Mobile picking robot

Abstract

The present invention relates to a mobile picking robot (1) for the automatic picking of objects (9), having a load handling manipulator (M), a sensor arrangement (10) and a controller which is connected for control purposes to the sensor arrangement (10) and to a drive of the load handling manipulator (M), wherein the load handling manipulator (M) has a robot arm (R) and a receiving tool (G), connected to the robot arm (R), for receiving the objects (9), wherein the sensor arrangement (10) is designed to detect a packing pattern of the objects (9) on a load carrier (Z), in particular a pallet (Z). The controller is designed to compare the detected packing pattern of the objects (9) on the load carrier (Z) with a reference packing pattern of the objects (9) on the load carrier (Z), and to determine a packing pattern deviation. The controller is also designed to activate, depending on the determined packing pattern deviation, the drive of the load handling manipulator (M) for the active position correction of at least one of the objects (9) arranged on the load carrier (Z).

Description

[0001] Description

[0002] Mobile picking robot

[0003] The invention relates to a mobile picking robot for the automatic picking of objects on a load carrier, comprising a load handling manipulator, a sensor arrangement and a controller, wherein the controller is designed to activate a drive of the load handling manipulator for the active position correction of objects on the load carrier depending on a specific packing pattern deviation of the objects on the load carrier, as well as a method for the active position correction of objects on the load carrier by a mobile picking robot.

[0004] Order picking refers to all methods for assembling specific objects, especially goods in warehouses or distribution centers, from a provided overall product range. The assembly is based on orders, such as customer orders or production orders. Recently, automated systems have been increasingly used for this purpose. For example, packages are picked by autonomously operated mobile order picking robots from a source position, such as a source pallet, and placed at a target position, such as a target pallet transported by the mobile order picking robot.

[0005] Typically, mobile picking robots are used for this purpose, which are designed in particular as at least partially autonomous, in particular fully autonomous, picking robots, which can independently pick up the packages at the corresponding source position by means of a robot arm, can independently transport the picked packages to the target position, and can independently set down the picked packages at the target position.

[0006] Mobile picking robots receive order data such as the order number, storage location coordinates, quantity, and weight of the goods, particularly automatically, from a central computer. For example, they can specifically target specific shelf compartments in high-bay warehouses and retrieve the desired item from the shelf compartment using a gripping system equipped with a pick-up tool. The pick-up tool can be designed as a gripper, for example, an adhesion gripper or a vacuum gripper.

[0007] Such mobile picking robots feature a load-handling manipulator, which typically includes a lifting mast or other lifting device for vertically positioning the picking tool or gripper in the rack and on the target pallet. Special kinematics of the robot arm are often used for the fully autonomous, mobile picking process.

[0008] Robots with standard kinematics, especially 6-axis industrial robots, are often too heavy, not designed for mobile use, and have kinematic limitations that make their use in this area difficult.

[0009] Robot arms with flat kinematics that can be moved vertically on a lifting mast are more advantageous. Such robot arms have several flat, i.e., horizontally arranged arm elements that span a cylindrical gripping area, ideal for working in narrow warehouses. Mobile order picking robots with flat arm kinematics are known, for example, from DE 10 2017 129 468 A1, DE 10 2017 130 577 A1, EP 3 868 519 A2, and EP 4098 590 A1.

[0010] During the automatic picking of packages on a load carrier, such as a pallet, by a mobile picking robot or other handling devices, the target position of the packages on the target pallet is determined based on sensor data according to the current state of the art. For this purpose, the target pallet and the packing pattern on it are recorded. This usually involves contactless 3D sensors, such as ToF (Time of Flight) or stereo cameras. From the sensor data, a suitable storage location for the next package is calculated, or a previously calculated storage location is validated. Even with a known packing pattern on the target pallet, which can usually be assumed for pallets packed purely robotically, validation of the storage position is often necessary, as various factors can lead to deviations.These include in particular the following factors: Tolerances in the dimensions of the packages; Incorrect information on the dimensions of the packages from the master data due to poor data quality; Setting of the packing pattern, particularly in the case of higher stacked pallets consisting of several layers and in the case of heavy packages, further intensified by the movement of the target pallet; Tolerances in the depositing position of the packages already deposited in the x-direction (horizontal longitudinal direction of the picking robot), y-direction (horizontal transverse direction of the picking robot) and i-direction (rotation around the vertical axis along the extension direction of the lifting mast) due to depositing with tolerances or due to subsequent displacement, for example due to dynamic influences when moving the target pallet; Disturbing elements on the target pallet, for example residues of adhesive tape or film.

[0011] Measuring the placement position of a package on the target pallet is subject to tolerances. The package must be placed at the calculated position with safety margins to prevent collisions with previously placed packages. Such collisions can cause packages to fall off the target pallet, which can lead to quality, availability, and safety issues.

[0012] In addition to the target positions, which are subject to tolerances, tolerances also arise when placing the package on the target pallet. Both errors add up and lead to larger safety distances between packages.

[0013] Safety clearances when placing packages on the target pallet lead to gaps between the packages and thus to a disadvantageous packing pattern on the target pallet. The packing pattern of the target pallet becomes less dense, resulting in higher pallet loads or not all packages fitting on the pallet up to the maximum height. In addition, the gaps make the packing pattern less stable, making it harder to stack high or requiring more effort for stabilization, for example, through the use of stretch film and interlayers.

