Multi-Pallet Robotic Palletizing for Stable Mixed-Case Loads
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing systems struggle to efficiently and stably stack heterogeneous items on pallets due to variations in size, weight, and shape, often resulting in unstable pallets that cannot be handled by equipment like forklifts and risk item damage.
Innovation Solution
A robotic system equipped with 3D cameras, force sensors, and sensor arrays determines item attributes and uses item type-specific models to grasp and place items, with human intervention if needed, and employs machine learning to optimize stacking and ensure stability, allowing simultaneous palletization on multiple pallets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If items are stacked manually by human workers using judgment and intuition, then the palletization process is flexible and adaptable to different item characteristics, but the process is slow and labor-intensive with inconsistent results
Solution Approach 1:
The patent replaces the manual mechanical stacking process with an automated robotic system. The robotic arm equipped with sensors and computer vision technology automatically identifies, grasps, and places items on pallets, eliminating the need for human workers to manually handle each item while maintaining adaptability through intelligent algorithms.
Solution Approach 2:
The system enables the robotic palletizer to autonomously make decisions about item placement without continuous human intervention. The computer vision system and control algorithms allow the robot to independently assess item characteristics, determine optimal stacking positions, and adjust to different item types, making the system self-sufficient in operational decision-making.
2Productivity
If items are stacked automatically by robotic systems, then the palletization process is fast and consistent, but the system struggles with heterogeneous items of varying sizes, weights, and shapes resulting in unstable pallets
Solution Approach 1:
The patent incorporates sensor arrays and computer vision systems that continuously monitor item characteristics and pallet configuration. This feedback mechanism allows the robotic system to detect item attributes such as size, weight, and shape in real-time, and adjust placement strategies accordingly to maintain pallet stability while operating at high speed.
Solution Approach 2:
The system dynamically adjusts stacking parameters based on detected item characteristics. The control algorithm modifies placement positions, orientations, and compression forces according to the specific attributes of each item, enabling the robotic system to handle heterogeneous items effectively while maintaining consistent high-speed operation.
3Quantity of substance
If items are densely packed to maximize space utilization, then storage and shipment efficiency is improved, but the pallet may become unstable and items may be damaged
Solution Approach 1:
The robotic system performs preliminary assessment of item characteristics and pallet configuration before finalizing each placement. The computer vision system and control algorithms pre-calculate optimal positions and orientations that maximize space utilization while ensuring stability, preventing damage before it occurs rather than reacting to problems after they arise.
Data Source
AI summary
A robotic system is disclosed. The system includes a communication interface, and one or more processors coupled to the communication interface and configured to: generate based at least in part on the received data a plan to stack the items on or in the destination location. For each item, the generating the plan includes determining the destination location based at least in part on a characteristic associated with the item, and at least one of (i) a characteristic of a platform or receptacle on which one or more items are to be stacked, and (ii) an existing stack of one or more items on the platform or receptacle. The destination location is determined from among a plurality of zones in which platforms or receptacles are disposed, and each of the plurality of zones are within a range of a robotic arm. A robotic arm is controlled to implement the plan.