Robotic Pick-and-Place Sequencing for Space-Constrained Product Stacking
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Solution Overview
Problem
Robotic systems in manufacturing environments are constrained by design, programming, and spatial limitations, leading to inefficient organization and movement of components.
Innovation Solution
A control system integrates with processing machinery and a robotic apparatus to optimize the stacking and placement of products based on size, number, and available space, determining a production order and target locations to enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a robotic system picks components from an assembly line and moves them to a destination, then the robotic system can automate manufacturing operations, but the robotic system is constrained by the order in which components arrive, spatial constraints of the destination, and sizes and shapes of components which prevent efficient organization
Solution Approach 1:
The system performs preliminary actions by determining the optimal stacking arrangement and production order before actual manufacturing begins. The control system calculates how components should be stacked in the destination area based on their sizes, shapes, and quantities, then sequences production to match this predetermined arrangement, allowing components to be placed directly into their final positions without subsequent rearrangement
Solution Approach 2:
The system dynamically adjusts the production sequence and stacking arrangement based on real-time factors including component arrival order, varying component dimensions, and available destination space. The control system continuously optimizes the manufacturing sequence to accommodate changing conditions while maintaining efficient space utilization in the destination area
2Volume of stationary object
If components are stacked in a destination area, then space utilization is improved, but determining the optimal stacking arrangement and production order requires complex calculations and coordination
Solution Approach 1:
The control system serves multiple functions simultaneously: it determines stacking arrangements, sequences production operations, coordinates the robotic system's picking and placing actions, and optimizes space utilization. This multi-functional approach consolidates what would otherwise require separate systems into a single integrated control platform, managing complexity through consolidation rather than multiplication of components
3Productivity
If the robotic system moves components to target locations as they are produced, then coordination between production and stacking is improved, but the system must precisely determine target locations and production sequencing
Solution Approach 1:
The system determines all target locations and the complete production sequence in advance before manufacturing begins. By pre-calculating the optimal arrangement and sequencing, the system eliminates the need for real-time decision-making during production, reducing precision requirements during execution while maintaining overall coordination efficiency
Solution Approach 2:
The system uses feedback from component arrival data, size measurements, and destination space availability to continuously refine and adjust the stacking arrangement and production sequence. This feedback loop ensures that the predetermined target locations remain optimal even as conditions change during the manufacturing process
Data Source
AI summary
A method for producing and sorting multiple products includes obtaining job data indicating a size and number of each of the products to be produced and sorted. The method also includes determining, based on both (i) the size and number of each of the products, and (ii) an available amount of space in a loading area, an order of production for the products. The method also includes causing a manufacturing system to produce each of the products according to the order of production, and operating a robotic apparatus to move each of the products into a target location in the loading area based on the order of production of the products.