[0014] In many state-of-the-art mobile picking robots, this results in a packing pattern of the packages on the target pallet deviating from an ideal reference packing pattern of the objects on the target pallet, so that in the state of the art there is a need for an active position correction of objects on target pallets or load carriers by mobile picking robots.

[0015] The present invention is based on the object of providing a mobile picking robot which is capable of actively correcting the position of objects on a load carrier.

[0016] This object is achieved according to a first aspect by a mobile picking robot for the automatic picking of objects, comprising a load handling manipulator, a sensor arrangement, and a controller which is connected in terms of control technology to the sensor arrangement and a drive of the load handling manipulator, wherein the load handling manipulator has a robot arm and a receiving tool connected to the robot arm for receiving the objects, wherein the sensor arrangement is designed to detect a packing pattern of the objects on a load carrier, in particular a pallet, wherein the controller is designed to compare the detected packing pattern of the objects on the load carrier with a reference packing pattern of the objects on the load carrier and to determine a packing pattern deviation, and wherein the controller is designedto activate the drive of the load handling manipulator for the active position correction of at least one of the objects arranged on the load carrier depending on the determined packing pattern deviation.

[0017] This achieves the technical advantage that, during a subsequent active position correction of at least one object by the load handling manipulator, an unfavorable packing pattern of the objects arranged on the load carrier can be changed into an advantageous packing pattern.

[0018] This makes it possible, for example, to reduce gaps between the objects on the load carrier and to align objects that protrude beyond the outer contour of the load carrier or objects that are offset inwards relative to the outer contour of the load carrier with the outer contour of the load carrier so that the outer edge of the objects is flush with the outer contour of the load carrier.

[0019] The active position correction thus results in a compaction of the objects on the load carrier, which not only increases the stability of the objects on the load carrier, but also leads to the number of objects positioned on the load carrier being maximized.

[0020] This allows a mobile picking robot loaded with objects on a load carrier or a target pallet to travel faster, since a more stable packing pattern of the objects on the load carrier significantly reduces the risk of the load carrier on the mobile picking robot falling over when cornering or braking sharply.

[0021] In addition, the denser packing pattern of the objects on the load carrier can mean that fewer securing measures for the objects on the load carrier are necessary, as, for example, wrapping the objects in film can be omitted, resulting in significant time and cost savings.

[0022] In addition, a correspondingly optimized packing pattern of the objects on the load carrier achieves a high process availability of the mobile picking robot, as there are fewer process interruptions, as the mobile picking robot can correct corresponding packing pattern deviations itself through active position correction and less intervention by an operator is necessary to correct errors.

[0023] A corresponding active position correction of at least one of the objects arranged on the load carrier comprises in particular an active position correction of a single object or a plurality of objects arranged on the load carrier.

[0024] In this case, the controller is particularly designed to, after an active position correction of one of the objects, again compare the subsequently obtained packing pattern of the objects on the load carrier with the reference packing pattern of the objects and determine a packing pattern deviation. Depending on the determined packing pattern deviation, the drive of the load handling manipulator is reactivated for the active position correction of at least one of the objects arranged on the load carrier. This allows an active position correction of several objects on the load carrier to be performed successively in order to iteratively approximate the optimal reference packing pattern.

[0025] As described in further detail below, the active position correction comprises a physical interaction of the load handling manipulator with at least one object arranged on the load carrier such that the position of the at least one object arranged on the load carrier is changed.

[0026] In this case, the active position correction can particularly comprise the displacement, pulling, and / or pushing of the at least one object arranged on the load carrier by the load handling manipulator. In this case, the active position correction can particularly comprise the gripping of the at least one object arranged on the load carrier, the lifting of the gripped object, and the setting down of the lifted, gripped object in a changed position on the load carrier or on the objects arranged on the load carrier.

[0027] According to one embodiment, the controller is designed to activate the drive of the load handling manipulator for the active position correction of at least one of the objects arranged on the load carrier when the determined packing pattern deviation exceeds a predetermined deviation threshold value.

[0028] This achieves the technical advantage that the control for active position correction is only activated when the specific packing pattern deviation is so significant that the predetermined deviation threshold is exceeded, thus avoiding unnecessary fine positioning in the mm range.

[0029] According to one embodiment, the controller is designed to determine, before activating the drive of the load handling manipulator for active position correction, depending on the packing pattern of the objects on the load carrier detected by the sensor arrangement, that no interfering contour is present which would result in a collision with the load handling manipulator and / or with the position-corrected object.

[0030] This achieves the technical advantage of introducing a safety level into the active position correction to prevent a collision of the load handling manipulator and / or the position-corrected object with an interfering contour, such as a foreign body or a mispositioned object.

[0031] If the controller determines, in particular depending on the packing pattern of the objects on the load carrier detected by the sensor arrangement, that an interfering contour is present, the controller is in particular designed not to activate the drive of the load handling manipulator for active position correction, wherein in particular a warning can be transmitted to an operator of the mobile order picking robot.

[0032] In particular, the controller is designed to determine an auxiliary packing pattern on the basis of the interference contour detected by the sensor arrangement and in dependence on the reference packing pattern, and the controller is designed to activate the drive of the load handling manipulator for the active position correction of at least one of the objects arranged on the load carrier in dependence on the determined auxiliary packing pattern.

