Note: Descriptions are shown in the official language in which they were submitted.
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ROBOTIC WRAPPING SYSTEM
PRIORITY
[0001] This application claims the benefit of U. S. Non-Provisional
Application No.
17/825,556, entitled, "ROBOTIC WRAPPING SYSTEM", filed on 26 May 2022 (Atty
Docket
No. lDFG 1008-2). This application also claims the benefit of U.S. Provisional
Patent Application
No. 63/194,840, entitled, "ROBOTIC WRAPPING SYSTEM," filed on 28 May 2021
(Atty.
Docket No. IDFG 1008-1). The priority applications are hereby incorporated by
reference herein
for all purposes.
BACKGROUND
[0002] The subject matter discussed in this section should not be
assumed to be prior art
merely as a result of its mention in this section. Similarly, a problem
mentioned in this section or
associated with the subject matter provided as background should not be
assumed to have been
previously recognized in the prior art. The subject matter in this section
merely represents
different approaches, which in and of themselves may also correspond to
implementations of the
claimed technology.
[0003] Processing timber involves a variety of tasks, such as
sawing, packaging, and
shipping product and the like. During processing, wooden logs are cut to
various sizes in a
timber mill or other facility and processed further into wood products, e.g.,
lumber, plywood,
laminates, particle board and others. Once complete, the final product must be
packaged up and
shipped off facility for distribution and sale. Stacks or bundles of like
product are wrapped with
packaging material to prevent damage due to dirt or weather, prevent slippage
and other benefits.
Often, this wrapping is a manual operation performed by workers. There are
many problems
with these traditional approaches; the tasks involved in wrapping wood
products can be
repetitive and thus error prone; stacks and bundles of wood products can slip
or spill presenting
danger of inflicting injury to the worker or damaging the product. The lack of
flexibility is also
compounded by the complexity of materials handling requirements for the
timber. Rough cut
timber is heavy and unwieldy, making the job of moving it into and out of the
work area
complex.
[0004] Conventional approaches to the problem of packaging timber
are not flexible, nor
scalable, nor cost effective, and are of very low efficiency, making their
usage in scalable timber
processing installations problematic. Often, conventional approaches require a
variety of
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different inflexible machines to perform the same task on different sizes
and/or shapes of
products. Sometimes, conventional approaches require additional energy to be
expended moving
timber among a larger variety of machines to perform processing.
[0005] An opportunity arises to develop better machines and
processes for packaging wood
products. Better, more easily operated, more effective and efficient apparatus
and systems may
result.
SUMMARY
[0006] A simplified summary is provided herein to help enable a
basic or general
understanding of various aspects of exemplary, non-limiting implementations
that follow in the
more detailed description and the accompanying drawings. This summary is not
intended,
however, as an extensive or exhaustive overview. Instead, the sole purpose of
this summary is to
present some concepts related to some exemplary non-limiting implementations
in a simplified
form as a prelude to the more detailed description of the various
implementations that follow.
100071 The technology disclosed relates to a robotic workstation
for packaging wood
products. The robotic workstation can achieve efficiencies of scale and so
forth, when packaging
(e.g., wrapping, etc.) product stacked into so-named "units" having dimensions
of approximately
40" to 54" in width, 12" to 36" height, and 6' to 20' in length. In one
configuration, the robotic
packaging workstation includes a plurality of robot manipulators arranged in
tandem to work on
product presented to the workstation. The manipulators are capable of moving
an end effector to
points in a three-dimensional work volume under programmed control of a
programmable robot
controller executing stored instructions. A fastener (e.g., staples, nails,
brads, glues, or other non-
threaded fasteners or screw drivers, or other threaded fasteners) and wrapping
tool head is
affixed to the end effector adapter plate. The fastener and wrapping tool head
further includes a
support structure, a fastener applicator, fastener storage, and one or more
grippers for grasping
wrapping material, a fastener low detection sensor and proximity switches.
[0008] An apparatus implementing the technology disclosed includes
fastener and grasping
tool for a robotic packaging workstation, that can include an adapter plate
couplable to an end
plate of a robot arm; a stapler having a tab feed mechanism for automatically
feeding staples; a
storage housing coupled to the stapler for dispensing staples; a stapler low
detection proximity
switch; and at least one mechanical gripper facilitating grasping of wrapping
material.
[0009] In a particular implementation, the technology disclosed
also provides a method of
packaging (e.g., wrapping, etc.) product stacked into so-named "units" having
dimensions of
approximately 40" to 54" in width, 12" to 36" height, and 6' to 20' in length.
The method can
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include receiving by a Programmable Logic Controller, information identifying
a wood product
unit to be received. The information can be received from a scanner, optical
sensor(s), network
connection or combinations thereof. The identifying information can include
selected ones of a
unit length, a unit width, a unit height, a unit ID, a product ID. The method
further includes
obtaining a portion of wrapping material appropriately sized using the
identifying information.
This can be achieved by at least a first plurality of robot manipulators
grasping an end of the
wrapping material, a motor with encoder feedback dispensing a length of
wrapping material
required to fully wrap the wood product unit, and at least a second plurality
of robot
manipulators grasping a trail end of the wrapping material prior to cutting
the wrapping material.
