Robotic Palletizing with Dual Grouping Stations for Higher Throughput
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Solution Overview
Problem
Current robotic palletizing systems face inefficiencies in maximizing the number of items palletized per unit of time due to operational limitations, particularly in handling partly stable and unstable items, which require additional securing steps, leading to increased downtime and reduced productivity.
Innovation Solution
A robotic palletizing system with a pregrouping station and a principal grouping station, where a palletizing robot selectively operates between pregrouping and principal grouping states, and a load securing machine operates between securing and non-operational states, allowing for simultaneous grouping and securing of items without intermediate transfers, optimizing operational time and increasing throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the palletizing robot waits for the load securing machine to complete securing before grouping the next items, then the securing operation can be completed properly, but the robot experiences increased idle time and reduced productivity
Solution Approach 1:
The system performs preliminary grouping actions at the pregrouping station before the securing operation is complete. The robot groups items into preliminary configurations that are then transferred to the principal grouping station, allowing the securing and grouping operations to overlap in time rather than execute sequentially
Solution Approach 2:
The grouping operation is divided into two segments: preliminary grouping at the pregrouping station and final grouping at the principal grouping station. This segmentation allows the robot to perform preliminary grouping while the securing machine operates, then complete the grouping process after securing, thereby eliminating idle time
2Device complexity
If the system uses a single grouping station, then the device complexity is reduced, but the operational efficiency and throughput are limited
Solution Approach 1:
The system is segmented into two functional stations: a pregrouping station for preliminary item configuration and a principal grouping station for final assembly. This spatial segmentation enables parallel operation of grouping and securing functions, increasing throughput without requiring a completely complex system architecture
Solution Approach 2:
The pregrouping station acts as an intermediary between the robot and the principal grouping station. It prepares item configurations in advance and transfers them to the principal grouping station, serving as a buffer that enables continuous operation and improves overall system throughput
Data Source
AI summary
A robotic palletizer system and method include selectively operating a palletizing robot between at least a pregrouping state, in which the palletizing robot groups to-be-grouped items at a pregrouping station, and a principal grouping state, in which the palletizing robot groups to-be-grouped items at a principal grouping station. The system and method further include selectively operating a load securing machine between a securing state, in which the load securing machine at least partially secures to be grouped items grouped at the principal grouping station, and a non-operational state. The palletizing robot can be operated in the pregrouping state during at least a portion of a time interval during which the load securing machine is operating in the securing state to secure the to-be-grouped items grouped at the principal grouping station.