Patent Grant
11001446
The described embodiments relate to systems and methods for picking up and dropping off a payload within an industrial facility, and in particular, to a pick-up-and-drop-off stand.
Self-driving material-transport vehicles are used to move payloads such as parts and inventory throughout industrial facilities such as factories and warehouses. As such, it is necessary to load payloads onto material-transport vehicles, and unload them from material-transport vehicles. While some material-transport vehicles such as fork lifts and pallet jacks may be equipped to lift a pallet directly off a floor, other material-transport vehicles are not similarly equipped. In these cases, an apparatus may be used to hold the payload in order to facility loading and unloading of the payload.
However, the addition of a new apparatus often creates problems for managers and operators of industrial facilities. For example, floor space in an industrial facility such as factories and warehouses is often considered scarce, and the efficient allocation of floor space is highly valued.
Furthermore conventional approaches to providing apparatus for holding a payload require some degree of human intervention. For example, human intervention may be required to identify when a payload has been loaded or unloaded from the apparatus.
In a first aspect, there is an apparatus for providing smart pick-up and drop-off. The apparatus comprises at least one vertical support member and at least one storage shelf supported by the at least one vertical support member. A payload transfer surface is also supported by the at least one vertical support member, and is located below the at least one storage shelf. The payload transfer surface has an access channel. A sensor associated with the payload transfer surface is used to sense the presence or absence of a payload on the payload transfer surface, and a communications sensor communicates a signal from the sensor. When the payload is present on the payload transfer surface, the signal indicates the presence of the payload, and when the payload is not present on the payload transfer surface, the signal indicates that the payload transfer surface is empty.
According to some embodiments, the access channel extends across the entire payload surface thereby defining two payload transfer surface sections.
According to some embodiments, each payload transfer surface section comprises a ballast.
According to some embodiments, the sensor is a limit switch or proximity sensor.
According to some embodiments, the communications transceiver is configured to communicate with a programmable logic controller.
According to some embodiments, the apparatus further comprises at least one second sensor associated with the payload transfer surface.
In a second aspect, there is a system for providing smart pick-up and drop-off. The system comprises a payload transfer surface supported by at least one vertical support member and a sensor associated with the payload transfer surface for sensing the presence or absence of a payload on the payload transfer surface. The system further comprises a fleet-management system in communication with the sensor for managing a fleet of self-driving vehicles, and at least one self-driving material-transport vehicle in communication with the fleet-management system. The sensor communicates a signal to the fleet-management system that indicates the presence or absence of the payload and the fleet-management system sends instructions to the vehicle based on the signal.
According to some embodiments, the system further comprises a storage shelf supported by the at least one vertical support member, located above the payload transfer surface.
According to some embodiments the self-driving material-transport vehicle comprises a lift appliance for elevating the payload, and the payload transfer surface comprises an access channel for accommodating the lift appliance.
According to some embodiments, the system comprises at least one second sensor associated with the payload surface.
According to some embodiments, the system further comprises a communications transceiver in communication with the sensor and the second sensor. The sensor and the second sensor are used to generate a signal indicative of the presence and the type of the payload, and the communications transceiver transmits the signal.
In a third aspect, there is a method for providing smart pick-up and drop-off. The method comprises sensing a presence or absence of a payload on a payload transfer surface using a sensor associated with the payload transfer surface. A fleet-management system receives a signal based on the sensed presence or absence of the payload on the payload transfer surface. Instructions are automatically provided to a self-driving material-transport vehicle with the fleet-management system, based on the signal.
According to some embodiments, the method further comprises autonomously driving the vehicle to the payload transfer surface based on the instructions.
According to some embodiments, the signal indicates the presence of the payload on the payload surface. The method further comprises, based on the instructions, autonomously positioning the vehicle under the payload transfer surface. A left appliance on the vehicle is then elevated through an access channel of the payload transfer surface such that the payload is elevated above the payload transfer surface. Then, the vehicle autonomously drives to a first distance from the payload transfer surface and lowers the lift appliance on the vehicle to a travel height. The vehicle then autonomously drives to a destination such that the payload is transported from the payload transfer surface to the destination location.
