Intermediate Layer Positioning via Optical Edge Detection
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Solution Overview
Problem
Existing automated palletizing systems face challenges in ensuring precise and stable placement of intermediate layers, particularly half-layers, which can lead to instability and inaccuracies during pallet formation due to slippage and misalignment, affecting the overall stability of the pallet composition.
Innovation Solution
A method and device utilizing independent suction and/or gripping devices to separate and position intermediate layers with high precision, employing sensor systems for optical detection of edges to guide the layers to their target positions, ensuring accurate alignment and placement on the pallet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual intermediate layers are separated from the stack using conventional gripper methods, then the intermediate layers can be placed on the pallet, but the intermediate layers slip or become misaligned, resulting in inaccurate positioning
Solution Approach 1:
A sensor system detects the actual position of the intermediate layer's outer edge during separation and transport. The control device processes this detected position information and adjusts the direction of movement of the suction/gripping device in real-time to compensate for deviations, ensuring the intermediate layer reaches its target position with high accuracy despite initial misalignment or slippage.
Solution Approach 2:
The patent replaces purely mechanical positioning methods with an automated control system that uses sensor detection and dynamic movement adjustment. Instead of relying solely on mechanical precision of the gripper and guide rails, the system uses optical/electronic sensors to detect position and computationally controls the actuator to achieve accurate placement, thereby improving both precision and reliability.
2Productivity
If multiple intermediate layers are stacked to form pallet levels, then the pallet can accommodate more articles, but the intermediate layers may not be exactly positioned, leading to pallet instability
Solution Approach 1:
The sensor system continuously monitors the position of each intermediate layer during the stacking process. The control device uses this feedback information to adjust the placement position of subsequent intermediate layers, ensuring that each layer is accurately positioned relative to the pallet center and previous layers, thereby maintaining pallet stability even as multiple layers are accumulated to increase capacity.
3Productivity
If the gripper moves back and forth to pick up and place intermediate layers, then the palletizing process can continue, but the positioning accuracy decreases after several consecutive removals
Solution Approach 1:
The sensor system detects the position of the intermediate layer at each pickup and placement operation. The control device accumulates position information and continuously adjusts the gripper's movement trajectory for each subsequent operation, compensating for any drift or cumulative error that occurs during repeated back-and-forth movements, thereby maintaining high positioning accuracy throughout the entire palletizing process.
Solution Approach 2:
The sensor system detects and records the position characteristics of the intermediate layer before the gripper picks it up. This preliminary position information is used by the control device to pre-calculate and adjust the optimal movement path, ensuring that even after multiple operations, the intermediate layer is placed with high accuracy by anticipating and compensating for potential positioning drift.
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 solution enables precise and stable assembly of intermediate layers on pallets, preventing instability and inaccuracies, thereby enhancing the overall stability and throughput of the palletizing process.
Implementation Method 1
at least two suction and/or gripping devices (3) for the separation of a respective individual intermediate layer (5) from at least two separate intermediate layer stacks (7)
Implementation Method 2
separated, the individual intermediate layers (5) are moved into a detection area of a sensor system (13), where an outer edge (6) running in the direction of movement is detected by means of an optical detection
Data Source
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AI summary
A method and a device (1) for handling individual intermediate layers (5) is disclosed. Within the scope of the method, an individual intermediate layer (5) arranged on top of the respective stack of intermediate layers (7) is removed from each of at least two separate stacks of intermediate layers (7). Furthermore, the individual intermediate layers (5) removed from the at least two separate stacks of intermediate layers (7) are moved into a recording range of a sensor unit (13), wherein each of the separated intermediate layers (5) enters a recording range of a sensor unit (13) of its own and the respective own sensor unit (13) detects an outer edge (6) running in the direction of movement of the respective intermediate layer (5), preferably by means of optical recording. Subsequently, the removed individual intermediate layers (5) reach a respective destination (Z1, Z2) while taking the respective, preferably optical, recording into account, and so the intermediate layers (5) reach their respective destination (Z1, Z2) in a predetermined position.