[0033] In this case, the information from the sensor array can be used to make intelligent decisions in the event of an error, such that the desired packing pattern is recalculated and an auxiliary packing pattern is determined on the basis of which the mobile picking robot can further build the target load carrier.

[0034] According to one embodiment, the packing pattern deviation comprises a position deviation of at least one object on the load carrier compared to a target position of the at least one object, and the controller for active position correction is designed to activate the drive of the load handling manipulator and to grip the at least one object having the position deviation, in particular by means of the picking tool, and to remove it from the load carrier, to carry out a change in the position of the gripped object, and to place the gripped object with the changed position again on the load carrier in the target position.

[0035] This achieves the technical advantage that by gripping the object, lifting the object, changing the position of the object and placing the object on the load carrier in the target position, an advantageous change in the detected packing pattern of the objects is achieved in order to bring the packing pattern closer to the reference packing pattern.

[0036] According to one embodiment, the packing pattern deviation comprises a position deviation of at least one object on the load carrier compared to a target position of the at least one object, and the controller for active position correction is designed to activate the drive of the load handling manipulator and to move the at least one object on the load carrier having the position deviation into the target position with the robot arm and / or with the picking tool.

[0037] This achieves the technical advantage that simply moving the object exhibiting the positional deviation on the load carrier is often sufficient to improve the detected packing pattern. Such movement of the object includes, in particular, pushing, pushing, pulling, and / or impacting the object. However, moving the object does not include lifting the object.

[0038] According to one embodiment, the receiving tool is designed as a vacuum gripper which has at least one vacuum suction cup with a vertically arranged suction surface for the active position correction of at least one of the objects arranged on the load carrier.

[0039] This achieves the technical advantage that the design of the picking tool as a vacuum gripper is particularly advantageous, since in this case the object does not have to be gripped with gripping arms, but the vacuum suction cup with a vertically arranged suction surface only has to be applied to one side surface of the object, and solely due to the existing vacuum provides sufficient holding force to carry out an active position correction with the object, for example by moving the object.

[0040] The picking tool designed as a vacuum gripper can in particular be used to grip the object, lift the object, change the position of the object and place the object on the load carrier in the desired position and / or the object can only be moved on the load carrier.

[0041] According to one embodiment, the mobile order picking robot has a positioning tool, wherein the load handling manipulator has a changing device which is designed to replace the receiving tool with the positioning tool, wherein the packing pattern deviation comprises a position deviation of at least one object on the load carrier compared to a target position of the at least one object, and wherein the controller for active position correction is designed to activate the changing device for changing the receiving tool with the positioning tool, and wherein the controller for active position correction is designed to activate the drive of the load handling manipulator and to move the at least one object on the load carrier having the position deviation into the target position using the positioning tool.

[0042] This achieves the technical advantage that, by using a pick-up tool and a positioning tool, different tools can be used for different active position corrections. While the pick-up tool picks up the object, the positioning tool moves it. Depending on the application, either the pick-up tool or the positioning tool can be arranged on the load handling manipulator using the changing device. In particular, the changing device comprises a cassette, in particular a rotatable cassette, into which the pick-up tool or the positioning tool can be accommodated. In particular, the positioning tool comprises an alignment block, which can be placed against the object and thus enable the object to be moved.

[0043] The positioning tool, in particular the alignment block, can be designed to be narrow, allowing it to be inserted into narrow gaps between the objects on the load carrier, thus enabling the object to be moved from the center of the pallet outwards. Alternatively, the positioning tool can also comprise a vertically aligned vacuum pad, in particular, to securely grip the object to be moved.

[0044] In particular, the positioning tool, in particular the alignment block, is carried on the mobile order picking robot or the positioning tool, in particular the alignment block, is stored at a defined location in the operating area of ​​the mobile order picking robot, so that the changing device achieves an effective change of the receiving tool by the positioning tool.

[0045] According to one embodiment, the load handling manipulator comprises a compensating element which is arranged between the robot arm and the receiving tool, wherein the compensating element is designed to allow relative movements between the robot arm and the receiving tool, wherein the packing pattern deviation comprises a positional deviation of at least one object on the load carrier compared to a target position of the at least one object, and wherein the controller for active position correction is designed to activate the drive of the load handling manipulator and to move the at least one object on the load carrier having the positional deviation into the target position using the receiving tool.

[0046] This achieves the technical advantage that the use of the compensation element, which is arranged between the robot arm and the pick-up tool, enables a particularly smooth movement of the object exhibiting the position deviation on the load carrier.

[0047] This is because if the pick-up tool hits the object with the position deviation too hard, the compensation element allows a relative movement between the robot arm and the pick-up tool, thereby weakening or dampening the impulse acting on the object, which can prevent damage to the object.

[0048] According to one embodiment, the sensor arrangement is designed to detect a further packing pattern of the objects on a load carrier after the active position correction has been carried out, wherein the controller is designed to compare the further detected packing pattern of the objects on the load carrier with the reference packing pattern of the objects on the load carrier and to determine a further packing pattern deviation, and wherein the controller is designed to activate the drive of the load handling manipulator for the active position correction of at least one of the objects arranged on the load carrier as a function of the determined further packing pattern deviation.