According to some embodiments, the payload is on the vehicle, and the signal indicates the absence of the payload on the payload transfer surface. The method further comprises autonomously driving the vehicle to a first distance from the payload transfer surface and elevating a lift appliance on the vehicle such that the payload is elevated to a height above the payload transfer surface. The vehicle then autonomously drives to the payload transfer surface such that the lift appliance enters an access channel of the payload transfer surface. Then, the lift appliance on the vehicle is lowered such that the payload is placed on the payload transfer surface, and the vehicle autonomously drives away from the payload transfer surface.
A preferred embodiment of the present invention will now be described in detail with reference to the drawings, in which:
Referring to
The system may also include communication networking equipment 114 such as wireless and wired networking equipment, and computing equipment 116 such as a server or computer terminal. According to some embodiments, a programmable logic controller (“PLC”) 118 may be included, for example, as a part of the industrial process equipment within a facility that may be controlled with an industrial control system.
The networking equipment 114 generally enables communications between the vehicle 110, the smart pick-up-and-drop-off shelves 112a and 112b (collectively referred to as the smart pick-up-and-drop-off shelves 112) and the computer 116 and the computer server 118 may be in communication with the communications network, via a wired connection or wirelessly via a wireless access point that is generally part of the networking equipment 114.
According to some embodiments, the vehicle 110 may be one of a plurality of vehicles, for example, a fleet of vehicles, and the fleet of vehicles may be in communication with a fleet-management system running on the computer 116.
According to some embodiments, the computer 116 may be a part of an industrial control system. For example, the computer 116 may be used, in part, as a SCADA system that provides an interface for a human user to monitor and control field instruments, PLCs (e.g. PLC 118), and other industrial control equipment in order to monitor and control an industrial process. According to some embodiments, the computer 116 may be a part of a fleet-management system that communicates with a fleet of vehicles (including the vehicle 110), for example, in order to provide information to or receive information from the vehicles, including the distribution of missions to the vehicles. According to some embodiments, more than one computer 116 may be used to provide any or all of an industrial control system and a fleet-management system.
The smart pick-up-and-drop-off shelves 112 generally include a sensor for generating an activation signal according to conditions sensed on or in proximity to a payload transfer surface 120 (individually labelled as payload transfer surfaces 120a and 120b). In the example shown in
According to some embodiments, a smart pick-up-and-drop-off shelving unit 112 may include a communications transceiver for communicating with the PLC 118 and/or the networking equipment 114. For example, a signal may be sent from the smart pick-up-and-drop-off shelving unit 112 in response to a change in the presence of a payload, which may be communicated to any or all of an industrial control system and a fleet-management system running on the computer 116.
Referring to
One or more storage shelves may be attached to the vertical members 210. In the example shown, two shelves 212a and 212b (collectively referred to as the shelves 212) are attached to the vertical members 210. Any number of shelves 212 may be attached to the vertical support members.
A payload transfer surface 214 is supported by the vertical members 210, and is located below the lowest storage shelf 212a. According to some embodiments, the inclusion of multiple storage shelves 212 and a payload transfer surface 214 allows for the efficient use of space within an industrial facility, by making efficient use of the vertical space for storage above the payload transfer surface 214, thereby making floor space available that would otherwise be occupied by a pick-up-and-drop-off stand within the shelves 212.
In the example of
According to some embodiments, the payload transfer surface sections 218 may comprise a solid structure similar to a shelf. According to some embodiments, such as is shown in
As used herein, the term “payload transfer surface” refers to the generally horizontal surface defined by the payload transfer surface sections and the access channel 216, upon which a payload can be placed. According to some embodiments, the payload transfer surface 214 may support a payload by using the horizontal member 220a as a payload-bearing member, in concert with the opposite payload-bearing member, not labelled, that comprises the payload transfer surface section 218a. Thus, even though the entire horizontal plane is referred to as the payload transfer surface 214, according to some embodiments, the payload may be supported by two or more horizontal members.
