Automated mixed palletizing system

Abstract

The present application relates to freight stacking and packing technology field, especially to an automatic mixed stacking and packing system, the automatic mixed stacking and packing system provided by the present application comprises: a cargo conveying unit; a cargo identification system for obtaining 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; an intelligent circulating identification and sorting unit, comprising: a circulating conveying unit, the input end of the circulating conveying unit is connected with the cargo conveying unit; a sorting unit for identifying the to-be-stacked cargo on the circulating conveying unit and adjusting the placement order and direction of the to-be-stacked cargo according to the virtual stacking scheme; a stacking and packing subsystem arranged at the output end of the circulating conveying unit for stacking, shaping, solidifying and packing the cargo; and a cargo carrier conveying unit connected with the stacking and packing subsystem, the whole system can realize full-automatic mixed stacking and packing of various specifications of cargo, and improve the operation efficiency.

Description

Technical Field

[0001] This invention relates to the field of freight palletizing and packaging technology, and in particular to an automated hybrid palletizing and packaging system. Background Technology

[0002] Cargo palletizing is widely used in freight, warehousing and logistics. In air freight, cargo palletizing and packing (often called "palletizing") is a crucial step, requiring the precise stacking of goods onto air cargo pallets to achieve maximum space utilization and safe transportation conditions.

[0003] Currently, palletizing in air freight primarily relies on manual labor. Workers first check the cargo information, then rely on their experience to determine the placement method, manually stacking the goods one by one onto the pallets, and finally securing them. While this traditional manual palletizing and packing method offers some flexibility, it suffers from serious technical drawbacks:

[0004] Inefficient: Manual palletizing typically takes 2-4 hours to complete the stacking of a standard container pallet, and the operating speed is far from meeting the high efficiency requirements of modern air freight.

[0005] Inconsistent quality: The quality of manual pattern making depends entirely on the experience level of the workers. The results of different workers may vary significantly, affecting space utilization and transportation safety.

[0006] High labor intensity: The board-making operation requires long hours of heavy physical labor, which can easily lead to worker fatigue, affecting the quality of the work and posing safety risks. In addition, the labor shortage and costs continue to rise.

[0007] Lack of standardization: The lack of unified operating standards and quality control systems makes it difficult to establish standardized operating procedures;

[0008] Limited optimization capabilities: It is difficult for humans to consider numerous constraints simultaneously and find the globally optimal palletizing scheme, resulting in low space utilization.

[0009] To improve the automation level of palletizing and packing operations, the industry has developed a number of automated devices and systems. Existing automated palletizing systems can handle standardized goods, but these devices are mainly suitable for single types of goods with regular shapes and standard dimensions, and lack effective handling capabilities for the diverse and irregularly shaped goods commonly found in air freight. Summary of the Invention

[0010] This invention provides an automated mixed palletizing and packaging system that can realize fully automated mixed palletizing and packaging of goods of various specifications, thereby improving operational efficiency.

[0011] In a first aspect, embodiments of the present invention provide an automated hybrid palletizing and packaging system, comprising: a goods conveying unit; a goods identification system for acquiring goods information on the goods conveying unit, constructing a three-dimensional model based on the goods information, and constructing a virtual palletizing scheme based on the three-dimensional model; an intelligent cyclic identification and sorting unit, comprising: a cyclic conveying unit, the input end of which is connected to the goods conveying unit; a sorting unit for identifying goods to be palletized on the cyclic conveying unit and adjusting the placement order and direction of the goods to be palletized according to the virtual palletizing scheme; a palletizing and packaging subsystem, located at the output end of the cyclic conveying unit, for palletizing, shaping, fixing, and packaging the goods; and a goods carrier conveying unit, connected to the palletizing and packaging subsystem, for conveying carriers to the palletizing and packaging subsystem.

[0012] In one possible implementation, the sorting unit is also used to verify the goods to be palletized on the cyclic conveying unit and form a layer-by-layer physical palletizing scheme based on a single target pallet type; wherein, the palletizing and packaging subsystem performs automated palletizing and packaging of goods according to the physical palletizing scheme.

[0013] In one possible implementation, the cargo identification system acquires cargo information including at least one of size, weight, shape, and cargo identification information.

[0014] In one possible implementation, the virtual palletizing scheme is generated through calculation based on a three-dimensional model of the goods, including a theoretical scheme for the combination of goods, stacking order, stacking direction, and stacking position.

[0015] In one possible implementation, the palletizing and packing subsystem includes: a palletizing storage location for temporarily storing goods to be palletized from the intelligent cyclic identification and sorting unit; a palletizing and packing location for carrying a carrier and placing goods on it; and a handling mechanism for moving the goods from the palletizing storage location to the palletizing and packing location and performing layered palletizing.

[0016] In one possible implementation, the palletizing and packaging position can be raised and lowered to cooperate with the handling mechanism for layered palletizing operations.

[0017] In one possible implementation, the palletizing and packing subsystem also includes a shaping barrier device arranged around the palletizing and packing position to control the palletizing boundary according to the target pallet shape.

[0018] In one possible implementation, the palletizing and packing subsystem also includes a securing device for securing the goods layer by layer during the palletizing process.

[0019] In one possible implementation, the cargo carrier conveying unit includes a first conveying unit and a second conveying unit, with the output end of the first conveying unit connected to the palletizing and packing subsystem and the input end of the second conveying unit connected to the palletizing and packing subsystem.

[0020] In one possible implementation, it also includes: an acceptance system for inspecting the goods on the second conveying unit; and an loading system located at the output end of the second conveying unit for loading the goods onto the machine.

[0021] In one possible implementation, the cargo transport unit includes a regular cargo inlet and an irregular cargo inlet.

[0022] In one possible implementation, the handling mechanism includes: a truss structure; and various lifting claws mounted on the truss structure, capable of automatically selecting the appropriate lifting claw based on the characteristics of the goods.

[0023] In one possible implementation, the handling mechanism is a mobile robotic arm device.

[0024] In one possible implementation, the fixing device is a film wrapping device, which works in conjunction with the descending action of the palletizing and packaging position to achieve spiral layer-by-layer fixing.

[0025] In one possible implementation, the shaped fencing device has a variable cross-section, which can adapt to different stacking requirements by adjusting the shape of the fencing.

[0026] In one possible implementation, the palletizing and packaging position is fixed, while the shaping enclosure device and the fixing device can be raised and lowered.

[0027] In one possible implementation, the palletizing and packaging subsystem implements palletizing and packaging through a cyclical process of enclosure positioning, layered palletizing, platform descent, and layer-by-layer fixing.

[0028] The automated hybrid palletizing and packaging system provided by this invention uses a cargo conveying unit to transport goods to a cargo identification system for information collection. The cargo identification system acquires key information such as the size, weight, and shape of the goods through various sensors and uses this information to construct a three-dimensional digital model of the goods. The intelligent cyclic identification and sorting unit provides multiple opportunities for cargo adjustment via a cyclic conveying unit. The sorting unit can identify the actual state of the goods on the cyclic conveying unit and precisely adjust the placement order and orientation of the goods according to a virtual palletizing scheme. The palletizing and packaging subsystem receives the sorted and adjusted goods and performs the actual palletizing and packaging operation according to the optimized scheme. The cargo carrier conveying unit is responsible for the transport of the carriers, ensuring smooth logistics connections throughout the system together with other conveying units. Through the system integration of the cargo conveying unit, cargo identification system, intelligent cyclic 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. Moreover, the system adopts a technical path of using a virtual palletizing scheme to guide the actual palletizing operation, fundamentally solving the technical problems of low efficiency and unstable quality in traditional manual palletizing. The entire system constructs a digital representation of goods through 3D modeling technology, generates a theoretically optimal virtual palletizing scheme based on digital information, and finally transforms the theoretical scheme into executable actual operation instructions through intelligent sorting units, realizing a complete technology chain from information collection to automated execution. Attached Figure Description

[0029] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0030] Figure 1 This is a top view of an automated hybrid palletizing and packaging system provided by the present invention.

