Patent Application
20240394643
The present invention relates to a system for integrating the handling and management of pallet interlayer material (PIM) in the palletizing/de-palletizing process.
Palletizing/de-palletizing consists of a process comprising the placement or removal of goods (e.g.: boxes, cases, totes, containers, etc.), layer upon layer, on a pallet. Frequently, in the pallet palletizing/de-palletizing process, layers of goods are separated by a Pallet Interlayer Material to increase pallet overall stability, facilitate handling and/or fulfil system or operational requirements. Further purposes of interlayer sheets include protection and separation of the product layers in a pallet during transport. Positioned at the bottom of the pallet, the pallet insert additionally prevents contamination and damage related to the use of a pallet: Damping, perforations, pallet marks and layer collapsing. When positioned between layers, the pallet interlayer separates the layers and avoids any contamination of a defective packaging. The interlayer also prevents friction and deterioration of the products. When positioned on the top of the pallet, the top sheet protects the last layer of products against dust and other contamination related to the transport or storage of double stacked pallets.
The pallet interlayer further ensures cohesion between the different units of palletized products. It also makes it possible to stiffen the load and it helps a better distribution of the weight of the palletized loads. Depending on the nature of the interlayer, it provides a flat surface that allows the stacking of irregularly shaped products or informs. Thanks to a palletizing pad with a non-slip surface, for example carrier plates or shipping boxes may be removed, and products may be directly palletized in their ready-to-sell packaging. Thus, in the case of a columnar palletization, an interlayer ensures the stability and the cohesion of the batteries which makes it possible to increase the height of the palletized load. In the production of these interlayers, materials such as single-type plastic sheets or different types of multilayer plastics such as Bubble Guard or twin wall sheets or a combination of carton sheets, boards and/or other pallets may be used.
Currently, the task of placement and/or removal of Pallet Interlayer Material is performed by either of two methods (or a combination of these): Manually, wherein a worker assesses or is informed of which pallet requires addition and/or removal of Pallet Interlayer Material and the type of Pallet Interlayer Material needed. In case of addition, the worker picks up the recommended material in the specific Pallet Interlayer Material buffering zone and carries and places the Pallet Interlayer Material on the pallet under assembly manually. In case of removal, the worker moves to the pallet under disassembly, picks up the PIM, carries and places the material to the specific Pallet Interlayer Material buffering zone.
In the case of automatic handling, a robotic system, e.g., a palletizing/de-palletizing system (PDS), such as those including industrial robots, robotic cells and/or robotic gantries, and/or automated vehicles, among others, is installed on the warehouse shop floor to perform palletizing/de-palletizing tasks and is additionally used to handle Pallet Interlayer Material and empty pallets inside the palletizing/de-palletizing area. The robotic system is commanded by a controlling system that defines which pallet, Pallet Interlayer Material and empty pallets, buffering zone and operation are to be performed.
These solutions both comprise disadvantages. Manual Pallet Interlayer Material and empty pallets handling presents drawbacks for being labour-intensive, time-consuming and potentially hazardous for workers due to significant loads being carried over considerable distances. Robotic Pallet Interlayer Material and empty pallets handling demands physical shop floor space to install required machinery and reduces PDS machine availability.
Furthermore, in both cases PDS operational availability is affected, either by performing the PIM picking and dropping tasks or by waiting for said tasks to be performed, therefore reducing system overall equipment effectiveness (OEE) and increasing operational costs. Finally, interlayers are available in various dimensions, thicknesses, and grammages and are developed according to customer-specific requirements. Thus, devices adapted to the handling of interlayer characteristics specifically are also advantageous.
EP14196379A relates to a warehouse and a corresponding method in which products or trays are stored by use of a motor-driven unmanned aerial vehicle. The storage positions are known only to a central computer.
WO 2017/216766 A1 relates to a palletizing/de-palletizing station for goods using drones.
WO 2016/154279 A1 relates to a drone warehousing system.
WO 2019/201466 A1 relates to the handling of articles and/or packing aids by means of drones. However, the drones do not operate in locations, where robotic systems, e.g., a palletizing/de-palletizing system (PDS), are also operating.
Therefore, there is a need for integrating handling and management of pallet interlayer material (PIM) in the palletizing/de-palletizing process and to increase overall equipment effectiveness (OEE) and thereby decrease operational costs.
This is achieved by the present invention by using latent overhead air space to perform transport and placing of Pallet Interlayer Material and empty pallets (PIM) amongst other tasks.
Accordingly, it is a first object of the invention to provide a method enabling automated supply of PIM into said existing PDS setup while being independent from a PDS setup but cooperating with and optimising it.
Thus, in a first aspect, the invention relates to the method for managing pallet interlayer material and empty pallets comprising the steps of receiving pallet data relating to one or more palletizing/de-palletizing device(s); moving an automated pallet interlayer overhead transport device (OTD) to a pallet interlayer or empty pallet supply zone in which at least one supply interlayer or empty pallet is located; gripping a target supply PIM with said OTD and transporting said pallet interlayer or empty pallet to or from the pallet for palletizing/de-palletizing.
Preferably, the OTD is equipped with at least one gripping device comprising one or more gripping means.
