Patent Application
20240308825
The present inventive concepts relate to the field of systems and methods in the field of autonomous and/or robotic vehicles. Aspects of the inventive concepts are applicable to any mobile robotics application involving manipulation. More specifically, the present inventive concepts relate to systems and methods of passively actuated sensor deployment in an autonomous mobile robot (AMR).
In autonomous mobile robots (AMRs), there is a need to be able to scan under the forks to detect objects during the pick and place sequences. It is important for AMRs to have awareness of the environment during travel and payload operations. Sensors may be obstructed by the AMR and/or payload and may be damaged by the forks when the forks are lowered to the floor.
There is a need to be able to scan under the forks to detect objects during the pick and place sequences. In various embodiments, to the sensor can be located so that in can detect objects below the forks and not be obstructed by the truck and/or payload. In various embodiments, the sensor is located below the forks. In various embodiments, the sensor is configured to retract back into the mast when the forks are lowered to protect the sensor when the forks are lowered to the floor. While an active deployment of the sensor is possible, a passive mechanism for deploying the sensor could be more cost effective and provide less complexity. In various embodiments, the sensor can take the form of one or more scanners.
In accordance with one aspect of the inventive concepts, provided is an autonomous mobile robot (AMR), comprising: a pair of forks coupled to a carriage that is height adjustable within a mast; an object sensor coupled to the carriage and passively movable between a first position above the forks when the forks are lowered and a second position below the forks when the forks are raised, wherein the object sensor is configured to detect objects under the forks when the forks are raised.
In various embodiments, the robot further comprises a deployment hard stop defining an upper limit of movement of the carriage relative to the mast and a retracting hard stop defining a lower limit of movement of the carriage relative to the mast.
In various embodiments, the robot further comprises a position feedback sensor configured to determine when the carriage is at its upper limit of movement when the feedback sensor engages the deployment hard stop, wherein the sensor is deployed when the position feedback sensor determines that the carriage is at its upper limit of movement.
In various embodiments, the position feedback sensor is configured to determine when the carriage is at its lower limit of movement when the feedback sensor engages the retracting hard stop, wherein the sensor is retracted into the mast when the position feedback sensor determines that the carriage is at its lower limit of movement.
In various embodiments, the object sensor is coupled to the carriage by a slide having a defined range of movement relative to the carriage.
In various embodiments, the slide is at a top of its range of motion relative to the carriage when the carriage is in contact with the retracting hard stop.
In various embodiments, the slide is at a bottom of its range of motion relative to the carriage when the carriage is in contact with the deployment hard stop.
In various embodiments, the robot further comprises a magnet at the deployment hard stop configured to prevent or dampen movement of the object sensor during robot and/or fork operation.
In various embodiments, the object sensor is or include a LiDAR scanner and/or camera.
In various embodiments, when the object sensor is in the first position, the object sensor is retracted in the mast.
In various embodiments, the pair of forks comprises a protection plate configured to protect the object sensor when the pair of forks are lowered.
In various embodiments, the robot further comprises a sensor bracket, the object sensor being positioned on the sensor bracket.
In various embodiments, the sensor bracket comprises a flange configured to engage a retracting hard stop defining a lower limit of movement of the carriage relative to the mast.
In various embodiments, the robot further comprises first and second cam roller slides extending along the height of the robot and at least one cam roller positioned in the cam roller slides, wherein the cam rollers being coupled to the sensor bracket.
In various embodiments, the robot further comprises a deployment hard stop defining an upper limit of movement of the carriage relative to the mast; a retracting hard stop defining a lower limit of movement of the carriage relative to the mast; a position feedback sensor configured to determine when the carriage is at its upper limit of movement when the feedback sensor engages the deployment hard stop; a slide coupled to the carriage having a defined range of movement relative to the carriage; a sensor bracket, wherein the object sensor being positioned on the sensor bracket.
In various embodiments, the robot further comprises a sensor mount configured to couple the sensor bracket to the slide.
