Advanced fastpicker system

Abstract

What is disclosed is A pick and place system (100) for manipulating non- rotationally symmetrical products (110, 110', 110'') within a defined workspace, the system comprising: a conveyor belt (120) for transporting the non-rotationally symmetrical products; at least one robotic arm (130, 130') equipped with an end effector for manipulating the products; a vision detection system (140) for identifying product characteristics including shape, size, and quality; a control system (150), configured to: (i) analyze the products (110, 110', 110'') on the conveyor belt (120) to identify product characteristics and occupied and available spaces; (ii) determine optimal groupings (210, 211, 212, 213) of products based on their identified characteristics to minimize space usage when packaged and to optimize for downstream handeling; (iii) optimize product handling order on the conveyor belt in a two-step process for the packaging and optimization at downstream handeling, comprising the steps of: (a) an initial step (161) of clearing space by selectively shifting or removing products to create buffer areas on the conveyor belt based on the identified occupied and available spaces; (b) a subsequent step (162) of forming patterns by grouping (210, 211, 212, 213) and arranging products into a predefined configuration selected from stacks, rows, or staggered formations; (iv) control the at least one robotic arm (130, 130') to execute the two-step optimization process and form the determined grouping (210, 211, 212, 213).

Description

[0001] Title: Advanced Fastpicker System

[0002] Description:

[0003] Technical field

[0004] The present invention relates to an advanced pick and place system and the field of automated product handling systems, and more particularly to the field of pick and place systems for manipulating non-rotationally symmetrical products.

[0005] Background of the invention

[0006] In the field of automated product handling, pick and place systems have long been utilized to efficiently manipulate and organize various items in manufacturing and packaging processes. These systems typically employ robotic arms, conveyor belts, and vision systems to handle products with precision and speed. Traditionally, such systems have been optimized for handling products with regular shapes and consistent sizes, allowing for straightforward programming and predictable outcomes.

[0007] However, the food industry, particularly in the production of baked goods like cookies, presents unique challenges for conventional pick and place systems. Cookies and similar products are often non-rotationally symmetrical, meaning their shape varies when rotated. Moreover, as natural products, cookies exhibit inherent variations in both shape and size. A round cookie is rarely perfectly circular, and a rectangular one seldom has exact right angles. This variability has been typically resolved by making sure the systems which handle these products and the packaging material in which the products are packaged, to have a sufficient level of tolerance to cope with such levels of variance and non-uniformity in the products.

[0008] The market trend towards minimizing packaging material has further complicated the situation. Manufacturers are now required to load products into increasingly smaller trays, demanding more precise and efficient handling techniques. This shift has exposed the limitations of existing pick and place systems when dealing with non-uniform, natural products. Current systems often struggle to optimize space utilization in these smaller packaging formats, leading to inefficiencies in the production line and potential waste of packaging materials.

[0009] Furthermore, the handling of defective or imperfect products presents an additional challenge. In the cookie production process, it's common to have a small percentage of products that don't meet quality standards due to size discrepancies, breakage, or other imperfections. Traditional systems often lack the flexibility to identify and appropriately manage these defective items within the production flow, potentially leading to disruptions or quality issues in the final packaged product.

[0010] It is therefore a goal of the present invention to provide an advanced pick and place system capable of efficiently handling non-rotationally symmetrical products with varying shapes and sizes, while optimizing space utilization in smaller packaging formats, thereby overcoming the above-mentioned disadvantages of the prior art at least in part.

[0011] Summary of the invention

[0012] In a first aspect, there is provided a pick and place system for manipulating non-rotationally symmetrical products within a defined workspace, the system comprising: a conveyor belt for transporting the non-rotationally symmetrical products; at least one robotic arm equipped with an end effector for manipulating the products; a vision detection system for identifying product characteristics including shape, size, and quality; a control system, configured to :

[0013] (i) analyze the products on the conveyor belt to identify product characteristics and occupied and available spaces;

[0014] (ii) determine optimal groupings of products based on their identified characteristics to minimize space usage when packaged and to optimize for downstream handeling;

[0015] (iii) optimize product handling order on the conveyor belt in a two-step process for the packaging and optimization at downstream handeling, comprising the steps of: (a) an initial step of clearing space by selectively shifting or removing products to create buffer areas on the conveyor belt based on the identified occupied and available spaces;

[0016] (b) a subsequent step of forming patterns by grouping and arranging products into a predefined configuration selected from stacks, rows, or staggered formations;

[0017] (iv) control the at least one robotic arm to execute the two-step optimization process and form the determined grouping.

[0018] In a second aspect, there is provided a method for manipulating non- rotationally symmetrical products within a defined workspace, the method comprising the steps of: transporting non-rotationally symmetrical products on a conveyor belt; identifying, using a vision detection system, product characteristics including shape, size, and quality; analyzing, by a control system, the conveyor belt to identify product characteristics and occupied and available spaces; determining optimal groupings of products based on their identified characteristics to minimize space usage when packaged and to optimize for downstream handling; optimizing product handling order on the conveyor belt in a two-step process for the packaging and optimization at downstream handling, comprising:

[0019] (a) an initial step of clearing space by selectively shifting or removing products to create buffer areas on the conveyor belt based on the identified occupied and available spaces;

[0020] (b) a subsequent step of forming patterns by grouping and arranging products into a predefined configuration selected from stacks, rows, or staggered formations; controlling at least one robotic arm to execute the two-step optimization process and form the determined optimal grouping.

[0021] In a third aspect, there is provided a computer program product comprising instructions which, when the program is executed by a computer, cause the computer to carry out the steps of the method of the first aspect. One or more aspects of the present invention relate to a pick and place system, method and computer program product for manipulating non-rotationally symmetrical products within a defined workspace. A pick and place system may be understood as an automated mechanism designed to grasp, move, and position objects from one location to another within a specified area. Non-rotationally symmetrical products refer to items that do not maintain the same shape or appearance when rotated around their central axis.