Based on the pallet data, the OTD receives instructions on how to move to avoid collision with the palletizing/de-palletizing device(s) and optionally other OTD's. Thus, the present invention makes it possible for the OTD to operate in the vicinity of an operating palletizing/de-palletizing device in safe zones, whereby improvements, such as significant saving of time during the processes, can be achieved. Thereby, the effectiveness of the entire system is improved. The location of the safe zones may vary and is adapted according to the pallet data and where the palletizing/de-palletizing device is operating
In one embodiment, the data relating to one or more palletizing/de-palletizing devices is acquired and/or sent by a palletizing/de-palletizing device. Thereby, the data relating to one or more palletizing/de-palletizing devices may advantageously be received and processed centrally in, e.g., a control system receiving said data.
In another embodiment, the data relating to one or more palletizing/de-palletizing devices is sent by at least one device other than a palletizing/de-palletizing device, such as a data processing apparatus forming part of a PDS or sensors located in the palletizing/de-palletizing area. Thereby, the received data relating to one or more palletizing/de-palletizing device may advantageously be processed centrally in, e.g., a control system receiving said data.
In one embodiment, the method for managing pallet interlayer material and empty pallets further comprises the step of assigning an area for palletizing/de-palletizing. Thus, assigning an area for palletizing/de-palletizing may advantageously be done autonomously, and possibly by processing data received for optimisation of palletizing/de-palletizing zone assignment and increasing OEE.
In an embodiment of the method, a control system, such as a warehouse control system or an overhead transport device control system, includes a software which predicts the position and movements of the palletizing/de-palletizing device based on the data and which coordinates the routing of one or more overhead transport devices by use of the predictions. Basically, the software will analyse the incoming data about the position and movements of the palletizer/de-palletizer and position of the pallets and based on this information, the software will decide whether or not an area is safe for drone operations. The information is transferred to the control system which will instruct the drones accordingly. In this manner, a very efficient palletizing/de-palletizing process is achieved.
In another embodiment, said method comprises the step of determining overhead transport device route, whereby the travel distances can advantageously be determined as shortest/fastest/safest/most energy efficient etc.
In a further embodiment, the method comprises determining overhead transport device route, wherein receiving pallet data comprises receiving positional and/or route data relating to a palletizing/de-palletizing device and/or an overhead transport device, thereby generating processed data for further increasing OEE through travel time reduction and collision avoidance.
In one embodiment, OTD route determination relates to a route of transport of a PIM from a staging zone to a palletizing/de-palletizing zone.
In another embodiment, OTD route determination relates to a route of return of an OTD from a palletization/de-palletization zone to a Parking Zone (PZ), Hover Zone (HZ) or a staging or supply zone.
In another embodiment, OTD route determination relates to a route of transport of a PIM from de-palletization zone to a supply zone or a HZ.
In another embodiment, OTD route determination relates to a route of transport of a PIM between two staging zones, or between a HZ or PZ and a staging zone or palletizing zone.
In a further embodiment, said method comprises the step of determining overhead transport device route for collision avoidance and providing route instructions to an overhead transport device, wherein receiving pallet data comprises receiving positional and/or route data relating to a palletizing/de-palletizing device or an overhead transport device, thereby further increasing OEE through travel time reduction and collision avoidance.
In a further embodiment, determining overhead transport device route for collision avoidance comprises checking a palletizing/de-palletizing device positional data and determining a second route for said overhead transport device such that collision of the overhead transport device with the palletizing/de-palletizing device is avoided. Thus, a palletizing/de-palletizing device position/planned operational trajectory is prioritised over the first planned route of the OTD. Thereby, completion of the task of a palletizing/de-palletizing device is prioritised, since typically more bulky, less manoeuvrable and in fewer numbers than OTDs in a palletizing/de-palletizing area, and OEE is thereby increased.
Positional data may include position coordinates, distance inferences, latest registered speed, apparent speed, predicted speed, max speed, planned route and/trajectory, height, inclination, direction etc.
In another embodiment, the method comprises the step of identifying or designating a pallet interlayer material supply zone or staging zone comprising at least one pallet interlayer material or empty pallet. Thus, assigning a pallet interlayer material supply zone or staging zone may advantageously be done autonomously and possibly by processing data received for optimisation of said zone assignment thereby increasing OEE.
In another embodiment, the method includes the step of sending instructions to the overhead transport device to move to said supply zone, to grip/grab a target supply PIM and/or transporting said PIM to or from the pallet for palletizing/de-palletizing.
In one embodiment, the PIM supply zone is an area different from the palletizing/de-palletizing area, such as a staging zone.
In another embodiment the PIM supply zone is the palletizing/de-palletizing area, and the target supply PIM is grasped by the overhead transport device from the top of a pallet. Within the context of such an embodiment, the PIM is dropped at a third location, such as a staging zone or a temporary storage zone.
In one embodiment, the data received comprises data identifying the pallet for palletizing/de-palletizing. In some situations, e.g. where only few pallets need palletizing/de-palletizing, the data received may advantageously comprise data identifying said pallets and/or the order of desired palletization/de-palletization. This data could, for example, advantageously be sent in a step triggered manually by an operator who has taken a decision on which pallets should be palletized/de-palletized, and possibly further decisions, such as in which order pallets should be palletized/de-palletized.
In another embodiment, the data received comprises data identifying PIM material requirements, such as, e.g., optimal gripping means requirements. Thus, in one embodiment the method further comprises the step of the OTD moving to an area, where switching of the type of gripping means may be performed and performing said switching so that the gripping means are attached to a gripping device of the OTD.
In a further embodiment, an OTD and/or griping means are arranged to be operable such that it may be adjusted and/or modified. The data processing apparatus may instruct adjustment of equipment and/or gripping means and/or modification according to, e.g., gripping means or OTD-acquired data, thereby increasing task success rate and OEE.
