Heuristic Palletizing Algorithm for Stable Package Stacks
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Solution Overview
Problem
Existing methods for automated palletizing of packages fail to consistently generate stable stacks, especially with mixed packages of varying dimensions, as they do not effectively assess and improve stability through overbuilding and tower configurations.
Innovation Solution
A heuristic method is proposed for automated palletizing that evaluates and generates stable package stacks by virtually adding packages to an initial configuration, assessing configurations based on partial stack heights, towers, and overbuildings, and propagating stability values from bottom to top, using a weighted sum of contact areas and corners for stability determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If packages are stacked using conventional methods, then the palletizing process is simple, but the stability of the package stack is insufficient
Solution Approach 1:
The patent applies preliminary action by pre-calculating and planning the entire package stack configuration before actual palletizing. The system virtually places packages to generate multiple candidate configurations, evaluates their stability characteristics in advance, and selects the optimal arrangement before physical execution, thereby achieving high stability without increasing operational complexity
Solution Approach 2:
The patent uses copying by creating virtual models of packages and their stack configurations in a digital environment. Multiple virtual configurations are generated and evaluated to identify the optimal arrangement, which is then replicated in the physical palletizing process. This allows stability optimization without adding physical complexity to the palletizing system
2Adaptability or versatility
If packages of varying dimensions are stacked, then the adaptability of the palletizing system increases, but the stability assessment becomes more difficult
Solution Approach 1:
The patent applies parameter changes by transforming the stability assessment into a computational evaluation of multiple parameters including partial stack heights, tower configurations, and overbuilding patterns. The system calculates characteristic values for each virtual configuration and uses these parameter-based assessments to objectively compare different package arrangements, making stability evaluation manageable for mixed packages of varying dimensions
Solution Approach 2:
The patent introduces an intermediary computational model that mediates between the physical packages and the stability assessment. This virtual modeling layer translates complex physical stability problems into evaluable computational parameters, enabling systematic assessment of mixed package configurations without direct physical measurement or complex manual analysis
3Reliability
If a brute force method is used to generate configurations, then all possible configurations are explored, but the computational efficiency decreases
Solution Approach 1:
The patent applies partial action by generating and evaluating only the necessary subset of configurations required to achieve optimal stability, rather than exhaustively exploring all possible arrangements. The system uses heuristics and evaluation criteria to focus computational resources on promising configurations, achieving reliable results with improved computational efficiency
Solution Approach 2:
The patent implements feedback by using evaluation results from virtual configuration assessments to guide subsequent configuration generation. The system learns from the stability characteristics of evaluated configurations and uses this feedback to prioritize and generate more promising arrangements, improving computational efficiency while maintaining reliability through iterative refinement
Data Source
AI summary
A method for the automatic palletizing of stable package stacks includes the steps of virtual generation of multiple follow-up configurations by adding packages to at least one initial configuration, assessment of these follow-up configurations, and pursuit of follow-up configurations that are assessed as good as initial configurations. These steps are repeated until a termination criterion is satisfied. The follow-up configurations are assessed on the basis of different partial stack heights, towers and/or overbuildings. Another version of the method includes the steps of virtual generation of a package stack, and determination of a characteristic stability value of a package of a layer of a virtual package stack on the basis of the characteristic stability value of packages on which the package rests.