WO2025259692A1 - Automated trailer loading systems and related methods - Google Patents

Automated trailer loading systems and related methods

Info

Publication number
WO2025259692A1
WO2025259692A1 PCT/US2025/033040 US2025033040W WO2025259692A1 WO 2025259692 A1 WO2025259692 A1 WO 2025259692A1 US 2025033040 W US2025033040 W US 2025033040W WO 2025259692 A1 WO2025259692 A1 WO 2025259692A1
Authority
WO
WIPO (PCT)
Prior art keywords
atls
cart
frame
drive beam
track
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2025/033040
Other languages
French (fr)
Inventor
Cory Richard Boudreau
Brett S. MCMICHAEL
Douglas Scott RODENKIRCH
Christopher Timothy Strahm
Patrick Timothy SWEENEY
Adam J. BREWSTER
Leonard John Kikstra
Matthew J. SVUEM
Jerry JACOBS
Jack M. FELTMEYER
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rite Hite Holding Corp
Original Assignee
Rite Hite Holding Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rite Hite Holding Corp filed Critical Rite Hite Holding Corp
Publication of WO2025259692A1 publication Critical patent/WO2025259692A1/en
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65GTRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G67/00Loading or unloading vehicles
    • B65G67/02Loading or unloading land vehicles
    • B65G67/04Loading land vehicles
    • B65G67/20Loading covered vehicles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65GTRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G43/00Control devices, e.g. for safety, warning or fault-correcting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65GTRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G69/00Auxiliary measures taken, or devices used, in connection with loading or unloading
    • B65G69/28Loading ramps; Loading docks
    • B65G69/2805Loading ramps; Loading docks permanently installed on the dock
    • B65G69/2811Loading ramps; Loading docks permanently installed on the dock pivoting ramps
    • B65G69/2817Loading ramps; Loading docks permanently installed on the dock pivoting ramps with fluid-operated means
    • B65G69/2829Loading ramps; Loading docks permanently installed on the dock pivoting ramps with fluid-operated means extensible by sliding parts

Definitions

  • This disclosure relates generally to dock levelers and, more particularly, to automated trailer loading systems and related methods.
  • Loading docks provide an area for vehicles (e.g., trucks, trailers, etc.) to move next to an elevated platform of a building (e g., a material handling facility) so that cargo can be readily transferred between the vehicle and the building.
  • vehicles e.g., trucks, trailers, etc.
  • a building e g., a material handling facility
  • FIG. 1 A is a perspective view of an example loading bay of an example loading dock implemented with an example automated trailer loading system (ATLS) in accordance with teachings disclosed herein.
  • ATLS automated trailer loading system
  • FIG. IB is a perspective view of the example loading bay of FIG. 1A shown from an exterior of the example loading dock.
  • FIG. 2A is a perspective view of the example ATLS of FIG. 1A and IB.
  • FIG. 2B is an exploded perspective view of the example ATLS of FIG. 2A.
  • FIG. 2C is a perspective view of an example actuator of the example ATLS of FIGS. 2A and 2B.
  • FIG. 2D is a perspective, cutaway view of the example actuator of FIG. 2C.
  • FIG. 2E is a side view of the example ATLS of FIG. 2 A in an example raised position.
  • FIG. 3 A is a top view of the example ATLS in an example first lateral position.
  • FIG. 3B is a side view of the example ATLS in the example first lateral position of FIG. 3A.
  • FIG. 3C is partial, bottom view of the example ATLS in the example first lateral position.
  • FIG. 3D is a top view of the example ATLS in an example second lateral position.
  • FIG. 3E is a side view of the example ATLS in the example second lateral position of FIG. 3D.
  • FIG. 3F is partial, bottom view of the example ATLS in the example second lateral position.
  • FIG. 3G is a top view of the example ATLS in an example third lateral position.
  • FIG. 3H is a side view of the example ATLS in the example third lateral position of FIG. 3G.
  • FIG. 31 is partial, bottom view of the example ATLS in the example third lateral position.
  • FIG. 3J is partial, enlarged view of the example ATLS of FIGS. 3A and 3B.
  • FIG. 4A is a perspective top view of an example movable frame of an example frame assembly of the example ATLS of FIGS. 11A, IB, 2A, and 2B.
  • FIG. 4B is a perspective bottom view of the example movable frame of FIG. 4 A.
  • FIG. 5A is a side view of the example ATLS of FIGS. 11A, IB, 2A, and 2B.
  • FIG. 5B is a perspective view of a portion of an example cart drive system of the example ATLS of FIG. 2 A.
  • FIG. 5C is a perspective view of an example first end cap of an example track of the example ATLS of FIGS. 1A. IB, 2A and 2B.
  • FIG. 5D is a perspective view of an example first track side wall of an example track of the example ATLS of FIGS. 1 A, IB, 2A and 2B.
  • FIG. 5E is a perspective view of an example second end cap of an example track of the example ATLS of FIGS. 1A, IB, 2A and 2B.
  • FIG. 6A is a perspective view of an example drive beam of the example ATLS of FIGS. 1A, IB, 2A and 2B.
  • FIG. 6B is an enlarged, partial perspective view of the example drive beam of FIG. 6A.
  • FIG. 7A is a partial perspective review view of an example drive system of the example ATLS of FIGS. 1A, IB, 2A and 2B.
  • FIG. 7B is a partial perspective review view of the example drive system of FIG. 7A.
  • FIG. 7C is another partial perspective view of the example drive system of FIGS. 7A and 7B.
  • FIGS. 8A-8F are various perspective views of an example cart of the example ATLS of FIGS. 1A, IB, 2A and 2B.
  • FIG. 8G is a perspective view of an example roller disclosed herein that can be used with the example ATLS of FIGS. 1A, IB, 2A and 2B.
  • FIG. 9A is a perspective view of example ATLS of FIGS. 1. 2A and 2B with example guide doors in example guide positions.
  • FIG. 9A is a perspective view of example ATLS of FIGS. 1, 2A and 2B with the example guide doors in example transfer positions.
  • FIG. 10A is a partial perspective front view of the example ATLS of FIGS. 1A, IB. 2A and 2B with an example sensor of an example scanner system shown in an example stored position.
  • FIG. 10B is a partial perspective front view of the example ATLS of FIG. 10A with the example sensor of the example scanner system shown in an example scanning position.
  • FIG. 10C is a front view of the example sensor of FIG. 10B.
  • FIG. 11A-11C are schematic illustrations of the ATLS 102 of FIGS. 1A, IB, 2A and 2B in an example scanning operation.
  • FIGS. 12A-12B are top views of the loading dock 100 of FIGS. 1A, IB, 2A and 2B illustrating an example first alignment operation.
  • FIG. 13A-13B are side views of the loading dock 100 of FIGS. 1 A, IB. 2A and 2B illustrating an example second alignment operation.
  • FIGS. 14A-14Q are perspective views of the example loading dock 100 of FIGS. 1A, IB, 2A and 2B and the example ATLS 102 at different operational positions of an example loading operation.
  • any part e.g., a layer, film, area, region, or plate
  • any part e.g., a layer, film, area, region, or plate
  • the referenced part is either in contact with the other part, or that the referenced part is above the other part with one or more intermediate part(s) located therebetween.
  • AVS Automatic Trailer Loading Systems
  • Slug loading systems include various components such as conveyors, sensors, and/or control systems. Goods and/or cargo placed on a conveyor of an ATLS in the order that will best use the trailer's interior space (e.g., cube).
  • Example methods, apparatus, and articles of manufacture disclosed herein provide automated trailer loading systems for positioning cargo or goods within a trailer or container. Additionally, example automated trailer loading systems disclosed herein significantly reduce a footprint/space required inside a loading dock compared to traditional automated trailer loading systems that take up as much as sixty feet in length (e.g., per dock door or loading bay of a loading dock) inside the loading dock or warehouse due to the fact that those other systems stage/load entire trailers at once as opposed to incrementally loading a trailer as the systems disclosed herein. Thus, example automated trailer loading systems disclosed herein do not require stage loading an entire load of a trailer and/or do not require moving an entire load into a trailer at once or simultaneously. Instead, loading can be staged or performed in intervals.
  • these systems can increase (e.g., maximize) a load capacity and/or reduce (e.g., minimize) wasted space, which can lead to significant cost savings and increased productivity.
  • slug loading systems offer improved safety and reduced risk of damage to the goods or cargo.
  • One or more sensors and/or control systems can be employed to improve (e.g., ensure precise) handling and/or placement of the cargo in the vehicle.
  • Example automated trailer loading systems disclosed herein employ a cart for supporting and/or moving goods within the trailer or container.
  • Example, automated trailer loading systems disclosed herein employ a drive system that can roll up to a stored position.
  • example drive systems disclosed herein can at least partially wind or roll up underneath a frame of the ATLS and/or underneath an upper surface of a floor of a loading dock (e.g., a warehouse).
  • at least a portion of a drive system of an example automated trailer loading system disclosed herein can store within a spiral track of the automated trailer loading system (e.g., a frame of the ATLS) positioned in a pit area of a loading dock and/or underneath a floor of a loading dock or w arehouse.
  • Material handling equipment e.g., a forklift
  • a forklift initially loads a cart of the ATLS from one end of the frame and the cart is moved or pushed into a loading area of a trailer or container via a drive system.
  • the example cart of example automated trailer loading system disclosed herein is retracted to a staging position within the tailer and adjacent the frame.
  • Guide doors of example ATLS disclosed herein move from a guiding position (e.g., a vertical position) to a staging or operating position (e.g., a horizontal position), wherein the material handling equipment loads the guide doors with additional cargo from the one end of the frame.
  • Example conveyors disclosed herein can be driven via one or more motors and/or transmission systems. Some example conveyors disclosed herein employ one or more push/pull chain and sprocket systems. For example, to retract the cart, the cart rolls into a large coil in a spiral track located in a cavity of the frame of the ATLS that is positioned in the building.
  • a drive system or drive beam (e.g., a chain) of an example automated trailer loading system can be approximately between 50 feet and 80 feet in length when fully extended (e.g., fully flat, or completely unwound). However, when w ound or stored (e.g., within a spiral track underneath a platform floor), example drive systems or drive beams disclosed herein can be approximately between 10 feet and 30 feet in length.
  • FIG. 1A is a perspective view of an example loading bay 101 of an example loading dock 100 implemented with an example automated trailer loading system (ATLS) 102 in accordance with teachings disclosed herein.
  • FIG. IB is another perspective view of the example loading bay 101 show n from an exterior of the example loading dock 100.
  • the loading bay 101 of the illustrated example can be a warehouse, cargo transport unit, and/or loading structure.
  • the loading bay 101 of the illustrated example includes a dock w all 104 defining a doorway 106 leading to a platform 108 (e.g., the doorw ay 106 allows access between an interior of the loading bay 101 and an exterior of the loading bay 101).
  • the example ATLS 102 of the of the illustrated example is positioned in the loading dock 100 at least partially extending underneath a floor 110 of the loading dock 100 adjacent the platform 108.
  • the ATLS 102 of the illustrated example is at least partially positioned in an opening or pit 112 formed in the platform and/or floor 110.
  • the ATLS 102 is positioned in the pit 112 and is offset relative to an exterior or dock face 114 of the dock wall 104.
  • the pit 112 can have a depth of between 2 feet and 10 feet.
