3D Vision Palletizer Calibration for Accurate Pallet Station Teaching

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Solution Overview

Problem

The inefficiencies in pallet load building processes due to subjective and time-consuming manual calibration of pallet loaders, leading to inconsistent system throughput and difficulties in identifying root causes of palletization inaccuracies, hinder optimal storage and retrieval system efficiency in retail distribution.

Innovation Solution

The implementation of a vision system with three-dimensional time of flight cameras and an electromagnetic sensor for fully automatic calibration and validation of palletizer cells, enabling consistent and efficient calibration of robotic palletizers, reducing human intervention and ensuring precise positioning and alignment of pallet loads.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual calibration is performed by human experts, then calibration can be completed with existing equipment, but the process is time-consuming and produces inconsistent results

Engineering Contradiction:

Improvecalibration consistencyVSAvoidcalibration time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical calibration processes with an automated vision-based system using cameras and electromagnetic sensors to detect pallet positions and automatically adjust loader parameters, eliminating human subjectivity and time consumption while improving calibration consistency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-calibration through automatic detection and adjustment mechanisms where the pallet loader autonomously identifies position deviations using vision systems and corrects them without human intervention, making the calibration process self-executing and repeatable

Inventive Principle:

Principle #25Self-service

2Device complexity

If manual calibration is used, then equipment complexity is minimized, but it becomes difficult to identify root causes of palletization inaccuracies

Engineering Contradiction:

Improvecalibration system complexityVSAvoidinaccuracy root cause detection

Core Design Contradiction:

Device complexityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent implements feedback mechanisms where vision systems continuously monitor pallet positions and loader operations, automatically recording and analyzing deviation data to identify root causes of inaccuracies, enabling systematic problem detection without significantly increasing overall system complexity

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system introduces intermediate sensing components (cameras, electromagnetic sensors) that act as mediators between the physical pallet/loader system and the control system, enabling precise measurement and diagnosis of positioning errors while keeping the core calibration mechanism relatively simple

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If automatic vision-based calibration is implemented, then calibration speed and consistency improve, but device complexity increases

Engineering Contradiction:

Improvecalibration throughputVSAvoidcalibration system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent employs multi-functional vision and sensing systems that perform multiple tasks including position detection, calibration verification, and error analysis simultaneously, increasing calibration throughput while minimizing the need for separate dedicated components that would increase complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution simplifies and accelerates the calibration process, ensuring consistent and accurate palletization across palletizer cells, enhancing system throughput and preventing misalignment issues, thereby improving the efficiency and reliability of storage and retrieval operations.

Implementation Method 1

at least one three-dimensional, time of flight, camera communicably coupled to the controller so as to three-dimensionally image

Methodology Applied

Scientific EffectTime of flight: Time of Flight

Data Source

PatentUS20230278221A1Apparatus and method for automatic pallet builder calibration

Publication Date: 2023.09.07 SYMBOTIC CANADA ULC

AI summary

A pallet building apparatus, for automatically building a pallet load of pallet load article units onto a pallet support, includes a frame defining a pallet station with a pallet building base for the pallet support, an articulated robot connected to the frame, at least one three-dimensional camera, connected to the frame separate and distinct of the articulated robot, and disposed to generate three-dimensional imaging of the pallet support on the pallet building base and of a pallet load build on the pallet support, a controller operably connected to the at least one articulated robot and the at least one three-dimensional camera, and an automatic calibration system for calibrating the articulated robot, the controller being communicably connected to the automatic calibration system, and being configured to automatically calibrate the articulated robot, from a substantially uncalibrated state, and automatically teach the articulated robot a location of the pallet station.