Robotic Singulation of Mixed Items in Cluttered Parcel Flow
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Solution Overview
Problem
Manual singulation of mixed items in parcel and distribution centers is labor-intensive and inefficient, and the use of robots is challenging due to the dynamic and cluttered nature of item arrival, making it difficult to identify, grasp, and separate items in an automated manner.
Innovation Solution
A robotic singulation system that uses a combination of computer vision, suction-based end effectors, and coordinated robotic arms to model item flow, anticipate item locations, and grasp items from a flowing pile, even in cluttered conditions, with the ability to invoke human assistance when necessary to maximize throughput and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual singulation is used, then labor flexibility is maintained, but productivity is low and labor costs are high
Solution Approach 1:
The system enables self-service through autonomous robotic arms that automatically identify, grasp, and place items without human intervention. The computer vision system continuously monitors the cluttered mix and autonomously determines grasp strategies, allowing the system to serve itself in the singulation process.
Solution Approach 2:
Manual mechanical operations are replaced with automated robotic systems. The patent substitutes human workers with robotic arms equipped with end effectors, controlled by computer vision and automated decision-making algorithms, thereby increasing productivity while maintaining flexibility.
2Productivity
If robots are used for singulation, then productivity increases, but the system struggles with cluttered and dynamic item flow
Solution Approach 1:
The computer vision system performs preliminary identification and analysis of items in the cluttered mix before the robotic arm attempts grasping. By pre-processing the scene understanding, determining item locations, and planning grasp strategies in advance, the system overcomes the challenges of dynamic and cluttered environments.
Solution Approach 2:
The system embraces the dynamic nature of the cluttered mix by continuously updating its perception and re-planning grasps in real-time. The robotic arm adjusts its motion and grasp strategy dynamically based on changing item positions and configurations, allowing it to operate effectively in non-static environments.
3Productivity
If multiple robots are coordinated, then collective throughput increases, but conflict and collision between robots may occur
Solution Approach 1:
The system employs continuous feedback loops where computer vision monitors all robotic arms and items in real-time, and the control system adjusts robot motions dynamically to prevent collisions. This closed-loop control ensures reliable coordination by constantly adapting to the current system state and resolving potential conflicts before they occur.
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 singulation system significantly enhances the efficiency and accuracy of item sorting by automating the singulation process, reducing labor costs and increasing collective throughput, while ensuring reliable machine-readable information capture for routing purposes.
Implementation Method 1
suction-based end effectors
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.