Thus, in one embodiment, determining PIM requirements includes processing OTD or gripping means-acquired data. Such processing requires OTDs and/or gripping means being arranged with sensors and may advantageously result in the determination of, e.g., equipment and/or PIM position recognition, equipment and/or PIM obstacles recognition, equipment and/or PIM collision avoidance, equipment positioning accuracy, equipment and/or swarm indoor flight, PIM type and condition recognition, PIM picking/placement accuracy.
In another embodiment, the method comprises the step of identifying a pallet for palletizing/de-palletizing. This step may be carried out, e.g., by a control system (CS) having received data relating to one or several PDSs and by processing the data, resulting in determining pallet interlayer material requirements.
The method can further comprise a step of taking pictures with a drone or OTD of the pallets being depalletized and determining whether there is a slip sheet on top of pallets. If it is determined that there is a slip sheet, then instructions for removing it is sent to an OTD, before the depalletizer is moving to the position is send to an OTD.
The method can further comprise a step using an OTD or a drone to take pictures and/or video shots of the pallets and assessing whether a pallet is “looking” unstable and needs a pallet interlayer material. The assessment can be done using AI algorithms, where the pictures and/or video shots are compared to pictures and/or video shots of a stable pallet or by comparing parameters extracted from said pictures and/or video shots with reference parameters.
In a further embodiment, the method is carried out in such a way that pallet interlayer material is interposed between layers of goods, on top of a layer of goods or beneath a layer of goods. Thus, a CS receives PDS related data and determines at what time a palletizing/def-palletizing device is to drop at least one pallet interlayer material on the pallet present in the palletizing/de-palletizing area, thereby resulting in pallet interlayer material being interpolated within at least two layers of goods or on top or beneath a layer of goods being or to be stacked.
Thus, in a second aspect, the invention relates to a computer-implemented method for managing pallet interlayer material comprising the steps:
By receiving pallet data relating to a palletizing/de-palletizing device, the method enables, inter alia, collection of data relating to pallet attributes, such as, but not limited to pallet identity, pallet location, pallet load and palletizing/de-palletizing status.
Pallet interlayer requirements may include, but are not limited to, determining quantity and/or quality of PIM required for a task, thus determining that a PIM is required, but possibly also determining what PIM is required according to PIM type, size, weight, impermeability to water and/or other fluids or solvents, wet strength, construction material, construction attributes, number of PIM units required, frequency of delivery required, distance between at least one OTD and at least one staging or supply zone, distance between at least one staging or supply zone to at least one palletizing/de-palletizing area, list of OTDs in an Overheads Transport System (OTS) optionally including metadata such as location, status, task list, power charge, planned itinerary, excluded routes, current speed, max speed, current payload, max payload, and sensor information, such as temperature, applied gripping means tensile pressure, maximum gripping means tensile pressure, camara data etc.
In one embodiment, pallet interlayer requirements are determined at least in part by a PDS and are communicated to the control system (CS).
In another embodiment, pallet interlayer requirements are determined by the CS such that the CS system processes the PIM requirements, assigns tasks to overhead transport devices and thereby coordinates PIM handling operations.
Pallet interlayer material requirements are determined according to dynamic criteria including, but not limited to, goods characteristics, interlayer material type, condition and/or availability, overhead transport device type, condition, speed of execution and/or availability.
Pallet data may include data relating to more than one pallet or palletizing process. Thus, comparisons may be carried out and prioritisation of tasks may be established according to pallet attributes and prioritisation criteria. Further, coordination between palletizing/de-palletizing actions and PIM dropping may advantageously be accomplished, leading to increase of OEE.
In one embodiment, the computer-implemented method for managing pallet interlayer material and empty pallets comprises providing instructions to one overhead transport device. Said instructions may include, but are not limited to, instructions to travel to an assigned location/area in the work area, releasing/attaching gripping means, releasing/attaching tools, docking to a charging station, gripping PIM, dropping PIM, recording sensor-acquired data, transferring raw or processed data to a CS or other device within the OTS etc.
In a further embodiment, said instructions include a route through three-dimensional space instructions such as to include and/or exclude specific flight routes and/or speed or flight height limitations, among others.
In another embodiment, said method comprises providing instructions to more than one OTD. Thus, the method is adapted to instructing the OTS or OTDs individually to operate successively, collaboratively and/or as a swarm, with two or more OTDs possibly handling the same PIM. Such an arrangement may advantageously enable the OTS to handle a sheet of interlayer material that a single OTD alone could otherwise not have carried. Further advantages include increased adaptability of OTDs to PIM of varying characteristics since a swarm can carry payloads exceeding the compatibility range of a single OTD. Thereby, adaptability of costs is achieved since OTDs of a same type may be combined to adapt to the PIM requirements for each task and there is no need for the purchase of OTDs of different types and/or with different PIM-compatibility features. These purposefully designed OTDs might spend considerable time not being operated due to limited adaptability to PIM requirements, thus diminishing OEE. This situation is advantageously avoided by use of two or more OTDs handling the same PIM. When operating in collaboration or as swarm, OTSs may be operable to jointly coordinate movement, positioning, collision avoidance, PIM identification, PIM verification and/or PIM picking, among others.
In one embodiment, the computer-implemented method for managing pallet interlayer material or empty pallets further comprises the step of assigning an area for palletizing/de-palletizing. Assigning an area for palletizing/de-palletizing may be the result of determining available PDSs and pallet interlayer material requirements according to the above-mentioned goods characteristics, interlayer material type, pallet type, condition and/or availability, overhead transport device type, condition, speed of execution and/or availability, amongst others. Thus, such a feature enables the method to further decrease operation times and to further increase OEE.
