Robot technology from Honeywell uses machine learning to improve productivity for unloading pallets.

The technology is designed to help warehouses and distribution centres automate the manual process of unloading pallets, reducing the operational risks of potential injuries and labour shortages.

Driven by machine learning and advances in perception and gripping technologies, the smart flexible depalletiser reduces the need for manual labour to break down pallet loads, roles that carry risk of injury to labour, experience high turnover and are difficult to staff. A typical medium- to large-sized distribution centre unpacks up to several thousand pallets per day, with the probability of errors, injuries and worker fatigue increasing during each shift.

“Even when manual operations are running smoothly without injuries, the physical, repetitive task of unloading pallets is variable and limited by human constraints,” said Thomas Evans, chief technology officer of Honeywell Robotics. “Our smart flexible depalletiser helps improve throughput by operating consistently without interruption over multiple shifts with minimal human interaction. With the labour constraints warehouses and distribution centres are seeing in filling these manual roles, this can be an ideal fit to help keep up with daily order volumes.”

The depalletiser’s articulated robotic arm is guided by vision and perception technologies, which allow cases to be picked from a single- or mixed-SKU pallet on a fixed or mobile location. Computer vision technology identifies the exact location of every case on the pallet, while perception software automatically recognises a wide variety of packaging. This technology allows for seamless handling of a continuous flow of pallets in any sequence without requiring any pre-programming or operator intervention.

The machine learning and motion planning optimises the movements of the robotic arm to increase picking speed and efficiency. The control logic also senses the weight of each item as the robot lifts it and automatically updates its gripping response to transfer each product securely and effectively. The more the robot picks, the more it learns and continues to improve in quickly and efficiently unloading pallets.

“Reliable depalletising rates are of growing importance as consumer preferences continue to accelerate the rate of packing and the increasing product mix warehouses and distribution centres handle every day,” said Evans. “These major technology improvements are driving fully automated solutions capable of meeting or exceeding the throughput of manual operations. Not only do these offer significant benefits to modern distribution centres and other fulfilment operations, the business case for their utilisation is also increasingly attractive.”

A recent Honeywell study revealed more than half of companies are more willing to invest in automation because of the pandemic and its lasting effects. The same study showed companies see increased speed of tasks, greater productivity and increased employee use and productivity as the top three potential benefits from automation.

The robot can work with pallet conveyance autonomous mobile robots, enabling continuous operation of the system while providing the flexibility to stage pallets and empty stacks virtually anywhere the robot can travel.

• One of the largest suppliers of fresh and frozen produce and fruit in the US midwest has deployed Honeywell’s mobile computers, tablets and software to help its mobile workers pick, pack and ship perishables. Castellini, one of the oldest produce companies in the country, has deployed Honeywell’s CK65 and CT40 mobile computers, its VM1 vehicle-mounted computers and RT10 tablets. These portable devices are all based on Honeywell’s Mobility Edge platform, which is designed to extend asset life, accelerate deployment and simplify management of mobility systems.