Vertical Finger End Effector for High Density Pallet Stacking
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Solution Overview
Problem
Conventional methods for stacking and palletizing containers, such as totes, often result in inefficient use of space and stability issues due to horizontal loading and the inability to handle containers of varying sizes and heights, leading to reduced throughput and increased equipment costs.
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 efficient placement on a pallet, enabling the stacking of containers of differing sizes and heights, and enhancing pallet stability and density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If containers are stacked horizontally one at a time, then the loading process is simple and equipment cost is low, but space utilization is inefficient and throughput is reduced
Solution Approach 1:
The end effector is divided into multiple independent fingers that can be independently controlled. Each finger can engage with individual containers, allowing the system to grasp multiple containers simultaneously while maintaining simple overall equipment architecture. This segmentation enables parallel handling of multiple containers, increasing throughput without proportionally increasing equipment complexity.
Solution Approach 2:
The system transitions from horizontal stacking to vertical stacking by orienting the end effector fingers vertically. This dimensional change allows multiple containers to be stacked in the vertical dimension simultaneously, dramatically improving space utilization and throughput. The vertical orientation of fingers enables engagement with container walls rather than tops, facilitating this dimensional transition.
2Adaptability or versatility
If containers of uniform size are used, then stacking is simple and stable, but adaptability to different container specifications is limited
Solution Approach 1:
The end effector employs dynamically adjustable fingers that can change their position and orientation during operation. Each finger is equipped with actuators that allow real-time adjustment of gripping force and position, enabling the system to adapt to containers of varying sizes and shapes. This dynamic capability provides versatility without requiring multiple specialized grippers for different container types.
Solution Approach 2:
The end effector design creates a universal gripping system where the same set of fingers can handle multiple container specifications. By positioning fingers to engage with vertical walls rather than container lids, and by enabling independent finger adjustment, the system achieves multi-functionality that accommodates various container dimensions while maintaining a single standardized gripping mechanism.
3Volume of moving object
If vertical stacking is implemented, then space utilization and pallet density improve, but stability control becomes more challenging
Solution Approach 1:
The end effector applies localized gripping forces at specific contact points on each container. By positioning fingers to engage with vertical walls and distributing gripping forces locally across multiple contact points, the system achieves stable vertical stacking. Each finger provides localized support and alignment, ensuring proper positioning while accommodating natural variations in container geometry.
Solution Approach 2:
The system incorporates feedback mechanisms that monitor the positioning and stability of stacked containers. Sensors detect the actual positions of containers and provide real-time feedback to the control system, which then adjusts finger positions and gripping forces accordingly. This closed-loop control ensures stable vertical stacking even when containers of varying sizes are involved, maintaining pallet integrity throughout the stacking process.
Data Source
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.