3D Vision Palletizing for Real-Time Case Placement Correction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional palletizing and depalletizing systems fail to achieve truly adaptive, real-time build variations for optimal pallet load building efficiency, leading to suboptimal time consumption and system bottlenecks in mixed case pallet load handling.
Innovation Solution
The implementation of a real-time adaptive palletizer cell equipped with a 3D time-of-flight camera vision system that generates three-dimensional imaging data to monitor and adjust the placement of case units on a pallet, allowing for continuous and adaptive pallet building by compensating for variances in the pallet support and case unit placement, thereby ensuring a time-optimal build process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional palletizing systems use electromagnetic radiation and optical mapping sensors to map the 3-D pallet load, then positioning accuracy relative to the pallet load is improved, but the system cannot achieve truly adaptive real-time build variations, leading to suboptimal build time
Solution Approach 1:
The system continuously captures 3-D images of the pallet load during construction and uses this real-time feedback to adjust the placement of subsequent cases. The controller compares the actual pallet load configuration with the planned configuration and modifies placement instructions dynamically, enabling adaptive real-time adjustments that improve both positioning accuracy and build efficiency
Solution Approach 2:
The system transitions from static pre-planned pallet construction to dynamic adaptive construction. The 3-D imaging system and controller operate continuously during the pallet building process, allowing the system to adapt to variations in case dimensions, pallet surface irregularities, and placement deviations in real-time, thereby optimizing build time while maintaining precision
2Quantity of substance
If the system aims for high packing density over 90%, then pallet load efficiency is improved, but the build process becomes time-consuming due to the complexity of solving the packing puzzle
Solution Approach 1:
The system pre-calculates an optimal pallet load plan before construction begins, using the known dimensions of cases and pallet constraints to determine the most efficient arrangement. This preliminary planning achieves high packing density targets (over 90%) while providing a structured framework that accelerates the actual building process by eliminating real-time decision complexity
Solution Approach 2:
The continuous 3-D imaging and real-time feedback system monitors the actual pallet load construction against the pre-calculated plan, making dynamic adjustments to maintain high packing density while accommodating variations. This feedback mechanism ensures the final pallet achieves target density without requiring time-consuming manual optimization during construction
3Device complexity
If conventional systems do not compensate for variances in pallet support and case unit placement, then the system complexity is reduced, but pallet load quality and stability deteriorate
Solution Approach 1:
The 3-D imaging system continuously monitors the actual positions and orientations of cases on the pallet, detecting variances from the planned configuration. The controller uses this feedback to calculate compensation adjustments and instruct the robotic system to correct placement errors in real-time, thereby maintaining high pallet load quality without requiring overly complex mechanical compensation mechanisms
Solution Approach 2:
The system replaces complex mechanical compensation mechanisms with a combination of 3-D vision sensing and software-based correction. Instead of using sophisticated mechanical devices to physically compensate for pallet surface irregularities and placement variations, the system uses optical measurement and computational algorithms to detect and correct deviations, reducing mechanical complexity while maintaining precision
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 enables efficient and adaptive pallet load building, correcting deviations in real-time to achieve higher packing densities and reduce build time, thereby enhancing overall system efficiency and pallet quality.
Implementation Method 1
at least one three-dimensional, time of flight, camera is disposed on one or more of the frame and the robot(s) so as to generate three-dimensional imaging data
Data Source
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.