JP2016540967A - Dynamic sensor system and method - Google Patents

Abstract

A sensor system includes a mounting member, an actuator disposed adjacent to the mounting member, and a sensor connected to the actuator and sensing a movement of an object using a signal. The actuator moves the sensor from the first sensing position to the second sensing position when the sensor cannot read the signal. [Selection] Figure 9

Description

CROSS REFERENCE TO RELATED APPLICATIONS This patent application is a continuation-in-part of U.S. Patent Application No. 13 / 801,109 filed on March 13, 2013, and is filed on Nov. 6, 2013. No. 073,431, which is incorporated herein in its entirety.

  The present invention relates to a dynamic sensor system for use in container transport.

  Shipment of goods is a complex and expensive process involving many parties, including shippers, manufacturers, wholesalers, and retailers. Current merchandise is various for shipping, for example 20 ', 40', 45 ', 48', and 53 '(about 6.1m, 12.2m, 13.7m, 14.6m, and 16.2m) Placed in a container of long length. Containers can be transported to a port via a ship or to a freight station via a train. The container can then be transferred from the port or cargo station to the tow trailer chassis for further shipping or distribution. Different sizes of chassis are available to accommodate different sizes of containers.

  Transporting containers onto the chassis is currently cumbersome and time consuming. Container transfer requires the crane or side loader operator or other personnel to be present when a tow trailer with an empty chassis arrives. If the crane operator or tow trailer driver is delayed, the tow trailer driver will have to wait until the crane operator is available to load the container onto the chassis. When the container is loaded on the chassis, the container is transferred to the next place by a tow trailer. The next destination may be another port or freight station, distribution center, or a warehouse or retail store where goods in a container are unloaded. In either case, the container will eventually be removed from the chassis. Again, as with loading the container onto the chassis, removing the chassis is cumbersome and time consuming, requiring both a crane operator or wharf personnel and a tow trailer driver.

  Some systems attempt to solve the above inefficiencies. For example, U.S. Pat. No. 7,231,065 (Peach et al.) Discloses a method and apparatus for performing optical character recognition of container codes and chassis codes that control cameras and handle container and chassis facility entry and exit. Is disclosed. The camera is used to identify when the track was in a particular gate lane within the facility. The camera is also used to determine whether the truck is a bobtail (ie, there is no chassis or container on the tow trailer), whether it is an empty chassis or a chassis with a container. In the latter case, the camera takes various images to measure the size of the container. The size of the container as well as other information is then used to handle the entry and exit of the truck. However, the method and apparatus disclosed by Peach et al. Does not provide an automated method for removing the container from the chassis or loading the container onto the chassis, when the driver positions the chassis in the gate lane. It also does not provide a signal system to assist. In addition, the system uses a camera to measure the size of the container, which can be expensive.

  US Pat. No. 5,142,658 (McMorran et al.) Discloses a container chassis positioning system. In this system, light traffic lights and cameras are used to assist the driver in loading and unloading and positioning the chassis at a pre-programmed stop point in the lane. However, this system requires the use of a crane to unload or load containers on the chassis. Therefore, the driver cannot drive the tow trailer to the next place until the crane is ready. In addition, a camera is required for positioning the chassis, which can be expensive.

  US Publication No. 2008/0219827 (Lanigan et al.) Discloses an in-line terminal system. The system includes a buffer that includes four side latch cylinders that engage the bottom corner casting of the container. The buffer can be used to unload containers from the chassis without the assistance of a crane. However, the system does not provide a buffer that can be used with different sized containers, nor does it provide an optical traffic light that assists the driver in positioning the chassis or container at an appropriate stop in the buffer.

  US Publication No. 2008/0219827 (Lanigan, Sr. et al.) Discloses a distribution system that includes a buffer. The buffer includes a movable shelf having contracted and extended positions. The system also includes a chassis having a support structure that can be raised or lowered using lift control. This support structure is used to place and raise the container on the support structure after the chassis and container are positioned in the buffer, thereby allowing the container to be transferred to the buffer. The buffer further includes at least one wheel guide that helps align the chassis within the buffer. The system allows the driver to load or unload containers without the assistance of a crane, but requires a chassis that is specifically matched to a lifting structure for raising and / or lowering the containers. Therefore, the system cannot be used with a standard chassis.

  For these reasons, a system that can economically load and unload containers of various sizes from a standard chassis without the need to use a crane would be a significant improvement in the art.

  In one embodiment of the present invention, a sensor system is disclosed. The sensor system includes a mounting member, an actuator disposed adjacent to the mounting member, and a sensor connected to the actuator and sensing movement of an object using a signal. The actuator moves the sensor from the first sensing position to the second sensing position when the sensor cannot read the signal.

  In another embodiment of the present invention, a method for transferring a container to a buffer using a sensor system having a distance sensor is disclosed. The method uses a plurality of sensors, including a thru beam sensor and a distance sensor, to sense movement entering a buffer of a container carried by the chassis, and a signal from the distance sensor to the container. And measuring the distance from the distance sensor to the container using the signal generated by the distance sensor. The method includes moving the distance sensor when the distance sensor cannot obtain a readable signal, measuring the length of the container based on data received from the plurality of sensors, and based on the length of the container. It also includes the step of guiding the operator using an optical traffic light to position the chassis in the buffer.

  In another embodiment of the invention, a positioning system for use in transferring a container to a buffer is disclosed. The positioning system includes an optical traffic light disposed adjacent to the buffer to guide an operator to position the chassis within the buffer, and a program logic controller associated with the positioning system. The positioning system also includes a through beam sensor that senses the movement of the container entering the buffer and outputs data to the program logic controller. The sensor system has a distance sensor that uses the signal to determine the distance to the container. The distance sensor is moved from the first sensing position to the second sensing position when no readable signal is acquired. The distance sensor outputs data to the program logic controller. The program logic controller calculates a container length based on the data received from the through beam sensor and the distance sensor, and provides an output signal to the optical signal device based on the data received from the container length and the distance sensor.

