WO2022146447A1

WO2022146447A1 - Automated truck delivery system for packages

Info

Publication number: WO2022146447A1
Application number: PCT/US2020/067761
Authority: WO
Inventors: Simon E. SABA
Original assignee: Saba Simon E
Priority date: 2020-12-31
Filing date: 2020-12-31
Publication date: 2022-07-07
Also published as: EP4271628A1

Abstract

An apparatus, system, and method for managing access to a plurality of bins containing packages to be delivered, that are housed within a cargo unit. The system eliminates a walk-in aisle typically used in a delivery panel van to fill the cargo area with a rotating sequence of bins. Multiple floors of bins can be accessed by raising and lowering floors. Additional access arises from using collapsible bins following delivery or removal of all packages therein.

Description

AUTOMATED 1 R. UK DELIVERY SYSTEM FOR PACKAGES

FIELD OF TECHNOLOGY

[0001] This disclosure relates generally to the technical field of package delivery, and in one example embodiment, this disclosure relates to a method, apparatus and system of an automated truck delivery system.

BACKGROUND

[0002] Most packages are delivered to residential and commercial addresses via a box truck, commercial panel van, or a light-duty van that offers overnight or second day expedited delivery or that offers a slower delivery date via ground service.

[0003] The global logistics companies that deliver these packages generate billion dollar revenues from freight-based trucking operation, air delivery services, parcel, package, courier services, and other delivery services. Efficiency is a key component of the profitable industry that provides a repetitive and understood process of picking up (or receiving), sorting, grouping, and transporting packages from an origin, followed by resorting, grouping, and delivering packages to a destination.

[0004] Residential and commercial delivery vehicles that actually deliver packages, parcels, and letters to the final destination typically include a center aisle in a cargo unit portion of the vehicle disposed behind a driver’s compartment. A center aisle that consumes approximately 33% of the cargo unit’s volume allows a delivery person to walk the aisle and locate a package or letter to be delivered from the vertically-stacked horizontal shelves on either side of the aisle. This translates into reduced cargo capacity efficiency, and potentially multiple trips to a warehouse to restock the delivery vehicle, which consumes time, fuel, and money.

[0005] Additionally, on panel vans and box trucks, accessing the cargo unit portion of the truck typically involves traversing stairs for ingress and egress, both out of a cab, and into a storage area of the vehicle. Elevated platforms, or floors, frequently result in leg and back injuries from large steps while carrying packages. This affects quality of life for delivery personnel, as well as insurance and medical costs, and other negative societal impacts. [0006] Lastly, the task of locating a package along a static set of non-descript shelves can be confusing and time-consuming. The delivery person may have to squat to see packages labels on a lowest shelf, or lean to see the package labels on a middle shelf, or stretch to reach packages on a top shelf. These exercises consume time, strain the delivery personnel, and reduce overall operational efficiency.

[0007] Automated systems exist for accessing goods in semi-trailers of long haul semi-trailer trucks (18-wheelers) on a pallet-level granularity from a single access point, with the access doors located at the back of the semi-trailer and not directly accessible from the driver cabin in the tractor. Complex and high-maintenance motorized systems move palletized containers in the semi-trailer. However, as a rule, the more complicated a system, the more breakdowns and the higher the maintenance requirements.

SUMMARY

[0008] An apparatus, system, and method for managing access to a plurality of bins, containing packages to be delivered, where the bines are housed within a cargo unit. The improvements provided by this disclosure include: i) a substantial reduction in the time to load packages into delivery trucks; and ii) a substantial reduction in time to access and retrieve packages in delivery truck during delivery. Additionally, traumatic and repetitive stress injuries are substantially reduced by implementing the present disclosure. Finally, a substantial increase in cargo carrying capacity for a same size vehicle are realized with the present improvements to automated package sorting, rotating, indexing, accessing and delivering.

[0009] The system eliminates a walk-in aisle typically used in a delivery panel van. This increases cargo-carrying capability by about 33% over a same size vehicle that does have a walk- in aisle. Instead of a manual search and find method to locate packages in stacked shelving in the delivery van, the present disclosure groups packages in bins according to a delivery route, then indexes (advances position of) the bins in the cargo unit area of the delivery van to the appropriate bin for the next delivery while in transit to the next delivery, in order to reduce wait time and to increase productivity. Bins completely fill the cargo unit area of the delivery vehicle (minus one bin’s footprint to allow for rotation of bins) in a full configuration. A cargo unit can also have as few as one bin, or any quantity between one bin and a full bin configuration. This increases the cargo carrying capability, and reduces warehouse trips to refill the van. This would make a COO’s performance look great.

[0010] Bins can also be located in a vertical dimension on one or more intermediate floors (or levels), thereby enhancing volumetric efficiency and overall utility of the van by up to another 33%. Bins are mechanically rotated (from a top-down view) on a given floor in the cargo area of the van according to a preplanned schedule, or according to a delivery person’s request for a specific package or altered driving route. When a bin is empty or sufficiently serviced (delivery attempts completed), the automated system rotates the bins in the cargo unit part of the vehicle to move up the next bin of packages to be delivered.

[0011] To reduce stress and strain on delivery personnel, the bin has an access cutout in its front wall for package retrieval and the bin is positioned at a package access port right next to the driver on the separator wall (between the cargo unit area from the driver compartment). The package access port is smaller than a size of a bin in order to retain the bin in the cargo unit. Thus, the driver only has to swivel out of their seat, reach into the adjacent bin for the next package to be delivered, and step off the van with the package in hand.

[0012] A key factor in an automated package management and delivery system is reliability and robustness. Complicated systems can be high-maintenance that erode any time or cost savings gleaned from the automation. Thus, the present disclosure seeks to provide a very efficient, near-minimalistic automation system that is robust, low-weight, low-cost, and low-complexity. The result is a system that is estimated to increase productivity and vehicle usage by up to approximately 50 percent. To accomplish this goal, propulsion systems are only utilized in corners of the cargo unit (and not in the intermediate stretches between the corners, though they can be used as boosters there too). Thus, at a ;minimum, no more than a total of four of the plurality of propulsion units are required for each of the plurality of floors for moving one or more of the plurality of bins disposed on each of the plurality of floors. Only one of the plurality of propulsion units is required for each of at least four different directions of movement of the plurality of bins inside the cargo unit in a given direction. For a given rotation direction, there are two opposing directions (forward/aft, port/starboard) on two orthogonal axes (X and Y). This corner location strategy reduces complexity, cost, and maintenance of the automated bin rotation system. [0013] Propulsion units include a motor-driven bi-directional wheels (e.g., omni wheel) upon which the flat bottom bins can be propelled. Another propulsion unit utilizes a piston driven arm or paddle that essentially pushes a backside (or pulls, e.g., via a front side) of a bin in the direction to be advanced (counter clockwise). The arm can remain in a vertical ‘up’ position to act as a stop against the bin, thereby preventing the bin from moving back into the open slot. The arm can be nested (tucked into a recessed trench in the floor between rollers) to not obstruct bins being loaded into and unloaded from the cargo unit. Both of these different propulsion units provide reliable and straightforward operation. No raising and lowering of bins is required to traverse the rotation circuit in the cargo unit. None of the plurality of propulsion units is required for a footprint area of the floor being at least two bins in at least one direction of a path for circulating the plurality of bins in the cargo unit (e.g., the forward/aft length of the rotational path in the cargo unit). Only one of the plurality of propulsion units is required to propel directly only one of a plurality of bins in at least one path in the cargo unit. At least one of the plurality of propulsion units has a power capacity to propel a plurality of bins disposed in its respective path. The one or more propulsion units comprise at least one of: i) a motorized roller unit; ii) an actuator pusher piston; iii) a chain or a belt drive; or iii) a mechanized lead screw unit.

[0014] To propel the bins on low-friction passive rollers (cylindrical or spherical) covering the intermediate stretch, the system relies on a domino (or bumper car) effect — the bin being propelled by the propulsion system bumps into any bin(s) in front it, thereby pushing them along the path as well. The rollers can be disposed in the each floor, thereby enabling an inexpensive flat bottom bin. Alternatively, the bin can have the rollers, casters, or omni-wheels built therein. For a van with a rectangular cargo unit floor plan, there is only one open slot without a bin (to enable the indexing of bins, aka rotation of the collection of bins, around the perimeter of the cargo unit). Thus, the system maintains a snug packing with only enough room for indexing one or more bins a distance of only approximately one bin stride (a bin length). The floors can be flat, or they can have a slight crown to bias bins against a forward wall and reduce jostling.