[0049] This achieves the technical advantage that, within the scope of an iterative process, after an active position correction of at least one of the objects arranged on the load carrier by detecting and evaluating the further packing pattern of the objects on the load carrier, a renewed active position correction of the same or other objects on the load carrier can be carried out.

[0050] According to one embodiment, the reference packing pattern of the objects comprises a target packing pattern of the objects on the load carrier previously detected by the sensor arrangement and / or the reference packing pattern of the objects can be calculated by the controller as a function of reference data stored in the controller, wherein the reference packing pattern of the objects is stored in particular in a memory of the controller, or wherein the controller is designed to receive the reference packing pattern of the objects from an external database via a communication interface of the mobile order picking robot and via a communication network.

[0051] This achieves the technical advantage that, depending on the application, the reference packing pattern of the objects is predetermined, i.e. corresponds to an ideal target packing pattern of the objects on the load carrier previously detected by the sensor arrangement, or that the reference packing pattern can be calculated or updated by the controller during the picking process, whereby in the latter case the advantage is achieved that greater flexibility is provided, since deviations and expected storage situations can be responded to.

[0052] The calculation or updating of the reference packing pattern can either be done locally by the control of the mobile picking robot or the control can receive the reference packing pattern of the objects via the communication network from an external database or an external server, which can provide advantageous computing power.

[0053] According to one embodiment, the sensor arrangement comprises at least one of the following sensors: 2D mono camera, 3D stereo camera, 3D time-of-flight camera, 2D / 3D LIDAR and combinations thereof.

[0054] This provides the technical advantage that advantageous packing pattern recognition can be achieved by the corresponding sensors.

[0055] According to one embodiment, the sensor arrangement is arranged on a boom of the mobile order picking robot, in particular on a boom designed to be height-adjustable, and / or the sensor arrangement is arranged on the robot arm and / or on the picking tool.

[0056] This achieves the technical advantage that the sensor arrangement arranged on a height-adjustable boom can advantageously be displaced in height, or the sensor arrangement arranged on the robot arm and / or on the picking tool can advantageously be moved freely in space in order to assume an optimal position of the sensor arrangement for detecting the packing pattern.

[0057] According to one embodiment, the controller is designed to determine, depending on the determined packing pattern deviation, whether an active position correction of the at least one object is possible or not possible, wherein, if it has been determined that an active position correction by the load handling manipulator is not possible, the controller is designed to determine a target position of a further object to be placed on the load carrier depending on the detected packing pattern, and to activate the load handling manipulator to grip and place the further object in the target position on the load carrier.

[0058] This achieves the technical advantage of incorporating an additional safety level in the event that an active position correction of a specific object by the load handling manipulator is not possible, in this case an active position correction of another object on the load carrier is carried out.

[0059] This object is achieved according to a second aspect by a method for the active position correction of objects on a load carrier by a mobile picking robot for the automatic picking of objects, wherein the mobile picking robot has a load handling manipulator with a picking tool for picking up the objects, a sensor arrangement, and a controller which is control-technically connected to the sensor arrangement and a drive of the load handling manipulator, wherein the method comprises the following method steps: detecting a packing pattern of the objects on a load carrier by the sensor arrangement; comparing the detected packing pattern of the objects on the load carrier with a reference packing pattern of the objects on the load carrier by the controller and determining a packing pattern deviation;and activating the drive of the load handling manipulator for the active position correction of at least one of the objects arranged on the load carrier as a function of the determined packing pattern deviation by the controller;

[0060] This achieves the technical advantage that an effective active position correction of at least one object arranged on the load carrier can be carried out.

[0061] According to one embodiment, the packing pattern deviation comprises a position deviation of at least one object on the load carrier compared to a target position of the at least one object, and the activation of the drive of the load handling manipulator for active position correction by the controller comprises gripping the at least one object having the position deviation, in particular by means of the picking tool, and removing the object from the load carrier, carrying out a position change of the gripped object, and placing the gripped, position-changed object in the target position again on the load carrier.

[0062] This provides the technical advantage of achieving effective repositioning of the gripped, position-changed object in the target position.

[0063] According to one embodiment, the packing pattern deviation comprises a position deviation of at least one object on the load carrier compared to a target position of the at least one object, and the activation of the drive of the load handling manipulator for active position correction by the controller comprises moving the at least one object on the load carrier having the position deviation into the target position.

[0064] This provides the technical advantage of achieving effective repositioning of the displaced, position-changed object in the target position.

[0065] Further advantages and details of the invention are explained in more detail by way of example with reference to the exemplary embodiments illustrated in the schematic figures. Figure 1 shows a mobile order-picking robot for the automatic order-picking of objects with a load-handling manipulator according to an exemplary embodiment of the present invention, Figure 2 shows a packing pattern of objects on a target load carrier of a mobile order-picking robot according to an exemplary embodiment of the present invention, and Figure 3 shows a schematic representation of a method for the active position correction of objects on a load carrier by a mobile order-picking robot for the automatic order-picking of objects. Figure 1 shows a mobile order-picking robot 1 for the automatic order-picking of objects 9 with a load-handling manipulator M according to an exemplary embodiment of the present invention.

[0066] The mobile picking robot 1 shown in Figure 1 is used for automatic picking, i.e. the assembly of certain objects, in particular goods in warehouses or goods distribution centers, from a provided overall assortment.