1 is an isometric view illustrating one embodiment of an optical positioning system. FIG. It is a top view which shows the optical positioning system of FIG. It is a left view which shows the optical positioning system of FIG. It is a front view which shows the optical positioning system of FIG. It is a rear view which shows the optical positioning system of FIG. It is an enlarged view which shows the support pad shown by FIG. FIG. 2 is an enlarged view showing the signal light shown in FIG. 1. It is a figure which shows the final stop distance corresponding to the container of various sizes. 2 is a flowchart illustrating one embodiment of a method for transporting a container using the optical positioning system of FIG. 6 is a flowchart illustrating another embodiment of a method for transporting a container using the optical positioning system of FIG. 6 is a flowchart illustrating another embodiment of a method for transporting a container using the optical positioning system of FIG. 6 is a flowchart illustrating yet another embodiment of a method for transporting a container using the optical positioning system of FIG. 1 is an isometric view illustrating one embodiment of a dynamic laser system. FIG. FIG. 6 is an isometric view illustrating another embodiment of a dynamic laser system. FIG. 15 is a flowchart illustrating a method of transferring a container to a buffer using the dynamic laser system of FIG. 13 or FIG. 14.

  An optical positioning system 20 for use in container transfer is disclosed. FIGS. 1-8 illustrate one embodiment of an optical positioning system 20 used in connection with the buffer 21, and FIGS. 9-12 illustrate containers using the optical positioning system 20 to or from the buffer 21. Fig. 2 shows various embodiments of a method for transporting a container. Generally, this buffer 21 is used for temporarily storing containers. The optical positioning system 20 enables the container to be transferred from the tow trailer chassis to the buffer 21 by the tow trailer operator without third party assistance. After being stored in the buffer 21, the container can be received by a tow trailer with an empty chassis. As described above, the optical positioning system 20 allows the tow trailer operator to remove the container from the buffer 21 without the need for a third party. The container can then be transferred to a destination, for example a warehouse, by a tow trailer.

  As used herein, the term “container” has its general and ordinary meaning and can include any type of container, such as an ISO container, a domestic container, a semi-trailer, an enclosure, and the like. In addition, the terms “tow truck, truck, and tow trailer” have their generally accepted meaning and are used interchangeably. These vehicles are used for towing, transporting and / or transporting containers. Further, as used herein, the term “buffer” refers to an apparatus or device for temporary storage.

  As shown in FIG. 1, the buffer 21 includes a first frame member 22 and a second frame member 24. Both the first frame member 22 and the second frame member 24 define a channel 25. In addition, one end of the buffer 21 is an inlet 26 and the other end is a rear frame 28.

  The first frame member 22 includes a first vertical support 30 and a second vertical support 32. A first lift beam 34 is disposed between the first and second vertical supports 30 and 32. In one embodiment, the first lift beam 34 is attached to the first vertical support 30 and the second vertical support 32 via mounting brackets 36A and 36B, respectively. Since the mounting brackets 36A and 36B are movably attached to the first and second vertical supports 30 and 32, they can slide in the vertical direction along these vertical supports. The movement of the mounting brackets 36A, 36B along the first vertical support 30 and the second vertical support 32 is controlled by vertical actuators 38A and 38B, respectively. In one embodiment, power is provided to the vertical actuators 38A, 38B by a motor 40 mechanically connected to each of the vertical actuators 38A, 38B. The motor 40 can be another type of motor, such as an electric motor or hydraulic. Pneumatic motors can also be used without departing from the scope and spirit of the present invention.

  The structure of the second frame member 24 is the same as that of the first frame member 22, and includes a first vertical support body 42 and a second vertical support body 44. The vertical supports 30, 32, 42, 44 can be secured to the ground by any method known in the art, such as anchor bolts or similar devices. A second lift beam 46, which is symmetrical with the first lift beam 34, is approximately in the first lift beam 34 between the first and second vertical supports 42, 44 of the second frame member 24. They are arranged in parallel. The mounting brackets 48A and 48B are movably attached to the first vertical support body 42 and the second vertical support body 44, respectively. The mounting brackets 48A, 48B are mechanically connected to vertical actuators 50A (not shown) and 50B (see FIG. 5), and along the first and second vertical supports 42, 44 by the vertical actuators 50A and 50B. Can be moved vertically. In one embodiment, power is provided to the vertical actuators 50A, 50B by a motor 40 mechanically connected to each of the vertical actuators 50A, 50B. In another embodiment, a single motor is used that provides power to the vertical actuators 38A, 38B and 50A, 50B. The vertical actuators 38A, 38B and 50A, 50B can be motorized screws, hydraulic cylinders, or any other similar device known in the art. In the case of a motorized screw, the motor can be electric, hydraulic, or pneumatic.

  The motor 40 is electrically connected to a program logic controller (“PLC”) 52. The PLC 52 controls the movement of the first lift beam 34 and the second lift beam 46 along the vertical supports 30, 32, and 42, 44 as will be described in more detail below. More specifically, PLC 52 controls vertical actuators 38A, 38B, and 50A, 50B via motor 40, thereby mounting brackets 36A, 36B, and second lift beams of first lift beam 34. 46 mounting brackets 48A and 48B are moved. In one embodiment, the PLC 52 is disposed adjacent to the rear frame 28. The vertical actuators 38A, 38B, and 50A, 50B are mounted on the mounting brackets 36A, 36B, and 48A, respectively, when the chassis carrying the container reaches its final stop distance, as described in the description of FIG. The PLC 52 is instructed to raise the first and second lift beams 34 and 46 through 48B. Similarly, when an empty chassis enters the buffer 21 to receive the container, the PLC 52 descends the first and second lift beams 34 and 46 via the mounting brackets 36A, 36B and 48A, 48B, respectively. Instruct the vertical actuators 38A, 38B and 50A, 50B to.