[0015] After a given floor of bins has been serviced (packages therein delivered or attempted) in the cargo unit, a different level floor (typically higher) will be vertically moved (down) to make its contents easily accessible via the package access port. Before an upper floor can move down, all bins on a first level will be free of contents, with straggler packages moved to the new level’s ‘undelivered’ bin. Alternatively, floors could be raised up, if a given height of the packages is suitable, with a top floor being pushed toward a top of the a cargo unit to allow a lower floor to be raise and/or be more accessible. Ultrasonic and/or weight sensors will confirm that all the bins on a given level are empty and suitable for compression. Bins on the first floor are collapsible. One design utilizes a collapsible corrugated rubber wall like an accordion. Another design collapses a bin to about half its original height by using a friction fit telescoping upper portion of the bin that slides under pressure from the upper floor to seat inside a barely larger lower portion of the bin. Resultantly, space is saved, and ease of access to another floor’s bins is accomplished.

[0016] Elevation, or vertical positioning, of a given floor is accomplished by a lift system, which can be gravity controlled or positive displacement controlled. A gravity weighted lift system relies on the weight of the bins and the floor to collapse bins on a lower level. The floor is kept in place at an upper level, or a lower accessible level by cables coupled to ceiling winches (one central, or one independent motor/winch for each of the four comers). A positive displacement lift system can use a jackscrew, a linear ball screw, scissors jack, or similar means that result in a specific displacement for given input, e.g., typically using mechanical advantage. Hydraulic and pneumatic systems can also be used as bladders, pistons, etc. Level and position sensors keep the floor and piers from binding.

[0017] The plurality of bins disposed in the cargo unit for operation of the system is equal to a quantity of a total number of bins for filing the entire floor space of the cargo unit minus one (to allow rotation of the bins around the perimeter of the cargo unit). Stated mathematically, the quantity of bins used in the system is equal N-l, where N equals a quantity of a floor area of the cargo unit divided by a footprint of a bin. Each of the plurality of bins is approximately a same size and is comprised of four sides, with at least a face portion of each side is approximately orthogonal to each other and is planar. Bins can also be cylindrical (or have rounded comers on a square bin). The benefit is not having edges that catch and hang up, but at the cost of lower space-efficiency. In the present embodiment, this quantity of bins is a requirement. In another embodiment, fewer bins can be used than said required amount, e.g., spacers can fill an extra void caused by a shortage of one bin, or indexing units can use longer reach or can retain an open space. Alternatively, a longer stroke arm is used to move bins to compensate for the fewer bins, with the arm remaining extended to keep a given bin in place (whereas a full configuration of bins would intrinsically keep themselves properly positioned because of the fitted space). An optional thermal mass is disposed in at least one of the plurality of bins for providing a desired thermal environment for packages disposed in the at least one bin.

[0018] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. Furthermore, the methods, operations, processes, systems, and apparatuses disclosed herein may be implemented in any means for achieving various aspects, and may be executed in a form of a machine-readable medium, and/or a machine accessible medium, embodying a set of instructions that, when executed by a machine or a data processing system (e.g., a computer system), in one or more different sequences, cause the machine to perform any of the operations disclosed herein. Other features will be apparent from the accompanying drawings and from the detailed description that follows. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.

BRIEF DESCRIPTION OF THE VIEW OF DRAWINGS

[0019] Example embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements and in which:

[0020] FIG. 1A is an isometric view of a delivery van 101 with a floor-mounted automated bin indexing system 100 awaiting loading, according to one or more embodiments.

[0021] FIG. IB is an isometric view of a delivery van with a floor-mounted automated bin indexing system being loaded with a lower level set of pre-sequenced bins containing packages, according to one or more embodiments.

[0022] FIG. 2A1 is an interior view of a package access port in the driver cabin, according to one or more embodiments.

[0023] FIG. 2A2 is an interior view of a package access port in the driver cabin with an optional package delivery robot, according to one or more embodiments.

[0024] FIG. 2B is an exterior view of a delivery van with an exterior door as the package access port, according to one or more embodiments. [0025] FIG. 3A1 is an isometric view of a floor plan for a delivery van using propulsion units only in the comers on each multi-level floor, according to one or more embodiments.

[0026] FIG. 3A2 is an isometric view of a floor plan for a delivery van using propulsion units only in the comers on each multi-level floor with a separate independent cargo box, according to one or more embodiments.

[0027] FIGS. 3B-3D are illustrations of a hydraulic-powered bin propulsion system and apparatus for indexing one or more bins in a circular pattern within the delivery van, according to one or more embodiments.

[0028] FIGS. 3E-3J are illustrations of an omni wheel powered bin propulsion system and apparatus for indexing one or more bins in a circular pattern within the delivery van, according to one or more embodiments.

[0029] FIGS. 4A-B are isometric views of a delivery van and apparatus with floor height adjustment using linear ball screws, according to one or more embodiments.

[0030] FIGS. 4C-4D are isometric views of a delivery van and apparatus with floor height adjustment using a winch and cable system, according to one or more embodiments.

[0031] FIGS. 5A-5D are orthographic projections of a collapsible flat-bottomed storage bin for use in an automated bin indexing system, according to one or more embodiments.

[0032] FIGS. 5E-5F are orthographic projections of a collapsible wheeled storage bin for use in an automated bin indexing system, according to one or more embodiments.

[0033] FIGS. 6A-6B is an illustration for loading and unloading sequencing of bins for a cargo unit, according to one or more embodiments

[0034] FIG. 6C is an illustration for a four-step cycle of indexing all bins on a horizontal plane by one position for a cargo unit of a delivery van. according to one or more embodiments

[0035] FIG. 6D is an arrangement of bins after two and after nine indexing cycles, according to one or more embodiments

[0036] FIG. 6E is an isometric view of a three-level version of the bin indexing system, according to one or more embodiments [0037] FIG. 6F is a multi vertical compartment container, according to one or more embodiments.

[0038] FIG. 6G is an isometric view of a multi-level bin indexing system with collapsed bins on a middle floor and with a lowered top floor for improved access to bins on the top floor, according to one or more embodiments.

[0039] FIG. 6H is an isometric view of a multi-level bin indexing system with collapsed bins on an upper and middle floor and with a raised lowest floor for improved access to bins on the lowest floor, according to one or more embodiments

[0040] FIG. 61 is an isometric view of a multi-level bin indexing system that rotates bins located on a vertical plane, according to one or more embodiments

[0041] FIG. 6J is an isometric view of a multi-level bin indexing that indexes a multi-level vertical plane of bins sideways for loading and unloading through one access door, according to one or more embodiments

[0042] FIG. 6K is a top view floor plan of a delivery van with a delivery robot station and ramp to deliver a package retrieved from a bin indexing system, according to one or more embodiments

[0043] FIGS. 7A-7B are functional block diagrams for implementing cargo unit space efficiency and package access ergonomics, respectively, according to one or more embodiments.

[0044] FIG. 8 is a flowchart of operation sequencing for an automated bin rotation system with optional multiple floors, according to one or more embodiments

[0045] FIG. 9 is a computing system for receiving data and transmitting instructions to operate an automated bin rotation system with multiple floors, according to one or more embodiments.

[0046] FIG. 10 is a mobile device for receiving data and transmitting instructions to operate an automated bin rotation system with multiple floors, according to one or more embodiments.

[0047] The drawings referred to in this description should be understood as not being drawn to scale, except if specifically noted, in order to show more clearly the details of the present disclosure. Same reference numbers in the drawings indicate like elements throughout the several views. Other features and advantages of the present disclosure will be apparent from accompanying drawings and from the detailed description that follows.

DETAILED DESCRIPTION

[0048] A method, apparatus and system for controlled-environment agriculture is disclosed. In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments. However, it will be evident that one skilled in the art may practice various embodiments within the scope of this disclosure without these specific details.

Bin Access Port -Loading

[0049] Referring now to FIG. 1A, an isometric view is shown of a delivery van with a floor- mounted automated bin indexing system awaiting loading, according to one or more embodiments. Upper floor 124U is presently loaded with a set of bins 122U. Loading is now ready for a lower set of bins to be inserted onto lower floor 124L via open bin access port 128 (rolling/rollup door), or alternatively double side-opening doors (not shown). Loading bins via the disclosed system is compatible with legacy methods and equipment.

[0050] A variety of floor rollers is shown for purposes of configurability, and which include any combination of spherical 126B and cylindrical 126R rollers, omni wheels 1260, any other type of rotary apparatus enabling low-friction translation and movement of bins in cargo unit 104. Conveyor roller ramps are shown butted up against delivery van (aka box van) 101 to allow a seamless transition of bins from a loading dock directly onto the floor rollers in cargo unit 104. Loading staff can simply push bins on the low friction rollers forward to the driver compartment wall. If rollers or omni wheels are powered, then they start to pull bins in the cargo unit 104 at first contact to bins. Alternatively, floor rollers can be selectively recessed below a main floor surface, in one embodiment, to allow pallet jacks or forklifts to roll into cargo unit 104 and deposit pallets to a most forward position against the driver compartment wall.

