponding lifting claw 432 according to the characteristics of the cargo.

[0092] In this invention, the combined configuration of the handling mechanism 43, comprising a truss structure 431 and a variety of lifting claws 432, achieves the beneficial effects of high-precision, wide-range, and adaptable cargo handling. The truss structure 431 provides a stable and reliable mechanical platform and precise three-dimensional positioning capabilities, while the various lifting claws 432 offer flexible gripping solutions for handling cargo with diverse characteristics. Together, they form a powerful handling system. This design not only ensures the accuracy and efficiency of handling operations but also significantly expands the system's adaptability to diverse cargo types, making it a core technical component for achieving high-quality automated palletizing.

[0093] Specifically, the truss structure 431, serving as the main framework of the handling mechanism 43, features high rigidity, a large span, and precise positioning. The truss structure 431 covers the entire palletizing area, providing a stable platform for the lifting claws 432 and ensuring accurate and repeatable handling operations. The design of the truss structure 431 also takes into account load capacity requirements, enabling it to carry cargo of varying weights, from lightweight packages weighing a few kilograms to heavy goods weighing hundreds of kilograms. A variety of lifting claws 432 are installed on the truss structure 431, providing specialized gripping solutions for cargo of varying shapes, materials, and sizes. For example, suction cup and / or clamping lifting claws 432 can be used for standard cartons; suction cup and / or wraparound lifting claws 432 for cylindrical cargo; suction cup lifting claws 432 for bagged cargo; and vacuum lifting claws 432 for sheet materials. The system automatically selects the appropriate lifting claw 432 based on cargo characteristics, achieving the most suitable gripping method.

[0094] In a specific embodiment, when palletizing an aviation pallet containing multiple types of cargo, the cargo to be handled includes eight standard cartons, four cylindrical containers, six flexible packaging bags, and two metal sheets. Traditional handling equipment using a single gripping method may not be able to effectively handle all types of cargo, especially since flexible packaging bags and metal sheets require completely different gripping methods. However, using a truss handling mechanism 43 configured with multiple lifting claws 432, the system automatically selects the appropriate lifting claw 432 based on cargo identification results: a clamping suction cup lifting claw 432 is used for the eight standard cartons, providing stable and reliable grip; an embracing lifting claw 432 is used for the four cylindrical containers to prevent rolling and slipping; a suction cup lifting claw 432 is used for the six flexible packaging bags to prevent packaging damage; and a vacuum suction lifting claw 432 is used for the two metal sheets to ensure smooth handling. The wide span design of the truss structure 431 enables the handling mechanism 43 to cover the entire operating area from the temporary storage position to the palletizing and packaging position 42, achieving efficient three-dimensional handling. The positioning accuracy of the entire handling process reaches ±5 mm, and the handling efficiency is increased by 40% compared with traditional methods.

[0095] In some embodiments, the transport mechanism 43 is a mobile robotic arm device.

[0096] In this invention, the design of a mobile robotic arm device for the transport mechanism 43 significantly enhances the flexibility and adaptability of the transport system. Compared to fixed transport equipment, mobile robotic arms offer a wider operating range and greater flexibility, enabling flexible adjustments to suit varying palletizing requirements and operating environments, providing another highly efficient technical option for automated palletizing systems. This design is particularly suitable for applications where the workspace is relatively compact or where frequent adjustments to the work layout are required.

[0097] Specifically, the mobile robotic arm device achieves full-scale operational capabilities in three-dimensional space by integrating a mobile platform and a multi-degree-of-freedom robotic arm. The mobile platform provides the robotic arm with flexible mobility within the palletizing operation area, and can adjust its position according to the distribution of goods and palletizing requirements; the multi-degree-of-freedom robotic arm has precise grasping and placement capabilities, and can adapt to various complex palletizing movement requirements. The mobile design allows the transport mechanism 43 to be free from the constraints of fixed tracks or fixed positions, and can flexibly respond to the palletizing needs of carriers of different specifications, and also facilitates the reconfiguration and upgrading of the system. The robotic arm device is usually equipped with advanced control systems and sensors, which can achieve high-precision positioning and force control to ensure the quality of cargo handling and placement.

[0098] In some embodiments, the fixing device 45 is a film wrapping device, which cooperates with the descending action of the stacking and packaging position 42 to achieve spiral layer-by-layer fixing.

[0099] In this invention, the film wrapping device 45 utilizes a film wrapping mechanism in conjunction with the descending motion of the stacking and packaging station 42 to achieve spiral, layer-by-layer securing, achieving efficient and stable cargo securing and excellent structural stability. This spiral, layer-by-layer securing method fully utilizes the ascending and descending motion of the stacking and packaging station 42, forming a three-dimensional securing structure through continuous spiral wrapping. This not only improves securing efficiency but also significantly enhances securing strength. This securing method is particularly suitable for multi-layer palletizing applications, enabling simultaneous securing operations during the palletizing process, achieving integrated palletizing and securing.

