How is the intelligent stacking technology of the palletizer realized?

The palletizer's intelligent stacking technology utilizes core technologies such as 3D dynamic algorithms, adaptive gripping, edge alignment, multi-arm collaboration, and AI self-learning, combined with high-precision sensors and intelligent control systems. This technology comprehensively improves space utilization, stacking stability, and flexibility. The following are specific implementation methods:

1. 3D Dynamic Algorithm: The Core Engine for Space Optimization

Automatically Calculate the Optimal Stacking Plan

Based on parameters such as item size, weight, and packaging material (such as cartons, bags, or barrels), the algorithm automatically determines the number of stacking layers and their arrangement. For example, using this technology, the Shuangcheng intelligent palletizer has increased the standard pallet capacity from 120 to 156 cartons, improving space utilization by 30%.

Mixed Pallet Design

For scenarios where multiple product categories coexist (such as e-commerce warehouses), the system identifies items of varying sizes and automatically creates a mixed pallet configuration with "large items supported on the bottom and small items in the back." Tests at one e-commerce warehouse showed a 28% increase in SKU capacity.

Adaptation for Special Scenarios

Protecting Fragile Items: A design with densely packed lower layers and gradually shrinking upper layers prevents damage caused by pressure from the top. After implementation at a 3C company, the breakage rate decreased by 40%.

Cold chain warehousing: Pre-set airflow channels within the pallet not only meet the ventilation needs of fresh produce, but also save 17% space compared to traditional methods with gaps.

II. Adaptive Gripping Technology: Addressing Diverse Product Forms

Adaptive Gripper System

Automatically adjusts gripping force and angle for different product forms, such as boxes, bags, and barrels, to avoid gaps caused by deformation. For example, Shuangcheng's intelligent palletizer supports both gripping methods, such as grippers and adaptive suction cups, to accommodate a wide range of material forms.

Vision Guidance and Force Feedback Control

Vision Positioning: Using industrial cameras and deep learning algorithms, visual positioning identifies the position and posture of goods, achieving a repeatable positioning accuracy of ±1mm. A modular palletizing line introduced by a dairy company allows for flexible switching between different packaging formats, such as Tetra Pak, glass bottles, and plastic barrels, through quick gripper changes, reducing changeover time to 15 minutes.

Force Feedback Control: The gripper is equipped with a pressure sensor to sense gripping force in real time, preventing deformation of thin-walled tubes or fragile items. A certain device can stably grasp steel plates 0.5-20mm thick and is compatible with 90% of steel pipe types.

III. Edge Alignment Technology: Reducing Misalignment Losses

High-Precision Sensor Real-Time Correction

Laser or vision sensors monitor the position of goods and automatically correct stacking deviations. This significantly reduces the 5%-10% misalignment losses common in traditional palletizing, ensuring that the edges of each layer are aligned and improving overall stability.

Cross-Stacking Enhances Stability

For regular boxed goods (such as beverages and daily necessities), a cross-stack method with each layer rotated 90° is used. Experimental data shows that this method can accommodate 15%-20% more goods than in-line stacking.

IV. Multi-Arm Collaboration and AI Autonomous Learning: A Breakthrough in Flexible Production

Collaborative Palletizer

Division of Labor and Collaboration: Multiple robotic arms work together, with some responsible for grasping goods and others for path planning. For example, a collaborative palletizer uses a PLC control system and AI algorithms to dynamically plan the motion trajectory of each robotic arm, achieving efficient collaboration. Safe Collaboration: Equipped with a safety protection system, it can sense the surrounding environment and the presence of people in real time, automatically adjusting operating speed or pausing operations, enabling safe collaboration with workers in the same workspace.

AI Palletizing Algorithm Self-Learning

When the packaging dimensions of a new product change, the equipment can autonomously learn the palletizing design using an AI algorithm, reducing the traditional two-day programming and debugging process to two hours. A home appliance company has successfully met the needs of small-batch customized production by adopting this technology.

V. Intelligent Control System: Data-Driven Decision-Making Hub

PLC and Industrial Computer Integration

After receiving sensor data, the control system coordinates the movements of actuators such as the robotic arm and conveyor belt through logical operations and motion control commands. For example, Shuangcheng's intelligent palletizer supports multiple programming instructions and customized processes, can simultaneously manage two types of box palletizing (A and B), and can store up to 60 palletizing recipes.

Digital Twin and Predictive Maintenance

Virtual Commissioning: Using digital twin technology, equipment operation is simulated to shorten on-site commissioning cycles. One company's case study shows that its digital twin system reduced commissioning time from five days to two. Fault Warning: Vibration sensors and temperature monitoring modules collect real-time equipment status data, providing 3-7 days' advance warning of faults such as lead screw wear, reducing unplanned downtime losses.
VI. Industry Application Cases Verifying the Technology's Value
Steel Industry: After a large steel mill introduced a fully automated palletizing line, its daily production capacity increased from 200 tons to 350 tons, while reducing labor costs by 65%.
Food Industry: After adopting Shuangcheng's intelligent palletizer, a food company saved over 500,000 yuan in annual warehousing costs and reduced its breakage rate by 40%.
E-commerce Warehousing: Through intelligent palletizing design, an e-commerce warehouse increased its SKU capacity by 28% and improved its inbound and outbound efficiency by 35%.