[0051] While cargo unit 104 is shown as an integral part of delivery van, aka a one-piece unibody step van, any cargo environment can benefit from the present disclosure. For example, larger box trucks, with a cargo box dropped on a frame with a separate chassis cab, can also utilize the present disclosure, albeit with a side package access door, since the cab is not coupled to the cargo unit. In addition, semi-trailers can utilize the present system, though they are typically used for long haul routes that do not access individual contents therein, but rather access whole pallets at a time, with the exception of local delivery small semi trailers.

[0052] Furthermore, while the present system is described as integrated with the chassis of the cargo unit, the system can also be modular and temporary. For example, a modular floor with integrated indexing units can be dropped on a flatbed truck or rail car, a pickup truck, or any other application that needs to access contents of a bin at a desired access point. Power can be provided by 12-volt system power, or compressed air or hydraulic unit for industrial or commercial applications.

[0053] Furthermore, not all applications have to be mobile. For example, a shipping container, aka a sea container, can benefit from the present disclosure, even though it is not self-propelled. Many applications for shipping containers are stationary, and can benefit from the automated access to contents without consuming precious storage volume for a walk-in aisle. Rail cars are another example that can benefit from automated indexing of bins to access contents, e.g., for passenger luggage or other package transport options. Finally, self-storage units can benefit from the present system, enabling owners to maximize content stored, while retaining accessibility to individual items in bins without requiring a total move-out of contents to reach the desired item at a back bottom corner of the storage unit. An insertable floor is assembled on the storage unit concrete base, with an electrical power supply to power the automated indexing.

[0054] Referring now to FIG. IB, an isometric view is shown of a delivery van 101 with a floormounted automated bin indexing system being loaded with a lower floor set of pre-sequenced bins containing packages, according to one or more embodiments. By pre-sequencing a group of bins (here 122L) for loading on a lower floor 124L, the contents therein can be sequentially accessed without excessive rotation of bins during transit. Completing the pre-sequencing of bins at a distribution facility means a delivery truck can be loaded quickly and efficiently, thereby enabling the truck asset and delivery person expertise to have a higher cycle time, and less down time. Bin labels can confirm sequencing and destination via either hard copy tags, an LCD display, or more probably a one or two-dimensional barcode, e.g., QR code, Bluetooth or RF tags, etc. that are accessible via a mobile device (cell phone, tablet, etc.) camera, or by fixed camera system, e.g., looking into cargo box area.

[0055] Compared to a random packing of goods in different bins, which would result in excessive rotation of bins and in consuming time, energy, and system lifespan, the present systematic packing and retrieval of goods disclosed herein for a planned route is more efficient. Thus, in the example illustrated, bin 1 has a destination A; bin 2 has a subsequent destination B, etc. The present system is well suited to out of sequence bins and packages as well. However, the system has a counter-clockwise (anticlockwise) rotation 132, when looking from the top. An alternative rotation of clockwise is possible, given a preference of the delivery service, and in another embodiment, the rotation occurs in multiple directions, thereby allowing a back and forth movement of bins. In one embodiment, a side door in the delivery van is positioned for access to one to two bins down from the currently accessed bin, in case a package needs to be accessed out of sequence for a uni-directional system. This is slightly less convenient than retrieving a package from a package access port in the driver cabin, but can be much faster than waiting for the bins to rotate to an out-of-sequence package.

[0056] The present embodiment is not bi-directional, in order to simplify weight, complexity, and cost of the system. Yet, in another embodiment, the system is bi-directional, especially with omni wheels whose rotation can be reversed easily with a bi-directional motor drive. A bidirectional system enables faster access to out-of-sequence packages.

Package Access Port

[0057] Referring now to FIG. 2A1, an interior view is shown of a package access port 204 in the driver cabin of a delivery van 101, according to one or more embodiments. The adjacent and proximate location of a package access port 204 next to a driver’s seat provides a substantial reduction in time to access and retrieve packages in delivery truck during a delivery run, for accessing packages in cargo area. Additionally, traumatic and repetitive stress injuries are substantially reduced by implementing the present disclosure. A simple swivel on the seat by the driver will position her to have access to the package right there at the access window 204. An adjusted floor height, e.g., 124L, described hereinafter, is programmable to a given driver’s height preference, thereby allowing access the packages in the bin with a minimum of bending [0058] The present system eliminates a walk-in aisle typically used in a delivery panel van. This increases cargo-carrying capability by about 33% for a same size vehicle. Instead of a manual search and find method to locate packages in stacked shelving in the delivery van, the present disclosure groups packages in bins according to a delivery route, then indexes the bins in the cargo unit area of the delivery van while in transit to reduce wait time and increase productivity. In the present embodiment, bins completely fill the cargo unit area of the delivery vehicle (minus one bin’s footprint to allow for rotation of bins). This increases the cargo carrying capability, reduces warehouse trips to refill the van, and simplifies the delivery person’s task.

[0059] Bins can also be located in a vertical dimension on one or more intermediate floors (or levels), e.g., upper floor 124U disposed above lower floor 124L, which are described in a subsequent figure. Multiple moveable floors in the cargo unit enhance the volumetric efficiency and overall utility of the delivery van by up to another 33%. Bins are mechanically rotated on a given floor in the cargo area of the van according to a preplanned schedule, or according to a delivery person’s request for a specific package or altered driving route. When a bin is empty or sufficiently serviced (delivery attempts completed), the automated system rotates the bins in the cargo unit part of the vehicle to move up the next bin of packages to be delivered.

[0060] To reduce stress and strain on delivery personnel, the bin has an access cutout width 208 and height 206 in its front wall for package retrieval and the bin is positioned at a package access port 204 right next to the driver on the separator wall (between the cargo unit area from the driver compartment). The package access port is smaller than a size of a bin in order to retain the bin in the cargo unit. Thus, the driver only has to swivel out of her seat, reach into the adjacent bin for the next package to be delivered, and step off the van with package in hand, with one trip off and one trip on the van.

[0061] Package access port 204 is sized with width 218 and height 216 that is large enough to provide access to packages, and small enough to retain bin 122U-1 width 218 and height 212 (214 collapsed bin 122L-1) safely in the cargo unit.

[0062] Optional sensors include, but are not limited to infrared sensor 238, ultrasonic sensor 239, camera and computer vision sensors 226 to examine bin identifier and/or contents in the bin for quality control, verification of route progress, damage to packages, thermal condition for packages (e.g., temperature-sensitive), etc. A stationary or centralized computing system or a mobile system, described in subsequent figures, utilizes a processor and memory to implement data transformation of sensor data, instructions, driver and customer input, etc. for i) status input/feedback to, and ii) optionally provide instructions/ status/ prognosis of delivery or package status. Specifically, computing system 250 (described more fully in apparatus 900 of FIG 9) is disposed in chassis of box van 101 to control the rotation and indexing of bins therein, via operating the pistons, solenoids, omni-rollers, powered rollers, etc. described in subsequent FIGS. 3B-3D, according to a pre-planned route, and a reconfigured route for traffic, accidents, package status changes, etc. Data is communicated between equipment (sensors, e.g., reader 122; transition section 151/152; bin indexing equipment 104, etc. via any medium (e.g., wired, wireless, fiber, line-of-sight, etc.)

Delivery Robot

[0063] Referring now to FIG. 2A2, an interior view is shown of a package access port in the driver cabin with an optional package delivery robot (bot) 240, according to one or more embodiments. The bot is capable of delivering packages from the disclosed box truck to a desired delivery location (address, lock box, recipient etc). An autonomous or partially autonomous vehicle consisting of wheels and/or tracks with the ability to switch from one method of propulsion to the other for the optimal mode according to a given terrain, including climbing up and down steps and other challenging environment.

[0064] Delivery robot 240 includes sensor module 243 with components such as IR, Camera(s), LIDAR etc along with GPS or other proximity and location sensing to enable movement of robot along a desired path to a desired location. Hub motors in one or more of the wheels 241 is powered by battery 245 that is charged by inductive coils 242-1/ 242-2 (one in bot 240 and one in box van). Robot arm 248 can hold package, and move package from bot 240 to the delivery location (porch, doorstep, etc.). Antennae 246 allows GPS tracking and wireless communication for control and delivery status, problems, and directions. A computing system 249 includes a processor, memory, and interface to antennae 246, etc., e.g., as shown in computing system 900 hereinafter.

[0065] Unmanned robot 240 will incorporate a learning mode whereby the robot can follow a delivery person, using sensor module 243 and learn the route to a particular delivery address. The robot will store the path route for that particular location in memory portion of computing system 249 to enable following the same path on future deliveries. An artificial Intelligence algorithm can be applied to the memory-stored path for that address to allow future improvements or modifications to the path for the purpose of efficiency improvements or to avoid new obstacles. The paths and routes learned and stored by each robot are stored and distributed locally or remotely such that other robots can follow the routes and paths learned by other robots. A delivery robot collects and stores data (locally and/or remotely) on the delivery details including time, location, package ID, (optional) signatures or other physical or electronic confirmation of delivery, and photographs of the delivered package at drop-off for use as verification that delivery was completed.

