Vision-Guided Twistlock Handling on Moving Container Vehicles
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Solution Overview
Problem
Conventional twistlock handling with robots requires multiple robots per vehicle side, leading to high costs and large handling station areas, which hinder efficient container loading and unloading processes.
Innovation Solution
A vision-based control system with a single robot per vehicle side, using a gripper and visual sensor to track and handle twistlocks in real-time, reducing the need for multiple robots and minimizing the handling station's size by predicting the twistlock's position based on image analysis and position correction parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple robots are deployed per vehicle side to handle twistlocks synchronously, then twistlock handling capability is improved, but the cost and device complexity increase significantly
Solution Approach 1:
The patent applies dynamics by transitioning from static, pre-positioned robots to a mobile robot that tracks the moving corner fitting. The robot dynamically adjusts its position and timing to synchronize with the vehicle's movement, allowing a single robot to perform the work previously requiring multiple static robots. This dynamic approach resolves the contradiction by maintaining high handling capability while reducing the number of robots needed.
Solution Approach 2:
The patent employs preliminary action through vision-based prediction. The visual sensor captures the corner fitting's position in advance, and the control unit calculates the future position based on the vehicle's speed and the robot's response time. This predictive positioning allows the robot to anticipate where the corner fitting will be when the gripper arrives, enabling successful twistlock handling with a single robot despite the vehicle's continuous movement.
2Productivity
If a large area is allocated for the twistlock handling station, then robots can handle twistlocks synchronously, but the handling station occupies excessive space and reduces quay efficiency
Solution Approach 1:
The patent resolves the area contradiction by making the robot mobile rather than stationary. The robot travels with the vehicle along its movement path, eliminating the need for a large fixed handling station area. This dynamic mobile approach allows efficient twistlock handling while minimizing the space occupied by the handling station infrastructure.
Solution Approach 2:
The patent replaces the mechanical system of multiple fixed robots with a single mobile robot controlled by vision-based positioning. This substitution eliminates the need for extensive mechanical infrastructure and large station areas, achieving the same handling functionality through a more space-efficient mobile platform guided by visual sensors and computational prediction.
3Measurement precision
If the vehicle stops at the handling position for twistlock operations, then robot handling precision is improved, but the overall handling time increases
Solution Approach 1:
The patent applies preliminary action by capturing the corner fitting's position in advance before the robot needs to act. The visual sensor takes the image at an early time point, and the control unit calculates the future position based on predicted displacement during the robot's response time. This allows the vehicle to maintain continuous movement while the robot accurately tracks and positions itself for twistlock handling, eliminating the need for the vehicle to stop.
Solution Approach 2:
The patent implements feedback through continuous vision-based position tracking. The visual sensor continuously monitors the corner fitting's position, and the control unit adjusts the robot's target position based on the vehicle's actual movement. This closed-loop feedback system enables the robot to maintain accurate positioning even as the vehicle moves, allowing handling operations to occur during vehicle motion without requiring stops.
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
This approach reduces the number of robots needed and the handling station's size, enhancing efficiency and reducing costs while maintaining high-speed twistlock handling capabilities.
Implementation Method 1
determine, based on the first image, a first position of the corner fitting at the moment when the first image is captured by the visual sensor
Data Source
AI summary
An apparatus and a method for handling twistlocks configured to lock a container onto a vehicle. The apparatus includes a gripper configured to grip one of the twistlocks to be mounted onto or dismounted from a corner fitting of a container. Further, the apparatus has a visual sensor configured to capture a first image of the corner fitting when the vehicle is moving in a twistlock handling station. The apparatus includes a control unit configured to obtain, from the visual sensor, the first image make some determinations based on the first image; and send a handling position such that the gripper moves to the handling position to handle the one of the twistlocks during the moving of the vehicle.