According to some embodiments, the horizontal member 220b may be used a ballast, which may be placed on the other side of the vertical support members 210b and 210d as the payload-bearing member 220a, such that horizontal members 220c and 220d are used as cantilevers.
The smart pick-up-and-drop-off shelving unit 200 includes a sensor or switch 222 such as a proximity sensor or limit switch. The sensor or switch 222 detects the presence or absence of a payload on the payload transfer surface 214. According to some embodiments, the sensor or switch 222 may detect any or all of a change in the presence or absence of the payload and the current state in the presence or absence of the payload. According to some embodiments, the smart pick-up-and-drop-off shelving unit 200 may include a communications transceiver (not shown) for sending a signal based on the sensor or switch 222. According to some embodiments, there may be more than one sensor or switch 222 in order to provide redundancy or to detect different form factors of payload.
The smart pick-up-and-drop-off shelving unit 200 enables an autonomous self-driving material-transport vehicle 224 to pick up and/or drop off a payload on the payload transfer surface 214. According to some embodiments, the vehicle 224 is equipped with a lift appliance 226. The lift appliance 226 is used to carry a payload on the vehicle 224 while the vehicle 224 is travelling. The lift appliance 226 may be raised or lowered so that the lift appliance 226 and/or a payload are elevated above the height of the payload transfer surface 214. According to some embodiments, either or both of the lift appliance 226 and the access channel 216 may be selected in order to have complementary dimensions. In other words, the width of the lift appliance 226 fits within the access channel 216 when the lift appliance 226 is in an elevated position.
In the case of a pick-up operation, a payload has previously been placed on the payload transfer surface 214. According to the embodiments of
In order to perform the pick-up operation, the vehicle 224 drives under the payload transfer surface 214 with the lift appliance 226 lowered so that the lift appliance 226 is positioned under the access channel 216. Once positioned, the lift appliance 226 is raised through the access channel 216 until it engages with the payload and elevated the payload above the payload transfer surface 214 (i.e. off of the payload-bearing members).
Once the lift appliance 226 has elevated the payload off of the payload transfer surface 214, the vehicle 224 drives out of the access channel 216. According to some embodiments, when the vehicle 224 has travelled to a payload-lift point 228, as marked by a cross in
In order to perform a drop-off operation, the vehicle drives with a payload on the lift appliance 226 and the lift appliance 226 in a lowered position for transporting the payload from its original location. The drop-off operation is similar to the pick-up operation, but with the order of the steps reversed. When the vehicle 226 is at the payload-lift point 228, the lift is raised so that the payload is elevated above the payload transfer surface 214. With the lift raised, the vehicle 226 drives into the access channel 216. Once the vehicle 226 is positioned within the access channel 216, the lift appliance is lowered, and the payload is placed on the payload transfer surface 214.
According to some embodiments, the payload-lift point 228 may be defined based on a particular distance from the smart pick-up-and-drop-off shelving unit 200. According to some embodiments, the payload-lift point 228 may be a particular point specified in the vehicle's mission, and defined relative to an electronic map of the facility. According to some embodiments, the vehicle 26 may stop at the payload-lift point 228 while the lift appliance 226 is being raised or lowered. According to some embodiments, the lift appliance 226 may be raised or lowered while the vehicle 226 is moving in general proximity of the payload-lift point 228.
Referring to
The drive system 302 includes a motor and/or brakes connected to drive wheels 310a and 310b for driving the vehicle 300. According to some embodiments, the motor may be an electric motor, combustion engine, or a combination/hybrid thereof. Depending on the particular embodiment, the drive system 302 may also include control interfaces that can be used for controlling the drive system 302. For example, the drive system 302 may be controlled to drive the drive wheel 310a at a different speed than the drive wheel 310b in order to turn the vehicle 300. Different embodiments may use different numbers of drive wheels, such as two, three, four, etc.
