Apparatus and method for building a pallet load

A method for user-automatic cooperative building of a pallet load of pallet load article units onto a pallet support, the method comprising:

• defining, with a frame, a pallet building base for the pallet support;
• transporting and placing, with at least one robot connected to the frame, the pallet load article units serially onto the pallet support so as to build the pallet load on the pallet building base;
• controlling, with a controller operably connected to the at least one robot, robot motion, relative to the pallet building base, and effecting therewith the building of the pallet load, and signaling, with a user interface coupled to the controller, a user for cooperation with the at least one robot effecting building of the pallet load;
• generating, with at least one three-dimensional, time of flight camera, three-dimensional imaging of the pallet load build on the pallet support on the pallet building base, wherein the at least one three-dimensional camera is communicably coupled to the controller;
• registering with the controller, from the at least one three-dimensional camera, real time three-dimensional imaging data embodying different corresponding three-dimensional images of each different one of the pallet load article units, of the pallet load build, and
• determining with the controller, in real time, from the corresponding real time three-dimensional imaging data, a build pallet load variance with respect to a predetermined reference, the build pallet load variance being determinative of at least one of an extraneous presence, of an extraneous object in the pallet load build, and of a mispresence of at least one article unit from the pallet load build;
• and
• generating, with the controller, in real time a robot motion signal and a user cooperation signal, both dependent on at least one of the real time determined build pallet load variance, the robot motion signal being generated in real time so as to be performed in real time by the robot building the pallet load build substantially coincident with the imaging of the pallet load build by the robot, wherein the pallet load build is built by substantially continuous placement of serially consecutive pallet load article units, wherein the consecutive pallet load article units are placed immediately prior or immediately after the imaging of the pallet load build showing the determined build pallet load variance, wherein
• the user cooperation signal defines to the user a deviant condition of the pallet load build and a cooperative action of the user so as to resolve the deviant condition depending on the determined at least one extraneous presence and mispresence.

A pallet load builder for automatically building pallet load article units onto a pallet support, the pallet load builder comprising:

• a frame defining a pallet building base for the pallet support;
• at least one articulated robot connected to the frame and configured for transporting and placing the pallet load article units serially onto the pallet support so as to build the pallet load on the pallet building base;
• a controller configured to effect the serially loading of the pallet load article units onto the pallet support so as to build the pallet load, wherein the controller effects generation, with at least one three-dimensional, time of flight camera, of three-dimensional imaging of the pallet load build on the pallet support on the pallet building base and registration of real time three-dimensional imaging data embodying different corresponding three-dimensional images of each different one of the pallet load article units, of the pallet load build, so as to determine, in real time, from the corresponding real time three-dimensional imaging data, a build pallet load variance with respect to a predetermined reference, the build pallet load variance including identifying at least one of a presence of an extraneous object in the pallet load build and of a mispresence of at least one pallet load article unit from the pallet load build, and
• wherein the controller generates, in real time, an articulated robot motion signal dependent on at least one of the real time determined build pallet load variance, the articulated robot motion signal being generated in real time so as to be performed in real time by the articulated robot building the pallet load build substantially coincident with the imaging of the pallet load build by the articulated robot, wherein the pallet load build is substantially continuously built by substantially continuous placement of serially consecutive pallet load article units, wherein the consecutive pallet load article units are placed at least one of immediately prior and immediately after the imaging of the pallet load build showing the determined build pallet load variance.

A pallet load builder for user-automatic cooperative building of pallet load article units onto a pallet support, the pallet load builder comprising:

• a frame defining a pallet building base for the pallet support;
• at least one robot connected to the frame and configured to transport and place the pallet load article units serially onto the pallet support so as to build the pallet load on the pallet building base;
• and
• a controller configured to control the at least one robot and robot motion and effect therewith the serially loading of the pallet load, and signal, with a user interface coupled to the controller, a user for cooperation with the at least one robot effecting building of the pallet load,
• wherein the controller is further configured to generate, with at least one three-dimensional, time of flight camera, three-dimensional imaging of the pallet load build on the pallet support on the pallet building base, wherein the at least one three-dimensional camera is communicably coupled to the controller, register, from the at least one three-dimensional camera, real time three-dimensional imaging data embodying different corresponding three-dimensional images of each different one of the pallet load article units, of the pallet load build, and determine, in real time, from the corresponding real time three-dimensional imaging data, a build pallet load variance with respect to a predetermined reference, the build pallet load variance being determinative of at least one of an extraneous presence, of an extraneous object in the pallet load build, and of a mispresence of at least one article unit from the pallet load build, and
• wherein the controller generates, in real time a robot motion signal and a user cooperation signal, both dependent on at least one of the real time determined build pallet load variance, the robot motion signal being generated in real time so as to be performed in real time by the robot building the pallet load build substantially coincident with the imaging of the pallet load build by the robot, wherein the pallet load build is built by substantially continuous placement of serially consecutive pallet load article units, wherein the consecutive pallet load article units are placed immediately prior or immediately after the imaging of the pallet load build showing the determined build pallet load variance, wherein
• the user cooperation signal defines to the user a deviant condition of the pallet load build and a cooperative action of the user so as to resolve the deviant condition depending on the determined at least one extraneous presence and mispresence.