At least the first plurality of robot manipulators can (pre-)position
themselves according to size
of the wood product unit incoming based upon or using the identifying
information
Alternatively, a detected or measured size of the wood product unit can be
used. The wood
product unit is received at a location determined by a presence sensor. The
method can include
determining by at least one robot manipulator a measured position of at least
one corner of the
wood product unit. The method also includes wrapping by the robot manipulators
the wood
product unit and applying fasteners to hold wrapping material in place. Upon
completion of the
wrapping, the wood product unit as packaged is advanced from an outfeed side
of a work
envelope using a materials handling system.
[0010] In one implementation, 4 robot manipulators (i.e., stapling
and grasping tools) can
wrap a unit of product working cooperatively. Various other combinations of
product sizes and
number of robotic manipulators can be implemented depending on requirements of
the wood
products processing facility.
[0011] Particular aspects of the technology disclosed are described
in the claims,
specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The included drawings are for illustrative purposes and
serve only to provide
examples of possible structures and process operations for one or more
implementations of this
disclosure. These drawings in no way limit any changes in form and detail that
may be made by
one skilled in the art without departing from the spirit and scope of this
disclosure. A more
complete understanding of the subject matter may be derived by referring to
the detailed
description and claims when considered in conjunction with the following
figures, wherein like
reference numbers refer to similar elements throughout the figures.
[0013] FIG. 1 illustrates a plan view of a robotic workstation for
packaging wood products.
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[0014] FIG. 2 illustrates a section view of a robotic workstation
for packaging wood
products.
[0015] FIG. 3 illustrates a left-side (infeed) view of a robotic
workstation for packaging
wood products.
[0016] FIG. 4A illustrates a left perspective view of a left side
end effector tool robotic
workstation for packaging wood products.
[0017] FIG. 4B illustrates a left side view of a left side end
effector tool robotic workstation
for packaging wood products.
[0018] FIG. 4C illustrates a plan view of a left side end effector
tool robotic workstation for
packaging wood products.
[0019] FIG. 4D illustrates a side view of a left side end effector
tool robotic workstation for
packaging wood products.
[0020] FIG. SA illustrates a left perspective view of a right side
end effector tool robotic
workstation for packaging wood products
[0021] FIG. 5B illustrates a left side view of a right side end
effector tool robotic
workstation for packaging wood products.
[0022] FIG. SC illustrates a plan view of a right side end effector
tool robotic workstation
for packaging wood products.
[0023] FIG. 5D illustrates a side view of a right side end effector
tool robotic workstation
for packaging wood products.
[0024] FIG. 6 illustrates a flowchart of a process for packaging
wood products.
[0025] FIG. 7A, 7B, 7C, and 7D illustrate composite, plan, front
and perspective views of
an example end effector for group 3 robot 13 of FIG. 1.
[0026] FIG. 8A, 8B, 8C, and 8D illustrate composite, plan, front
and perspective views of
an example end effector for group 2 robot 12 of FIG. 1.
[0027] FIGS. 9A and 9B show implementation of an electronics
architecture used by the
robot in which a controller processes input data comprising at least actuation
data from the
actuators of the actuation system, image data from visual sensors in the
robot, and tactile data
from tactile sensors in the robot, and generates actuator command data.
DETAILED DESCRIPTION
[0028] The following description will typically be with reference
to specific structural
embodiments and methods. It is to be understood that there is no intention to
be limited to the
specifically disclosed embodiments and methods but that other features,
elements, methods and
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embodiments may be used for implementations of this disclosure. Preferred
embodiments are
described to illustrate the technology disclosed, not to limit its scope,
which is defined by the
claims. Those of ordinary skill in the art will recognize a variety of
equivalent variations on the
description that follows. Unless otherwise stated, in this application
specified relationships, such
as parallel to, aligned with, or in the same plane as, mean that the specified
relationships are
within limitations of manufacturing processes and within manufacturing
variations. When
components are described as being coupled, connected, being in contact or
contacting one
another, they need not be physically directly touching one another unless
specifically described
as such. Like elements in various embodiments are commonly referred to with
like reference
numerals.
[0029] A more sophisticated robotic packaging system and method is
provided for improved
efficiency in packaging processed wood products. Implementations efficiently
wrap product
stacked into so-named "units" having dimensions of approximately 40" to 54" in
width, 12" to
36" height, and 6' to 20' in length. Prior to wrapping, the relevant
information pertaining to the
unit of lumber is passed along to the wrapping programmable logic controller
(PLC), including a
unit length, a unit width, a unit height, a unit ID, a product ID, and
potentially others. While the
product is traversing the sawmill floor into the robotic packaging
workstation, the programmable
logic controller utilizes this unit dimensional information to command robot
manipulators
comprising the robotic workstation to obtain the appropriately sized (correct
width) wrapping
material (e.g., paper, bubble wrap, woven polypropylene, or the like).
[0030] FIG. 1 illustrates a plan view 100 of a robotic workstation
14 for packaging wood
products.
[00311 Robotic workstation 14 nominally includes a plurality of
robot manipulators 10, 11,
12 and 13 (hereafter "robots" or "robot manipulators" or "manipulators" or
"arms") arranged
into a leading edge group comprising robots manipulators 11 and 13 and a
trailing edge group
comprising manipulators 10 and 12; the arrangement being relative to a
materials handling
system 40 (conveyor or the like) that -feeds" product (e.g., unit 9) through
the workstation 14
along a roughly linear path approximately bisecting the workstation 14.
