3D Vision Palletizing for Real-Time Load Build Variation
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Solution Overview
Problem
Conventional palletizing systems fail to provide adaptive, real-time build variation for achieving time-optimal pallet load building, leading to inefficiencies in storage, sortation, and transport processes.
Innovation Solution
The implementation of a real-time adaptive palletizer/depalletizer cell equipped with a 3D time of flight camera vision system, which generates real-time 3D imaging data to inform robotic placement and compensate for variances in pallet and case unit positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional palletizing systems are used, then the system structure is simple and easy to operate, but the pallet load building time is not time-optimal and packing density cannot be maximized
Solution Approach 1:
The system pre-calculates the optimal pallet load configuration and build sequence before actual palletizing begins. The controller stores multiple pallet load configurations with different packing densities and build times, allowing the system to select and execute the time-optimal configuration in advance, thereby achieving fast pallet load building without real-time computation delays
Solution Approach 2:
The system dynamically adjusts the pallet load building process by selecting from multiple pre-calculated configurations based on real-time requirements. The controller can switch between different packing densities and build sequences, making the system adaptable and efficient without requiring complex real-time optimization algorithms
2Quantity of substance
If high packing density is pursued, then the pallet load efficiency improves, but the build time increases significantly
Solution Approach 1:
Multiple pallet load configurations with varying packing densities are pre-calculated and stored in the controller. The system selects the configuration that achieves the required density while minimizing build time, avoiding the need to compute optimal arrangements in real-time during actual palletizing operations
3Productivity
If adaptive real-time build variation is implemented, then the pallet load building becomes time-optimal, but the device complexity and cost increase
Solution Approach 1:
The system achieves adaptive real-time build variation through pre-calculated configurations rather than complex real-time sensing and computation. By storing multiple pallet load configurations with different characteristics, the system can adapt to varying requirements by selecting appropriate pre-computed solutions, maintaining simplicity while achieving efficiency
Solution Approach 2:
The system uses pre-calculated pallet load configurations as templates or copies that can be rapidly selected and executed. Instead of computing unique optimal solutions for each palletizing task, the system replicates and adapts from pre-computed configurations, reducing computational complexity while maintaining optimality
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 substantially continuous and adaptive pallet load building, optimizing build time and ensuring high packing densities, thereby enhancing overall system efficiency and pallet quality.
Implementation Method 1
3D time of flight camera vision system, which generates real-time 3D 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.