Flexible Mixed-Case Pallet Sequencing for Stable Robot Build Rates
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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 sequencing from the mixed case pallet plan, 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 a fixed sequencing system is used for pallet building, then the system structure is simple, but the system cannot adapt to heterogeneous case dimensions and SKUs, leading to reduced productivity and stability issues
Solution Approach 1:
The sequencing system transitions from a fixed, static configuration to a dynamic, reconfigurable one. The patent implements a controller that can generate and modify case placement sequences in real-time based on the actual dimensions and characteristics of cases being palletized. This allows the system to adapt its sequencing logic dynamically without requiring physical reconfiguration, resolving the contradiction between adaptability and complexity.
Solution Approach 2:
The system changes the parameters of the sequencing process based on input case characteristics. The controller receives case dimension data and adjusts the placement sequence parameters accordingly, optimizing pallet building for each unique set of cases. This parameter-based approach enables high adaptability while maintaining a relatively simple system architecture, as the complexity is managed through software logic rather than mechanical complexity.
2Reliability
If real-time adjustments for anomalies are implemented, then the reliability of pallet building is improved, but the system complexity and processing time increase
Solution Approach 1:
The system performs preliminary actions by pre-planning the case placement sequence before actual pallet building begins. The controller generates the complete sequence in advance based on case characteristics and pallet requirements, allowing for anomaly detection and correction before the physical palletizing process starts. This preliminary sequencing reduces real-time processing demands while maintaining high reliability through advance problem identification.
Solution Approach 2:
The system implements feedback mechanisms where the controller monitors the pallet building process and compares actual case placement against the planned sequence. When anomalies are detected (such as misplaced cases or dimensional variations), the system provides feedback and generates corrective sequence adjustments. This closed-loop control improves reliability by ensuring errors are caught and corrected, while the feedback-based approach efficiently manages processing time by only reprocessing affected portions of the sequence.
3Adaptability or versatility
If the sequencing is decoupled from the pallet plan generation, then the flexibility and adaptability of case placement is improved, but the system complexity increases
Solution Approach 1:
The system segments the pallet building process into distinct functional modules: case characterization, sequence generation, and execution control. The controller is divided into separate functional units that handle different aspects of the sequencing logic independently. This segmentation allows each module to be optimized separately, increasing overall flexibility while managing complexity through modular design. The decoupling of sequencing from pallet plan generation is achieved through this segmented architecture, where each segment handles its specific task with well-defined interfaces.
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.