In a further embodiment a plurality of palletizing/de-palletizing areas with a plurality of palletizing/de-palletizing zones and staging zones are considered; thus, the computer-implemented method for managing pallet interlayer material and empty pallets comprises the step of assigning a zone for palletizing/de-palletizing and/or a staging zone by first processing data relating to several PDSs and/or staging zones and determining/selecting an appropriate and/or optimised PDS and staging zone.
In a further embodiment, said method further comprises the step of determining that a staging zone should be assigned as a temporary storage zone.
In a further embodiment, the computer-implemented method for managing pallet interlayer material and empty pallets further comprises the steps:
Thereby, a method for transporting PIM by picking, dropping and/or moving PIM while avoiding collisions with PDS or other devices is advantageously achieved.
Thereby, the method for handling of pallet interlayer material intelligently and automatically handles PIM within the palletizing/de-palletizing process without use of PDS and/or manual labour.
The hover zone HZ is a zone established in the latent aerial space above and within the palletizing/de-palletizing area. The HZ may be understood as any unoccupied aerial space comprised above the line of the machines and/or structures inside the palletizing/de-palletizing area. A HZ is not to be considered as a fixed location, instead, as a virtual region in the palletizing/de-palletizing area in which the OTD is waiting. The advantages of a HZ are that the OTD hovers and waits close to the usage area and hence time is saved and OEE is increased.
In some embodiments, a plurality of HZs may be assigned, modified and/or removed by a CS dynamically, and a plurality of OTDs can be held in or given instruction to move to a single and/or a plurality of HZs simultaneously. Assignment and usage of HZ(s) may be carried out by the method of the invention further comprising the steps of determining best PIM picking and placement, sequencing/resequencing of tasks, selection of OTDs and assigned routes, reduction of PIM handling time, amongst others.
In some embodiments, a plurality of OTDs and/or gripping means can be selected, activated and/or managed by the CS to pick and place PIM in a plurality of PIM placement locations simultaneously and/or subsequently. This enables a plurality of PIM picking operations to be performed by a plurality of OTSs concurrently, either deploying a single or a plurality of OTDs operating individually or collaboratively to handle PIM.
In a third aspect, the invention relates to a data processing apparatus comprising means for carrying out the steps:
By carrying out said steps, the data processing apparatus advantageously controls an overhead transport device. Said controlling by, e.g., a control system, results in a coordinated interaction between PDS(s) and overhead transport device(s) which in turn increases OEE.
In another embodiment, the data processing apparatus further comprises means for determining additional parameters, such as pallet interlayer material requirements as described herein above, assigning an area for palletizing/de-palletizing, and/or receiving positional and/or route data relating to a palletizing/de-palletizing device or an overhead transport device route for collision avoidance. In particular, the data processing apparatus comprises means for determining data as described within the context of the other aspects of the invention. Thereby, additional data may be managed, stored and/or processed centrally, and OEE is advantageously further increased.
It is a further object of the invention to provide a PIM transport system that is mechanically independent from an existing PDS setup and that allows an automated supply of PIM into said existing PDS setup while cooperating and optimising it.
Thus, in a further aspect, the invention relates to a system comprising:
By the overhead transport device comprising gripping means, the device may advantageously be specifically adapted to pick up interlayer material of specific types/characteristics and transport it to its intended location with decreased chances of the PIM being dropped in a non-intended location or damaged, thus increasing OEE.
In one embodiment, the OTD is equipped with a plurality of gripping means types, sizes, shapes and operability; equipment with different gripping means may be employed simultaneously or individually.
In another embodiment, the OTD is arranged to switch gripping means or tools either manually e.g., with a suction, push-fit, snap-fit or screw mechanism or autonomously, e.g., with mechanism adapted to combine with a gripping means switching station, thereby advantageously allowing gripping means and tools to be interchangeable and expanding the range of adaptability of the OTD.
By the data processing apparatus or control system being communicatively connected to at least one overhead transport device, said apparatus or control system may advantageously send instructions to said overhead transport device efficiently.
In one embodiment, the overhead transport system comprises one overhead transport device. In another embodiment, the overhead transport system comprises a plurality of overhead transport devices. Thereby, the overhead transport system is advantageously able to pick PIM from at least one staging or supply zone and to drop PIM at least one palletizing/de-palletizing zone.
By the system comprising a data processing apparatus or a control system communicatively connected to said OTS, the system is advantageously capable of assessing best efficiency for a task autonomously and subsequently executing said task. Further, by providing a PIM transport system, which allows an automated supply of PIM, the invention provides a PIM transport system which is physically and/or mechanically independent from the PDS setup while operating collaboratively with it. This fulfils at least some of the objects of the present invention, namely, increasing OEE and reducing operational costs. Also, by providing a PIM transport system which is physically and/or mechanically independent from an existing PDS setup, the invention provides integration of a PIM system with said existing (gantry-like) PDS system without the need for installation of additional support structures on the shop floor (requiring precious shop floor space). Further, the integration of said system into an existing PDS setup allows the implementation of the method described herein above into an existing PDS setup while cooperating with it and optimising it.
In another embodiment, the system comprises UCSs embedded or combined with other Control Systems (CS) such as, but not limited to: Warehouse Control System (WCS), Programmable Logic Controller systems (PLC), Warehouse Execution System or Warehouse Management System (WMS).
