Robotic Loading Trajectories for Moving Sorter Units
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Solution Overview
Problem
Existing automated systems face challenges in efficiently loading and extracting objects of random dimensions and shapes onto/from moving transport units in sorting systems, leading to incorrect positioning and reduced payload capacity.
Innovation Solution
An automated system that processes geometric data of objects on moving transport units to optimize handling trajectories, allowing objects to be loaded or extracted with reduced cycle time and increased payload capacity by minimizing the average path taken by the handling system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If robots are used to pick and place objects of random dimensions and shapes onto moving transport units, then automation is improved, but positioning accuracy deteriorates
Solution Approach 1:
The system uses detection devices (cameras, sensors) to continuously monitor object positions on transport units and provides feedback to the control device. When incorrect positioning is detected, the system automatically generates correction trajectories and executes them through the robot, forming a closed-loop feedback control system that maintains positioning accuracy despite automation.
Solution Approach 2:
The system performs preliminary detection and analysis of object positions before final placement. The control device pre-calculates correction trajectories and prepares correction actions in advance, allowing the robot to make precise adjustments before the object is fully placed on the transport unit, thereby ensuring positioning accuracy is maintained throughout the automation process.
2Manufacturing precision
If correction actions are taken to fix incorrect positioning, then positioning accuracy is improved, but cycle time increases
Solution Approach 1:
The system implements a multi-level detection and correction strategy where critical positioning errors are detected and corrected quickly through streamlined processes. The control device prioritizes corrections based on severity, allowing minor positioning deviations to be skipped or handled rapidly while focusing correction resources on significant errors, thereby reducing overall cycle time impact.
Solution Approach 2:
The system performs preliminary detection of positioning errors during the normal operation flow rather than after completion. By detecting and initiating correction actions during the transport process itself, the system avoids adding separate correction cycles, thereby minimizing the time penalty associated with positioning corrections.
3Reliability
If the handling system follows a conservative trajectory to avoid collisions, then safety is improved, but productivity decreases
Solution Approach 1:
The trajectory generation device dynamically adjusts handling trajectories based on real-time detection of object positions, transport unit speeds, and spatial relationships. Rather than using fixed conservative paths, the system calculates optimal dynamic trajectories that adapt to current system state, allowing faster movement when safe and more cautious movement when objects are in critical positions, thereby maintaining both safety and productivity.
Solution Approach 2:
The system continuously monitors object positions and transport unit movements, using this feedback to dynamically recalculate and adjust handling trajectories. This real-time feedback enables the system to take calculated risks and optimize path speeds while maintaining collision avoidance, rather than relying on predetermined conservative trajectories that reduce productivity.
Data Source
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AI summary
The invention relates to an automated system for transporting and/or sorting objects (3) comprising : automated means of transport (1) that include transport units (2) designed to transport objects (3); a handling system (4) equipped with a gripping system (5) and operable to load objects (31) onto the automated means of transport (1); and electronic processing and control means configured to receive data relating to the position and speed of the transport units (2) and data indicative of the geometric characteristics and/or dimensions of the objects (3) transported, process the data received and control the operation of the handling (4) and gripping (5) systems on the basis of the processed data. The processing and control means, in order to load a first given object (31) on a first predetermined transport unit (21), are programmed to: determine a first trajectory to be executed by the handling system (4) over N first objects (3) transported by the transport units (2) to reach said first predetermined transport unit (21), wherein N is an integer greater than zero; determine a first maximum height between the heights of the N first objects (3); control the handling system (4) and the gripping system (5) so that they execute the first trajectory holding the first given object (31) at a height such that a lower surface of said first given object (31) remains above said first determined maximum height and, upon reaching the first predetermined transport unit (21), place the first given object (31) on said first predetermined transport unit (21).