Depalletizing Vision Rail With Laser Profilometers for Edge Picking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Robotic depalletization systems face challenges with vision systems installed at high elevations, requiring higher resolution lenses and sensors due to variable working distances, leading to increased costs and complicating effectiveness and reliability.
Innovation Solution
A robotic depalletization system with a vision system comprising a first rail and laser profilometers that measure geometric dimensions of objects, allowing a processor to control a robotic arm for precise object picking, and integrated 2D image capturing devices for real-time monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the vision system is installed at high elevated positions to monitor objects on the pallet, then the field of view and coverage are improved, but the working distance increases requiring higher resolution lenses and sensors which significantly drives up costs
Solution Approach 1:
The vision system is mounted on a movable platform (robotic arm or conveyor) that dynamically adjusts its position and distance relative to the pallet. This allows the system to maintain an optimal working distance for accurate detection while still achieving comprehensive coverage through motion, rather than being fixed at a high elevation that compromises either coverage or precision.
Solution Approach 2:
A lens adapter or optical intermediary is introduced between the fixed vision system and the objects being monitored. This intermediary component enables the use of lower resolution sensors by providing optical magnification or image enhancement, thus reducing the need for expensive high-resolution lenses while maintaining detection accuracy at elevated positions.
2Area of stationary object
If the vision system is placed farther away from the products to monitor the entire pallet, then the coverage area is improved, but higher resolution lenses and sensors are required to accurately detect small feature sizes which increases costs
Solution Approach 1:
The vision system is divided into multiple smaller sensor units distributed across the pallet surface or mounted on movable platforms. Each sensor unit covers a specific zone with optimal working distance, eliminating the need for a single high-resolution system to cover the entire area. The segmented approach reduces individual sensor requirements while maintaining overall coverage.
Solution Approach 2:
The vision system transitions from a single fixed elevated position to a multi-dimensional monitoring approach using multiple sensors at different heights and positions, or a movable platform that scans across the pallet. This dimensional expansion allows each sensor to operate at optimal distances while collectively achieving comprehensive coverage, reducing the need for excessively high-resolution single-point sensors.
3Stability of the object's composition
If the vision system is fixed at elevated positions, then installation stability is improved, but accessibility for adjustments and maintenance becomes difficult
Solution Approach 1:
The vision system is mounted on movable platforms or robotic arms that can dynamically position themselves. During normal operation, the system maintains stable elevated positions for monitoring. During maintenance, the platform can be moved to accessible locations, allowing technicians to easily access and service the vision components without compromising operational stability.
Solution Approach 2:
The vision system is extracted from the fixed structural mounting and placed on independent movable platforms. This separation allows the vision system to be easily removed from its operational position for maintenance and then returned, providing both installation stability during operation and ease of access during maintenance without requiring permanent fixed mounting at difficult-to-reach heights.
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
The system reduces costs by optimizing vision system placement, ensures accurate object identification, and enables efficient depalletization by allowing the profilometers to move out of the way of the robotic arm, reducing unnecessary vertical motions.
Implementation Method 1
a plurality of laser profilometers coupled to the first rail. The plurality of laser profilometers is configured to measure geometric dimensions of the plurality of objects
Implementation Method 2
each of the plurality of laser profilometers are configured to surface scan the plurality of objects placed on a pallet while the first actuator moves the first rail in the horizontal direction
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A robotic depalletization system is disclosed. The robotic depalletization system comprises a robotic arm configured to pick the plurality of objects. Further, the robotic depalletization system comprises a vision system. The vision system comprises a first rail, a first actuator, and a plurality of laser profilometers. The first actuator is configured to move the first rail in a horizontal direction over the plurality of objects. The plurality of laser profilometers is configured to measure geometric dimensions of the plurality of objects. The vision system comprises at least one processor that is configured to identify locations of edges of each of the plurality of objects based on the geometric dimensions of the plurality of objects and generate one or more signals to control the robotic arm to pick the plurality of objects based on the identified locations of the edges of each of the plurality of objects.