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The secret science behind mixed-case robotic palletizing

Every day, millions of packages move through warehouses around the world.

Big logistics companies are turning to smart robots to handle these packages faster than ever before. New generation robots can pick up and handle boxes of different sizes and weights, just like our hands and minds can.

 

Evolution of robotic arms in logistics

That wasn’t always the case.

Not long ago, robots could only stack boxes that were all the same size. Which was fine when warehouses only shipped one type of product.

But today’s customers order many different items at once and there is an increasing need to automatically handle mixed-case pallets. This created a new challenge for warehouse robots.

Newer robotic arms are different. They can be equipped to see, think and move like never before. Companies like ABB, FANUC and KUKA have created arms that can lift anything from tiny boxes to heavy crates, as well as twist and turn in six different axis, just like a human arm.

 

Next-generation robotic software intelligence

But the real magic happens in the robot’s brain.

New generation robotic software enables the robots to move faster, with greater accuracy, while avoiding possible collisions and inefficient robotic arm movement.

It also uses artificial intelligence (AI) and machine, deep learning algorithms to get better at its job. If we talk about packages in a logistics center, this process resembles the way a child learns to recognize different toys.

The robots analyze thousands of pictures of boxes and palletizing patterns, to learn from each one, and make wiser choices when choosing the appropriate palletizing scenario.

Additionally, the new software helps robots understand what they’re looking at. Special cameras can scan each box and tell the robot its size and weight. The robot then decides the best way to pick it up in fractions of a second.

These smart systems can spot even tiny differences between packages. They can read barcodes, measure exact sizes and even check if a box is damaged.

The software may also learn to plan and pre-decide where each box needs to go before it picks it up. In case something unusual happens, it has the ability to make box selection and collision-free trajectories re-calculation right away.

The above advancements give us the freedom to decide if we want to implement a sequenced or an on-the-fly mixed palletizing procedure. Picking and stacking packages as they come (on-the-fly) can be a reliable method today and offers greater flexibility, based on the modern vision and AI systems. However, sequenced palletizing with pre-planned product flows still leads the race in efficiency. When our systems know the exact product mix in advance, they can optimize patterns for maximum stability and throughput.

Today’s warehouse and distribution center robots can also work alongside people safely. They have special sensors to warn them when someone is nearby. If a person gets too close, the robot slows down or stops. This increases the confidence that robots and humans can share the same workspace with minimum risks.

 

Breaking the mixed-case palletizing code

When stacking different-sized boxes today, robots can use smart math to keep everything balanced.

They know that heavy boxes go on the bottom. They also make sure no box will fall off the stack. The software plans each move carefully, like a game of 3D Tetris. It can even run multiple pallet stability analysis tests, to ensure sturdy transportation and handling.

Special algorithms help robots solve tough packing puzzles, including in their calculation parameters like weight, size and how fragile each box is.

The robots can also use application feedback to learn which patterns work best for different types of boxes. They remember successful stacking patterns and use them again. When they find a better way to stack boxes, they update their knowledge.

Moreover, the software constantly checks that each layer is stable and calculates exactly how much weight each box can handle without getting crushed.

 

Hardware-software Integration

Modern robotic hands are just as impressive as their brains.

Some use suction cups to lift boxes. Others have special fingers that can grip different shapes. Many robots can even switch between different tools while they work.

These robotic hands have special sensors that feel how tight they’re gripping. Too loose, and boxes might fall. Too tight, and they might damage the package. The software adjusts the grip strength perfectly for each box.

Using high-precision force sensors, the robots can “feel” if something isn’t right. For example, if a box is heavier than expected, they adjust their movements to keep the packages, the robots and the nearby humans safe from damage and harm.

The best part?

These robots can basically talk to each other.

When many of them work together, they share information about where they are and what they’ll be doing. This communication can happen with or without a dedicated PLC and prevents the robots from crashing into each other or trying to pick up the same box.

Modern automation and computer networks can keep all the robots connected, disregarding the individual communication protocol used. This way they can share their plans and adjust their movements in real time, where each robot knows exactly what it should do and where the others are.

In highly-connected logistics centers, the warehouse management system (WMS) tells each robot what to do next. Today, however, robots can be smart enough to figure out the best way to do their job. They can even “decide to help each other”, if one robot gets too busy.

 

Future developments

As online shopping trend grows, mixed-case palletizing robots are expected to become even more important to run everyday logistics procedures.

New application software can help the robots see better and move faster. It can also ensure direct communication with self-driving forklifts and automatic storage systems.

The future of warehouse robots looks exciting. Soon, they’ll be able to handle any kind of package without external help.

The secret to their successful deployment is a functional mix of smart software, reliable hardware, application know-how and careful planning.

At Progressive Robotics, we help our clients in logistics solve the mixed-case palletizing riddle with intuitive and intelligent robotics software.

To find out how this could work in your case, book a free demo with us here.

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