Robotic palletizing system and method

1. A robotic palletizing method comprising:

selectively operating a palletizing robot between at least a pregrouping state, in which the palletizing robot groups to-be-grouped items at a pregrouping station, and a principal grouping state, in which the palletizing robot groups to-be-grouped items at a principal grouping station; and selectively operating a load securing machine between a securing state, in which the load securing machine at least partially secures to-be-grouped items grouped at the principal grouping station, and a non-operational state, the method further comprising operating the palletizing robot in the pregrouping state during at least a portion of a time interval during which the load securing machine is operating in the securing state to secure the to-be-grouped items grouped at the principal grouping station.

2. The method of claim 1 , further comprising operating the palletizing robot in the principal grouping state when the load securing machine is in the non-operational state.

3. The method of claim 1 , wherein the pregrouping station corresponds to a first location at which the palletizing robot is operable to group to-be-grouped items while operating in the pregrouping state; and

wherein the principal grouping station corresponds to a second location at which the palletizing robot is operable to group to-be-grouped items while operating in the principal grouping state, with the first location being horizontally spaced-apart from the second location, wherein the pregrouping station and the principal grouping station are simultaneously within reach of the palletizing robot.

4. The method of claim 1 , wherein items are grouped at the pregrouping station as a pregrouped set from the palletizing robot operating in the pregrouping state; and

wherein the method further comprises:

if the to-be-grouped items grouped at the principal grouping station are in a full capacity condition and secured, removing the to-be-grouped items from the principal grouping station and transferring the pregrouped set from the pregrouping station to the principal grouping station; and then

operating the palletizing robot in the principal grouping state to group a principal set of to-be-grouped items at the principal grouping station following the transfer to the principal grouping station.

5. The method of claim 4 , further comprising securing the pregrouped set transferred to the principal grouping station before operating the palletizing robot in the principal grouping state to group to-be-grouped items over the pregrouped set.

6. The method of claim 1 , further comprising:

if a full capacity condition at the principal grouping station is not reached, operating the palletizing robot in the principal grouping state;

if the full capacity condition at the principal grouping station is reached, operating the load securing machine in the securing state until the to-be-grouped items grouped at the principal grouping station have been secured; and

while the load securing machine operates in the securing state, operating the palletizing robot in the pregrouping state.

7. The method of claim 6 , wherein items are grouped at the pregrouping station as a pregrouped set from the palletizing robot operating in the pregrouping state; the method further comprising: upon completing the securing of the items grouped at the principal grouping station:

transferring the secured grouped items from the principal grouping station to an area downstream of the principal grouping station;

transferring the pregrouped set of items from the pregrouping station to the principal grouping station; and

operating the palletizing robot in the principal grouping state to group a principal set of items at the principal grouping station following the transfer of the pregrouped set of items from the pregrouping station to the principal grouping station.

8. The method of claim 1 , further comprising:

if at least one of a full capacity condition and an unstable condition at the principal grouping station is not reached, operating the palletizing robot in the principal grouping state;

if at least one of the full capacity condition and the unstable condition at the principal grouping station is reached, operating the load securing machine in the securing state until the to-be-grouped items grouped at the principal grouping station have been secured; and

while the load securing machine operates in the securing state and if an unstable condition at the pregrouping station is not reached, operating the palletizing robot in the pregrouping state whereby to-be-grouped items are grouped at the pregrouping station as a pregrouped set of items; otherwise, configuring the palletizing robot in an idle state.

9. The method of claim 8 , further comprising: if the unstable condition at the principal grouping station is reached and following operating the load securing machine in the load securing state; operating the palletizing robot in the principal grouping state to group additional items at the principal grouping station.