[0067] The order picking robot 1 has a mobile (moving) autonomous platform 2, on which a vertically aligned lifting mast 3 is attached, with a lifting carriage 4 attached to it for height adjustment. The load handling manipulator M is attached to the lifting carriage 4; in the illustrated embodiment, this is a horizontally aligned robot arm R. The robot arm R is composed of several arm elements 5, 6, 7, 8. The arm elements 5, 6, 7, 8 are each articulated to one another via vertically aligned arm joint rotation axes. The last arm element 8 is articulated to the picking tool G, designed as a gripper G, via a vertical wrist rotation axis (not visible in Figure 1). The arm elements 5, 6, 7, 8 are arranged one below or one above the other and form a flat kinematics of the robot arm R. The target load carrier Z, designed as a target pallet Z, is arranged on the industrial truck 1 and can be moved with it.As shown in Figure 1, the objects 9 picked by the picking robot 1 are placed on the target load carrier Z.

[0068] A sensor arrangement 10, shown only schematically in Figure 1, is designed to detect a packing pattern of the objects 9 on the target load carrier Z. As shown only schematically in Figure 1, the sensor arrangement 10 is arranged on a height-adjustable boom 11 of the mobile order-picking robot 1, thereby ensuring a good, reproducible field of view of the sensor arrangement 10. Alternatively or additionally, the sensor arrangement 10 can also be attached to the load handling manipulator M.

[0069] Thus, the sensor arrangement 10 can view from above the objects 9 already stacked on the target load carrier Z. In this way, the sensor arrangement 10 can detect and monitor the current packing pattern and thus the actual state on the target load carrier Z.

[0070] In particular, the sensor arrangement 10 comprises at least one of the following sensors: 2D mono camera, 3D stereo camera, 3D time-of-flight camera, 2D / 3D LIDAR and combinations thereof.

[0071] The sensor arrangement 10 is connected in terms of control technology to a controller of the mobile order-picking robot 1 (not shown in Figure 1), wherein the controller is further connected in terms of control technology to a drive of the load-handling manipulator M (not shown in Figure 1). The controller can in particular be integrated into the sensor arrangement 10 or the controller can be designed as a component different from the sensor arrangement 10.

[0072] Thus, the sensor arrangement 10 is designed to detect a packing pattern of the objects 9 on the target load carrier Z, and the controller is designed to activate the load handling manipulator M to move the objects 9.

[0073] The sensor signals provided by the sensor array 10 are processed and interpreted in the controller. Thus, the sensor array 10 enables both sensor-assisted localization of the target load carrier Z relative to the robot arm R and free space detection on the target load carrier Z with respect to the target position and collision-free placement movement of the robot arm R.

[0074] The control system of the order-picking robot 1 is designed according to the invention to compare the packing pattern of the objects 9 on the target load carrier Z, detected by the sensor arrangement 10, with a reference packing pattern (desired state) of the objects 9 on the target load carrier Z and to determine a packing pattern deviation. The control system is designed according to the invention to activate the drive of the load handling manipulator M for the active position correction of at least one of the objects 9 arranged on the target load carrier Z, depending on the determined packing pattern deviation. In the order-picking robot 1 according to the invention, the sensor arrangement 10 thus detects the current packing pattern on the target load carrier Z, and the active position correction of one or more objects 9 on the target load carrier Z results in a continuous comparison of the current packing pattern (actual state) with the reference packing pattern (desired state) of the target load carrier Z.

[0075] Thus, with the aid of the sensor signals provided by the sensor arrangement 10, both the target position and the space required for the depositing movement of the load handling manipulator M can be checked for possible interfering contours, e.g. due to slipped and / or fallen objects 9, in order to ensure collision-free depositing.

[0076] Activating the corresponding active position correction of at least one of the objects 9 arranged on the load carrier Z is described in more detail below.

[0077] Here, the packing pattern deviation can comprise a position deviation of at least one object 9 on the target load carrier Z compared to a target position of the at least one object 9. For active position correction, the controller is first designed to activate the drive of the load handling manipulator M and to grip the at least one object 9 exhibiting the position deviation, in particular by means of the picking tool G, and to remove it from the target load carrier Z, subsequently to change the position of the gripped object 9, and then to place the gripped, position-changed object 9 again in the target position on the target load carrier Z.

[0078] Alternatively or additionally, if the packing pattern deviation comprises a position deviation of at least one object 9 on the target load carrier Z compared to a target position of the at least one object 9, in this case the controller for active position correction can be designed to activate the drive of the load handling manipulator M and to move the at least one object 9 exhibiting the position deviation on the load carrier into the target position using the robot arm R and / or the pick-up tool G. For active position correction, the pick-up tool G can be moved laterally to the object 9 exhibiting the position deviation and the object 9 can be moved into the target position.

[0079] In this case, the receiving tool G can be designed as a vacuum gripper which has at least one vacuum suction cup with a vertically arranged suction surface for the active position correction of at least one of the objects 9 arranged on the load carrier.

[0080] Alternatively or additionally, the mobile order picking robot 1 can have a positioning tool, in particular an alignment block, wherein the load handling manipulator M has a changing device which is designed to replace the receiving tool G with the positioning tool, wherein the packing pattern deviation comprises a position deviation of at least one object 9 on the load carrier compared to a target position of the at least one object 9. In this case, the controller is designed for active position correction to activate the changing device for changing the receiving tool with the positioning tool, and the controller is designed for active position correction to activate the drive of the load handling manipulator M and to use the positioning tool to move the at least one object 9 on the load carrier exhibiting the position deviation into the target position.