[0100] Specifically, the wrapping device secures the cargo with high-strength plastic film, featuring low material cost, simple operation, and effective securing. This spiral, layer-by-layer securing relies on the precise coordination of the wrapping device and the descending motion of the palletizing and packaging station 42: After a layer of cargo is palletized, the wrapping device begins wrapping that layer, while the palletizing and packaging station 42 descends simultaneously. These two synchronized movements form a spiral wrapping trajectory. This spiral wrapping not only secures each layer of cargo tightly but also effectively connects the different layers to form a unified, fixed structure. This layer-by-layer securing method ensures that each layer of cargo possesses a stable structural strength before it bears the weight of the upper layer, preventing structural deformation caused by weight pressure.

[0101] In one specific embodiment, when stacking a 3.0-meter-high pallet of aviation cargo, six layers are required, each approximately 50 centimeters high. Traditional wrapping methods require wrapping after all cargo has been palletized. This not only takes a long time to secure, but also can cause deformation of the bottom layer due to excessive pressure. However, with the spiral layer-by-layer wrapping method, the wrapping device immediately begins wrapping after the first layer of cargo is completed. The stacking and packaging station 42 simultaneously descends 50 centimeters, forming multiple spiral wrapping tracks during its descent to tightly wrap the first layer of cargo. The second layer is then stacked, and spiral wrapping is repeated again, and so on, until the entire pallet is stacked and secured. Throughout this process, securing and stacking operations occur simultaneously, eliminating any additional time. The resulting fixed structure exhibits a three-dimensional spiral shape. By utilizing the stacking and packaging station 42's upward movement, the fixing device 45 coordinates the reverse wrapping action in the height direction, achieving 100% wrap coverage. This method improves the securing strength by 60% compared to traditional methods, enabling it to withstand the shock and vibration of transportation.

[0102] Traditionally, cargo securing has typically involved overall packaging, such as wrapping the entire pallet with plastic film, strapping tape, or shrink film after palletizing. While relatively simple to operate, this approach has significant technical drawbacks: First, the timing of securing is inappropriate; if securing is performed only after palletizing, the underlying cargo may have already deformed. Second, the securing effect is limited; the overall packaging often only addresses the external surface, while the internal structure lacks sufficient connection strength. Third, operational efficiency is low, requiring additional securing time and extending the overall cycle. Fourth, adaptability is poor; for taller pallets, the difficulty and effectiveness of overall securing are reduced.

[0103] In the embodiments of the present invention, the use of a spiral layer-by-layer fixing mechanism of a film wrapping device effectively solves the technical problems of traditional fixing methods. The application of the film wrapping device provides an efficient and economical fixing method. The use of plastic film is not only low-cost, but also has good toughness and wrapping properties. The design of the descending and ascending action of the stacking and packaging position 42 realizes the synchronization of fixing and stacking operations, greatly improving work efficiency. The spiral layer-by-layer fixing method forms a three-dimensional fixing structure, and the fixing strength far exceeds that of traditional flat fixing. More importantly, this fixing method can adapt to various heights and complexities of stacking types, whether it is a simple regular stacking type or a complex variable cross-section stacking type, and can achieve a good fixing effect. The application of spiral layer-by-layer fixing technology not only improves the quality and efficiency of cargo fixing, but also lays a technical foundation for the promotion of automated stacking systems in applications requiring higher stability.

[0104] In some embodiments, the shaping enclosure device 44 has a variable cross-section setting, which can adapt to different stacking requirements by adjusting the enclosure shape.

[0105] In this invention, the variable cross-section of the shaping enclosure device 44, which can be adjusted to accommodate different pallet configurations, allows the palletizing system to flexibly adapt to diverse pallet configurations and optimize space utilization. This variable cross-section shaping enclosure device 44 overcomes the limitations of traditional fixed-size enclosures, dynamically adjusting the enclosure's shape and size based on different carrier specifications and cargo characteristics, providing technical support for the implementation of various complex pallet configurations. This design is particularly suitable for applications requiring the handling of multiple carrier specifications or the implementation of variable cross-section palletizing.

[0106] Specifically, the variable-section shaping enclosure device 44 can achieve multi-dimensional adjustment of the enclosure shape through modular enclosure units and flexible adjustment mechanisms. The shaping enclosure device 44 can adjust its cross-sectional area according to the requirements of the pallet type, adapting to different size requirements from small packages to large goods; the geometric shape of the enclosure can be adjusted from a standard rectangle to a special shaped cross-section; the enclosure size can be dynamically adjusted during the palletizing process to meet the palletizing requirements of variable-section pallets. The ability to adjust the shape of the enclosure enables the system to adapt to various carrier specifications commonly used in air transportation, such as pallets of different sizes, containers of special shapes, etc., and it can also optimize the pallet design according to the characteristics of the cargo, thereby improving space utilization and load efficiency.

