WO2017120079A1

WO2017120079A1 - Autonomous box transport system

Info

Publication number: WO2017120079A1
Application number: PCT/US2016/068929
Authority: WO
Inventors: David Wayne RUSSELL
Original assignee: Russell David Wayne
Priority date: 2016-01-05
Filing date: 2016-12-28
Publication date: 2017-07-13

Abstract

This disclosure describes a comprehensive autonomous box transport system for point of delivery and order fulfillment services.

Description

SPECIFICATION TITLE OF INVENTION Autonomous Box Transport System

CROSS-REFERENCE TO RELATED APPLICATIONS US 62/275,059 1/5/2016

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM

LISTING COMPACT DISK APPENDIX

Not Applicable

FIELD

[0001] This invention relates generally to the field of package transport, and more specifically to the method and system of an autonomous box transport vehicle.

BACKGROUND

[0002] While robotic aid vehicles are in use to help transport loose goods for order fulfillment services, once the goods are packaged into cardboard boxes for shipping the problems and solutions are very similar for both order fulfillment and point of shipping operations. In a normal transaction boxed goods are stacked at a loading dock waiting for transport vehicles. Humans then load the truck and dispatch it to a shipping company. Once the goods are sorted to their destinations at the shipping depot, some may be re-loaded onto other trucks or they may be loaded into air freight containers, and eventually back onto trucks. The goods are then resorted at the delivery depot into assigned delivery trucks which deliver the goods to the actual destination address. Much of this human effort can be reduced by employing Autonomous Box Transport vehicles, often referred to as "box trolls" or ABTs.

BRIEF DESCRIPTION OF THE INVENTION

[0003] The Automated Box Transport (ABT) vehicle is comprised of three main components: 1) a guidance system that allows for autonomous operation such as but not limited to a Safe Temporal Vector Integration Engine (STeVIE), 2) a grasping mechanism for random sized boxes, and 3) a cooperative trajectory/path planning system to efficiently coordinate a large number of ABTs. The data structure comprised of the output of trajectory planning system which is executed by the ABT will hereafter be referred to as a trackpath.

[0004] In use, the planning system is provided a list of packages arriving into the depot. These could be directly from the fulfillment center or by truck, rail car, container, etc. They may be randomly distributed in the load or arranged in a pre-determined order. If for example the delivery vehicle is equipped with Autonomous Shelving Units (ASU), the planning system has a direct communications link and list of all packages including their exact location within the transport carrier and can begin deployment processing before the shipment even arrives. If not, then packages are unloaded and made available on the shipping floor or by using conveyors to the ABT fleet.

[0005] In the case where the delivery vehicle is equipped with autonomous shelving, offloading begins as soon as the vehicle docks with the loading platform. Each movement of the ABT from its current location to a given shelving unit is computed by the trajectory planning system such as but not limited to a 4D Autorouter algorithm given the order and position of each box in the vehicle and a 3D model of the vehicle shelving system, warehouse, and warehouse shelving system. In another embodiment if the initial delivery truck were packed by an automated box packing system, the current location of every box in the truck could also be known, which information could be forwarded to the planning system such that the unload process could also be planned and automated before the truck arrived.

[0006] The resulting trackpath is downloaded to the ABT along with a synchronized time of execution. The trackpath execution unit within the ABT executes the trackpath, traversing the depot, entering the vehicle, positioning above the box, checking its labeling, grasping and lifting the box, then transferring the box either directly to another loading platform or to another autonomous shelving unit. In concert, the source and destination ASUs are directed by synchronized trackpath data structures to cycle the desired box to the ABT loading platform. Once off-loading is complete the transport vehicle is released or readied to be reloaded and the ABTs return to other duties or go into charging mode.

[0007] In another embodiment in certain circumstances the ABT may simply hold the box for some period of time, acting as a storage unit, until its destination route or platform is readied for it to deliver the package.

[0008] A fully deployed transport chain containing ABTs for movement and ASUs for storage can implement a full transport system such that no human labor is required from the time a customer drops a package at a delivery location or kiosk until that package is picked up by its addressee.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different figures indicates similar or identical components or features.

[0010] The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. The illustrative embodiments, however, as well as a preferred mode of use, further objectives, and features thereof will best be understood by reference to the following detailed description of illustrative embodiments of the present disclosure when read in conjunction with the accompanying drawings, wherein:

[0011] FIG. 1 depicts a view of an exemplar ABT.

[0012] FIG. 2 depicts the underside of the ABT.

[0013] FIG. 3 depicts an example of a guidance tile.

DETAILED DESCRIPTION OF INVENTION [0014] The following detailed description illustrates embodiments of the invention by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the disclosure, describes several embodiments, adaptations, variations,

alternatives, and use of the disclosure, including what is currently believed to be the best mode of carrying out the disclosure. The disclosure is described as applied to an exemplary embodiment namely, systems and methods of autonomous box transport. However, it is contemplated that this disclosure has general application to vehicle management systems in industrial, commercial, military, and residential applications.

