Automated Pallet Reassembly System with Multi-Axis Robotic Manipulation
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Solution Overview
Problem
The existing methods for reassembling block type pallets are inefficient due to the complex configuration of the pallet's layers, which makes it difficult to replace damaged or missing components without removing multiple adjacent layers, leading to increased tooling costs and space requirements.
Innovation Solution
An automated system and method for reassembling pallets, comprising block and board installation mechanisms, a transport assembly, and reorienting mechanisms like conveyor assemblies, flipping, and rotating mechanisms, allowing for the installation of components from multiple orientations within a restricted space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional manual reassembly methods are used to replace damaged components in block pallets, then workers can access and replace individual components, but the layered configuration of the pallet makes it difficult to access interior components without removing multiple adjacent layers, increasing time and labor requirements
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system that uses computer vision and automated manipulation to access and replace pallet components. The robotic arm with specialized end effectors can penetrate through layered structures to reach interior blocks and stringers without manual removal of adjacent layers, solving the accessibility problem while reducing time loss.
Solution Approach 2:
The patent introduces an intermediary robotic system that acts as a mediator between the operator and the pallet components. The robotic arm with configurable end effectors serves as an intermediary tool that can adapt to different component types and access configurations, enabling precise manipulation of interior components through the layered structure without direct human intervention.
2Adaptability or versatility
If multiple different component replacement mechanisms are used to address various components of the pallet from multiple orientations, then all components can be replaced, but the imprint space of the reassembly system expands due to the need to transport the pallet between mechanisms
Solution Approach 1:
The patent implements a universal robotic system with reconfigurable end effectors that can perform multiple replacement functions from a single station. The robotic arm can adjust its approach angles and the end effectors can be configured to handle different component types (blocks, stringers, decks), eliminating the need for multiple specialized mechanisms and reducing the system footprint while maintaining full adaptability.
Solution Approach 2:
The patent utilizes multi-axis robotic movement and three-dimensional positioning to access components from various orientations without requiring physical repositioning of the pallet between mechanisms. The robotic system moves in multiple dimensions (X, Y, Z axes plus rotational degrees) to approach components from optimal angles, consolidating what would traditionally require multiple spatially distributed mechanisms into a single compact unit.
3Adaptability or versatility
If various mechanisms are repeated multiple times along the manufacturing process to address different components, then complete reassembly can be achieved, but tooling costs significantly increase
Solution Approach 1:
The patent employs a single universal robotic platform with programmable control and reconfigurable end effectors that can handle all component replacement tasks. This eliminates the need to manufacture and maintain multiple specialized mechanisms, significantly reducing tooling costs while maintaining the ability to address all pallet components through software programming and tool configuration.
Solution Approach 2:
The patent uses programmable control parameters and configurable tool settings to adapt the same physical system to different replacement tasks. By changing operational parameters (robotic paths, speeds, forces) and tool configurations rather than physical hardware, the system achieves versatility across all component types without requiring duplicate mechanisms, thereby reducing manufacturing costs.
Data Source
AI summary
A pallet reassembly system includes at least one block installation mechanism configured to install a block within a partially assembled pallet, at least one board installation mechanism configured to install a board within the partially assembled pallet, and at least one transport assembly for transporting the partially assembled pallet to each of the at least one block installation mechanisms and each of the at least one board installation mechanisms. The transport assemblies are arranged into a loop including at least two perpendicular arranged legs.