Blog | Automating Complex Truck Unloading with RockyOne

Truck unloading remains one of the toughest warehouse processes to automate. Cartons arrive in different sizes and weights, with varying stack patterns and often changing SKUs. XYZ Robotics’ RockyOne Mobile Manipulation Robot (MMR) begins unloading once the container door opens. It handles highly variable mixed-case loads in real dock environments, streamlining inbound operations.

Identifying Cartons Without Prior Data

RockyOne identifies cartons without prior SKU information. It captures each carton’s 3D dimensions in real time, even when cartons vary in size and are stacked in unpredictable patterns.

This information allows RockyOne to plan a safe pick-to-place trajectory for every carton, avoiding collisions during unloading. It can also place cartons according to downstream requirements, such as aligning their long sides with the conveyor.

Placing Cartons in the Required Orientation

Beyond its adaptable picking capabilities, RockyOne can place cartons in the orientation required by downstream operations. For example, it can position each carton with its label facing forward for barcode scanning.

When necessary, RockyOne also controls conveyor movement for secondary positioning adjustments. This ensures the correct carton orientation for subsequent processing.

Retrieving Recessed Top-Layer Cartons

Top-layer cartons may sit farther back in the container than the cartons below, placing them beyond the reach of conventional grippers.

RockyOne’s gripper includes an extendable bottom support with suction cups mounted at the front. The suction cups pull recessed cartons forward, bringing them within reach of the main gripper. The main gripper then picks the carton and continues unloading without manual intervention.

RockyOne automates challenging mixed-case unloading tasks, including identifying unknown cartons, placing them in required orientations, and retrieving recessed loads. It delivers reliable automation for complex inbound operations and has been deployed in Germany, the United Kingdom, Japan, China, and other markets. Its applications span footwear and apparel, home appliances, home furnishings, tobacco, and more.

Learn more in our latest whitepaper, or contact us to discuss your inbound automation needs.