[0032] Robot manipulators 10, 11, 12 and 13 can include a base 3
enabling the robot to be
affixed to the sawmill floor directly or via a platform 2 to facilitate travel
of the robot
manipulator in order to process different sizes and/or shapes of product 9. In
one
implementation, base 3 comprises an M710 BASE 13.5. In the layout illustrated
by FIG. 1,
leading edge group manipulators 11 and 13 are mounted to a platform 2
nominally comprising
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two (2) linear rails of nominally 3.5m in length, that enables the robots 11
and 13 to move along
the y-direction of FIG. 1 in order to accommodate different sizes of product
9.
[00331 A robot controller (not shown in FIG. 1 for clarity sake)
controls the motions of robot
manipulators 10, 11, 12 and 13 under direct operator control and/or by
programmed logic.
Implementation specifics vary considerably, however in one example a
Controllogix PLC is
used to implement the robot controller.
[00341 An end effector tool 50, 51 is coupled to the robot
manipulators 10, 11, 12, and 13
and are able to be moved within the work envelope of the robot to which it is
mounted in order
to wrap product (e.g., unit 9) fed by materials handling system 40 under
control of the robot
controller. Preferable end effector tool implementations embody staple
mechanism(s), staple
feed mechanisms, gripper(s) for grasping wrapping material(s) etc., sensors
and proximity
switches. End effector tools 50, 51 are described in detail hereinbelow with
reference to
examples illustrated by FIGS. 4A-4D, FIGS. 7A-7D and FIGS. 5A-5D, FIGS. 8A-8D,
respectively.
[00351 Robot manipulators 10, 11, 12, and 13 are preferably an
industrial grade articulating
robot arms (manipulators) capable of moving laterally approximately +/- 4 feet
from a starting
position. Implementations efficiently wrap product stacked into so-named
"units" having
dimensions of approximately 40" to 54" in width, 12" to 36" height, and 6' to
20' in length. In
one implementation, a highly customized FANUC M-710C 45M robotic arms
implement robot
manipulators 10, 11, 12, and 13. In one implementation, robot manipulator 10
includes feedback
from servos that drive motions of the robot, such as torque, arbor speed,
robot force exerted,
collision detection and others. Other implementations can be realized using
any of a number of
industrial-purpose commercially available robots made by Fanuc, ASEA, Kuka,
ABB, Yaskawa
and the like.
[0036] Material handling system 40 preferably includes chain-way,
conveyors, indexers, and
the like to move units of product 9 into the workstation 14 and to move
packaged units of
product 9 out of the workstation 14.
[0037] Tool stations 220, 221 provide locations for end effector
tools 50, 51 to be picked up
by and dropped off by the robot manipulators 10, 11, 12, and 13 In a presently
preferrable
configuration, each one of the robot manipulators 10, 11, 12, and 13 can swap
fastener tools at
the tool stations 220, 221, either at the same time or individually. Tool
stations 220, 221 can
implement stapler refilling in some implementations. Robot manipulators 10,
11, 12, and 13 can
drop off an end effector tool 50, 51 when a sensor indicates that the
particular tool is low/out of
staples and pick up a freshly loaded end effector tool. Once a stapler is
refilled, it is put in the
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'Full' Area. A proximity sensor (not shown in FIG. 1 for clarity sake) detects
the presence of a
refilled stapler and indicates to the appropriate robot that there is one
ready for it to grab.
[0038] FIG. 2 illustrates a section view 200 of section A-A a
robotic workstation for
wrapping wood products. In section A-A view 200 of the robotic workstation 14,
robot 11 of the
leading edge group comprising robots manipulators 11 and 13 and a robot 10 of
the trailing edge
group comprising manipulators 10 and 12 are depicted at the outfeed side and
the infeed side of
the workstation 14. Also shown is material handling system 40 and example of
wood product
unit 9.
[0039] FIG. 3 illustrates a left-side (infeed) view of a robotic
workstation for packaging
wood products. In left side view 300 of the robotic workstation 14, robot 10
and 12 of the
trailing edge group comprising manipulators 10 and 12 are depicted at the
infeed side of the
workstation 14. Also shown is material handling system 40 and example of wood
product unit 9.
Tool stations 220, 221 are also shown.
[0040] FIG. 4A illustrates a left perspective view of a left side
end effector tool robotic
workstation for packaging wood products.
[00411 FIG. 4B illustrates a left side view of a left side end
effector tool robotic workstation
for packaging wood products. In a presently preferrable configuration, groups
1, 2, 3, and 4 will
use end effectors individual to that group. Fastener tools will be similar
between right side group
1, 3 and left side group 2, 4. End effector tool 50 includes an adapter plate
couplable to an end
plate of a robot arm via tool changes 400; a support structure 401, a stapler
(or other fastener
dispenser) 404 having a tab feed mechanism for automatically feeding staples
or other fasteners;
a storage housing 402 coupled to the stapler 404 for dispensing staples or
other fasteners; a
stapler (or other fastener) low detection proximity switch (not shown in FIG.
4B).; and one or
more mechanical grippers 430a-430d facilitating grasping of wrapping material.
Implementations can be configured to include one or more of a vacuum actuated
gripper, an
adhesive gripper, a magnetic gripper, a servo (electric) gripper,
hydraulically actuated gripper, a
pneumatically actuated gripper or combinations thereof In a presently
preferrable
implementation, motion and actuation on the end effector depicted in FIG. 4B
is pneumatically
controlled. Fastener types implemented can include, e.g., staples, nails,
brads, glues, or other
non-threaded fasteners or screw drivers, or other threaded fasteners
Optionally, multiple
grippers can be included to accommodate different heights of wood product
units.
