Working Principles of Intelligent Loading Robots

Intelligent loading robots are sophisticated machines designed to enhance efficiency and accuracy in various loading and unloading tasks. At the heart of these robots are several critical components, including sensors, actuators, and control systems. Each of these elements plays a significant role in the robot’s functionality.

Sensors are the primary input devices that allow the robot to perceive its environment. These can range from simple proximity sensors to advanced LIDAR systems and computer vision cameras. The data collected by these sensors are processed in real-time to create a detailed map of the surroundings, enabling precise navigation and object detection. Actuators are the output devices that translate electrical signals into physical movements, allowing the robot to perform tasks such as lifting, moving, and placing objects.

The control systems serve as the brain of the intelligent loading line, integrating inputs from the sensors and sending appropriate commands to the actuators. Advanced control algorithms, often powered by machine learning, are employed to optimize the robot’s actions. Machine learning enables the robot to improve its performance over time by learning from previous tasks and adapting to new situations. Computer vision technologies allow the robot to recognize and classify objects, enhancing its ability to handle diverse items with varying shapes and sizes.

Real-time data processing is another crucial aspect that ensures the robot can make quick and accurate decisions. This capability is essential for tasks such as path planning, where the robot determines the most efficient route to its destination while avoiding obstacles. Algorithms for path planning, object detection, and obstacle avoidance are integral to the robot’s performance. These algorithms rely on complex mathematical models and real-time analytics to ensure smooth operation.

Practical applications of these principles can be seen in various industries. For instance, in a warehouse setting, an intelligent loading robot can autonomously navigate aisles, identify and pick up items from shelves, and transport them to designated areas. Case studies have shown significant improvements in operational efficiency and accuracy, demonstrating the potential of these technologies in real-world scenarios.

Type of Intelligent Loading Robots

1. Intelligent swing-arm bagged cement automatic loading robot
Product use：Satisfy the high-speed loading demand of bagged cement, the efficiency can reach 120-150 tons/hour.

2. Intelligent truss type automatic loading robot
Product Use: Applicable to large-scale warehousing and fertilizer, chemical, railroad, port bagged products loading site requirements, efficiency of 40-90 tons / hour, to meet a variety of models (including high-bar models with stretching and high requirements for breaking the bag of bagged materials)

3. Double robot loading equipment
Product Use: To meet the high speed loading demand of bagged materials, the efficiency can reach 1200 bags/hour.

4. Carton loading robot
Product use: applicable to the loading of boxed materials on-site needs, the efficiency of 600 boxes / hour, applicable to the chemical industry, food, tobacco bulk boxed materials production and transportation industry.

The system consists of the following main components:
1. Write card system: the weight of the goods to be withdrawn into the card
2. Visual system: recognizes the vehicle and guides it to stop.
3. card reading system: read out the weight of the goods written on the card and transmit it to the computer.
4. Radar detection system: detects the dimensions of the vehicle and transmits them to the computer.
5. Calculation system of palletizing method: to analyze the vehicle size and cargo loading for comprehensive calculation and determine the way of loading packages.
6. central control system: is the whole system of data processing, command center
7. Dust collection system: collects dust in the loading position to ensure clean production.

Key Features of Intelligent Loading Robots

Intelligent loading robots have revolutionized the logistics and supply chain sectors by offering advanced features that significantly enhance operational efficiency. One of the standout characteristics of these robots is their autonomous navigation capability. Equipped with sophisticated sensors and algorithms, intelligent loading robots can independently maneuver through complex environments, avoiding obstacles and optimizing routes for maximum efficiency. This level of autonomy reduces the need for human intervention, thereby minimizing labor costs and human error.

Adaptability is another crucial feature that sets intelligent loading robots apart from traditional systems. These robots can handle a wide range of loads, varying in size, shape, and weight. This versatility is achieved through advanced gripper technologies and adaptable loading mechanisms. Whether dealing with fragile items or bulky goods, intelligent loading robots can adjust their handling techniques to suit the specific requirements of each load, ensuring safe and secure transportation.

Environmental adaptability is equally important. Intelligent loading robots are designed to operate in diverse conditions, from controlled warehouses to more challenging outdoor environments. Robust construction and advanced environmental sensors enable these robots to function reliably, regardless of temperature fluctuations, humidity, or uneven surfaces. This adaptability ensures that operations can continue smoothly across various settings.

The user interface of intelligent loading robots is designed for ease of use and seamless integration into existing systems. Operators can interact with these robots through intuitive software applications, allowing for straightforward programming and real-time monitoring. User-friendly dashboards and control panels make it easy to set parameters, track performance metrics, and diagnose issues, facilitating a more efficient workflow.

highly effective

(1) High detection efficiency
Vehicle model identification is completed within 8-20 seconds.
(2) High loading efficiency
The loading efficiency is 100~150 tons/hour, which is higher than the operation efficiency of automatic bag inserting machine. The front end of the production line can be operated by automatic bale insertion machine.
(3) Production line coordination
Optimized production can be achieved by the joint control and adjustment of packaging machine, automatic bag inserting machine and conveying line.

intelligent

(1) Large-area parking, no need for vehicle centering
Intelligent identification system can meet the large-area parking of vehicles;
Highly flexible movement of the loader can meet the large-area parking of vehicles, and it has automatic correction function for loading problems caused by incorrect parking position.
(2) Adaptive matching of optimal palletizing type
With the optimal palletizing intelligent algorithm, the system determines the palletizing pattern independently according to the loading tonnage and vehicle type. The loading quantity and palletizing pattern can be modified manually.

