3D ToF Palletizing for Continuous Mixed-Case Load Building
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Solution Overview
Problem
Conventional palletizing systems fail to provide adaptive, real-time build variations for achieving time-optimal pallet load building, leading to inefficiencies in packing density and build time in mixed case pallet loads.
Innovation Solution
A palletizer cell equipped with a 3D time-of-flight camera vision system that generates real-time three-dimensional imaging data to identify variances in pallet load builds, allowing for adaptive compensation and optimal placement of case units, enabling continuous and efficient pallet construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional palletizing systems use electromagnetic radiation and optical mapping sensors to map the 3-D pallet load, then positioning accuracy relative to the pallet load is improved, but build time increases and time-optimal pallet load building cannot be achieved
Solution Approach 1:
The patent replaces conventional electromagnetic radiation and optical mapping sensors with a time-of-flight camera that uses flight time of light to directly measure distances. This substitution maintains measurement precision while significantly reducing the time required to map the pallet load, enabling time-optimal pallet load building.
Solution Approach 2:
The patent changes the measurement parameter from traditional optical mapping methods to time-of-flight measurement. By measuring the flight time of light rather than using complex optical mapping, the system achieves both high positioning accuracy and reduced build time, resolving the contradiction between precision and speed.
2Quantity of substance
If high packing density is achieved by solving the pallet load build puzzle, then packing efficiency is improved, but build time increases making the process non-time-optimal
Solution Approach 1:
The patent replaces complex optical mapping systems with time-of-flight camera technology, enabling real-time 3D imaging that facilitates high packing density achievement without increasing build time. The faster measurement capability allows the system to optimize packing arrangements in real-time.
Solution Approach 2:
The patent enables continuous real-time imaging and measurement during the pallet building process. This continuity allows the system to maintain high packing density while achieving time-optimal builds by making adjustments in real-time rather than requiring multiple measurement passes.
3Extent of automation
If conventional 3-D mapping systems are used for pallet load building, then automation positioning is improved, but adaptive real-time build variation capability is lost
Solution Approach 1:
The patent replaces conventional 3-D mapping systems with time-of-flight camera technology that provides real-time depth information. This substitution maintains automation positioning capabilities while enabling adaptive real-time build variation through rapid, continuous measurement feedback.
Solution Approach 2:
The patent implements real-time feedback through continuous time-of-flight measurements during pallet building. This feedback mechanism enables the automated system to adapt to build variations in real-time, maintaining both automation positioning accuracy and adaptive capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system ensures time-optimal pallet load building by continuously adapting to variances, improving packing density and reducing build time, thus enhancing overall system efficiency and pallet quality.
Implementation Method 1
A palletizer cell is provided with a 3D time-of-flight camera that generates real-time three-dimensional imaging data so as to detect and map the pallet load structure
Data Source
AI summary
A pallet building apparatus for automatically building a pallet load of pallet load article units onto a pallet support including a frame defining a pallet building base, at least one articulated robot to transport and place the pallet load article units, a controller to control articulated robot motion and effect therewith a pallet load build, at least one three-dimensional, time of flight, camera to generate three-dimensional imaging of the pallet support and pallet load build, wherein the controller registers, from the three-dimensional camera, real time three-dimensional imaging data embodying different corresponding three-dimensional images of the pallet support and pallet load build, to determine, in real time, from the corresponding real time three-dimensional imaging data, a pallet support variance or article unit variance and generate in real time an articulated robot motion signal, the articulated robot motion signal being generated real time so as to be performed real time by the at least one articulated robot between placement of at least one pallet load article unit and a serially consecutive pallet load article unit enabling substantially continuous building of the pallet load build.