[0081] In this case, the positioning tool, in particular the alignment block, is carried on the mobile picking robot 1 or must be available at a defined location in the warehouse so that the changing device can replace the receiving tool G with the positioning tool.

[0082] The positioning tool, in particular the alignment block, can also be designed to be narrow in order to perform pushing movements from the center of the target load carrier Z outwards. This can be necessary in order to reach the outer contour of the target load carrier Z and not become increasingly narrower towards the top. The pushing can be carried out by quasi-statically applying a force in the desired direction of movement, or by impulsive pushing of the object 9. Depending on the surface of the object 9, e.g. cardboard or film-coated, the pushing can cause an upper object 9 to break away from the object 9 below, thereby enabling more targeted moving. The target can be achieved by evaluating the TCP or the positioning tool, in particular the alignment block, as well as by the image-based sensor arrangement 10 initially used. The correction process can also be carried out iteratively in small steps.

[0083] The goal of the active position correction of one or more objects 9, for example, through a shifting process, is to stabilize the target load carrier Z. This can be achieved by eliminating gaps between the objects 9 and pushing the objects 9 inward or outward to the target position, in particular calculated by the "PackPatternGenerator," which calculates the reference packing pattern. In particular, pulling outward can be useful if this ensures that the outer edge of the object 9 is aligned with the outer edge of the target load carrier Z.

[0084] In particular, the load handling manipulator M can comprise a compensating element which is arranged between the robot arm R and the receiving tool 8. The compensating element is designed to allow relative movements between the robot arm R and the receiving tool 8, wherein the packing pattern deviation comprises a positional deviation of at least one object 9 on the load carrier Z compared to a target position of the at least one object 9, and wherein the controller for active position correction is designed to activate the drive of the load handling manipulator M and to use the receiving tool to move the at least one object 9 on the load carrier Z exhibiting the positional deviation into the target position.

[0085] By using the elastic compensating element, a particularly gentle positioning of the objects 9 can be achieved.

[0086] In order to prevent unnecessary activation in the event of minimal deviations of the objects 9, the controller can be designed to activate the drive of the load handling manipulator M for the active position correction of at least one of the objects 9 arranged on the load carrier Z when the determined packing pattern deviation exceeds a predetermined deviation threshold value.

[0087] In order to carry out a safe active position correction, the controller can in particular be designed to determine, before activating the drive of the load handling manipulator M for the active position correction, as a function of the packing pattern of the objects 9 on the load carrier Z detected by the sensor arrangement 10, that no interfering contour is present which would result in a collision with the load handling manipulator M and / or with the position-corrected object 9.

[0088] Through active position correction and thus the subsequent positioning of objects 9 during compaction, a more stable target load carrier Z can be created, which has advantages during picking. This allows the mobile picking robot 1 to move faster, since the target load carrier Z cannot fall over during braking or cornering, thus saving time.

[0089] Furthermore, fewer external stabilization measures are required; the load can, for example, be secured during the picking process by (partial) wrapping, which is particularly unnecessary with more stable target load carriers Z. Higher process availability is achieved because there are fewer process interruptions. The mobile picking robot can correct minor errors / deviations itself, thus requiring less user intervention for troubleshooting.

[0090] Through the active position correction of objects 9 on the target load carrier Z, errors in the positioning of the object 9 by the gripper can be compensated. Such errors can also arise from design features of the gripper, e.g., because the gripper is located on both sides of the object 9, creating a gap. Thus, this invention also allows such gripper principles to be used without compromising the stability of the target load carrier Z.In particular, the sensor arrangement 10 is designed to detect a further packing pattern of the objects 9 on a load carrier Z after the active position correction has been carried out, wherein the controller is designed to compare the further detected packing pattern of the objects 9 on the load carrier Z with the reference packing pattern of the objects 9 on the load carrier Z and to determine a further packing pattern deviation, and wherein the controller is designed to activate the drive of the load handling manipulator M for the active position correction of at least one of the objects 9 arranged on the load carrier Z as a function of the determined further packing pattern deviation.

[0091] This ensures, in the context of at least one further, in particular several iterative steps, that the desired reference packing pattern is achieved as precisely as possible in the end.

[0092] In particular, the reference packing pattern of the objects 9 comprises a target packing pattern of the objects 9 on the target load carrier Z previously detected by the sensor arrangement 10 and / or the reference packing pattern of the objects 9 can be calculated by the controller depending on reference data stored in the controller.

[0093] In this case, the reference packing pattern of the objects 9 is stored in particular in a memory of the controller, or the controller is designed to receive the reference packing pattern of the objects 9 from an external database via a communication interface of the mobile order picking robot 1 and via a communication network.

[0094] In particular, the controller is designed to determine, depending on the determined packing pattern deviation, whether an active position correction of the at least one object 9 is possible or not possible, wherein, if it has been determined that an active position correction by the load handling manipulator M is not possible, the controller is designed to determine, depending on the detected packing pattern, a target position of a further object 9 to be placed on the load carrier Z, and to activate the load handling manipulator M to grip and place the further object 9 in the target position on the load carrier Z.

