Centralized Palletizing Patterns for Multi-Robot Adaptability
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Solution Overview
Problem
Current automated palletizing systems are not adaptable to different packing conditions and environments, and most palletizing software is designed for a single robot or not based on any robot, limiting their flexibility and efficiency.
Innovation Solution
A centralized palletizing software system that stores stacking patterns for multiple robots in a central database, using non-dimensional data to reduce the number of patterns needed and allowing for easy expansion to accommodate additional robots, with automated pattern selection and integration with programmable logic controllers (PLCs).
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If palletizing software is designed for a single robot or not based on any robot, then the software can operate independently, but the system lacks adaptability to different packing conditions and environments
Solution Approach 1:
The patent segments the palletizing software into modular components: a centralized pattern library storing stacking patterns, robot-specific interface modules, and configuration files. This segmentation allows the core pattern library to remain adaptable while robot-specific adaptations are handled through separate interface layers, resolving the contradiction between adaptability and complexity.
Solution Approach 2:
The patent creates a universal centralized pattern library that serves multiple robots and different packing conditions. The pattern library stores generic stacking patterns that can be applied across different robot types and environments, providing multi-functionality. Robot-specific adaptations are achieved through configuration parameters rather than separate software instances, enhancing adaptability without proportionally increasing complexity.
2Ease of operation
If stacking patterns are stored individually for each robot, then each robot has dedicated patterns, but pattern maintenance becomes laborious and time-consuming
Solution Approach 1:
The patent merges all robot-specific stacking patterns into a single centralized pattern library. Instead of maintaining separate pattern files for each robot, the system consolidates patterns centrally with robot identification embedded in the pattern data structure. This merging eliminates redundant pattern copies and enables single-point maintenance, directly addressing the contradiction between operational ease and time investment.
Solution Approach 2:
The system uses digital copying mechanisms where patterns are stored once centrally and automatically distributed to multiple robots as needed. When a pattern is updated in the central library, the change is automatically copied to all relevant robots, eliminating manual pattern replication and reducing maintenance time while maintaining pattern accessibility for each robot.
3Manufacturing precision
If the system stores detailed dimensional data for each pattern, then pattern precision is high, but the number of patterns that need to be stored increases significantly
Solution Approach 1:
The patent transforms detailed dimensional pattern data into parameter-based definitions. Instead of storing complete geometric descriptions for each pattern, the system stores compact parameter sets (e.g., case dimensions, pallet dimensions, stacking geometry ratios) that can be scaled and adapted. This parameterization maintains precision by allowing accurate calculation of stacking patterns for various case sizes while dramatically reducing the number of stored patterns through mathematical generalization.
Solution Approach 2:
The system transitions from storing three-dimensional detailed pattern geometries to storing two-dimensional parameter relationships and scaling factors. By defining patterns through dimensional ratios and mathematical relationships rather than explicit 3D coordinates, the system reduces data storage requirements while maintaining the ability to generate precise stacking patterns for any given case and pallet size combination.
Data Source
AI summary
A palletizing system includes one or more palletizers. A database is configured to maintain a stacking pattern library containing multiple stacking patterns for the palletizers. A computer is operatively connected to the database. The computer is configured to automatically select a stacking pattern for a selected one of the palletizers. In other words, the computer is configured to change the stacking pattern of one of the palletizers without changing the other palletizers. The database is configured to maintain unique palletizer identifiers used for identifying individual palletizers to promote expandability.