Robotic Unloader/Loader Automation for Conveyor Palletization
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Solution Overview
Problem
Current truck and container unloading processes are inefficient, labor-intensive, and lack a comprehensive end-to-end automation solution, particularly in transitioning from unloading to palletization, which is costly and lacks features like barcode scanning and orientation.
Innovation Solution
A robotic system utilizing multi-modal perception, autonomous robots with RGB-Depth, Laser, and computer vision, and fleet coordination to unload and load trucks or containers, integrating with material handling systems, and employing real-time perception and force control to handle mixed items, with adaptable hardware and software configurations for various tasks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual unloading is used, then labor flexibility is maintained, but productivity is low and safety risks increase
Solution Approach 1:
The robotic system performs unloading operations autonomously without continuous human intervention. The robot navigates, identifies, grasps, and places items automatically, with humans only providing initial setup and oversight, thereby achieving self-service automation that improves productivity while maintaining manageable complexity
Solution Approach 2:
The patent replaces manual human labor with an automated robotic system equipped with sensors, computer vision, and robotic manipulators. This substitution of mechanical and cognitive human functions with automated systems directly addresses the contradiction by enabling high-speed automated unloading while managing complexity through modular system design
2Extent of automation
If existing automation products are used, then some unloading tasks are automated, but end-to-end container unloading to palletization is not achieved
Solution Approach 1:
The patent merges multiple previously separate automation functions into a single integrated robotic system that performs container unloading, item identification, and palletization in one continuous automated workflow. This consolidation achieves end-to-end automation while managing complexity through unified system architecture rather than multiple separate systems
Solution Approach 2:
The robotic system is designed with multi-functionality to handle various unloading scenarios and perform multiple tasks including navigation, item identification via computer vision, grasping with adaptive force control, and palletization. This universal design achieves comprehensive automation coverage while avoiding the complexity of multiple specialized systems through a single versatile platform
3Productivity
If automated unloading systems are implemented, then productivity increases, but capital investment requirements increase
Solution Approach 1:
The robotic system is divided into functional modules including navigation module, computer vision module, force control module, and palletization module. This segmentation allows for targeted investment in specific high-impact components while using off-the-shelf technology for other parts, reducing overall capital requirements compared to fully custom integrated systems while maintaining high productivity
Solution Approach 2:
The system employs adaptive force control that dynamically adjusts grasping parameters based on real-time sensor feedback and item characteristics. This parameter adaptation enables the use of standardized, lower-cost robotic manipulators rather than requiring expensive specialized end-effectors for each item type, thereby reducing capital investment while maintaining high unloading efficiency
Data Source
AI summary
A robotic unloader/loader system is disclosed. The system includes a first robot configured to autonomously approach and enter a truck or other container and unload items from the truck or other container by placing each item on an outbound conveyor or other material handling equipment; and a set of one or more additional robots configured to work outside the truck or other container, including by picking items from the conveyor or other material handling equipment, from a position to which the items have been conveyed by the conveyor or other material handling equipment, and placing each item in a corresponding one of a plurality of destination locations.