[0107] In a specific embodiment, when handling the palletizing task of adapting to a variety of carriers (pallets) in air cargo, the system needs to handle the common 318cm×244(122)cm×192(300)cm chamfered rectangular stacking type and the special 606cm×244cm×163cm rectangular stacking type. The traditional fixed shaping enclosure device 44 can only adapt to a specific carrier (pallet) specification. For carriers (pallets) of different specifications, the entire set of enclosure equipment needs to be replaced, which is costly and inefficient. After adopting the variable cross-section shaping enclosure device 44, the system can flexibly adapt to the requirements of different carriers (pallets): for 318cm×244cm pallets, the shaping enclosure device 44 is adjusted to the corresponding rectangular cross-section; for large 606cm×244m pallets, the shaping enclosure device 44 is adjusted to the corresponding cross-section. In some special cases, for stacks with a trapezoidal longitudinal section, variable cross-section stacking can also be achieved. The shaping enclosure device 44 adjusts the length and angle of each side to form a trapezoidal cross-section that matches the target stack. That is, the bottom layer adopts a larger cross-sectional area to obtain better stability, and the upper layer adopts a smaller cross-sectional area to adapt to the shape requirements of the aircraft: for a chamfered rectangular container pallet of 318cm×244(122)cm×192(300)cm, the bottom is stacked with a larger size of 318cm×244cm, and the shaping enclosure device 44 can gradually shrink to a smaller size of 318cm×122cm at the top above 192cm. This flexibility allows the same set of equipment to handle a variety of different stacking requirements, and the equipment utilization rate and economy are significantly improved.

[0108] In the embodiment of the present invention, the limitations of traditional fixed enclosures are effectively solved by adopting the innovative design of the variable-section shaping enclosure device 44. The variable-section setting enables the shaping enclosure device 44 to be flexibly adjusted according to actual needs, greatly expanding the scope of application of the equipment; the ability to adjust the shape of the enclosure supports various complex stacking requirements; the function of adapting to different stacking requirements provides technical support for the deployment of the system in diverse application scenarios. More importantly, the variable-section shaping enclosure device 44 provides a technical means for optimizing space utilization. By accurately matching the carrier size and cargo characteristics, higher space utilization efficiency and better load distribution can be achieved. This technological innovation not only improves the flexibility and economy of the palletizing system, but also lays a technical foundation for achieving more intelligent stacking optimization. It is an important technological advancement that promotes the development of automated palletizing technology to a higher level.

[0109] In some embodiments, the stacking and packaging position 42 is fixed, and the shaping enclosure device 44 and the fixing device 45 can be raised and lowered.

[0110] In this invention, by providing a fixed stacking and packaging station 42 and employing a retractable shaping enclosure device 44 and a fixed-shape device 45, flexibility in equipment configuration and cost control are achieved. This differentiated lifting configuration is optimized based on the functional characteristics and operational requirements of each device, ensuring the implementation of key functions while controlling system complexity and costs. The fixed stacking and packaging station 42 provides a stable and reliable carrier platform, while the retractable shaping enclosure device 44 and fixed-shape device 45 provide the necessary flexibility for dynamic operations.

[0111] Specifically, the fixed design of the stacking and packaging position 42 takes into account the convenience of on-site deployment and the stability requirements of the carrier. The fixed setting avoids the mechanical complexity of foundation pit construction and the carrying platform, improves the reliability of the system and reduces investment and maintenance costs. The carrier needs to bear the weight of the goods and the operating force of the handling equipment during the stacking process, and the fixed design can provide more stable support. The liftable setting of the shaping enclosure device 44 enables it to adjust its height in line with the progress of stacking, providing a bottom enclosure at the beginning of stacking, and gradually rising as the stacking height increases, always providing effective boundary control for the stacking operation. The liftable setting of the solid device 45 enables it to perform film wrapping operations at an appropriate height, and through coordinated actions with the shaping enclosure device 44, the process requirements of layer-by-layer fixation are achieved.

[0112] In some embodiments, the palletizing and packaging subsystem 4 implements palletizing and packaging according to a cyclic process of enclosure positioning, layered palletizing, platform lowering, and layer-by-layer fixing.

[0113] In the present invention, the palletizing and packaging subsystem 4 implements a cyclical process of palletizing and packaging, including enclosure positioning, layered palletizing, platform lowering, and layer-by-layer securing. This establishes a standardized and normalized automated palletizing process, achieving consistent quality assurance and significantly improved operational efficiency. This cyclical process breaks down the complex palletizing and packaging process into four standardized steps, each with clear technical requirements and quality standards. This cyclical execution enables the high-quality construction of multi-layer pallets. The cyclical process design ensures that each layer of palletizing is performed under the same process conditions, ensuring consistent quality across the entire pallet.

