Robotic Baggage Handling

An Integrated Robotic System that places regular random Luggageinto ULD Containers and Transport Carts

Bernd Schnoor Norbert CottoneBerndSchnoor@kuka-roboter.de NorbertCottone@kuka-innotec.de

KUKA Roboter GmbH KUKA InnoTec GmbH

Bluecherstrasse 144, 86165 Augsburg Germanyhttp://www.kuka-roboter.de

Exhibit 1: Baggage loading Cell

ABSTRACTFor the past several decades now, baggage-handling systems at major airports havesuccessfully deployed automated conveyorsystems and intelligent sorter technologies.Nevertheless, the most difficult operation in theentire baggage handling process is stillperformed manually, and entails the physicalloading of baggage into ULDs and ontotransport carts. This operation remains adifficult and extremely labor intensive endeavorthat is both physically demanding and fraughtwith numerous disability injuries, as well ashigh employee turnover.

The baggage loading process works as follows:initially, a laser scanner views each piece ofluggage; it measures height, length and widthand furthermore it identifies and discriminatesprecisely what kind of baggage is beingpresented, such as whether it is a hard side

suitcase, soft bag, rucksack, golf bag, cartoncase, or any other special configuration. Amechanical end stop is positioned on theconveyor according to the size of the piece ofluggage for a centered grip. The data from thesensor system also is given to an intelligentpacking pattern generator which calculatesdynamically the best position in the container oron a cart for the piece of luggage to be placedas next in order to achieve the highest loadingdensity.

Exhibit 2: The baggage loading process

Baggage drop off

Identification of baggage

Classification of sizes & baggage type

Weight detection

Measuring deformation

Baggage buffering (2-6 pieces)

Calculation of optimum loading sequence

Feeding and centering

Strapping

Robotic baggage positioning

1 INTRODUCTIONWith an automated baggage loading process(please refer to Exhibit 1), passenger baggageprofiling can be upgraded to a very highefficiency. All luggage data is available in thecell or robot controller, and has the capability ofbeing accessed from any location. The positionof each piece of luggage in a container or on acart can be saved, graphically visualized, andprinted or saved on a smart chip (RFID), whichcan be attached to the security transportstrapping on the luggage. This technologicaladvancement will shorten the inordinatenumber of delays in departures, and also serveto dramatically increase overall security.Moreover, and most importantly from anoverall security perspective, this is the leastsecure aspect of the entire baggage handlingsystem due to the number of human beingsinvolved in the handling of baggage during thissegment of the process. Automation of thissegment, coupled with the incorporation ofexplosive detection devices into an overallintegrated robotic system, will go a long waytoward achieving safe and secure baggagehandling operations, while at the same timecontributing toward the restoration of passengerconfidence in the overall safety of air travel.This newly developed system utilizestechnology that has been jointly developed forthe warehouse distribution industry. It can alsobe applied to upgrading existing airportbaggage handling and logistics systems.KUKA first began its research and developmentefforts on automated stacking processes in1997. These early efforts focused on twoseperate but very similar robotic applications:(1) baggage loading; and, (2) order picking /mixed palletizing in distribution warehouses forgroceries (Please refer to Exhibit 3).

Exhibit 3: Similar Tasks:Baggage Handling and Order Picking

2 CELL CONFIGURATION

2.1 Robot Technology

One of the basic components of the baggageloading cell is a standard KUKA robot (KR)with a PC-based robot controller (KRC2) alongwith the KUKA control panel (VGA, 256colors). Please refer to Exhibit 4.

Exhibit 4: KUKA Robot (KR), Controller(KRC2), and Control Panel (KCP)

The robot control software essentially consistsof three major components or elements as listedbelow:• “VxWorks” from company WindRiver

Systems, Inc. as the real time operatingsystem

• “MS Windows” from Microsoft forinterfacing with the operator

• The KUKA robot language (KRL) forcontrolling the robot

KUKA utilizes standardized off-the-shelfrobotic accessories, including all types ofenergy supplies, power conditioning and controlsystems, safety features, fieldbus interfaces,linear units, etc. Moreover, with a software toolcalled “PC-Duo”, KUKA robotic baggagehandling systems can be easily connected toany kind of SCADA system for real timesystem monitoring, data acquisition, and tamperfree reporting. Due to the PC-based controller,we were capable of adapting and transferring allrecent developments from the PC-office worldto the industrial world. For example, KUKAoffers its customers a web-based remotediagnostic for preventive maintenance wherebyeach robot gets its own homepage.

2.2 Gripper Technology

A breakthrough component of the baggageloading system is the gripper technology that

has been deployed to handle virtually all piecesof baggage, regardless of size and composition.Various survey on airports were done. (Forexample refer to Exhibit 5). All results of thesesurveys demonstrated that there are no standardtypes of baggage, there are no standard sizes, orstandard weights.

