Automated Tote Palletizing With Vertical Column Stacking

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Solution Overview

Problem

Conventional methods for loading containers onto pallets, such as totes, often result in inefficient use of space and stability issues due to horizontal stacking and limited reachability, especially when dealing with containers of varying sizes and heights, leading to reduced throughput and potential 'flowering' problems.

Innovation Solution

An automated system utilizing an end effector with vertically oriented fingers to stack and move totes in a column, allowing for precise vertical alignment and placement of multiple totes on a pallet, enhancing stability and density, and enabling the use of robotic arms to efficiently handle and position totes of differing sizes and heights.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If containers are stacked horizontally one at a time, then the loading process is simple to operate, but the space utilization is inefficient and stability is poor

Engineering Contradiction:

Improveloading process simplicityVSAvoidspace utilization

Core Design Contradiction:

Ease of operationVSQuantity of substance

Solution Approach 1:

The system segments the loading process into two distinct phases: vertical stacking phase where multiple containers are stacked to full height, and horizontal placement phase where complete columns are positioned on the pallet. This segmentation enables efficient space utilization while maintaining operational simplicity through automated control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from traditional horizontal-only stacking to a three-dimensional approach by stacking containers vertically to their full height before placing them on the pallet. This vertical dimension exploitation significantly improves space utilization and pallet stability.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Device complexity

If containers are stacked horizontally one at a time, then the equipment structure is simple, but the throughput is reduced

Engineering Contradiction:

Improveequipment structureVSAvoidthroughput

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The system merges multiple container handling operations into a single automated sequence. The robotic arm performs both vertical stacking and horizontal placement in one continuous motion, and multiple containers are stacked simultaneously before being placed on the pallet, thereby increasing throughput without proportionally increasing equipment complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The automated system eliminates idle time between loading operations by maintaining continuous robotic motion. The arm continuously stacks containers vertically and then continuously places complete columns on the pallet, ensuring useful action continues without interruption and maximizing throughput.

Inventive Principle:

Principle #20Continuity of useful action

3Adaptability or versatility

If containers of varying sizes are accommodated, then the system is more versatile, but stability issues arise due to 'flowering' problems

Engineering Contradiction:

Improvecontainer size accommodationVSAvoidpallet stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

Instead of placing containers horizontally row by row on the pallet, the system inverts the approach by stacking containers vertically to their full height first, creating stable columns, and then placing these complete columns on the pallet. This inversion eliminates the 'flowering' instability problem by ensuring each column is self-stabilizing before placement.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The system performs preliminary vertical stacking of containers to their full height before placing them on the pallet. This preliminary action creates stable, self-supporting columns that can accommodate containers of varying sizes without compromising pallet stability, as the vertical stacking provides structural integrity before horizontal placement.

Inventive Principle:

Principle #10Preliminary action

4Ease of manufacture

If horizontal rows are completed layer by layer, then the loading method is conventional and easy to implement, but equipment footprint is large

Engineering Contradiction:

Improveimplementation simplicityVSAvoidequipment footprint

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

The system exploits the vertical dimension by stacking containers to their full height before placement, rather than spreading them out horizontally. This vertical orientation reduces the horizontal equipment footprint while maintaining implementation simplicity through automated robotic control that manages the vertical stacking sequence.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS11161691B2Container palletizing system

Publication Date: 2021.11.02 AMAZON TECH INC

AI summary

A system and method for automated palletization of totes and cuboid containers includes an end effector having fingers projecting outwardly. The fingers may engage recesses in the totes. Alternatively, actuators on fixed fingers can move gripping surfaces into engagement with the totes or containers. Or actuators on a body of the end effector can move the fingers, which include gripping surfaces.