In various embodiments, the robot further comprises first and second cam roller slides extending along the height of the robot and at least one cam roller positioned in the cam roller slides, wherein the cam rollers being coupled to the sensor bracket.
In accordance with one aspect of the inventive concepts, provided is a passively actuated sensor kit for use with a robotic vehicle having a pair of forks coupled to a carriage that is height adjustable within a mast, the kit comprising: an object sensor configured to couple to the carriage and passively move between a first position above the forks when the forks are lowered and a second position below the forks when the forks are raised, wherein the object sensor is configured to detect objects under the forks when the forks are raised; a deployment hard stop defining an upper limit of movement of the carriage relative to the mast and a retracting hard stop defining a lower limit of movement of the carriage relative to the mast; and a position feedback sensor configured to determine when the carriage is at an upper limit of movement when the feedback sensor engages the deployment hard stop, wherein the sensor is deployed when the position feedback sensor determines that the carriage is at its upper limit of movement.
In various embodiments, the kit further comprises a slide, wherein the object sensor is couplable to the carriage by the slide to have a defined range of movement relative to the carriage.
In various embodiments, the slide is at a top of its range of motion relative to the carriage when the carriage is in contact with the retracting hard stop.
In various embodiments, the slide is at a bottom of its range of motion relative to the carriage when the carriage is in contact with the deployment hard stop.
In various embodiments, the kit further comprises a magnet at the deployment hard stop configured to prevent or dampen movement of the object sensor during robot and/or fork operation.
In various embodiments, the object sensor is or includes a LiDAR scanner and/or camera.
In various embodiments, when the object sensor is in the first position, the object sensor is configured to retract into the mast.
In various embodiments, the kit further comprises a protection plate configured to couple to the pair of forks to protect the object sensor when the pair of forks is lowered.
In various embodiments, the kit further comprises a sensor bracket, the object sensor being positioned on the sensor bracket.
In various embodiments, the sensor bracket comprises a flange configured to engage a retracting hard stop defining a lower limit of movement of the carriage relative to the mast.
In various embodiments, the kit further comprises first and second cam roller slides extending along the height of the robot and at least one cam roller positioned in the cam roller slides, wherein the cam rollers being coupled to the sensor bracket.
In accordance with one aspect of the inventive concepts, provided is a robotic vehicle having a pair of forks coupled to a carriage that is height adjustable within a mast and including a passively actuated sensor system, comprising: n object sensor configured to couple to the carriage and passively move between a first position above the forks when the forks are lowered and a second position below the forks when the forks are raised, wherein the object sensor is configured to detect objects under the forks when the forks are raised; a deployment hard stop defining an upper limit of movement of the carriage relative to the mast; a retracting hard stop defining a lower limit of movement of the carriage relative to the mast; a position feedback sensor configured to determine when the carriage is at its upper limit of movement when the feedback sensor engages the deployment hard stop; a slide coupled to the carriage having a defined range of movement relative to the carriage; and a sensor bracket coupled to the slide, wherein the object sensor is coupled to the sensor bracket.
In various embodiments, the robot further comprises a sensor mount configured to couple the sensor bracket to the slide.
In various embodiments, the robot further comprises first and second cam roller slides extending along the height of the robot and at least one cam roller positioned in the cam roller slides, wherein the cam rollers being coupled to the sensor bracket.
The present invention will become more apparent in view of the attached drawings and accompanying detailed description. The embodiments depicted therein are provided by way of example, not by way of limitation, wherein like reference numerals refer to the same or similar elements. In the drawings:
It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are used to distinguish one element from another, but not to imply a required sequence of elements. For example, a first element can be termed a second element, and, similarly, a second element can be termed a first element, without departing from the scope of the present invention. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
It will be understood that when an element is referred to as being “on” or “connected” or “coupled” to another element, it can be directly on or connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly on” or “directly connected” or “directly coupled” to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.).
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.