[0031] Figure 2 This is a schematic diagram of the structure connecting a palletizing and packaging subsystem, a circulating conveying unit, and a cargo carrier conveying unit provided by the present invention.

[0032] Figure 3 This is a schematic diagram of the planar structure connecting a palletizing and packaging subsystem and a cargo carrier conveying unit provided by the present invention.

[0033] Figure label:

[0034] 1. Cargo conveying unit; 11. Regular cargo entrance; 12. Irregular cargo entrance;

[0035] 2. Cargo identification system;

[0036] 3. Intelligent cyclic identification and sorting unit; 31. Circulating conveying unit; 32. Sorting unit;

[0037] 4. Palletizing and Packaging Subsystem; 41. Palletizing Temporary Storage Location; 42. Palletizing and Packaging Location; 43. Handling Mechanism; 431. Truss Structure; 432. Lifting Claws; 44. Shaped Enclosure Device; 45. Fixing Device;

[0038] 5. Cargo transport unit; 51. First transport unit; 52. Second transport unit; 53. Transport vehicle;

[0039] 6. System acceptance;

[0040] 7. System installation. Detailed Implementation

[0041] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0042] The following is combined Figure 1-3 This invention provides an automated hybrid palletizing and packaging system, comprising: a cargo conveying unit 1, a cargo identification system 2, an intelligent cyclic identification and sorting unit 3, a palletizing and packaging subsystem 4, and a cargo carrier conveying unit 5, wherein:

[0043] The cargo identification system 2 is used to acquire cargo information on the cargo conveying unit 1; construct a three-dimensional model based on the cargo information, and construct a virtual palletizing scheme based on the three-dimensional model.

[0044] The intelligent circular identification and sorting unit 3 includes: a circular conveying unit 31, the input end of which is connected to the goods conveying unit 1; and a sorting unit 32, which is used to identify the goods to be stacked on the circular conveying unit 31 and adjust the placement order and direction of the goods to be stacked according to the virtual stacking scheme.

[0045] The palletizing and packaging subsystem 4 is located at the output end of the circulating conveyor unit 31 and is used for palletizing and packaging goods.

[0046] The cargo carrier conveying unit 5 is connected to the palletizing and packing subsystem 4 and is used to convey the carrier 53 to the palletizing and packing subsystem 4.

[0047] In this invention, the integration of a cargo conveying unit 1, a cargo identification system 2, an intelligent cyclic identification and sorting unit 3, a palletizing and packaging subsystem 4, and a cargo carrier conveying unit 5 achieves the beneficial effect of fully automated palletizing throughout the air cargo process. This system employs a virtual palletizing scheme to guide actual palletizing operations, fundamentally solving the technical problems of low efficiency and unstable quality associated with 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, and finally transforms the theoretical scheme into executable operational instructions through an intelligent sorting unit, realizing a complete technical chain from information collection to automated execution.

[0048] Specifically, the cargo conveying unit 1 is responsible for transporting the goods to be processed to the cargo identification system 2 for information collection. The cargo identification system 2 acquires key information such as the size, weight, and shape of the goods through various sensors and uses this information to construct a three-dimensional digital model of the goods. The circular conveying unit 31 in the intelligent circular identification and sorting unit 3 provides multiple opportunities for the goods to be adjusted. The sorting unit 32 can identify the actual state of the goods on the circular conveying unit and make precise adjustments to the placement order and orientation of the goods according to the virtual palletizing scheme. The palletizing and packaging subsystem 4 receives the sorted and adjusted goods and performs the actual palletizing and packaging operation according to the optimized scheme. 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.

[0049] In one specific embodiment, when handling mixed cargo in air freight, including bags of different sizes, irregularly shaped goods, and standard pallets, traditional manual palletizing requires experienced workers to adjust the placement of each item according to its characteristics. This process not only takes several hours but also relies entirely on the worker's experience level, easily leading to problems such as low space utilization and uneven center of gravity distribution. However, with the automated mixed palletizing and packaging system of this invention, the cargo identification system 2 can complete the information collection and 3D modeling of all cargo within seconds, and the generation of a virtual palletizing scheme takes only a few minutes. The intelligent cyclic identification and sorting unit 3, through multiple rounds of cyclic adjustments, can adjust the cargo to its optimal state. The entire palletizing and packaging process can be completed within 30 minutes, improving efficiency by 4-6 times compared to manual operation. More importantly, the palletizing scheme generated by the automated system achieves theoretically optimal levels in terms of space utilization and center of gravity distribution, and the consistency and stability of palletizing quality far surpass that of manual operation.

[0050] In related technologies, traditional air cargo palletizing mainly relies on manual labor. Workers need to estimate the size, weight, and other physical characteristics of the cargo based on their personal experience, and then judge how to place the cargo to achieve optimal space utilization and load distribution. While this method has a certain degree of flexibility and can handle various irregularly shaped cargoes and special situations, it has obvious technical drawbacks: First, the work efficiency is extremely low, with manual palletizing of a standard container typically taking 2-4 hours; second, the quality is unstable, with varying levels of experience among workers leading to inconsistent palletizing quality; third, the labor intensity is high, with prolonged heavy physical labor easily causing worker fatigue, which in turn affects work quality and safety; and fourth, standardization is impossible, lacking a unified work standard and quality control system.

[0051] In this embodiment of the invention, the construction of a complete automated hybrid palletizing and packaging system completely transforms the traditional operating mode. The application of the cargo identification system 2 makes cargo information acquisition fast, accurate, and standardized, while 3D modeling technology provides a reliable data foundation for subsequent palletizing scheme generation. The introduction of virtual palletizing schemes realizes a shift from experience-based reliance to scientific computing; theoretically optimal palletizing schemes can be obtained through algorithm optimization. The design of the intelligent cyclic identification and sorting unit 3 solves the problem of conversion between theoretical schemes and actual execution, ensuring the feasibility of the scheme through a cyclic adjustment mechanism. The automated execution capability of the palletizing and packaging subsystem 4 eliminates the instability factors of manual operations, achieving efficient, accurate, and consistent palletizing operations. The integrated design of the entire system not only significantly improves operational efficiency but, more importantly, establishes standardized operating procedures, laying a technological foundation for the modernization of air cargo palletizing operations.

[0052] In some embodiments, the sorting unit 32 is also used to verify the goods to be palletized on the cyclic conveying unit 31 and form a layer-by-layer physical palletizing scheme based on a single target pallet type; wherein, the palletizing and packaging subsystem 4 performs automated palletizing and packaging of goods according to the physical palletizing scheme.

[0053] In this invention, the beneficial effect of transforming a theoretical virtual solution into a practically executable solution is achieved through the verification function of the sorting unit 32 and the generation of the physical palletizing scheme. The sorting unit 32 is not only responsible for adjusting the position and orientation of the goods, but more importantly, it undertakes the function of scheme verification and optimization. By verifying the goods to be palletized on the cyclic conveying unit 31, deviations between the virtual palletizing scheme and the actual situation can be identified and corrected, ensuring that the final generated physical palletizing scheme has high operability and reliability. This dual-scheme mechanism fundamentally solves the contradiction between theoretical optimality and practical feasibility, achieving a perfect combination of intelligent decision-making and actual execution.

[0054] Specifically, the verification function of sorting unit 32 verifies whether the goods have been adjusted to the required position according to the virtual palletizing scheme by re-identifying and confirming the status of the goods on the circulating conveyor unit 31. During the verification process, the system checks whether the actual position, orientation, and status of the goods are consistent with the information in the virtual scheme. If a deviation is found, sorting unit 32 will sound an alarm and make secondary adjustments. The generation of the physical palletizing scheme is a further optimization based on the virtual palletizing scheme, combined with factors such as the actual status of the goods, equipment capacity, and environmental conditions. It organizes the palletizing operation sequence layer by layer, taking a single target pallet type as the unit. After receiving the physical palletizing scheme, the palletizing and packaging subsystem 4 can execute automated palletizing and packaging operations according to a clear instruction sequence, avoiding uncertainties in the execution process.

