Automated palletizing cases having mixed sizes and shapes

A method for stacking cases on a pallet, the method comprising the steps of:

• supplying cases to a buffer in a random order without reordering the cases prior to placement on a pallet;
• defining rules for selecting cases from the buffer to be placed on the pallet;
• determining physical characteristics of the buffer cases including dimensions of a case base and case height;
• determining available locations on the pallet where each buffer case can be placed;
• applying the rules sequentially in a variable prioritized order to at least a portion of the
• buffer cases and the available locations until at least one buffer case is identified;
• identifying a selected buffer case that satisfies any one of the rules and a corresponding location on the pallet for the selected buffer case, wherein each rule application includes the steps of implementing a stability criterion for each random case and a three-dimensional region defining the currently available places providing optimal use of space on the pallet and ensuring stability of the stacked cases;
• and
• using an industrial robot, placing the selected buffer case on the pallet in the corresponding location before applying the rules sequentially to identify another one of the buffer cases.

A method for stacking cases on a pallet, the pallet including at least one case stacked thereon, the method comprising the steps of:

• supplying cases to a buffer in a random order without reordering the cases prior to placement on a pallet;
• determining physical characteristics of cases in the buffer including dimensions of a case height;
• determining physical characteristics of the at least one case in the pallet including dimensions of a case height;
• comparing the physical characteristics of at least one of the cases in the buffer to the at least one case on the pallet;
• identifying one of said pallet cases having a case height equal to a case height of a selected buffer case and a corresponding position adjacent the one pallet case for the selected case, wherein the identifying step includes the steps of implementing a stability criterion for each random case and a three-dimensional region defining the currently available places providing optimal use of space on the pallet and ensuring stability of the stacked cases;
• and
• using an industrial robot, placing the selected buffer case on the pallet at the corresponding position before identifying another one of the buffer cases.

An automated method for stacking random cases on a pallet comprising the steps of:

• randomly providing cases along a conveyor system;
• conveying the random cases to a buffer;
• determining dimensions characteristics of each random case in the buffer;
• executing a priority sequence at the highest priority rule, wherein the priority sequence includes the steps of implementing a stability criterion for each random case and a three-dimensional region defining the currently available places providing optimal use of space on the pallet and ensuring stability of the stacked cases;
• evaluating the highest priority rule based on each random case in the buffer and the regions available for placing cases on the pallet;
• determining a position on the pallet for at least one case in the buffer;
• with an industrial robot, placing a selected case on the pallet in a selected position within an available region;
• exiting the highest priority rule;
• refilling the buffer with cases;
• repeating the execution and evaluation of the highest priority rule, including implementing a stability criterion for each random case and defining a region, based on each case in the refilled buffer and the updated regions available for placing cases on the pallet;
• applying a second sequential priority rule when a position is not available for at least one case in the buffer after evaluating the highest priority rule, and including the steps of:
• evaluating a subsequent sequential priority rule based on each case in the buffer and the regions available for placing cases on the pallet wherein the priority sequence includes the steps of implementing a stability criterion for each random case and a three-dimensional region defining the currently available places providing optimal use of space on the pallet and ensuring stability of the stacked cases;
• determining a position on the pallet for at least one case in the buffer;
• with an industrial robot, placing a selected case on the pallet in a selected position within an available region;
• and
• exiting the subsequent sequential priority rule.