  • the ATLS 102 loads cargo inside a cargo area 116 of a trailer or vehicle 118. As described in greater detail below, the ATLS 102 moves into and out of the cargo area 116 of the vehicle 118 during a loading/unloading operation.
  • each loading bay 101 of an example loading dock can include an ATLS 102 disclosed herein.
  • FIG. 2A is a perspective top view of the example ATLS 102 of FIG. 1 A and FIG. IB.
  • FIG. 2B is an exploded view of the ATLS 102 of FIG. 2A.
  • the ATLS 102 of the illustrated example includes a frame assembly 202, a cart 204 (e.g., a shuttle), and guide doors 206.
  • the ATLS 102 of the illustrated example includes a first guide door 206a positioned adjacent or on a first side 208 of the frame assembly 202 and a second side door 206b positioned adjacent or on a second side 210 of the frame assembly 202 (e.g., opposite the first side 208).
  • the frame assembly 202 includes an inner platform 212 (e.g., a rear platform) adjacent a rear side or rear end 214 of the frame assembly 202 and a transition platform 216 (e.g., a front platform) positioned adjacent a front side or front end 218 of the frame assembly 202.
  • the inner platform 212 of the illustrated example can be used to transition cargo from the floor 110 (FIG. 1A) onto the cart 204 and/or the guide doors 206, as described in greater detail below.
  • the transition platform 216 provides a pathway or transition for the cart 204 to enable the cart 204 to move between the frame assembly 202 and the cargo area 116 of the vehicle 1 18 (FIG. 1 A).
  • the inner platform 212 of the illustrated example includes a plurality of rollers 212a to facilitate transfer or cargo from the interior of the warehouse onto the ATLS 102.
  • the inner platform 212 includes a conveyor or belt to move the cargo to the ATLS 102.
  • the inner platform 212 is a smooth, flat, non-movable surface.
  • the rollers 212a are substantially similar or identical to upper rollers 804 of FIG. 8 A.
  • the frame assembly 202 of the illustrated example mounts or couples the ATLS 102 to the pit 112 of the loading dock 100.
  • the frame assembly 202 has a rectangular shape.
  • the frame assembly 202 can have a square shape and/or any other suitable shape.
  • the frame assembly 202 of the illustrated example includes a movable frame 220 and a fixed frame 222 (e.g., a support structure).
  • the fixed frame 222 mounts the movable frame 220 to the loading dock 100.
  • the fixed frame 222 of the illustrated example includes a plurality of beams 224 (e g., steel beams).
  • the beams 224 are fastened or welded to each other to define a rectangular shape.
  • the beams 224 of the fixed frame 222 define a cavity 222a (e g., a space or volume) to receive at least a portion of the movable frame 220.
  • the movable frame 220 can move relative to the fixed frame 222 to enable alignment of the cart 204 (e.g.. and the transition platform 216 and/or the inner platform 212) relative to the cargo area 116 of the vehicle 118.
  • the ATLS 102 of the illustrated example can move in a plurality of different positions (e.g., six-degrees of freedom) to align (e.g., coaxially align) the cart 204 relative to the cargo area 116 of the vehicle 118 prior to performing a loading/unloading operation.
  • the movable frame 220 can move relative to the fixed frame 222 and/or the loading dock 100.
  • the fixed frame 222 is fixed relative to the loading dock 100 and the movable frame 220 can move relative to the loading dock 100.
  • the ATLS 102 of the illustrated example can move vertically (e.g., up and down), laterally (e.g., sideways) in a direction between side walls of the doorway 106, and/or in a skewed or angular direction where the front end 218 of the movable frame 220 can be move relative to the rear end 214 of the movable frame 220, and/or the rear end 214 of the movable frame 220 can move laterally relative to the front end 218.
  • the ATLS 102 of the illustrated example includes a first alignment system 226 (e.g.. a vertical alignment system).
  • the first alignment system 226 includes a plurality of vertical actuators 228 (e.g., linear actuators).
  • the vertical actuators 228 are coupled to the movable frame 220.
  • the vertical actuators 228 of the illustrated example are positioned in respective comers 230 (e.g., four comers) of the frame assembly 202.
  • FIG. 2C is a perspective view of the example vertical actuator 228 of FIGS. 2 A and 2B.
  • FIG. 2D is a perspective, cutaway view of the example vertical actuator 228 of FIG. 2C.
  • the vertical actuator 228 of the illustrated example includes an actuator end 228a (e.g., a piston) and a cylinder 228b (e.g., a base).
  • the cylinder 228b of the actuator is coupled to a housing 260 (e.g., a mounting bracket).
  • the housing 260 encloses or encompasses the cylinder 228b of the vertical actuator 228.
  • the actuator end 228a (e.g.. a piston) of the vertical actuators 228 is coupled (e.g...
  • the base 260 that slidably couples within pockets 231 formed in respective comers 230 of the movable frame 220.
  • Each of the pockets 231 has an area or opening (e.g.. a perimeter) that is larger than an area or perimeter of the base 260.
  • the vertical actuators 228 e.g., the base 260
  • the vertical actuators 228 are slidably coupled to the respective pockets 231.
  • the vertical actuators 228 can move with the movable frame 220 laterally or sideways and can cause the movable frame 220 to move vertically.
  • the housing 260 of the illustrated example can move relative to the fixed frame 222.
  • the housing 260 has a bottom surface 260a that engages a pit floor.
  • the housing 260 of the illustrated example includes a glide pad 328 (FIG. 3 J, rollers, bearings, etc.) on the bottom surface 260a of the housing 260.
  • the first alignment system 226 can move the movable frame 220 in a first vertical direction 232 (e.g., an upward direction in the orientation of FIGS. 2A and 2B) and a second vertical direction 234 (e.g., a downward direction in the orientation of FIGS. 2A and 2B), and/or can tilt the front end 218 of the frame assembly 202 relative to the rear end 214 in the longitudinal and/or horizontal directions.
  • extension of the vertical actuators 228 causes the movable frame 220 to move (e.g., lift) away from the fixed frame 222 and retraction of the vertical actuators 228 causes the movable frame 220 to move toward the fixed frame 222.
  • the actuator end 228a can move the movable frame 220 relative to the fixed frame 222 and/or the housing 260 in the vertical directions 232. 234.
  • FIG. 2D shows the actuator end 228a at different stroke positions 262. 264, and 266.
  • Each of the vertical actuators 228 can be operated independently and can cause a respective one of the comers 230 to move relative to another respective one of the comers 230.
  • respective ones of the corners 230 of the movable frame 220 can be positioned at different heights (e.g., vertical heights or stroke positions).
  • the first alignment system 226 can be employed to adjust a height (e.g., a vertical height) and/or a slope (e.g., a tilt or vertical angle) of the ATLS 102 between the front end 218 and the rear end 214 of the movable frame 220.
  • a height e.g., a vertical height
  • a slope e.g., a tilt or vertical angle
  • the vertical actuators 228 adjacent the front end 218 of the ATLS 102 can be actuated or extended to a length greater than a length or extension of the vertical actuators 228 adjacent the rear end 214 of the ATLS 102 to tilt or slope the cart 204 downwardly in a direction between the front end 218 and the rear end 214.
  • the vertical actuators 228 adjacent the front end 218 of the ATLS 102 can be actuated or retracted to a length that is less than a length or extension of the vertical actuators 228 adjacent the rear end 214 of the ATLS 102 to tilt or slope the cart 204 upwardly in a direction between the front end 218 and the rear end 214
  • the first alignment system 226 of the illustrated example includes four vertical actuators. However, in some examples, the first alignment system 226 can include one actuator, two actuators, six actuators and/or any number of actuators.
  • FIG. 2E is a side view' of the example ATLS 102 of the illustrated example shown in an example vertically displaced position 270.
  • the front end 218 of the frame assembly 202 is raised relative to the rear end 214 such that the front end is sloped or angled relative to the rear end 214 in the longitudinal direction of the ATLS 102.
  • the actuator ends 228a of the vertical actuators 228 associated with or adjacent the front end 218 are raised or extended to a position (e.g., a stroke position) that is greater than a position (e.g., stroke position) of the vertical actuators 228 associated with the rear end 214 of the ATLS 102.
  • a position e.g., a stroke position
  • the pockets 231 associated with the vertical actuators 228 adjacent the front end 218 move with the movable frame 220 in an upward direction in the orientation of FIG. 2E and the housing 260 remains stationary. Additionally, the pockets 231 associated with the vertical actuators 228 adjacent the rear end 214 of the movable frame 220 are located at approximately a mid-point of a height (e.g., a vertical height) of the housing 260. Thus, the pockets 231 do not interfere with vertical movement of the movable frame 220 and/or the vertical actuators 228, but enable the vertical actuators 228 move laterally or sideways via a second alignment system 236 (e.g.. a lateral alignment system). As a result, in the illustrated example of FIG.
  • a second alignment system 236 e.g. a lateral alignment system
  • the front end 218 to be at a higher elevation than the rear end 214 of the ATLS 102.
  • the vertical actuators 228 associated with the rear end 214 can be moved to a position (e.g., a stroke position) that is greater than a position (e.g., a stroke position) of the vertical actuators 228 associated with the front end 218 to enable the rear end 214 to be at a higher elevation in the vertical direction than an elevation of the front end 218.
  • the vertical actuators 228 can each be actuated to different vertical positions (e.g., stroke positions) to orient the movable frame 220 to any desired position.
  • vertical alignment system can include a plurality of pivotal links adjacent respective ones of the corners of the frame assembly 202.
  • Each of the links includes a first arm, a second arm. and a hinge.
  • the first arm is coupled (e.g., fastened, welded, or otherw ise fixed) to the first frame portion at a first end of the first arm and a second end of the first arm opposite the first end is coupled to the hinge.
  • the second arm is coupled (e.g., fastened, welded, or otherwise fixed) to the second frame portion at a third end of the second arm and a fourth end of the second arm opposite the first end is coupled to the hinge.
  • the first arm is coupled to the second arm via the hinge.
  • each of the pivotal links includes an actuator.
  • the actuator includes a first end coupled to the first frame portion of the first arm of the pivotal link and a second end coupled to the second frame portion.
  • the ATLS 102 of the illustrated example includes a second alignment system 236 (e.g., a lateral alignment system).
  • the second alignment system 236 of the illustrated example includes a first lateral actuator 238 (e.g.. a first actuator or front end drive) and a second lateral actuator 240 (e.g., a second actuator or a rear end drive).
  • the first lateral actuator 238 and the second lateral actuator 240 can be operated independently of each other.
  • the second alignment system 236 of the illustrated example includes two lateral actuators. However, in some examples, the second alignment system 236 can include one actuator, three actuators, six actuators and/or any number of actuators.
  • FIG. 3 A is a top view of the example ATLS 102 in an example first lateral position 301 (e.g., an initial or centered position).
  • FIG. 3B is a side view of the example ATLS 102 of FIG. 3 A.
  • FIG. 3C is a bottom view of the example frame assembly 202 and the second alignment system 236 of the ATLS 102 of FIGS. 3A.
  • FIG. 3D is a top view of the example ATLS 102 in an example second lateral position 303 (e.g.. a first skewed position).
  • FIG. 3E is a side view of the example ATLS 102 of FIG. 3D.
  • FIG. 3F is a bottom view of FIG. 3D.