[0066] Referring now to FIG. 2B, an exterior view is shown of a delivery van with an exterior door as the package access port, according to one or more embodiments. As described above, a mis-sequenced package in a bin that has already passed the package access port is still accessible via an external side door 242 (for a counter-clockwise rotating bin system). If the cargo unit is nearly full with bins, then an external access door is the best alternative to retrieving said package without having to wait for the system to index a uni-directional system through nearly the entire set of bins.

Propulsion Units

[0067] Referring now to FIG. 3A1, an isometric view is shown of a floor plan for a delivery van using propulsion units only in the corners on each multi-level floor, according to one or more embodiments.

[0068] A key factor in an automated package delivery system is reliability and robustness. Complicated systems can be high-maintenance that erode any time or cost savings gleaned from the automation. Thus, the present disclosure seeks to provide a minimalistic automation system that is robust, low-weight, low-cost, and low-complexity. The result is a system that is estimated to increase productivity and vehicle usage by up to approximately 50 percent. To accomplish this goal, the disclosure only utilizes propulsion systems in corners 304 of the cargo unit (and not in the intermediate stretches between the comers, though they can be used as boosters at those locations as well). Thus, no more than a total of four of the plurality of propulsion units are required for each of the plurality of floors 124U and 124L, for moving one or more of the plurality of bins disposed on each of the plurality of floors. Only one of the plurality of propulsion units is required for each of at least four different directions of movement of the plurality of bins inside the cargo unit in a given direction. In addition, in one embodiment, a single set of propulsion units is positioned and utilized for multiple floors, e.g. upper and lower, thereby reducing chassis weight and reducing complexity. For a given rotation direction, there are two opposing linear directions (forward/aft, port/starboard) on two orthogonal axes (X and Y). This comer location strategy reduces complexity, cost, and maintenance of the automated bin rotation system. A simpler alternative of an oval shaped pattern can be used in lieu of a square path, with the tradeoff of using less surface area of the cargo unit.

[0069] Referring now to FIG. 3A2, an isometric view is shown of a floor plan for a delivery van using propulsion units only in the corners on each multi-level floor with a separable (removable) and independent cargo box 340, according to one or more embodiments. Flanges or hooks 342 located around periphery of top of box 340 allows removal of and placement of said cargo box 340 onto chassis of box van 101. Pins 362 on the chassis of box van 101 and receptacles 363 in the box 340 allow mating, alignment, and retention of box 340 onto chassis 101. One or more electrical plugs 361 on box 340 automatically align and engage/di sengage into one or more power source receptacles 360 on chassis of box van 101 when box 340 is installed or removed from chassis of box van 101. Box 340 has access window 204-A that aligns with chassis access window 204-B, with padding around the periphery of window 204-B to seal the gap between the box 340 and chassis of box van 101, thereby avoiding water leakage. In the present embodiment, cargo box 340 is preloaded for a given route with bins and packages (only partially illustrated in figure for clarity), arranged in a direction with the route chosen for driver of box van 101. This configuration and system allows for pre-loading of packages and bins, and for swapping of cargo boxes between box vans 101 when one has a mechanical problem and needs to be replaced with a working box van. It also allows for quick turnover in vehicles. For exam- le, a returned box van 101 with leftover packages can be hoisted off box van 101, set aside for post-processing and cleanup, while a new pre-loaded cargo box 340 in immediately hoisted in set onto chassis of box van 101 with a new load of packages and bins arranged for the subsequent delivery route. The whole process can be accomplished in a matter of minutes, whereas a prior methodology of manually cleaning out and loading a fixed cargo box with fixed shelves could take hours.

[0070] Alternatively, instead of lifting and lowering cargo box 340, it can be rolled onto a bed of box van 101 and locked into place with claims, hooks, gates, pins, etc. (not shown) that would retain all three axes of cargo box 340. Also, electrical receptacles 360 and plus 361 can be loosely cabled and accessible for manual connection, e.g., by loader/driver, instead of automatically coupled upon insertion of cargo box 340 onto chassis of box van 101.

[0071] Referring now to FIGS. 3B-3D, illustrations are shown of a hydraulic-powered bin propulsion system 300B and apparatus for indexing one or more bins in a circular pattern within the delivery van, according to one or more embodiments. The present propulsion system is located in comer locations of floor 124L and has an exemplary footprint of 310A width and 312A height, which is less than two bins’ footprint of 310-Band 312B shown in FIG. 3C. This corner location leaves open a surface area portion 314 on floor 124L for passive equipment such as rollers, which thereby reduces weight, complexity, and cost of the automated package management and delivery system. Recessed cavity 323 in floor 124L allows arm 322 to be stowed (folding path 327) for movement of bins during loading and unloading. For small cargo unit dimensions, the hydraulic unit 320 can be stacked at different depths in the floor to avoid interference with each other. A roller wheel 329, e.g., made of rubber, on the end of arm 322 enables a smooth transition from arm stroke imparted onto a bin. As shown in FIG. 3D, hydraulic unit 320 includes a hydraulic cylinder 326, piston, and a hinged joint 324 that links the arm 322 to piston/piston rod 333. A stroke of hydraulic-powered bin propulsion system 300B need only be slightly more than a length of one bin, and not more than two bins’ length (as the advancement of the row of bins is typically limited to a single bin. Alternatively, the stroke could be a width or length of cargo area minus the dimension of one bin for a lean bin loading, with a minimum of two bins. For a minimalistic loading of a single bin, e.g., an express delivery, that bin is held in place in cargo unit area, close to access port 204. The hydraulic- powered bin propulsion system 300B can push a backside (or pulls, e.g., via a front side) of a bin in the direction to be advanced (e.g., counter clockwise). The arm can remain in an ‘up’ position to act as a stop against a bin, thereby preventing the bin from moving back into an open slot.

[0072] Referring now to FIGS. 3E-3J, illustrations are shown of an omni wheel powered bin propulsion system 300E and apparatus for moving one or more bins in a circular pattern via linear paths and orthogonal turns within the delivery van, according to one or more embodiments. Similar to FIG. 3B, the present propulsion system is located in comer locations of floor 124L and a similar exemplary footprint. Comer propulsion system 330A moves a bin in direction 331 A, while corner propulsion system 330B moves a bin in direction 33 IB; comer propulsion system 330C moves a bin in direction 331C, and corner propulsion system 330D moves a bin in direction 33 ID. Together, the propulsion systems rotate a bin in four straight- line paths to complete a cycle, or a square circle around an inside perimeter of the cargo unit.

[0073] FIG. 3F illustrates an exemplary omni wheel drive system 330B in more detail, including a motor 334, and driveline 332 to drive shafts 336 for one or more omni wheels. Vector 338 is the direction an incoming bin slides on the wheels. The omni wheels then power the bin in vector direction 339. FIG. 3G and 3H illustrate the omni-directional capability of the omni wheel 350. Omni wheel 350 is comprised of free-spinning 356 multiple barrel rollers 352 disposed circumferentially around the outside of wheel web 354. Barrel rollers 352 allow the bin to be pushed onto the omni wheel, per vector 338. Then the powered shaft turns omni wheel 350 in rotation direction 358, which is also shown in section view A-A. An advantage of the omni wheel drive system 330B is that it has motor-driven bi-directional wheels (e.g., omni wheel) upon which the flat bottom bins can be propelled. To provide more effective use of forward propulsion, one embodiment utilizes a rough or corrugated bottom surface of bins to provide a better grip surface for the omni wheel (beyond a static coefficient of friction of the wheel against a flat bottom bin).

[0074] Both these propulsion units 320 and 330 provide reliable and straightforward operation. No raising and lowering of bins is required to traverse the counter-clockwise rotation circuit in the cargo unit. None of the plurality of propulsion units is required for a footprint of at least two bins in at least one direction of a path for circulating the plurality of bins in the cargo unit (e.g., the forward/aft length of the rotational path in the cargo unit). Only one of the plurality of propulsion units is required to propel only one of a plurality of bins directly in at least one path in the cargo unit. At least one of the plurality of propulsion units has a power capacity to propel a plurality of bins disposed in its respective path. The one or more propulsion units comprise at least one of: i) a motorized roller unit; ii) an actuator pusher piston; iii) a chain or a belt drive; or iii) a mechanized lead screw unit.