[0015] As used herein, an element or step recited in the singular and preceded with the word "a" or "an" should be understood as not excluding plural elements or steps, unless such exclusion is explicitly recited. Furthermore, references to "one embodiment" of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

[0016] FIG. 1 depicts a perspective view of one embodiment of an ABT. The main body of the vehicle 100 contains the control system and batteries or other power unit. In this embodiment the main body is rectangular but the dimensions of the ABT can vary widely depending on the range of boxes it is expected to grasp and the space within which it is expected to maneuver. In another embodiment it may be circular or some other aspect ratio.

[0017] In one embodiment the main body can be raised or lowered via mechanical lift mechanisms 110 attached to the wheels 120. In this embodiment four wheels are implemented, but in other embodiments more or fewer wheels, tracks, fork lifts, or rail trucks could be implemented without altering the intent of this invention. In this case without limitation two of the lift arms are powered and two are not, and two of the wheels are powered and the other two are not.

[0018] The autonomous control system is primarily concerned with interpreting the trackpath such that it specifies movement from where it is now to where it should be to accurately follow the trackpath loaded from the planning system. To do this, it has to know its current location with an acceptable degree of accuracy. In order to provide for scanning of the package, obstacle avoidance, and current location determination, a combination of scanning cameras or other sensors such as but not limited to 3D, single lens 3D, multiple lens 3D, LIDAR, RADAR, or acoustic or capacitive proximity sensors 130 is implemented on the ABT. The ABT can travel in any direction depending on the implementation.

[0019] In this embodiment two single lens 3D cameras are implemented, one looking down and the other scanning forward. In other embodiments different sensors for each action could be implemented or multiple sensors. The sensors may be gimbal mounted, moveable, or fixed.

[0020] In one embodiment the grasping mechanism 140 is attached to the undercarriage of the main body, which positions itself in the proper orientation and height to mate with the package 150. A wide size of boxes can be accommodated by one grasping mechanism but to handle an even wider array of sizes the ABTs can be sized appropriately from very small to very large. In this embodiment a Large, Medium, and Small ABT fleet is matched with L, M, and S automated storage units in the warehouse.

[0021] In other embodiments the randomly sized boxes could be placed within standardized sized containers such as without limitation plastic bins for transport such that the range of boxes is minimized but the complexity of the transport mechanism is increased.

[0022] In order to accurately determine its present location anywhere within the facility, in this embodiment a set of guidance tiles 160 are laid down on the floor of the facility. In other embodiments other internal and external positioning sensors could be implemented both in the warehouse and within the platform such as but not limited to motion capture cameras, beacons, or Enhanced GPS.

[0023] In other embodiments the known locations of other vehicles, landmarks, beacons, or information detectable by sensors within the platform may contribute to its location, obstacle avoidance, and scene analysis functions.

[0024] In Figure 2, the undercarriage of the ABT is depicted above the target package 200. When the ABT approaches the box the first step is for the imaging system to measure the box and read the label to ensure that the information about the box already loaded into the trackpath data structure is valid. This allows the ABT to alter orientation if necessary and position itself above the package. The main body and grasping mechanism is then lowered to contact the top of the package.

[0025] In one embodiment the grasping mechanism is comprised of two smaller side rails 220 and two segmented long rails 210. Upon contact with the top of the box the short rails 220 traverse inward until they contact and center the box. A series of small protrusions on the surface create micro-indentations in the cardboard for grip strength. Knowing the location of the small side rails the control system can then engage only the segments of the long rail that will pass between them, providing secure adhesion on four sides.

[0026] The lifting mechanisms in the legs then elevate the main body and the package by a few inches. Strain gauges in the control system determine whether the box has been lifted. In some cases a pressure plate in the bottom of the control system may add a downward force to the box to keep it engaged with the lift mechanism if the box is very light.

[0027] In other embodiments the grasping mechanism itself may be lowered from the chassis or a U-Shaped carriage might grasp the box from around the sides. One skilled in the art would recognize that such reconfigurations of the grasping mechanism itself would not alter the invention overall.

[0028] Figure 3 depicts a guide tile 300. In order to determine its exact location, guide tiles may be installed on the floor of the facility. In this embodiment each tile contains concentric circles in red coloration 310, horizontal lines in green coloration 320, and vertical lines in blue coloration 330. This allows the imaging system to determine exact floor location from any image with high accuracy.