  As best shown in FIG. 2, buffer 21 includes two guide tracks 54A and 54B. The guide tracks 54A and 54B are disposed substantially parallel to each other between the first frame member 22 and the second frame member 24. Guide tracks 54A, 54B are provided to guide the wheels of the chassis into the buffer 21. The guide tracks 54A, 54B can be secured to the ground in any manner known in the art, such as anchor bolts or similar devices, and the first and second frame members 22 and 24 can be secured to the ground. It is possible to weld to the bottom plate.

  As shown in FIGS. 1 to 3, the four support pads 56 </ b> A, 56 </ b> B, 56 </ b> C, and 56 </ b> D are movably attached to the first lift beam 34 at a distance from each other. Further, the four support pads 58A, 58B, 58C, and 58D are movably attached to the second lift beam 46 at a distance from each other. Support pads 56A-D correspond to support pads 58A-D, respectively. For example, the support pad 56A is disposed at a position opposite to the support pad 58A, and the support pads 56A and 58A are disposed at substantially the same point along the first lift beam 34 and the second lift beam 46, respectively (FIG. 2). And FIG. 3). In addition, six of the eight support pads (56A-C and 58A-C) are in close proximity to the first vertical supports 30 and 42 of the first and second frame members 22 and 24, respectively. The remaining two support pads (56D and 58D) are positioned adjacent to the second vertical supports 32 and 44 of the first and second frame members 22 and 24, respectively.

  Support pad actuators 60A, 60B, 60C, and 60D are attached to each of the support pads 56A, 56B, 56C, and 56D and the first lift beam 34, respectively. Similarly, support pad actuators 62A, 62B, 62C, and 62D are attached to each of the support pads 58A, 58B, 58C, and 58D and the second lift beam 46, respectively. Although a total of eight support pads are shown, any number of support pads 56 and 58 and corresponding support pad actuators 60 and 58, respectively, as long as sufficient pads are provided to adequately support various sized containers. 62 can be included. In one embodiment, as shown in Table 1 below, the number of support pads 56, 58 used for the 20 ′ container is four and the support pads 56, 58 used for the 40′-53 ′ container. The number of is six. Table 1 also shows specific support pads used in this embodiment to support a specific size container.

  The support pad actuators 60 </ b> A to 60 </ b> D and 62 </ b> A to 62 </ b> D are electrically connected to the PLC 52. The PLC 52 controls the horizontal movement of the support pads 56A-D and 58A-D via the support pad actuators 60A-D and 62A-D, respectively. Support pads 56A-D and 58A-D are movable from a first position 64 to a second position 66. In one embodiment, the first position 64 can be a contracted position as shown in FIG. 4, and the second position 66 can be an extended position as shown in FIG. In another embodiment, the first position 64 can be an extended position (see FIG. 5) and the second position 66 can be a retracted position (see FIG. 4).

  When in the extended position 66, the support pads 56 and 58 are positioned below the lower surface of the container. When the container is positioned in the buffer 21 for storage, the support pads 56A-D are moved from the retracted position 64 to the extended position 66. When the container is placed on an empty chassis for transfer, the support pads 56A-D are moved from the first position 64 (extended position) to the second position 66 (contracted position). Corresponding support pads can be moved separately or together. For example, in one embodiment, support pads 56A and 58A can be moved simultaneously from first position 64 to second position 66 along with 56B and 58B, 56C and 58C, and 56D and 58D. However, in this embodiment, the support pads are typically moved in opposing pairs of groups as shown in Table 1. In this way, the buffer 21 can handle all containers having the typical container length shown in Table 1.

  FIG. 6 shows an enlarged view of support pad 58D and support pad actuator 62D in the default retracted position. Support pads 56A-D, 58A-D and support pad actuators 60A-D, 62A-D all include the same components, differing only in which side of the support pad the actuator is located. Therefore, only the support pad 58D and the support pad actuator 62D will be described in detail. In one embodiment, the support pad actuator 62D includes an electric linear actuator 68 and a coupling assembly 70. The connection assembly 70 is attached to the support pad 58D via the protrusion 72. The support pad 58D includes a lower portion 74, a first upper portion 76, and a second upper portion 78. In one embodiment, the lower portion 74 and the second upper portion 78 each comprise a steel plate and the first upper portion 76 includes a slip pad 80. The slip pad 80 contacts the lower surface of the container to prevent the container from slipping down when the container is being transferred to or from the traction trailer. The slip pad 80 can be made of urethane or any similar material. The support pad 58D is adjacent to the support pad frame 82 on the left side, the rear portion, and the right side. In one embodiment, the support pad frame 82 includes four support bars 84A, 84B, 84C, and 84D that are fixedly attached to the second lift beam 46 in this example. Support pad frame 82 also includes four movable rollers 86A, 86B, 86C, and 86D that are each attached to support bars 84A, 84B, 84C, and 84D using fasteners 88. The lower portion 74 of the support pad 58D is placed on the rollers 86A-D and when the support pad 58D is moved from the first position 64 to the second position 66 or vice versa, the rollers 86A-86. Engage with D.

  Near the entrance 26 of the buffer 21 adjacent to the first vertical support 30 of the first frame member 22 is an optical signal 90 of the optical positioning system 20 (see FIGS. 1, 2 and 7). The optical signal 90 is attached to the light post 92 and is electrically connected to the PLC 52. The light traffic light 90 guides the operator of the tow trailer entering the buffer 21 by providing a visible signal of the position of the chassis in the buffer 21. As best shown in FIGS. 4, 5, and 7, the optical signal 90 includes a light bar 94. The light bar 94 includes a plurality of rows of lights 96A, B,. In one embodiment, a display (not shown) may be provided adjacent to the light bar 94 that includes text describing the light coloring system. In one embodiment, LED light is used. However, any type of lighting device known in the art, such as an incandescent bulb, can be used. The light bar 94 includes a first light set 98, a second light set 100, and a third light set 102. The first light set 98 includes a green LED. The second light set 100 consists of yellow LEDs, and the third light set 102 consists of red LEDs. The second light set 100 further includes light subsets 104A, B,. Each of the light subsets 104A, B,... N is composed of at least one row of yellow LEDs. Using green, yellow, and red LEDs means that these specified colors are generally “advanced” or “maintained speed”, “decelerated” or “reduced speed” and “stopped” by all vehicle operators, respectively. Is preferable because it is understood to mean.

