Autonomous Stacking Robot for Multi-Axis Feature Alignment
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Solution Overview
Problem
Current methods for stacking elements, such as pallets and containers, in warehouses or manufacturing facilities lack the precision and autonomy to efficiently align and interlock elements in multiple degrees of freedom, often requiring manual intervention and limited flexibility in movement.
Innovation Solution
An autonomous vehicle equipped with a controllable end-effector and sensors that can move in four, five, or six degrees of freedom, allowing it to align and stack elements by detecting compatible features and adjusting its position and orientation to mate complementary features on multiple elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional forklifts or drivable machinery are used to stack elements, then basic stacking functionality is achieved, but precision and autonomy are insufficient, requiring manual intervention
Solution Approach 1:
The patent replaces traditional mechanical control systems with an autonomous navigation system that uses sensors (LIDAR, cameras, RFID readers) and processors to detect element positions, calculate alignment vectors, and automatically control the end-effector's movement in multiple degrees of freedom, achieving both high autonomy and precision without manual intervention
Solution Approach 2:
The system performs self-alignment by automatically detecting the second element's features, calculating the required alignment vectors, and adjusting its own position and orientation through autonomous control of the end-effector's multiple degrees of freedom, eliminating the need for external guidance or manual operation
2Productivity
If manual intervention is used for stacking, then flexibility in handling various elements is maintained, but efficiency and operational capacity are reduced
Solution Approach 1:
The end-effector is designed with dynamic capability to move in multiple degrees of freedom (forward/backward, up/down, left/right, and rotational movements), allowing it to adapt its position and orientation automatically to handle various element types and configurations, maintaining flexibility while operating autonomously at high speed
Solution Approach 2:
The autonomous vehicle is equipped with a universal end-effector system that can detect and handle different types of elements (pallets, containers, boxes) using the same multi-degree-of-freedom mechanism, enabling the system to perform multiple stacking operations with diverse elements without requiring manual intervention or reconfiguration
3Adaptability or versatility
If the vehicle moves in limited degrees of freedom, then device complexity is reduced, but the ability to align and interlock elements in various orientations is insufficient
Solution Approach 1:
The control system is segmented into independent modules, each responsible for controlling a specific degree of freedom of the end-effector (forward/backward movement, up/down movement, left/right movement, and rotational movements). This modular architecture manages complexity by allowing each module to operate independently while contributing to the overall multi-orientation stacking capability
Data Source
AI summary
An example autonomous vehicle includes a body configured for movement along a surface and an end-effector to hold a first element having first and second features that mate to complementary third and fourth features on a second element. At least one of the end-effector or the body is controllable to move in at least four degrees of freedom. The autonomous device includes one or more sensors to detect the second element and to obtain information for locating the third and fourth features of the second element or other compatible device. The autonomous device also includes a control system to control at least one of the end-effector or the body to move in the at least four degrees of freedom to stack the first element on top of the second element.