[0075] To propel the bins on low-friction passive rollers (cylindrical or spherical) covering the intermediate stretch, the system relies on a domino effect — the bin being propelled by the propulsion system bumps into any bin(s) in front it, thereby pushing them along the path as well. The rollers can be disposed in the each floor, thereby enabling an inexpensive flat bottom bin. Alternatively, the bin can have the rollers, swivel casters or omni-wheels built therein, as described in a subsequent figure. For a delivery van with a rectangular cargo unit floor plan, there is only one open position in the circuit without a bin (to enable the movement of a first bin, thereby opening a position for another bin to take its previous location). Thus, the system maintains a snug packing with sufficient room for indexing one or more bins a distance of only approximately one bin stride (a bin length). The floors can be flat, or they can have a slight crown to bias bins against a forward wall and reduce jostling.

[0076] FIG. 31 illustrates a use of omni-wheel propulsion at each of the four corners of the floor of the cargo unit. This is sufficient to rotate all the bins on that floor plan to complete a clockwise or counter-clockwise path around the internal perimeter of the cargo unit in an extremely compact and low-complexity design. FIG. 3J provides the same omni-wheel propulsion, but with a floor covering over the majority of the omni wheel, exposing only a top portion of the omni wheel that would contact the bins (not shown).

Adjustable Floor Height and Multiple Floor Levels

[0077] Referring now to FIGS. 4A-D, different embodiments of floor height adjustment apparatus are described. Floor height adjustments can be used for different size bins, different heights of delivery drivers, and other factors that reduce repetitive stress and traumatic injuries. In addition, floor height adjustments can be used when multiple floors are included in the automated package management system.

[0078] Regarding multiple floors, bins can also be located in a vertical dimension on one or more and floors (or levels), including a lower (bottom) floor 124L, an upper (top) floor 124U, and possible intermediate floors (shown in later figures), thereby enhancing volumetric efficiency and overall utility of the van by up to another 33%. Bins are mechanically rotated on a given floor in the cargo area of the van according to a preplanned schedule, or according to a delivery person’s request for a specific package or altered driving route. When a bin is empty or sufficiently serviced (delivery attempts completed), the automated system rotates the bins in the cargo unit part of the vehicle to move up the next bin of packages to be delivered.

[0079] After a given floor of bins has been serviced (packages therein delivered or attempted) in the cargo unit, a different level floor (typically higher) will be vertically moved (down) to make its contents more accessible via the package access port 204. Before an upper floor can move down, all bins on a first level will be free of contents, with straggler packages moved to the new level’s ‘undelivered’ bin. Ultrasonic, camera, (shown in FIG. 2A) and/or weight sensors will confirm that all the bins on a given level are empty and suitable for compression. Bins on a lower floor, 124L are collapsible. One design utilizes a corrugated rubber wall like an accordion. Another design collapses a bin to about half its original height by using a friction fit telescoping upper portion of the bin that slides under pressure from the upper floor to seat inside a barely larger lower portion of the bin. Resultantly, space is saved, and ease of access to another floor’s bins is accomplished. Elevation, or vertical positioning, of a given floor is accomplished by a lift system, which can be gravity controlled or positive displacement controlled.

[0080] Referring specifically to FIG. 4A, an isometric view is shown of a delivery van 101 and a floor height adjustment system 400A using linear ball screws, according to one or more embodiments. System 400A adjusts a height 406, such that bins disposed on floor 124U are accessible via package access port 204. Each comer of floor 124U includes a floor height adjustment apparatus 400A-400D. Any means for mechanically adjusting a floor 124U equally and evenly among the corners without binding is a suitable mechanism. Several example embodiments of a floor height adjustment apparatus are provided herein.

[0081] Referring now to FIG. 4B, an enlarged view B-B taken from FIG. 4A illustrates the mechanism of a linear of floor height adjustment apparatus 420. A linear ball screw 424, driven by an electric motor 426 on threaded shaft 422, is positioned at each comer 420A-420D to drive the vertical position 406 to a higher or lower position. When not in adjustment, floor height remains constant. Other forms of positive displacement lift systems include a jackscrew, scissors jack, or similar means that result in a specific displacement for given input, e.g., typically using mechanical advantage. Hydraulic and pneumatic systems can also be used as bladders, pistons, etc.

[0082] Referring now to FIGS. 4C-D, isometric views are shown of a delivery van and apparatus with floor height adjustment using a winch and cable system 400C, according to one or more embodiments. The present system 400C is gravity powered and is controlled by cables coupled to coordinated ceiling winches at each corner (or one central winch, alternatively disposed in a floor or sidewall). A gravity weighted lift system relies on the weight of the bins and the floor to lower the floor, e.g., 124U, and optionally collapse empty bins on a lower level. The floor is kept in place at an upper level, or a lower accessible level by cables coupled to ceiling winches (one central, or one independent motor/winch for each of the four corners. Level and position sensors keep the floor and piers from binding. FIG. 4D illustrates exemplary winch and cable system 400, including a ceiling winch with motor 432 and spool (or drum) 434 for winding cable 438, and anchor 436 in floor 124U.

Bin Configuration

[0083] Referring now to FIGS. 5A-5D, orthographic projections are shown of a collapsible flat- bottomed storage bin 501 A for use in an automated bin indexing system, according to one or more embodiments. Expanded bin 501A is shown in FIG. 5A as a top view, FIG. 5B as a front view, and FIG. 5C as a side view. Each bin that is used on a same floor or for a sized propulsion unit displacement (or stroke) has approximately the same dimensions of width and length so that advancing each bin has a same effect on the other bins in the sequence. Bin 501 A is comprised of four sides, with at least a face portion 506 of each side being approximately orthogonal to each other and approximately planar. The flat face allows a domino effect of pushing one bin effectively transferring the force forward to other bins in the path of the bin being acted on by the propulsion unit. Having a non-orthogonal face might cause a direction vector that is not along a path of the rotation system in the cargo unit. To reduce stress on delivery personnel, the bin has an access cutout 508 in its front wall for package retrieval from a package access port shown in FIG. 2A.

[0084] Bin bottom 516 is flat in the present embodiment, or it can have a rough or slightly corrugated bottom surface (not shown) to allow omni wheels (FIG. 3E) to have a better grip surface beyond a static coefficient of friction of the wheel against a flat bottom bin. Bin 501A optionally includes a thermal unit 510, such as a passive frozen mass (blue ice) or a passive heat source (a heated mass), or such as an active heating or cooling device. Controls 514 on thermal unit 510 set the desired temperature and communicate condition of thermal unit 510, e.g., via wireless 520 such as built in WiFi or Bluetooth disposed in or on bin wall.

[0085] Bins used on a lower floor in a delivery van are preferably collapsible. One design utilizes a collapsible corrugated rubber wall (not shown) similar to an accordion. The current embodiment collapses a bin from an extended height 512B to a reduced height 512C about half its original height by using a friction fit telescoping upper portion 502U of the bin that slides under pressure from the upper floor to seat inside a barely larger lower portion 502L of the bin 501A. FIG. 5D shows a front view of a collapsed bin 501C. Resultantly, space is saved, and ease of access to another floor’s bins is accomplished.

[0086] Referring now to FIGS. 5E-5F, orthographic projections are shown of a collapsible storage bin with omni wheels on the bottom surface for use in an automated bin indexing system, according to one or more embodiments. The configuration of bin would be used on a delivery van floor that is flat. A propulsion unit of a push or pull chain, belt, arm or piston would be useful on this configuration of bin. While the present embodiment illustrates a single splitline and the container having two halves, the present disclosure is capable of more than two sections for the collapsible bin. For example, ten telescoping splits for a container could exist; with the collapsed configuration have nine of the splits fitting within a last, or tenth, section. This configuration would have a collapsed height that is about 10% of its full height, thereby allowing for efficient collapsing between floor levels, and the resulting repositioning of a level with full bins for delivery.

Operation of Bin Management in Delivery Vehicle

[0087] Referring now to FIGS. 6A-6B, an illustration is shown for loading and unloading sequencing of bins for a cargo unit, according to one or more embodiments

[0088] Conveyor or roller systems push bins (contains) directly into the truck. Each container is loaded in accordance with delivery routes with first packages to be delivered as stowed in container 1, which faces the package access port 204 of FIG. 2A. See FIG. IB for exemplary sequencing of bins for delivery location.

[0089] This design improves on the conventional delivery van, which consumes approximately 33-50% of the volume inside a box truck as walking area for a driver instead of storage space. The present design utilizes nearly the entire cargo space/ volume (e.g., approximately 9/10ths) for package storage, which enables fewer trucks to deliver more packages and lower operating costs

[0090] A box truck (aka delivery van) can consist of a plurality of containers, or bins, that move within the box truck in a rectangular or similar pattern around a vertical axis. One embodiment is shown in FIGS. 6C and 6D. [0091] Specifically referring now to FIG. 6C, an illustration is shown for a four-step cycle of indexing all bins on a horizontal plane by one position for a cargo unit of a delivery van, according to one or more embodiments. Bins can use a four-step movement during the delivery route. This can be done while vehicle is stationary or while moving between stops. Each step shows process beginning view and end view. Driver and delivery robots have easy access to containers present in the front right side by package access port. When the packages in the container are delivered, a signal is provided to load the next container in the front right position and the 4-step process start.