[0029] In other embodiments the guide geometry may not be visible to humans but may be visible under different lighting spectra or by the use of crystalline ink, magnetometry, IR spectra, or other methods. Location may also be discernable by other methods such as ceiling mounted cameras, RF emissions, IR beacons or other techniques. In this embodiment the guide tile also includes a QR code at the center 340 which has a unique ID as a secondary check that the tile in question correlates to the location as determined by the control system. [0030] In other embodiments a 5-color mapping scheme could be implemented such that 5 unique IDs are randomly distributed across the floor. Other embodiments may include other encoding schemes or none at all. In this embodiment the center of the guidance tile also contains an inductive RF transmission coil. This allows the ABT, once it has completed its trackpath assignment, to position itself over any tile and lower itself to the ground to receive charging current. This location would then be the initial location for its next assignment. In the case where this location may be inconvenient for other operations, the planning system can make that determination and instruct the ABT to move to another location for charging.

[0031] In other embodiments charging may be via direct electrical coupling and performed at the sides of the depot or other locations as dictated by the needs of the facility. Electrical couplings could be repeated from one side of the ABT to another so that one ABT contacts the wall charging contacts, and then another ABT could dock with the first to receive its charge current.

[0032] Once the ABT has reached the location specified in its trackpath instructions, it again lowers the package and then retracts the grasping mechanism. Then the ABT can exit away from the drop location if so instructed by its trackpath.

[0033] While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention. Further, different illustrative embodiments may provide different benefits as compared to other illustrative embodiments. The embodiment or embodiments selected are chosen and described in order to best explain the principles of the embodiments, the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.

[0034] The flowcharts and block diagrams described herein illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various illustrative embodiments. In this regard, each block in the flowcharts or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function or functions. It should also be noted that, in some alternative implementations, the functions noted in a block may occur out of the order noted in the figures. For example, the functions of two blocks shown in succession may be executed substantially concurrently, or the functions of the blocks may sometimes be executed in the reverse order, depending upon the functionality involved.

Claims

The invention claimed is:

1) An application specific autonomous vehicle capable of grasping and lifting shipping containers then delivering them to another location as directed by a series of navigation instructions.

2) The system of 1 where the vehicle's autonomous control system is based on having a preloaded time and location movement data structure such as but not limited to a trackpath.

3) The system of 1 where the cooperative movement of multiple vehicles is planned by 4D Autorouting algorithms utilizing 3D models of the area of operation.

4) The system of 1 where the control system is based on dedicated hardware accelerator platforms.

5) The system of 1 where the control system is implemented using Von Neumann, Harvard, or other architecture Central Processing Unit executing software or firmware instructions.

6) The system of 1 where the vehicle's navigation instructions are based on trackpath data structures, splines, or other mathematically consistent data structures.

7) The system of 1 where the navigation instructions are provided by geometric waypoints, real-time navigation cues, base plus offset calculations, relative mechanical offsets, or other descriptions of positional and/or temporal translation.

8) The system of 1 where a grasping mechanism consisting of segmented horizontal and vertical grip plates causing micro-indentations is implemented.

9) The system of 1 where known/standardized container designs, box sizes and/or materials allow for simpler and/or stronger grasping mechanisms, forklifts, cranes, or other lifting mechanism.

10) The system of 1 where current location is accurately determined by guidance tiles

consisting of some combination of mathematical geometry such as but not limited to circular, parabolic, horizontal, and vertical lines to establish exact geometry from any single image.

11) The system of 1 where current location is determined by some combination of fixed

camera, triangulation, interferometry, magnetometry, IR beacons, RF transmission strength or other method. 12) The system of 1 where some combination of sensory systems such as but not limited to single lens 3D, multiple lens 3D, LIDAR, interferometry, magnets, guidance tiles, or audio or capacitive proximity detection is used to measure the container and read the package labeling, provide obstacle avoidance, and determine location.

13) The system of 1 where labeling is read via laser scanner, 2D imaging, RFID, Near Field Communication, serial communication, or other information transmission technique.

14) The system of 1 where obstacle avoidance and distance measurements are not required or use proximity sensors, 2D imaging, dual camera 3D imaging, 3D via focus adjustments, or 3D via synthetic aperture, LIDAR or other distance measurement techniques.

15) The system of 1 where the box transport vehicle may temporarily act as a storage device holding the package until paths, loading vehicles, or other loading areas are cleared for it to proceed.

16) The system of 1 where a floor area or simple shelving area is temporarily utilized as a storage location holding the package with the location being denoted by the path planning system such that subsequent vehicle paths, other boxes, and the pickup vehicle can all be routed to or around the package.

17) The system of 1 where the known locations of all packages are forwarded to the path planning system before a shipment arrives due to the use of autonomous shelving units within the vehicle.

18) The system of 1 where known locations of all packages are forwarded to the path

planning system before a shipment arrives because automated packing systems were utilized within the vehicle.

19) The system of 1 where recharging of the vehicle could be accomplished via floor tile or wall charging stations.

20) The system of 1 where the recharging voltage could be forwarded to contact points or inductive coils on the other three sides and or top/bottom of the vehicle such that other vehicles could then utilize those charge points in addition to the original facilities based charge points.