[0022] The system comprises a conveyor belt for transporting the non-rotationally symmetrical products. A conveyor belt may be a continuous loop of material used to move items from one place to another. This arrangement allows for efficient and continuous movement of products through the workspace, enabling high-throughput processing and reducing manual handling requirements.

[0023] It is preferred, that the pick and place system and method operates on a single conveyor belt, where both the picking and placing of products are performed without transferring the products to a separate conveyor or handling system. This setup simplifies the process by allowing all manipulation to occur on the same conveyor, which presents unique challenges related to space management and the coordination of product movements on the belt. The system is configured to maintain efficient operation by continuously analyzing product characteristics and available spaces on the conveyor, ensuring that the arrangement, grouping, and placement of products occur seamlessly within the same work area. This approach not only optimizes space usage but also minimizes the complexity of the system, avoiding the need for additional conveyors or transfer mechanisms.

[0024] The system includes at least one robotic arm equipped with an end effector for manipulating the products. A robotic arm is a programmable mechanical limb capable of performing various tasks, while an end effector is a device attached to the end of the robotic arm designed to interact with objects. This configuration provides precise and flexible manipulation of products, allowing for complex movements and adaptability to different product shapes and sizes.

[0025] A vision detection system for identifying product characteristics including shape, size, and quality is part of the system. A vision detection system uses cameras and image processing algorithms to analyze visual data. This arrangement enables real-time assessment of product attributes, facilitating accurate sorting and handling decisions, and enhancing overall quality control.

[0026] The system incorporates a control system configured to analyze the conveyor belt to identify occupied and available spaces but also the product characteristics. This functionality allows for efficient space utilization and optimized product placement, potentially increasing the overall capacity of the system. Moreover, the vision system determines the product characteristics which are relevant for selecting which products to move to clear space and which products to select for forming the patterns by grouping them into stacks, rows or staggered formations. Product characteristics is to be broadly interpreted, and as used in the context of the present description, refer to a set of identifiable physical or visual attributes of the products being manipulated by the pick and place system. These characteristics are critical for determining how the products are handled, grouped, and arranged on the conveyor belt. Examples of such characteristics include, but are not limited to, the shape of the product (e.g., rectangular, circular, irregular), the size (e.g., dimensions, volume), the weight of the product, and surface properties (e.g., smooth, textured, or adhesive). Additional characteristics may include color, material composition, flatness or curvature of the product’s main surfaces, and fragility or rigidity. The system’s vision detection system analyzes these characteristics to make informed decisions about product grouping, space utilization, and optimal placement for both packaging and downstream handling.

[0027] The control system is also configured to determine optimal groupings of products based on their identified characteristics to minimize space usage and to optimize for downstream handeling. This arrangement allows for intelligent decisionmaking in product organization, leading to more efficient packaging and reduced material waste.

[0028] The control system is thus configured to determine optimal groupings of products based on their identified characteristics to minimize space usage and to optimize for downstream handling. This arrangement allows for intelligent decisionmaking in product organization, leading to more efficient packaging and reduced material waste. Although the system introduces additional handling steps by first moving products to clear space and then forming groups, these steps are designed to ensure that the overall handling of the entire production line is optimized. By pre- organizing the products in a way that facilitates smoother operations further downstream, the system compensates for the added complexity at this station. This strategic pre-arrangement enables subsequent stations, such as packaging or sorting systems, to operate more efficiently, reducing bottlenecks, minimizing reprocessing, and improving overall throughput. Therefore, the benefits gained at later stages of the production process outweigh the minor drawback of introducing additional steps at the current stage.

[0029] The control system is further configured to optimize product arrangement on the conveyor belt in a two-step process. The first step involves clearing space by selectively shifting or removing products to create buffer areas on the conveyor belt on the identified occupied and available spaces. This arrangement allows for dynamic reorganization of products on the conveyor, potentially reducing bottlenecks and improving overall system efficiency.

[0030] The second step of the optimization process involves forming patterns by grouping and arranging products into a predefined configuration selected from stacks, rows, or staggered formations. This functionality enables efficient use of available space and can lead to more compact and stable product arrangements.

[0031] Lastly, the control system is configured to control the at least one robotic arm to execute the two-step optimization process and form the determined grouping. This integration of control and execution ensures that the optimized arrangements are accurately implemented, potentially leading to improved system performance and reliability.

[0032] The products may be arranged on or introduced onto the conveyor belt in a highly dense configuration, with minimal unoccupied space between them. The conveyor belt is predominantly filled with products, presenting a crowded arrangement that maximizes the initial product load. This dense product distribution can be organized in various ways. In some instances, the products may be arranged in a structured pattern, such as aligned rows and columns, creating a grid-like formation on the conveyor belt. Alternatively, the products might be deposited onto the conveyor in a random or pseudo-random manner, without any predetermined order or alignment. This initial crowded state of the conveyor belt, whether structured or random, presents a challenging environment for the pick and place system, necessitating sophisticated space optimization strategies to effectively manipulate and rearrange the products. The pick and place system according to the present disclosure addresses the challenges posed by the highly dense configuration of the products on the conveyor belt, and irregularly shapes of these products with highly efficient way of control of the robotic arm. The inventors had the insight to employ a vision detection system that identifies product characteristics including shape, size, and quality, enabling the system to apply an efficient control algorithm to adapt to the inherent variability of natural products. This capability allows for precise manipulation of each item, regardless of its unique form, overcoming the limitations of traditional systems designed for uniform products.

[0033] The control system's two-step optimization process represents a surprising and distinguishing way of employing product arrangement techniques. The inventors recognized that by implementing an initial step of clearing space through selectively shifting or removing products to create buffer areas on the conveyor belt, the system could effectively handle densely packed conveyors. This approach enables dynamic reorganization of products, even in scenarios where the conveyor is initially filled to capacity with little free space. By creating strategic buffer areas, the system adeptly manages the challenges associated with manipulating products in tightly confined spaces.

