Apparatus and method for automatic pallet builder calibration

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

• a frame defining a pallet station with a pallet building base for the pallet support;
• an articulated robot connected to the frame and having a drive section with multiple independent drive axis arranged in a robot reference frame, the articulated robot being configured so as to transport and place the pallet load article units onto the pallet support so as to build the pallet load on the pallet building base, the articulated robot having an end effector configured to hold the pallet load article unit in transport;
• a controller:
• operably connected to the at least one articulated robot, the controller being configured to control articulated robot motion, relative to the pallet building base, and effect therewith a pallet load build of the pallet load, and
• disposed to generate three-dimensional imaging of the pallet support on the pallet building base and of the pallet load build on the pallet support;
• and
• an automatic calibration system, for calibrating the articulated robot, including at least one three-dimensional camera, the at least one three-dimensional camera is connected to the frame and is configured to three-dimensionally image at least one of part of the articulated robot, and the pallet support or pallet load build on the pallet building base;
• wherein the controller is communicably connected to the automatic calibration system so as to automatically calibrate, with the three-dimensional image, the articulated robot from a substantially uncalibrated state, and automatically teach the articulated robot a datum of the pallet station and characterizing a placement location for each of the pallet load article units placed with the end effector that builds the pallet load on the pallet support.

A method for automatically building, with a pallet building apparatus, a pallet load of pallet load article units onto a pallet support, the method comprising:

• providing a pallet building apparatus comprising:
• a frame defining a pallet station with a pallet building base for the pallet support,
• an articulated robot connected to the frame and having a drive section with multiple independent drive axis arranged in a robot reference frame, and an end effector configured to hold the pallet load article unit in transport,
• at least one three-dimensional camera, connected to the frame separate and distinct of the articulated robot,
• a controller operably connected to the at least one articulated robot and the at least one three-dimensional camera, the controller being configured to control articulated robot motion, relative to the pallet building base, and effect therewith the pallet load build of the pallet load, and
• an automatic calibration system for calibrating the articulated robot, where the controller is communicably connected to the automatic calibration system;
• transporting and placing, with the articulated robot, the pallet load article units onto the pallet support so as to build the pallet load on the pallet building base;
• generating, with the at least one three-dimensional camera, three-dimensional imaging of the pallet support on the pallet building base and of a pallet load build on the pallet support;
• automatically calibrating, with the controller, the articulated robot, from a substantially uncalibrated state;
• automatically teaching, with the controller, the articulated robot a location of the pallet station resolving a position of the end effector to the pallet station to build the pallet load with placement of the pallet load article units on the pallet support;
• and
• calibrating, with the controller, the at least one three-dimensional camera relative to the end effector.

A method for automatically building, with a pallet building apparatus, a pallet load of pallet load article units onto a pallet support, the method comprising:

• providing a pallet building apparatus comprising:
• a frame defining a pallet station with a pallet building base for the pallet support,
• an articulated robot connected to the frame and having a drive section with multiple independent drive axis arranged in a robot reference frame, and an end effector configured to hold the pallet load article unit in transport,
• a controller operably connected to the at least one articulated robot, and
• an automatic calibration system for calibrating the articulated robot and including at least one three-dimensional camera, the at least one three-dimensional camera is connected to the frame and is configured to three-dimensionally image at least one of part of the articulated robot, and the pallet support or pallet load build on the pallet building base;
• transporting and placing, with the articulated robot, the pallet load article units onto the pallet support so as to build the pallet load on the pallet building base;
• controlling, with the controller, articulated robot motion, relative to the pallet building base, and effecting therewith a pallet load build of the pallet load;
• and
• generating, with the controller, three-dimensional imaging of the pallet support on the pallet building base and of the pallet load build on the pallet support;
• wherein the controller is communicably connected to the automatic calibration system and automatically calibrates, with the three-dimensional image, the articulated robot from a substantially uncalibrated state, and automatically teaches the articulated robot a datum of the pallet station, characterizing a placement location for each of the pallet load article units placed with the end effector that builds the pallet load on the pallet support.