10. The method of claim 8 , further comprising: if the full capacity condition at the principal grouping station is reached, the load securing machine operates in the load securing state and the palletizing robot operates in the pregrouping state, whereby additional to-be-grouped items are grouped at the pregrouping station as part of the pregrouped set of items; and

wherein upon completing the securing of the items grouped at the principal grouping station following reaching the full capacity condition:

transferring the secured grouped items from the principal grouping station to an area downstream of the principal grouping station;

transferring the pregrouped set of items from the pregrouping station to the principal grouping station; and

operating the palletizing robot in the principal grouping state to group a principal set of items at the principal grouping station following the transfer of the pregrouped set of items from the pregrouping station to the principal grouping station.

11. The method of claim 10 , further comprising: if the unstable condition at the pregrouping station is reached and following transfer of the pregrouped set from the pregrouping station to the principal grouping station, operating the load securing machine in the securing state prior to further operating the palletizing robot in the principal grouping state, and simultaneously, operating the palletizing robot in the pregrouping state to group to-be-grouped at the pregrouping station while the load securing machine operates in the securing state.

12. The robotic palletizing method of claim 1 , further comprising:

receiving a pallet at the principal grouping station;

receiving another pallet at the pregrouping station; and

wherein, in the pregrouping state, the palletizing robot groups to-be-grouped items onto the pallet received at the pregrouping station;

wherein, in the principal grouping state, the palletizing robot groups to-be-grouped items onto the pallet received at the principal grouping station; and

transferring the pallet received at the pregrouping station, after having a pregrouped set of to-be-grouped items grouped thereon, from the pregrouping station to the principal grouping station; and then

operating the palletizing robot in the principal grouping state to group a principal set of to-be-grouped items onto the pallet following the transfer to the principal grouping station.

13. The method of claim 12 , further comprising operating the load securing machine in the securing state after transfer of the pallet having the pregrouped set of to-be-grouped items grouped thereon to the principal grouping station prior to further operating the palletizing robot in the principal grouping state; and

simultaneously, operating the palletizing robot in the pregrouping state to grouped to-be-grouped items onto another pallet received at the pregrouping station while the load securing machine operates in the securing state.

14. The method of claim 13 , further comprising operating the load securing machine in the securing state after completing grouping of the principal set of to-be-grouped items; and simultaneously operating the palletizing robot in the pregrouping state to group to-be-grouped items onto another pallet received at the pregrouping station while the load securing machine operates in the securing state.

15. A robotic palletizer system comprising:

a pregrouping station;

a principal grouping station;

a palletizing robot selectively operable in a pregrouping state, in which the palletizing robot groups to-be-grouped items at the pregrouping station as a pregrouped set of to-be-grouped items, and a principal grouping state, in which the palletizing robot groups to-be-grouped items at the principal grouping station;

a pregrouped set transfer assembly configured to transfer the pregrouped set of to-be-grouped items from the pregrouping station to the principal grouping station;

a load securing machine selectively operable in a securing state, in which the load securing machine at least partially secures the to-be-grouped items grouped together at the principal grouping station, and a non-operational state; and

a controller operatively connected to the palletizing robot, to the pregrouped set transfer assembly, and the load securing machine and being configured to transmit control signals to the palletizing robot, the pregrouped set transfer assembly, and the load securing machine to cause the palletizing robot to be selectively operated between the pregrouping state and the principal grouping state and to cause the load securing machine to be selectively operated between the securing state and the non-operational state.

16. The robotic palletizer system of claim 15 , wherein the palletizing robot is configured to operate in the principal grouping state when the load securing machine is operating in the non-operational state; and

wherein the palletizing robot is configured to operate in the pregrouping state during at least a portion of a time interval during which the load securing machine is operating in the securing state to secure the to-be-grouped items grouped at the principal grouping station.

17. The robotic palletizer system of claim 15 , wherein the pregrouping station corresponds to a first location at which the palletizing robot is operable to group to-be-grouped items while operating in the pregrouping state; and

wherein the principal grouping station corresponds to a second location at which the palletizing robot is operable to group to-be-grouped items while operating in the principal grouping state, with the first location being horizontally spaced-apart from the second location.

18. The robotic palletizer system of claim 15 , wherein the pregrouped set transfer assembly comprises a conveyor operable for transferring the pregrouped set of to-be-grouped items from the pregrouping station to the principal grouping station.