[0034] In more detail what is meant with these buffer areas is that the system achieves these buffers by for example first adjusting the spacing between products in their original pattern in which they are infeed into the system. For example, products like cookies may initially be placed closer together on the conveyor, which initially add an extra step of handling, and which thus suggests inefficient use of time and resources. The system can shift some products closer to each other, freeing up small areas on the belt. And although this adds an extra step, introducing extra handling time and resources, it provides a surprising overall increase in efficiency downstream the processing line as these newly created buffer areas provide the necessary space for subsequent product handling and grouping steps, which can then be done in a more efficient and effective manner. This dynamic adjustment ensures that even when the conveyor appears fully loaded, there is still room to optimize product placement for better handling efficiency of the overall processing line. Moreover, the optimized product placement due to the dynamic adjustment also enables systems and packaging at smaller tolerances, which is beneficial as well. Surprisingly, the subsequent step of forming patterns by grouping and arranging products into predefined configurations such as stacks, rows, or staggered formations directly addresses the market demand for minimizing packaging material. This capability allows the system to optimize space utilization in smaller trays, a key requirement in modern packaging processes. The inventors realized that by determining optimal groupings based on identified product characteristics, the system could minimize space usage while accommodating the irregular shapes and sizes of non-rotationally symmetrical products.

[0035] The system's approach to handling defective or imperfect products represents another unexpected advancement. The inventors had the foresight to integrate the identification of product quality into the vision detection system and incorporate this information into the grouping and arrangement decisions. This allows the system to manage these items effectively within the production flow, reducing disruptions and maintaining the quality of the final packaged product, thus addressing a significant challenge in the food industry.

[0036] The combination of these features results in a pick and place system that offers a comprehensive solution to the complex problems presented by handling non- uniform, natural products in increasingly compact packaging formats. By seamlessly integrating advanced vision detection, intelligent space optimization, and flexible product manipulation, the system achieves a level of efficiency and adaptability that surpasses conventional approaches in the field of automated product handling.

[0037] Product grouping and stacking according to a certain pattern formation may be arranged to minimize space usage in trays by combining different-sized products, aligning the longest axes of products, and utilizing one or multiple robots to rearrange products on the conveyor belt. The system's ability to handle densely packed conveyors and create strategic buffer areas facilitates the management of challenges associated with manipulating products in tightly confined spaces. This approach enables dynamic reorganization of products, even in scenarios where the conveyor is initially filled to capacity with little free space.

[0038] Pattern formation may be understood as the system's ability to form various configurations such as stacks, rows, groups, and staggered patterns, allowing for optimal space utilization while meeting predefined requirements. In the context of this disclosure, the system is particularly designed to operate with a congested or full conveyor. A “congested” supply of products or “full / near-full conveyor” denotes an operating state in which, prior to any patternformation action, no lay-down position is available within the robot’s working envelope that meets the minimum requirements for safely depositing a product, whether temporarily or permanently.

[0039] Conventional systems may handle congested inflow provided that downstream headroom exists, i.e. , free space ahead of the congested flow, to advance or push back products until a suitable position emerges. By contrast, the present disclosure addresses continuous congested operation without usable downstream headroom. Any incidental micro-gaps that do appear on the conveyor are below the threshold required for safe manipulation and therefore cannot be relied upon for advancing / pushing-back unless a dedicated space-creation step is performed first.

[0040] A lay-down position, in the context of the present disclosure also referred to a “lay-down spot”, is a contiguous free surface area on the conveyor at least equal to the product’s projected footprint and preferably including a minimum manipulator work allowance, i.e., the local clearance required for the end-effector (e.g., fingers or a vacuum interface) to place and release the product without collision. In a fullconveyor state, picking one product alone typically does not free sufficient area to lay down another product, at least one additional, coordinated displacement is required.

[0041] This constraint frequently arises in compact cells with multiple small robots having circular work zones (e.g., 0 400-500 mm), where one robot “hand” is effectively missing to simultaneously lift product A and re-park product B to create the space needed to place A onto C and start forming the stack, row or staggered group. The invention therefore precedes any grouping operation with a dedicated spacecreation phase that fabricates a lay-down spot in advance within the relevant conveyor segment. That lay-down spot may be created inside the working zone of the robot that will perform the formation, or it may be pre-provisioned upstream by another robot and proceed into the formation zone while being reserved.

[0042] Accordingly, the system ensures the availability of at least one safe lay- down spot inside the robot’s workcell despite near-full product occupancy, thereby enabling uninterrupted pattern-formation on a congested belt. Hence, while an extra robot “hand” might be able to buffer products during a congested cycle, the proposed system avoids this hardware addition by pre-clearing with the same robot or with an upstream robot under a coordinated schedule that maintains the buffer until needed.

[0043] This present disclosure uses clearing spaces as “buffer area” which is to be understood a robot-created, reserved free-space patch on the conveyor within a robot’s working envelope, generated proactively as a first, discrete step to enable subsequent local rearrangement and pattern-formation under full-conveyor conditions. The buffer area is not an inventory queue; it is a work-space artifact specifically created and sized to allow later manipulations (e.g., to re-park B while A is being lifted) and can persist for a predefined horizon (e.g., several cycles or across multiple workcells upstream).

[0044] By contrast, conventional systems apply the concept of buffering in a completely different way, either by laying of products in a dedicated buffer zone outside the conveyor belt which provides side parking / buffers off the main belt (for example dedicated parking shelves / belts) to balance supply rate variation with off-belt inventory, or by advancing or pushing back products so that a desired number is present before release. In the latter its buffer is an on-belt accumulation to complete a group when too few items are available. Neither of these known solutions address making local free space on a congested belt in a continuous product supply.

[0045] To implement this principle, the control system executes a structured two- step algorithm comprising:

[0046] (S1) Space-creation (pre-clearing): selectively shift / slide / re-park identified products to create one or more buffer areas within the target workcell. This phase uses vision-derived attributes (shape, size, curvature, defect flags) and local density maps to (i) target chains of mutual blockage, (ii) minimize total travel, and (iii) comply with gripper kinematics and safety margins.

