Singulator Vision-Guided Pallet Layer Break-Up

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Solution Overview

Problem

Existing singulation systems are not capable of efficiently breaking up pallet layers to handle closely packed products and do not provide a simple means to orient outputted parcels, limiting their suitability for handling pallets and ensuring proper orientation of singulated products.

Innovation Solution

A singulator system comprising a layer break-up mechanism, a vision system for product characterization and positioning, and robots equipped with tools to grip and orient products, allowing for the separation and alignment of products from a pallet layer into a predetermined output line.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If existing singulation systems are used, then products can be singulated one at a time, but the systems cannot efficiently break up pallet layers of closely packed products

Engineering Contradiction:

Improvesingulation efficiencyVSAvoidability to handle pallet layers

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The system segments the pallet layer into individual products using a break-up system with multiple conveyors that create gaps between closely packed products, enabling subsequent robotic singulation of each product individually

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A vision system acts as an intermediary between the break-up system and robotic singulator, capturing images to determine the two-dimensional location of each product's perimeter and providing positioning information for accurate robotic handling

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If existing singulation systems are used, then products can be singulated, but there is no simple means to orient the outputted parcels

Engineering Contradiction:

Improveproduct orientation capabilityVSAvoidorientation mechanism complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The vision system provides feedback on the position and orientation of each product, allowing the robotic singulator to adjust its gripping and placement actions to achieve the desired output orientation without complex mechanical orientation mechanisms

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system replaces complex mechanical orientation mechanisms with a robotic singulator that uses vision-guided positioning and controlled product placement to achieve orientation, simplifying the overall device complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9359150B2Singulator

Publication Date: 2016.06.07 SYMBOTIC CANADA ULC

AI summary

The problem of singulating products that are provided in a pallet layer is solved by breaking up the pallet layer so that each product can be handled separately by a robot tool and outputted in at least one line according to a predetermined orientation. The singulator includes a layer drop zone that receives a pallet layer of products, a break-up system that separates the products by creating gaps therebetween, yielding separated products, a vision system that determines characteristics and position of each separated product; and a robot equipped with a tool that receives information indicative of the characteristics and position of said each separated product to grip and position each separated product onto an output station within at least one line.