  A warning lamp 106 is disposed on the top of the light post 92. In one embodiment, the warning light 106 emits a flashing red light. The warning light 106 can be of any size, but it needs to be large enough for the tow trailer operator to easily see with the tow trailer side mirror and / or rearview mirror. In addition, an emergency stop button 107 is disposed below the light post 92 and below the light bar 94. The emergency stop button 107 can be pressed by an operator to immediately stop the optical positioning system 20 at any time.

  The optical positioning system 20 also includes a chassis sensor 108 and a through beam sensor 110. A chassis sensor 108 and a through beam sensor 110 are also arranged near the entrance 26 of the buffer 21. The chassis sensor 108 senses the movement of an object entering the buffer 21, that is, the chassis. Similarly, the through beam sensor 110 senses the movement of an object entering the buffer 21, that is, the container, and is used to measure the length L of the container.

  The chassis sensor 108 can be an ultrasonic sensor. The through beam sensor 110 includes a separate receiving unit and transmitting unit. In one embodiment, the through beam sensor receiver 112 is attached to the light post 92. As best shown in FIG. 7, the through beam sensor receiver is attached to a light post 92 behind the light bar 94. A transmitter post 116 is disposed at a position substantially opposite the light post 92 and adjacent to the first vertical support 42 of the second frame member 24. A through beam sensor transmitter 120 is attached to the transmitter post 116. The through beam receiver 112 and the through beam sensor transmitter 120 together form a through beam sensor 110 that allows the light post 92 and the light post 92 to sense any length of container entering the buffer 21, respectively. The transmitter post 116 is disposed at a predetermined height. Further, the through beam sensor 110 may be a through beam laser or photoelectric sensor, or other transmitter and receiver device.

  As shown in FIGS. 1, 4, and 5, the rear frame 28 of the optical positioning system 20 includes a crossbar member 122 and a rear support member 124. A distance sensor post 126 is disposed at a distance from the rear frame 28. A container distance sensor 128 and chassis distance sensors 130A and 130B are attached to the distance sensor post 126. The distance sensor post 126 is shown as being disposed approximately at the midpoint between the first frame member 22 and the second frame member 24. Although the center position is preferable, the distance sensor post 126 has the first and second frame members 22 and 24 as long as the visibility from the container distance sensor 128 or the chassis distance sensor 130A, 130B to the container or the chassis is not obstructed. It can be arranged at any position between.

  The container distance sensor 128 measures the distance from the container distance sensor 128 to the container. The chassis distance sensor 130A is used to measure the distance from the chassis distance sensor 130A to the chassis having a length of 20 '. The chassis distance sensor 130B is used to measure the distance from the chassis distance sensor 130B to a chassis having a length of 40 ', 45', 48 ', or 53'. All the distance sensors 128 and 130A, 130B are electrically connected as inputs to the PLC 52.

The container distance sensor 128 and the chassis distance sensors 130A and 130B are composed of a single unit, and include both a transmitter and a receiver. For example, in one embodiment, the container distance sensor 128 and chassis distance sensors 130A, 130B may comprise a laser system such as a DT series distance sensor marketed under the trademark SICK ^™ . The container distance sensor and the chassis distance sensor may be other suitable proportional distance sensing devices. In use, the container distance sensor 128 and the chassis distance sensors 130A and 130B of the optical positioning system 20 measure the time taken for the transmitted beam to be reflected by an object (eg, container or chassis) and return to the distance sensor receiver. To do. This time measurement is converted into a distance measurement signal proportional to the distance from the distance sensor to the object. Thereafter, this distance measurement signal is transmitted to the PLC 52.

  Motor 40, vertical actuators 38A, 38B, and 50A, 50B, PLC 52, support pad actuators 60A-D, 62A-D, light traffic light 90, light bar 94, various lights 98, 100, 102, and 106, and a plurality Power can be provided to the electrical components of the optical positioning system 20 including the sensors 108, 110, 128, and 130 via a standard power grid or using a stand-alone engine-driven generator. To connect the aforementioned components to a power source, the wire 132 can run along the outer portions of the first lift beam 34 and the second lift beam 46.

  A method for transporting a container using the optical positioning system 20 is also disclosed. As shown in FIG. 9, an embodiment of a method for transporting a container includes a step 200 for backing a chassis with a container back into a buffer, a step 202 for sensing the rear end of the container, and a front end of the container. Step 204, step 206 for calculating the length of the container, step 208 for calculating the final stop distance of the container, step 210 for storing the final stop distance in the PLC, and step 212 for sensing the longitudinal position of the container. And a step 214 of operating the light bar based on the relationship between the final stop distance and the position of the container, and a step 216 indicating on the light bar that the final stop distance has been reached.

  As shown in FIG. 10, another embodiment of a method for transporting a container includes using a plurality of sensors to sense 230 a movement of a container carried by a chassis into a buffer, and a plurality of sensors. A step 232 for calculating the length of the container based on the data received from the step 234, a step 234 for guiding the operator using an optical signal to position the chassis in the buffer based on the length of the container, and an association with the buffer Extending a plurality of support pads formed below the container; step 238 for raising the support pads to support the container; and step 240 for pulling the chassis out of the buffer.

  FIG. 11 shows a step 250 of backing an empty chassis into the storage buffer to retrieve the stored container, a step 252 for sensing the longitudinal position of the chassis, and a step 254 for reading the previously stored final stop distance. And a step 256 for operating the light bar based on the previously stored relationship between the final stopping distance and the position of the chassis, and a step 258 for indicating on the light bar that the chassis has reached the final stopping distance. Another embodiment of a method for transporting a container is disclosed.