[0047] And in a dedicated next step (S2) Pattern-formation is performed, wherein the buffer created in S1 is or can be used if need. In S2 the target pattern if formed (e.g., stacks, rows, staggered formations) which execution of S2 can be guarantied due to S1 as this allows temporarily staging one or more items into the pre-cleared buffer area, while composing the pattern at a distinct placement area. Hence, phases S1 and S2 are temporally and logically discrete. The buffer is made first, then used.

[0048] The which-to-move decision in S1 may use, in an example, specific vision- derived product characteristics, comprising one or more of shape, longest axis, curvature, flatness, defect status, and / or local density rather than only lead / trail counts. This contrasts with conventional known systems, which decides to advance / push-back primarily from numerical availability relative to a target group size. The present approach chooses space-liberating moves that maximize downstream pattern feasibility and minimize re-work.

[0049] Pick-and-place systems operating in the food industry typically face the technical challenge of maintaining continuous pattern formation and high throughput when the conveyor becomes densely loaded with irregular products. Conventional solutions in the prior art aim to handle such congestion by introducing mechanical or spatial redundancy. Systems may spread products over a longer belt, add side buffers or recirculation lines, reduce feed rate, or install auxiliary manipulators to relieve local crowding. Each of these approaches carries drawbacks: spreading lowers density and increases footprint, side buffers complicate cleaning and control, reduced feed rates limit productivity, and extra robots lead to cost, coordination overhead, and potential collision zones. The challenge is that the system must remain stable under continuous inflow, provide space for precise manipulation, and maintain high efficiency without enlarging the installation or adding mechanical subsystems.

[0050] In search for an improvement one would most naturally consider extending or broadening the conveyor to create more space, lowering the line speed, or adding off-line accumulation buffers, since these measures are well known and compatible with existing control logic. Introducing an active manipulation within an already congested zone would be seen as counterintuitive, as it introduces an extra handling step and may risk interference and cycle delays. Known solutions teach away from manipulating or reserving space inside the dense product flow as their principles are based on availability of headroom, side storage, or temporary halting of product zones rather than on-line reorganisation under full occupancy.

[0051] The system according to the present disclosure is based on the insight of recognising that congestion can be resolved without extending hardware or lowering throughput, by dynamically creating functional workspace within the same conveyor segment. The proposed system treats space on the conveyor as a controllable resource that can be generated, reserved, and consumed in synchrony with pick-and- place actions. This approach is surprising because it enables continuous high-density operation where conventional designs would require reduced flow or additional handling stations. The resulting effect is a compact and efficient manipulation process capable of maintaining precision and throughput under conditions that would otherwise be unmanageable by the established methods of the prior art.

[0052] In an example, the system according to the present disclosure comprises multi-robot lines. Such a system may pre-provision buffer areas upstream of the patterning cell in anticipation of forthcoming needs calculated from the in-feed state, downstream pattern plan, and time-of-flight of items. The lay-down spot exists before S2 starts and can be maintained over distance (e.g., carried along a conveyor segment) until it enters the target robot’s workspace.

[0053] The system according to the present disclosure is thus configured to address a steady-state regime with continuous high-density inflow. Unlike start-up scenarios (where headroom exists at the leading edge), the conveyor remains persistently near-full, so neither pushing articles forward to a upstream group nor draining into side buffers, resolves the local work-space deficit at the pattern locus. The disclosed S1 / S2 approach maintains throughput without lengthening the conveyor or widening the line.

[0054] In an example, the system may be configured to perform pattern-formation in three dimensions, wherein the control system is arranged to position products not only along the X- and Y-axes of the conveyor but also along the Z-axis, such that stacks or multi-layer arrangements of products are formed directly on the conveyor. It may be provided that three-dimensional pattern-formation may be understood as an arrangement in which the products are placed in vertically superposed layers with defined orientations, allowing the system to form stable groups or stacks suitable for compact packaging. An effect is that vertical stacking within the same conveyor footprint increases throughput density while maintaining the conveyor’s overall length, providing a more efficient use of space and a reduction of mechanical transfers between different levels.

[0055] In an example, the control system may be configured to apply layer-wise compensation when forming a three-dimensional pattern, wherein a second layer is positioned in relation to the first layer such that irregularities of the lower layer are at least partly compensated. It may be provided that layer-wise compensation may be understood as an adjustment of product placement in upper layers by means of relative offsets or angular orientations to ensure that the center of gravity of each product lies within a stable support area. An effect is that stacks become self-stabilising even when the products have irregular shapes, so that the system can process non-rotationally symmetrical goods with less risk of tilting or collapse during downstream transport.

[0056] In an example, the system may be configured to determine and control the rotation of each product around its vertical axis during pattern-formation, wherein the rotational position is selected according to shape parameters of the products and the intended arrangement. It may be provided that rotation about the vertical axis may be understood as the control of in-plane orientation of each product relative to its neighbours in a pattern layer. An effect is that products with non-uniform outlines can be positioned such that complementary contours interlock or alternate, increasing the packing density and mechanical stability of the formed pattern while maintaining accurate placement.

[0057] In an example, the control system may be configured to evaluate the stability of each intermediate arrangement during the stacking operation, wherein the arrangement is considered stable if a predetermined stability criterion derived from geometric and mass parameters is fulfilled. It may be provided that evaluating stability may be understood as computing or estimating the support polygon and the vertical projection of the centre of mass of each partial stack within the conveyor workspace. An effect is that unstable configurations can be avoided in real time, reducing error recovery movements and the need for re-sorting, which contributes to higher overall throughput and reduced processing load in downstream systems.

[0058] In an example, the control system may be configured to define and size a specific buffer area on the conveyor, wherein the buffer area is determined according to at least one or more of the projected footprint of the products to be handled, an additional manipulator work allowance, a temporal reservation period, and a spatial safety margin relative to neighbouring products. It may be provided that a buffer area may be understood as a contiguous, reserved region on the conveyor surface that is temporarily kept free from products and movements, its dimensions and duration being actively managed by the control system. An effect is that the buffer area becomes a predictable workspace rather than an incidental empty patch, enabling controlled and collision-free operations in a densely occupied product flow.