[0092] Referring now to FIG. 6D, an arrangement is shown of bins after two and after nine indexing cycles, according to one or more embodiments. The four step process is completed (typically while driving) starting with container 1 then 2 then 3 etc. until container 9. The containers are filled to match the delivery route with first deliveries loaded in container 1 and last deliveries stored in container 9.

[0093] A box truck may have a single level moving platform or a multi level moving platform. The moving platforms can have a static (fixed) elevation or may have a dynamic (variable) elevation with respect to the truck or with respect to other moving or static platforms, or levels. Thus, each level of bins would have a designated rotation of bins as shown here. The levels are individually movable up or down to position the bins at the ideal desired height. In the case of a human (example the driver) unloading, the height of the sub-container level may be such as to minimize driver bending and hence preventing driver injury. Each of the levels may be raised or lowered to the desired ideal height range as shown in FIGS. 6E to 6J.

[0094] Referring now to FIG. 6E, an isometric view is shown of a three-level version of the bin indexing system, according to one or more embodiments. System can have several stacked individually operated levels in lieu of the typical rack system. Each level is separately operated. The vertical elevation of each level can be adjusted so as the have it at near ideal height for unloading to prevent driver injuries, and to improve speed of removing boxes from containers.

[0095] Referring now to FIG. 6F, a multi vertical compartment container is shown, according to one or more embodiments. In a simpler embodiment, the container is made up of vertical subcompartments that follow the 4-step process as a complete unit. This configuration, while simpler, does not benefit from the vertical elevation-changing enhancement as shown in FIG.

6F

[0096] Referring now to FIG. 6G, an isometric view is shown of a multi-level bin indexing system with collapsed bins on a middle floor and with a lowered top floor for improved access to bins on the top floor, according to one or more embodiments. After delivering the mid level packages, the top level is lowered to the ideal loading height. The actuation mechanism for each level is independent.

[0097] Referring now to FIG. 6H, an isometric view is shown of a multi-level bin indexing system with collapsed bins on an upper and middle floor and with a raised lowest floor for improved access to bins on the lowest floor, according to one or more embodiments. After delivering the top level floor of packages, the bottom level is elevated to the ideal loading height. The intention of adjusting the height of the various floor to the desired ideal height is to 1) prevent driver injuries as they load or unload the packages by preventing bending down to retrieve packages and 2) to improve the efficiency of loading and unloading of packages The number of levels (3) is arbitrary, more or fewer levels are possible. Raising or lowering of levels depends on user defined “ideal” loading height. In a different embodiment, the packages move in a combination of forward, backward, up and down (around a “horizontal axis” either clockwise or counterclockwise as viewed from the side. System may have single loop or a plurality of such loops.

[0098] Referring now to FIG. 61, an isometric view is shown of a multi-level bin indexing system that rotates bins located on a vertical plane, according to one or more embodiments. In an alternative embodiment, rather than rotating the bins around a “vertical axis” (a top-down view), the bins are rotated around a “horizontal axis” by moving forward, then down, then back, then up. In an alternative embodiment, the bins are rotated around a “horizontal axis” by moving forward, then down, then back, then up in a “oval” configuration

[0099] Referring now to FIG. 6J, an isometric view is shown of a multi-level bin indexing that indexes a multi-level vertical plane of bins sideways for loading and unloading through one access door, according to one or more embodiments. A box truck can contain several of the rotating apparatuses. In FIG. 6J, only two floors are shown for illustration. Each of these apparatus can move left or right to position in the ideal location for loading and unloading the entire set of sub-containers.

[00100] The movement of containers can be accomplished by way of several roller conveyors to accomplish the sub-container movements within the truck and for loading onto the truck and for removal from the truck. In different embodiments sub-containers can be wheeled by casters, omni-wheel, Mecanum -wheels, etc., that allow movement in two or more directions, so as to allow for transport around corners or at right angles, as shown in FIG. 1A. Wheels can be guided down a path by a groove, channel, or rail on which they fit in, or ride on, respectively. Rails can alternatively guide sub-containers, etc. along the programmable routes on which they will proceed. Sub-containers can be self-propelled or externally propelled. External propulsion can be a piston plunger 118 or similar method of advancing or indexing bins. By a domino effect, an end bin or cart is propelled or translated, which in turn translates the balance of the sub-containers or trays in front of the end bin or cart. Corners or curves are accommodated by having plungers pushing in different directions, e.g., orthogonally for a square corner, etc. Alternatively a continuous drive could be a tow chain, tow rope, tow cable, etc. onto which subcontainers can be selectively clamped for propulsion. Alternatively, or in combination, a ceiling conveyor can also transport bins, as suspended by cable, rope, etc.

Referring now to FIG. 6K, a top view floor plan is shown of a delivery van with a delivery robot station and ramp to deliver a package retrieved from a bin indexing system, according to one or more embodiments. See FIG. 2A2 for more detail on a bot configuration. A small helipad for drone use, disposed just above the ground robots station, opens to enable UAV delivery drone to fly out to deliver packages. The box truck, in one embodiment, includes a robot “parking garage” for one or more UDRs. It includes a direct connection or wireless charging station to recharge the robot between deliveries and before / after the delivery route is complete. A window opening / door opening into the cab enables the UAV delivery robots to enter and exit the cab and loading area

Function Diagram

[00101] Referring now to FIGS. 7A-7B, functional block diagrams are shown for implementing cargo unit space efficiency and for package access ergonomics, respectively, according to one or more embodiments. These function block diagrams 700A and 700B are implemented in apparatus, method, and system figures disclosed herein.

[00102] FIG. 7A illustrates a function of cargo unit efficiency 702, which has as key elements, the elimination of a walk-in aisle 704A and a use of the full height 704B of the cargo unit, even if above normal adult capability without assistance. The resultant functions in clued an increase in floor space efficiency 704 and an increase in volumetric efficiency 706.

[00103] FIG. 7B illustrates a package accessing functionality of the present disclosure. By utilizing an input route map 720A, a priority of package 720B, and repositioning a bin with the package for the next destination 720C to all match each other, the resultant functions of access ergonomics 724 and delivery productivity 722 are substantially improved.

Flowchart

[00104] Referring now to FIG. 8, a flowchart 800A is shown of operation sequencing for an automated bin indexing system with multiple floors for accessing packages, according to one or more embodiments. Flowchart 800A is implemented in apparatus and system illustrated in FIGS. 1A through 7B, inclusive, including control by computing system 900, 1000.

[00105] Operation 802 receives a plurality of bins via a bin access port in the cargo unit, as shown in FIG. 1A. Input 802A indexes, or positions packages in bins and sequences the bins according to an anticipated delivery route, as shown in FIGS. IB, and 6A-6D.

[00106] Operation 804 inquires whether a package for a next destination is at the package access port, as illustrated in FIG. 2A. If ‘yes,’ then the desired package for the next destination is retrieved and processed (delivered), per output 804A. If ‘no,’ then operation 806 arises.

[00107] In operation 806, the bins are rotated, or repositioned, such that the bin with the package at correctly positioned at the package access port for the user to access the package quickly for the delivery. Inputs to operation 806 include 806A, which performs said repositioning of the bins ‘in transit’, thereby saving precious time upon arrival at the destination. Another input is 806B, which provides wireless updates of traffic, verifying correct location (via GPS), and using updated delivery context such as priority, and updated delivery instructions, address changes, etc. The outputs of operation 806 include output 806C to propel the plurality of bins via the one or more propulsion units, and output 806D to convey the plurality of bins on a plurality of roller units, both of which are illustrated in as described in FIGS. 3A-3H. A variety of scanning capabilities (barcode, QR, RFID etc) are used to identify package physical locations of packages and bins from loading onto the box truck, and throughout the entire delivery process until the delivery to customer.

[00108] The next operation is 808, which inquires whether a different floor of bins is needed, or if a floor of bins needs its height adjusted. If ‘no,’ then flowchart 800A returns to operation 804. If yes, then operation 810 arises. An input to operation 808 is an input 808 A as to whether a given floor is depleted. The floor could be a new upper level floor that is replacing a lower level floor (whose contents have all been delivered or removed from said bins on said level). Alternatively, the floor could have bins with packages that just need to have a different height level (e.g., change from a tall to a short driver making deliveries with the same truck).

[00109] In operation 810, a height of a floor is adjusted. Input 810A performs a safety check as to whether persons are clear from a floor lowering, and whether any packages remain in the bins located on the floor to be collapsed. FIG. 2A illustrates the use of sensors to detect whether any additional packages remain in bins on a given floor. The driver can also visually inspect bins passing by before lowering an upper floor onto a lower floor. When clear, output 810B performs the collapsing of bins on a lower floor by lowering an upper floor on a lower floor (or by raising a lower floor into a fixed position upper floor). Flowchart 800A then returns to operation 804.

