Charging Container Pallet Stacking for Terminal Alignment
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Solution Overview
Problem
Improper palletization of containers with electrical terminals for charging electronic devices leads to reduced compressive load bearing capacity and increased damage during transit, as the terminals may not make effective electrical contact, necessitating an optimal stacking pattern that ensures electrical connectivity throughout the stack.
Innovation Solution
A method and system utilizing a computer vision system and robotic arm to identify and align the electrical terminals on containers and a pallet, ensuring electrical contact between them, with the robotic arm stacking containers based on determined optimal patterns to facilitate simultaneous charging during transport or storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional palletization patterns are used to stack containers, then the stacking process is simple and fast, but the electrical terminals do not make effective contact and the compressive load bearing capacity is reduced
Solution Approach 1:
The system performs preliminary identification of terminal locations on each container using computer vision before stacking begins. This advance knowledge allows the robotic arm to plan and execute precise stacking patterns that ensure terminal alignment, resolving the contradiction between reliable electrical contact and simple stacking processes
Solution Approach 2:
The stacking pattern is dynamically adjusted based on the identified terminal locations of individual containers. Rather than using a fixed conventional pattern, the system adapts the stacking arrangement to match the specific terminal configurations, ensuring effective electrical contact while maintaining operational efficiency
2Quantity of substance
If boxes are overlapped to increase stack density, then more containers fit on the pallet, but the compressive load bearing capacity of underlying boxes is reduced by up to 50%
Solution Approach 1:
The system applies different stacking strategies to different regions of the pallet based on terminal locations and container characteristics. By locally optimizing each stacking position rather than using a uniform pattern, the system achieves high density while distributing compressive loads appropriately to maintain the strength of underlying containers
Solution Approach 2:
The computer vision system creates a digital model or map of terminal locations for each container. This copied information is then used to plan stacking patterns that replicate successful alignment configurations, enabling high-density stacking without compromising the structural integrity of the stack
3Area of stationary object
If containers extend past the edge of the pallet to maximize space utilization, then the pallet capacity increases, but the compressive load bearing capacity is reduced by 33% and damage likelihood increases
Solution Approach 1:
The system optimizes stacking in the vertical dimension by creating multiple layers with carefully controlled terminal alignment. This allows maximum pallet utilization through vertical stacking rather than horizontal extension, maintaining structural stability by keeping all containers within the pallet boundaries while achieving high capacity through multi-level arrangement
Data Source
AI summary
A system and method palletize containers having electrical terminals for charging electronic devices packaged therein. First, a stacking pattern is determined on the basis of the sizes, shapes, and locations of electrical terminals on both the pallets and the containers to be stacked. These data may be read, for example, with a computer vision system that uses an articulating robotic arm, and may be encoded in a two-dimensional barcode on each pallet and/or container. Next, the robotic arm stacks the container so that its terminals make electrical contact with terminals on the pallet, or on a previously-stacked layer of containers. Then, the placement is tested to ensure that a good electrical connection exists vertically through the entire stack. Once the pallet is finalized, all electronic devices carried thereon may be simultaneously charged during transit or storage.