Robotic Palletizing With Real-Time Stacking Plan Updates
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Solution Overview
Problem
Traditional robotic packing systems lack adaptability and flexibility to handle deviations in package sequence, location, orientation, and real-time conditions, requiring pre-determined plans and expensive sequencing machines, which are resource-intensive and laborious.
Innovation Solution
A robotic system with a 3D packing mechanism that generates real-time dynamic packing plans based on current conditions, using a temporary storage area and discretization mechanism to process packages in any order, eliminating the need for pre-labeling and sequencing machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional offline packing simulators are used to predetermine packing sequences and arrangements, then packing plans can be generated in advance, but the system cannot adapt to real-time deviations in package sequences, locations, orientations, or unexpected errors during packing operations
Solution Approach 1:
The patent implements dynamic packing plans that are continuously updated during packing operations based on real-time sensor feedback about package positions, orientations, and any deviations from the plan. The system transitions from static offline planning to dynamic real-time planning, allowing the packing sequence and arrangement to adapt to actual conditions as they occur during operation
Solution Approach 2:
The system incorporates real-time feedback mechanisms using sensors to monitor package positions, orientations, and packing progress. This feedback is continuously fed back to the control system, which then adjusts the packing plan dynamically to correct deviations and handle unexpected errors, creating a closed-loop control system that improves reliability
2Manufacturing precision
If sequencing machines are used to order packages before robot pickup, then packages can be provided in the correct sequence, but the system becomes resource-intensive, expensive, and laborious
Solution Approach 1:
The patent extracts and eliminates the need for separate sequencing machines by integrating sequence management directly into the robotic picking system. The robot controller now handles sequencing logic, using sensor feedback to identify and pick packages in the correct order without requiring external sequencing equipment, thereby reducing resource consumption and system complexity
Solution Approach 2:
The system enables self-service sequencing where the robotic system itself determines and executes the correct package sequence based on real-time information about package locations and orientations. The robot autonomously identifies which package to pick next and adjusts its path and gripper positioning accordingly, without needing external sequencing machinery to prepare packages in advance
3Productivity
If traditional packing systems require fixed sequences and predetermined plans, then packing operations can follow a set schedule, but the system lacks flexibility to handle deviations in package characteristics, locations, or real-time requirements
Solution Approach 1:
The patent implements dynamic packing plans that are continuously updated during packing operations based on real-time sensor feedback about package positions, orientations, and any deviations from the plan. The system transitions from static offline planning to dynamic real-time planning, allowing the packing sequence and arrangement to adapt to actual conditions as they occur during operation
Solution Approach 2:
The system dynamically changes operational parameters such as picking sequence, gripper positioning, robot path, and placement locations based on real-time package characteristics. The control system adjusts these parameters on-the-fly to accommodate variations in package size, shape, orientation, and location while maintaining efficient packing speeds
Data Source
AI summary
A robotic system for arranging packages at a destination in a specified arrangement. The robotic system processes incoming packages, stores the packages in a temporary storage area, executes a simulate function to generate or update a simulated stacking plan, determines the occurrence of a palletizing trigger, and places the packages on the pallet according to the simulated stacking plan upon determining the occurrence of the palletizing trigger. The palletizing trigger can be one of a time limit trigger, a uniform layer trigger, a storage capacity trigger, or receiving a placement initiation command.