[0042] In left side view of left side end effector tool 50 for the
leading group 3 robot 13 is
shown.
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[0043] FIG. 4C illustrates a plan view of a left side end effector
tool robotic workstation for
packaging wood products. Left side end effector 50 includes support structure
401 couplable to
an end effector adapter plate via tool changers (not shown in FIG. 4C) and
supporting, stapler
404, storage housing 402 and grippers 430a-430d. Noteworthy comparing FIG. 4C
and FIG. 5C
is that at least one gripper 430a is capable of rotating 90 degrees; thereby
facilitating grasping
packaging materials in a variety of positions.
[0044] FIG. 4D illustrates a side view of a left side end effector
tool robotic workstation for
packaging wood products.
[0045] FIG. 5A illustrates a left perspective view of a right side
end effector tool robotic
workstation for packaging wood products.
[0046] FIG. 5B illustrates a left side view of a right side end
effector tool robotic
workstation for packaging wood products. A fastener (e.g., staples, nails,
brads, glues, or other
non-threaded fasteners or screw drivers, or other threaded fasteners) and
wrapping tool head 51
is affixed to the end effector adapter plate via tool changes 500. The
fastener and wrapping tool
head further includes a support structure 501, a fastener applicator 504,
fastener storage 502, and
one or more grippers 530a-530d for grasping wrapping material driven by drive
mechanism 512,
and some fastener low detection sensor and proximity switches (not shown in
FIG. 5B).
Implementations can be configured to include one or more of a vacuum actuated
gripper, an
adhesive gripper, a magnetic gripper, a servo (electric) gripper,
hydraulically actuated gripper, a
pneumatically actuated gripper or combinations thereof In a presently
preferrable end effector
configuration, fastener tooling from groups I and 3 is the same, and that of
groups 2 and 4 is also
the same. In some configurations, tooling for each group is built using the
like components in
different configurations that are individual to each group. Fastener types
implemented can
include, e.g., staples, nails, brads, glues, or other non-threaded fasteners
or screw drivers, or
other threaded fasteners. Optionally, multiple grippers can be included to
accommodate different
heights of wood product units.
[0047] FIG. 5C illustrates a plan view of a right side end effector
tool robotic workstation
for packaging wood products. Right side end effector 51 includes support
structure 501
couplable to an end effector adapter plate via tool changers (not shown in
FIG. 5C) and
supporting, stapler 504, storage housing 502 and grippers 530a ¨ 530d
Noteworthy comparing
FIG. 4C and FIG. 5C is that at least one gripper 530a is capable of rotating
+/- 90 degrees;
thereby facilitating grasping packaging materials in a variety of positions.
[0048] FIG. 5D illustrates a side view of a right side end effector
tool robotic workstation
for packaging wood products.
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[0049] FIG. 6 illustrates a flowchart of a packaging process for
wood products and other
units of products.
[0050] In a step 602, after unit is strapped, the relevant
information identifying the product
(e.g., pertaining to the unit of lumber) is received by the Wrapping PLC
System. Identifying
information can comprise selected ones of: a unit length, a unit width, a unit
height, a unit ID, a
product ID, others.
[0051] In a step 604, the unit is advanced toward the paper
dispensing station. While the
unit is traversing, the Wrapping PLC System utilizes the Unit Dimensional
Information to obtain
the appropriately sized wrapping material (e.g., paper, bubble wrap, woven
polypropylene or the
like) of the correct width. Once the leading two robots (11, 13) grab the end
of the paper, a motor
with encoder feedback dispenses the length of paper required to fully wrap the
incoming unit.
The trailing two robots (10, 12) then grab the trail end of the paper and it
is cut. In a presently
preferrable configuration, the lumber wrap feed mechanism is separate from the
robots being
controlled by the same PLC. The wrapping material is fed and cut from a
modified overhead
feeder. Existing lumber wrap feed and cutting mechanisms may be modified for
the space and
control requirements of the robots. Some implementations include modifications
made to
existing equipment that is already in place and being used in manual lumber
wrapping.
[0052] In a step 606, robots 11, 13 preposition themselves in the
wrapping location for the
incoming unit (location depends on unit length).
[0053] In a step 608, the Unit of product 9 comes in and stops at
the same location (+/- 3") as
determined by a Photo Array, optical array, or other non-tactile presence
sensor or pressure or
presence or other tactile sensor.
[0054] In a step 610, Near End Robots (12, 13) make a pass above
the unit of product 9 to
determine the exact location of the corner of the unit. This passes an offset
for all dimensional
movements of the robots to precisely know the location of all points.
[0055] In a step 612, the four robots then begin the wrapping
process substantially
contemporaneously in time. At folding points of the wrapping material, a
staple is fired through
a custom plastic tab and into the unit securing the wrapping material to the
unit.
[0056] In a step 614, upon completion of the wrapping process, the
unit advances out of the
area and the sequence is reset for the next unit_
[0057] In one implementation, an average cycle time, independent of
unit size, of
approximately 1 min and 15 seconds from time unit stops in wrapping position.