Exhibit 5: Standard Baggage (Survey at BA)

Due to these experiences it became clear thatthe gripper principle had to be extremelyflexible in order to be capable of handling avariety of different types of luggage as well as awide range of sizes.

This technology is comprised of the followingmajor elements:

• A standard strapping machine which isactually used for securing carton cases fortransportation.

• A very simple gripper that is essentially aplate that can be adjustable in width basedon the size of a particular piece of luggage.

The strap can either be left on the luggage (amicro chip can be fixed at the strap to supportthe passenger baggage profiling; this alsoimproves the security), or can be cut by aspecial cutting device that is integrated in thegripper, rolled up, and removed (Please refer toExhibit 6).

Exhibit 6: Gripper for Baggage Handling withCutting and Roll Up Mechanism

With this gripping mechanism, all types ofluggage can be handled with only one tool. Thestraps are strong enough for baggage weightsup to 130 pounds.

The most important externality in thedevelopment process was related to the impactof the strapping to the luggage surface.Consideration was given to the strappingtension which had to be high enough to handleall types of luggage in any orientation, yet notdamage the surface of the suitcases or bags. Toachieve this goal FEM calculations wereapplied to varying strap tensions, gripper sizesand differing types of baggage (Refer to Exhibit7).

Exhibit 7: FEM analysis (suitcase entangledwith straps)

As a result of these investigations we provedthat this gripping principle caused no damageduring the handling of the luggage in allorientations and degrees of movement.

Others 7.6 %

Backpacks 5.1 %

Cases, Piece goods 3.9 %

Bags 20.2 %Suitcases 63.2 % (hard shell, soft side, trolley)

2.3 The Sensor System

The information regarding the size of the nextpiece of luggage comes from a standardindustrial laser scanner that is located above thebaggage conveyor in front of the strappingmachine creating a three-dimensional scan foreach piece of luggage. (Refer to Exhibit 8).

Exhibit 8: Standard trolley and scan results

Furthermore, there is a wide range of additionalinformation that we obtain by scanning theluggage. For example the system is capable ofrecognizing wheels and handles. Therefore itcan automatically distinguish between thedifferent types of baggage. This information isimportant to enhance the overall process: Forexample when a trolley is handled by the robotit ensures that the handle can not slide out andcause collisions.

2.4 The Loading Algorithm (LOGO)

As soon as a piece of luggage arrives on aconveyor to the strapping machine, the robotmoves the gripper plate to the position wherethe piece of luggage and the gripper can bestrapped together. In parallel, the loadingalgorithm program (LOGO) determines theoptimum position for the piece of luggage to beplaced in the container or on the cart. Thiscalculation is comprised of the size of a singlepiece of luggage and the current packingpattern. (Please refer to Exhibit 9).Moreover, the packing/palletizing algorithm iscapable of multiple container loading. As aresult, luggage can be apportioned to differentULDs and/or transfer carts by the roboticsystem based on given parameters such as classof service (1st class, business class, or economyclass) and also destination. This algorithmcalculates the position of each piece of luggagewith respect to both high load density and loadstability.

Exhibit 9: Palletizing Algorithm andApplication Software

3 SUMMARYThe cycle time for this baggage loading systemwill be at the most 12 seconds per piece ofluggage. In an optimized process, it is estimatedthat the turnover will be somewhere between300 and 400 pieces per hour for each installedrobot. Moreover, the KUKA baggage loadingsystem requires only a very small footprint, andis well suited for fast track retrofitting ofexisting logistic systems found in most majorairports today. In addition, with theincorporation of explosive detection devices theautomatic baggage loading system should go along way toward simultaneously alleviatingbaggage security problems at major airports andalso restoring public confidence in airtransportation systems from the standpoint ofthe flying public.

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fluss Logistik: 7. Jahrestagung AirportLogistics, VDI-Berichte 1729, VDI-VerlagGmbH, Duesseldorf 2002

[2] Schraft, R.D.; Schmierer, G.:“Serviceroboter“, Springer-Verlag, BerlinHeidelberg 1998

[3] Wurll, Ch..: “Pick To Pallet – AutomatedOrder Picking with Industrial Robots”, in“Robotik 2002 – Leistungsstand –Anwendungen – Visionen – Trends, VDI-

Bericht Nr. 1679, June 19./20., 2002”,Germany

[4] Wurll, Ch.: “Pick From Belt - AutomatedOrder Picking with Industrial Robots”, inProceedings of the 33rd InternationalSymposium on Robotics, Stockholm 2002