  Yet another embodiment of a method for transporting a container is shown in FIG. 12, which provides a buffer 270 where a container is positioned on a plurality of support pads associated with the buffer, and a chassis entering the buffer. A step 272 of sensing the movement of the container using a plurality of sensors, a step 274 for reading stored data relating to the container including the length of the container, a stored data for positioning the chassis under the container, and Step 276 for guiding the operator using a light signal that lights in a specific color based on data received from a plurality of sensors; Step 278 for lowering the plurality of support pads and placing the container on the chassis; Step 280 for moving the plurality of support pads from the bottom of the container to the contracted position; And step 282 to pull out the chassis to be from the buffer, consisting of.

  In operation, when attempting to transfer the container 134 from the chassis 136 to the buffer 21, the tow trailer operator unlocks the container 134 to the chassis 136 before entering the buffer 21, resulting in the container 134 being buffered by the buffer 21. It can be freely removed from the chassis 136. Since the chassis 136 enters the buffer 21 at a low speed (that is, less than 5 mph (about 8 km / h)), there is little risk that the container 134 shifts to an inappropriate position on the chassis 136 or falls from the chassis. When the container 134 is unlocked, the operator begins to back the tow trailer into the buffer 21. The wheels of the chassis engage with guide tracks 54A and 54B near the entrance 26. The guide tracks 54A, 54B guide the chassis 136 relatively linearly into the buffer 21, thereby preventing the chassis 136 from entering the buffer 21 at an inappropriate angle.

  When the chassis sensor 108 senses an object entering the bay (eg, chassis), the container distance sensor 128 is activated and a data signal including a measurement of the distance from the container distance sensor 128 to the container is transmitted to the PLC 52. When the rear end of the container 134 interrupts the through beam laser of the through beam sensor 110, the data signal from the container distance sensor 128 is interrupted by the PLC 52. When the front end of container 134 passes through beam sensor 110 at point A (see FIG. 8), distance measurement from container distance sensor 128 to container 134 is resumed at PLC 52.

  Each specific length L container has a corresponding final stop distance 138B. The final stop distance 138B of each container length L is stored in the PLC 52 before use. For example, as shown in FIG. 8, the final stop distance 138B of the 20 ′ container is 414.4 inches (about 1052.6 centimeters), and the final stop distance 138B of the 40 ′ container is 174.5 inches (about 443. The final stop distance 138B of the 45 'container is 126 inches (about 320.0 centimeters), and the final stop distance 138B of the 48' container is 90 inches (about 228.6 centimeters). , 53 'container has a final stop distance 138B of 30 inches (about 76.2 centimeters).

  FIG. 8 also shows a point at which the through beam laser of the through beam sensor 110 retransmits. The through beam laser of the through beam sensor 110 retransmits at point A for all different container lengths L. When at point A, each container 134 is at a specific distance 138A from the container distance sensor 128. For example, in an embodiment, at point A, the 20 'container is 455.5 inches (about 1157.0 centimeters) from the container distance sensor 128 and the 40' container is 214 inches (about 543. centimeters) from the container distance sensor 128. 6 '), 45' container is 154 inches from container distance sensor 128, and 48 'container is 118 inches from container distance sensor 128 (about 299.7 cm). Meters), and the 53 ′ container is 58 inches from the container distance sensor 128 (about 147.3 centimeters). These distances 138A are stored in the PLC 52 before use. Thus, when the container distance sensor 128 is activated by re-transmission of the through beam laser of the through beam sensor 110 at point A, the PLC 52 is used with the measured distance from the container distance sensor 128 to the container 134 when the container is at point A. The program logic calculates the container length L, which is recorded and stored in the PLC 52. The optical positioning system 20 then guides the operator of the chassis 136 into the buffer 21 via the PLC 52 using the container length measurement and the corresponding final stop distance 138B.

  The data received by the PLC 52 from the container distance sensor 128 is used to instruct the light traffic light 90 to turn on a specific set of LEDs. More specifically, when the container 134 enters the buffer 21 for the first time, the light signal 90 is activated by the PLC 52 to turn on the first light set 98 (ie, green LED) on the light bar 94. When the container length L and the final stop distance 138B are calculated, the illumination of the light bar 94 proceeds to the second light set 100 (ie yellow LED). The container distance sensor 128 moves from the point A where the through beam laser of the through beam sensor 110 retransmits to a deeper position in the buffer 21 (ie, a point closer to the rear frame 28). Continue to send data about distance measurements. Accordingly, the PLC 52 instructs the light traffic light 90 to turn on the light subsets 104A, B,... N of the second light set 100 based on continued input from the container distance sensor 128. The light subsets 104A, B,... N light up progressively on the light bar 94 (see FIG. 7). This progression of lighting continues until the container reaches its final stop distance 138B. If it is determined that the final stop distance 138B has been reached based on the measured value acquired from the container distance sensor 128, the PLC 52 instructs the optical signal device 90 to turn on the third light set 102 (for example, red LED). The third light set 102 on the light bar 94 emits a constant red light. If the operator continues to back the chassis into the buffer 21 and the final stop distance 138B is exceeded, the red LED 102 will flash, thereby notifying the operator that the chassis has traveled too far. By illuminating different light sets and subsets along the light bar 94, the light traffic light 90 of the light positioning system 20 guides the operator of the tow trailer to position the container in the buffer 21.

  When the final stop distance 138B is reached and the container 134 conveyed by the chassis 136 is no longer moving, the PLC 52 moves from the default contracted position (first position) 64 to the extended position (second position) 66. Instruct specific support pads 56 and 58 to: As shown in Table 1, in one embodiment, for example, if a 20 ′ container is in the buffer 21, the support pads 56A, 56C, and 58A, 58C will move from the retracted position 64 to the extended position 66. . When properly selected support pads 56 and 58 reach the extended position 66, the PLC 52 is pre-programmed to suit the size of the container from a lower default starting position than any chassis or chassis / container combination. Instructs motor 40 to raise first and second lift beams 34 and 46, respectively, to height. Further, the first and second lift beams 34 and 46 raise the container 134 to a height above the chassis 136, thereby allowing the chassis 136 to be easily pulled out of the buffer 21, and also the chassis 136. Prevents the chassis 136 from coming into contact with the underside of the container 134 as it moves out of the buffer 21. When the container 134 is lifted from the chassis 136, the empty chassis 136 is pulled out of the buffer 21 by the operator.