In a further embodiment, the system comprises CS operable with wireless protocols such as Zigbee, Sigfox, Bluetooth, BLE, Z-Wave, 4G, 5G, or WiFi.
In a further embodiment, the overhead transport system comprises at least one type or a combination of types of overhead transport devices selected from the group comprising but not being limited to drones, unmanned aerial vehicles (UAVs), multi-copters, multi-cable winch systems and mini cranes. Each of these types bears its own advantages, for example, drones and UAVs are very manoeuvrable, precise, and may be easily combined and coordinated to form clusters displaying swarm behaviour which may provide an easily scalable platform to adapt to different workloads. Multi-copters can lift more weight, thus being indicated for picking and transporting more than one PIM at a time or heavier PIMs. Further, drones and multi-copters can fly “around” the gantry crane-like gripping means of a PDS, thereby avoid crashes as they are not bound to fixed trajectories. Multi-cable winch systems are cheap to install and to operate, since these are based on simple mechanics with few, elementary components. Mini-cranes are robust and can bear the heaviest loads.
In a further embodiment, the overhead transport system comprises more than one type of overhead transport device. Thereby, an adjustable system is achieved, which may adapt to different setups, e.g., comprising more than one PDS each having different characteristics. Alternatively, different types of OTDs may be used or the same type of OTD with different characteristics, such as two drones with diverging speed and/or autonomy characteristics: By using two different types of drones PIM transport time may further be reduced and OEE increased. For example, one drone type may have a relatively slow execution and/or travel speed but may have a comparatively high energy efficiency and rarely requires recharging. This type of drone or other UAV can thus, fly for a comparatively long time. A second type of drone type may display faster execution and/or travel speeds, but may need frequent recharging. In such an embodiment, the second drone provides a continuous PIM feed to a temporary zone, such as a spare staging zone, speed not being of interest for this continuous supply; said first drone is used for quick supply of PIM to the pallet where and when it is needed. Thereby, PIM delivery speed is increased, and PIM delivery rate is more easily guaranteed, thus advantageously increasing OEE. In such a setup, the temporary zone may be advantageously closely located to the palletizing/de-palletizing zone.
In one embodiment, the data processing apparatus is a stand-alone device, such as a computer communicatively connected to the overhead transport system and adapted for carrying out CS functions.
In another embodiment, the data processing apparatus according to the invention is comprised within the overhead transport system.
In yet a further embodiment, the data processing apparatus is comprised within the overhead transport device. Thereby, each OTD may comprise a data processing apparatus and may, thus, communicate with other OTDs in the OTS, and thereby advantageously adapt to changing parameters more efficiently, i.e., without need for processing of all data relating to the OTS by a central data processing apparatus which is limited by its own data processing capacity. The overhead transport systems may, thus, be advantageously capable of autonomously performing tasks such as flying, hovering, picking PIM, placing PIM, docking to power charging, displacing, locating, positioning, assessing optimal trajectory, avoiding collision, coordinating group flight, among other functionalities. This arrangement also provides increased safety for the system of the invention, since a malfunction of one data processing apparatus would only affect the functionality of the one OTD, and not that of the entire OTS.
In a further embodiment, the system comprises collision detection means. Such means may include sensors such as movement sensors, optical lenses capable of detecting light in the visible, IR or UV ranges, acoustic or electromagnetic sensors amongst others. Such sensors may include any device capable of detecting a change in environmental parameters, such as light or sound, but also parameters generated or inferred by movement of other devices or components of the system or, e.g., the OTD itself. Thus, Passive Infrared (PIR), ultrasonic, microwave, tomographic and combined types of sensors, amongst others, are contemplated.
Also, potentiometric position sensors (resistance-based); inductive position sensors; eddy current-based position sensors; capacitive position sensors; magnetostrictive position sensors; hall effect-based magnetic position sensors; fibre-optic position sensors; optical position sensors and ultrasonic position sensors amongst others are also contemplated. By the system comprising such means, the system is provided with a real-time data source which may serve to optimise by coordination and/or prioritisation of an OTD based on location and/or trajectory information thereby advantageously increasing OEE.
In a further embodiment, an OTD comprises sensors that enable the performance of additional tasks, such as, but not limited to, quality and safety inspections, inventory control, PIM quality inspection, and procedure tests. An OTD may further comprise technologies and/or a mix of technologies such as: cameras, lasers, ultra-sound, LIDAR, WiFi, LiFi, Bluetooth, near-field communication (NFC), radio, magnetic positioning, dead reckoning, behavioural analytics, and image recognition, amongst others.
In another embodiment, the OTD is equipped with at least one tool enabling the OTD to perform maintenance and service functions.
In a further embodiment, the gripping means suitable for working in combination with an OTD is equipped with at least one sensor. Such a sensor may be an optical sensor, or a mechanical pressure-sensing element, such as bellow type, bourdon & helical type or diaphragm types. A gripping means may further comprise technologies and/or a mix of technologies such as: cameras, lasers, ultra-sound, Lidar, WiFi, LiFi, Bluetooth, near-field communication (NFC), radio, magnetic positioning, dead reckoning, behavioural analytics, and image recognition, amongst others. The inclusion of such sensors may advantageously enable the OTD or gripping means to collect data relating to placement accuracy, gripping strength, OTD location (by use of static or mobile reference points in the three-dimensional space surrounding the OTD) etc.
In one embodiment, indoor navigation and position technologies and/or sensors may be embedded in an OTD, PDS and/or CS.