[0055] In related technologies, existing automated palletizing systems typically employ a single palletizing scheme generation mechanism, which directly generates and executes palletizing instructions based on cargo information. While this approach is simple and efficient, it has significant technical drawbacks. First, it lacks a scheme verification mechanism. If there are errors in cargo information recognition or if the cargo shifts during transport, directly executing the original scheme may lead to palletizing failure. Second, it lacks adaptability and cannot cope with dynamic changes in cargo status. Third, it has poor error handling capabilities; once an anomaly occurs, the system often has to stop and await manual intervention.

[0056] In this embodiment of the invention, a dual-guarantee system is established by introducing the verification function of the sorting unit 32 and the generation mechanism of the physical palletizing scheme. The verification function of the sorting unit 32 is equivalent to adding a quality checkpoint before palletizing, ensuring the accuracy and feasibility of the palletizing scheme by reconfirming the actual condition of the goods. The generation of the physical palletizing scheme is based on the virtual scheme and optimized for practicality, maintaining the guiding role of theoretical optimization while fully considering the constraints of actual execution. The layer-by-layer organization based on a single target pallet type makes the palletizing operation more orderly and controllable, reducing the complexity and error rate during execution. 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 achieving truly stable and reliable automated palletizing operations.

[0057] 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.

[0058] 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 scheme generation, ensuring that the entire automated hybrid palletizing and packaging system can accurately understand and process various types of cargo. By acquiring multiple attribute information of the cargo, the system can build a more accurate cargo model, thereby generating a more reasonable and feasible palletizing scheme.

[0059] Specifically, dimensional information includes the geometric parameters of the goods, such as length, width, and height, which form the basis for spatial planning and palletizing arrangement; 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, whether there are protrusions, surface flatness, and packaging type, which affects the palletizability and stability of the goods; and goods identification information includes business information such as the goods' number, category, attributes, special requirements, place of origin, destination, and time, which helps the system make more intelligent palletizing decisions. The goods identification system 2, by integrating multiple sensors and identification technologies, can simultaneously acquire this information from different dimensions, establishing a complete digital profile for the goods.

[0060] In one specific embodiment, when processing mixed cargo in a batch of air freight, the cargo identification system 2 encountered various cargo types, including standard cartons, cylindrical cargo, irregularly shaped bags, and palletized cargo. For standard cartons, the system primarily acquires their precise dimensions and weight information; for cylindrical cargo, in addition to acquiring basic dimensions, the system specifically identifies their circular cross-sectional features to consider rolling protection during palletizing; for irregularly shaped bags, the system determines their flexibility through shape recognition and arranges them in a more stable position during palletizing; for palletized cargo, the system identifies their special requirements through cargo identification information to ensure appropriate protection and placement during palletizing. By acquiring this multi-dimensional information, the virtual palletizing scheme generated by the system fully considers the characteristics of each type of cargo, ultimately achieving a safe, stable, and efficient palletizing effect.

[0061] In related technologies, traditional cargo identification systems often only focus on basic cargo identification information, failing to comprehensively acquire information on other dimensions such as size, weight, and shape. This single-dimensional information acquisition method has obvious limitations: First, the information is incomplete; cargo identification information alone cannot fully understand the specific physical characteristics of the cargo. Second, there is insufficient decision-making basis; lacking sufficient information support, it is difficult to generate the optimal palletizing scheme. Third, it has poor adaptability and cannot effectively handle cargo with various special shapes and requirements. Fourth, there are security risks; insufficient consideration of key factors such as weight distribution and stability may lead to palletizing safety hazards.

[0062] In this embodiment of the invention, a multi-dimensional information acquisition mechanism significantly improves the comprehensiveness and accuracy of cargo identification. Acquiring dimensional information provides precise geometric constraints for spatial planning; acquiring weight information enables the system to rationally plan load distribution, avoiding problems such as top-heavy loads or localized overloading; acquiring morphological information allows the system to identify and process cargo with various special shapes, improving the system's adaptability; acquiring cargo identification information enables the system to understand the business attributes and special requirements of the cargo, achieving 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. This allows the entire automated hybrid palletizing and packaging system to cope with more complex and diverse cargo handling needs, laying a solid technical foundation for achieving truly intelligent automated packaging for air cargo.

[0063] In some embodiments, 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 order, stacking direction and stacking position of the goods.

[0064] In this invention, the cargo identification system includes an algorithm system. Based on a 3D model of the cargo, the algorithm system calculates and generates a theoretical virtual palletizing scheme that includes cargo combination form, stacking order, stacking direction, and stacking position, achieving the beneficial effects of scientific and standardized palletizing planning. The generation process of the virtual palletizing scheme employs computer algorithm optimization technology, which can quickly calculate the theoretically optimal palletizing configuration while considering various factors such as spatial constraints, weight distribution, and stability requirements. This computational scheme generation method completely changes the traditional palletizing planning mode that relies on experience-based judgment, realizing a shift from subjective experience to objective science.

[0065] Specifically, the generation process of the virtual palletizing scheme first involves spatial analysis based on a 3D model of the goods, using computer geometric algorithms to determine the spatial relationships and combination possibilities between different goods. Determining the combination of goods involves effectively combining goods of different sizes and shapes to achieve optimal space utilization. Planning the stacking order requires considering factors such as the weight, stability, and fragility of the goods, ensuring that heavy goods are placed 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 goods in 3D space to ensure no interference between goods while maintaining the stability of the overall structure. The entire scheme generation process is based entirely on mathematical calculations and logical reasoning, exhibiting a high degree of scientific rigor and repeatability.

[0066] In one specific embodiment, when processing the palletizing task of an air cargo container, the system needs to handle 15 items of different sizes, including 5 large cartons, 6 medium-sized packages, and 4 small precision equipment packages. Traditional manual planning may require experienced workers to spend 1-2 hours on trial placement and adjustments, and the plans of different workers may vary significantly. In contrast, the digital palletizing scheme is generated in just tens of seconds. The system uses 3D model analysis to determine the optimal cargo combination: 5 large cartons as the bottom layer, 6 medium-sized packages in the middle layer, and 4 small precision equipment packages on the top layer; the stacking order follows the principle of from heaviest to lightest and from largest to smallest; the stacking position is precisely calculated to ensure a centered center of gravity and structural stability. The final generated virtual palletizing scheme 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.

[0067] In related technologies, traditional palletizing scheme planning mainly relies on human experience, with workers making subjective judgments and placing items based on the appearance characteristics of the goods and their personal experience. This approach has significant technical limitations: First, it is highly subjective, with different workers having different levels of experience and judgment standards, resulting in inconsistent scheme quality; second, it is inefficient, as manual planning requires a lot of time for thinking and trial and error; third, it has limited optimization potential, as the large number of goods in a single order makes it difficult for humans to simultaneously consider all constraints and find the globally optimal solution; and fourth, it has low standardization, lacking unified planning standards and evaluation systems.

[0068] In this embodiment of the invention, a computational generation mechanism based on a 3D model is introduced to achieve the scientific and standardized planning of palletizing schemes. Analysis based on the 3D model ensures the geometric accuracy of the scheme, avoiding errors that may arise from manual estimation; the computational generation method makes scheme planning fast and efficient, significantly shortening planning time; the complete information including cargo combination form, stacking order, and stacking position makes the scheme highly operable; the positioning of the theoretical scheme allows this scheme to provide scientific guidance for subsequent practical adjustments. More importantly, this computational generation method has high consistency and repeatability; the same cargo input will inevitably produce the same optimal scheme, laying the foundation for the standardization of palletizing operations. The introduction of virtual palletizing schemes not only improves the efficiency and quality of palletizing planning, but more importantly, establishes a scientific decision-making mechanism, providing key technical support for realizing a truly intelligent automated palletizing system.