Computing System

[00110] Referring now to FIG. 9, a computing system 900 is shown for receiving data and transmitting instructions to operate an automated bin rotation system with multiple floors, according to one or more embodiments. Specifically, computing system implements the operations shown in flowchart 800A of FIG. 8 and the functions of FIG. 7 for the hardware illustrated in FIGS 1A-6J.

[00111] Exemplary computing device 900 includes components and functionality that can be applied to several devices in a host system such as a personal computer, minicomputer, mainframe, server, and cloud-based resources, each of which are capable of executing instructions to accomplish the functions and operations described herein. Computing device 900 includes components such as a processor 902 coupled to a memory 904, 905, and/or storage 912. In particular, processor 902 can be a single or multi-processor core, for processing data and instructions. Memory 904, 905, and/or storage 912 are used for storing and providing information, data, and instructions, including in particular computer-usable volatile memory 904, e.g. random access memory (RAM), and/or computer-usable non-volatile memory 905, e.g. read only memory (ROM), and/or a data storage 912, e.g., flash memory, or magnetic or optical disk or drive. Computing device 900 also includes optional inputs, such as i) an alphanumeric input device 908, e.g. a keyboard, or touch screen, with alphanumeric function keys for object driven menus; ii) a keypad button; iv) a microphone with voice recognition software running on processor 902 or any device allowing a player to respond to an input; v) an optional cursor control device 910, e.g., a roller ball, trackball, mouse, etc., for communicating user input information and command selections to processor 902; vi) an optional display device 906 coupled to bus 916 for displaying information; and an optional input/output (I/O) device 914 for coupling system with external entities, such as a modem for enabling wired or wireless communications between a system and an external network such as the Internet, a local area network (LAN), wide area network (WAN), virtual private network (VPN), etc. Coupling medium 916 of components can be any medium that communicates information, e.g., wired or wireless connections, electrical or optical, parallel or serial bus, etc.

[00112] The computing device is only one example of a suitable computing environment and is not intended to suggest any limitation as to the scope of use or functionality of the present technology. The client sensors and service stations can be smart devices (e.g., Internet of Things, loT, devices), with sufficient processors, memory, graphics, and input/output (I/O) capabilities to operate their respective portion of the software. Alternatively, client sensors and service stations can be a thin client, e.g., a dumb device, which only has a capability or is only used to a capability of displaying results and accepting inputs or sending sensor data. Neither should the computing environment be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in the exemplary computing system. The present technology may be described in the general context of computer-executable instructions, including program modules, executed by a computer. Generally, program modules include routines, programs, objects, components, data structures, etc., that perform particular tasks or implement particular abstract data types. The present technology may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote computer-storage media including memory-storage devices, e.g., server farms and databases disposed in the cloud.

[00113] Processor 902 includes function that to process data from sensors including, but are not limited to, bin and/or content identification 122 (barcode, QR code, Bluetooth or RF tags, etc.), weight sensor, as well as environmental sensors such as moisture / humidity sensor, gas chromatography sensor (for hazmat cargo), gas spectroscopy sensor, infrared sensor (for thermally sensitive cargo), ultrasonic sensor, camera and computer vision sensors, etc.

[00114] And processor 902 is used to process said data using tools such as machine learning (ML), deep learning (DL), artificial intelligence (Al) based on data set gathering, database comparison, correlation studies, inference engines (Bayesian, Hidden Markov, etc.) and other statistical and predictive tools (Kalman filtering) to provide instructions/ status/ prognosis to box van 101, bin rotation, and delivery route, via wireless antenna 251 and/or sensors. Data provided from operations in FIG. 8 are entered into a database of storage unit 412 of computing systems 900 for these functions. An operation inquires whether the data from a data communication operation when compared against the selected delivery, routing, etc. procedure, e.g., delivery productivity operation 722 is on par. For the analyses in this operation, different algorithms and deep learning to interpret the data and trends, will be used to help decide whether further modification to the bin indexing, delivery route, etc. for box van 101 is required to provide optimum delivery and ergonomics, e.g., function 724. Again, processor 902/1002 of computing systems 900/1000 is tasked with this evaluation. User input can be used to validate and calibrate the expert system. Training operations of the method 700 and 800 over time provides the system with an ever-increasing database knowledge to better tune algorithms and responses.

Mobile Device

[00115] Referring now to FIG. 10, a mobile device 1000 is shown for receiving data and transmitting instructions to operate an automated bin rotation system with optional multiple floors, according to one or more embodiments. Specifically, mobile device unilaterally or in conjunction with computing system 900 implements the operations shown in flowchart 800A of FIG. 8 and the functions of FIG. 7 for the hardware illustrated in FIGS 1A-6J. [00116] Mobile device 1000, aka a personal communication device such as a cell phone, tablet, smart watch, smart ring, etc. includes a rake receiver 1001 to receive signals from antennae 1038 and communicate both the voice and dual tone multiple frequency (DTMF) 1031 to processor 1002 with digital signal processing (DSP) 1008, which provide the CODEC/MODEM, and other signal processing functions. Alternatively one or more signals may be provided by wired connection 1036, such as Ethernet, coaxial, or optical cable, etc. Processor 1002 includes a baseband processor 1009 configured to provide recognizable voice output 1032, voice recognition modules, or DTMF tones to audio amplifier 1014, coupled thereto. This can be implemented in one of multiple methods. SIM card/ caller identification block 1020 provides the identification features used by an entity accessing mobile device 1000, via transmitter 1004 and antennae 1038 or cable 1036, to verify the identity of the user. Keypad / display 1018 coupled to baseband processor and application processor allows the user of mobile device 1000 to input data and instructions to configure the system and control parameters as needed.

[00117] Processor 1002 is used to process data from one or more of the sensors described for processor 902, including but not limited to, bin identification and/or contents 122, etc., as stored and retrieved from memory 1050 or storage 1051, which also contain program instructions, and data including package identification. Additionally, processor 1002 is used to process said data using tools such as machine learning (ML), deep learning (DL), artificial intelligence (Al) based on data set gathering, inference engines (Bayesian, Hidden Markov, etc.) and other statistical and predictive tools (Kalman filtering) to provide instructions/ status/ prognosis to box van 101 on a delivery location by delivery location basis, via wireless antenna 1038 or wired connection 1036 to service stations and/or sensors. Processor 1002 in one embodiment includes a neural network portion for simulating artificial intelligence, or a quantum computing capability for simulating complex interactions of growth metrics and variables.

References:

[00118] References to methods, operations, processes, flowcharts, systems, modules, engines, and apparatuses disclosed herein are implementable in any means for achieving various aspects, including being carried out by a hardware circuit or a plurality of circuits (e.g., CMOS based logic circuitry), firmware, software and/or any combination of hardware, firmware, and/or software, the latter being in a form of a machine-readable medium, e.g., computer readable medium, embodying a set of instructions that, when executed by a machine such as a processor in a computer, server, etc. cause the machine to perform any of the operations or functions disclosed herein. Functions or operations may include receiving, transporting, delivering, transferring, sensing, recording, instructing, measuring, detecting, and the like.

[00119] The term “machine-readable” medium includes any medium that is capable of storing, encoding, and/or carrying a set of instructions for execution by the computer or machine and that causes the computer or machine to perform any one or more of the methodologies of the various embodiments. The “machine-readable medium” shall accordingly be taken to include, but not limited to non-transition tangible medium, such as solid-state memories, optical and magnetic media, compact disc and any other storage device that can retain or store the instructions and information. The present disclosure is also capable of implementing methods and processes described herein using transition signals as well, e.g., electrical, optical, and other signals in any format and protocol that convey the instructions, algorithms, etc. to implement the present processes and methods. The memory device or similar electronic computing device manipulates and transforms data represented as physical (electronic) quantities within the devices’ registers and memories into other data similarly represented as physical quantities within the devices’ memories or registers or other such information storage, transmission, or display devices.

[00120] Exemplary computing systems, such as a personal computer, minicomputer, mainframe, server, etc. that are capable of executing instructions to accomplish any of the functions described herein include components such as a processor, e.g., single or multiprocessor core, for processing data and instructions, coupled to memory for storing information, data, and instructions, where the memory can be computer usable volatile memory, e.g. random access memory (RAM), and/or computer usable non-volatile memory , e.g. read only memory (ROM), and/or data storage, e.g., a magnetic or optical disk and disk drive). Computing system also includes optional inputs, such as alphanumeric input device including alphanumeric and function keys, or cursor control device for communicating user input information and command selections to processor, an optional display device coupled to bus for displaying information, an optional input/output (I/O) device for coupling system with external entities, such as a modem for enabling wired or wireless communications between a system and an external network such as, but not limited to, the Internet. Coupling of components can be accomplished by any method that communicates information, e.g., wired or wireless connections, electrical or optical, address/data bus or lines, etc.

