3D Vision-Guided Palletizing for Real-Time Build Variance Compensation
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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 three-dimensional time of flight camera vision system that generates real-time imaging data to identify variances in pallet load builds, allowing for adaptive compensation and optimal placement of case units, ensuring continuous and efficient pallet construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional palletizing systems use fixed positioning and pre-programmed paths, then device complexity is reduced, but adaptability to real-time build variations deteriorates
Solution Approach 1:
The system employs a vision system that captures images of the pallet build in real-time, processes these images to detect variances from the planned build, and feeds this information back to the controller. The controller then adjusts robotic positioning and placement decisions dynamically, enabling adaptive response to actual build conditions without requiring complex manual reprogramming.
Solution Approach 2:
The patent replaces fixed mechanical positioning systems with a vision-guided robotic system. Instead of relying on pre-configured mechanical guides and fixed paths, the system uses optical sensing (vision system) combined with software processing to determine placement locations, allowing flexible adaptation to build variations through intelligent control rather than mechanical rigidity.
2Productivity
If high packing density is achieved through optimized pallet load building, then productivity is improved, but build time increases due to the complexity of solving the packing puzzle
Solution Approach 1:
The system performs preliminary planning of the pallet build using software that calculates optimal case placement sequences and positions before actual robotic execution. This pre-computation of the packing puzzle solution allows the robotic system to execute placements efficiently without real-time decision delays, achieving high density while maintaining fast build times.
Solution Approach 2:
The vision system creates a digital copy or representation of the actual pallet build by capturing images and processing them into a detectable format. This digital model is then compared with the planned build configuration, enabling rapid verification and adjustment without physical measurement, thus reducing build time while maintaining high packing efficiency.
3Manufacturing precision
If conventional systems lack real-time variance detection, then device complexity is reduced, but manufacturing precision of pallet load builds deteriorates
Solution Approach 1:
The vision system continuously monitors the pallet build process by capturing images at various stages. The processed image data is fed back to the controller, which compares actual case positions with planned positions and makes precise adjustments to robotic placement operations, ensuring high manufacturing precision through real-time closed-loop control.
Solution Approach 2:
The patent replaces traditional mechanical measurement and positioning verification systems with a vision-based detection system. Instead of using physical sensors, calipers, or manual measurement devices, the system uses optical imaging and software processing to detect case positions, orientations, and build variances, achieving high precision with greater flexibility and less mechanical complexity.
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 enables time-optimal pallet load building by continuously adapting to variances, improving packing density and reducing build time through real-time feedback and compensation, thereby enhancing overall system efficiency.
Implementation Method 1
at least one three-dimensional, time of flight, camera (310C) disposed on one or more of the frame (300F) and the one or more robots (14)
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.