[0069] In some embodiments, the palletizing and packaging subsystem 4 includes: a palletizing temporary storage position 41 for temporarily storing goods to be palletized from the intelligent cycle identification and sorting unit 3; a palletizing and packaging position 42 for carrying a carrier; and a handling mechanism 43 for transporting goods from the temporary storage position to the palletizing and packaging position 42 and performing layered palletizing.

[0070] In this invention, by setting up a modular configuration of the palletizing storage position 41, the palletizing and packaging position 42, and the handling mechanism 43, the efficient collaboration and flexible operation of the palletizing and packaging subsystem 4 are achieved. This modular design decomposes the complex palletizing and packaging process into mutually coordinated but functionally independent operating units, which not only improves the system's operational efficiency but also enhances its maintainability and scalability. The buffering effect of the palletizing 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 achieves high-precision transfer of goods from temporary storage to final palletizing.

[0071] Specifically, the palletizing temporary storage location 41 serves as a temporary storage area for goods from the intelligent circular identification and sorting unit 3. It can accommodate sorted and adjusted goods awaiting palletizing, providing a stable supply of goods for subsequent palletizing operations. The palletizing and packaging location 42 is specifically designed to carry the goods carrier, providing a stable working platform for palletizing operations. Its design must consider the size and load-bearing requirements of the carrier. The handling mechanism 43, as the key equipment connecting the temporary storage location and the palletizing and packaging location 42, is responsible for accurately transporting the goods from the temporary storage location to the designated position in the palletizing and packaging location 42, and performing layered palletizing operations according to the physical palletizing plan. The three functional modules work together to form a complete palletizing and packaging operation process. Each module focuses on a specific function, ensuring both the professionalism of the operation and the overall efficiency.

[0072] In one specific embodiment, when processing a batch of goods that need to be palletized onto an aviation container, the intelligent cyclic identification and sorting unit 3 completes the adjustment and transport of goods to the palletizing temporary storage position 41 at a rate of 6 pieces per minute. The palletizing temporary storage position 41 can accommodate 12 pieces of goods at the same time, providing sufficient operational buffer for the handling mechanism 43. Following the instructions of the physical palletizing scheme, the handling mechanism 43 transports goods from the palletizing temporary storage position 41 to the palletizing and packaging position 42 for precise placement at a rate of 4 pieces per minute. Due to the speed difference, without the buffer of the palletizing temporary storage position 41, the sorting unit 32 may need to wait frequently, or the handling mechanism 43 may face insufficient goods supply. However, with the palletizing temporary storage position 41, the system can effectively balance this speed difference. The sorting unit 32 can continuously deliver goods to the temporary storage position, and the handling mechanism 43 can continuously retrieve goods from the temporary storage position for palletizing, significantly improving the overall system efficiency.

[0073] In related technologies, traditional palletizing systems often use a direct docking method, where goods are directly transferred from the conveyor system to the palletizing location. While this method seems simple, it has significant technical drawbacks. First, it lacks a buffer mechanism, and speed mismatches between upstream and downstream equipment can easily lead to system bottlenecks. Second, it lacks operational flexibility, as handling equipment needs to perform complex operations within a limited space, making it prone to interference. Third, it has low reliability, as problems in any link can affect the operation of the entire system. Fourth, it is difficult to maintain, as the high degree of functional coupling means that equipment maintenance may require stopping the entire system.

[0074] In this embodiment of the invention, the modular design effectively solves the technical problems of traditional methods. The palletizing temporary storage position 41 provides an important buffer function, not only solving the speed matching problem but also providing a time window for the system to handle anomalies. The dedicated design of the palletizing and packaging position 42 ensures that the carrier has a stable working platform, improving palletizing accuracy and quality. The independent design of the handling mechanism 43 allows it to focus on goods handling and precise placement, improving operational efficiency and accuracy. More importantly, this modular design greatly enhances the maintainability of the system; each module can be maintained and upgraded independently without affecting the normal operation of other modules. The workflow of moving goods from the temporary storage position to the palletizing and packaging position 42 and performing layered palletizing ensures both the orderliness of the operation and the precision of the operation, providing a reliable technical guarantee for achieving high-quality automated palletizing and packaging.

[0075] In some embodiments, the palletizing and packaging position 42 can be raised and lowered to cooperate with the handling mechanism 43 for layered palletizing operations.

[0076] In this invention, the adjustable height of the palletizing and packaging position 42, in coordination with the handling mechanism 43, achieves the beneficial effect of efficient and precise layered palletizing operations. The design of the adjustable palletizing and packaging position 42 cleverly solves the problem of working height during multi-layer palletizing. By dynamically adjusting the height of the working platform, the handling mechanism 43 can always perform palletizing operations at the most suitable height, ensuring both operational accuracy and improved efficiency. This lifting and coordinating mechanism also creates conditions for subsequent layer-by-layer fixing operations, making it a key technical feature for achieving automated palletizing and packaging.

[0077] Specifically, the height-adjustable palletizing and packing station 42, through a precise lifting mechanism, can automatically adjust its height according to the progress of the palletizing operation. At the start of palletizing, the packing station is at its highest position, facilitating the placement of the first layer of goods by the handling mechanism 43. After the first layer is completed, the packing station lowers by a preset height, ensuring that the height of the second layer matches the height at which the first layer was completed. The handling mechanism 43 can then continue palletizing the second layer without adjusting its operating height. This process continues until the entire pallet is completed. This design ensures that the operating height of the handling mechanism 43 remains constant, avoiding frequent height adjustments and improving operational efficiency and accuracy. Simultaneously, the height-adjustable design also coordinates with the rhythm of the layered palletizing operation, providing a stable working platform for each layer.

[0078] In one specific embodiment, when palletizing an air cargo stack with a height of 3.0 meters, it needs to be stacked in 5 layers, each layer being approximately 60 centimeters high. Traditional fixed-height palletizing methods require the handling 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 handling mechanism 43 needs to continuously adjust its gripping and placing height, which not only increases the overall size of the equipment but also reduces operational accuracy and efficiency. However, with the design of the liftable palletizing and packing position 42, the working height of the handling mechanism 43 is always maintained at a fixed height of approximately 60 centimeters above the surface of the packing position. After each layer is completed, the packing position automatically lowers by 60 centimeters to prepare for the next layer. This method not only simplifies the control algorithm of the handling mechanism 43 but also significantly improves palletizing accuracy, controlling the placement error of each layer of goods within ±5 millimeters, far exceeding the accuracy level of traditional methods.

[0079] In related technologies, traditional palletizing systems typically employ a fixed-height palletizing platform, requiring the handling equipment to continuously adjust its operating height as the number of palletizing layers increases. This approach has significant technical limitations: First, the overall equipment height is high, necessitating a wide range of height adjustment capabilities for the handling equipment, increasing 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 is often at the equipment's maximum travel, maximizing accuracy errors when palletizing the foundation layer. Only as the palletizing height increases, does the positioning accuracy of the handling equipment improve with the increased rigidity of the equipment. Third, operational efficiency is low, with frequent height adjustments increasing operation time. Fourth, there are stability risks; working at height increases equipment failure and safety risks.

[0080] In this embodiment of the invention, the innovative design of a liftable palletizing and packaging station 42 effectively solves the technical problems of traditional methods. The liftable design shifts the complexity of the palletizing operation from the handling mechanism 43 to the packaging station, and the lifting mechanism is simpler and more reliable than complex robotic arm adjustments. The design for layered palletizing operations in conjunction with the handling mechanism 43 ensures that each layer of palletizing is performed under the same operating conditions, guaranteeing consistent operational accuracy and quality. The handling mechanism 43 does not require extensive height adjustments, simplifying its mechanical structure and control system, and improving the reliability and maintainability of the equipment. More importantly, this design lays the foundation for subsequent layer-by-layer fixing operations. The descent of the liftable palletizing and packaging station 42 can perfectly coordinate with the working rhythm of the fixing device 45, achieving synchronous palletizing and fixing, significantly improving the overall efficiency of the packaging system.

[0081] In some embodiments, the palletizing and packing subsystem 4 further includes a shaping barrier device 44, which is arranged around the palletizing and packing position 42 and is used to adjust the barrier size according to the target pallet shape to control the palletizing boundary.