According to some embodiments, additional wheels 312 may be included (as shown in
The vehicle control system 304 comprises a processor 314, a memory 316, a computer-readable non-transitory medium 318, and a communications transceiver 120, such as a wireless transceiver for communicating with a wireless communications network (e.g. using an IEEE 802.11 protocol or similar, also known as “WiFi”).
One or more sensors 306, 308a, and 308b may be included in the vehicle 300. For example, according to some embodiments, the sensor 306 may be a LiDAR device (or other optical/laser, sonar, or radar range-finding sensor). The sensors 308a and 308b may be optical sensors, such as video cameras. According to some embodiments, the sensors 308a and 308b may be optical sensors arranged as a pair in order to provide three-dimensional (e.g. binocular or RGB-D) imaging.
The vehicle control system 304 uses the medium 318 to store computer programs that are executable by the processor 314 (e.g. using the memory 316) so that the vehicle control system 304 can provide automated or autonomous operation to the vehicle 300. Furthermore, the vehicle control system 304 may also store an electronic map that represents the known environment of the vehicle 300, such as a manufacturing facility, in the media 318.
For example, the vehicle control system 304 may plan a path for the vehicle 300 based on a known destination location and the known location of the vehicle. Based on the planned path, the vehicle control system 304 may control the drive system 302 in order to drive the vehicle 300 along the planned path. As the vehicle 300 is driven along the planned path, the sensors 306, and/or 308a and 308b may update the vehicle control system 304 with new images of the vehicle's environment, thereby tracking the vehicle's progress along the planned path and updating the vehicle's location. In other embodiments, the vehicle control system 304 may rely in part or in whole on a user-defined path.
Since the vehicle control system 304 receives updated images of the vehicle's environment, and since the vehicle control system 304 is able to autonomously plan the vehicle's path and control the drive system 302, the vehicle control system 304 is able to determine when there is an obstacle in the vehicle's path, plan a new path around the obstacle, and then drive the vehicle 300 around the obstacle according to the new path.
According to some embodiments, the vehicle control system 304 may additionally provide a computer server. For example, the processor 314, the memory 316, the medium 318, and the communications transceiver 120 may be configured in order to provide a web server (e.g. using HTTP) which may be made available on a local-area network (LAN), wide-area network (WAN, or over the Internet. The server may be configured to provide components of the systems and methods described herein, such as for providing vehicle information to a monitoring device.
A lift appliance 322 may be attached to the vehicle 300, and may be in communication with the vehicle control system 304. The lift appliance generally includes a lift or elevator mechanism, such as a mechanism comprising any or all of a scissor lift, lead-screw, rack and pinion, telescopic lift, etc., and a linear actuator such as a hydraulic cylinder, pneumatic cylinder, motor, etc. In some cases, the lift or elevator mechanism may combine extension and actuation features, such as a helical band actuator.
The lift appliance 322 may communicate with the vehicle control system 304 so that the lift appliance 322 can be operated (e.g. raised or lowered) in coordination with other movements of the vehicle 300. For example, when the vehicle 300 travels to a particular location and stops at the location, the lift or elevator mechanism of the lift appliance 322 may be automatically raised or lowered.
The lift appliance 322 may include a payload platform, such as at the top of the lift or elevator mechanism. A payload platform is generally used to transport a payload, such as a pallet, a container, or another type of item. According to some embodiments, the size and/or shape of the payload platform may be selected in order to complement (e.g. engage with) a pick-up and drop-off stand, for example in relation to the access channel 218.
Referring to
The method 400 begins at step 410 when the presence or absence of a payload is sensed on the payload transfer surface. Generally, the same sensor or switch may detect both the presence or absence of the payload. For the sake of explanation, the method 400 is described in respect of sensing the presence of a payload on the payload transfer surface. As such, any or all of the steps of method 400 in
According to some embodiments, a sensor or switch may detect the presence or absence of the payload, and/or a chance in the presence or absence of the payload. According to embodiments, the switch may be polled (e.g. via the communications transceiver) in order to determine the current state of the sensor or switch. For example, any or all of a fleet-management system, industrial control system, and PLC may poll (e.g. read from) the sensor or switch. According to some embodiments, the state of the sensor or switch, indicating the presence or absence of the payload, may be transmitted to any or all of a fleet-management system, industrial control system, and PLC.
