Robotic Singulation Using 3D Item Flow Modeling and Suction Grasping
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Solution Overview
Problem
Manual singulation of items in parcel and distribution centers is labor-intensive and inefficient, and the use of robots is challenging due to the cluttered mix of items and dynamic flow, making it difficult to identify, grasp, and separate items in an automated manner.
Innovation Solution
A robotic singulation system that uses a combination of robotic arms with suction-based end effectors and multi-view sensor arrays to model item flow, anticipate item locations, and grasp items from a flowing pile, coordinating multiple robots to maximize throughput and avoid collisions, with the option to invoke human assistance when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual singulation is performed by human workers, then items can be separated and placed in defined spaces, but the process becomes labor-intensive and inefficient with suboptimal collective throughput
Solution Approach 1:
The system enables automated singulation where robotic arms with suction end effectors autonomously pick items from cluttered mixes and place them on conveyors, eliminating the need for manual human operation while maintaining high throughput efficiency
Solution Approach 2:
The patent replaces manual mechanical handling with automated robotic systems that use suction-based end effectors to grasp and transport items, substituting human labor with programmable mechanical systems that operate continuously at high speeds
2Extent of automation
If robotic arms are used to perform singulation, then automation is achieved, but it becomes difficult to identify, grasp, and separate items due to cluttered mixes and dynamic flow
Solution Approach 1:
The patent introduces suction-based end effectors as intermediaries between the robotic arm and items, enabling reliable grasping of diverse items from cluttered mixes by creating vacuum bonds that adapt to different item shapes, sizes, and materials
Solution Approach 2:
The system performs preliminary actions by using vision systems to identify and plan grasping strategies before the robotic arm moves, anticipating item locations and preparing suction end effectors in advance to handle the dynamic flow and cluttered conditions
3Productivity
If multiple robots are coordinated to maximize throughput, then collective efficiency improves, but system complexity and collision avoidance requirements increase
Solution Approach 1:
The patent implements feedback mechanisms where sensors continuously monitor the positions and states of multiple robotic arms and items, allowing the control system to adjust trajectories and timing in real-time to maximize throughput while preventing collisions between robots
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 system significantly increases the efficiency of item singulation and sorting by automating the process, reducing labor costs and improving collective throughput, while ensuring accurate placement and orientation of items for downstream machine processing.
Implementation Method 1
robotic arms with suction-based end effectors to model item flow, anticipate item locations, and grasp items from a flowing pile
Data Source
AI summary
A robotic singulation system is disclosed. In various embodiments, sensor data including image data associated with a workspace is received. The sensor data is used to generate a three dimensional view of at least a portion of the workspace, the three dimensional view including boundaries of a plurality of items present in the workspace. The three dimensional view as generated at successive points in time is used to model a flow of at least a subset of said plurality of items through at least a portion of the workspace. The model is used to determine and implement a plan to autonomously operate a robotic structure to pick one or more items from the workplace and place each item singly in a corresponding location in a singulation conveyance structure.