[0082] In this invention, by setting up a shaping enclosure device 44 around the palletizing and packaging position 42 and adjusting the enclosure size according to the target pallet shape to control the palletizing boundary, the beneficial effects of precise pallet shape control and palletizing quality assurance are achieved. As a boundary control mechanism in the palletizing process, the shaping enclosure device 44 not only provides clear spatial constraints for the palletizing operation but also adapts to the size requirements of different pallet shapes through dynamic adjustment capabilities, ensuring that the final palletizing result conforms to the preset shape and size specifications. This proactive 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.

[0083] 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 stacking.

[0084] Optionally, the enclosed space of the shaping barrier device 44 can also be configured to be variable. The shaping barrier device 44, arranged around the palletizing and packing positions 42, forms an adjustable three-dimensional boundary frame that can be dynamically adjusted according to the specific size requirements of the target pallet type. Before the palletizing operation begins, the shaping barrier device 44 automatically adjusts its initial internal space size according to the determined pallet size of the target pallet type, setting precise boundary constraints for the upcoming palletizing operation. During the palletizing process, the shaping barrier device 44 provides clear placement boundary guidance for the handling mechanism 43. Goods must be placed within the space defined by the shaping barrier device 44; any placement exceeding the boundary will be promptly mechanically guided, detected, and corrected. The shaping barrier device 44 also has a certain support function, especially for goods at the edges, providing necessary lateral support to prevent displacement or tipping of goods during palletizing.

[0085] In one specific embodiment, when stacking an air cargo stack with dimensions of 318cm × 244cm (122cm) × 192cm (300cm), the shaping barrier device 44 first adjusts its internal dimensions to a base area of ​​318cm × 244cm and a height of 192cm according to the target stack. During the stacking process, the handling mechanism 43 places the goods layer by layer according to the actual stacking plan, and the shaping barrier device 44 ensures that each item is accurately placed within the designated boundaries. When an item may exceed the boundaries due to size errors or placement deviations, the boundary constraints of the shaping barrier device 44 immediately take effect to prevent the item from exceeding the predetermined range. For items placed at the edge of the stack, the shaping barrier device 44 provides reliable lateral support to prevent the items from shifting during the stacking process. At heights above 192cm, the shaping enclosure device 44 gradually reduces the internal dimensions to a limit size of 318cm×122cm by adjusting the enclosure width. The final stack size is precisely controlled within the variable cross-section stack size, with the boundary error controlled within ±5mm, fully meeting the stringent requirements of air transport for cargo stack accuracy.

[0086] In related technologies, 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, as relying solely on the positioning accuracy of handling equipment easily leads to cumulative errors; second, stability is insufficient, lacking boundary constraints, making goods prone to displacement during palletizing; third, adaptability is poor, unable to be adjusted according to the requirements of different pallet types, especially the adjustment of boundary dimensions during the palletizing process; and fourth, quality control is difficult, lacking real-time boundary monitoring and error correction mechanisms.

[0087] In this embodiment of the invention, a proactive boundary control mechanism is established by setting up a dedicated shaping barrier device 44. The device's placement around the palletizing and packing position 42 ensures comprehensive boundary control of the entire palletizing area. The ability to adjust the barrier size according to the target pallet type allows the system to adapt to various pallet requirements. The boundary control function not only provides spatial constraints but also enables real-time quality monitoring. More importantly, the shaping barrier device 44 provides physical protection for palletizing operations. Even if the handling mechanism 43 experiences slight positioning errors, the shaping barrier device 44 can promptly guide and correct them, preventing the error from escalating and spreading. This design not only improves palletizing accuracy but also enhances the system's fault tolerance, providing crucial technical support for achieving stable and reliable automated palletizing. The application of the shaping barrier device 44 enables the automated palletizing system to completely surpass the accuracy level of manual palletizing, laying a solid foundation for the practical application of automated packaging in air cargo.

[0088] 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.

[0089] In this invention, the fixing device 45 secures the goods layer by layer during the palletizing process, achieving a significant improvement in palletizing stability and structural integrity. The layer-by-layer fixing mechanism of the fixing device 45 changes the traditional overall fixing method. By immediately fixing each layer in small intervals after completion, it ensures that each layer of goods has at least two rounds of fixed clamping, ensuring the stability of palletizing and shaping, and preventing deformation or displacement of lower layers due to pressure from the weight of upper layers. This small-interval layer-by-layer fixing method not only improves the overall stability of the palletizing structure but also provides technical support for handling mixed goods of different weights and shapes, making it a core technical feature for achieving high-quality automated palletizing and packaging.

[0090] Specifically, the small-pitch, layer-by-layer fixing process of the fixing device 45 is carried out simultaneously with the palletizing operation. After the handling mechanism 43 completes the palletizing of one layer of goods, the fixing device 45 immediately fixes that layer. That is, after each layer is completed, the lifting platform of the palletizing and packing position 42 lowers no more than one layer's distance, and the shaping barrier device 44 continues to provide effective support, maintaining the stack shape. The fixing device 45 then quickly applies wrapping film and strapping for reinforcement. The fixing process typically uses wrapping film, strapping, or other fixing materials to stabilize all the goods in that layer into a unified whole, forming 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. Simultaneously, layer-by-layer fixing effectively connects different layers, forming an integrated three-dimensional structure, significantly improving the structural strength and stability of the entire stack.

[0091] In one specific embodiment, when stacking an air cargo stack containing a mix of light and heavy goods, the bottom layer consists of 20 heavy-duty crates weighing 50 kg each, the middle layer consists of 40 medium-duty crates weighing 30 kg each, and the top layer consists of 20 light-duty goods weighing 15 kg each. If a traditional method of securing the entire stack is used, the bottom heavy-duty crates might deform under the weight of the upper layers (approximately 1500 kg), especially paper packaging, which could experience compression deformation, leading to decreased stability of the entire stack. However, by using a layer-by-layer securing method, after the bottom 20 heavy-duty crates are placed, the securing device 45 immediately wraps and secures them, forming a stable bottom structure; then the middle layer of goods is placed and secured again; finally, the top layer of goods is placed and secured. This method ensures that each layer of goods has sufficient structural strength to bear the weight of the upper layers, and the resulting stack maintains good structural stability at a total height of 1.8 meters, fully meeting the safety requirements of air transport.

[0092] In related technologies, traditional palletizing and fixing typically employs a whole-stack fixing method, where the entire pallet is uniformly fixed after all goods have been stacked. While this method is relatively simple to operate, it has significant technical drawbacks: First, it lacks structural stability, as the bottom layer of goods must bear the weight of the entire pallet, and without side support, it is highly susceptible to deformation or damage. Second, it has poor adaptability, proving ineffective for handling goods with mixed weights. Third, it poses high safety risks, as the stability of the entire pallet depends entirely on the stacking of the goods before fixing, creating a risk of collapse. Fourth, the fixing effect is limited, as whole-stack fixing often only treats the surface, leaving the internal structural connections weak.

[0093] In this embodiment of the invention, the innovative mechanism of small-pitch layer-by-layer shaping and fixing effectively solves the technical problems of traditional methods. The fixing design during the palletizing process organically combines fixing and palletizing operations, improving overall operational efficiency. The small-pitch layer-by-layer fixing method ensures that each layer of goods has independent structural strength; even if a problem occurs in one layer, it will not affect the stability of other layers. The fixing process involves not only surface fixing but also structural connections, forming a truly integrated structure. More importantly, this small-pitch layer-by-layer fixing mechanism provides the technical possibility for handling various complex combinations of goods. Whether it is a mixture of light and heavy, mixed sizes, or goods of different shapes, a stable and reliable palletizing structure can be obtained through layer-by-layer fixing. The application of the fixing device 45 not only improves the palletizing quality but also significantly enhances the safety of the palletizing structure during transportation, providing key technical support for realizing a truly practical automated palletizing and packaging subsystem 4.