[0095] Figure 2 shows a packing pattern of objects on a target load carrier Z of a mobile order picking robot according to an embodiment of the present invention.

[0096] Figure 2 shows only the target load carrier Z of the mobile order picking robot 1, on which a plurality of objects 9 designed as packages are stacked in several levels and form a packing pattern.

[0097] As can be seen from Figure 2, the objects 9 have a packing pattern which can be detected by a sensor arrangement 10 of the mobile order picking robot 1 (not shown in Figure 2), wherein the packing pattern deviates from a reference packing pattern in the case shown in Figure 2.

[0098] Thus, the controller is designed to activate the drive of the load handling manipulator M for the active position correction of at least one of the objects 9 arranged on the target load carrier Z, depending on the determined packing pattern deviation.

[0099] Figure 3 shows a schematic representation of a method for the active position correction of objects on a target load carrier Z by a mobile picking robot 1 for the automatic picking of objects 9 according to an embodiment of the present invention.

[0100] The method 20 comprises, as a first method step, the detection 21 of a packing pattern of the objects 9 on a load carrier Z by the sensor arrangement 10.

[0101] The method 20 comprises, as a second method step, comparing 22 the detected packing pattern of the objects 9 on the load carrier Z with a reference packing pattern of the objects 9 on the load carrier Z by the controller and determining a packing pattern deviation. The method 20 comprises, as a third method step, activating 23 the drive of the load handling manipulator M for actively correcting the position of at least one of the objects 9 arranged on the load carrier Z as a function of the determined packing pattern deviation by the controller.

[0102] List of reference symbols

[0103] M Load handling manipulator

[0104] Z load carrier or pallet

[0105] R robot arm

[0106] G Pick-up tool, gripper

[0107] 1 mobile picking robot

[0108] 2 Autonomous Platform

[0109] 3 lifting mast

[0110] 4 lifting carriages

[0111] 5 First arm element

[0112] 6 Second arm element

[0113] 7 Third arm element

[0114] 8 Fourth arm element

[0115] 9 Object

[0116] 10 Sensor arrangement

[0117] 11 booms

[0118] 20 Methods for the active position correction of objects on a load carrier by a mobile picking robot for the automatic picking of objects

[0119] 21 First step: Capture a packing pattern of the objects

[0120] 22 Second process step: Comparing the recorded packing pattern of the objects on the load carrier with a reference packing pattern of the objects and determining a packing pattern deviation

[0121] 23 Third process step: Activating the drive of the load handling manipulator for active position correction

Claims

Patent claims 1. A mobile order-picking robot (1) for the automatic order-picking of objects (9), comprising a load-handling manipulator (M), a sensor arrangement (10), and a controller which is connected for control purposes to the sensor arrangement (10) and a drive of the load-handling manipulator (M), wherein the load-handling manipulator (M) has a robot arm (R) and a receiving tool (G) connected to the robot arm (R) for receiving the objects (9), wherein the sensor arrangement (10) is designed to detect a packing pattern of the objects (9) on a load carrier (Z), in particular a pallet (Z), characterized in that the controller is designed to compare the detected packing pattern of the objects (9) on the load carrier (Z) with a reference packing pattern of the objects (9) on the load carrier (Z) and to determine a packing pattern deviation, and wherein the controller is designedto activate the drive of the load handling manipulator (M) for the active position correction of at least one of the objects (9) arranged on the load carrier (Z) depending on the determined packing pattern deviation.

2. Mobile order picking robot (1) according to claim 1, characterized in that the controller is designed to activate the drive of the load handling manipulator (M) for the active position correction of at least one of the objects (9) arranged on the load carrier (Z) when the determined packing pattern deviation exceeds a predetermined deviation threshold value.

3. Mobile order picking robot (1) according to claim 1 or 2, characterized in that the control is designed, before the activation of the drive of the load handling manipulator (M) for active position correction, depending to determine from the packing pattern of the objects (9) on the load carrier (Z) detected by the sensor arrangement (10) that there is no interfering contour which would result in a collision with the load handling manipulator (M) and / or with the position-corrected object (9).

4. Mobile order picking robot (1) according to one of the preceding claims, characterized in that the packing pattern deviation comprises a position deviation of at least one object (9) on the load carrier (Z) compared to a target position of the at least one object (9), and wherein the controller for active position correction is designed to activate the drive of the load handling manipulator (M) and to grip the at least one object (9) having the position deviation, in particular by means of the picking tool (G), and to remove it from the load carrier (Z), to change the position of the gripped object (9), and to place the gripped object (9) with the changed position again on the load carrier (Z) in the target position.

5. Mobile order picking robot (1) according to one of the preceding claims, characterized in that the packing pattern deviation comprises a position deviation of at least one object (9) on the load carrier (Z) compared to a target position of the at least one object (9), and wherein the controller for active position correction is designed to activate the drive of the load handling manipulator (M) and to move the at least one object (9) having the position deviation on the load carrier (Z) into the target position with the robot arm (R) and / or with the picking tool (G).

6. Mobile order picking robot (1) according to claim 4 or 5, characterized in that the picking tool (G) is designed as a vacuum gripper which has at least one vacuum suction cup with a vertically arranged suction surface for the active position correction of at least one of the objects (9) arranged on the load carrier (Z).

