Robotic Pallet Assembly with Preplanned Layout for Mixed Parcels
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Solution Overview
Problem
Current palletizing processes in supply chain management are not fully automated due to the non-uniformity of packages, requiring human intervention and leading to inefficiencies, health risks, and increased logistics costs, especially when dealing with heterogeneous objects.
Innovation Solution
An automated system using a robotic gripper arm and logistics platform to assemble pallets from packages of varying sizes, guided by a control device that generates a pallet plan based on package dimensions and orientations, optimizing the layout and reducing manual handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual handling is used for pallet assembly, then flexibility in handling heterogeneous packages is maintained, but productivity is reduced and health risks increase
Solution Approach 1:
The system uses automated vision systems and robotic grippers that can independently identify, grasp, and position packages of varying sizes without human intervention. The robotic system serves itself by adapting to heterogeneous package dimensions through real-time detection and adjustment of gripper parameters
Solution Approach 2:
The robotic gripper dynamically changes its operational parameters (grasp force, position, orientation) based on detected package characteristics. The system adjusts gripper opening width, positioning coordinates, and placement angles according to each package's specific dimensions to maintain handling flexibility while achieving high-speed automated assembly
2Productivity
If automated robotic assembly is implemented, then productivity and consistency are improved, but the system becomes more complex
Solution Approach 1:
The robotic gripper is designed as a universal end-effector that can handle multiple package types and sizes with a single device configuration. The vision system and control algorithm work together to recognize various package geometries and automatically adjust parameters, eliminating the need for multiple specialized grippers or complex reconfiguration mechanisms
Solution Approach 2:
The vision system performs preliminary detection and characterization of packages before the robotic gripper executes assembly operations. The system pre-calculates optimal grasp points, gripper orientations, and placement positions based on detected package dimensions, simplifying the actual robotic execution phase and reducing real-time computational complexity
3Ease of operation
If packages are oversized to accommodate varying item sizes, then handling becomes easier, but logistics costs and environmental impact increase
Solution Approach 1:
The system replaces manual handling considerations with automated robotic manipulation capabilities. The robotic gripper can precisely grasp and position packages of any size without requiring additional protective materials or oversized packaging, as the robot's controlled movements prevent shifting and damage that would otherwise require excessive packaging
Data Source
Figure 1~2
AI summary
A method for automatically assembling a pallet (103) supporting a set of packages (101) belonging to an order, comprising the steps of: - receiving information (3) relating to the set of packages, including at least dimensions for each package; - creating a pallet plan from this information; - routing packages (101) to a conveyor (105) on a sub-platform assigned to the order; - storing the packages (101) received by the conveyor (105) in a temporary storage area (104) using a robotic gripper arm (102); - when the set of packages is stored in the temporary storage area, assembling the pallet (103) using the gripper arm (102), selecting the packages in the storage area (104) according to an order determined by the pallet plan, and positioning them successively according to this pallet plan.