Robotic Palletizing of Mixed Items With Sensor-Guided Final Positioning
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Solution Overview
Problem
Current methods for palletizing and depalletizing heterogeneous items are inefficient and prone to instability due to the variety of item sizes, weights, and shapes, often requiring manual intervention and relying on human judgment, which can lead to unstable stacks and item damage.
Innovation Solution
A robotic system equipped with 3D cameras, force sensors, and a library of item types and grasp strategies uses programmable algorithms to identify and stack items, adjusting plans dynamically based on sensor data and human feedback to ensure stability and efficient packing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual stacking by human workers is used, then item selection and placement can be done with human judgment, but the process is slow and inconsistent
Solution Approach 1:
The robotic system autonomously identifies items, determines optimal placement locations, and executes stacking operations without continuous human intervention. The system uses sensors to detect item characteristics and automatically adjusts stacking strategies, enabling the system to serve itself in the palletizing process while maintaining high speed and consistency
Solution Approach 2:
The patent replaces manual human operations with an automated robotic system that uses computer vision, sensors, and control algorithms to perform item identification, decision-making, and physical stacking. This substitution of mechanical and cognitive human functions with automated systems resolves the contradiction by achieving both operational capability and high productivity
2Ease of manufacture
If items are stacked in arrival order, then the process is simple, but the pallet stack becomes unstable
Solution Approach 1:
The robotic system performs preliminary analysis of item characteristics using sensors and computer vision before stacking. It pre-determines the optimal stacking sequence and placement locations based on item weight, size, shape, and other properties. This preliminary planning ensures stable pallet construction while maintaining process simplicity, as the system automatically executes the pre-calculated stacking plan
Solution Approach 2:
The system dynamically adjusts stacking strategies based on real-time sensor data and item characteristics. Rather than following a fixed static sequence, the robotic system adapts its stacking plan as it processes each item, optimizing for stability while maintaining operational simplicity through automated decision-making algorithms
3Productivity
If a robotic system is used for palletizing heterogeneous items, then productivity increases, but the system complexity increases
Solution Approach 1:
The robotic system is designed with multi-functional capabilities to handle diverse item types, sizes, and weights using a single integrated platform. The system incorporates universal end-effectors, adaptive grippers, and flexible positioning mechanisms that can accommodate heterogeneous items without requiring multiple specialized devices, thereby achieving high productivity while controlling overall system complexity
Solution Approach 2:
The system dynamically adjusts operational parameters such as gripper force, positioning precision, and stacking speed based on detected item characteristics. By changing parameters rather than changing hardware configurations, the system handles heterogeneous items efficiently without increasing physical complexity, maintaining high productivity through software-based adaptability
4Productivity
If heavy items are placed on top of light items, then stacking is faster, but the pallet becomes unstable and items may be damaged
Solution Approach 1:
The robotic system performs preliminary assessment of item weight and structural properties using sensors before placement. It pre-determines the correct stacking sequence to ensure heavy items are placed on the bottom and lighter items on top, preventing instability and damage. This preliminary planning maintains high stacking speed by avoiding rework while ensuring reliability through proper weight distribution
Data Source
AI summary
Techniques are disclosed to use a robotic arm to palletize or depalletize diverse items. In various embodiments, data associated with a plurality of items to be stacked on or in a destination location is received. A plan to stack the items on or in the destination location is generated based at least in part on the received data. The plan is implemented at least in part by controlling a robotic arm of the robot to pick up the items and stack them on or in the receptacle according to the plan, including by for each item: using one or more first order sensors to move the item to a first approximation of a destination position for that item at the destination location; and using one or more second order sensors to snug the item into a final position.