Automated Depalletizing Apparatus for Oriented Packaging
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Solution Overview
Problem
Manual labor is inefficient and costly for depalletizing empty packaging materials, such as bags, which requires operator training and can lead to errors and safety issues, and existing automated systems cannot handle multiple objects in varying orientations and configurations.
Innovation Solution
A deployment apparatus with an article detector and removal system that uses image processing to determine the orientation and position of non-overlapped articles on a support surface, allowing for automated selection and removal of articles, including packaging materials, and reorientation for efficient deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual labor is used for depalletizing bags, then operator flexibility and adaptability are maintained, but labor costs increase and operator errors occur
Solution Approach 1:
The patent replaces manual mechanical operation with an automated system comprising a detector that identifies bag orientations and a robotic manipulator that executes removal actions. The detector captures images of bags on the pallet, determines their orientations, and feeds this information to the manipulator which automatically selects and removes bags according to predetermined criteria, eliminating manual labor while maintaining adaptability to various bag configurations.
Solution Approach 2:
The system enables self-service automation where the detector and manipulator work autonomously to depalletize bags without human intervention. The detector continuously monitors bag orientations, the controller processes this information according to stored criteria, and the manipulator executes removal actions automatically, creating a self-contained automated depalletizing system.
2Productivity
If automated systems are used for depalletizing, then labor costs are reduced, but existing systems cannot handle multiple objects in varying orientations
Solution Approach 1:
The robotic manipulator is designed with universal capability to handle bags in multiple orientations (0°, 45°, 90°, 135°) through a single unified system. The detector captures images and determines orientations for any bag configuration, and the manipulator adapts its movement and grasping actions accordingly, making the system versatile enough to handle varied bag arrangements without requiring separate specialized equipment for each orientation.
Solution Approach 2:
The system incorporates a feedback loop where the detector continuously monitors bag orientations, feeds this information to the controller, which then adjusts the manipulator's actions accordingly. This real-time feedback mechanism enables the automated system to adapt to varying bag configurations and maintain high productivity across different orientations.
3Quantity of substance
If multiple bag orientations are used on pallets, then surface utilization is maximized, but detection and selection complexity increases
Solution Approach 1:
The detector creates a visual copy (image) of the pallet surface showing all bag orientations, and the controller processes this visual information to identify individual bags based on their orientations. By working with image data rather than physically measuring each bag, the system simplifies the detection process while accurately determining bag positions and orientations for optimal selection.
Solution Approach 2:
The system segments the pallet surface into individual detection zones corresponding to each bag position, and the controller processes images to identify bags in each segment separately. This segmentation approach allows the complex task of detecting multiple oriented bags to be broken down into simpler individual detections, reducing overall system complexity while maintaining the ability to handle varied orientations.
Data Source
AI summary
A deployment apparatus (1) adapted to remove articles (14) located on a support surface (5), the articles (14) being located in a plurality of orientations and positions on the support surface (5). The deployment apparatus (1) includes; an article detector (2) capable of determining an orientation and position of at least one article located on the support surface (5), a removal system (4) capable of engaging with and removing an article (14) from the support surface (5), a maneuvering system (3) capable of positioning the removal system (4) to engage with a selected article and deploying an engaged article to a predetermined position and/or orientation.