[0094] 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 packing subsystem 4, and the input end of the second conveying unit 52 is connected to the palletizing and packing subsystem 4.

[0095] In this invention, the bidirectional conveying configuration of the cargo carrier conveying unit 5, including a first conveying unit 51 and a second conveying unit 52, achieves the beneficial effects of efficient bidirectional flow of carriers and goods and seamless system logistics. The first conveying unit 51 is responsible for conveying empty carriers to the palletizing and packing subsystem 4, while the second conveying unit 52 is responsible for conveying loaded goods out of the system. This bidirectional separation design avoids mutual interference between carriers and goods in the same channel, improving system throughput and operational safety. The bidirectional conveying configuration also creates conditions for continuous system operation, enabling parallel processing of carrier supply and goods output.

[0096] Specifically, the output of the first conveying unit 51 is connected to the palletizing and packing subsystem 4, and is specifically responsible for conveying empty carriers, such as aviation pallets or other carrier platforms, to the palletizing and packing position 42. The design of the first conveying unit 51 needs to consider the size specifications, weight characteristics, and conveying speed requirements of the carriers to ensure that the carriers can arrive at the palletizing and packing position 42 accurately and in a timely manner. The input of the second conveying unit 52 is connected to the palletizing and packing subsystem 4, and is specifically responsible for conveying the palletized and packed goods from the palletizing and packing position 42 to the subsequent acceptance, inspection, or loading stages. The design of the second conveying unit 52 needs to consider the total weight after loading, the stack size, and the transportation stability requirements to ensure that the loaded goods can be transported safely and stably.

[0097] In one specific embodiment, during continuous palletizing operations for air freight, the first conveying unit 51 delivers empty pallets to the palletizing and packing subsystem 4 at a frequency of one pallet every 10 minutes. The palletizing and packing subsystem 4 takes approximately 25 minutes to complete the palletizing and packing operation for one pallet. The second conveying unit 52 then delivers the packed pallets to the acceptance area for quality inspection. If a single conveying channel is used, the input of empty pallets and the output of loaded pallets must occur in the same channel, which can cause congestion and lead to waiting times between vehicles and cargo. However, with a bidirectional, separate conveying configuration, the first conveying unit 51 can continuously deliver empty pallets to the system, and a suitable buffer area is provided at the palletizing and packing position 42 to temporarily store 2-3 empty pallets. The second conveying unit 52 can continuously deliver packed pallets out of the system without interfering with the input empty pallets. This configuration enables continuous operation of the entire system, significantly improving its processing capacity and operational efficiency.

[0098] In some embodiments, the system further includes: an inspection system 6 for inspecting goods on the second conveying unit 52; and an loading system 7, located at the output end of the second conveying unit 52, for loading goods onto the machine.

[0099] In this invention, the acceptance system 6 inspects the goods on the second conveying unit 52, and the loading system 7 processes the goods for loading, achieving beneficial effects in packaging quality control and subsequent process integration. The acceptance system 6, as a crucial link in quality control, ensures that all palletized and packaged goods meet preset quality standards and transportation requirements, promptly identifying and addressing quality issues to prevent substandard products from entering subsequent stages. The loading system 7, as a key link in process integration, systematically transfers inspected and qualified goods into the loading process, achieving seamless integration from automated packaging to practical application.

[0100] In some embodiments, the cargo conveying unit 1 includes a regular cargo inlet 11 and an irregular cargo inlet 12.

[0101] In this invention, the cargo conveying unit 1, with its categorized conveying design including a regular cargo inlet 11 and an irregularly shaped cargo inlet 12, achieves the beneficial effects of specialized processing of goods of different shapes and improved system adaptability. The separate design of the regular cargo inlet 11 and the irregularly shaped cargo inlet 12 takes into account the diverse characteristics of cargo shapes, providing the most suitable conveying channels and processing methods for goods with different features. This not only improves the efficiency of cargo conveying but also creates favorable conditions for subsequent identification and processing. This categorized conveying design reflects the system's deep understanding and technical response to the needs of handling complex cargo.

[0102] Specifically, the regular cargo inlet 11 is designed to handle goods with standard geometric shapes, such as cuboid cartons, cylindrical drums, and standard palletized goods. These goods are characterized by their regular shape, relatively standard dimensions, and ease of automated processing. The design of the regular cargo inlet 11 is optimized for these characteristics, including standardized conveying equipment, standardized placement requirements, and efficient identification processes. The irregular cargo inlet 12 is designed to handle goods with irregular shapes, special dimensions, or non-standard packaging, such as flexible packaging bags, irregularly shaped containers, oversized or oversized goods, and fragile items. These goods require special handling methods and more flexible identification mechanisms. The design of the irregular cargo inlet 12 takes these special requirements into account, providing more flexible conveying methods and more refined handling processes.

[0103] In one specific embodiment, when processing a batch of air freight orders containing multiple types of goods, including 15 standard cartons, 8 cylindrical containers, 5 flexible packaging bags, 3 irregularly shaped precision equipment, and 2 oversized special goods, a single-entry design would require all goods to be processed in the same channel, reducing transport efficiency and potentially causing processing difficulties due to differences in cargo characteristics. However, with a categorized entry design, the 15 standard cartons and 8 cylindrical containers enter the system through the regular cargo entry 11. Because these goods are regularly shaped and of standard size, they can be transported and identified at a higher speed, with each item processed in approximately 30 seconds. The 5 flexible packaging bags, 3 irregularly shaped packaging devices, and 2 oversized goods enter the system through the irregular cargo entry 12. Although these goods require more meticulous handling, the specialized processing flow reduces the processing time to approximately 90 seconds per item, saving about 40% of the time compared to processing in the regular cargo channel. Overall, the categorized transport design improves the system's average processing efficiency by 25%.

[0104] In some embodiments, the handling mechanism 43 includes: a truss structure 431; and a variety of lifting claws 432 disposed on the truss structure 431, which can automatically select the appropriate lifting claw 432 according to the characteristics of the goods.

[0105] In this invention, the combination of a handling mechanism 43, comprising a truss structure 431 and various lifting grippers 432, achieves the beneficial effects of high precision, wide range, and versatility in cargo handling. The truss structure 431 provides a stable and reliable mechanical platform and precise three-dimensional positioning capabilities, while the various lifting grippers 432 offer flexible gripping solutions for handling goods with different characteristics. Together, they form a powerful handling system. This design not only ensures the precision and efficiency of handling operations but also significantly expands the system's adaptability to different types of goods, making it a core technological equipment for achieving high-quality automated palletizing.

[0106] Specifically, the truss structure 431, serving as the main frame of the handling mechanism 43, features high rigidity, large span, and precise positioning. The truss structure 431 covers the entire palletizing operation area, providing a stable motion platform for the lifting grippers 432, ensuring the accuracy and repeatability of the handling operations. The design of the truss structure 431 also considers load-bearing capacity requirements, capable of supporting goods of various weight levels, from light packaging of a few kilograms to heavy goods of hundreds of kilograms. Multiple lifting grippers 432 are installed on the truss structure 431, providing specialized gripping solutions for goods of different shapes, materials, and sizes. For example, suction cups and / or clamping grippers 432 can be used for standard cartons, suction cups and / or wrap-around grippers 432 can be used for cylindrical goods, suction cup grippers 432 can be used for bagged goods, and vacuum suction grippers 432 can be used for sheet materials. The system can automatically select the appropriate lifting gripper 432 based on the characteristics of the goods, achieving the most suitable gripping method.

[0107] In one specific embodiment, when handling a palletizing task for an air cargo container containing multiple types of goods, the goods to be handled include 8 standard cartons, 4 cylindrical containers, 6 flexible packaging bags, and 2 metal sheets. Traditional handling equipment with a single gripping method may not be able to effectively handle all types of goods, especially since flexible packaging bags and metal sheets require completely different gripping methods. However, with a truss handling mechanism 43 configured with multiple lifting grippers 432, the system automatically selects the appropriate lifting gripper 432 based on the cargo identification results: a clamping suction cup lifting gripper 432 is used for the 8 standard cartons, ensuring stable and reliable gripping; a wrap-around lifting gripper 432 is used for the 4 cylindrical containers to prevent rolling and slippage; a suction cup lifting gripper 432 is used for the 6 flexible packaging bags to avoid packaging damage; and a vacuum suction lifting gripper 432 is used for the 2 metal sheets to ensure smooth handling. The large span design of the truss structure 431 allows the handling mechanism 43 to cover the entire working 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 the traditional method.