  • FIG. 3G is a top view of the example ATLS 102 in an example third lateral position 305 (e.g., a second skewed position).
  • FIG. 3H is a side view of the example ATLS 102 of FIG. 3G.
  • FIG. 31 is a bottom view of FIG. 3G.
  • the frame assembly 202 of the illustrated example is coupled to and/or movable by the alignment system 200.
  • the first lateral actuator 238 adjusts the front end 218 of the ATLS 102 (e.g., the movable frame 220) relative to the rear end 214 and the second lateral actuator 240 adjusts the rear end 214 of the ATLS 102 (e.g., the movable frame 220) relative to the front end 218.
  • the first lateral actuator 238 and the second lateral actuator 240 are linear actuators.
  • the first lateral actuator 238 of the illustrated example is coupled to the movable frame 220 and the fixed frame 222.
  • a first end 302 (e.g., a piston end) of the first lateral actuator 238 is coupled (e.g., fixed to) a front end 304 of the movable frame 220 (e.g., via a mounting bracket) and a second end 306 (e.g., a cylinder end) of the first lateral actuator 238 is coupled (e.g.. mounted) adjacent to a front end 308 of the fixed frame 222 (e.g., via a mounting bracket).
  • the second lateral actuator 240 of the illustrated example is coupled to the movable frame 220 and the fixed frame 222.
  • a first end 310 e.g., a piston end
  • a second end 314 e.g., a cylinder end
  • a first end 310 e.g., a piston end
  • a second end 314 e.g., a cylinder end
  • the second lateral actuator 240 is coupled (e.g., mounted) adjacent to a rear edge 316 of the fixed frame 222 (e.g., via a mounting bracket).
  • the first and second lateral actuators 238, 240 can move or actuate (e.g., independently or in coordination) to modify a positioning of the movable frame 220 relative to a reference (e.g., a reference line 318 corresponding to a position of the vehicle 1 18).
  • the second alignment system 236 can be employed to move the front end 304 and/or the rear end 312 in a first lateral direction 320 and/or a second lateral direction 322 to angle the movable frame 220 and, thus, position the ATLS 102 (e.g., the cart 204), in alignment with respect to a vehicle or trailer (e.g., the vehicle 118).
  • the second alignment system 236 can be employed to move the front end 304 and the rear end 312 (e.g., simultaneously or a same distance) in a first lateral direction 320 (e.g. an upward direction in the orientation of FIG. 3C) and a second lateral direction 322 (e.g. a downw ard direction in the orientation of FIG. 3C) opposite the first lateral direction 320 to offset a lateral position of the movable frame 220 relative to the reference line 318 and/or the fixed frame 222 (e.g., to position the ATLS 102 (e.g.. the cart 204) in alignment with respect to the vehicle 118).
  • a first lateral direction 320 e.g. an upward direction in the orientation of FIG. 3C
  • a second lateral direction 322 e.g. a downw ard direction in the orientation of FIG. 3C
  • the ATLS 102 can move laterally in the first lateral direction 320 and the second lateral direction 322 based on coordinated movements of the first and second lateral actuators 238, 240 (e.g., simultaneous movement or movement of a same stroke length of the first and second lateral actuators 238. 240 in extension or retraction). Further, the ATLS 102 can rotate in a first angular direction 324 (e.g., a clockwise direction in the orientation of FIGS. 3C and 3F) based on an extension of the first lateral actuator 238 and/or retraction of the second lateral actuator 240. The ATLS 102 can rotate in a second angular direction 326 (e.g., a counterclockwise direction in the orientation of FIG. 3C) based on a retraction of the first lateral actuator 238 and/or extension of the second lateral actuator 240.
  • a first angular direction 324 e.g., a clockwise direction in the orientation of FIGS. 3C and 3F
  • the first lateral actuator 238 and the second lateral actuator 240 are positioned at similar or identical stroke length positions to cause the movable frame 220 to move to the first lateral position 301.
  • the front end 304 of the movable frame 220 is parallel or aligned with the front end 308 of the fixed frame 222
  • the rear end 312 of the movable frame 220 is parallel or aligned with the rear edge 316 of the fixed frame 222.
  • the front end 308 of the movable frame 220 and the rear end 312 of the movable frame 220 are central located relative to the first side 208 and the second side 210 of the frame assembly 202.
  • the first lateral actuator 238 and the second lateral actuator 240 are positioned at different stroke positions such that the first lateral actuator 238 is at a first stroke position that is less than a second stroke position of the second lateral actuator 240.
  • the front end 304 of the movable frame 220 is angled or non-parallel (e.g., skewed) relative to the front end 308 of the fixed frame 222
  • the rear end 312 of the movable frame 220 is angled or non-parallel (e.g., skewed) relative to the rear edge 316 of the fixed frame 222 such that the rear end 312 is closer to the second side 210 of the fixed frame 222 than the first side 208 of the fixed frame 222.
  • the first lateral actuator 238 and the second lateral actuator 240 are positioned at different stroke positions such that the first lateral actuator 238 is at a first stroke position that is greater than a second stroke position of the second lateral actuator 240.
  • the front end 304 of the movable frame 220 is angled or non-parallel (e.g., skewed) relative to the front end 308 of the fixed frame 222
  • the rear end 312 of the movable frame 220 is angled or non-parallel (e.g., skewed) relative to the rear edge 316 of the fixed frame 222 such that the rear end 312 is closer to the first side 208 of the fixed frame 222 than the second side 210 of the fixed frame 222.
  • the operating limits of the first lateral actuator 238 and the second lateral actuator 240 define a lateral operating limit and/or an angular operating limit of the ATLS 102.
  • the ATLS 102 is laterally movable between a full extension position or stroke of the first and second lateral actuators 238, 240 and a full retraction position or stroke of the first and second lateral actuators 238, 240.
  • the lateral operating limit of the ATLS 102 can be defined by a maximum length of the first and second lateral actuators 238, 240 (at full extension stroke) and a minimum length of the first and second lateral actuators 238, 240 (at full retraction stroke).
  • the ATLS 102 can rotate in the first angular direction 324 (e.g., a clockwise direction in the orientation of FIGS. 3C and 3F) between a full retraction position or stroke of the second lateral actuator 240 and a full extension position or stroke of the first lateral actuator 238.
  • the ATLS 102 can rotate in the second angular direction 326 (e.g.. a counterclockwise direction in the orientation of FIG. 3C) between a full retraction position or stroke of the first lateral actuator 238 and a full extension position or stroke of the second lateral actuator 240.
  • the angular operating limit of the ATLS 102 can be defined by a maximum clockwise rotation and a maximum counterclockwise rotation.
  • the second alignment system 236 is limited from rotating or translating the ATLS 102 beyond the extension/retraction capabilities of the first and second lateral actuators 238, 240 (as defined by the lateral operating limit and the angular operating limit).
  • FIG. 3J is an enlarged, partial perspective view of the example second alignment system 236 of FIGS. 3A-3I.
  • the second alignment system 236 of the illustrated example includes glide pads 328.
  • the glide pads 328 are coupled to the vertical actuators 228.
  • the glide pads 328 can be coupled to the movable frame 220.
  • the glide pads 328 of the illustrated example are coupled or positioned at each comer of the movable frame 220 (e.g.. via the vertical actuators 228).
  • the glide pads 328 include a plurality of rollers 330 that engage a floor (e.g., the floor of the pit) to facilitate movement of the movable frame 220 in the first and second lateral directions 320, 322.
  • the rollers can be wheels, balls, spheres and/or any other suitable rollers for reducing friction.
  • FIG. 4A is a perspective top view of the example ATLS 102 of FIGS. IA-IB and 2A-2B.
  • FIG. 4B is a perspective bottom view of the example ATLS 102 of FIG. 4A.
  • the movable frame 220 of the illustrated example includes a first frame portion 402 (e.g., an upper frame portion) and a second frame portion 404 (e.g., a lower frame portion) spaced from the first frame portion 402.
  • the movable frame 220 defines a cavity’ 406 between the first frame portion 402 and the second frame portion 404.
  • the ATLS 102 of the illustrated example includes a cart drive system 408.
  • the cart 204 is coupled (e.g., tethered) to the frame assembly 202 via the cart drive system 408.
  • the cart drive system 408 moves the cart 204 into and out of the cargo area 116 of the vehicle 118 during a loading/unloading operation.
  • the cart drive system 408 of the illustrated example moves the cart 204 in a linear direction relative to (e.g., away from and/or towards) the frame assembly 202.
  • the cart drive system 408 of the illustrated example moves the cart 204 in a first linear direction 410 (e.g.. a forward direction) and a second linear direction 412 (e.g., a rearward direction) opposite the first linear direction 410 in the orientation of FIGS. 4 A and 4B.
  • a first linear direction 410 e.g.. a forward direction
  • a second linear direction 412 e.g., a rearward direction
  • the cart drive system 408 of the illustrated example includes a track 414, a drive beam 416, and a motor 418.
  • the track 414 houses or receives the drive beam 416 (e.g., contains or confines the drive beam 416 when the cart drive system 408 and/or the cart 204 are in a stored position).
  • the drive beam 416 is in a stored configuration 420 (e.g., a fully stored position)
  • at least a portion of the drive beam 416 is stored within a perimeter and/or volume (e.g.. the cavity’ 406) of the movable frame 220.
  • At least some of the drive beam 416 is hidden from view in the stored configuration 420 because the track 414 stores the drive beam 41 in a loop (e g., harbored in the track 414) beneath the platform 1 11 8 and/or an upper surface 422 of the first frame portion 402.
  • the drive beam 416 is positioned above the platform 108 and/or on top of or above the upper surface 422 of the first frame portion 402.
  • the drive beam 416 is flat or straight in the extended configuration.
  • the track 414 of the illustrated example is positioned underneath the cart 204. Specifically, the track 414 is positioned (e.g., within the cavity 406 or space) between the first frame portion 402 and the second frame portion 404. Specifically, the track 414 is positioned between the first side 208 of the frame assembly 202 (e.g., the first frame portion 402) and a second side 210 of the frame assembly 202 and positioned between the first frame portion 402 and the second frame portion 404. In other words, the track 414 is at least positioned partially underneath the first frame portion 402.
  • a portion of the track 414 extends from underneath the first frame portion 402 and toward the upper surface 422 of the first frame portion 402 adjacent a rear edge 424 of the first frame portion 402 opposite a front end 426.
  • the track 414 is positioned along a longitudinal or center axis 428 of the movable frame 220 and/or the cart 204.
  • the track 414 of the illustrated example includes a first track provided adjacent the first side 208 of the frame assembly 202 and a second track provided adjacent the second side 210 of the frame assembly 202.
  • the ATLS 102 can include a plurality of drive systems and/or tracks positioned between the first side 208 and the second side 210 of the frame assembly 202.
  • the ATLS 102 can include a first track positioned along the center axis 428 of the frame assembly 202 (e.g., as shown in FIG. 4 A), a second track positioned along the first side 208 of the frame assembly 202 and a third track positioned along the second side 210 of the frame assembly 202.
  • the track 414 of the illustrated example is a housing 430 having a first track side wall 432 and a second track side wall 434 spaced from the first track side wall 432 by a thickness T.
  • the first track side wall 432 and the second track side wall 434 define a cavity 436 within which the drive beam 416 is positioned and/or stored.