[0114] Specifically, as the first step in each cycle, fence positioning sets precise boundary constraints for the upcoming palletizing layer through the shaping fence device 44 to ensure the accuracy of the goods placement; as the second step, layered palletizing places all the goods on that layer in the predetermined position and order according to the actual palletizing plan; as the third step, the platform descends, preparing for the next layer of palletizing through the descending action of the palletizing and packaging position 42, while also creating conditions for the fixing operation; as the fourth step, layer-by-layer fixing fixes the goods on the layer that has just been palletized to ensure its structural stability. These four steps form a complete process cycle, and through repeated execution, a multi-layer pallet is constructed. The standardized design of the cyclic process ensures the quality of the palletizing of each layer, avoiding quality differences caused by inconsistent operations.

[0115] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate, and the components shown as units may or may not be physical units. That is, they may be located in one place or distributed across multiple network units. Some or all of the modules may be selected based on actual needs to achieve the objectives of the present embodiment. Persons of ordinary skill in the art will be able to understand and implement the present invention without inventive effort.

[0116] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. An automated mixed palletizing and packaging system, characterized in that: include: Cargo transport unit (1); A cargo identification system (2) is used to obtain cargo information on the cargo conveying unit (1), construct a three-dimensional model based on the cargo information, and construct a virtual palletizing plan based on the three-dimensional model; Intelligent cycle identification and sorting unit (3), comprising: a circulating conveying unit (31), wherein an input end of the circulating conveying unit (31) is connected to the cargo conveying unit (1); A sorting unit (32) is used to identify the goods to be palletized on the circulating conveying unit (31) and adjust the placement order and direction of the goods to be palletized according to the virtual palletizing plan; A palletizing and packaging subsystem (4), provided at the output end of the circulating conveying unit (31), is used for palletizing, shaping, solidifying, and packaging goods; A cargo carrier conveying unit (5) is connected to the palletizing and packing subsystem (4) and is used to convey the carrier to the palletizing and packing subsystem (4).

2. The automated mixed palletizing and packaging system according to claim 1, characterized in that: The sorting unit (32) is also used to review the goods to be palletized on the circulating conveying unit (31), and to form a layer-by-layer physical palletizing plan based on a single target pallet type; The palletizing and packing subsystem (4) performs automated palletizing and packing of goods according to the physical palletizing scheme.

3. The automated mixed palletizing and packaging system according to claim 1, characterized in that: The cargo information acquired by the cargo identification system (2) includes at least one of size, weight, shape and cargo identification information.

4. The automated mixed palletizing and packaging system according to claim 1, characterized in that: The virtual palletizing scheme is generated by calculation based on a three-dimensional model of the goods, and includes a theoretical scheme for the combination form, stacking sequence, stacking direction and stacking position of the goods.

5. The automated mixed palletizing and packaging system according to any one of claims 1 to 4, characterized in that: The palletizing and packaging subsystem (4) includes: A palletizing temporary storage location (41) for temporarily storing goods to be palletized from the intelligent cycle identification sorting unit (3); A stacking and packing position (42) for carrying a carrier and stacking goods thereon; The transport mechanism (43) is used to transport the goods from the palletizing temporary storage position (41) to the palletizing and packaging position (42) and perform layered palletizing.

6. The automated mixed palletizing and packaging system according to claim 5, characterized in that: The stacking and packaging position (42) can be raised and lowered to cooperate with the transport mechanism (43) to perform layered stacking operations.

7. The automated mixed palletizing and packaging system according to claim 6, characterized in that: The palletizing and packaging subsystem (4) further comprises a shaping enclosure device (44), which is arranged around the palletizing and packaging position (42) and is used to control the palletizing boundary according to the target pallet shape.

8. The automated mixed palletizing and packaging system according to claim 7, characterized in that: The palletizing and packing subsystem (4) further includes a fixing device (45) for fixing the goods layer by layer during the palletizing process.

9. The automated mixed palletizing and packaging system according to claim 8, characterized in that: The cargo carrier conveying unit (5) comprises a first conveying unit (51) and a second conveying unit (52), wherein the output end of the first conveying unit (51) is connected to the palletizing and packaging subsystem (4), and the input end of the second conveying unit (52) is connected to the palletizing and packaging subsystem (4); and further comprises: an acceptance system (6) for inspecting the goods on the second conveying unit (52); The loading system (7) is arranged at the output end of the second conveying unit (52) and is used for loading and processing goods.

10. The automated mixed palletizing and packaging system according to claim 1, characterized in that: The cargo conveying unit (1) comprises a regular cargo inlet (11) and a special-shaped cargo inlet (12).

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