Robot Box Palletizing with Tilt-and-Pivot Alignment
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Solution Overview
Problem
Robots face challenges in accurately and efficiently palletizing boxes due to issues with strength, compensation for perception errors, and maintaining the integrity of the box stack.
Innovation Solution
A method and system for a robot to palletize boxes by receiving a target box location, positioning the box at an initial offset position, tilting it, shifting it in multiple directions to align with the target, and releasing it to pivot into place, using sensor data for compensation and force/velocity thresholds for alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the robot positions the box directly at the target location, then the palletization process is simple and fast, but the box may not align properly with adjacent boxes due to perception errors and robot positioning inaccuracies
Solution Approach 1:
The robot performs preliminary actions by positioning the box at an initial offset position before the target location, tilting the box at a predetermined angle, and then shifting it in multiple directions (first direction to first alignment position, then second direction to target location). These preliminary positioning and orientation adjustments compensate for perception errors and ensure proper alignment with adjacent boxes, resolving the contradiction between alignment precision and process complexity.
2Manufacturing precision
If the robot uses a simple release mechanism, then the device is simple and fast, but the box cannot self-align properly with the target location and adjacent boxes
Solution Approach 1:
The robot releases the box in a tilted state at an initial position offset from the target location, allowing the box to self-align through controlled shifting in multiple directions and pivoting toward the boundary edge after release. The box's own gravity and geometry enable it to achieve proper alignment with adjacent boxes without requiring complex active control mechanisms during the release phase, thus resolving the contradiction between placement precision and operational simplicity.
3Productivity
If the robot moves the box quickly to the target location, then the palletization speed is high, but the box may disrupt adjacent boxes or fail to align properly
Solution Approach 1:
The robot segments the box movement into multiple distinct phases: (1) positioning at initial offset position, (2) tilting at predetermined angle, (3) shifting in first direction to first alignment position, (4) shifting in second direction to target location, and (5) release with pivoting. This segmentation allows each phase to be optimized independently - some phases can move quickly while others perform precise alignment - thereby maintaining high overall productivity while ensuring box stack integrity and proper alignment.
4Manufacturing precision
If the robot compensates for perception errors using vision system data, then the positioning accuracy is improved, but the processing time and system complexity increase
Solution Approach 1:
The robot receives sensor data from the vision system and determines compensation distances in advance before executing the palletization task. By calculating the first compensation distance in the first direction and the second compensation distance in the second direction beforehand, and incorporating these into the initial offset position, the system compensates for perceived position differences without requiring real-time adjustments during execution, thus improving positioning accuracy while minimizing additional processing time.
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 solution enables the robot to accurately and efficiently palletize boxes with minimal gaps or disruptions, improving the reliability and precision of the palletization process.
Implementation Method 1
tilting, by the robot, the box at an angle relative to a ground plane... releasing, by the robot, the box from the robot, the release of the box causing the box to pivot toward a boundary edge of the target box location
Data Source
AI summary
A method for palletizing by a robot includes positioning an object at an initial position adjacent to a target object location, tilting the object at an angle relative to a ground plane, shifting the object in a first direction from the initial position toward a first alignment position, shifting the object in a second direction from the first alignment position toward a second alignment position, and releasing the object from the robot to pivot the object toward the target object location.