SICE-ICASE International Joint Conference 2006

Oct. 18-21, 2006 in Bexco, Busan, Korea

1 INTRODUCTION

This paper will focus on palletizing, which is a form
of unitizing. Palletizing refers to a uniform load stacked
on a wooden pallet, using a pre-determined case pattern
sequence and given number of layers [1]. (Fig.1)



Fig. 1 Robot Palletizer

The process of palletizing typically involves the
stacking of boxes, trays, bundles, bags, pails or drums in
a predetermined pattern configuration. This paper will
focus on the use of boxes only, as they make up the vast
majority of palletizing application. Actually, the number
of case patterns that can be programmed into a fully
automatic palletizer is virtually limitless; however,
when a pattern is programmed into a palletizer, it is not
simply a software change in the controller itself. One of
the biggest problems of manufactures is building loads
to customers specifications.



Fig. 2 Proposed schematic of Palletizing simulator

We propose the off-line robot palletizing simulator to
combine Fast Algorithm and 3-D robot simulator using
trajectory optimization algorithm. Fig.2 shows basic
schematic of this simulator.

2. FAST ALGORITHM

2.1 Steudels Heuristic Algorithm

The objective of the pallet loading problem (PLP) is
to maximize the number of products loaded onto a pallet
that is used for the transportation and storage of
products. We can reduce the distribution and storage
costs of product by increasing pallet utilization.
Fast Algorithm proposed in this study is basically,
Robot Palletizing Simulation Using Heuristic Pattern Generation and
Trajectory Optimization
SungJin Lim
1
, SeungNam Yu
2
, MaingKyu Kang
3
and ChangSoo Han
4

1
Department of Mechanical Engineering, Hanyang University, Seoul, Korea
(Tel : +82-31-400-4062; E-mail: brass_79@hotmail.com)
2
Department of Mechanical Engineering, Hanyang University, Seoul, Korea
(Tel : +82-31-400-4062; E-mail: hymecer@gmail.com)
3
Department of Industrial Engineering, Hanyang University, Seoul, Korea
(Tel : +82-31-400-5110; E-mail: dockang@logistex.hanyang.ac)
4
Department of Mechanical Engineering, Hanyang University, Seoul, Korea
(Tel : +82-31-400-5247; E-mail: cshan@hanyang.ac.kr)


Abstract: Palletizing task is necessary to promote efficiency of keeping and shipping task. This is, however one of
the most monotonous and heavy laborious work in the factory. So, many types of Robot palletizing system have been
developed. But many robot motion commands is still depends on the teach pendent. That is, the operator input the
motion command line one by one. It is very troublesome and most of all, user must know how to type the code. So we
propose the new GUI Interface of Palletizing System that can be used more conveniently. To do this, we use the
algorithm of PLP, "Fast Algorithm" and realize the 3-D Auto-Patterning Visualization.
The usages of 3-D pattern are following. First, an operator can identify the result of own task and edit it. Second, pass
the position value of objects to a robot simulator. Using that position, palletizing operation can be simulated. We use the
"Hyundai HHI series" and analyze the kinematics and dynamics to realize into a robot simulator. In this paper we
propose the 3-D patterning algorithm and 3-D robot palletizing simulator, and apply the A* algorithm to find the
optimal robot trajectory.

Keywords: PLP(Pallet Loading Problem), Fast Algorithm, Pallet loading Pattern, A* Algorithm, Robot Simulator
SICE-ICASE International Joint Conference 2006
Oct. 18-21, 2006 in Bexco, Busan, Korea


improved algorithm to compare with the 4-block pattern
heuristic algorithm which proposed Steudel.



Fig. 3 Steudels Heuristic Algorithm

Typical pattern of Stuedels heuristic algorithm
represented Fig.3. This heuristic finds the 4-block
pattern where each block is a homogeneous pattern with
the same box orientation [2]. This heuristics consist of
two phases. First, an initial solution is made with the
combination of
i
L and
i
W that maximizes the
utilization of all four pallet edges. Dynamic
programming (DP) was applied to find the combination
and the initial solution has one of the four patterns
shown in Fig.4. An initial solution that has a central hole
sufficiently large to load more than one box in the case
of P1 and P3, or an infeasible pattern, such as P2 and P4,
due to the overlapped area,









Fig. 4 Four patterns of the initial solution

This will involve the second phase. In the second
phase, Treatment 1 is Fixing (
3
L ,
3
W ) and (
4
L ,
4
W ),
resize
1
L and
2
L and Treatment 2 is Fixing (
1
L ,
1
W )
and (
4
L ,
4
W ), resize
2
W and
3
W . We can choose the
better solution to compare the first and second method.


(a) (b)

Fig. 5 Treatment of Steudels Algorithm
(a) Treatment 1, (b) Treatment 2

2.2 The Fast Algorithm

2.2.1 Definition

The Fast Algorithm which we proposed has similar
process to generate the initial solution of 4 patterns. And
additionally, we adapt our Treatment 3 to apply the
heuristic recursively to the central hole in the following
three methods to remove the overlapped area. (Fig.6)



Fig. 6 Treatment of the Fast Algorithm

(1) In the first method: the boxes that are cut by the two
horizontal edges of the overlapped area.
(2) In the second method: the boxes that are cut by the
two vertical edges.
(3) In the third method: the boxes that are cut by the left
vertical edge and the lower horizontal edge.

