Robotic Pallet Dismantling for Variable Board Positioning

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Solution Overview

Problem

The manual dismantling of wooden pallets is inefficient due to manufacturing inconsistencies, requiring labor-intensive processes that are not well-suited for automation, and existing automated systems fail to accommodate these variations effectively.

Innovation Solution

An automated system comprising a saw and a robotic manipulator with a multi-axis robotic arm and end-of-arm tool, capable of positioning, orienting, and moving pallets relative to the saw to accommodate varying sizes and constructions, using sensors to measure dimensions and adjust the cutting process accordingly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual dismantling is used to accommodate manufacturing inconsistencies, then adaptability to pallet variations is improved, but productivity and efficiency deteriorate

Engineering Contradiction:

Improveadaptability to pallet variationsVSAvoiddismantling efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The robotic manipulator employs dynamic control to adapt to manufacturing inconsistencies in pallets. The system uses real-time sensing and control algorithms to adjust the dismantling process for each pallet's unique characteristics, enabling automated operation while maintaining adaptability to variations in board spacing, orientation, and positioning.

Inventive Principle:

Principle #15Dynamics

2Productivity

If automated dismantling systems are implemented to improve productivity, then efficiency is improved, but adaptability to manufacturing inconsistencies deteriorates

Engineering Contradiction:

Improvedismantling efficiencyVSAvoidaccommodation of pallet variations

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The system incorporates feedback mechanisms through sensors that detect the actual positions and orientations of pallet boards. This information is fed back to the control system, which adjusts the manipulator's movements and cutting operations accordingly, enabling automated dismantling while accommodating manufacturing inconsistencies in each pallet.

Inventive Principle:

Principle #23Feedback

3Adaptability or versatility

If complex automated systems with sensing and adjustment capabilities are used to accommodate variations, then adaptability is improved, but device complexity deteriorates

Engineering Contradiction:

Improvedetection and accommodation of inconsistenciesVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system replaces complex mechanical adjustment mechanisms with sensor-based detection and software-controlled manipulator movements. Instead of using multiple mechanical sensors and physical adjustment devices, the invention uses vision systems and position sensors combined with algorithmic control to achieve adaptability, thereby reducing mechanical complexity while maintaining versatility.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11305453B2Dismantling system

Publication Date: 2022.04.19 ALLIANCE AUTOMATION LLC

AI summary

A system for dismantling a pallet includes a feed system configured to convey the pallet along a direction of travel. The feed system has a measuring station and a staging area. The measuring station is configured to obtain dimensions of the pallet. A saw is configured to dismantle the pallet. A manipulator includes a robotic arm. The manipulator is configured to move the pallet from the staging area to the saw for dismantling.