  • the housing 430 is coupled or fixed to the first frame portion 402.
  • a first edge 438 (e.g., a first longitudinal edge) of the track 414 (e.g., of each of the track side walls 432, 434) is coupled to the first frame portion 402 and a second edge 440 (e.g., a second longitudinal edge) of the track 414 (e.g., of each of the track side walls 432, 434) is suspended or projects the first frame portion 402.
  • the second edge 440 (e.g.. a second longitudinal edge) of the track 414 (e.g.. of each of the track side walls 432, 434) is coupled to the second frame portion 404 and the first edge 438 protrudes or projects from the second frame portion 404.
  • FIG. 5A is a cross-sectional side view of the ATLS 102 of FIG. 4A and 4B.
  • FIG. 5B is a perspective view of the example track 414 of FIGS. 4A and 4B.
  • FIG. 5C is a perspective view of a first end cap 502 of the track 414 of FIGS. 4A and 4B.
  • FIG. 5D is a perspective view of a first side wall 504 of the track 414 of FIGS. 4A and 4B.
  • FIG. 5E is a perspective view of a second end cap 506 of the track 414 of FIGS. 4A and 4B.
  • FIGS. 5C-5E illustrate the first track side wall 432 of the track 414 of FIGS. 4A and 4B.
  • the second track side wall 434 of the track 414 is a mirror image of the first track side wall 432 of the track 414 of FIGS. 4A and 4B.
  • the track 414 of the illustrated example has a spiral, oval or serpentine shape or pathway 500.
  • the track 414 includes a plurality of channels 508 having an oblong shape formed and/or supported by the housing 430 to form the serpentine pathway.
  • the first end cap 502 couples to a front edge 511 of the first side wall 504 and the second end cap 506 couples to a rear edge 512 of the first side wall 504.
  • the first end cap 502, the first side wall 504 and the second end cap 506 define the channels 508 that align to define respective track portions 510.
  • the first end cap 502 includes a plurality of curved channels 508a
  • the first side wall 504 includes a plurality of straight channels 508b
  • the second end cap 506 includes a plurality 7 of curved channels 508c.
  • the second end cap 506 includes an outlet 508d that is positioned adjacent to the upper surface 422 of the first frame portion 402.
  • the first end cap 502 provides the outlet 508d of the track 414 that enables the drive beam 416 to move above (e.g., on top of) the first frame portion 402 (e.g., from underneath the first frame portion 402).
  • the channels 508 can be provided (e.g., cut, grooved, extruded, etc.) in the first side wall 504, the first end cap 502 and the second end cap 506.
  • the first end cap 502, the second end cap 506 and the first side wall 504 can be integrally formed as a single piece or structure.
  • the track 414 of the illustrated example includes a plurality of track portions 510 (e.g., vertically spaced track portions, loops, channels, etc.).
  • the track 414 includes a first track portion 510a, a second track portion 510b. a third track portion 510c, a fourth track portion 51 Od and a fifth track portion 51 Oe.
  • the track portions 51 Oa-51 Oe receive the drive beam 416 to enable the drive beam 416 to w ind or collapse in a serpentine pattern when the drive beam 416 is in a stored position. For instance, in the stored position, the drive beam 416 is positioned within the track portions 510a-510e of the track 414 of the ATLS 102 (e.g...
  • the drive beam 416 of the illustrated example is snaked or wounded underneath the first frame portion 402 via the track 414.
  • the track 414 e.g., the vertically separated channels 510a-510e
  • the drive beam 416 extends (e.g., unfolds or unrolls) from the track 414 and moves into the cargo area 116 of the vehicle 118.
  • the track 414 maintains an orientation of the drive beam 416 during deployment.
  • FIG. 6A is a perspective view of the drive beam 416 of FIGS. 4A-4B.
  • FIG. 6B is a partial, enlarged portion of the drive beam 416 of FIG. 4A.
  • the drive beam 416 of FIGS. 6A and 6B is shown in a coiled or stored configuration 600.
  • the drive beam 416 of the illustrated example is foldable, deflectable, or bendable. In this manner, the drive beam 416 of the illustrated example can roll up, wind, coil or otherwise fold to the stored configuration 600 (e.g.. as shown in FIG. 5 A).
  • the drive beam 416 is a continuous drive beam having a length between a leading end 602 (e.g., edge) and a trailing end 604 (e.g., edge).
  • the trailing edge or end 604 of the drive beam 416 snakes around the channels 508 of the track 414 in the curved or serpentine pattern and the leading end 602 is positioned adjacent the outlet 508d.
  • the drive beam 416 of the illustrated example can be folded into loops 606a-e that correspond with respective ones of the track portions 510a-d of FIGS. 5A-5E.
  • a first loop 606a is positioned in the first track portion 510a.
  • a second loop 606b is positioned in the second track portion 510b
  • a third loop 606c is positioned in the third track portion 510c
  • a fourth loop 606d is positioned in the fourth track portion 510d
  • a fifth loop 606e is positioned in the fifth track portion 510e.
  • the drive beam 416 exits the track 414 and extends in a substantially straight configuration.
  • the drive beam 416 of the illustrated example can have a total extended length of approximately between 65 feet and 75 feet (e.g., 70 feet).
  • the platform 108 and/or the ATLS 102 can have a length of approximately between 5 feet and 20 feet (e.g., 15 feet).
  • the drive beam 416 can be configured to accommodate a cargo bed (e.g., the cargo area 116) having a length of approximately 53 feet.
  • the drive beam 416 of the illustrated example includes a plurality of drive beam links 608 that interconnect to provide a continuous drive beam and enable the drive beam 416 to roll or bend about the track 414 when the drive beam 416 moves to the stored configuration 600.
  • the drive beam 416 of the illustrated example includes a drive chain 610 (e.g., a roller chain, a chain, etc.) and a cover 612.
  • the drive chain 610 interacts or interfaces with the cart drive system 408 and the cover 612 interacts or interfaces with the track 414.
  • the drive beam 41 includes a cable carrier channel 616 provided by the cover 612.
  • the cable carrier channel 616 can cany' one or more power cords, communication cables, and/or other cords or cables of the ATLS 102.
  • the drive chain 416 of the illustrated example includes a plurality of chain links 618 and the cover 612 of the illustrated example includes a plurality of cover links 620.
  • a respective one 618a of the chain links 618 and a respective one 620a of the cover links 620 provides a respective one 608a of the drive beam links 608.
  • Each of the chain links 618 are pivotally coupled and/or interconnected to provide a continuous drive chain and each of the cover links 620 are pivotally coupled and/or interconnected to provide a continuous cover.
  • a respective one 620a of the cover links 620 is coupled to and/or houses a respective one 618a of the chain links 618.
  • respective ones of the cover links 620 encase, encompass, or surround respective ones of the chain links 618.
  • Each of the cover links 620 of the illustrated example includes a first link side wall 622, a second link side wall 624 spaced from the first link side wall 622, and a plate 626 coupling the first link side wall 622 and the second link side wall 624.
  • the plate 626 is coupled to the first link side wall 622 and the second link side wall 624 via fasteners 628 (e.g., screws).
  • the plate 626 can be coupled to the first and second link side walls 622, 624 via welding and/or any other suitable fastener.
  • Each of the cover links 620 of the illustrated example also includes a first plate side wall 630 extending from a first side of the plate 626 and/or adjacent the first link side wall 622 and a second plate side wall 632 extending from a second side of the plate 626 and/or adjacent the second link side wall 624.
  • the plate 626, the first plate side wall 630 and the second plate side wall 632 define a channel portion 616a of the cable carrier channel 616.
  • each of the cover links 620 of the illustrated example includes a first roller 614a coupled to the first link side wall 622 and a second roller 614b coupled to the second link side wall 624.
  • the first roller 614a projects in a direction away from the first link side wall 622 and the second roller 614b projects in a direction away from the second link side wall 624.
  • the cover links 620 e.g., and the drive chain 618) move within the cavity' 436 (FIG. 4B) formed between the first track side wall 432 of the track 414 and the second track side wall 434 of the track 414, with the first roller 614a interfacing with (e.g., engaging) the channels 508 of the first track side wall 432 of the track 414 and second roller 614b interfacing with (e.g., engaging) the channels 508 of the second track side wall 434 of the track 414.
  • the cover links 620 can couple to the chain links 618 via a fastener, welding, and/or any other suitable fastener(s).
  • the cover 612 provides rigidity to the drive beam 416 when in an extended position.
  • the drive beam 416 e.g., the cover links 620
  • each of the first link side wall 622 and the second link side wall 624 include a tab or lip 638 projecting from a front edge of the cover links 620 and a groove or shoulder 640 formed on a rear edge of the cover links 620.
  • the lip 638 of the first one 608a of the drive beam links 608 engages (e.g., is received by) the shoulder 640 of a second one 608b of the drive beam links 608 (e.g., immediately) adjacent (e.g., in front of) the first one 608a of the drive beam links 608.
  • the lips 638 and the shoulders 640 of adjacent ones of the drive beam links 608 disengage or move away from each other to enable the drive beam 416 to bend in a first direction 644 (e.g., a downward direction).
  • the lips 638 and the shoulders 640 of adjacent ones of the drive beam links 608 engage to prevent the drive beam 416 from bending or flexing in a second direction 646 (e.g., an upward direction) opposite the first direction 644.
  • An upward flex of the drive beam 416 (e.g., in the second direction 646) is limited by interference provided between respective ones of the lips 638 of the cover links 620 touching or engaging respective ones of the shoulders 640 of adjacent ones of the cover links 620.
  • the lips 638 engage or interact with the shoulders 640 to provide a rigid drive beam.
  • the ground or surface on which the drive beam 416 moves prevents rotation of the drive beam in the first direction 644 and the locking interface (e.g.. provided by the lips 638 and the shoulders 640) prevents rotation of the drive beam 416 in the second direction 646, thereby providing a rigid characteristic to the drive beam 416.
  • the cover links 620 prevent pivotal movement of the drive beam links 608 in the second direction 646 (e.g., a collapsed configuration).
  • the drive beam 416 is not supported on a flat surface and/or bends out of alignment in the first direction 644 (e.g., a downward rotation in the orientation of FIGS.
  • adjacent drive beam links 608 can rotate or pivot relative to each other and the drive beam 416 can bend or collapse to the stored configuration 600.
  • the drive beam 416 and/or the drive beam links 608 can pivot relative to each other to enable the drive beam 416 to move (e.g., snake) along the track 414 to the stored configuration
  • FIG. 7A is a perspective rear view of the ATLS 102 of FIGS. 1A, IB, 2A and 2B.
  • FIG. 7B is an enlarged, partial view of the ATLS 102 of FIG. 7A.
  • FIG. 7C is a partial cross-sectional view of the cart drive system 408 of FIG. 7A.
  • the drive beam 416 of the illustrated example is coupled or tethered to the cart 204. Specifically, the drive beam 416 of the illustrated example is coupled (e g., fixed or fastened) to a rear end or rear edge 702 of the cart 204 via a bracket 704.
  • the bracket 704 includes a first flange 704a to couple to a first side of the drive beam 416 and a second flange 704b to couple to a second side of the drive beam 416.
  • a chain link 706 of the leading end 602 of the drive beam 416 of the drive beam 416 can be coupled to the bracket 704 via a locking pin.
  • the drive beam 416 can be welded to the bracket 704.