In the context of the inventive concepts, and unless otherwise explicitly indicated, a “real-time” action is one that occurs while the AMR is in-service and performing normal operations. This is typically in immediate response to new sensor data or triggered by some other event. The output of an operation performed in real-time will take effect upon the system so as to minimize any latency.
According to the present inventive concepts, a robotic vehicle includes a passively actuated sensor system. In some embodiments, the passively actuated sensor system includes a sensor or scanner located below the forks of the mobile robot in order to detect objects and not be obstructed by the truck and/or payload. The sensor is retractable back into the mast when the forks are lowered in order to protect the sensor when the forks are lowered to the floor. The system passively deploys/retracts a sensor when a certain fork height is achieved. A passive mechanism for deploying the sensor saves money and reduces complexity. The passively actuated sensor system may be implemented with any automated lift system requiring sensing toward the forks/payload. The passively actuated sensor system can be in communication with a drive and/or navigation system of the robotic vehicle. The passively actuated sensor system can also be in communication with a load engagement system that controls the raising and lowering of the forks, e.g., top stop or suspend operation of the forks in response to detection of an object.
In some embodiments, the passively actuated sensor system can take the form of a kit configured as an optional augmentation to a mobile robot, e.g., AMR. In some embodiments, the system can take the form of a robot vehicle including a passively actuated sensor system.
In various embodiments, the sensor can be or include a camera, a stereo camera, and/or a laser range scanner, such as a LiDAR sensor (Light Detection and Ranging sensor). The sensor can be a 2D sensor or a 3D sensor, or a combination thereof.
In this embodiment, the AMR 100 includes a payload area 102 configured to transport a pallet 104 loaded with goods 106. The AMR 100 can comprise a battery area 112 for holding one or more batteries. In various embodiments, the one or more batteries can be configured for charging via a charging interface 113. The AMR 100 can also include a main housing 115 within which various control elements and subsystems can be disposed, including those that enable the AMR to navigate from place to place.
The AMR 100 may include a plurality of sensors 150 that provide various forms of sensor data that enable the AMR to safely navigate throughout an environment, engage with objects to be transported, and avoid obstructions. In various embodiments, the sensor data from one or more of the sensors 150 can be used for navigation, including avoidance of detected objects, obstructions, hazards, humans, other robotic vehicles, and/or congestion during navigation. The sensors 150 can include one or more cameras, stereo cameras 152, radars, and/or laser imaging, detection, and ranging (LiDAR) scanners 154. One or more of the sensors 150 can form part of a 2D or 3D high-resolution imaging system.
In some embodiments, such as the one shown in
As seen in
When retracted, the sensor 200 rests inside the mast above the forks 110a,b, as seen in
To retract the sensor 200, the forks 110a,b are lowered until the sensor 200 makes contact with the retracting hard stop 260. The forks 110a,b will continue to move downward causing the deployment hard stop 230 to no longer make contact and the position feedback sensor 250 will no longer be active. The forks 110a,b can be lowered to the ground while the sensor 200 remains stationary inside the mast.
The sensor 200 provides data to improve the robotic vehicle's 100 awareness of the environment during travel and payload operations. According to various embodiments, the passively actuated sensor system provides a view behind the forks 110a,b when the truck 100 is traveling in a forks-forward direction in order to detect potential obstacles when the forks 110a,b are at payload carry height. According to various embodiments, the system allows the sensor 200 to scan for the front of a shelf/table (also known as apron detection) to allow the robot 100 to closely approach a payload pickup/drop location and getting the outriggers very close to the table structure for load transactions. According to various embodiments, the system allows the sensor 200 to scan for the surface of a shelf/table (also known as free space checking) to assure the area is free of obstacles or other payloads in placement and determine the best location to place the payload.
According to various embodiments, the sensor 200 is retracted into the mast of the AMR 100 when the forks 110a,b are lowered to the floor. The sensor 200 remains in the retracted position until the forks 110a,b have reached a predetermined height, which is sensed by the position feedback sensor 250, and the deployment hard stop 230 is engaged. The hard stop 230 defines a physical termination to the path of the carriage 220. At which point, the sensor 200 moves upward and downward with the forks 110a,b until the sensor 200 makes contact with the retracting hard stop 260. When the sensor 200 makes contact with the retracting hard stop 260, the sensor 200 is retracted into the mast of the AMR 100.
