Mixed-Case Pallet Layering for Stable Automated Palletizing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional systems face challenges in building efficient, stable, and automated mixed case pallets for retail distribution, particularly when dealing with highly heterogeneous cases, as they struggle with packing efficiency, pallet stability, and the separation of items like food products, which affects food safety and overall logistics efficiency.
Innovation Solution
An automated storage and retrieval system that includes a palletizer capable of generating mixed case pallets with a structured layer architecture, where each layer consists of non-intersecting, free-standing stacks of mixed cases of substantially equal heights, allowing for efficient use of vertical space and stable pallet formation, incorporating autonomous robots and advanced control systems for precise case management and placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated palletizers are used to build mixed case pallets, then labor costs are reduced, but packing efficiency deteriorates due to difficulty in achieving optimal space utilization
Solution Approach 1:
The system performs preliminary actions by pre-planning the entire pallet build sequence before physical construction begins. The robot controller calculates the optimal pallet pattern, determines case placement positions, and sequences operations in advance, enabling automated systems to achieve packing efficiencies comparable to manual methods while maintaining automation benefits.
Solution Approach 2:
The palletizer system incorporates dynamic adaptability through its controller, which can adjust pallet building strategies in real-time based on case dimensions, store requirements, and pallet space utilization. This dynamic decision-making enables automated systems to optimize packing efficiency for each unique scenario rather than following rigid predetermined patterns.
2Adaptability or versatility
If cases are arranged in highly heterogeneous mixed case pallets, then store replenishment flexibility is improved, but pallet stability deteriorates
Solution Approach 1:
The system applies local quality by assigning specific placement positions and orientations to individual cases based on their dimensions, weight, and stability characteristics. The robot controller evaluates each case's properties and determines optimal placement locations that maximize overall pallet stability while accommodating heterogeneous case mixes, rather than using uniform placement rules.
Solution Approach 2:
The system uses a virtual pallet template or digital model that replicates the desired stable pallet structure before physical construction. This virtual copy allows the controller to simulate and validate the stability of heterogeneous case arrangements before execution, ensuring that replenishment flexibility is achieved without compromising pallet stability.
3Object-affected harmful factors
If food items are separated from non-food items on pallets, then food safety is improved, but device complexity increases
Solution Approach 1:
The system merges multiple functions into the single robot controller: case identification, food safety classification, pallet pattern generation, and physical placement. By combining these functions in one intelligent controller rather than requiring separate dedicated systems for each function, the implementation of food safety separation remains relatively simple while still achieving the safety benefits.
Data Source
AI summary
An automated palletizer includes an automated package pick device capable of moving packages from a package deposit section to a pallet to form a pallet load from packages, a controller that is operably connected to the automated pick device, the controller having a pallet load generator configured to determine a pallet load structure of mixed packages, the pallet load generator being programmed so that it determines the load structure from mixed package layers overlaid over each other at least one of the mixed package layers being formed of stacks of mixed packages, top and bottom surfaces of the stacks corresponding to the at least one mixed package layer respectively forming top and bottom surfaces of the at least one mixed package layer that are substantially flat. The controller generates commands for the pick device to build the pallet load from the load structure determined by the pallet load generator.