Robotic Palletizing of Mixed Items With Stable Stack Planning
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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 types, often requiring human judgment and intervention, which can lead to unsafe and inefficient handling.
Innovation Solution
A robotic system equipped with 3D cameras, force sensors, and end effectors like suction-based and gripper-style tools uses item-specific models and dynamic libraries to programmatically select and place items on a pallet, adjusting strategies based on real-time sensor data and human feedback to ensure stability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If human workers manually select and stack items on pallets based on judgment and intuition, then the palletized stack stability is improved, but the productivity and efficiency deteriorate
Solution Approach 1:
The robotic system autonomously selects and stacks items without human intervention. The robot uses sensors to detect item attributes and automatically determines optimal stacking sequences, enabling the system to serve itself rather than requiring human workers to manually select and place each item.
Solution Approach 2:
The patent replaces the human mechanical system (manual selection and stacking) with an automated robotic system equipped with sensors and control algorithms. The robot uses vision systems and force sensors to detect item properties and automatically executes stacking operations, substituting human judgment and physical manipulation with mechanical automation.
2Productivity
If items are stacked quickly without careful selection, then the productivity is improved, but the stability and safety of the palletized stack deteriorate
Solution Approach 1:
The robotic system performs preliminary detection and analysis of item attributes before stacking. Sensors scan and characterize each item's properties (weight, dimensions, shape) in advance, allowing the control system to pre-determine the optimal stacking sequence and placement positions, ensuring stability is maintained while enabling rapid execution.
Solution Approach 2:
The system uses real-time feedback from sensors during the palletizing process to adjust stacking decisions. Force sensors detect item placement stability and provide feedback to the control system, which dynamically adjusts subsequent stacking operations to maintain overall stack stability while continuing at high speed.
3Productivity
If a robotic system is introduced to automate palletizing, then the productivity is improved, but the device complexity increases
Solution Approach 1:
The robotic system is designed with multi-functional capabilities to handle diverse item types. The robot can adapt to different item geometries, weights, and packaging formats using a single unified platform with interchangeable end effectors and programmable control logic, reducing the need for multiple specialized devices while maintaining high productivity.
Solution Approach 2:
The system manages complexity by dynamically adjusting operational parameters rather than requiring complex hardware modifications. The control system modifies stacking patterns, gripper forces, and motion trajectories based on detected item properties, allowing the same physical system to handle varied items through software parameter changes rather than mechanical reconfiguration.
4Measurement precision
If sensors and advanced control systems are added to the robotic system, then the measurement precision and stability detection are improved, but the device complexity and cost increase
Solution Approach 1:
The patent combines multiple sensing functions into an integrated sensor system. The robotic platform incorporates vision sensors, force sensors, and tactile sensors that work together as a unified detection system, merging multiple measurement capabilities into a single coordinated system that reduces overall complexity while improving comprehensive measurement precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The robotic system enables efficient and stable palletization and depalletization of diverse items with minimal human intervention, improving handling safety and efficiency by dynamically adapting to item attributes and environmental conditions.
Implementation Method 1
suction-based and gripper-style tools
Data Source
AI summary
Data associated with a plurality of items to be stacked on or in a destination location is received. The data associated with the plurality of items enables a first attribute associated with a first item of the plurality of items to be identified. 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 includes with respect to the first item a plan, determined based at least in part on the first attribute, to place the first item in a stackable container along with one or more other items and to place the stackable container, once filled, in a corresponding location on or in the destination location. The plan is implemented at least in part by controlling a robotic arm to pick up the items and stack them on or in the destination location according to the plan.