In a further embodiment, OTDs and/or griping device(s) may be arranged to be either manually or automatically adjusted, converted and/or modified, e.g., gripping prongs may be adjusted in several ways to suit PIM requirements, e.g., by altering the angle between prongs and/or padding construction material for increased gripping capability. Such a feature advantageously further increases adaptability of the gripping means and of the OTD thereby increasing OEE.
In a further embodiment, the system comprises a palletizing/de-palletizing device. By comprising at least one PDS, the system parts may be more readily adapted to communicate efficiently thus increasing OEE.
In one embodiment, the invention comprises a plurality of PDSs operating individually or combined. In a further embodiment, the plurality of PDSs of the invention present a plurality of configurations individually, advantageously allowing for palletizing/de-palletizing of goods of different nature simultaneously. Such an embodiment requires that determining pallet interlayer material requirements comprises processing the data relating to the plurality of PDSs and thereby determining pallet interlayer material requirements according to the invention.
In a further embodiment, the overhead transport device, the data processing apparatus and/or the PDS is configured to be communicatively connected by wireless means. Thereby, ease of installation is increased, such as the ease of adding or removing devices, e.g., overhead transport devices and/or PDSs to the systems are increased and shop floor space and overhead space is uncluttered, thereby again reducing the risk of accidents and increasing OEE. Further, OEE is increased because of the lack of obstruction in the overhead space.
In a further aspect, the invention relates to a method of changing a tool of a palletizing/de-palletizing device such as a robot, a gantry, a bridge crane or the like, said method comprises the steps of
The advantage of using overhead transport devices in an automated tool change operation is that the down time is decreased and further the latent space is utilised so that there is no interference with other possible devices etc. Thereby, the OEE is increased.
Another advantage is that multiple PDSs across a large area can share multiple tools and thereby reduce the number of needed tools and transport system for tools. It also allows storing the tools any place in the building thus optimising storage space.
In a preferred embodiment, the tool change involves at least two overhead transport devices so that a first overhead transport device can carry the replacement tool and a second overhead transport device can carry the tool being replaced. This can further decrease the down time of the palletizing/de-palletizing device and thereby increase the OEE.
In a preferred embodiment, the method of changing a tool of a palletizing/de-palletizing device further comprises the step of
The route can be determined as an optimal path based on parameters such as collision avoidance, utilisation of the latent space, fastest route, location of hover zones, routes of at least one other overhead transport device.
The advantage of determining a route of travel is that an overall optimum of the OEE for several palletizing/de-palletizing devices can be found instead of optimising only for the individual palletizing/de-palletizing device.
In an even more preferred embodiment, the method of changing a tool of a palletizing/de-palletizing device further comprises the step of
It is to be understood that the term “replacement tool” comprises both replacing for service but also switching for another tool for picking alternative products. Example Tool A can pick apples and Tool B can pick bananas, the OTS supplies the tool for the current task.
In another aspect, the invention relates to a computer program comprising instructions which cause the computer to carry out the method of the invention disclosed herein above, when the program is executed by a computer.
In a final aspect, the invention relates to a computer-readable medium having stored thereon the computer program disclosed herein above. By said program being stored on a computer-readable medium, OEE may be further optimised by storing optimised code, result of “machine learning”, and may thereby make said code be more readily accessible. Further, data relating to PIM management optimisation may also be advantageously stored on the same medium, thereby providing a plug-and-play device for management of several PDS setups.
In the following, example embodiments are described according to the invention:
In the following, the invention is described in detail through embodiments thereof that should not be thought of as limiting to the scope of the invention.
Pallet Interlay Material (PIM), “pallet interlay” or “interlay”: Material placed between layers of goods on a pallet to, e.g., stabilise the load. PIM also includes empty pallets.
Palletizing/de-palletizing System (PDS): An expensive bridge crane, robot or gantry designed to automate the picking and placement of goods on pallets. May comprise one or more palletizing/de-palletizing devices and/or control systems.
Overhead Transport Device (OTD): Less expensive drones, cable winches or mini-cranes that use dead air space above the palletizing zone to relieve the expensive PDS of lighter tasks.
Control System (CS): Hardware and/or software that integrates with the PDS to coordinate tasks performed by overhead transport devices.
Park Zone (PZ): An area within the palletizing zone where OTDs charge, change gripping means, are serviced or otherwise idle until assigned a task.
Hover Zone (HZ), “overhead space”, “overhead air space”, “dead overhead space” or “dead space”: The HZ may be understood as any unoccupied aerial space comprised above the line of the machines and/or structures inside the palletizing/de-palletizing area.
The term “palletizing area” as used herein, designates an area of a warehouse, wherein pallets are layered on top of each other by a PDS, OTD or other means. A palletizing area typically comprises one or more palletizing zones.
A “palletizing zone”, as used herein, is meant as the specific location of a palletizing area, where pallets are stacked or are to be stacked. Thus, a palletizing zone may be either a physical or a virtual location, both of which are not to be considered as fixed locations, instead, as regions that may be designated freely at different locations within the palletizing/de-palletizing area to increase OEE.
The terms “pick”, grasp” or “grip” as used herein relate to the action of contacting an item, typically a PIM, and lifting it by means of gripping means so to clear it from other items in its surroundings and it becomes possible to transport said item more easily.
The terms “drop” or “placing” as used herein mean the action carried out by an overhead transport device placing a pallet interlayer (PIM) on a pallet top layer. Also, when a PIM is grasped from a pallet top layer and the supply zone is the de-palletizing zone, these terms refer to the release of said PIM by the overhead transport device at a third location, such as a temporary storage zone. The PIM may also be an empty pallet which is “placed” or “dropped” by one or more OTD's.