At step 412, a signal is transmitted based on the state of the sensor or switch (i.e. based on the presence of the payload). According to some embodiments, the signal may be transmitted to any or all of the vehicle, fleet-management system, industrial control system, and PLC.
At step 414, instructions are provided to the vehicle based on the signal. According to some embodiments, the instructions may be in the form of a mission to be executed by the vehicle. According to some embodiments, the instructions may be provided to (and/or generated by) any or all of the vehicle, fleet-management system, industrial control system, and PLC. Generally, the instructions include instructions for the vehicle to pick up the payload from the payload transfer surface, and include, for example, the location of the payload transfer surface.
At step 416, the vehicle autonomously drives to the payload transfer surface. At step 418, the vehicle autonomously positions itself under the payload transfer surface. According to some embodiments, the vehicle autonomously positions itself so that the lift appliance is aligned with the access channel in the payload transfer surface.
At step 420, the lift appliance is elevated through the access channel so that the payload is lifted off the payload transfer surface.
At step 422, the vehicle drives away from the payload transfer surface, with the payload carried by the lift appliance, and the lift appliance in a raised position. When the vehicle is at or in proximity of a payload-lift point, the lift appliance is lowered to a transport position. According to some embodiments, the payload-lift point may be determined based on a distance from the payload transfer surface at which the payload is clear from hitting the payload transfer surface when the lift appliance lowers the payload. According to some embodiments, the vehicle may stop at the payload-lift point while the lift appliance is lowered. According to some embodiments, the vehicle may continue to drive while the lift appliance is lowered.
At step 424, the vehicle autonomously drives to the destination location associated with the payload (e.g. where the payload is to be delivered). According to some embodiments, the destination location may be provided along with the instructions during step 414, or at another time.
Referring to
The method 500 begins at step 510 when the presence or absence of a payload is sensed on the payload transfer surface. Generally, the same sensor or switch may detect both the presence or absence of the payload. For the sake of explanation, the method 500 is described in respect of sensing the absence of a payload on the payload transfer surface.
At step 512, a signal is transmitted based on the state of the sensor or switch (i.e. based on the absence of the payload). According to some embodiments, the signal may be transmitted to any or all of the vehicle, fleet-management system, industrial control system, and PLC.
At step 514, instructions are provided to the vehicle based on the signal. According to some embodiments, the instructions may be in the form of a mission to be executed by the vehicle. According to some embodiments, the instructions may be provided to (and/or generated by) any or all of the vehicle, fleet-management system, industrial control system, and PLC. Generally, the instructions include instructions for the vehicle to drop off the payload from the payload's original location on to the payload transfer surface, and include, for example, the location of the payload transfer surface.
At step 516, the vehicle autonomously drives towards the payload transfer surface. According to some embodiments, when the vehicle is at or around a payload-lift point, the payload is elevated to a height above the payload transfer surface by raising the lift mechanism.
At step 518, the vehicle autonomously drives under the payload surface. According to some embodiments, the vehicle autonomously positions itself so that the raised lift mechanism aligned for entry into the access channel.
At step 520, the lift appliance is lowered through the access channel so that the payload is left on the payload transfer surface.
At step 522, the vehicle autonomously drives away from the payload transfer surface.
The present invention has been described here by way of example only. Various modification and variations may be made to these exemplary embodiments without departing from the spirit and scope of the invention, which is limited only by the appended claims.
This application claims priority from U.S. Provisional Patent Application No. 62/552,725, filed 31 Aug. 2017, and titled “APPARATUS, SYSTEMS, AND METHODS FOR PAYLOAD PICK-UP AND DROP-FF WITH A SELF-DRIVING MATERIAL-TRANSPORT VEHICLE”, the contents of which are incorporated herein by reference for all purposes.
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