3D Vision Palletizing for Continuous Adaptive Load Building
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Solution Overview
Problem
Conventional palletizing and depalletizing systems fail to provide adaptive, real-time solutions for building pallet loads efficiently, leading to suboptimal time and resource utilization in storage and retrieval systems, particularly in mixed case scenarios where high packing density and time-optimal building are simultaneously required.
Innovation Solution
The implementation of a real-time adaptive palletizer cell equipped with a three-dimensional time of flight camera vision system that generates and processes 3D imaging data to inform robotic placement, allowing for continuous and adaptive adjustment of pallet load building, correcting variances and deviations in real-time to ensure optimal pallet construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional palletizers with 3-D mapping systems are used, then automation positioning relative to the pallet load is improved, but time-optimal building of pallet loads is not achieved due to lack of real-time adaptive adjustment
Solution Approach 1:
The system implements real-time feedback by continuously capturing images of the pallet load build structure during construction, comparing actual placement against the plan, and immediately adjusting subsequent placement operations. This closed-loop control enables time-optimal building by correcting deviations as they occur rather than detecting them after completion.
Solution Approach 2:
The palletizer system performs self-correction by automatically detecting placement variances and adjusting its own operations without external intervention. The system monitors its own build process in real-time and autonomously modifies placement parameters to maintain optimal efficiency and accuracy.
2Quantity of substance
If high packing density is pursued, then pallet load efficiency is improved, but build time increases making the process time-suboptimal
Solution Approach 1:
The system pre-plans the entire pallet load build structure before construction begins, determining the optimal placement sequence for high density. By calculating the complete arrangement in advance and then executing with real-time adjustments, the system achieves high packing density without time penalties.
Solution Approach 2:
The system dynamically adapts the build process by continuously monitoring actual placement against the plan and adjusting subsequent operations in real-time. This dynamic control enables the system to maintain high packing density while optimizing build speed, as deviations are corrected immediately rather than requiring rework later.
3Productivity
If adaptive real-time adjustment is implemented, then time-optimal pallet building is achieved, but device complexity increases due to vision system requirements
Solution Approach 1:
The system replaces complex mechanical measurement and positioning systems with a vision-based approach. Instead of using sophisticated mechanical sensors and encoders to track pallet build, the system uses image capture and processing to detect placement, simplifying the mechanical complexity while enabling real-time adaptive control.
Solution Approach 2:
The system creates a digital copy (image) of the physical pallet load build structure and compares this copy against the planned arrangement. This optical copying approach simplifies the measurement system compared to direct mechanical measurement, enabling real-time verification with simpler sensors and actuators.
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 approach enables the construction of pallet loads in a time-optimal manner, improving efficiency and adaptability, thereby enhancing the overall performance of storage and retrieval systems by ensuring high packing density and minimizing bottlenecks.
Implementation Method 1
at least one three-dimensional, time of flight, camera
Data Source
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AI summary
A pallet building apparatus for automatically building a pallet load of pallet load article units onto a pallet support including a frame defining a pallet building base, at least one articulated robot to transport and place the pallet load article units, a controller to control articulated robot motion and effect therewith a pallet load build, at least one three-dimensional, time of flight, camera to generate three- dimensional imaging of the pallet support and pallet load build, wherein the controller registers, from the three- dimensional camera, real time three-dimensional imaging data embodying different corresponding three-dimensional images of the pallet support and pallet load build, to determine, in real time, from the corresponding real time three-dimensional imaging data, a pallet support variance or article unit variance and generate in real time an articulated robot motion signal, the articulated robot motion signal being generated real time so as to be performed real time by the at least one articulated robot between placement of at least one pallet load article unit and a serially consecutive pallet load article unit enabling substantially continuous building of the pallet load build.