The OTDs are controlled by the Control System (CS), and the CS is communicatively connected to the PDS and other warehouse systems.
Further,
Further, the example of
The terms “staging zone”, “PIM supply zone” or “supply zone” are to be understood as a zone in PIM or empty pallets being arranged to be picked and/or used during the palletizing/de-palletizing process.
The term “palletizing/de-palletizing zone” is to be understood as a zone in which goods are placed on or removed from a pallet under assembly or disassembly during the palletizing/de-palletizing process.
The invention may include a plurality of palletizing/de-palletizing areas with a plurality of palletizing/de-palletizing zones (1) and staging zones (2).
The palletizing/de-palletizing zones and staging zones are not to be seen as fixed locations, instead, a Control System (CS) assigns a zone as palletizing/de-palletizing zone (9) when performing a pallet assembly/disassembly process.
The at least one type of PIM is assigned to at least one PIM location in at least one staging zone (15) by the CS. In some embodiments, a plurality of PIM types and locations (19) may be available in the palletizing/de-palletizing area (10). The CS may be operable to assign, unassign, alter and/or manage PIM location(s).
OTSs (7) may be held in a Parking Zone (PZ) (16). The PZ (16) is a location adapted to host OTS(s) and may assume a plurality of configurations, such as: Parking station, charging station, buffering area, gripping means switch area, amongst others.
In some embodiments, one PZ may accommodate a plurality of OTDs (7), and a plurality of PZ(s) can be assigned in the palletizing/de-palletizing area (10).
In some embodiments of the disclosure, an integrated method of dynamic pallet interlayer material handling is provided. In the drawings, reference numeral 10 generally designates an embodiment of an integrated system for dynamic pallet interlayer material handling. Shown in
The pallet/goods transportation system (4) is instructed by the CS to arrange the goods (11) to be palletized/de-palletized in at least one palletizing/de-palletizing zone (1) or staging zone (2).
The PDS and other systems determine the PMI requirements from PDS related data and communicate them to the CS system.
The CS system processes the PMI requirements, assigns tasks to overhead transport systems and coordinates PIM handling operations based on a combination of criteria including (but not limited to) pay load, material type, equipment condition and availability, and speed.
At least one OTD (5.1) is selected and activated to pick PIM from at least one palletizing/de-palletizing (target) zone (13.1) and drop PIM to at least one staging zone (13.2) or pick PIM from at least one staging zone (13.2) and place to at least one palletizing/de-palletizing zone (13.1).
Selection of the at least one OTD (5.1) to perform PIM handling is instructed by the CS, which determines said selection by using one or more parameters, such as, for instance OTD location, configuration, charging status, distance to PIM pick location and PIM placement location, possible OTD routes and pallet assembly/disassembly order, amongst others.
When an OTD, e.g., held in a PZ, is selected and activated to perform a PIM handling task, it moves to perform the assigned task.
In cases where an OTD is selected to perform a second PIM handling task before concluding a task already in progress, the CS may be operable to overrule existing OTD commands, such as: Selection, routing, location and/or gripping means, amongst others, instructing PIM pick and placement via sequencing/re-sequencing of tasks.
The at least one selected OTD (5.1) might be activated via wireless protocol to perform the PIM handling task. Once activated, the at least one OTS (5.1) confirms its activation to the CS, and thereupon or concomitantly moves to at least one PIM picking location (13.2).
When positioned over the PIM picking location (13.2), the at least one OTD (5.1) performs alignment, identification and verification of at least one PIM, verifying, e.g.: PIM type, PIM damage status, PIM integrity and/or PIM overall conditions. For the purpose of PIM identification, PIM verification and alignment of the at least one OTD (5.1) with the PIM, and verification, the OTD may employ at least one gripping means and/or PDS sensors and/or indoor navigation and positioning technologies communicatively connected to the said OTD or CS.
In case the at least one overhead transport system (OTS) is deemed unsuitable for the palletizing/de-palletizing process, the at least one OTS may be instructed to remove the unsuitable PIM to a secondary staging zone and proceed to verification of a next PIM.
After verification and acceptance of the at least one PIM, the at least one OTD (5.1) picks the at least one PIM and transports it to at least one PIM placement location (13.1). OTD and/or gripping means may be arranged to monitor PIM grip status continuously and perform dynamic gripping adjustments. Position of the at least one OTD (5.1) and/or its gripping means is monitored by either on- or offboard positioning technologies, indoor navigation, and/or sensors, and communicated to the CS which instructs and optimises the route of the at least one OTS (5.1) dynamically, position and/or movements from the PIM picking location (13.2) to the PIM placement location (13.1).
After the selected OTD (5.1) has placed PIM on location (13.1), the CS instructs the OTD (5.1) to dispatch to a next PIM placement on a new or the same palletizing/de-palletizing zone (21.1). However, OTD (17.2) is better positioned to place the next PIM, since it already has PIM gripped and presents a shorter route to location (17.2). Therefore, CS may opt to re-sequence OTD (17.2) to location (21.1) instead of selecting and instructing OTD (5.1) to move to a PIM picking location and to the PIM placement location (21.1) afterwards.
The same may happen regarding OTD (17.1) in relation to palletizing/de-palletizing zone (21.2): Once OTD (17.1) is in better position to perform the PIM placement task faster, CS may determine that OTD (17.1) is best for fulfilling the task instead of OTD (5.1) or OTD (17.2).
