Mobile Robot Unit Load Assembly With Marker-Based Alignment
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Solution Overview
Problem
Existing item handling systems face inefficiencies in forming and processing unit loads due to suboptimal item placement and handling operations, particularly in facilities using mobile robots and mechanized apparatuses, which can lead to unstable loads and require manual rearrangement.
Innovation Solution
A system and method involving a mobile robot with sensors and a server that generates a task definition for optimal item placement and handling operations, using markers and alignment data to accurately position the robot relative to handling apparatuses, enabling automated assembly of unit loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual item placement is used in existing item handling systems, then flexibility in handling various items is maintained, but item placement precision is insufficient leading to unstable unit loads and requiring manual rearrangement
Solution Approach 1:
The patent replaces manual mechanical placement with an automated mobile robot system that uses sensors (cameras, depth sensors) and computer vision algorithms to detect item positions and autonomously place items on unit loads. The robot controller receives image data, processes it to determine optimal placement positions, and executes precise placement operations, eliminating manual intervention while achieving high placement precision.
Solution Approach 2:
The system enables the mobile robot to autonomously perform the entire item placement process without human assistance. The robot independently navigates to pick locations, identifies items using its sensors, determines optimal placement positions on unit loads, executes placement operations, and returns for additional items. This self-service capability achieves precise placement while reducing system complexity compared to fully manual operations.
2Productivity
If automated mobile robots are deployed for item handling, then productivity and order fulfillment speed are improved, but positioning accuracy relative to handling apparatuses is insufficient requiring manual intervention
Solution Approach 1:
The patent implements a feedback mechanism where markers are placed on handling apparatuses and detected by sensors on the mobile robot. The robot controller continuously monitors the relative position between the robot and the handling apparatus by detecting these markers, and automatically adjusts the robot's position to achieve precise alignment. This closed-loop feedback system ensures high positioning accuracy while maintaining fast order fulfillment speeds.
Solution Approach 2:
The patent introduces markers as intermediary objects that facilitate precise positioning between the mobile robot and handling apparatuses. These visual markers serve as a communication bridge, allowing the robot to accurately locate and align with handling apparatuses without complex direct sensing. The markers simplify the positioning task while enabling high-speed automated operations.
3Stability of the object's composition
If suboptimal item placement is used in existing systems, then device complexity is reduced, but unit load stability deteriorates requiring manual rearrangement operations
Solution Approach 1:
The patent applies preliminary action by having the robot controller calculate and determine optimal item placement positions on the unit load before the actual placement occurs. The system analyzes item characteristics, unit load configuration, and stability requirements in advance, then guides the robot to place each item at the pre-determined optimal position. This preliminary planning ensures unit load stability from the outset, eliminating the need for manual rearrangement operations.
Data Source
AI summary
A method includes: obtaining a task definition for a mobile robot, the task definition including (i) a position on an item support carried by the mobile robot, and (ii) an identifier of an item to be placed at the position to form a unit load with the item support; controlling the mobile robot carrying the item support to travel to a pick location for receiving the item from a picker; controlling an output device to render an indication of the position for the picker at the pick location; responsive to placement of the item at the position by the picker, controlling the mobile robot to travel to a handling location.