(3) High motion precision
The motion precision of the highly flexible loading robot is ensured by the intelligent motion control algorithm, which realizes small error control of the motion speed and motion trajectory of the three directional degrees of freedom of the motion part, and the control precision reaches 0.5 cm.
(4) One-button start
One-key start by swiping the card, simple operation, no manual intervention throughout.
(5) Rich and friendly data interface
With the function of data interaction between different departments, finance, sales, access control, central control, ERP, MES ……, the interface open design, scalability.

(6) Multi-machine on-site management
With the central control integration management function, multiple automatic loading robots can be supervised and controlled using the enterprise server, reducing the number of on-site supervisors.
(7) Cloud information management
Equipment operation status information can be uploaded to the cloud to realize remote information management.
(8) Intelligent diagnosis
Based on the equipment operation information returned by 5G+cloud technology, it adopts advanced algorithms to analyze the equipment status, and realizes the functions of fault pre-diagnosis, troubleshooting, maintenance prompts and manual interaction.

Based on 5G technology, it realizes low-latency remote management, debugging and control services, collects data from the customer’s use site in real time, and intuitively displays it in real time on the control system’s big screen. Through the real-time collection of data from the production site and the cloud integration of data with external connection points, electromechanical engineers carry out debugging and maintenance of the products according to the operation data, realizing remote debugging and maintenance services.

stabilise

(1) It can effectively deal with the problems of continuous bag, horizontal bag and diagonal bag on the production line.
(2) Intelligent and dynamic adjustment of the height of the bag falling, avoiding the occurrence of broken bags.
(3) High fault tolerance, the vertical bag in the equipment will not affect the operation of the equipment.

eco-friendly

(1) The loading area is technically sealed as a whole, with a single side fixed overall dust removal method and a large air volume to avoid dust spillage. Dust removal is not limited by time to avoid dust escape.
(2) Separate closed dust removal for the dust escape area on the production line.
(3) Each moving joint and rotating position is lubricated with grease to avoid oil dripping effectively.

Simple structure and reliable operation

(1) The package has a single motion posture on the device with no transitions.
(2) The equipment has few moving parts and single action.
(3) The moving parts are all motor-driven, simple and reliable.
(4) As much as possible using standard parts.
(5) Modular design.

Simple mechanisms and a single transfer path for the goods achieve long and reliable operation of the equipment. Standardized and modular design ensures easy maintenance of the equipment.

flexibility

It can be adapted to the vast majority of vehicles on the market, such as flatbed trucks, high-bar plate trucks, tractors, tricycles, trailers and so on. Getting rid of the traditional laser distance detection method, it can also recognize the vehicles with diagonal stretching bars in the carriages, and the product is more adaptable. It can meet the loading requirements of vehicles with different width bags and different pallet types, and realize the loading of vehicles with different widths (including single-axle vehicles) from one column, two columns, three columns, three-and-a-half columns, four columns, etc. It can also effectively deal with the abnormality of consecutive bags and horizontal bags, and deal with the broken bags according to the user’s requirements, and make up for the bags automatically.

surety

(1) Each component has gone through strict design calculation and simulation to ensure that the mechanical structure of the product has sufficient strength.
(2) A perfect product quality control system is established, including incoming inspection, processing inspection and factory test, etc. to strictly control product quality.
(3) Multiple safety protection measures are set up, such as software safety limit, mechanical safety limit, fall prevention safety device, safety guard, safety warning light, voice prompts and real-time monitoring system, etc., to ensure the stable, reliable and safe operation of the product.
(4) The loading process is unmanned, which effectively avoids occupational disease hazards and personal injuries in the loading process, and makes the loading process safer.

energy conservation

The total power of the equipment is about 29KW, and the actual running power is about 7-9KW; the standby power is lower than 0.1KW; the energy consumption is low, and the input-output ratio is even lower.

Low retrofit costs and fast payback

No need to change the existing site layout and environment, reduce the cost of enterprise workshop transformation, while the equipment is reserved for dust removal interface, can be connected with a variety of common mobile dust removal equipment on the market, adaptability, low transformation costs. According to the actual situation of the enterprise, after adopting the automatic loading machine, only the labor cost per ton of cement is expected to save 1.5 yuan to 3.5 yuan, and the investment recovery is fast.

after-sales service

(1) The product structure is simple, and most of the maintenance parts are common standard parts, which are convenient to purchase and can be quickly replaced, which is convenient for the maintenance and upkeep in the later stage; it can realize the user’s self-maintenance.
(2) Remote online diagnostic system (data cloud platform), real-time monitoring of the equipment, the operating data sent to the cloud in real time, emergency treatment of abnormalities online, the first time to provide the most effective technical support.
(3) Professional after-sales team, 24h standby, non-remote areas within 24h to the customer site for abnormal processing, to protect the customer’s normal operation.

Efficiency and accuracy are at the forefront of intelligent loading robot design. Features such as collision detection and emergency stop functions enhance safety, protecting both the robots and their human counterparts. These safety mechanisms are crucial in preventing accidents and ensuring a secure working environment.

Integrating intelligent loading robots into existing logistics and supply chain systems offers numerous benefits. Beyond reducing labor costs, these robots contribute to increased operational efficiency by optimizing load handling and minimizing downtime. As a result, businesses can achieve higher throughput and improved overall productivity, making intelligent loading robots a valuable investment for any modern logistic operation.