19. The robotic palletizer system of claim 18 , further comprising a principal set transfer assembly configured to transfer to-be-grouped items grouped and secured at the principal grouping station from the principal grouping station to an area downstream of the principal grouping station.

20. The robotic palletizer system of claim 19 , wherein the principal set transfer assembly comprises a conveyor operable for transferring the secured to-be-grouped items from the principal grouping station to the area downstream of the principal grouping station.

21. The robotic palletizer system of claim 15 , wherein the controller is configured to:

if a full capacity condition is present at the principal grouping station, control the load securing machine to operate in the securing state to secure to-be-grouped items grouped at the principal grouping station and control the palletizing robot to operate in the pregrouping state to group to-be-grouped items at the pregrouping station as the pregrouped set of items; and

otherwise, control the load securing machine to operate in the non-operational state and the palletizing robot to operate in the principal grouping state.

22. The robotic palletizer system of claim 15 , wherein the controller is configured to:

if at least one of a full capacity condition and an unstable condition is present at the principal grouping station, control the load securing machine to operate in the securing state to secure to-be-grouped items grouped at the principal grouping station; and, if a non-unstable condition is present at the pregrouping station, control the palletizing robot to operate in the pregrouping state to group to-be-grouped items at the pregrouping station as the pregrouped set of items; and

if a non-unstable condition and a non-full capacity condition is present at the principal grouping station, control the load securing machine to operate in the non-operational state and the palletizing robot to operate in the principal grouping state.

23. The robotic palletizer system of claim 15 :

wherein, in the pregrouping state, the palletizing robot groups to-be-grouped items onto a pallet received at the pregrouping station; and

wherein, in the principal grouping state, the palletizing robot groups to-be-grouped items onto a pallet received at the principal grouping station.

24. The robotic palletizer system of claim 23 , further comprising a conveyor operable for transferring the pallet received at the pregrouping station to the principal grouping station.

25. The robotic palletizer system of claim 24 , wherein the palletizing robot is operable to group the pregrouped set of to-be-grouped items onto the pallet received at the pregrouping pallet; and

wherein the palletizing robot is further operable to add additional ones of the to-be-grouped items onto the pallet following transfer thereof to the principal grouping station.

26. The robotic palletizer system of claim 25 , wherein the load securing machine is configured to operate in the securing state after transfer of the pallet having the pregrouped set of to-be-grouped items grouped thereon to the principal grouping station prior to further operating the palletizing robot in the principal grouping state; and

wherein the palletizing robot is configured to operate in the pregrouping state to group to-be-grouped items onto another pallet received at the pregrouping station while the load securing machine operates in the securing state.

27. The robotic palletizer system of claim 25 , wherein the load securing machine is configured to operate in the securing state after completing adding additional ones of the to-be-grouped items; and

wherein the palletizing robot is configured to operate in the pregrouping state to group to-be-grouped items onto another pallet received at the pregrouping station while the load securing machine operates in the securing state.

28. A robotic palletizing method comprising:

selectively operating a palletizing robot between at least a pregrouping state, in which the palletizing robot groups to-be-grouped items at a pregrouping station as a pregrouped set, and a principal grouping state, in which the palletizing robot groups to-be-grouped items at a principal grouping station;

selectively operating a load securing machine between a securing state, in which the load securing machine at least partially secures to-be-grouped items grouped at the principal grouping station, and a non-operational state; and

if the to-be-grouped items grouped at the principal grouping station are in a full capacity condition and secured, removing the to-be-grouped items from the principal grouping station and transferring the pregrouped set from the pregrouping station to the principal grouping station.

29. The method of claim 28 , further comprising:

if the full capacity condition at the principal grouping station is not reached, operating the palletizing robot in the principal grouping state;

if the full capacity condition at the principal grouping station is reached, operating the load securing machine in the securing state until the to-be-grouped items grouped at the principal grouping station have been secured; and

while the load securing machine operates in the securing state, operating the palletizing robot in the pregrouping state.