  • the ATLS 102 of the illustrated example includes the motor 418.
  • the motor 418 is mounted or coupled to the second frame portion 404 adjacent to the rear end 214 of the frame assembly 202.
  • the motor 418 of the illustrated example is coupled to the drive beam 416 via a transmission 708.
  • the transmission 708 of the illustrated example includes a drive belt 710, a plurality of gears and/or sprockets 712, and a drive shaft 714 to operatively couple an output shaft 716 of the motor 418 and the drive beam 416.
  • the drive shaft 714 includes a first gear or sprocket 712a to interface with the drive belt 710 and a second gear 712b to interface with the drive chain 618.
  • the second gear 712b includes teeth 718 that engage with the chain links 618 to push or pull the drive beam 416 relative to the track 414.
  • Rotation of the output shaft 716 in a first rotational direction 720 about an axis of rotation 724 via the first motor causes the drive beam 416 to retract to the stored configuration 600 and rotation of the output shaft 716 in a second rotational direction 722 opposite the first rotational direction 720 about the axis of rotation 724 via the motor 418 causes the drive beam 416 to move to an extended or operational position.
  • FIGS. 8A-8G are various views of the cart 204 or FIGS. 2A and 2B.
  • FIG. 8A is a perspective top view of the cart 204.
  • FIG. 8B is an enlarged, partial view of the cart 204 of FIG. 8A.
  • FIG. 8C is another enlarged, partial view of the cart 204 of FIGS. 8A and 8B.
  • FIG. 8D is an alternative roller disclosed herein.
  • FIG. 8E is a partial, rear perspective view of the cart 204 of FIGS. 8A and 8B.
  • FIG. 8F is a perspective bottom view of the cart 204 of FIGS. 8A and 8B.
  • FIG. 8G is a partial perspective view of the cart 204 of FIG. 8F.
  • the cart 204 of the illustrated example includes a cart frame 802, a plurality of surface or upper rollers 804 (e.g., anti-friction rollers) and a plurality of lower rollers 806 (e.g., anti-friction rollers).
  • the cart frame 802 includes a plurality of longitudinal beams 808 for rotatably coupling the upper rollers 804 and/or the lower rollers 806 to the cart frame 802 and a plurality 7 of braces 810 extending between and/or coupled to adjacent ones of the longitudinal beams 808 to support and/or reinforce the longitudinal beams 808.
  • the cart frame 802 is tethered to the movable frame 220 via the drive beam 416. In other words, the cart frame 802 and/or the cart 204 is coupled to the movable frame 220 only via the drive beam 416.
  • the cart 204 of the illustrated example includes the upper rollers 804.
  • the upper rollers 804 facilitate positioning (e.g., receiving and/or removal) of a load on the cart 204.
  • the cart 204 of the illustrated example includes the lower rollers 806 (FIGS. 8F and 8G).
  • the lower rollers 806 reduce friction between a ground floor (e.g., a support floor, a floor of the vehicle) when the cart 204 moves (e.g., slides) on surfaces.
  • the upper rollers 804 can extend below the upper surface 811 of the cart 204. However, the upper rollers 804 do not engage a ground surface on which the cart 204 traverses during a loading/unloading operation.
  • the upper rollers 804 include a first set 804a of upper rollers 804 (e.g., rotatably coupled between a first pair of longitudinal beams 808), a second set 804b of upper rollers 804 (e.g., rotatably coupled between a second pair of longitudinal beams 808), a third set 804c of upper rollers 804 (e.g., rotatably coupled between a third pair of longitudinal beams 808). and a fourth set 804d of upper rollers 804 (e.g., rotatably coupled between a fourth pair of longitudinal beams 808).
  • the cart 204 of the illustrated example includes strips or covers 812 to cover gaps 814 formed between the longitudinal beams 808.
  • the upper rollers 804 of the illustrated example includes one or more drive rollers 816 and a plurality of follower rollers 818.
  • the drive rollers 816 of the illustrated example drive or cause rotation of the follower rollers 818.
  • the upper rollers 804 are rotatably coupled to (e g., journaled at) adjacent ones of the longitudinal beams 808.
  • the upper rollers 804 of the illustrated example include rotational axes 819 that are non-parallel (e.g., perpendicular) relative to a longitudinal axis 820 and/or a direction of movement 822 of the cart 204.
  • the upper rollers 804 rotate in a first rotational direction 824 to move a cargo load in a direction from the rear edge 702 of the cart toward a front edge 827 of the cart 204.
  • the drive rollers 816 can be controlled by a control system 1114 (e.g., programmable circuitry) and/or can be manually operated during a loading/unloading operation.
  • the drive rollers 816 of the illustrated example include a motor (e.g., contained within the roller) that rotates an output shaft of the drive rollers 816.
  • a motor e.g., contained within the roller
  • the roller transmission 830 of the illustrated example includes a plurality of belts 832 and a plurality' of pulleys 834.
  • a belt 832 interconnects or couples to pulleys of adjacent upper rollers 804.
  • An output shaft of each of the upper rollers 804 includes a pulley 834 to receive the belt 832 (e.g.. a belt-driven pulley system or transmission).
  • rotation of a drive roller 816a operatively coupled to a follower roller 818a via the roller transmission 830 causes rotation of the follower roller 818a.
  • the upper rollers 804 have the same diameter.
  • the drive rollers 816 can have a diameter that is different than (e.g. , greater than or less than) a diameter of the follower rollers 818. Also, any ratio of drive rollers to follower rollers can be used.
  • the lower rollers 806 of the illustrated example are coupled to a bracket 840 and protrude below the upper rollers 804.
  • the lower rollers 806 do not engage the upper rollers 804. In other words, the lower rollers 806 do not interfere with the upper rollers 804 during operation.
  • the lower rollers 806 have a diameter that is smaller than a diameter of the upper rollers 804.
  • the cart 204 of the illustrated example includes a lead-in ramp 844 (e.g., a guide ramp, a leading edge, a ramp, a lip, etc.).
  • the lead-in ramp 844 is tapered to facilitate removal of a load (e.g., enables pallets on the cart 204 to slide off smoothly) from the cart 204 when the load is delivered into the vehicle 118 (e.g., pallets are deposited into the cargo area 116) and the cart 204 of the ATLS 102 is extracted (e.g., removed or retracted) from the vehicle 118.
  • the cart 204 of the illustrated example includes guide rollers 846.
  • the guide rollers 846 are positioned adjacent to the front edge 827 of the cart frame 802 and aft of the lead-in ramp 844.
  • the guide rollers 846 each have a rotational axis 848 that is non-parallel (e.g., perpendicular) relative to the rotational axes 819 of the upper rollers 804.
  • the guide rollers 846 can be mounted at an angle such that the rotational axes 848 of the guide rollers 846 are angled (e.g., non-perpendicular) relative to the rotational axes 819 of the upper rollers 804.
  • the guide rollers 846 are coupled to the cart 204 via brackets 850.
  • the guide rollers 846 of the illustrated example include a first guide roller 846a positioned on a first side of the cart 204 and a second guide roller 846b positioned on a second side of the cart 204 opposite the first side.
  • FIG. 8G is a side view of another example roller 890 that can be used with the ATLS 102 disclosed herein.
  • the roller 890 of the illustrated example includes a housing 892 that houses a ball 894 (e.g., a sphere).
  • the ball 894 can rotate in any direction within the housing 892.
  • the roller 890 of FIG. 8D can be used in lieu of and/or in addition to, for example, the guide rollers 846, the lower rollers 806, the pad 328, and/or can be coupled underneath the lead-in lip 826.
  • FIG. 9A is a perspective view of the ATLS 102 of FIGS. 2A and 2B with the guide doors 206 shown in an example guide position 900.
  • FIG. 9B is another perspective view of the ATLS 102 of FIGS. 2A and 2B with the guide doors 206 shown in an example transfer position 902.
  • the guide doors 206 are movable between the guide position 900 at which the guide doors 206 are positioned perpendicular relative to the upper surface 422 of the frame assembly 202 and the transfer position 902 at which the guide doors 206 are substantially parallel relative to the upper surface 422 of the frame assembly 202.
  • the guide doors 206 are in an upright position (e.g., a vertical position).
  • the guide doors 206 can flank cargo positioned on the cart 204.
  • the transfer position 902 the guide doors 206 are in a lower or flat position (e.g., a horizontal position). In other words, the guide doors 206 are folded or positioned on top of the upper surface 422 of the movable frame 220.
  • the guide doors 206 enable transfer of cargo from the rear end 214 of the frame assembly 202 to the front end 218 of the frame assembly 202 (e.g., and onto the cart 204).
  • the guide doors 206 include a first guide door 904 (e.g., a panel) pivotally coupled to the first side 208 of the frame assembly 202 and a second guide door 906 (e.g., a panel) pivotally coupled to the second side 210 of the frame assembly 202.
  • the first guide door 904 pivots about a first pivot axis 904a and the second guide door 906 pivots about a second pivot axis 906a.
  • the first pivot axis 904a and the second pivot axis 906a are substantially parallel relative to the center axis 428 of the frame assembly 202.
  • the ATLS 102 of the illustrated example includes a guide door drive system 908.
  • the guide door drive system 908 of the illustrated example includes a plurality of actuators 910.
  • the actuators 910 includes a first set 910a of actuators 910 to operate the first guide door 904 and a second set 910b of the actuators 910 to operate the second guide door 906.
  • a first end 912 e.g., a piston end
  • each actuator 910 is coupled to a respective one of the guide doors 206 and a second end 914 (e.g..
  • each actuator 910 is coupled to the frame assembly 202 (e.g., the second frame portion 404 of the movable frame 220).
  • the frame assembly 202 e.g., the second frame portion 404 of the movable frame 220.
  • movement of the actuators 910 from a retracted position to an extended position causes the guide doors 206 to rotate about the respective pivot axes 904a, 906a from the guide position 900 to the transfer position 902 and movement of the actuators 910 from an extended position to a retracted position causes the guide doors 206 to pivot about the respective pivot axes 904a, 906a from the transfer position 902 to the guide position 900.
  • the guide doors 206 of the illustrated example include a plurality of guide door rollers 916.
  • the guide door rollers 916 of the illustrated example include can include one or more drive rollers, one or more driven rollers, and/or a mix of drive rollers and follower rollers.
  • Each of the guide doors 206 includes a guide door frame 918 including beams 920 to rotatably couple the guide door rollers 916 (e.g., substantially similar to the cart frame 802).
  • the guide door rollers 916 of the guide doors 206 include rotational axes that are substantially parallel relative to the rotational axes 819 (FIGS.
  • the guide doors 206 can be structured or configured substantially similar to the cart 204 and/or the guide door rollers 916 of the guide doors 206 can be structured or configured substantially similar to the upper rollers 804 of the cart 204.
  • one or more of the guide door rollers 916 can be tethered via a transmission (e.g., a belt-pulley transmission of FIGS. 8A-8F) to operatively couple two or more other ones of the guide door rollers 916.
  • the guide doors 206 each have a width that provide a gap 922 between respective inner edges 924 of the guide doors 206 to receive the drive beam 416 therebetween when the guide doors 206 are in the transfer position 902.
  • the guide doors 206 are pivoted downward on top of and/or above the first frame portion 402 of the movable frame 220 when the cart 204 is removed or positioned away from the first frame portion 402.