[0058] FIGS. 7A, 7B, 7C, and 7D illustrate composite, plan, front
and perspective views of
an example end effector 50 for group 3 robot 13 of FIG. 1. Now with reference
to FIG. 7C, end
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effector tool 50 includes an adapter plate couplable to an end plate of a
robot arm via tool
changes (not shown in FIG. 7C); a support structure 701, a fine wire stapler
704 (or other
fastener dispenser) having a tab feed mechanism for automatically feeding
staples or other
fasteners; a storage housing 702 coupled to the stapler 704 for dispensing
staples or other
fasteners; a stapler (or other fastener) low detection proximity switch (not
shown in FIG. 7C);
and one or more mechanical gripper(s) 730a, 730b, 730c, and 730d that can be
pneumatically
actuated facilitating grasping of wrapping material. An air cylinder 710
provides tipping out of
stapler 704 enabling the stapler 704 to be positioned in place to insert
staples, and removed as
needed. Implementations can be configured to include one or more of a vacuum
actuated gripper,
an adhesive gripper, a magnetic gripper, a servo (electric) gripper,
hydraulically actuated gripper,
a pneumatically actuated gripper and/or combinations thereof.
[00591 With further reference to FIG. 7C, a servo powered linear
actuator 740 is disposed
along support structure 701 and connected to and between gripper 730a and
730d. Action of
actuator 740 permits the distance between gripper 730a and 730d to be varied
under control of
the wrapping programmable logic controller (PLC). A distance detection device
742 detects
positions of one or more of gripper 730a and 730d; thereby enabling the servo
actuator 740 to
control the distance between gripper 730a and 730d. The function of the servo
actuator 740,
distance detection device 742 and support structure 701 form a linear rail
gripper enabling the
wrapping system to accommodate for different package layer heights.
[00601 In a presently preferrable implementation, motion and
actuation on the end effector
depicted in FIG. 7C is pneumatically actuated however, implementations based
upon other
prime mover(s) that that convert energy from an energy source into motive
power may be
realized. Fastener types implemented can include, e.g., staples, nails, brads,
glues, or other non-
threaded fasteners or screw drivers, or other threaded fasteners. Optionally,
multiple grippers can
be included to accommodate different heights of wood product units.
[00611 Noteworthy is that at least one gripper e.g., gripper 730a
is capable of rotating +/- 90
degrees about its longitudinal axis actuated by gripper rotation assembly 780
that is powered by
a pneumatic or other prime mover that that converts energy from an energy
source into motive
power; thereby facilitating grasping packaging materials in a variety of
positions.
[00621 FIGS. 8A, 8B, 8C, and 8D illustrate composite, plan, front
and perspective views of
an example end effector 51 for group 2 robot 12 of FIG. 1. End effector 51 is
depicted in FIG.
8C with like structures having like numerals to those of FIG. 7C.
Specifically, with reference to
FIG. 8C, end effector tool 51 includes an adapter plate couplable to an end
plate of a robot arm
via tool changes (not shown in FIG. 8C); a support structure 801, a fine wire
stapler 804 (or
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other fastener dispenser) having a tab feed mechanism for automatically
feeding staples or other
fasteners; a storage housing 802 coupled to the stapler 804 for dispensing
staples or other
fasteners; a stapler (or other fastener) low detection proximity switch (not
shown in FIG. 8C);
and one or more mechanical gripper(s) 830a, 830b, 830c, and 830d that can be
pneumatically
actuated facilitating grasping of wrapping material. An air cylinder 810
provides tipping out of
stapler 804 enabling the stapler 804 to be positioned in place to insert
staples, and removed as
needed. Implementations can be configured to include one or more of a vacuum
actuated gripper,
an adhesive gripper, a magnetic gripper, a servo (electric) gripper,
hydraulically actuated gripper,
a pneumatically actuated gripper and/or combinations thereof.
[00631 With further reference to FIG. 8C, a servo powered linear
actuator 840 is disposed
along support structure 801 and connected to and between gripper 830a and
830d. Action of
actuator 840 permits the distance between gripper 830a and 830d to be varied
under control of
the wrapping programmable logic controller (PLC). A distance detection device
842 detects
positions of one or more of gripper 830a and 830d; thereby enabling the servo
actuator 840 to
control the distance between gripper 830a and 830d. The function of the servo
actuator 840,
distance detection device 842 and support structure 801 form a linear rail
gripper enabling the
wrapping system to accommodate for different package layer heights.
[0064] In a presently preferrable implementation, motion and
actuation on the end effector
depicted in FIG. 8C is pneumatically actuated however, implementations based
upon other
prime mover(s) that that convert energy from an energy source into motive
power may be
realized. Fastener types implemented can include, e.g., staples, nails, brads,
glues, or other non-
threaded fasteners or screw drivers, or other threaded fasteners. Optionally,
multiple grippers can
be included to accommodate different heights of wood product units.
[00651 Noteworthy is that at least one gripper e.g., gripper 830a
is capable of rotating +/- 90
degrees about its longitudinal axis actuated by gripper rotation assembly 880
that is powered by
a pneumatic or other prime mover that that converts energy from an energy
source into motive
power; thereby facilitating grasping packaging materials in a variety of
positions.
Electronics Architecture
[00661 FIG. 9A is a simple functional block diagram of the robot
10. In FIG. 9A, the
electronics architecture 900A comprises the central control unit 902 that
controls the actuators
including sources of motive force and, therefore the linkages, joints, and
gripper/end effector,
etc. of the robot 10, using the command generator 914 and/or the pre-processor
944.
