Adaptive Manipulator for Palletizing with Variable Feed Sequences
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Solution Overview
Problem
Existing palletizing systems are prone to interruptions and reduced throughput when one or more transport lanes experience disruptions, as they require uninterrupted supply from multiple lanes to maintain layer formation and palletization processes.
Innovation Solution
A method and device that utilize a program-controlled manipulator to adaptively pick up and position articles from multiple, spatially distant feed stations without a fixed sequence, allowing for flexible movement paths and variable transfer speeds to maintain throughput even with partial or complete interruptions in transport lanes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple transport lanes are used to supply articles to the layer formation station, then the productivity and throughput of the palletizing system are improved, but the system becomes vulnerable to interruptions and jams that stop the entire grouping process
Solution Approach 1:
The control system dynamically adapts the manipulator's movement sequence based on real-time sensor feedback about article availability at different feed stations. When one transport lane is interrupted or jammed, the system automatically recalculates and executes alternative pickup sequences from remaining operational lanes, maintaining continuous layer formation without stopping the entire process
Solution Approach 2:
The system changes operational parameters (manipulator trajectory, pickup sequence, transfer timing) based on the detected state of transport lanes. Sensors monitor article presence and conveyance status, triggering parameter adjustments in the control program to optimize manipulator paths and maintain throughput despite variations in lane availability
2Ease of operation
If a fixed movement sequence is used by the manipulator to pick up articles from feed stations, then the control process is simplified, but the system cannot adapt to varying delivery frequencies and interruptions in transport lanes
Solution Approach 1:
Sensors at each feed station detect article presence and conveyance status, providing real-time feedback to the control system. This feedback enables the control program to dynamically adjust the manipulator's pickup sequence and movement parameters, allowing adaptation to varying delivery frequencies and lane interruptions while maintaining automated control
Solution Approach 2:
The manipulator control transitions from a static fixed sequence to a dynamic adaptive sequence that responds to real-time conditions. The control system continuously monitors feed station status and automatically recalculates optimal pickup paths, balancing operational simplicity with adaptability through automated decision-making
3Manufacturing precision
If the manipulator waits for articles to arrive at feed stations before picking them up, then positioning precision is improved, but the overall throughput is reduced due to waiting time
Solution Approach 1:
The system performs preliminary positioning of articles on transport lanes before they reach the feed stations, using sensors to detect article locations upstream. The manipulator is pre-positioned and ready to pickup articles as they arrive, eliminating waiting time while maintaining positioning accuracy through coordinated motion control
Solution Approach 2:
The manipulator maintains continuous operation by overlapping its movement cycles with article conveyance. While the manipulator moves to position for the next pickup, articles continue to be conveyed to feed stations. This continuous action eliminates idle waiting time while preserving positioning precision through synchronized motion planning
Data Source
AI summary
The invention relates to a method for forming palletizable layers (22, 28) of adjacent articles (16), multipacks (17) or the like at a layer-forming location using at least one program-controlled manipulator (20) for picking up one or more articles (16) or multipacks (17) at, and/or transferring them to, at least two spatially remote and/or spatially offset feeding stations and for positioning the articles (16) or multipacks (17), by rotation and/or displacement in predeterminable release positions at the layer-forming location, wherein, in dependence on a current supply situation of the articles (16) or multipacks (17) at the at least two feeding stations, the at least one manipulator (20) picks up the articles (16) or multipacks (17) selectively and without any fixed sequence, at the feeding stations and transfers them, with flexible adaptation of the respective transfer path, to the release position. The invention also relates to a corresponding apparatus for forming planar layers (22, 28) of articles (16) using a layer-forming location and at least one manipulator (20). The feeding stations are assigned sensor devices (52) which are intended for detecting the degree to which the feeding stations are occupied by conveyed articles (16) and which are coupled to a control device (54) for activating the at least one manipulator (20).