  • a front edge 920a of the guide doors 206 can be positioned adjacent the rear edge 702 of the cart 204 (e.g., the cart 204 is positioned in the cargo area 116 adjacent the guide doors ).
  • the guide door rollers 916 and/or the guide door frame 918 are above an uppermost surface of the drive beam 41 .
  • the guide doors 206 do not interfere with the cart drive system 408 and/or the drive beam 416 when the guide doors 206 are in the transfer position 902.
  • FIG. 10A is a partial perspective front view of the example ATLS 102 of FIGS. 1, 2A and 2B with an example sensor assembly 1000 of an example scanner system shown in an example stowed position 1002.
  • FIG. 10B is a partial perspective front view of the example ATLS 102 of FIG. 10A with the example sensor assembly 1000 of the example scanner system shown in an example scanning position 1004.
  • FIG. 10C is a front view of the example sensor assembly 1000 of FIG. 10B.
  • the example sensor assembly 1000 of the example ATLS 102 is provided (e.g., housed) within the transition platform 216.
  • the sensor assembly 1000 of the illustrated example is positioned adjacent the front end 218 of the ATLS 102.
  • the sensor assembly 1000 includes an arm 1006 and a sensor 1008 carried by the arm 1006.
  • the arm 1006 e.g., an outer surface 1010 of the arm 1006 is flush mounted with the upper surface 422 of the first frame portion 402 of the movable frame 220.
  • the stowed position 1002 the sensor 1008 is hidden from view and/or is positioned underneath the first frame portion 402 of the movable frame 220.
  • the example arm 1006 may be a portion of the first frame portion 402 of the movable frame 220 of the ATLS 102.
  • the arm 1006 can be built or integrated with the first frame portion 402 of the movable frame 220 of the ATLS 102.
  • the sensor 1008 can be stowed underneath or below the cart 204 and/or flush mounted relative to a travel path of the cart 204 of the ATLS 102 after a scanning operation so that the sensor assembly 1000 does not interfere with a loading/unloading operation.
  • the sensor 1008 is positioned on a distal end of the arm 1006 (e.g., support arm, lever arm, elongated arm, etc.).
  • the sensor 1008 of the illustrated example includes a first sensor 1008a and a second sensor 1008b.
  • the first sensor 1008a performs a first scan (e.g., a horizontal scan) of the cargo area 11 and the second sensor 1008b performs a second scan (e.g., a vertical scan) of the cargo area 1 16.
  • the example arm 1006 is pivotable (e.g., rotatable) about an axis 1012 defined by a hinge 1014. As shown in FIG.
  • the sensor assembly 1000 includes an example sensor actuator 1016 to rotate (e.g.. push/pull on) the arm 1006 about the hinge 1014 to adjust a position of the sensor assembly 1000 between the stowed position 1002 and the scanning position 1004.
  • the ATLS 102 can include a control system 1114 (e.g., programmable circuitry) that commands the sensor actuator 1016 to pivot the arm 1006 between the stowed position 1002 and the scanning position 1004.
  • the sensor 1008 may be a two dimensional (2D) LIDAR sensor, a three- dimensional (3D) LIDAR sensor, a camera, etc.
  • the sensor assembly 1000 can employ time of flight technology to scan the cargo area 116 and determine information regarding a position of the vehicle relative to a reference (e.g. a longitudinal axis of the ATLS 102), a length of the cargo area 116, a lateral position of the vehicle 118 relative to the reference, an angular position of the vehicle 1 18 relative to the reference and/or any other information.
  • a reference e.g. a longitudinal axis of the ATLS 102
  • a control system e.g., processor circuitry, programmable circuitry, programmable logic controllers, etc.
  • receives and/or processes data e.g., feedback signals
  • data e.g., feedback signals
  • FIG. 11A-11C are schematic illustrations of the ATLS 102 of FIGS. 1 A, 2B, 2A and 2B in an example scanning operation.
  • FIGS. 11 A is a side view of the example loading dock 100 with the vehicle 118 parked at the loading dock 100 and the ATLS 102 performing an example scanning operation 1100.
  • FIG. 1 IB is a partial perspective view of the ATLS 102 and the loading dock 100 of FIG. 11 A.
  • FIG. 11C is another perspective view of FIGS. 11A and 1 IB showing the cargo area 116 of the vehicle 118.
  • the sensor assembly 1000 moves from the stowed position 1002 to the scanning position 1004 via the sensor actuator 1016.
  • the example sensors 1008 projects one or more beams 1102, 1104 (e.g., laser beams) to perform the scanning operation 1100.
  • the first sensor 1008a performs a scan (e.g., a two-dimensional scan) in a first direction (e.g., a horizontal direction or between the inner side walls 1106 of the vehicle 118) and the second sensor 1008b performs a scan in a second direction (e.g., a vertical direction or between an upper roof surface 1108 and a floor 1110) different than the first direction (e.g., perpendicular relative to the first direction).
  • a scan e.g., a two-dimensional scan
  • a first direction e.g., a horizontal direction or between the inner side walls 1106 of the vehicle 118
  • the second sensor 1008b performs a scan in a second direction (e.g., a vertical direction or between an upper roof surface 1108 and a floor 1110) different than the first direction (e.g., perpendicular relative to the first direction).
  • the ATLS 102 of the illustrated example includes a control system.
  • the control system 1114 receives and/or processes signals (e.g., feedback signals) from the sensor 1008 to determine information regarding the cargo area 1 16 and/or the vehicle 118 including, but not limited to, a vehicle reference 1116 of the vehicle 118, a width of an opening of the vehicle 118 (e.g., between the inner side walls 1106), a height of the opening of the vehicle 118, a depth or length of the cargo area 116, obstructions within the cargo area 116, an orientation of the vehicle 118 relative to areference of the ATLS 102 and/or the doorway 106, a vertical position of the ATLS 102 relative to the vehicle 118 (e.g., the floor 11 10 of the cargo area 116), and/or other information regarding a position of the vehicle 1 18 relative to the loading dock 100 and/or information regarding the cargo area 116.
  • signals e.g., feedback signals
  • the sensor assembly 1000 can detect and/or determine positional information associated with the cargo area 116. the vehicle 118, and/or the ATLS 102.
  • the sensor 1008 can determine positional information of the inner side walls 1106, the floor 1110 and/or the upper roof surface 1108 of the vehicle 118, an end wall 1112 of the vehicle 118, a length of the vehicle 118 and/or any other information relating to the vehicle 118.
  • the control system 1114 determines the vehicle reference 1 116 for adjusting the ATLS 102 relative to the vehicle reference 1116.
  • the control system 1 114 can determine a lateral position of the vehicle reference 1116 and/or an angular slope 1118 of the vehicle reference 1116 relative to horizontal 1120.
  • the vehicle reference 1116 is a central or longitudinal axis of the cargo area 116 and/or the vehicle 118 (e g., the trailer) when parked on a driveway 1122 of the loading dock 100 and restrained (e.g., by a vehicle restraint) for a loading operation.
  • FIGS. 12A-12B are top views of the loading dock 100 of FIGS. 1A, IB, 2A and 2B illustrating an example lateral alignment operation 1200.
  • FIG. 12A is a top view of the example ATLS 102 in an example first lateral position 1202 (e.g., an initial or reference position) relative to the example vehicle 118.
  • FIG. 12B is a top view of the example ATLS 102 in an example second lateral position 1204 (e.g., an adjusted lateral position) relative to the vehicle 118.
  • the sensor assembly 1000 is in the scanning operation 1100 to scan the cargo area 116 of the vehicle 118 (e.g., via the sensor 1008).
  • the ATLS control system determines the vehicle reference 1116 (e.g., a longitudinal axis or reference) of the vehicle 1 18 relative to (e.g., compared to) an ATLS reference 1208 (e.g., a longitudinal axis) of the ATLS 102.
  • the control system 1 1 14 determines that the ATLS reference 1208 is misaligned (e.g., is not axially or coaxially aligned) relative to the vehicle reference 1116.
  • the ATLS 102 e.g., the ATLS reference 1208 is skewed, off- center, angled, tilted, offset, etc.
  • the misalignment between the ATLS 102 and the vehicle 118 can limit or prohibit deployment of the cart 204 of the ATLS 102. For example, if the cart 204 were to deploy and/or extend into the vehicle 118 while the ATLS 120 is misaligned relative to the vehicle 118, the cart 204 can contact/intersect one of the inner side walls 1106.
  • FIG. 12B shows the ATLS 102 in an adjusted position (e.g., the second lateral position 1204) after a lateral and/or angular adjustment of the ATLS 102 relative to the vehicle 118 (e.g., the vehicle reference 1116) (e.g., from the first lateral position 1202 of FIG. 12A).
  • the control system 1114 adjusts a lateral position of the ATLS 102 (e.g.. to adjust for misalignment of the ATLS 102 relative to the vehicle 118 shown in FIG. 12A).
  • control system 1114 of the ATLS 102 can determine a lateral and/or angular offset of the ATLS 102 (e.g., in a horizontal plane) relative to the vehicle reference 1116 and, in turn, move the ATLS 102 to align (e.g., axially align) the ATLS reference 1208 with the vehicle reference 1116 of the vehicle 1 18 (e.g., in the horizontal plane).
  • the ATLS reference 1208 can be adjusted to be parallel relative to the vehicle reference 1116 laterally or in the orientation of FIGS. 12A and 12B (e.g., the horizontal plane). Adjustment(s) can be made via the second alignment system 236 described in connection with FIGS. 3A-3C. For example, in the example of FIG.
  • the second alignment system 236 can be employed to move the rear end 312 of the ATLS 102 in the first lateral direction 320 by extending the first end 310 (e.g., the piston end) of the second lateral actuator 240 to move the rear end 312 of the movable frame 220 relative to (e.g., in an upward direction in the orientation of FIG. 12B relative to) the front end 304 of the movable frame 220 and, thus, change an angular position of the ATLS reference 1208 (e.g., in the horizontal plane in the orientation of FIGS. 12A and 12B).
  • first end 310 e.g., the piston end
  • the second lateral actuator 240 to move the rear end 312 of the movable frame 220 relative to (e.g., in an upward direction in the orientation of FIG. 12B relative to) the front end 304 of the movable frame 220 and, thus, change an angular position of the ATLS reference 1208 (e.g., in the horizontal plane in the orientation of FIG
  • the movable frame 220 can be moved in the first lateral direction 320 or the second lateral direction 322 via the second alignment system 236 by actuating (e.g., extending or retracting) the first lateral actuator 238 and the second lateral actuator 240 to the same stroke position (e.g., simultaneously or sequentially).
  • the adjusted position of the ATLS 102 is aligned (e.g., axially aligned) with the vehicle reference 1116 corresponding to a position of the vehicle 118.
  • FIG. 13A-13B are side views of the loading dock 100 of FIGS. 1, 2 A and 2B illustrating an example vertical alignment operation 1300.
  • FIG. 13A is a side view of the example ATLS 102 in an example first vertical position 1302 (e.g., an initial or reference position) relative to the example vehicle 118.
  • FIG. 13B is a side view of the example ATLS 102 in an example second vertical position 1304 (e.g., an adjusted vertical position) relative to the vehicle 118.
  • the sensor assembly 1000 is in the scanning operation 1 100 to scan the cargo area 116 of the vehicle 118 (e.g., via the sensor 1008).
