Flexible Pallet Sequencing for Stable Mixed-Case Builds
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Solution Overview
Problem
Automated storage and retrieval systems face inefficiencies in building mixed case pallets due to the heterogeneity of case dimensions and SKUs, leading to stability issues and operational challenges in fulfilling customer orders.
Innovation Solution
A flexible sequencer system decouples the generation of mixed case pallet arrangement plans from the sequencing process, allowing for optimal and flexible case placement sequences that are unconstrained by pallet structure and case characteristics, enabling real-time adjustments for anomalies and ensuring continuous pallet building.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional pallet building systems use fixed sequencing methods to arrange cases on pallets, then the mechanical and structural arrangement can be simplified, but the system cannot adapt to heterogeneous case dimensions and SKUs, leading to instability and inefficiency in mixed case pallet construction
Solution Approach 1:
The system implements dynamic sequencing where the case placement sequence is not fixed but adapts in real-time based on case characteristics, pallet state, and stability requirements. The sequencer continuously adjusts the placement order to accommodate heterogeneous cases while maintaining operational efficiency.
Solution Approach 2:
The system changes operational parameters (placement sequence, positioning coordinates, handling speed) based on case dimensions, weight, and SKU characteristics. This allows the same mechanical system to handle diverse case types by dynamically adjusting parameters rather than requiring different mechanical configurations.
2Productivity
If the system uses rigid predetermined case placement sequences, then operational procedures can be simplified, but the system cannot resolve misqueues or handle anomalies, leading to interruptions in pallet building continuity
Solution Approach 1:
The sequencing system incorporates feedback mechanisms that monitor case arrival sequences, pallet building progress, and anomaly detection. When misqueues or anomalies are detected, the system receives feedback and dynamically recalculates the optimal placement sequence to maintain continuous operation and resolve issues in real-time.
Solution Approach 2:
The system performs preliminary sequencing calculations and prepares alternative placement sequences in advance, so when anomalies or misqueues occur during pallet building, pre-computed alternative sequences can be immediately activated without interrupting the pallet build rate.
3Productivity
If cases are arranged without considering stability constraints during sequencing, then the sequencing process can be faster and simpler, but the resulting pallet structures become unstable and may fail to meet structural requirements
Solution Approach 1:
The system performs preliminary stability assessment and sequence optimization before actual case placement. By pre-calculating stable placement sequences that account for case dimensions, weight distribution, and pallet structure requirements, the system ensures stability is built into the sequencing plan from the beginning, avoiding the need for slow corrective adjustments during placement.
Data Source
AI summary
An automated palletizer for building a mixed case pallet comprising of a case infeed that feeds mixed cases provides an input queue feed sequence of mixed cases to at least one pallet building robot that is communicably connected to the case infeed and accesses the mixed cases of the input queue feed sequence. The robot receives mixed cases in the input queue feed and place mixed cases according to the input queue feed so as to effect building the mixed case pallet at a predetermined and substantially steady placement rate which the controller is communicably connected to the case infeed and the at least one pallet building robot. The controller is designed to generate a complete and stable mixed case arrangement plan that completes a predetermined whole part of the mixed case pallet that describes a predetermined planned location and pose for each case of the mixed case arrangement plan.