[0059] In another example, the areal size of the buffer area may be defined as at least equal to the largest product footprint within a currently processed set, increased by a manipulator work allowance that corresponds to the lateral and vertical clearance required for safe gripper approach and withdrawal. It may be provided that the manipulator work allowance may be understood as the minimal envelope needed by the end-effector for secure handling of products, considering its geometry and trajectory. This way the buffer area always accommodates the physical presence of both the product and the gripper path, ensuring that handling motions remain kinematically feasible even in crowded conditions.

[0060] In another example, the control system may be configured to assign a temporal reservation window to each buffer area, wherein the reservation window defines the time interval during which the buffer remains free until its consumption by a subsequent manipulation. It may be provided that a temporal reservation window may be understood as a time-based allocation of conveyor surface resources under real-time control logic. This way this spatial and temporal planning are unified, allowing the system to coordinate multiple robots without mutual interference and to minimise idle waiting time, thereby optimising bandwidth and computational scheduling.

[0061] In another example, the control system may be configured to maintain a spatial safety margin around the buffer area, wherein the safety margin defines a nointerference zone between the buffer and neighbouring products. It may be provided that the safety margin may be understood as a guard region established in the control coordinates to prevent accidental overlap due to product tolerances or vision inaccuracies.

[0062] In another example, the control system may be configured to verify that each defined buffer area is reachable within the operating limits of the corresponding manipulator, wherein unreachable regions are automatically excluded from buffer allocation. It may be provided that reachability verification may be understood as a kinematic feasibility check ensuring that every motion into and out of the buffer can be executed without exceeding robot constraints. This way the control software avoids dynamically infeasible trajectories and reduces computation for real-time path corrections, leading to smoother motion planning and lower processor utilisation.

[0063] In another example, the control system may be configured to optimise the position and size of multiple buffer areas by simulation of different density distributions of products on the conveyor and by evaluation of the resulting travel distances of the manipulator. It may be provided that such optimisation may be understood as an iterative computation in which the buffer parameters are tuned to minimise total motion cost while maintaining sufficient operational space. Thereby the system dynamically adapts its workspace allocation to varying product flows, achieving higher throughput, reduced actuator travel, and efficient use of processing power for motion planning.

[0064] In an example, the system may be configured such that the patternformation sequence for three-dimensional stacking is optimised to maintain the minimal travel distance of the end-effector along all three axes while ensuring that each new product is placed in a dynamically stable configuration. It may be provided that optimisation of the stacking sequence may be understood as computing an order of placement that minimises the combined displacement vector of the end-effector between consecutive picks and placements while respecting the stability conditions. An effect is that the system achieves a reduction in motion path length and cycle time, leading to improved energy efficiency and reduced wear of mechanical components, and allowing the control unit to allocate processing power more efficiently.

[0065] In an example, the control system is configured to optimize the product handling order on the conveyor belt for packaging and downstream handling. The control system selects products for forming patterns based on various characteristics to ensure efficient use of space and stability during transport. These characteristics include combining different-sized products to optimize space utilization, aligning the longest axes of the products to improve stability in the formed patterns, and arranging products based on the flatness of their main surfaces to enhance stackability. Additionally, the system compensates for product curvature or irregularities by pairing items with complementary shapes, thereby forming more stable groupings or stacks. The control system also considers non-uniform physical properties, such as asymmetry or surface irregularities, to ensure that even products with handling difficulties can be effectively grouped. By addressing these factors, the system not only optimizes space utilization and stability at the current handling stage but also improves overall efficiency and throughput for downstream processes.

[0066] In an example, the vision detection system is configured to identify nonregular products, which are characterized by handling difficulties such as irregular shapes and / or sizes, while still being suitable for their intended use. The system then enables the control system to strategically stack these non-regular products with one or more regular products at the bottom to maintain stability. This approach allows for the efficient inclusion of non-regular products in the packaging process, reducing waste. By placing regular products, which do not exhibit handling difficulties, at the bottom of stacks, the system ensures structural integrity of the formed patterns, potentially minimizing the risk of stack collapse and product damage during transport.

[0067] In an example, the system further comprises multiple robotic arms, wherein the control system is configured to coordinate the multiple robotic arms to simultaneously rearrange products on the conveyor belt, and wherein preferably the robotic arms are configured to enter each other's work area, while avoiding collisions and optimizing task distribution. It may be provided that multiple robotic arms are coordinated for simultaneous product rearrangement. This feature may increase the system's throughput by allowing parallel processing of products. The coordinated movement of multiple arms can potentially reduce cycle times and improve overall efficiency of the pick and place operation. Furthermore, the robotic arms are preferably configured to enter each other's work area, while avoiding collisions and optimizing task distribution. This capability allows the system to make full use of the available workspace, ensuring smooth, efficient operation without interruptions due to arm interference, thus further enhancing system performance.

[0068] In an example, the control system is further configured to minimize the travel distance of products during rearrangement to reduce cycle times and increase throughput. It may be provided that the control system minimizes product travel distance. This feature can lead to faster processing times by optimizing the movement paths of products. Reduced travel distances may result in lower energy consumption by the robotic arms and decreased wear on system components, potentially extending the operational lifespan of the equipment.

[0069] In an example, the predefined configurations further include groupings that combine products of different sizes to optimize space utilization in a target tray or packaging. It may be provided that product groupings combine different sizes for optimal space use. This feature allows for more efficient packing of products in their final packaging, potentially reducing the amount of packaging material required and lowering shipping costs. The ability to mix product sizes may also provide greater flexibility in meeting various packaging requirements.

[0070] In an example, the system further comprises a matrix gripper configured to pick up a group of arranged products as a single unit. It may be provided that a matrix gripper picks up product groups as single units. This feature can significantly reduce the number of individual pick and place operations required, potentially increasing the overall speed of the packaging process. Handling groups of products as single units may also improve the stability of arranged patterns during transfer to final packaging.