2.2.2 Schematic of Fast Algorithm

We do not consider the all size of blocks; therefore
this algorithm has more rapid calculation time. First
phases initial solutions find the combination rather than
using DP and define the 4 parameters. (Fig.7)
a : When maximize the length of block and dispose the boxes
lengthwise, maximal possible number of box = l 5
a : When maximize the length of block and dispose the boxes
lengthwise, minimal possible number of box = l 2
b : When maximize the width of block and dispose the boxes
lengthwise, maximal possible number of box = w 8
b : When maximize the width of block and dispose the boxes
lengthwise, minimal possible number of box = w 2



Fig. 7 A Parameters of Fast Algorithm

In the first phase, make combinations of (L1, W1)
such as ) , ( b a , ) , ( b a , ) , ( b a and ) , ( b a and given
(
1
L ,
1
W ) is the width and length of the other blocks
can be determined.
SICE-ICASE International Joint Conference 2006
Oct. 18-21, 2006 in Bexco, Busan, Korea
|
|
.
|

\
|
(

= = l
l
W W
w
w
L L
W L W L
1 1
4 4 2 2
, ) , ( ) , (
(1)
) , ( ) , (
1 1 3 3
W L W L = (2)
After making the four initial solutions in the first
phase, redefine these solutions by applying the three
treatments in the second phase

2.2.3 Computational Experience

We implemented the algorithm in Visual C++ 6.0 and
compiled it with the maximized-speed option.

Table 1 The test result problem of small size

(L,W,l,w) Amount of box loaded
(1000,1000,205,159) 30
(1000,1000,200,150) 33
(22,16,5,3) 23
(30,22,7,4) 23
(14,10,3,2) 23
(53,51,9,7) 42
(34,23,5,4) 38
(57,44,12,5) 41
(87,47,7,6) 97
(1200,800,176,135) 38
(L: Length of Pallet, W: Width of Pallet
l: Length of Box, w: Width of Box)

Upper result acquired from a computer of
K6-350MHz CPU and 64MB RAM. All problems were
calculated within 1 second and resulted in optimal
solutions [2]. This algorithm test is about two
dimensional pattern generation of boxes and its
calculation speed. To use this algorithm, however,
consider the three dimensional space and physical
constraint of box loading. To realize this, we consider
the three constraint condition of palletizing, which is
approach direction of robot hand to the pallet, multiple
box gripping and weight center of palletized boxes.
More information about this condition is referred to [3].



Fig. 8 Pallet Pattern Generation Software
To use this algorithm to the industrial robot system,
we developed GUI interface for a pallet loading
problem using Fast Algorithm (Fig.8) and Fig.9 shows
the calculated target position of each box.



Fig. 9 Box target position (Robot Coordinates)

3. THE DEVELOPMENT OF 3-D ROBOT
SIMULATOR

3.1 Overview

For an industrial robot, to generate the palletizing
task, several methods had been introduced and used.
First one is On-line teaching the robot using teach
pendent or mimic and memorize the workers motion.
Second one is Off-line method which is to generate task
data using computer and download it to the robot
controller. Especially, we focus to the Off-line task
generation and simulation using robot simulator. In this
phase, we represent three dimensional robot simulator
based on the dimension data of our real target machine,
HX300 which is a 6-axis industrial robot of Hyundai
Heavy Industrial Co. This robot model is realized by
commercial CAD modeler, and GUI interface is
developed using OpenGL and MFC of Microsoft
Visual C++.
To solve and analyze the forward and inverse
kinematics equation, we use D-H table and Lagrangian
Dynamic Equation. And this simulator is possible to
compute and display the joint torque, angle, angular
acceleration simultaneously.

3.2 Computation and Development of Robotic
system

We solve the transformation matrix of each joint
space and derive the inverse kinematical equation. And
we compute the energy equation of potential and kinetic
energy of system using Lagrangian equation; finally we
acquire the following equations (More detail equations
are referred to [4-5])

j
i j
j
i
ij
q
A A A A
q
T
U

=
) (
1 1
" "
(3)
SICE-ICASE International Joint Conference 2006
Oct. 18-21, 2006 in Bexco, Busan, Korea


(

=
=

= =
i
p
i
r
r p
T
ir i
T
i i ip
I i
q q U dm r r U Trace
dK K
1 1
) (
2
1


(4)
(
i
A : transformation matrix of th i joint space
i
q : th i joint angle)
)] ( [
2
1
) (
2
1
0
6
1
6
1
2
) (
6
1 1 1
i i
i
T
i
i
i act i
r
i
i
p
i
r
p
T
ir i ip
r T q m q I
q q U J U Trace P K L

= =
= = =
+
= + =

(5)
(
i
J : Pseudo inverse matrix to express
i
T
i i
dm r r

term)

To build the dynamic equation, we differentiate each
term and we derive the following equations.

k
j
j ijk i act i j ij i
q q D q I q D T

=
+ + =
6
1
6
) (
(6)

=
=
6
) , max(
) (
j i p
T
pi p pj ij
U J U Trace D (7)

=
=
6
) , , max(
) (
k j i p
T
pi p pjk ijk
U J U Trace D (8)
p pi
i p
T
p i
r U q m D

=
=
6
(9)

i
T is angular acceleration inertia,
ij
D is inertia of
actuator,
ijk
D is Coriolis term and Centrifugal force
and
i
D is gravity term. Using these equations, we
realize the three dimension robot simulator as Fig.10.