Hence, sequencing and re-sequencing of PIM pick & placement tasks reduce OTD displacements, thus improving the efficiency of the OTS and PDS (3) and the palletizing/de-palletizing process. Further, OTDs may be instructed to modify, substitute, include and/or exclude route, speed, flight height limitations, among others from the PIM pick & placement process.
The at least one PDS performs consecutive goods pick and placement operations to fulfil at least one pallet assembly/disassembly.
PDS palletizing/de-palletizing operations may be interpolated with PIM pick & placement tasks.
PIM removal from the top of a staging pallet may be performed by the OTS before PDS(s) starts palletizing/de-palletizing operations.
In
Some of the staging zones function as temporary storage zones (
When performing PIM placement, the activated OTS (5.1) is positioned over the PIM placement location (13.1). The OTS (5.1) verifies the PIM placement location (13.1) and places the at least one PIM in the assigned location.
Alignment between OTSs (5.1), gripping means and PIM placement location (13.1) employs one or more of OTD, gripping means, PDS and/or gripping means sensors and indoor navigation technologies, among others, to verify: Type of PIM on specific placement location, completion of PIM placement status, PIM delivery sequence, among others. PIM placement completion confirmation is communicated to CS by OTD (5.1) and/or gripping means with use of wireless protocols.
After release of the at least one PIM, the activated OTS (5.1 and 5.2) displaces to a secondary location (13.2 and 13.3) away from the PIM placement locations (20), allowing the at least one PDS (3) to proceed with placing more goods on the pallets under assembly/disassembly in palletizing/de-palletizing zones (20). OTS displacement to secondary position may be commanded by CS and takes into consideration: palletizing/de-palletizing orders, WMS orders and/or WCS orders, battery level, next PIM pick & placement task(s), among others. An invention(s) secondary position may be assigned to an HZ, PZ, staging zone or palletizing/de-palletizing zone.
Once a PIM pick and placement task has been concluded, the OTS is instructed by the CS to start a new PIM handling task, move to a PZ (16) or to a HZ, to wait for further instructions. If no additional PIM pick & placement tasks is required, OTDs are instructed to a PZ (16). CS determination of a following action for the OTS may use received data relating to: PIM pick & placement orders and locations, palletizing/de-palletizing orders, WCS orders, WMS orders, OTD power supply status, OTD and/or gripping means type and maintenance status, among others. Communication between OTDs, gripping means, PDSs and CSs employs wireless protocol.
Turning now to
However, according to the invention, one or more drones 601 (OTD) may also be operating in the area, where the pallets A-I are localised in particular for managing pallet interlayer material and empty pallets. To avoid collision between the palletizer/de-palletizer 605 and drones 601, the drones receive instructions about the position of the palletizer/de-palletizer 605 and the arm 606 and gripping device 607 and the information that the palletizer/de-palletizer 605 will be operating in the palletizer/de-palletizer zone PDSZ (indicated with dotted lines and including pallet A, B and I), and the one or more drones 601 should avoid this zone and only operate in the drone zone or hover zone HZ (indicated with dotted lines and including pallet D, E, F, G and H, and may in principle also include pallet C). The location of the zones PDSZ and HZ will vary depending on which pallets A-I the palletizer/de-palletizer 605 has to operate, and the drones 601 will be instructed accordingly about the location of the safe zone, the drone zone HZ, in which the drones can operate.
According to the invention, one or more drones 701 can operate for managing pallet interlayer material on the pallets A-F and empty pallets among the pallets A_F. In the illustrated example, the drones 701 can operate along the line of pallets D, E and F forming a drone zone HZ while the palletizer/de-palletizer 705 can operate along the line of pallets A, B and C forming a palletizer and de-palletizer zone PDSZ. Thus, the drones will receive instruction that the drones 701 should operate in the drone zone HZ and avoid the palletizer and de-palletizer zone PDSZ.
If more than one drone is operating in the drone zone HZ, then each drone will receive instructions about which route it should use to avoid interference/collision with other drones. In principle, the drone zone or hover zone HZ is the space where the palletizer/de-palletizer is not operating and as mentioned, the drone zone is adaptive and will be localised where the palletizer/de-palletizer is not active, i.e. the palletizer/de-palletizer zone PDSZ will also be adapted to where the palletizer/de-palletizer is active.
This is illustrated in
The palletizer/de-palletizer handles 3,600 picks, the ratio of layers vs. empty pallets is 3/1, meaning that the palletizer/de-palletizer handles 2,400 picks of wares and 1,200 empty pallets to ensure the right distribution flow. By adding in the beforementioned drone system, the current 1,200 PIM picks can be outsourced, releasing the palletizer/de-palletizer to handle additionally 1,200 picks, ensuring a 33% increase in layer picking throughput.
In principle, the use of the invention leads to major improvements in the performance of the palletizing/de-palletizing device(s). By defining the palletizer/de-palletizer zone PDSZ and the drone zone HZ, it is possible to allow the drone in the vicinity of an operating palletizing/de-palletizing device without risk of collision. In this manner, it is possible to achieve major saving of time in the processes, such as up to about 70%.
By using the method according to the invention, a very efficient operation of a warehouse can be achieved, as the handling processes of pallet interlayer material and empty pallets can be improved.
| Number | Date | Country | Kind |
|---|---|---|---|
| 22154977.7 | Feb 2022 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2023/052372 | 2/1/2023 | WO |