  • the vehicle 118 e.g., the vehicle reference 1116
  • the vertical misalignment between the ATLS 102 and the vehicle 118 can limit or prohibit deployment of the cart 204 of the ATLS 102.
  • FIG. 13B shows the ATLS 102 in a vertically adjusted position (e.g., the second vertical position 1304) after a vertical adjustment of the ATLS 102 relative to the vehicle 1 18 (e g., relative to the vehicle reference 1116 ofthe vehicle 1 18) from the first vertical position 1302 shown in FIG. 13A (e.g., the second lateral position 1204 of FIG. 12B).
  • the control system 1114 adjusts a vertical position of the ATLS 102 (e.g., to adjust for misalignment of the ATLS 102 relative to the vehicle 118 in the vertical direction shown in FIG. 13 AB).
  • the adjusted position (e.g., the second vertical position 1304) of the ATLS 102 of FIG. 13B is aligned (e.g., coaxially aligned) with the vehicle reference 1116 corresponding to a position of the vehicle 118.
  • the control system 1114 of the ATLS 102 can determine a vertical offset of the ATLS 102 (e.g., in a vertical plane) relative to the vehicle reference 1116 and, in turn, move the ATLS 102 to align (e.g., coaxially align) the ATLS reference 1208 with the vehicle reference 1116 (e.g., in the vertical plane). Adjustment(s) can be made via the first alignment system 226 described in connection with FIGS. 2A-2B. For example, in FIG. 13B, the first alignment system 226 can be employed to move the front end 304 of the movable frame 220 in the first vertical direction 232 (e.g., upward in the orientation of FIG.
  • the ATLS reference 1208 can be moved angularly (e.g., tilted) in a longitudinal direction to align with (e.g., match) the slope or angle of the vehicle reference 1116.
  • the movable frame 220 can be moved to adjust a longitudinal slope of the ATLS 102 between the front end 304 and the rear end 312 of the movable frame 220 (e.g., as shown in FIG. 13B) and/or can be moved to adjust a lateral slop of the ATLS 102 between the first side 208 and the second side 210 of the movable frame 220.
  • the ATLS 102 (e.g., the movable frame 220) of the illustrated example can be adjusted or moved in different degrees of freedom (e.g., six degrees of freedom) to coaxially align the ATLS reference 1208 relative to the vehicle reference 1116 and/or move the ATLS 102 in parallel alignment with the cargo area 116.
  • the ATLS 102 can be adjusted via the movable frame 220 such that the cart 204 is parallel relative to floor 1110 of the cargo area 116.
  • the upper surface 422 of the movable frame 220 is adjusted via the control system 1114 to be substantially parallel (e.g., within a threshold limit) relative to the floor 1110 of the cargo area 116.
  • FIGS. 14A-14Q are perspective views of the example loading dock 100 of FIGS. 1, 2A and 2B and the example ATLS 102 at different positions 1400-1436 of an example loading operation.
  • the loading operation commences after tire control system 1114 aligns the ATLS 102 relative to the vehicle reference 11 16 so that the cart 204 is substantially parallel relative to the floor 1110 of the cargo area 116 (e.g., the position of the ATLS 102 of FIG. 13B).
  • the sensor assembly 1000 is moved to the stowed position 1002 via the sensor actuator 1016 as shown in FIG. 10A.
  • the cart 204 is in an initial or stored position 1438 (e.g., a home or stored position) when the drive beam 416 is in the stored configuration 600. Additionally, the guide doors 206 are in the guide position 900 (e.g., a vertical orientation). In the guide position 900. the guide doors 206 flank the cart 204. Thus, the cart 204 is positioned on the movable frame 220 between the first guide door 904 and the second guide door 906.
  • FIG. 14B illustrates the ATLS 102 at an example second position 1402.
  • the ATLS 102 employs the cart drive system 408.
  • the ATLS 102 causes the motor 418 to rotate in the second rotational direction 722.
  • an exposed portion 1444 of the drive beam 416 exits the track 414 and pushes the cart 204 (e.g., and the first cargo 1442a) inside the cargo area 116 of the vehicle 118.
  • the exposed portion 1444 of the drive beam 416 interlocks to provide a rigid structure or push bar when the drive beam 416 exits the track 414.
  • a non-exposed portion 1448 of the drive beam 416 remaining in the track 414 can bend or curve (e.g., a non-locked condition) to snake or move around the channels 508 of the track 414 as the drive beam 416 exits the track 414.
  • the floor 1110 prevents the exposed portion 1444 of the drive beam 416 from bending or flexing in the first direction 644 (FIG. 6B) (e.g., a downward direction) and the locking features (e.g., the lips 638 and the shoulders 640) prevent the exposed portion 1444 of the drive beam 416 from bending or flexing in the second direction 646 (FIG.
  • the cart 204 moves from the stored position 1438 towards an extended position or drop-off position 1440 (FIG. 14D) adjacent to the end wall 1112 of the cargo area 116.
  • the upper rollers 804 of the cart 204 do not rotate.
  • the ATLS 102 causes the guide doors 206 to rotate (e.g.. about the respective pivot axes 904a, 906a) from the guide position 900 to the transfer position 902 via the guide door drive system 908.
  • the guide doors 206 are positioned flat or parallel on (e.g., directly on top of) the upper surface 422 of the movable frame 220.
  • the rollers 212a of the inner platform 212 transfers the cargo on the guide doors 206 when the guide doors 206 are in the flat position.
  • FIG. 14C illustrates the ATLS 102 at an example third position 1404.
  • the cart drive system 408 continues to advance or cany 7 the first cargo 1442a toward the end wall 1112 of the cargo area 116.
  • a second cargo 1442b e.g., a second portion of the total cargo load
  • FIG. 14D illustrates the ATLS 102 at an example fourth position 1406.
  • the cart drive system 408 moves the cart 204 and the first cargo 1442a to a first position or the drop-off position 1440 adjacent the end wall 1 112.
  • the drive beam 416 is fully exposed and/or in an extended position (e.g., 48-53 feet) and traverses a length L (e.g., a total length or total longitudinal length) of the cargo area 116.
  • a gap (G) is provided between the first cargo 1442a and the end wall 1112.
  • the gap (G) is provided by the lead-in ramp 844.
  • the gap (G) can be, for example, one inch, two inches, five inches and/or any other suitable distance (e.g., a length of the lead-in ramp 844).
  • the gap (G) provides space to enable the second cargo 1442b to move in the first linear direction 410 when the second cargo 1442b is removed from the cart 204.
  • the lead-in ramp 844 engages the end wall 1112. With the first cargo 1442a and the cart 204 positioned adjacent the end wall 11 12 at the drop-off position 1440, the upper rollers 804 of the cart 204 are operated to rotate in the first rotational direction 824.
  • the cart drive system 408 is commanded to move the cart 204 in the second linear direction 412.
  • the cart drive system 408 is commanded to operate in the first rotational direction 720 to retract the exposed portion 1444 of the drive beam 416 within the track 414 and move the cart 204 in the second linear direction 412 toward the ATLS 102.
  • the cart 204 can move in the second linear direction 412 as the upper rollers 804 rotate in the first rotational direction 824.
  • the upper rollers 804 rotate in the first rotational direction 824 and the cart 204 is pulled away from the end wall 1112 and toward the ATLS 102 simultaneously to remove the first cargo 1442a from the cart 204.
  • the upper rollers 804 cause the first cargo 1442a to transfer off or from the cart 204 in the first linear direction 410 onto the floor 1110 of the cargo area 116 as the cart 204 retracts in the second linear direction 412.
  • FIG. 14F illustrates the example ATLS 102 in an example fifth position 1410.
  • the cart 204 moves to a staging position 1454 adjacent to the frame assembly 202 and/or the guide doors 206.
  • the cart 204 is not positioned on the guide doors 206, but the rear edge 702 of the cart 204 is positioned adjacent to the guide doors 206.
  • a portion of the cart 204 overlaps or spans across an interface or gap between the vehicle 118 and the dock wall 104.
  • FIG. 14G illustrates the ATLS 102 in an example sixth position 1412.
  • the second cargo 1442b transfers from the guide doors 206 to the cart 204.
  • the guide door rollers 916 rotate in the first rotational direction 824, which causes the second cargo 1442b to transfer, move or otherwise slide from the guide doors 206 to the cart 204 in the first linear direction 410 (e.g., a forward direction).
  • the upper rollers 804 of the cart 204 can be rotated in the first rotational direction 824 to facilitate transfer of the second cargo 1442b from the guide doors 206 to the cart 204.
  • operation of the guide door rollers 916 and/or the upper rollers 804 can be sequentially or simultaneously.
  • FIG. 14J illustrates the ATLS 102 in an example ninth position 1418.
  • the cart 204 is returned to the staging position 1454 and a third cargo 1442c is positioned on the guide doors 206.
  • FIG. 14K illustrates the ATLS 102 in an example tenth position 1420, at which the third cargo 1442c is transferred to the cart 204 while the cart 204 is at the staging position 1454.
  • the guide door rollers 916 are rotated in the first rotational direction 824 to cause the third cargo 1442c to transfer, slide or move onto the cart 204 and off the guide doors 206.
  • FIG. 14L illustrates the ATLS 102 in an example eleventh position 1422.
  • the cart 204 is driven in the first linear direction 410 to another drop-off position 1458 that provides the gap (G) between the second cargo 1442b and the third cargo 1442c.
  • the upper rollers 804 of the cart 204 are rotated in the first rotational direction 824 and the cart is driven in the second linear direction 412 to remove the third cargo 1442c from the cart 204 in the first linear direction 410 (e.g., thereby reducing or eliminating the gap (G)) and onto the floor 1110 of the cargo area 116 adj acent to the second cargo 1442b.
  • FIG. 14M illustrates the ATLS 102 in an example twelfth position 1424.
  • a fourth cargo 1442d has been positioned in the cargo area 116 by moving the cart 204 to the staging position 1454.
  • FIG. 14N illustrates the ATLS 102 in an example thirteenth position 1426, which illustrates the fifth cargo 1442e transferred from the guide doors 206 onto the cart 204 while the cart 204 is in the staging position 1454.
  • FIG. 140 illustrates the ATLS 102 in an example fourteenth position 1428.
  • the guide doors 206 are moved to the guide position 900.
  • the actuators 910 are actuated to pivot the guide doors 206 about the pivot axes 904a, 904b to the guide position 900.
  • the cart 204 has access to the upper surface 422 of the frame assembly 202.
  • the upper rollers 804 are activated to rotate in the first rotational direction 824 to move the fifth cargo 1442e from the upper surface 811 of the cart 204 and onto the floor 1110.
  • FIG. 14P illustrates the ATLS 102 in an example fifteenth position 1430.
  • the cart 204 moves to the initial or stored position 1446 via the cart drive system 408.
  • the cart drive system 408 is operated to rotate in the first rotational direction 720 to move the cart 204 in the second linear direction 412 (e.g., a rearward direction) on the upper surface 422 of the movable frame 220.
  • the drive beam 416 is retracted to the stored configuration 600 (e g., a fully retracted position).
  • the control system 1114 of the example ATLS 102 can control the different drive systems to perform an alignment operation (e.g., as shown in FIGS. 12A-12B and BABB) and the loading operation shown in FIGS. 14A-14Q.
