Automated Pallet Stacking via Vacuum Robot and Pattern Selection
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Solution Overview
Problem
Existing methods for stacking boxes on pallets face challenges such as labor intensity, time consumption, variability in stack stability, high initial costs, and risk of damage due to inflexibility in handling variable box sizes and delicate products.
Innovation Solution
An automated method using a picking robot with a vacuum system, predefined stacking patterns, and communication with a warehouse management system to optimize box selection and stacking, minimizing damage and ensuring efficient use of space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual stacking is used, then operational flexibility is maintained, but labor intensity and time consumption increase
Solution Approach 1:
The system uses a camera to automatically detect box dimensions and a computer to calculate optimal stacking patterns without human intervention. The robot then autonomously executes the stacking, making the system self-sufficient while maintaining flexibility through automated adaptation to variable box sizes.
2Productivity
If automated palletizing machines are used, then speed and consistency are improved, but initial costs and device complexity increase
Solution Approach 1:
The system divides the stacking task into distinct modules: a camera for detection, a computer for calculation and pattern selection, and a robot for execution. This segmentation allows each component to be optimized independently and simplifies the overall system compared to traditional integrated palletizing machines.
3Productivity
If automated systems handle variable box sizes, then productivity is maintained, but stacking stability and placement accuracy deteriorate
Solution Approach 1:
The computer calculates the optimal stacking pattern in advance based on detected box dimensions and selected criteria (e.g., stability, space utilization). This preliminary calculation ensures that the robot executes a pre-optimized arrangement that guarantees stack stability before any physical stacking occurs.
Solution Approach 2:
The system dynamically adjusts stacking parameters such as pattern selection, box orientation, and placement position based on the detected dimensions of variable-sized boxes. This adaptive parameter adjustment maintains optimal stack stability regardless of box size variations.
4Productivity
If automated systems are used, then productivity increases, but risk of damage to delicate goods increases
Solution Approach 1:
The camera continuously detects box dimensions and provides feedback to the computer, which adjusts the stacking pattern and robot movements accordingly. This real-time feedback loop allows the system to adapt to delicate boxes by modifying handling parameters to minimize damage risk while maintaining productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enhances efficiency, accuracy, and safety by reducing human effort, minimizing errors, and optimizing storage space while adapting to diverse product sizes and conditions.
Implementation Method 1
A picking robot is used to pick and stack the boxes, wherein the picking robot includes a vacuum system for holding the box
Data Source
AI summary
The present invention relates to a computer-implemented method for stacking boxes on a pallet, wherein the method includes: automatically selecting a combination of boxes from a predefined set of boxes with different predetermined volumes based on specifications of a received order, providing ordered items from the received order in the boxes of the selected combination of boxes, arranging the boxes, selecting a stacking pattern from a database for stacking the selected combination of boxes on the pallet, stacking the selected combination of boxes according to the selected stacking pattern on the pallet using the picking robot. The invention also relates to a computer-implemented system for stacking boxes on a pallet, comprising: a processing unit, means for arranging the boxes, a database, a module, and a picking robot.