Stowage Pattern Calculation for Irregular Box Stacking
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Solution Overview
Problem
Conventional techniques lack an effective method for calculating suitable stacking positions of irregularly conveyed box-shaped articles with different dimensions, leading to unstable stacking and reduced bottom area usage in palletizing systems.
Innovation Solution
A stowage pattern calculation device that calculates positions for stacking box-shaped articles using a combination calculation part to generate stable layers with constant height and rectangular shape, determining optimal stacking positions based on the type, dimensions, and remaining articles, and adjusting for irregular conveyance orders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If articles are stacked preferentially in a height direction, then stacking speed is improved, but bottom area becomes small and stability is low
Solution Approach 1:
The system dynamically adjusts the stacking strategy based on the actual conveyance order of articles. The calculation device computes disposition patterns in real-time according to the sequence of conveyed articles, transitioning from a fixed predetermined pattern to a dynamic adaptive pattern that optimizes both stability and efficiency for the current article sequence.
Solution Approach 2:
The invention changes the optimization parameters from purely height-direction prioritization to a balanced approach considering bottom area utilization and stability. The calculation device evaluates multiple disposition patterns and selects those that maintain adequate bottom area coverage while achieving efficient stacking, thereby improving stability without sacrificing productivity.
2Productivity
If a predetermined disposition pattern is determined in advance, then stacking efficiency is improved, but adaptability to irregular conveyance orders is reduced
Solution Approach 1:
The system transitions from a static predetermined disposition pattern to a dynamic calculation-based approach. The calculation device computes the disposition pattern based on the actual sequence of conveyed articles, enabling the system to adapt to irregular conveyance orders while maintaining stacking efficiency through real-time optimization.
Solution Approach 2:
The system incorporates feedback from the actual conveyance order of articles into the disposition pattern calculation. By monitoring the sequence of conveyed articles and adjusting the stacking pattern accordingly, the system achieves both efficiency and adaptability, resolving the contradiction between predetermined patterns and irregular conveyance.
3Ease of operation
If articles are stacked without calculating optimal positions, then operational complexity is reduced, but bottom area utilization is poor and stability is low
Solution Approach 1:
The calculation device automatically computes the optimal disposition pattern based on the conveyed article sequence and storage area constraints. This self-service approach eliminates the need for manual positioning decisions while achieving optimal bottom area utilization and stacking stability, thereby maintaining operational simplicity without sacrificing performance.
Solution Approach 2:
The system changes from no calculation or simple rules to an optimized calculation approach that specifically targets bottom area utilization and stability parameters. The calculation device evaluates multiple disposition patterns and selects those that maximize bottom area coverage and stability, improving these parameters without significantly increasing operational complexity.
Data Source
AI summary
A stowage pattern calculation device calculates positions of articles irregularly conveyed. The plurality of articles have a box shape and include articles having dimensions different from each other. The stowage pattern calculation device includes a combination calculation part which calculates a combination of the articles constituting a layer formed in a storage area and selects a layer of the articles based on types of the articles, a height of the layer, and an area of the layer. The stowage pattern calculation device includes a position determination part which calculates a first probability of completion of the layer and determines positions at which the articles are stacked based on a positional relationship between a robot and the storage area and the first probability.