  As shown in FIGS. 11 and 12, when attempting to transfer the container 134 from the buffer 21 to an empty chassis, the optical positioning system 20 operates in substantially the same manner. The wheels of the chassis 136 engage the guide track 54 while the tow trailer is backed into the buffer 21 by the operator. As described above, the length L of the container 134 previously transferred to the buffer 21 is recorded and stored in the PLC 52. The stored container length L and the corresponding final stop distance 138B provide the optical positioning system 20 with the data necessary to guide the tow trailer operator into the buffer 21 to receive the container 134.

  When the empty chassis 136 passes through the entrance 26, the light signal 90 and the chassis sensor 108 are activated. In this configuration, since the container length L is already known, the through beam sensor 110 is not used. Also, the container distance sensor 128 is not used. Instead, one of the chassis distance sensor 130 </ b> A and the chassis distance sensor 130 </ b> B is used to provide the PLC 52 with data relating to the movement of the chassis 136 entering the buffer 21, and the PLC 52 then sends a signal to the optical signal 90. provide. As described above, the chassis distance sensor 130A is used for a container having a length 20 ', and the chassis distance sensor 130B is used for a container having a length 40', 45 ', 48', or 53 '. Since the 20 'chassis is generally higher than the 40'-53' container chassis, two chassis distance sensors 130A and 130B are required. The PLC 52 instructs either the chassis distance sensor 130A or the chassis distance sensor 130B to operate based on the stored container length L. Similar to when the container 134 is transferred to the buffer 21, the light traffic light 90 guides the operator when the chassis 136 is positioned in the buffer 21 to receive the container 134. Based on the measured distance from the current position of the chassis 136 to the final stop distance 138B, the PLC 52, as described above with respect to the transfer of the container 134 from the chassis 136 to the buffer 21, respectively, Instruct the optical signal 90 to turn on the second or third light set 98, 100, 102 and the light subsets 104A, B,.

  When the final stop distance 138B is reached, the PLC 52 instructs each motor 40 to lower the first and second lift beams 34 and 46 to a default height that is low enough not to interfere with the chassis 136. . The motor 40 continues to lower the first and second lift beams 34 and 46 until the container 134 is lowered onto the chassis 136 and reaches the default start position. Upon reaching the default starting position for each of the first and second lift beams 34 and 46, the PLC 52 instructs the pre-extended support pads 56 and 58 to move from the extended position 66 to the retracted position 64. . After the support pads 56 and 58 are contracted, the operator can pull out the chassis carrying the container from the buffer 21. After the operator pulls the chassis 136 and the container 134 out of the buffer 21, the operator must fix the container 134 to the chassis 136 for transfer.

  The optical positioning system 20 described above can also be used with an overhead crane. In the present embodiment, the overhead crane places the container on the buffer 21. The first and second lift beams 34 and 46 are in the raised position and the appropriate support pads 56A-D and 58A-D, determined based on the length of the container, are in the extended position and receive the container. Since the guidance system on the overhead crane positions the container in the correct position on the lift beams 34 and 46, the container can be properly lowered onto the empty chassis as described above.

  Since the chassis and container surfaces are not uniform by the manufacturer, fixed distance sensors such as the aforementioned container and chassis distance sensors 130A, 130B may not necessarily obtain a readable or accurate signal for transmission to the PLC 52. For example, the surface of a chassis or container may have different colors, reflective labels, latches, stickers, signs, etc. that block distance sensor signals that are located at various locations on the chassis or container. Even if the signal generated by the fixed distance sensor is readable, this non-uniformity of the chassis and container surface may prevent the fixed distance sensor from obtaining accurate distance data for the container or chassis.

  In order to address these issues, in another embodiment of the optical positioning system 20, a dynamic sensor system 300 is provided. As shown in FIG. 13, the dynamic sensor system 300 includes a mounting member 302, a distance sensor 312, and a distance sensor actuator 304 to which the distance sensor 312 is connected. The distance sensor actuator 304 can be disposed on or adjacent to the mounting member 302 and is electrically connected to and driven by the motor 306. The motor 306 can be disposed on or adjacent to the mounting member 302 and can be a servo-type motor or other suitable electronic control motor. The motor 306 optionally includes a motor cover 308 to protect the motor 306 from users, sun, rain, wind, and other external elements. A motor control box 310 may be disposed on the mounting member 302. The motor control box 310 provides the electronic equipment necessary to connect the motor 306 that powers the actuator 304 to the PLC 52 and allows data or command signals to be sent to and received from the PLC 52. Other control arrangements that directly control the motor 306 using a CAN bus can also be used.

  The distance sensor actuator 304 raises and lowers the distance sensor 312 vertically to various heights along the mounting member 302. In this embodiment, a single distance sensor 312 measures the distance to a container, a 20 foot chassis, or a chassis having a length of 40-53 feet. Since the distance sensor 312 includes both a transmission part and a reception part (not shown), signals can be transmitted and received. The distance sensor 312 can be a laser system or the like. The distance sensor 312 provides the received signal to the PLC 52. The PLC 52 then transmits separate signals to the optical traffic light 90 using the signals received by the distance sensor 312. Although not shown in the drawings, it is contemplated that the distance sensor 312 can move in a horizontal, diagonal, or circular direction. The distance sensor 312 can include a sensor cover 314 to protect the distance sensor 312 from damage caused by the user and external elements such as wind, sun, and rain.