[0071] In an example, the control system is further configured to adapt the product groupings based on specific tolerance requirements for different positions within a stack or pattern. It may be provided that product groupings are adapted based on positional tolerance requirements. This feature allows for precise control over product placement, potentially improving the stability and appearance of final packaged products. Adapting to specific tolerances may also enable the system to handle a wider range of product variations while maintaining consistent packaging quality.

[0072] In an example, the control system is configured to determine optimal positions for forming patterns on the conveyor belt while accounting for the presence of defective products that cannot be moved, according to obstructing or interfering caused by these defective products in further downstream handling processes. It may be provided that pattern formation considers immovable defective products. This feature allows the system to work around constraints imposed by defective products, potentially reducing system stoppages and maintaining production flow. The ability to adapt patterns in real-time based on product quality may lead to more efficient use of conveyor belt space.

[0073] In an example, the system is configured to operate with the conveyor belt initially filled almost to full capacity, and the control system is adapted to create buffer spaces within this occupied conveyor belt. It may be provided that buffer spaces are created within a occupied conveyor belt. This feature allows the system to operate efficiently even under high-load conditions, potentially increasing overall throughput. The creation of strategic buffer spaces may provide the flexibility needed for complex rearrangement operations without requiring additional conveyor belt length. It is expressed, that in this example, the system operates with the conveyor belt near full capacity, but not entirely without space, which allows the creation of these strategic buffer spaces. In an example, in the initial step of clearing space, the control system is further configured to identify chains of product blockages on the conveyor belt where adjacent products impede efficient pattern formation and prioritize the breaking of these chains by selectively relocating key products to available spots on the conveyor belt, thereby creating strategic buffer areas that facilitate subsequent pattern formation. It may be provided that the system identifies and breaks chains of product blockages. This feature may improve the efficiency of the space-clearing process by targeting critical areas of congestion. The strategic relocation of key products can potentially create more effective buffer areas, facilitating smoother subsequent pattern formation.

[0074] In an example, the control system, in executing the initial step of clearing space, is further configured to analyze the density distribution of products on the conveyor belt, identify high-density zones where product manipulation is most constrained, and create buffer areas preferentially within or adjacent to these high- density zones to maximize the impact on subsequent pattern formation capabilities. It may be provided that buffer areas are created based on product density analysis. This feature allows for more intelligent space management on the conveyor belt, potentially improving the efficiency of subsequent pattern formation. Targeting high-density zones for buffer creation may lead to more effective use of available space and smoother overall product flow.

[0075] In an example, during the initial step of clearing space, the control system is further configured to evaluate multiple potential buffer creation strategies, simulate the impact of each strategy on subsequent pattern formation possibilities, and select and implement the buffer creation strategy that optimizes both immediate space clearing and long-term pattern formation potential across the conveyor belt. It may be provided that multiple buffer creation strategies are evaluated and simulated. This feature may lead to more optimal space utilization by considering both short-term and long-term impacts of buffer creation. The ability to simulate and select the best strategy can potentially result in improved overall system performance and adaptability to varying product loads and configurations.

[0076] In an additional embodiment, the pick and place system described herein can be applied to a system referred to as a flexible or flex capper. The flex capper system leverages the core fastpicker algorithm to arrange products, such as cookies, into precise patterns without requiring interchangeable components. Unlike conventional capping systems that rely on extensive alignment mechanisms, such as guide plates, rollers, and stoppers, the FLEX Capper eliminates the need for strict product tolerances and mechanical guides. This allows for the handling of products of various shapes and sizes, including non-standard items like cookies with irregular shapes or decorative forms, such as race cars.

[0077] This flex capper system handles products such as cookies in accordance with the first aspect of the present disclosure, and which arranges cookies into alternating rows of top and bottom cakes, preparing them for cream deposition and final assembly into sandwiches. By employing the pick and place system of the first aspect, the cookies are manipulated into the required positions, typically by sliding (approximately 70% of the operations) or lifting (about 30%), utilizing buffer areas on the conveyor belt to ensure precise alignment. The fixed nozzle positions of the cream depositor and capper mechanism dictate the final placement of the products, and the system ensures proper alignment despite the limited flexibility in the positional arrangement. This embodiment is directed to the system's ability to handle non- uniform, irregularly shaped products with minimal mechanical complexity, further optimizing the product handling and sandwich-making processes without requiring interchangeable components for the system.

[0078] In another aspect, there is provided a pick and place system corresponding to the system of the first aspect, and designed for manipulating non- rotationally symmetrical products within a defined workspace. The system includes a conveyor belt for transporting the products and at least one robotic arm equipped with an end effector for manipulation. A control system is configured to analyze the available and occupied spaces on the conveyor belt and optimize product handling through a two-step process. This process comprises an initial step of clearing space by selectively shifting or removing products to create buffer areas on the conveyor belt. Subsequently, in the second step, the system forms patterns by grouping and arranging products into predefined configurations, such as stacks, rows, or staggered formations. The control system coordinates the movement of the robotic arm to execute the two-step optimization process and ensure efficient product arrangement on the conveyor belt. This approach increases the system's overall throughput and enhances the precision of downstream handling, while minimizing space usage and reducing bottlenecks in the production flow. Hence, the system according to this aspect, is directed to clearing space to be able to form patterns of product groups, irrespective of the products characteristics such as shape, surface curvature, size, non-uniformity, etc., which characteristics are taken into account in the system according to the first aspect.

[0079] It is to be understood that each feature described in the context of an example relating to one aspect of the invention, is similarly applicable to other aspects of the invention, including but not limited to method, the computer-implemented method, a computer program product, and a data carrier signal, where applicable. Each feature thus contributes to the overall functionality and technical advantages of the invention in its various embodiments.

[0080] Similarly, any advantages discussed in relation to specific features of the first aspect of the present disclosure, are equally pertinent to method, the computer- implemented method, the computer program product, and the data carrier signal or other aspects of the present disclosure.

