Mixed-Case Pallet Sequencing for Stable Robotic Palletizing
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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 that decouples the generation of the mixed case pallet arrangement plan from the placement sequence, allowing for optimal and flexible sequencing of cases, enabling continuous and efficient pallet building despite anomalies, and ensuring stability and real-time adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed sequencing system is used for pallet building, then the mechanical and structural arrangement can be simplified, but the system cannot adapt to variations in case dimensions and SKUs, leading to inefficiencies
Solution Approach 1:
The patent implements a dynamic sequencing system where the placement sequence is not fixed but determined in real-time based on case characteristics. The system continuously adapts the build sequence according to the actual dimensions, weight, and SKU of cases being palletized, transforming a static mechanical system into a dynamic responsive one that optimizes for stability and efficiency with each unique pallet build scenario.
Solution Approach 2:
The system changes operational parameters (placement sequence, stacking pattern, consolidation approach) based on the specific parameters of the cases being handled. By analyzing case dimensions, weight, and SKU information, the system dynamically adjusts sequencing parameters to achieve optimal pallet stability and build efficiency for each unique combination of cases.
2Productivity
If cases are palletized in a fixed sequence, then the palletizing process is straightforward, but anomalies in case feed sequence cause interruptions and reduce productivity
Solution Approach 1:
The system incorporates feedback mechanisms that continuously monitor the case feed sequence and compare it against the optimal build sequence. When anomalies or deviations are detected, the system receives feedback about the actual case characteristics and dynamically recalculates the placement sequence to maintain continuous operation, preventing interruptions and maintaining high productivity despite variations in case arrival order.
Solution Approach 2:
The system performs preliminary analysis of case characteristics and pre-determines the optimal placement sequence before actual pallet building begins. By anticipating potential issues with case feed sequence and pre-planning alternative sequences, the system can smoothly handle anomalies without interruption, ensuring continuous operation and maintaining high pallet build rates.
3Stability of the object's composition
If mechanical arrangement of the pallet cell is optimized, then structural stability is improved, but the interface to the automated storage and retrieval engine remains a bottleneck
Solution Approach 1:
The system creates a universal interface between the pallet cell and the automated storage and retrieval engine that can handle multiple case types, dimensions, and SKUs through a single standardized connection point. This multi-functional interface allows the system to maintain optimized mechanical arrangements for pallet stability while simultaneously accommodating the diverse output requirements of the storage and retrieval engine, eliminating the bottleneck effect.
Data Source
AI summary
An automated palletizer for building a mixed case pallet, the automated palletizer including a case infeed that feeds mixed cases to provide an input queue feed sequence of mixed cases. At least one pallet building robot communicably connected to the case infeed and configured to receive the mixed cases in the input queue feed sequence of mixed cases, and place the mixed cases according to and dependent on the input queue feed sequence of mixed cases so as to effect building the mixed case pallet at a predetermined substantially steady placement rate. A controller communicably connected to the case infeed and at least one pallet building robot, and being configured so as to generate a complete and stable mixed case arrangement plan that completes at least a predetermined whole part of the mixed case pallet and that describes a predetermined planned location and pose for each case.