Sensor-Guided Conveyor Loading for Accurate Pick-and-Place
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Solution Overview
Problem
Existing loading and unloading systems are inefficient, inconsistent, and simplistic, often requiring unnecessary vertical movements and lacking parallel pathways for transporting objects, and are unable to accurately identify pick points on objects.
Innovation Solution
A system comprising a support structure with sensors and manipulators that monitor interior areas to align object edges with conveyors, allowing for efficient pick and place operations using horizontal movements, and a controller to manage these operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing loading and unloading systems are used, then the system structure is simple, but the efficiency and consistency of loading/unloading operations deteriorate due to unnecessary vertical movements and lack of parallel pathways
Solution Approach 1:
The system divides the loading/unloading process into distinct operational zones (first zone for loading, second zone for unloading) with separate conveyors for each direction. This segmentation allows parallel processing of multiple objects simultaneously, eliminating unnecessary vertical movements and improving overall efficiency while maintaining manageable system complexity through modular zone design.
Solution Approach 2:
The patent introduces parallel pathways that extend the system horizontally rather than vertically. By using multiple conveyors operating in parallel at different horizontal positions, the system eliminates the need for vertical movements and enables simultaneous loading and unloading operations, thereby improving productivity without proportionally increasing complexity.
2Measurement precision
If existing systems are used, then the device complexity is low, but the precision of identifying pick points on objects deteriorates
Solution Approach 1:
The system replaces manual or simple mechanical positioning methods with an automated vision-based detection system. Sensors and cameras capture object positions and characteristics, while a controller processes this data to precisely identify pick points. This substitution of mechanical systems with sensor-based automation significantly improves measurement precision despite the increased complexity of the control system.
Solution Approach 2:
The system uses optical copies (images) of objects captured by sensors and cameras to identify pick points without physically contacting or manipulating the objects first. This allows for precise digital analysis and identification of pick points, improving accuracy while keeping the physical manipulation system relatively simple.
3Reliability
If existing systems are used, then the system structure is simple, but the consistency of loading and unloading operations deteriorates
Solution Approach 1:
The system incorporates sensors that continuously monitor object positions and conveyor movements, feeding this information back to the controller. The controller uses this feedback to make real-time adjustments, ensuring consistent and reliable loading/unloading operations. This closed-loop control system improves operational consistency despite the increased complexity of the control architecture.
Solution Approach 2:
The system performs preliminary detection and positioning of objects using sensors and cameras before the actual loading/unloading operation. This preliminary action ensures that all necessary information is gathered and processed in advance, allowing for consistent and reliable execution of the main operation while maintaining a structured, multi-component system.
Data Source
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AI summary
An example system and associated methods are provided herein. In some embodiments, the system includes an apparatus. In some embodiments, the apparatus includes a support structure comprising an interior area. In some embodiments, the apparatus includes a transport apparatus coupled to the support structure and configured to move a unit through the interior area. In some embodiments, the unit comprises an object and a pallet configured to support the object. In some embodiments, the apparatus includes a plurality of sensors. In some embodiments, each of the plurality of sensors is configured to monitor a portion of the interior area. In some embodiments, first sensor of the plurality of sensors is configured to detect that a bottom edge of the object is in line with an object conveyor. In some embodiments, the apparatus includes one or more manipulators.