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[0067] The robot 10 includes main robot body 910, including the
kinematic chain, and the
actuation system 920. The robot 10 includes a central control unit 902 (i.e.,
controller) that in
this example comprises a command generator 914 and a pre-processor 944. The
controller is in
communication with the plurality of actuators and the sensors, and operates
the components on
the kinematic chain. The controller includes a feedback loop receiving
feedback data derived
from or including the actuator data and sensor data as feedback input, trained
to generate
actuator command data 912 to cause the robot to execute a task to manipulate
the object
responsive to the feedback data, under direct operator control and/or by
programmed logic.
Implementation specifics vary considerably, however in one example a
Controllogix PLC is
used to implement the robot controller. Training may be implemented using
programming by an
operator at operators console 905. In other embodiments, machine learning
algorithms and
techniques are used to generate, or augment existing, commands to the robot
10.
[0068] The actuation system 920 can include sources of motive
force, e.g., electric motors,
hydraulic cylinders, pneumatic cylinders and the like, coupling actuators,
e.g., linkages, springs,
levers, and so forth, and sensors affixed to one or the other, e.g., encoders,
position sensors,
combinations thereof, or the like. The actuation system 920 provides actuation
data 922 to the
central control unit 902, and receives actuator command data 912, including
actuator commands,
from the central control unit 902. Also, the robot 10 includes as described
above, optical / visual
sensors 930 generating image data 932 and range data, tactile sensors 940 in
this example
generating tactile sensor data 942, proximity sensors 950 in this example
generating object
proximity data 952 relative to the end effectors, and pressure sensors 960 in
this example
generating contact pressure data 962. The actuation data 922, the image data
932, the tactile
sensor data 942, the object proximity data 952, and the contact pressure data
962 are provided to
the central control unit 902.
[0069] The command generator 914 can plan motion of the robot
manipulator and use this
motion plan to generate a sequence of commands commanding the joints to for
the robot for the
purposes of advancing the robot to a goal state provided by the pre-processor
944 to the
command generator 914.
[0070] The pre-processor 944 can process the actuation data 922,
the image data 932, the
tactile sensor data 942, the object proximity data 952, and the contact
pressure data 962 to
produce a state vector for the robot 10. This state vector is produced in a
time frame and manner
as needed to control the state of the robot 10 and is accessible to task
programming provided to
the robot 10 via the operators console 905. The pre-processor 944 can include
one or more
trained neural networks used for the purpose of deriving feedback data for
input the neural
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network that generates the command data. Also, the command generator can
include one or more
trained neural networks. In some implementations, the command generator and
the pre-processor
comprise neural networks trained end-to-end using reinforcement learning.
Other training
procedures can be applied as well, including separate training of the neural
networks in the
controller.
[0071] Thus, the central control unit 902 processes input data
comprising at least the
actuation data 922 from the actuators of the actuation system 920, the image
data 932 from the
visual sensors 930 if present, and if present, other sensor data such as the
tactile sensor data 942
from the tactile sensors 940 in the right hand end effector 51 and the left
hand end effector 50,
and generates actuator command data 912.
[0072] In some implementations, with reference to FIG. 9B, the
electronics architecture
900B further comprises distributed local controllers that are responsible for
low-level motor
control, including current, velocity, and position control, evaluation of the
joint sensors, output
control signals to the actuator power electronics, parameterization of the
actuator controllers,
e.g., for gain scheduling, and data acquisition from the force/torque sensors
and inertial measure
measurement system. Each local controller can handle a set of actuators (e.g.,
one, two, or three
actuators). Cable harnesses connect the actuator sensors, actuators, drives to
the local controllers.
The central control unit 902 and the local controllers can communicate by a
high speed
communication interface such as CAN, FireWire, or SERCOS, supporting real-time
control in
which each new set of actuator commands is based on feedback data that
indicates the effects of
the immediately preceding command set on the pose of the robot and the object
of the task.
Controller
[0073] The central control unit 902 includes the command generator
914 and the pre-
processor 944, in this example, implementing a control loop that includes
processing the input
data for an instant time interval, and generating the actuator command data
912 for use in a next
time interval.
[0074] The central control unit 902 is also configured with a
system file including a program
file (e.g., program file 906) that specifies the task(s) to be executed by the
robot 10. The program
file can identify the task in a sequence of sub-tasks, along with goal
positions, goal angles,
maximum and minimum values for sampling the goal positions and the goal
angles, policy paths
and trajectories, policy speedup coefficients, and feedback actions. Each
"task" can be
implemented to be triggered based upon a set of detected input conditions,
duty cycle, operator
command issued at the operators console 905 or otherwise. In one
implementation, a set of
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weights generated by training a neural network system, including a trained
neural network in a
feedback loop receiving feedback data derived from or including the actuator
data and the sensor
data as feedback input, trained to generate actuator command data to cause the
robot to execute
the task to manipulate the object, or the robot in preparation for
manipulation of an object, in
response to the feedback data. The neural network system that can be trained
using
reinforcement learning algorithms and configured with a policy that implements
the control
feedback loop. The neural network system can use neural networks like a multi-
layer perceptron
(MLP), a feed-forward neural network (FENN), a fully connected neural network
(FCNN), a
convolutional neural network (CNN), and a recurrent neural network (RNN).
