📋 Case Study

Palletizing Robot Path Optimization for High-Speed E-Commerce Fulfillment

Vibration-induced misalignment causing 8% pallet collapse rate at 120 cycles/hour

🏗️ Project Overview

Automated fulfillment center serving Amazon Prime logistics in Ohio

🎯 Challenge

Vibration-induced misalignment causing 8% pallet collapse rate at 120 cycles/hour

🔧 Design Approach

Quintic spline interpolation with jerk-limited acceleration ramping; integration of real-time load sensing to adapt TCP orientation

📐 Design Diagram

AI-generated project design illustration

📐 Key Calculations

Jerk-Limited Acceleration Ramp Time

t = √(2·a_max/j_max)

Result: 0.12 s

Eliminates high-frequency resonance

TCP Orientation Deviation Budget

θ_max = arctan(d/L)

Result: ±0.8°

Maintains layer stability

📊 Results

99.97% pallet integrity, 14% throughput increase, 22% reduction in servo wear

💡 Lessons Learned

• •Jerk limits must be tuned per axis—not just global
• •Load-dependent orientation correction prevents cascading errors

✅ Key Takeaways

• 1Jerk limits must be tuned per axis—not just global
• 2Load-dependent orientation correction prevents cascading errors