Robot Box Palletizing with Tilted Two-Step Alignment
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Solution Overview
Problem
Robots face challenges in palletizing boxes due to their strength, which can lead to pushing, sliding, or toppling of boxes, and inaccuracies in positioning, resulting in poor stacking integrity and gaps between boxes, especially when handling boxes with different weights or weight distributions.
Innovation Solution
A method and robot system that includes receiving a target box location, positioning the box at an initial offset, tilting it, and shifting it in specific directions to align and release it to pivot onto adjacent boxes, using sensor data for compensation and contact force/velocity thresholds to ensure accurate and gap-free stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the robot uses its strength to position boxes, then positioning speed is improved, but box integrity deteriorates due to pushing, sliding, or toppling
Solution Approach 1:
The patent introduces an intermediary alignment mechanism where the robot positions the box in an initial position offset from the target location, then uses controlled shifting movements to align the box with adjacent boxes before final placement. This intermediary alignment process allows the robot to use minimal force while achieving precise positioning, preventing pushing, sliding, or toppling of boxes.
2Manufacturing precision
If the robot positions boxes directly at target location, then positioning precision is improved, but adaptability deteriorates when handling boxes with different weights
Solution Approach 1:
The patent applies preliminary action by positioning the box at an initial position that is offset from the target box location before final placement. The robot performs alignment movements in controlled directions (first direction to satisfy first alignment distance, then second direction to satisfy second alignment distance) to ensure precise positioning. This preliminary positioning and alignment process allows the robot to adapt to boxes of different weights and dimensions while maintaining consistent positioning precision through controlled shifting movements rather than direct forceful placement.
3Productivity
If the robot releases the box without alignment, then operation speed is improved, but stacking integrity deteriorates due to gaps between boxes
Solution Approach 1:
The patent performs preliminary alignment actions before releasing the box. The robot shifts the box in a first direction to satisfy a first alignment distance, then shifts it in a second direction to satisfy a second alignment distance, ensuring the box is properly aligned with adjacent boxes before release. This preliminary alignment ensures stacking integrity and eliminates gaps between boxes while maintaining operational efficiency through automated controlled movements.
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 system enables reliable and efficient palletization of boxes with minimal gaps, maintaining the integrity of the stack by compensating for positioning errors and accommodating varying box weights, improving the robot's ability to handle boxes of different sizes and shapes.
Implementation Method 1
The end-effector may include a plurality of suction cups configured to apply a suction force to grasp the box
Implementation Method 2
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
Figure 1A
Figure 1B
Figure 1C
AI summary
A method (300) for palletizing includes receiving a target box location (202) for a box (20) grasped by a robot (100). The method also includes positioning the box at an initial position (212) adjacent to the target box location and tilting the box at an angle relative to a ground plane (12). The method further includes shifting the box from the initial position in a first direction (D1) to a first alignment position (222, 222a) that satisfies a threshold first alignment distance (224, 224a), shifting the box from the first alignment position in a second direction (D2) to the target box location that satisfies a threshold second alignment distance (224, 224b), and releasing the box held by the robot. The release of the box causes the box to pivot toward a boundary edge (24) of the target box location.