Automated Pallet Loading with Sensor-Based Stack Adaptation
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Solution Overview
Problem
Existing methods for loading pallets with packages using robots face inaccuracies and inefficiencies due to deviations between theoretical and real package stacks, leading to suboptimal use of space, potential collisions, and incorrect stability assessments, especially when dealing with deformable packages.
Innovation Solution
A system that uses sensors to detect the real package stack, adapt the mathematical-physical model to match the actual stack, and adjust the placement positions and stability criteria accordingly, allowing for more accurate and gentle handling of packages and improved stability assessments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If packages are dropped from a sufficient distance above their desired position to avoid collisions, then collision risk is reduced, but positioning accuracy deteriorates and position inaccuracy increases
Solution Approach 1:
The system performs preliminary detection of the real package stack position before package placement, using sensor data to identify actual package locations and deviations from the model. This preliminary information is used to adjust the placement strategy, allowing packages to be dropped from optimal heights that avoid collisions while maintaining accuracy.
Solution Approach 2:
The system continuously compares the model-based desired positions with sensor-detected real positions, using this feedback to dynamically adjust placement parameters. When deviations are detected, the system modifies drop heights and trajectories in real-time, resolving the contradiction between safe dropping distances and positioning precision.
2Device complexity
If the package stack model is used without adaptation, then computational simplicity is maintained, but space utilization deteriorates due to incorrect maximum height determination
Solution Approach 1:
The system transitions from a static, fixed model to a dynamic model that adapts in real-time based on sensor feedback. The model parameters (particularly package positions and stack height) are continuously updated to reflect actual conditions, enabling accurate determination of maximum stack height and optimal space utilization without excessive complexity.
Solution Approach 2:
The system modifies key model parameters (package positions, dimensions, stack height) based on detected deviations from reality. By dynamically adjusting these parameters, the system maintains accurate space utilization calculations while keeping the overall model structure manageable and computationally efficient.
3Manufacturing precision
If force-regulated approach strategies are used, then positioning accuracy is improved, but package deformation increases for softer packages
Solution Approach 1:
The system replaces force-regulated mechanical approach strategies with sensor-based positional control. Instead of using contact forces to regulate approach, the system uses optical or other non-contact sensors to detect package positions and guides the manipulator to precise locations without physical contact during detection, avoiding deformation of soft packages while maintaining accuracy.
4Device complexity
If the model deviates from the real package stack, then initial model simplicity is maintained, but stability assessment reliability deteriorates leading to stack failures
Solution Approach 1:
The system implements continuous feedback between sensor detection and model updating. Real package stack positions are detected and compared with model predictions, and stability assessments are performed based on the updated model that reflects actual conditions. This feedback loop ensures reliable stability assessment while maintaining a relatively simple model structure.
Data Source
AI summary
A method and system for loading a loading carrier, in particular pallets, with packages by means of an automated manipulator, a model of a package stack on the loading carrier is automatically determined, an initial desired position for a package in the mode is determined, the package stack is detected on the loading carrier, a deviation between the detected package stack and the model is determined, the package is placed by the manipulator, and the steps are repeated until a termination criterion is reached.