[0108] In some embodiments, the handling mechanism 43 is a mobile robotic arm device.

[0109] In this invention, the use of a mobile robotic arm in the handling mechanism 43 significantly enhances the flexibility and adaptability of the handling system. Compared to fixed handling equipment, the mobile robotic arm offers a larger operating range and greater flexibility, allowing for flexible adjustments based on different palletizing requirements and operating environments, providing another efficient technological option for automated palletizing systems. This design is particularly suitable for applications with relatively compact operating spaces or those requiring frequent adjustments to the work layout.

[0110] Specifically, the mobile robotic arm device integrates a mobile platform and a multi-degree-of-freedom robotic arm, achieving omnidirectional operation capabilities in three-dimensional space. The mobile platform provides the robotic arm with flexible movement within the palletizing area, allowing it to adjust its position according to cargo distribution and palletizing requirements. The multi-degree-of-freedom robotic arm possesses precise gripping and placement capabilities, adapting to various complex palletizing motion requirements. The mobile design frees the handling mechanism 43 from the limitations of fixed tracks or fixed positions, enabling flexible responses to the palletizing needs of different sized carriers and facilitating system reconfiguration and upgrades. The robotic arm device is typically equipped with advanced control systems and sensors, achieving high-precision positioning and force control to ensure the quality of cargo handling and placement.

[0111] In some embodiments, the fixing device 45 is a wrapping device, which works in conjunction with the descending action of the palletizing and packing position 42 to achieve spiral layer-by-layer fixing.

[0112] In this invention, the fixing device 45 employs a wrapping device in conjunction with the descending motion of the palletizing and packing position 42 to achieve spiral layer-by-layer fixing, resulting in efficient and stable cargo fixing and excellent structural stability. This spiral layer-by-layer fixing method fully utilizes the lifting and lowering motion of the palletizing and packing position 42, forming a three-dimensional fixing structure through continuous spiral winding. This not only improves fixing efficiency but also significantly enhances fixing strength. This fixing method is particularly suitable for multi-layer palletizing applications, enabling simultaneous fixing during the palletizing process and achieving integrated palletizing and fixing.

[0113] Specifically, the wrapping device uses high-strength plastic film to wrap and secure goods, offering advantages such as low material cost, ease of operation, and excellent securing effect. The spiral-style layer-by-layer securing relies on the precise coordination between the wrapping device and the descending movement of the palletizing and packing position 42: after one layer of goods is stacked, the wrapping device begins wrapping that layer, while the palletizing and packing position 42 begins to descend; the synchronized movements of both create a spiral wrapping trajectory. This spiral wrapping not only tightly secures each layer of goods but also effectively connects different layers, forming a unified, fixed structure. This layer-by-layer securing method ensures that each layer of goods possesses stable structural strength before bearing the weight of the layer above, preventing structural deformation due to weight pressure.

[0114] In one specific embodiment, when stacking an air cargo stack with a height of 3.0 meters, it needs to be stacked in 6 layers, each layer being approximately 50 centimeters high. Traditional whole-stuff wrapping requires all cargo to be stacked beforehand, which is not only time-consuming but also risks deforming the bottom layer due to excessive pressure. However, with the spiral layer-by-layer fixing method, once the first layer is stacked, the wrapping device immediately begins wrapping. Simultaneously, the stacking and packaging position 42 descends 50 centimeters, forming multiple spiral wrapping tracks during the descent to tightly wrap the first layer. Then, the second layer is stacked, and the spiral wrapping is repeated, and so on, until the entire stack is completed and secured. Throughout the process, the fixing and stacking operations are performed simultaneously, without adding extra time. The final fixed structure presents a three-dimensional spiral shape. Utilizing the upward movement of the stacking and packaging position 42, the fixing device 45 coordinates with the reverse wrapping action in the height direction, achieving 100% coverage and increasing the fixing strength by 60% compared to traditional methods, enabling it to withstand various impacts and vibrations during transportation.

[0115] In related technologies, traditional cargo securing typically involves using integral packaging, such as wrapping the entire stack with plastic film, strapping, or shrink wrap after palletizing. While this method is relatively simple to operate, it has significant technical drawbacks: First, the timing of securing is inappropriate, as securing the goods after palletizing may result in deformation of the bottom layer; second, the securing effect is limited, as integral packaging often only treats the outer surface, leaving insufficient strength for the internal structural connections; third, the operational efficiency is low, requiring additional securing time and extending the overall operation cycle; and fourth, it has poor adaptability, with both the difficulty and effectiveness of integral securing decreasing for taller stacks.

[0116] In this embodiment of the invention, the spiral layer-by-layer fixing mechanism using a wrapping device effectively solves the technical problems of traditional fixing methods. The application of the wrapping device provides an efficient and economical fixing method. The use of plastic film is not only inexpensive but also has good toughness and wrapping properties. Combined with the design of the lowering and raising movements of the palletizing and packing position 42, the fixing and palletizing operations are synchronized, significantly improving operational efficiency. The spiral layer-by-layer fixing method forms a three-dimensional fixing structure, with fixing strength far exceeding that of traditional planar fixing. More importantly, this fixing method can adapt to various heights and complex stacking patterns, achieving good fixing results whether it is a simple regular stack or a complex variable cross-section stack. The application of spiral layer-by-layer fixing technology not only improves the quality and efficiency of goods fixing but also lays the technical foundation for the promotion of automated palletizing systems in applications requiring higher stability.

[0117] In some embodiments, the shaped fencing device 44 is configured with a variable cross-section, enabling it to adapt to different stacking requirements by adjusting the shape of the fencing.

[0118] In this invention, the variable cross-section of the shaping enclosure device 44, which can adapt to different stacking requirements by adjusting the shape of the enclosure, achieves the beneficial effects of flexible adaptation to diverse stacking requirements and optimized space utilization in the palletizing system. The variable cross-section shaping enclosure device 44 overcomes the limitations of traditional fixed-size enclosures, dynamically adjusting the shape and size of the enclosure according to different carrier specifications and cargo characteristics, providing technical support for the realization of various complex stacking configurations. This design is particularly suitable for applications requiring the handling of carriers of various specifications or the implementation of variable cross-section palletizing.

[0119] Specifically, the variable cross-section shaping fencing device 44, through modular fencing units and a flexible adjustment mechanism, can achieve multi-dimensional adjustment of the fencing shape. The shaping fencing device 44 can adjust its cross-sectional area according to stacking requirements, adapting to different size needs from small packages to large goods; it can adjust the geometry of the fencing, from standard rectangles to special irregular cross-sections; and it can dynamically adjust the fencing dimensions during stacking to meet the stacking requirements of variable cross-section stacking. This ability to adjust the fencing shape allows the system to adapt to various carrier specifications commonly found in air transport, such as different sized pallets and specially shaped containers, while also optimizing the stacking design according to cargo characteristics, improving space utilization and load-bearing efficiency.

[0120] In a specific embodiment, when handling palletizing tasks in air freight that require adaptation to various carriers (pallets), the system needs to handle common cuboid pallet shapes of 318cm×244(122)cm×192(300)cm and special cuboid pallet shapes of 606cm×244cm×163cm. Traditional fixed shaping fencing devices 44 can only adapt to one specific carrier (pallet) specification. For different specifications of carriers (pallets), the entire fencing equipment needs to be replaced, which is costly and inefficient. However, by using variable cross-section shaping fencing devices 44, the system can flexibly adapt to the requirements of different carriers (pallets): for 318cm×244cm pallets, the shaping fencing device 44 is adjusted to the corresponding rectangular cross-section; for large 606cm×244cm pallets, the shaping fencing device 44 is adjusted to the corresponding cross-section. In certain 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 type. That is, the bottom layer uses a larger cross-sectional area to obtain better stability, while the upper layer uses a smaller cross-sectional area to adapt to the shape requirements of the aircraft. For a chamfered rectangular container pallet stack type of 318cm×244(122)cm×192(300)cm, the bottom layer 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 needs, and the equipment utilization rate and economy are significantly improved.

