Automated Palletizer Controller for Stable Tier Layouts
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Solution Overview
Problem
Manual palletizing of items of different sizes is costly, slow, and prone to human error, leading to potential product damage and instability during shipment.
Innovation Solution
An automated palletizer system comprising container buffers, sensors for measuring container dimensions, a pallet loading machine, and a controller that computes optimal tier layouts based on stability, area, and volume utilization metrics to arrange containers efficiently on a pallet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual palletizing is used, then operators can rely on experience to stack containers stably, but the process is costly and slow
Solution Approach 1:
The patent replaces manual mechanical palletizing with an automated robotic system that uses computer vision and algorithms to calculate optimal container arrangements. The robotic arm mechanically places containers according to computed layouts, eliminating manual labor while maintaining stability through systematic algorithms that consider container dimensions, weights, and stacking patterns.
Solution Approach 2:
The system performs preliminary calculations of optimal tier layouts before actual palletizing begins. The controller computes multiple candidate layouts, evaluates them based on stability metrics, and selects the best arrangement in advance. This preliminary planning enables the robotic system to execute palletizing efficiently without real-time decision delays.
2Ease of operation
If manual palletizing is used, then operators can arrange items, but human error leads to product damage
Solution Approach 1:
The patent replaces human operators with an automated robotic system controlled by computer algorithms. The robotic arm executes precise movements to place containers, eliminating human error in positioning and handling. The system consistently applies proper stacking techniques and handles containers with controlled force, ensuring product safety without relying on human skill or attention.
Solution Approach 2:
The system uses vision sensors to detect container positions, dimensions, and orientations, providing feedback to the controller. This feedback enables real-time adjustments to the palletizing process, ensuring containers are placed correctly and safely. The closed-loop control system monitors and corrects positioning errors, preventing product damage.
3Productivity
If automated palletizing is implemented, then speed and accuracy improve, but system complexity increases
Solution Approach 1:
The patent employs a multi-functional integrated system where a single robotic platform performs vision-based container detection, dimensional measurement, layout calculation, and physical palletizing. The controller serves multiple functions by managing sensor data acquisition, algorithm execution, and robotic actuation. This universal system handles various container types and sizes without requiring separate specialized equipment for each function.
Solution Approach 2:
The patent introduces a software controller as an intermediary between the sensors and the robotic arm. This controller mediates the complex interactions by processing sensor data, calculating optimal layouts using algorithms, and translating these calculations into robotic movement commands. The intermediary software layer manages system complexity by providing a unified control interface and coordinating all automated functions.
4Productivity
If containers of varying sizes are palletized, then shipping efficiency improves, but arranging them stably becomes more difficult
Solution Approach 1:
The patent applies different placement strategies to different container sizes and positions within the tier. The algorithm calculates optimal orientations and positions for each container based on its specific dimensions, weight, and the local structural requirements. Larger containers may form the base while smaller ones fill gaps, with each container's placement optimized for local stability rather than applying a uniform arrangement pattern.
Solution Approach 2:
The system dynamically adjusts placement parameters such as container orientation angles, position coordinates, and stacking heights based on the specific dimensions and properties of each container. The algorithm modifies these parameters to achieve stable configurations for mixed-size containers, considering factors like center of gravity, contact surfaces, and inter-container support relationships.
Data Source
AI summary
An automated palletizer system comprises a plurality of container buffers and a sensor for measuring containers in the buffers. A controller computes a selected tier layout for building by a pallet loading machine in a tier of a pallet within a defined periphery. The controller computes candidate tier layouts, each comprising a two-dimensional arrangement of containers in the buffers. The controller calculates a value of a tier quality metric for each candidate layout, representing at least one of stability, area utilization and volume utilization. One of the candidate layouts is selected based on the tier quality metric and the pallet loading machine arranges containers according to the selected tier layout.