Pallet Sorting Using Sensor Fusion and ML Path Routing
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Solution Overview
Problem
Existing pallet sorting systems lack efficient methods for grading and sorting pallets based on physical properties, leading to inefficiencies in pallet handling and management.
Innovation Solution
A pallet sorting system utilizing a conveyor system, loading assembly, and machine learning to analyze pallet data from sensors, determining a conveyance path, and using a lifting mechanism to sort pallets into stacking assemblies based on their condition and type.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual pallet sorting methods are used, then operational simplicity is maintained, but sorting accuracy and efficiency deteriorate
Solution Approach 1:
The patent replaces manual mechanical sorting operations with an automated system using sensors, machine learning algorithms, and robotic mechanisms. Sensors capture pallet images and data, machine learning models analyze the data to determine pallet grades and optimal destinations, and robotic mechanisms execute the sorting actions, thereby improving sorting accuracy while managing system complexity through modular design.
Solution Approach 2:
The system enables pallets to be automatically identified, classified, and routed without human intervention. The machine learning model autonomously makes sorting decisions based on sensor data, and the conveyor system automatically directs pallets to appropriate stacking assemblies, reducing reliance on manual labor and improving consistency.
2Productivity
If traditional pallet handling methods are used, then equipment simplicity is maintained, but handling efficiency deteriorates
Solution Approach 1:
The conveyor system operates continuously to transport pallets through the sorting facility, eliminating idle time between sorting operations. The system maintains continuous data collection, analysis, and sorting actions, ensuring that pallets are processed without interruption and maximizing throughput efficiency.
Solution Approach 2:
The system performs preliminary data collection and analysis on pallets as they enter the sorting area. Sensors capture pallet characteristics beforehand, and the machine learning model pre-determines sorting decisions before the pallet reaches the discharge point, enabling smooth and efficient routing without delays.
3Productivity
If basic conveyor systems are used, then system simplicity is maintained, but space utilization efficiency deteriorates
Solution Approach 1:
The system utilizes three-dimensional stacking assemblies to store sorted pallets vertically, maximizing space utilization. Instead of linear arrangement, pallets are stacked in multiple layers within designated areas, effectively using vertical space and reducing the facility's footprint while maintaining organized storage by pallet grade.
Data Source
AI summary
A method for conveying a pallet through a pallet sorting system having a conveyor system and a loading assembly. The method includes receiving a pallet at a first position of the conveyor system or the loading assembly. A first sensor senses a first set of pallet data and a second sensor senses a second set of pallet data. A module receives the first set of pallet data and the second set of pallet data. The module selectively communicates at least one subset of pallet data from the first set of pallet data, the second set of pallet data, or a combination thereof to a machine learning module, which uses the subset of pallet data to determine a third set of pallet data. The third set of pallet data is used to determine a conveyance path for the pallet.