Robotic Dunnage Placement for Flexible Wallboard Handling
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Solution Overview
Problem
Existing warehouse systems for handling wallboard panels require manual placement of dunnage strips, which is labor-intensive and inflexible, and the use of permanent dunnage reduces warehouse flexibility and can cause damage to equipment.
Innovation Solution
A robotic system for placing pre-stacked dunnage strips using a robot arm with suction cups and a glue dispenser, programmed to place dunnage strips according to panel size, eliminating the need for manual placement and permanent dunnage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual placement of dunnage strips is used, then operator flexibility in positioning is maintained, but labor intensity increases and placement precision decreases
Solution Approach 1:
The patent replaces manual mechanical placement with an automated robotic system that uses vision guidance and programmable positioning. The robot arm with suction cup end effector automatically picks up dunnage strips and places them in precise locations based on digital instructions, eliminating manual labor while maintaining positioning accuracy through software control.
Solution Approach 2:
The system changes the state of dunnage strip placement from manual discretionary positioning to automated precision positioning based on programmable parameters. The robotic system can be programmed with specific placement patterns, spacing requirements, and positioning coordinates, allowing flexible adaptation to different panel sizes and configurations through software parameter changes rather than physical reconfiguration.
2Reliability
If permanent dunnage is installed on warehouse floor, then dunnage positioning is fixed and reliable, but warehouse flexibility and space utilization are reduced
Solution Approach 1:
The patent transitions from static permanent dunnage installation to dynamic temporary placement. The robotic system places dunnage strips temporarily on the warehouse floor only where and when needed for specific panel sizes. This dynamic approach allows the warehouse floor to remain flexible and adaptable to different panel configurations while ensuring reliable dunnage positioning through automated precision placement for each operation.
Solution Approach 2:
The system performs preliminary automated placement of dunnage strips in the exact positions required before panel installation begins. The robotic system calculates and executes the precise placement pattern based on panel dimensions and storage requirements, ensuring dunnage is positioned reliably in advance without committing to permanent installation, thereby preserving warehouse flexibility.
3Manufacturing precision
If fixed dunnage strips are used, then dunnage placement consistency is improved, but equipment damage risk from forklift impact increases
Solution Approach 1:
The patent treats dunnage strips as temporary, disposable elements rather than permanent installations. The robotic system places individual dunnage strips that can be easily replaced if damaged by forklift impact. This approach maintains placement consistency through automated precision positioning while eliminating the hazard of permanent dunnage that could cause equipment tipping, as damaged strips are simply removed and replaced without affecting warehouse safety.
4Extent of automation
If automated guided vehicles are used for transport, then operator labor is reduced, but permanent dunnage installation is required which reduces warehouse flexibility
Solution Approach 1:
The robotic dunnage placement system serves multiple functions: it prepares the warehouse floor for AGV operations by placing temporary dunnage strips, maintains warehouse flexibility by not requiring permanent installation, and can be reprogrammed to accommodate different panel sizes and storage configurations. This universal system supports automated transport while preserving the ability to reconfigure warehouse layouts as needed.
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
Reduces operator labor, maintains warehouse flexibility, and prevents equipment damage by automating dunnage strip placement, ensuring safe and efficient handling of wallboard panels.
Implementation Method 1
A robot arm tool having at least one suction cup and a glue dispensing nozzle
Implementation Method 2
a glue dispensing nozzle... the glue dispensing nozzle deposits a supply of glue upon an upper surface of the dunnage strip
Data Source
AI summary
A system is provided for robotically placing dunnage strips for receiving wallboard panels, including providing a robot with a robot arm with a tool having at least one suction cup and a glue dispenser; presetting in the robot a plurality of dunnage location programs, each associated with a particular wallboard panel size or thickness; and providing a dunnage cube with a plurality of stacked dunnage strips. Upon the selection of a preset wallboard panel dunnage location, the robot arm uses the suction cup to select and lift a strip from dunnage cube. Then, the robot arm places the strip upon the warehouse floor in a predesignated location per the preset program, and the glue dispenser on the robot deposits glue upon the strip. The robot repeats the dunnage strip selection, lifting, placement and deposition of glue to multiple dunnage strips until the preset arrangement is completed per the program.