Robotic Box Palletizing with Tilted Placement and Pivot 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 palletization with gaps or spaces between boxes, especially when dealing with boxes of different weights or weight distributions.
Innovation Solution
A robot system that positions a box at an initial offset adjacent to the target location, tilts it, and shifts it in multiple directions to align and release it gently, using sensor data for compensation and contact force/velocity thresholds to ensure precise placement without disrupting adjacent boxes, employing an inverted pendulum body and end-effector with suction cups for grasping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the robot uses its strength to position boxes quickly, then productivity increases, but the boxes may be pushed, slid, or toppled causing poor palletization
Solution Approach 1:
The robot performs preliminary positioning actions by placing the box at an initial position offset from the target location, then gradually shifts it to the final position. This multi-stage approach allows the box to be placed gently without disruption while maintaining efficient overall operation
Solution Approach 2:
The robot dynamically adjusts its manipulation strategy based on the box's weight and position. It tilts the box at an angle during positioning and uses controlled shifting movements rather than direct placement, adapting its actions to prevent box disruption while maintaining productivity
2Manufacturing precision
If the robot positions the box directly at the target location, then manufacturing precision improves, but the box may disrupt adjacent boxes due to robot strength
Solution Approach 1:
The robot places the box at an initial position offset from the target location, then performs controlled shifting movements to reach the final position. This preliminary positioning approach allows precise placement while minimizing direct impact forces on adjacent boxes
Solution Approach 2:
The robot tilts the box at an angle and uses controlled shifting movements to counteract the potential harmful effect of direct placement. This preliminary anti-action prevents the box from disrupting adjacent boxes while achieving precise target location placement
3Manufacturing precision
If the robot uses vision system for position compensation, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The robot uses a vision system to detect the actual position of the box and adjacent boxes, then compensates for position errors by calculating offset distances. This feedback mechanism enables precise palletization while using standard robotic components
Solution Approach 2:
The patent replaces complex mechanical positioning mechanisms with a vision-based detection and compensation system. The vision system captures images, calculates position offsets, and adjusts the robot's movement accordingly, substituting mechanical complexity with computational simplicity
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 space between them, maintaining the integrity of the stack and reducing human labor and fatigue in logistics operations.
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 the box from the robot may cause the box to pivot toward a boundary edge of the target box location
Data Source
AI summary
A method for palletizing includes receiving a target box location for a box grasped by the end-effector, the box having a top surface, a bottom surface, and side surfaces. The method also includes positioning the box at an initial position adjacent to the target box location and tilting the box at an angle relative to a ground plane where the angle is formed between the ground plane and the bottom surface. The method further includes shifting the box from the initial position in a first direction to a first alignment position that satisfies a threshold first alignment distance, shifting the box from the first alignment position in a second direction to the target box location that satisfies a threshold second alignment distance, and releasing the box from the end-effector. The release of the box causes the box to pivot toward a boundary edge of the target box location.