Each cam roller slide 300 includes three adjustable attachment points 310, as seen in
The sensor 200 is positioned on a sensor block 290. The sensor block 290 is mounted on a sensor bracket 340. The cam rollers 320 are coupled to the sensor bracket 340.
The sensor block 290 is coupled to a sensor mount 350 which is coupled to the slide 210 in
The cam roller slides 300 are coupled to the AMR 100 by brackets 330.
The brackets 330 are slotted to prevent binding, as seen in
As seen in
In some embodiments, there is approximately 1.9 inches of clearance from the bottom of the sensor bracket 340 and the floor; however, the present inventive concepts are not limited thereto. The front of the sensor 200 is protected by the protection plate 400 at this height, as seen in
As seen in
As seen in
As seen in
The roller assembly 600 further includes a position sensor flag 550 and retracting hard stop flags 565. As seen in
The position sensor 520 of the rail assembly 500 senses the position sensor flag 550 to verify a fully deployed position, as seen in
In a fully deployed position, as seen in
The position sensor 520 confirms that the sensor 200 is fully deployed at a repeatable location relative to the forks 110a,b. The sensor 200 will move upward and downward with the forks 110a,b as long as the retracting hard stop flags 565 do not make contact with the retracting hard stops 560, as seen in
To retract the sensor 200, the forks 110a,b are lowered until the retracting hard stop flags 565 make contact with the retracting hard stops 560. At which time, the magnet 570 is released and the sensor 200 slides into its protected position as the forks 110a,b continue to lower to the ground, as seen in
The forks 110a,b can be lowered to the ground while the sensor 200 remains stationary inside the mast. The front of the sensor 200 is protected by the protection plate 400 at this height.
While the inventive concepts have been described as deploying a sensor in a vertical linear motion, the concepts can be deployed in other manners. For example, the sensor can be deployed using rotational or linear motion, or a combination thereof.
While the inventive concepts have been described within the context of robotic vehicles and AMR fork lifts, the concepts can be deployed in other systems and contexts. That is, in its simplest form, the inventive concepts include passively deploying a sensor to see under an object when that object is raised, then retracting the sensor to a protected position, when the object is lowered towards or to the ground. This could include anything that is raised and lowered (forks, platforms, elevators, etc.). As examples, in some embodiments the inventive concepts can be implemented with cranes, elevators, man-lifts, etc.).
While the foregoing has described what are considered to be the best mode and/or other preferred embodiments, it is understood that various modifications may be made therein and that the invention or inventions may be implemented in various forms and embodiments, and that they may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim that which is literally described and all equivalents thereto, including all modifications and variations that fall within the scope of each claim.
The present application claims priority to U.S. Provisional Appl. No. 63/324,190 filed on Mar. 28, 2022, entitled PASSIVELY ACTUATED SENSOR DEPLOYMENT, which is incorporated herein by reference in its entirety. The present application may be related to U.S. Provisional Appl. No. 63/430,184 filed on Dec. 5, 2022, entitled Just in Time Destination Definition and Route Planning; U.S. Provisional Appl. No. 63/430,190 filed on Dec. 5, 2022, entitled Configuring a System that Handles Uncertainty with Human and Logic Collaboration in a Material Flow Automation Solution; U.S. Provisional Appl. No. 63/430,182 filed on Dec. 5, 2022, entitled Composable Patterns of Material Flow Logic for the Automation of Movement; U.S. Provisional Appl. No. 63/430,174 filed on Dec. 5, 2022, entitled Process Centric User Configurable Step Framework for Composing Material Flow Automation; U.S. Provisional Appl. 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| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US23/16617 | 3/28/2023 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63324190 | Mar 2022 | US |