Fig. 10 Robot Simulator for Palletizing Task

The performance test of upper simulator combined
with Fast algorithm is explained to [3].
4. CONFIGURATION SPACE

Palletizing task, generally, is composed of several
palletizing components. These are auxiliary, but on the
other hand, they are obstacle for the palletizing robot.
The goal of this study is to find the optimal path
considering obstacles hence we apply the concept of
configuration space to solve this problem.
The configuration means variables to express a
position and direction of object exactly, and
configuration space means all of the space where
configurations are possible to acquire [6].
Using this concept, define a coordinate for
configuration. In this coordinate, each point approached
by robot gripper is expressed by joint angles
(configuration; posture) of robot palletizer. Each set of
configuration are displayed as following figure.



Fig. 11 Obstacles Expressed in Configuration Space

Fig.11 shows the example of generation of
configuration space. Left side of figure describes a
palletizing task layout. First, on the basis of joint of base
frame, rotate the imaginary plane 360 degree. In this
progress plane scan the objects surrounding robot, and
generate the outline of a section. This outline, include
the inside of it, could be considered as obstacle. In this
paper, grope this outline using end effecter of robot and
generate the free move zone and obstacle zone in the
configuration space as shown in the right side of Fig.10.
This figure is necessary to generate the optimal path
using A* algorithm described in the next chapter.

5. APPLICATION OF A* ALGORITHM
FOR TRAJECTORY GENERATION

The A* method is a through, robust planning technique
that will determine the minimum cost path and
determine if no safe path exist [7].
In this study, use this technique to find the optimal
path between gripping point (Starting point) and place
down point (End point). A* technique is outlined below.
To begin a rectangular grid is produced in which the
cells are either safe or forbidden. The planning begins at
the starting point and the cells adjacent to this cell are
probed. On the basis of a cost function, the cell with the
minimum cost is explored next [8-9].
Using this algorithm, we tabulate the results of
simulation of predefined palletizing task.
SICE-ICASE International Joint Conference 2006
Oct. 18-21, 2006 in Bexco, Busan, Korea
Table 2 Palletizing Task Simulation and Generation of Optimal Trajectory

Step Task Layout Configuration Space Enlarged Image Elapsed Time (sec)
1

3.132818
2

0.384636
3

12.267289
4

9.734590
5

0.981018
6

4.182875
7

2.315868
8

1.931879
SICE-ICASE International Joint Conference 2006
Oct. 18-21, 2006 in Bexco, Busan, Korea


As shown table 2, generate the optimized robot
traveling path from configuration space using A*
algorithm.

6. CONCLUSION AND FUTURE WORK

In this paper, we proposed Fast Algorithm for PLP,
3-D robot simulator and schematic of combination of
two systems. To develop total off-line palletizing
simulator, however, the computing time for optimized
trajectory generation is need to be faster. As shown fifth
column of table 2, the computing time of each step is
remarkably different as the position placing down. We
implemented the algorithm in Visual C++ 6.0 and
AMD 2.0GHz computer with 1 GB of RAM was used
to test the algorithm.
Fig.12 shows current status of our research. As a
future work, we step the progress and . The former
is to reduce the computing time and load, the latter is to
combine the current optimization algorithm with 3-D
robot simulator.



Fig. 12 Development Process

REFERENCES

[1] Michael A. Hernan I, An Introduction to
Automated Palletizing, Anderson Technical
Services, Inc., 850 Morrison Road Chillicothe,
Ohio, 45601, 2000
[2] Young-Gun G, Maing-Kyu Kang, A fast algorithm
for two-dimensional pallet loading problems of
large size, European Journal of Operational
Research 2001, pp. 193-202, 2000
[3] Seung-Nam Yu, Heu-Kwon Yoon, Sung-Jin Lim,
Young-Hoon Song and Chang-Soo Han, The
development of Robot Palletizing S/W using
Fast Algorithm and 3-D Robot Simulator, In
proceeding of Korean Society of Mechanical
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[4] Sung-Jin Lim, A Study on analyzing inverse
kinematics and inverse dynamics of 6 DOF
articulated robot, Hankuk Aviation University,
2004
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Analysis, Systems, Applications, Prentice Hall,
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M. Yang, Collison-Free Path Planning of
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[8] T. Lozano-Perez, A Simple Motion Planning
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[9] C.W Warren, J.C. Danos, and B.W. Mooring, An
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