[0081] Brief description of the drawings

[0082] The present disclosure will be explained in more detail below by means of examples of a device according to the present disclosure shown in the drawings, in which:

[0083] Fig. 1 shows a pick and place system according to an aspect of the present disclosure;

[0084] Fig. 2 shows various groupings of products in different formations, according to an aspect of the present disclosure;

[0085] Fig. 3 illustrates packaging constraints of two products in a box, and away of loading the box according to an aspect of the present disclosure;

[0086] Fig. 4a and 4b illustrate other packaging constraints of two products in a box, and other aways of loading the box according to an aspect of the present disclosure;

[0087] Fig. 5 shows pick and place system according to an aspect of the present disclosure, for a capper system. Detailed Description

[0088] Figure 1 provides a detailed representation of the pick and place system 100 for manipulating non-rotationally symmetrical products 110, 110', 110". The pick and place system described herein is particularly suited for handling products, specifically in the context of the present disclosure these may be cookies, baked goods, and other similar food products. Examples include various types of cookies such as round, rectangular, or irregularly shaped cookies, including sandwich cookies where top and bottom layers must be precisely aligned for cream deposition. The system is designed to efficiently handle products like biscuits, crackers, and wafers, which may vary in size and shape due to the natural variability in baking processes. Additionally, other snack items such as small cakes, pastries, or delicate confections, which require careful handling to avoid breakage, can also be efficiently manipulated. The system is capable of grouping, stacking, and arranging these non-rotationally symmetrical products to optimize space utilization during packaging. The ability to compensate for product curvature, surface irregularities, and size variations is particularly advantageous for handling cookies and similar baked goods, ensuring precise alignment and efficient packaging for downstream processes.

[0089] The system 100 illustrated in figure 1 also shows a conveyor belt 120 that is responsible for transporting the products through the workspace, while the robotic arms 130, 130', in this example there are two but these may be combined into one but also there may be three or more. The robotic arms are equipped with end effectors perform the picking and placing operations. A vision detection system 140 identifies the product characteristics, such as shape, size, and quality, and relays this information to the control system 150. The control system 150 plays an important role in optimizing product handling by identifying occupied and available spaces and executing the two-step process. The first step 161 involves clearing space by shifting or removing certain products to create buffer areas, followed by the second step 162, where the products are grouped and arranged into predefined patterns such as stacks, rows, or staggered formations. In the figure 1 , there are several products, of which some may have similar shapes, sizes and other properties or characteristics. However, in more detail, they differ. Most may be identified as regular products. But some may even be considered and identified as non-regular products, which are characterized by handling difficulties such as irregular shapes and / or sizes, while still being suitable for their intended use, whereas the regular products as defined as those products that do not exhibit these handling difficulties. Some of the non-regular products may even be broken, as illustrated by product 115.

[0090] Figure 2 shows in more detail examples of the different product groupings and formations that the system can achieve. The stack 210 showcases how multiple products 110, 110', 110" can be arranged in a stable vertical formation. This stack of uneven products is stacked in such a way that a stable formation is formed, even the unevenness of the individual products. The figure also illustrates other stacks 211 or staggered formations 212 which demonstrate alternative configurations that can optimize space and product stability. Notably, stack 212 includes both regular and nonregular products, with the regular product placed at the bottom for enhanced stability. This configuration addresses handling difficulties posed by irregular shapes. The variety of configurations showcased in this figure highlights the system's versatility in adapting to different product shapes and sizes.

[0091] Figure 3 presents a packaging scenario where two larger products 311 , 312 cannot fit into the packaging box 310 due to size constraints. However, when one large product 321 is paired with a smaller product 2322, they fit efficiently into the box 320. This example illustrates the system’s ability to optimize space utilization by combining different-sized products, i.e. by the control system to selects products based on their size and shape to optimize space usage in trays or packaging.

[0092] Figures 4a and 4b expand on the packaging challenges. In Figure 4a, a box 410 contains two larger products 411 , 412 that do not fit efficiently, while two smaller products 421 , 422 are placed in another box 420 that fits perfectly. This demonstrates the impact of size on packaging. Figure 4b takes this a step further by showing a large product 431 combined with a smaller product 432 in box 430 with different orientations 440, 441 , 442. This illustrates an embodiment of the system which is adapted to fully filled conveyor belts and creates buffer spaces to achieve optimal product grouping.

[0093] Figure 5 illustrates on a so called flex capper system 500 that applies the pick and place mechanism of the invention to align cookies for cream deposition. This embodiment demonstrates the flexibility of the system in handling non-rotationally symmetrical products 511 , 512, wherein some are facing with the top side up 511 , and others with the top side down 512. These products, such as cookies, can be irregular in shape and size. Some may even be non-regular product such as defective products 515 which may be hard, or even impossible to manipulate. By utilizing buffer areas on the conveyor belt, the system ensures precise product alignment for cream deposition and capping, reflecting the broader application of the invention. This is illustrated by the three steps in the process line, 521 , 522, 523. In the first step, 521 , the products are infed in random, non-structured manner or in other words without pattern. The first initial step 161 , 522 of manipulating, the system 500 makes room by clearing space by selectively shifting or removing products to create buffer areas on the conveyor belt based on the identified occupied and available spaces. These cleared buffer areas are clearly visible in the step 522. In the next subsequent step 162, 523, patterns are formed by grouping and arranging products into a predefined configuration, here the formation or configuration is a row of cookies with top side up 511 , followed by a row of cookies with top side down 512. The flex capper system minimizes mechanical complexity by eliminating the need for strict product tolerances or interchangeable components, further optimizing the overall production process.

[0094] Overall, the system's ability to dynamically clear space, form patterns, and handle irregular products ensures efficiency in high-capacity environments. The control system's sophisticated algorithms, paired with vision detection, allow for realtime adjustments, reducing bottlenecks and improving throughput. The described embodiments and their corresponding figures demonstrate how the system addresses practical challenges in both product handling and packaging. The modular design also allows for flexibility in adapting to various products and operational constraints, offering a comprehensive solution to modern pick and place needs.