Example of the
reinforcement learning algorithms include deterministic policy gradient
algorithms, and policy-
gradient actor-critic algorithms like deep deterministic policy gradient
(DDPG) with hindsight
experience replay (HER) and distributed distributional deterministic policy
gradient (D4PG).
[0075] The input data 1002 can includes the range image data 932
from the visual sensors
930 indicating the orientation and position of the work piece 9 and the end
effectors 50, 51 in
three dimensions and time, and the actuation data 922 from the actuators of
the actuation system
920. The input data 1002 can further include the tactile sensor data 942 from
the tactile sensors
940 in right hand end effector 51 and the left hand end effector 50. The input
data 1002 can
further include the object proximity data 952 from the proximity sensors 950.
The input data
1002 can further include the contact pressure data 962 from the pressure
sensors 960. The input
data 1002 can further include external motion tracking data from an external,
stand-alone motion
tracking system like OptiTrackTm type motion capture system that tracks motion
of the robot 10
and the object in a three-dimensional space. The input data 1002 can be used
as feedback data in
the feedback loop, and can be used to derive feedback data, and both.
[0076] The actuator command data 912 updates one or more of the
actuator parameters of
the actuators. Examples of the actuator command data 912 include position
updates, absolute
positions, angle updates, absolute angles, torque updates, absolute torques,
speed updates,
absolute speeds, velocity updates, absolute velocities, acceleration updates,
absolute
accelerations, rotation updates, and absolute rotations. The actuator command
data 912 is used to
update the respective states of the actuators in the next time interval, which
in turn causes the
tendons, the joints, the body parts, and the robot 10 to transition to a
different state (e.g, tension,
position, orientation) in the next time interval.
[0077] The actuator command data 912 can include commands for each
of the actuators or
only a subset of the actuators. Each command can include an actuator ID, and a
numerical value
or values used to drive the actuator to a next state.
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[0078] In the implementation listed above, the actuator command
data 912 provided as
output of the controller comprising a vector of drive changes for differential
positioning, or a
vector of position mode target positions, or a vector of force/torque values,
and various
combinations of differential mode commands, position mode command as suitable
for the
actuators under control.
[0079] The actuators execute the commands specified in the actuator
command data 912 and
generate the actuation data 922 for the next time interval, and cause
generation of the image data
932 by the visual sensors 930 and the tactile sensor data 942 by the tactile
sensors 940 for the
next time interval. The process is iterated by the control loop implemented by
the controller 930.
[0080] In some implementations, the actuator command data 912
generated by the controller
902 is processed by a calibration module (not shown) that generates a
calibrated version of the
actuator command data 912 which is specific to the configuration of the robot
10. The calibrated
version of the actuator command data is used to update the respective states
of the actuators.
[0081] Additional features included in various implementations of
the robotic packaging
workstation 14 include the use of sensors such as (i) encoders (4) for paper
feed measurement;
(ii) current transducers allowing the system to automatically detect a stall
or jamb condition of a
robot manipulator and signal for assistance; and (ii) area sensors for
detection of entry into a
danger zone. Additionally, implementations can include the end effector
including hardware and
control logic in the PLC to implement automatic label placement on the
packaged unit. Some
implementations can include unit centering to reduce the variation of travel
of the robot
manipulators to accommodate different unit positionings. Some implementations
include lathe
breaking. Some implementations will include provisions for automatically
reloading the staple
or other fasteners.
[0082] As mentioned above, multiple robot manipulators (or robotic
workstations) can be
combined, such that the robot manipulators are spaced apart by, for example 8
feet. For sake of
clarity, a single robot workstation can include multiple robot manipulators
(e.g., 4 or more), as
mentioned above, multiple robotic workstations can be implemented, where each
robot
workstation includes a more or fewer robot manipulators. The number of robot
manipulators is
dictated by the maximum dimensions of the product unit. The robot manipulators
can be
coordinated to perform wrapping and stapling in coordinated moves at the same
time An
example system can handle efficiently wrapping/packaging product stacked into
units having
dimensions of approximately 40- to 54- in width, 12- to 36- height, and 6' to
20' in length.
Product unit sizes can be detected using sensors, or optimally received from
saw mill floor
controllers via wired or wireless network and used to determine where each
robot manipulator
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would need to be positions and the size and quantity of wrapping material to
be fee and cut. This
information is calculated and then passed from a programmable logic controller
(PLC) to each of
the robot manipulators for initial positioning and subsequent packaging.
Some Particular Implementations
[0083] We describe various implementations of robotic packaging
workstation.
[0084] The technology disclosed can be practiced as a system,
method, or article of
manufacture. One or more features of an implementation can be combined with
the base
implementation. Implementations that are not mutually exclusive are taught to
be combinable.
One or more features of an implementation can be combined with other
implementations. This
disclosure periodically reminds the user of these options. Omission from some
implementations
of recitations that repeat these options should not be taken as limiting the
combinations taught in
the preceding sections ¨ these recitations are hereby incorporated forward by
reference into each
of the following implementations.