  A container height sensor 316, a 20 foot chassis height sensor 318A, and a 40-50 foot chassis height sensor 318B may also be disposed on or adjacent to the mounting member 302. The container height sensor 316 is positioned approximately 70 inches from the ground (about 177.8 centimeters). The 20 foot chassis height sensor 318A is positioned approximately 54 inches (about 137.2 centimeters) from the ground, and the 40-50 foot chassis height sensor 319B is approximately 48 inches (about 121.9 centimeters) from the ground. Placed in. The container height sensor 316, the 20 foot chassis height sensor 318A, and the 40-50 foot chassis height sensor 318B may be proximity switches or other similar devices.

  The container height sensor 316 and chassis height sensors 318A and 318B are activated by the PLC 52 and are used to send a signal to the PLC 52 that the distance sensor 312 has reached the location or height of the particular sensor. For example, the container height sensor 316 generates a signal to the PLC 52 when the distance sensor 312 reaches the height of the container height sensor 316, which is the default sensing height. At that time, the PLC 52 sends a signal to the distance sensor actuator 304 so as to stop the movement of the distance sensor 312. Similarly, the chassis height sensor 318A or 318B sends a signal to the PLC 52 when the distance sensor 312 reaches 20 or 40-53 feet chassis height sensors 318A and 318B. The PLC 52 can then instruct the distance sensor actuator 304 to stop the movement of the distance sensor 312.

  In operation, when the container 134 on the chassis 136 enters the buffer 21, the through beam laser of the through beam sensor 110 is retransmitted, and the distance sensor 312 starts measuring the distance to the container 134. The distance sensor 312 sends a signal and strikes the container with a default sensing height for approximately 0.1 seconds to obtain a readable signal. When the readable signal is acquired, the data is transmitted to the PLC 52, and the container length L and the final stop distance 138B are calculated in the same manner as described above. This information is then used by the light signal 90 to guide the operator.

  If the distance sensor 312 does not receive a readable signal for any reason, the distance sensor 312 is approximately 0.20 inches from the default or first position 322A via the sensor actuator 304 from the first position. Meter) down to a second position 322B. The distance sensor 312 transmits the signal again, and if it hits the container for approximately 0.1 seconds and no readable signal is acquired, the distance sensor 312 is moved by the sensor actuator 304 to a third position approximately 0.20 inches below the second position. Moved to 322C. The distance sensor 312 continues to transmit signals, which will hit the container at each location and will be lowered by 0.20 inches until a readable distance measurement is obtained. However, if no readable signal is acquired and the distance sensor reaches the 40-53 foot chassis height sensor 318B, an error message is generated and sent to the PLC 52. At this point, the light traffic light 90 stops working and the operator can redo the procedure or manually back the chassis 136 and container 134 into the buffer 21.

  Assuming that a readable signal has been acquired, the chassis 136 and the container 134 continue to enter the buffer 21. When the distance sensor 312 confirms that the container 134 is at its final stop distance 138B, the optical traffic light 90 turns on the red light set on the light bar 94. The container 134 is then lifted from the chassis 136 by the support pads 56, 58 and the lift beams 34, 46 as described above.

  When the container 134 is raised to its proper transfer height by the support pads 56, 58 and the lift beams 34, 46, the empty chassis is withdrawn. Next, the distance sensor actuator 304 automatically lowers the distance sensor 312 to an appropriate vehicle body sensing height based on the container length L information stored in the PLC 52. The chassis height sensors 318A and 318B are used to send a signal to the PLC 52 that the appropriate chassis sensing height has been reached. For example, if a 20 foot container is in the buffer, the 20 foot chassis height sensor 318A is activated and notifies the PLC 52 when the distance sensor 312 reaches the chassis sensing height.

  Based on the known length L of the container 134 previously confirmed by the PLC 52, an input position command is provided to the distance sensor actuator 304, thereby positioning the distance sensor 312 at an appropriate height and storing the stored container. A signal can be generated for an empty 20 foot chassis or 40-53 foot chassis back into buffer 21 for retrieval. Again, if for some reason the distance sensor 312 does not generate a readable distance measurement for the chassis 136, the distance sensor actuator 304 will be able to measure the readable distance measurement while being backed into the buffer 21 to retrieve the stored container. The distance sensor 312 is automatically lowered by approximately 0.20 inches until a value is acquired. If the distance sensor 312 reaches point B and no readable signal is acquired, the light traffic light 90 will stop working and the operator may redo the procedure or manually back the chassis 136 and container 134 into the buffer 21. it can.

  FIG. 14 illustrates another embodiment of the dynamic sensor system 300. In the present embodiment, the dynamic sensor system 300 includes a filter system 400. Filter system 400 is used when there is too much signal to distance sensor 312 due to the presence of reflective material on container 134 or chassis 136.

  Filter system 400 includes a filter actuator 402, an arm member 404, a filter positioning mechanism 406, and a filter 408. Filter 408 can be a film or lens, such as a LAMIN-x ™ film, or other suitable optical filter material. The filter actuator 402 is connected to the mounting member 302 and the arm member 404, and can move the arm member 404 in the vertical direction. The arm member 404 is connected to the filter actuator 402 at one end and protrudes horizontally from the mounting member 302. The arm member 404 is connected to the filter positioning mechanism 406 via the second end. Filter positioning mechanism 406 includes an extension member 410. The filter positioning mechanism 406 also includes electronics (not shown) necessary to communicate with the PLC 52 and to move the filter 408 from the storage position 412 to the engagement position 414.

  The default position of filter 408 is storage position 412. In the retracted position 412, the filter 408 is positioned away from the distance sensor 312 so that the filter does not interfere with the signal 416 of the distance sensor 312. The storage position can be a vertical or upright position. When the filter 408 is used, the filter positioning mechanism 406 moves the filter 408 from the retracted position 412 to the engaged position 414 via the extension member 410. In the engaged position 414, the filter 408 is placed in front of the distance sensor 312 so that the distance sensor signal 416 passes through the filter 408.