[0095] Based on the above description, a skilled person may provide modifications and additions to the method and arrangement disclosed, which modifications and additions are all comprised by the scope of the appended claims.

[0096] It will be clear that the intention of the above description is to shed light on the working of possible embodiments of the present invention, and not to limit the scope of protection of the invention. Starting from the description, a person skilled in the art is able to conceive of and use various embodiments that fall within the inventive concept and scope of protection of the present invention.

Claims

CLAIMS1. A pick and place system (100) for manipulating non-rotationally symmetrical products (110, 110’, 110”) within a defined workspace, the system comprising: a conveyor belt (120) for transporting the non-rotationally symmetrical products; at least one robotic arm (130, 130’) equipped with an end effector for manipulating the products; a vision detection system (140) for identifying product characteristics including shape, size, and quality; a control system (150), configured to:(i) analyze the products (110, 110’, 110”) on the conveyor belt (120) to identify product characteristics and occupied and available spaces;(ii) determine optimal groupings (210, 211 , 212, 213) of products based on their identified characteristics to minimize space usage when packaged and to optimize for downstream handeling;(iii) optimize product handling order on the conveyor belt in a two-step process for the packaging and optimization at downstream handeling, comprising the steps of:(a) an initial step (161) of clearing space by selectively shifting or removing products to create buffer areas on the conveyor belt based on the identified occupied and available spaces;(b) a subsequent step (162) of forming patterns by grouping (210, 211 , 212, 213) and arranging products into a predefined configuration selected from stacks, rows, or staggered formations;(iv) control the at least one robotic arm (130, 130’) to execute the two-step optimization process and form the determined grouping (210, 211 , 212, 213).

2. The pick and place system according to claim 1 , wherein the control system is further configured to optimize the product handling order on the conveyor belt for the packaging and optimization at downstream handeling, by configuring thecontrol system to select the products for forming the patterns according to one or more of: combining different-sized products to optimize space utilization; aligning the longest axes of the products to ensure stability in the formed patterns; arranging products based on the flatness of their main surface to improve stackability; compensating for curvature or irregularities of the products by pairing products with complementary shapes to form stable groupings or stacks; taking into account the non-uniformity of the products' physical properties, such as asymmetry or surface irregularities, to form stable groupings or stacks.

3. The pick and place system according to claim 1 , wherein the vision detection system is configured to: identify non-regular products, which are characterized by handling difficulties such as irregular shapes and / or sizes, while still being suitable for their intended use, and wherein regular products as defined as those products that do not exhibit these handling difficulties; enable the control system to stack these non-regular products with one or more regular product at the bottom to maintain stability.

4. The pick and place system according to claim 1 , further comprising multiple robotic arms, wherein the control system is configured to coordinate the multiple robotic arms to simultaneously rearrange products on the conveyor belt, and wherein preferably the robotic arms are configured to enter each other's work area, while avoiding collisions and optimizing task distribution.

5. The pick and place system according to claim 1 , wherein the control system is further configured to minimize the travel distance of products during rearrangement to reduce cycle times and increase throughput.

6. The pick and place system according to claim 1 , wherein the predefined configurations further include groupings that combine products of different sizes to optimize space utilization in a target tray or packaging.

7. The pick and place system according to claim 1 , further comprising a matrix gripper configured to pick up a group of arranged products as a single unit.

8. The pick and place system according to claim 1 , wherein the control system is further configured to adapt the product groupings based on specific tolerance requirements for different positions within a stack or pattern.

9. The pick and place system according to claim 1 , wherein the control system is configured to determine optimal positions for forming patterns on the conveyor belt while accounting for the presence of defective products that cannot be moved, according to obstructing or interfering caused by these defective products in further downstream handling processes.

10. The pick and place system according to claim 1 , wherein the system is configured to operate with the conveyor belt initially filled to capacity, and the control system is adapted to create buffer spaces within this fully occupied conveyor belt.

11. The pick and place system according to claim 1 , wherein in the initial step of clearing space, the control system is further configured to: identify chains of product blockages on the conveyor belt where adjacent products impede efficient pattern formation; prioritize the breaking of these chains by selectively relocating key products to available spots on the conveyor belt, thereby creating strategic buffer areas that facilitate subsequent pattern formation.

12. The pick and place system according to claim 1 , wherein the control system, in executing the initial step of clearing space, is further configured to: analyze the density distribution of products on the conveyor belt;identify high-density zones where product manipulation is most constrained; create buffer areas preferentially within or adjacent to these high-density zones to maximize the impact on subsequent pattern formation capabilities.

13. The pick and place system according to claim 1 , wherein during the initial step of clearing space, the control system is further configured to: evaluate multiple potential buffer creation strategies; simulate the impact of each strategy on subsequent pattern formation possibilities; select and implement the buffer creation strategy that optimizes both immediate space clearing and long-term pattern formation potential across the conveyer belt.

14. A method for manipulating non-rotationally symmetrical products within a defined workspace, the method comprising the steps of: transporting non-rotationally symmetrical products on a conveyor belt; identifying, using a vision detection system, product characteristics including shape, size, and quality; analyzing, by a control system, the conveyor belt to identify product characteristics and occupied and available spaces; determining optimal groupings of products based on their identified characteristics to minimize space usage when packaged and to optimize for downstream handling; optimizing product handling order on the conveyor belt in a two-step process for the packaging and optimization at downstream handling, comprising:(a) an initial step of clearing space by selectively shifting or removing products to create buffer areas on the conveyor belt based on the identified occupied and available spaces;(b) a subsequent step of forming patterns by grouping and arranging products into a predefined configuration selected from stacks, rows, or staggered formations;controlling at least one robotic arm to execute the two-step optimization process and form the determined optimal grouping.

15. A computer program product comprising instructions which, when the program is executed by a computer, cause the computer to carry out the steps of the method according to claim 14.

Images