[0085] A system implementation of the technology disclosed includes
a robotic workstation
for packaging wood products. The robotic packaging workstation can achieve can
handle
efficiently wrapping/packaging product stacked into units having dimensions of
approximately
40" to 54" in width, 12" to 36" height, and 6' to 20' in length. In one
configuration, the robotic
packaging workstation includes a robot manipulator capable of moving an end
effector adapter
plate to points in a three-dimensional work volume under programed control of
a programmable
robot controller executing stored instructions. A fastener and wrapping tool
head is affixed to the
end effector adapter plate. The fastener and wrapping tool head further
includes a support
structure, a fastener applicator, a fastener storage, and one or more grippers
for grasping
wrapping material.
[0086] This system implementation and other systems disclosed
optionally include one or
more of the following features. System can also include features described in
connection with
methods disclosed. In the interest of conciseness, alternative combinations of
system features are
not individually enumerated. Features applicable to systems, methods, and
articles of
manufacture are not repeated for each statutory class set of base features.
The reader will
understand how features identified in this section can readily be combined
with base features in
other statutory classes.
[0087] One robotic packaging workstation implementation further
includes a materials
handling system moving work units into the work volume and packaged work units
out of the
work volume.
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[0088] One robotic packaging workstation implementation further
includes wrapping
material feed for feeding wrapping material to the robot manipulators.
[0089] One robotic packaging workstation implementation further
includes a plurality of
encoders for measuring a quantity of wrapping material being fed.
[0090] One robotic packaging workstation implementation further
includes at least one tool
station to receive fastener and wrapping tool heads for attaching by the robot
manipulators at the
end effector adapter plate.
[0091] In one robotic packaging workstation implementation, the
fastener and wrapping tool
head further includes a sensor indicating an amount of fastener loaded into
the fastener storage.
[0092] In one robotic packaging workstation implementation, the
fastener storage is capable
of holding 380 staples.
[0093] In one robotic packaging workstation implementation, the
fastener storage is capable
of holding 500 staples.
[0094] One robotic packaging workstation implementation further
includes plurality of rails
disposed approximately parallel to a path of work units flowing through the
workstation and
upon which each of the first plurality of robot manipulators is attached;
thereby enabling the first
plurality of manipulators to traverse a path approximately parallel to the
path of work units
flowing through the workstation.
[0095] An apparatus implementation of the technology disclosed
includes fastener and
grasping tool for a robotic packaging workstation, that can include an adapter
plate couplable to
an end plate of a robot arm; a fastener applicator having an automatic feeder;
a storage housing
coupled to the fastener applicator for dispensing fasteners; a fastenerlow
detection proximity
switch; and at least one mechanical gripper facilitating grasping of wrapping
material.
[0096] An apparatus implementation of the technology disclosed
includes fastener and
grasping tool for a robotic packaging workstation, that can include an adapter
plate couplable to
an end plate of a robot arm; a stapler having a tab feed mechanism for
automatically feeding
staples; a storage housing coupled to the stapler for dispensing staples; a
stapler low detection
proximity switch; and at least one mechanical gripper facilitating grasping of
wrapping material.
[0097] One fastener and grasping tool for a robotic packaging
workstation implementation
further includes a mechanism for attaching and detaching the adapter plate
from the end plate of
the robot arm under control of a programmable logic controller.
[0098] One fastener and grasping tool for a robotic packaging
workstation implementation
further includes multiple grippers that accommodate different heights of
product units.
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[0099] A method implementation of the technology disclosed includes
a method of
packaging wood product units. The method can include receiving by a
Programmable Logic
Controller, information identifying a wood product unit to be received, the
identifying
information comprising selected ones of: a unit length, a unit width, a unit
height, a unit ID, a
product ID. The method further includes obtaining a portion of wrapping
material appropriately
sized using the identifying information, to include at least first plurality
of robot manipulators
grasping an end of the wrapping material, a motor with encoder feedback
dispensing a length of
wrapping material required to fully wrap the wood product unit, and at least
second plurality of
robot manipulators grasping a trail end of the wrapping material prior to
cutting the wrapping
material. At least the first plurality of robot manipulators can perform
prepositioning themselves
according to size of the wood product unit incoming using the identifying
information. The wood
product unit is received at a location determined by a presence sensor. The
method further
includes determining by at least one robot manipulator a measured position of
at least one corner
of the wood product unit. The method also includes wrapping by the robot
manipulators the
wood product unit and applying fasteners to hold wrapping material in place.
Upon completion
of the wrapping, advancing the wood product unit as packaged from an outfeed
side of a work
envelope using a materials handling system can also be part of the method.
[00100] Each of the features discussed in this particular implementation
section for the first
system implementation apply equally to this method implementation. As
indicated above, all the
system features are not repeated here and should be considered repeated by
reference.
[00101] Other implementations may include a non-transitory computer readable
storage
medium storing instructions executable by a processor to perform a method as
described above.
Yet another implementation may include a system including memory and one or
more processors
operable to execute instructions, stored in the memory, to perform a method as
described above.
[00102] In one implementation of our method, wrapping takes approximately 1
min and 15
seconds from time the wood product unit stops in wrapping position.
[00103] In one implementation of our method, height of the wood product unit
is within a
range of 12" to 3 6" .
[001041 In one implementation of our method, width of the wood product unit is
within a
range of 40" to 54"
[00105] In one implementation of our method, length of the wood product unit
is within a
range of 6' to 20'.
[00106] In one implementation of our method, the first manipulators are
positioned within the
robotic packaging workstation based upon a unit length of the wood product
unit.
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[00107] In one implementation of our method, the method further includes
cutting the
wrapping material.
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