  In use, the distance sensor 312 initiates signal transmission, which hits a designated target on the container or chassis at the starting height. As described above, the starting height of the distance sensor 312 is whether the chassis 136 that carries the container 134 enters the buffer 21 or whether an empty chassis enters the buffer 21 to take out the stored container. Depending on the container sensing height, the 20-foot chassis sensing height, or the 40-53-foot chassis sensing height may be used. If no readable signal is received by distance sensor 312 at the starting height, filter 408 is moved to engagement position 414 by filter positioning mechanism 406 so that signal 416 of distance sensor 312 passes through filter 408. If a readable distance measurement is obtained, the data is sent to the PLC 52 to calculate the container length L and the final stop distance 138B. This information is then used by the light signal 90 to guide the operator.

  However, if no readable signal is acquired, the distance sensor 312 and the filter 408 in the engaged position 414 are lowered to a height approximately 0.2 inches below the starting height by the distance sensor actuator 304 and filter actuator 402, respectively. The distance sensor 312 transmits the signal again through the engaged filter, and if this hits a container or chassis and no readable signal is acquired, the distance sensor 312 and filter 408 are lowered again by approximately 0.2 inches. This continues until a readable signal is obtained as described above or an error message is generated.

  In another embodiment, a method for transporting a container using a sensor system having a distance sensor is shown in FIG. The method senses at least movement entering the buffer of the container carried by the chassis using a plurality of sensors, including a through beam sensor and a distance sensor, and sends a signal from the distance sensor to the container. Step 502 and Step 504 of measuring the distance from the distance sensor to the container using the signal generated by the distance sensor. The method includes a step 506 of moving the distance sensor when the distance sensor cannot obtain a readable signal, a step 508 of calculating a container length based on data received from a plurality of sensors, and a length of the container. Step 510 for guiding the operator using an optical signal to position the chassis in the buffer. The method can further include moving a filter associated with the distance sensor from the retracted position to the engaged position when the distance sensor cannot obtain a readable signal.

  It will be apparent to those skilled in the art that many modifications to the present invention can be made in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is for the purpose of enabling those skilled in the art to make and use the invention and teach the best mode of carrying out the same. ing. Exclusive rights are reserved for all modifications within the scope of the appended claims.

Claims (20)

A mounting member;
An actuator disposed adjacent to the mounting member;
A sensor connected to the actuator and sensing a movement of an object using a signal,
The actuator is configured to move the sensor from a first sensing position to a second sensing position when the sensor cannot read the signal.
Sensor system.   The sensor system according to claim 1, wherein the object is a container or a chassis.   The sensor system of claim 1, wherein a distance between the first sensing location and the second sensing location is approximately 0.20 inches (5.08 mm).   The actuator moves the sensor from the second sensing position to the third sensing position if the sensor cannot read the signal generated when the sensor is positioned at the second sensing position; The sensor system according to claim 1.   The sensor system according to claim 1, further comprising a filter connected to the actuator, wherein the filter is movable from a retracted position to an engaged position.   6. The sensor system of claim 5, wherein when the filter is in the engaged position, the signal of the sensor is positioned in front of the sensor to pass through the filter.   The sensor system of claim 6, wherein the filter is positioned away from the sensor when in the retracted position.   The sensor system according to claim 1, wherein the sensor comprises a laser system.   The sensor system according to claim 1, wherein the actuator moves the sensor in a vertical direction.   The sensor system according to claim 1, wherein the actuator is operated via a motor. Sensing movement entering a buffer of a container carried by the chassis using a plurality of sensors including a through beam sensor and a distance sensor;
Transmitting a signal from the distance sensor to the container;
Measuring the distance from the distance sensor to the container using the signal generated by the distance sensor;
Moving the distance sensor if the distance sensor cannot obtain a readable signal;
Measuring the length of the container based on data received from the plurality of sensors;
Guiding the operator with an optical signal to position the chassis within the buffer based on the length of the container and transferring the container to the buffer using a sensor system having a distance sensor how to.   The method of claim 11, wherein moving the distance sensor comprises moving the distance sensor from a first sensing position to a second sensing position.   The method of claim 12, wherein the distance sensor transmits a signal to the container when in the second sensing position.   If the distance sensor is unable to obtain a readable signal, the method further comprises moving a filter associated with the sensor system from a retracted position to an engaged position when the filter is in the engaged position. 12. The method of claim 11, wherein the method is previously positioned.   The method of claim 14, wherein the signal passes through the filter when the filter is in an engaged position. Extending a plurality of support pads associated with the buffer to the underside of the container;
Raising the plurality of support pads to support the container;
Lifting the container from the chassis;
The method of claim 11, further comprising the step of withdrawing the chassis from the buffer. A positioning system used in transferring a container to a buffer,
An optical traffic light disposed adjacent to the buffer for guiding an operator to position a chassis within the buffer;
A program logic controller associated with the positioning system;
A through beam sensor for sensing the movement of the container entering the buffer and outputting data to the program logic controller;
A sensor system having a distance sensor that measures a distance to the container using a signal, and moves the distance sensor from a first sensing position to a second sensing position when a readable signal is not acquired And
The distance sensor outputs data to the program logic controller;
The program logic controller calculates the length of the container based on the data received from the through beam sensor and the distance sensor,
The program logic controller provides an output signal to the optical traffic light based on the length of the container and the data received from the distance sensor.
Positioning system. The buffer is
A first frame member having first and second vertical supports, wherein a first movable lift beam is disposed between and attached to the first and second vertical supports. 1 frame member;
A second frame member having third and fourth vertical supports, wherein a second movable lift beam substantially parallel to the first movable lift beam is between the third and fourth vertical supports. A second frame member disposed on and attached thereto,
A plurality of support pads associated with the buffer that engage and support the underside of the container;
The positioning system of claim 17, further comprising: a set of guide tracks disposed between the first and second frame members.   The positioning system according to claim 17, wherein the sensor system further includes an actuator that moves the distance sensor from the first sensing position to the second sensing position.   18. The positioning system of claim 17, wherein the sensor system includes a filter that is movable from a retracted position to an engaged position, the filter being positioned in front of the distance sensor when in the engaged position.