[0121] In this embodiment of the invention, the innovative design of the variable cross-section shaping barrier device 44 effectively solves the limitations of traditional fixed barriers. The variable cross-section allows the shaping barrier device 44 to be flexibly adjusted according to actual needs, significantly expanding the applicability of the equipment; its ability to adjust the barrier shape supports various complex palletizing requirements; and its adaptability to different palletizing requirements provides technical support for the system's deployment in diverse application scenarios. More importantly, the variable cross-section shaping barrier device 44 provides a technical means to optimize space utilization. By precisely matching the carrier size and cargo characteristics, it can achieve higher space utilization efficiency and better load distribution. This technological innovation not only improves the flexibility and economy of the palletizing system but also lays the technical foundation for more intelligent palletizing optimization, representing a significant technological advancement that propels automated palletizing technology to a higher level.

[0122] In some embodiments, the palletizing and packaging position 42 is fixed, while the shaping enclosure device 44 and the fixing device 45 can be raised and lowered.

[0123] In this invention, the palletizing and packaging position 42 is fixed, while the shaping enclosure device 44 and the fixing device 45 are height-adjustable, achieving both flexibility in equipment configuration and cost control. This differentiated height configuration is optimized based on the functional characteristics and operational requirements of each device, ensuring the realization of key functions while controlling system complexity and cost. The fixed palletizing and packaging position 42 provides a stable and reliable carrier platform, while the height-adjustable shaping enclosure device 44 and the fixing device 45 provide the necessary flexibility for dynamic operations.

[0124] Specifically, the fixed design of the palletizing and packaging station 42 considers the convenience of on-site deployment and the stability requirements of the carrier. The fixed design avoids the construction of a foundation pit and the mechanical complexity of the support platform, improving system reliability and reducing investment and maintenance costs. During palletizing, the carrier needs to withstand the weight of the goods and the operating force of the handling equipment; the fixed design provides more stable support. The height-adjustable design of the shaping enclosure device 44 allows it to adjust its height in accordance with the progress of palletizing. It provides a bottom layer of enclosure in the initial stage of palletizing and gradually rises as the palletizing height increases, always providing effective boundary control for the palletizing operation. The height-adjustable design of the fixing device 45 allows for wrapping operations at an appropriate height, achieving the process requirement of layer-by-layer fixing through coordinated action with the shaping enclosure device 44.

[0125] In some embodiments, the palletizing and packaging subsystem 4 implements palletizing and packaging according to a cyclical process of enclosure positioning, layered palletizing, platform descent, and layer-by-layer fixing.

[0126] In this invention, the palletizing and packaging subsystem 4 employs a cyclical process of enclosure positioning, layered palletizing, platform descent, and layer-by-layer fixing to achieve palletizing and packaging. This establishes a standardized and regulated automated palletizing operation process, achieving the beneficial effects of ensuring consistent operational quality and significantly improving operational efficiency. This cyclical process decomposes the complex palletizing and packaging process into four standardized operational steps, each with clear technical requirements and quality standards. Through cyclical execution, high-quality construction of multi-layered pallets is achieved. The design of the cyclical process ensures that each layer of palletizing is carried out under the same process conditions, guaranteeing the consistency of the overall pallet quality.

[0127] Specifically, the first step in each cycle is enclosure positioning. The shaping enclosure device 44 sets precise boundary constraints for the upcoming palletizing layer, ensuring accurate goods placement. The second step is layered palletizing, where all goods in the layer are placed in predetermined positions and sequences according to the actual palletizing plan. The third step is platform descent, where the lowering action of the palletizing and packaging position 42 prepares for the next layer of palletizing and creates conditions for fixing. The fourth step is layer-by-layer fixing, where the goods in the newly palletized layer are fixed to ensure structural stability. These four steps form a complete process cycle, achieving multi-layered pallet construction through repeated execution. The standardized design of the cyclical process ensures the quality of each layer's palletizing, avoiding quality differences caused by inconsistent operations.

[0128] 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 can be selected to achieve the purpose of this embodiment according to actual needs. Those skilled in the art can understand and implement this without any creative effort.

[0129] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An automated mixed palletizing and packaging system, characterized in that, include: Cargo transport unit (1); The cargo identification system (2) is used to acquire cargo information on the cargo conveying unit (1), construct a three-dimensional model based on the cargo information, and construct a virtual palletizing scheme based on the three-dimensional model. The cargo information acquired by the cargo identification system (2) includes at least one of size, weight, shape and cargo identification information. The intelligent circular identification and sorting unit (3) includes: A circulating conveying unit (31) is connected to the cargo conveying unit (1) at its input end. The sorting unit (32) is used to identify the goods to be palletized on the circular conveying unit (31) and adjust the placement order and direction of the goods to be palletized according to the virtual palletizing scheme. The sorting unit (32) is also used to re-identify and confirm the goods to be palletized on the circular conveying unit (31) to check whether the actual position, direction and status of the goods are consistent with the information of the virtual palletizing scheme. When the inspection results show that they are inconsistent, the goods are actively adjusted through the cyclic adjustment mechanism until they meet the requirements of the virtual palletizing scheme. Based on the virtual palletizing scheme, the goods are further optimized by taking a single target pallet type as a unit, combined with the actual goods status, equipment capacity and environmental conditions, and the posture of the goods is adjusted. The palletizing operation sequence is organized in a layer-by-layer manner to form a physical palletizing scheme. The palletizing and packaging subsystem (4) is located at the output end of the circulating conveying unit (31) and is used for palletizing, shaping, fixing and packaging goods. The palletizing and packaging subsystem (4) performs automated palletizing and packaging of goods according to the physical palletizing scheme. The palletizing and packaging subsystem (4) includes a palletizing and packaging position (42) for carrying the carrier and placing goods on it. The 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). A shaping enclosure device (44) is set around the palletizing and packaging position (42) and is used to control the palletizing boundary according to the target pallet shape. The shaping enclosure device (44) has a variable cross section and includes modular enclosure units and an adjustment mechanism. The adjustment mechanism dynamically adjusts the enclosure units according to the pallet shape parameters of the physical palletizing scheme to ensure that the final palletizing result conforms to the target pallet shape.

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

3. The automated hybrid palletizing and packaging system according to claim 1 or 2, characterized in that, The palletizing and packaging subsystem (4) includes: Palletizing temporary storage location (41) is used to temporarily store goods to be palletized from the intelligent cycle identification and sorting unit (3); The handling mechanism (43) is used to move goods from the palletizing storage location (41) to the palletizing and packing location (42) and perform layered palletizing.

4. The automated hybrid palletizing and packaging system according to claim 3, characterized in that, The palletizing and packaging position (42) can be raised and lowered to cooperate with the handling mechanism (43) for layered palletizing operations.

5. The automated hybrid palletizing and packaging system according to claim 4, characterized in that, The palletizing and packaging subsystem (4) also includes a fixing device (45) for fixing the goods layer by layer during the palletizing process.

6. The automated hybrid palletizing and packaging system according to claim 5, characterized in that, 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 packing subsystem (4), and the input end of the second conveying unit (52) is connected to the palletizing and packing subsystem (4). It also includes: The inspection system (6) is used to inspect the goods on the second conveying unit (52); The loading system (7) is located at the output end of the second conveying unit (52) and is used for loading cargo.

7. The automated hybrid palletizing and packaging system according to claim 1, characterized in that, The cargo conveying unit (1) includes a regular cargo inlet (11) and an irregular cargo inlet (12).

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