7. Mobile order picking robot (1) according to one of the preceding claims, characterized in that the mobile order picking robot (1) has a positioning tool, wherein the load handling manipulator (M) has a Having a changing device which is designed to replace the receiving tool (G) with the positioning tool, wherein the packing pattern deviation comprises a position deviation of at least one object (9) on the load carrier (Z) with respect to a target position of the at least one object (9), and wherein the control for active position correction is designed to activate the changing device for changing the receiving tool (G) with the positioning tool, and wherein the control for active position correction is designed to activate the drive of the load handling manipulator (M) and to move the at least one object (9) having the position deviation on the load carrier (Z) into the target position using the positioning tool.

8. Mobile order picking robot (1) according to one of the preceding claims, characterized in that the load handling manipulator (M) comprises a compensating element which is arranged between the robot arm (R) and the picking tool (G), wherein the compensating element is designed to allow relative movements between the robot arm (R) and the picking tool (G), wherein the packing pattern deviation comprises a position deviation of at least one object (9) on the load carrier (Z) compared to a target position of the at least one object (9), and wherein the controller for active position correction is designed to activate the drive of the load handling manipulator (M) and to move the at least one object (9) exhibiting the position deviation on the load carrier (Z) into the target position using the picking tool (G).

9. Mobile order picking robot (1) according to one of the preceding claims, characterized in that the sensor arrangement (10) is designed to detect a further packing pattern of the objects (9) on a load carrier (Z) after the active position correction has been carried out, wherein the controller is designed to compare the further detected packing pattern of the objects (9) on the load carrier (Z) with the reference packing pattern of the objects (9) on the load carrier (Z) and to determine a further packing pattern deviation, and wherein the controller is designed to activate the drive of the load handling manipulator (M) for the active position correction of at least one of the objects (9) arranged on the load carrier (Z) depending on the determined further packing pattern deviation.

10. Mobile order-picking robot (1) according to one of the preceding claims, characterized in that the reference packing pattern of the objects (9) comprises a target packing pattern of the objects (9) on the load carrier (Z) previously detected by the sensor arrangement (10) and / or the reference packing pattern of the objects (9) can be calculated by the controller as a function of reference data stored in the controller, wherein the reference packing pattern of the objects (9) is stored in particular in a memory of the controller, or wherein the controller is designed to receive the reference packing pattern of the objects (9) from an external database via a communication interface of the mobile order-picking robot (1) and via a communication network.

11. Mobile order picking robot (1) according to one of the preceding claims, characterized in that the sensor arrangement (10) comprises at least one of the following sensors: 2D mono camera, 3D stereo camera, 3D time-of-flight camera, 2D / 3D LIDAR and combinations thereof.

12. Mobile order-picking robot (1) according to one of the preceding claims, characterized in that the sensor arrangement (10) is arranged on a boom (11) of the mobile order-picking robot (1), in particular on a boom (11) designed to be height-adjustable, and / or that the sensor arrangement (10) is arranged on the robot arm (R) and / or on the receiving tool (G).

13. Mobile order picking robot (1) according to one of the preceding claims, characterized in that the controller is designed to determine, depending on the determined packing pattern deviation, whether an active position correction of the at least one object (9) is possible or not possible, wherein the controller is designed, if it has been determined that an active position correction by the load handling manipulator (M) is not possible, to determine a target position of a further object (9) to be placed on the load carrier (Z) depending on the detected packing pattern, and to activate the load handling manipulator (M) to grip and place the further object (9) in the target position on the load carrier (Z).

14. Method (20) for the active position correction of objects (9) on a load carrier (Z) by a mobile picking robot (1) for the automatic picking of objects (9), wherein the mobile picking robot (1) has a load handling manipulator (M) with a receiving tool (G) for receiving the objects (9), a sensor arrangement (10), and a controller which is connected for control purposes to the sensor arrangement (10) and a drive of the load handling manipulator (M), characterized in that the method (20) comprises the following method steps: Detecting (21) a packing pattern of the objects (9) on a load carrier (Z) by the sensor arrangement (10); Comparing (22) the detected packing pattern of the objects (9) on the load carrier (Z) with a reference packing pattern of the objects (9) on the load carrier (Z) by the control and determining a packing pattern deviation; and Activating (23) the drive of the load handling manipulator (M) for the active position correction of at least one of the objects (9) arranged on the load carrier (Z) as a function of the determined packing pattern deviation by the control system.

15. The method according to claim 14, characterized in that the packing pattern deviation comprises a position deviation of at least one object (9) on the load carrier (Z) compared to a target position of the at least one object (9), and in that the activation (23) of the drive of the load handling manipulator (M) for active position correction by the controller comprises gripping the at least one object (9) having the position deviation, in particular by means of the picking tool (G), and removing the object (9) from the load carrier (Z), carrying out a change in position of the gripped object (9), and depositing the gripped, position-changed object (9) in the target position again on the load carrier (Z).

16. Method according to claim 14 or 15, characterized in that the packing pattern deviation comprises a position deviation of at least one object (9) on the load carrier (Z) compared to a desired position of the at least one object (9), and that the activation (23) of the drive of the load handling manipulator (M) for active position correction by the control system comprises the displacement of the at least an object (9) having the position deviation on the load carrier (Z) into the desired position.

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