[00121] The computing system is only one example of a suitable computing environment and is not intended to suggest any limitation as to the scope of use or functionality of the present technology. Neither should the computing environment be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in the exemplary computing system. The present technology may be described in the general context of computer-executable instructions, such as program modules, being executed by a computer. Generally, program modules include routines, programs, objects, components, data structures, etc., that perform particular tasks or implement particular abstract data types. The present technology may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote computer-storage media including memory-storage devices.

[00122] For example, the various devices, modules, analyzers, generators, etc. described herein may be enabled and operated using hardware circuitry (e.g., CMOS based logic circuitry), firmware, software and/or any combination of hardware, firmware, and/or software (e.g., embodied in a machine-readable medium). Similarly, the modules disclosed herein may be enabled using software programming techniques. For example, the various electrical structure and methods may be embodied using transistors, logic gates, and electrical circuits (e.g., application specific integrated ASIC circuitry and/or in Digital Signal; Processor DSP circuitry; FPGA).

[00123] The present disclosure is applicable to any type of network including the Internet, an intranet, and other networks such as local area network (LAN); home area network (HAN), virtual private network (VPN), campus area network (CAN), metropolitan area network (MAN), wide area network (WAN), backbone network (BN), global area network (GAN), or an interplanetary Internet. Furthermore, the type of medium can be optical, e.g., SONET, or electrical, and the protocol can be Ethernet or another proprietary protocol.

[00124] Methods and operations described herein can be in different sequences than the exemplary ones described herein, e.g., in a different order. Thus, one or more additional new operations may be inserted within the existing operations or one or more operations may be abbreviated or eliminated, according to a given application, so long as substantially the same function, way and result is obtained.

[00125] As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include,” “including,” and “includes” mean “including, but not limited to” the listed item(s).

[00126] Various units, circuits, or other components may be described as “configured to” perform a task or tasks. In such contexts, “configured to” is a broad recitation of structure generally meaning “having circuitry that” performs the task or tasks during operation. As such, the unit/circuit/component can be configured to perform the task even when the unit/circuit/component is not currently on. In general, the circuitry that forms the structure corresponding to “configured to” may include hardware circuits. Similarly, various units/circuits/components may be described as performing a task or tasks, for convenience in the description. Such descriptions should be interpreted as including the phrase “configured to.” Reciting a unit/circuit/component that is configured to perform one or more tasks is expressly intended not to invoke 35 U.S.C. § 112, paragraph six, interpretation for that unit/circuit/component.

[00127] The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching without departing from the broader spirit and scope of the various embodiments. The embodiments were chosen and described in order to explain the principles of the invention and its practical application in the best way, and thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents.

Claims

CLAIMS I/We claim:

1. A system for managing access to a plurality of bins housed within a cargo unit, the system comprising: one or more propulsion units disposed in the cargo unit for propelling the plurality of bins within the cargo unit; a bin access port for loading and unloading the plurality of bins into and out of the cargo unit; and a plurality of roller units on which the one or more of the plurality of bins move.

2. The system of claim 1 wherein: the cargo unit does not require a walk-in aisle for accessing a package stored in the cargo unit, thereby increasing a usable storage space surface area for packages in the cargo unit; and the cargo unit is a storage area portion of a box truck.

3. The system of claim 1 further comprising: a plurality of floors for storing and moving the plurality of bins within the cargo unit thereby increasing a usable storage space volume for packages in the cargo unit; and wherein: each of the plurality of floors independently stores and moves a respective portion of the plurality of bins from other floors of the plurality of floors; and the cargo unit is a storage space portion of the box truck.

4. The system of claim 3 further comprising: a lift system coupled to at least one of the plurality of floors upon which the plurality of bins is storable and movable; and wherein: the lift system adjusts a vertical location of the at least one of the plurality of floors for improved accessibility of one or more of the plurality of bins.

5. The system of claim 1 wherein

33 a first plurality of bins disposed on a lower floor are collapsible to allow an upper floor to move lower and thereby provide easier access to at least a portion of the plurality of bins stored on the upper floor.

6. The system of claim 3 wherein: each of the plurality of floors, that store and move a respective plurality of bins, comprise a portion of the plurality of roller units and a portion of the plurality of propulsion units.

7. The system of claim 3 wherein: no more than a total of four of the plurality of propulsion units are required for each of the plurality of floors for moving one or more of the plurality of bins disposed on each of the plurality of floors.

8. The system of claim 1 wherein: each of at least one of the plurality of propulsion units is disposed only in a respective corner portion of the cargo unit.

9. The system of claim 1 further comprising: a package access port disposed in a wall of the cargo unit in order to retrieve a package therefrom; and wherein: the package access port is smaller than a size of a bin.

10. The system of claim 1 wherein: only one of the plurality of propulsion units is required for each of at least four different directions of movement of the plurality of bins inside the cargo unit in a given path.

11. The system of claim 1 wherein:

34 none of the plurality of propulsion units is required for a footprint of at least two bins in at least one direction of a path for circulating the plurality of bins in the cargo unit.

12. The system of claim 1 wherein: the cargo unit comprises a floor on which the plurality of propulsion units and the plurality of rollers are disposed; and only one of the plurality of propulsion units is required to propel only one of a plurality of bins directly in at least one path in the cargo unit.

13. The system of claim 1 wherein: at least one of the plurality of propulsion units has a power capacity to propel a plurality of bins disposed in its respective path.

14. The system of claim 1 wherein: the plurality of bins is equal to a quantity of N-l of to be disposed in the cargo unit for operation of the system; and where N equals a quantity of a floor area of the cargo unit divided by a footprint of a bin.

15. The system of claim 1 wherein: the plurality of roller units are comprised of at least two of any combination of: a cylindrical roller unit, a spherical roller unit, a caster, or an omni wheel; and the plurality of roller units is disposed on either a bottom surface of a bin or a top surface of a floor.

16. The system of claim 1 further comprising: a plurality of bins; and wherein each of the plurality of bins is approximately a same size and is comprised of four sides; at least a face portion of each side is approximately orthogonal to each other and is planar.

17. The system of claim 1 further comprising: a thermal mass disposed in at least one of the plurality of bins for providing a desired thermal environment for packages disposed in the at least one bin.

18. The system of claim 1 wherein: the one or more propulsion units comprise at least one of: i) a motorized roller unit; ii) an actuator pusher piston; or iii) a chain or a belt drive.

19. The system of claim 1 wherein: the cargo unit housing the plurality of bins is a separable and independent unit from a chassis of a delivery vehicle; and the cargo unit is capable of being pre-loaded with packages arranged and accessible in a sequence corresponding to a predetermined delivery route.

20. The system of claim 1 further comprising: a delivery robot disposed in a delivery vehicle; and wherein the robot is at least partially autonomous to deliver a package from the delivery vehicle to a destination; and the robot receives at least one support function from the system comprising: a power source, a delivery instruction, and an artificial intelligence data input.

21. The system of claim 1 further comprising: a delivery vehicle further comprising: an autonomous driving module; and wherein: the delivery vehicle houses the cargo unit; and the delivery vehicle is at least partially autonomous to drive to a destination to deliver a package.

22. A method for managing access to packages disposed in a plurality of bins housed within a cargo unit, the method comprising: receiving the plurality of bins via a bin access port in the cargo unit; conveying the plurality of bins on a plurality of roller units; and propelling the plurality of bins via one or more propulsion units.

23. The method of claim 22 further comprising: accessing packages stored in the cargo unit; and wherein: the accessing operation does not require a walk-in aisle in the cargo unit, thereby increasing a usable storage space surface area for the packages in the cargo unit; and the cargo unit is a storage area portion of a box truck.

24. The method of claim 22 further comprising: adjusting a vertical height of a floor on which at least a portion of the plurality of bins is disposed, in order to increase a usable storage space volume for bins in the cargo unit and in order to provide a more convenient access to any packages disposed in the portion of the plurality of bins.

25. The method of claim 22 further comprising: moving and accessing a plurality of bins disposed on each of a plurality of floors on a sequential floor-by-floor basis.

26. The method of claim 22 further comprising: collapsing a group of bins disposed on a lower floor to allow an upper floor to move lower and thereby provide improved access to at least a portion of the plurality of bins stored on the upper floor.

27. The method of claim 22 wherein: the operation of propelling the plurality of bins on a given floor requires a motive force from no more than a total of four of the plurality of propulsion units for each of a plurality of floors.

37 method of claim 22 wherein: an operation of positive retainment is not required for the plurality of bins during transportation in the cargo unit.

38