  • the control system 1114 of the illustrated example can receive signals or information (e.g., data, feedback signals, etc.) from the sensor assembly 1000 to perform an alignment operation and operate the first alignment system 226 and/or the second alignment system 236 to align the ATLS reference 1208 relative to vehicle reference 1116 to establish a parallel or substantially parallel (e.g., within between one degree and ten degrees of parallel) relationship between the floor 1110 of the cargo area 116 and the cart 204 and/or the movable frame 220 of the frame assembly 202.
  • signals or information e.g., data, feedback signals, etc.
  • control system 1114 can receive information (e.g., data, feedback signals, etc.) from one or more sensors (e.g., a proximity sensor, an encoder, a weight sensor, etc.) to perform the loading operation of FIGS. 14A-14Q.
  • sensors e.g., a proximity sensor, an encoder, a weight sensor, etc.
  • a proximity sensor can be provided adjacent a forward edge of the lead-in ramp 844 to determine when a drop-off location has been reached by sensing the end wall 1112 and/or a cargo positioned in the cargo area 116.
  • a sensor can be positioned adjacent the doorway 106 to detect the cart 204 in the staging position 1454.
  • A, B, and/or C refers to any combination or subset of A, B, C such as (1) A alone, (2) B alone, (3) C alone, (4) A with B, (5) A with C, (6) B with C, or (7) A with B and with C.
  • the phrase “at least one of A and B” is intended to refer to implementations including any of (1) at least one A, (2) at least one B, or (3) at least one A and at least one B.
  • the phrase “at least one of A or B” is intended to refer to implementations including any of (1) at least one A, (2) at least one B, or (3) at least one A and at least one B.
  • any part e.g., a layer, film, area, region, or plate
  • any part e.g., a layer, film, area, region, or plate
  • the referenced part is either in contact with the other part, or that the referenced part is above the other part with one or more intermediate part(s) located therebetween.
  • connection references may include intermediate members between the elements referenced by the connection reference and/or relative movement between those elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and/or in fixed relation to each other. As used herein, stating that any part is in “contact” with another part is defined to mean that there is no intermediate part between the two parts.
  • the descriptor “first” may be used to refer to an element in the detailed description, while the same element may be referred to in a claim with a different descriptor such as “second” or “third.” In such instances, it should be understood that such descriptors are used merely for identifying those elements distinctly within the context of the discussion (e.g., within a claim) in which the elements might, for example, otherwise share a same name.
  • substantially,” “approximately” and “about” modify their subjects/values to recognize the potential presence of variations that occur in real w orld applications. For example, “substantially,” “approximately” and “about” may modify dimensions that may not be exact due to manufacturing tolerances and/or other real world imperfections as will be understood by persons of ordinary skill in the art. For example, “substantially,” “approximately” and “about” may indicate such dimensions may be within a tolerance range of +/- 10% unless otherwise specified herein.
  • the phrase “in communication.” including variations thereof, encompasses direct communication and/or indirect communication through one or more intermediary components, and does not require direct physical (e.g., wired) communication and/or constant communication, but rather additionally includes selective communication at periodic intervals, scheduled intervals, aperiodic intervals, and/or one-time events.
  • programmable circuitry is defined to include (i) one or more special purpose electncal circuits (e.g., an application specific circuit (ASIC)) structured to perform specific operation(s) and including one or more semiconductor-based logic devices (e.g., electrical hardware implemented by one or more transistors), and/or (ii) one or more general purpose semiconductor-based electrical circuits programmable with instructions to perform specific functions(s) and/or operation(s) and including one or more semiconductorbased logic devices (e.g., electrical hardware implemented by one or more transistors).
  • ASIC application specific circuit
  • programmable circuitry examples include programmable microprocessors such as Central Processor Units (CPUs) that may execute first instructions to perform one or more operations and/or functions, Field Programmable Gate Arrays (FPGAs) that may be programmed with second instructions to cause configuration and/or structuring of the FPGAs to instantiate one or more operations and/or functions corresponding to the first instructions, Graphics Processor Units (GPUs) that may execute first instructions to perform one or more operations and/or functions, Digital Signal Processors (DSPs) that may execute first instructions to perform one or more operations and/or functions, XPUs, Network Processing Units (NPUs) one or more microcontrollers that may execute first instmctions to perform one or more operations and/or functions and/or integrated circuits such as Application Specific Integrated Circuits (ASICs).
  • CPUs Central Processor Units
  • FPGAs Field Programmable Gate Arrays
  • DSPs Digital Signal Processors
  • XPUs Network Processing Units
  • NPUs Network
  • an XPU may be implemented by a heterogeneous computing system including multiple types of programmable circuitry (e.g., one or more FPGAs, one or more CPUs, one or more GPUs, one or more NPUs, one or more DSPs, etc., and/or any combination(s) thereof), and orchestration technology (e.g., application programming interface(s) (API(s)) that may assign computing task(s) to whichever one(s) of the multiple types of programmable circuitry is/are suited and available to perform the computing task(s).
  • programmable circuitry e.g., one or more FPGAs, one or more CPUs, one or more GPUs, one or more NPUs, one or more DSPs, etc., and/or any combination(s) thereof
  • orchestration technology e.g., application programming interface(s) (API(s)) that may assign computing task(s) to whichever one(s) of the multiple types of programmable circuitry is/are suited and available

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Loading Or Unloading Of Vehicles (AREA)
  • Warehouses Or Storage Devices (AREA)

Abstract

Automated trailer loading systems and related methods are disclosed. An automated trailer loading system includes a frame defining a cavity, a track at least partially in the cavity of the frame, a cart movable relative to the frame between an extended position and a retracted position, and a drive beam movable within the track between an extended position and a retracted position. The drive beam is to at least one of push or pull the cart. The drive beam to at least partially bend when in the retracted position.

Description

AUTOMATED TRAILER LOADING SYSTEMS AND RELATED METHODS
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This patent claims the benefit of U.S. Provisional Patent Application No. 63/658,783, filed June 11, 2024, US. Provisional Patent Application No. 63/658,779, filed on June 11, 2024, U.S. Provisional Patent Application No. 63/658,777, filed on June 11, 2024, and U.S. Provisional Patent Application No. 63/755,896, filed on February7 7, 2025. U.S. Provisional Patent Application No. 63/658,783, US. Provisional Patent Application No. 63/658.779, U.S. Provisional Patent Application No. 63/658,777. and U.S. Provisional Patent Application No. 63/755,896 are incorporated by7 reference herein in their entireties. Priority to U.S. Provisional Patent Application No. 63/658,783, US. Provisional Patent Application No. 63/658.779, U.S. Provisional Patent Application No. 63/658,777, and U.S. Provisional Patent Application No. 63/755,896 is hereby claimed.
FIELD OF THE DISCLOSURE
[0002] This disclosure relates generally to dock levelers and, more particularly, to automated trailer loading systems and related methods.
BACKGROUND
[0003] Loading docks provide an area for vehicles (e.g., trucks, trailers, etc.) to move next to an elevated platform of a building (e g., a material handling facility) so that cargo can be readily transferred between the vehicle and the building.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 A is a perspective view of an example loading bay of an example loading dock implemented with an example automated trailer loading system (ATLS) in accordance with teachings disclosed herein.
[0005] FIG. IB is a perspective view of the example loading bay of FIG. 1A shown from an exterior of the example loading dock.
[0006] FIG. 2A is a perspective view of the example ATLS of FIG. 1A and IB.
[0007] FIG. 2B is an exploded perspective view of the example ATLS of FIG. 2A. [0008] FIG. 2C is a perspective view of an example actuator of the example ATLS of FIGS. 2A and 2B.
[0009] FIG. 2D is a perspective, cutaway view of the example actuator of FIG. 2C.
[0010] FIG. 2E is a side view of the example ATLS of FIG. 2 A in an example raised position.
[0011] FIG. 3 A is a top view of the example ATLS in an example first lateral position.
[0012] FIG. 3B is a side view of the example ATLS in the example first lateral position of FIG. 3A.
[0013] FIG. 3C is partial, bottom view of the example ATLS in the example first lateral position.
[0014] FIG. 3D is a top view of the example ATLS in an example second lateral position.
[0015] FIG. 3E is a side view of the example ATLS in the example second lateral position of FIG. 3D.
[0016] FIG. 3F is partial, bottom view of the example ATLS in the example second lateral position.
[0017] FIG. 3G is a top view of the example ATLS in an example third lateral position.
[0018] FIG. 3H is a side view of the example ATLS in the example third lateral position of FIG. 3G.
[0019] FIG. 31 is partial, bottom view of the example ATLS in the example third lateral position.
[0020] FIG. 3J is partial, enlarged view of the example ATLS of FIGS. 3A and 3B.
[0021] FIG. 4A is a perspective top view of an example movable frame of an example frame assembly of the example ATLS of FIGS. 11A, IB, 2A, and 2B.
[0022] FIG. 4B is a perspective bottom view of the example movable frame of FIG. 4 A.
[0023] FIG. 5A is a side view of the example ATLS of FIGS. 11A, IB, 2A, and 2B.
[0024] FIG. 5B is a perspective view of a portion of an example cart drive system of the example ATLS of FIG. 2 A.
[0025] FIG. 5C is a perspective view of an example first end cap of an example track of the example ATLS of FIGS. 1A. IB, 2A and 2B.
[0026] FIG. 5D is a perspective view of an example first track side wall of an example track of the example ATLS of FIGS. 1 A, IB, 2A and 2B. [0027] FIG. 5E is a perspective view of an example second end cap of an example track of the example ATLS of FIGS. 1A, IB, 2A and 2B.
[0028] FIG. 6A is a perspective view of an example drive beam of the example ATLS of FIGS. 1A, IB, 2A and 2B.
[0029] FIG. 6B is an enlarged, partial perspective view of the example drive beam of FIG. 6A.
[0030] FIG. 7A is a partial perspective review view of an example drive system of the example ATLS of FIGS. 1A, IB, 2A and 2B.
[0031] FIG. 7B is a partial perspective review view of the example drive system of FIG. 7A.
[0032] FIG. 7C is another partial perspective view of the example drive system of FIGS. 7A and 7B.
[0033] FIGS. 8A-8F are various perspective views of an example cart of the example ATLS of FIGS. 1A, IB, 2A and 2B.
[0034] FIG. 8G is a perspective view of an example roller disclosed herein that can be used with the example ATLS of FIGS. 1A, IB, 2A and 2B.
[0035] FIG. 9A is a perspective view of example ATLS of FIGS. 1. 2A and 2B with example guide doors in example guide positions.
[0036] FIG. 9A is a perspective view of example ATLS of FIGS. 1, 2A and 2B with the example guide doors in example transfer positions.
[0037] FIG. 10A is a partial perspective front view of the example ATLS of FIGS. 1A, IB. 2A and 2B with an example sensor of an example scanner system shown in an example stored position.
[0038] FIG. 10B is a partial perspective front view of the example ATLS of FIG. 10A with the example sensor of the example scanner system shown in an example scanning position.
[0039] FIG. 10C is a front view of the example sensor of FIG. 10B.
[0040] FIG. 11A-11C are schematic illustrations of the ATLS 102 of FIGS. 1A, IB, 2A and 2B in an example scanning operation.
[0041] FIGS. 12A-12B are top views of the loading dock 100 of FIGS. 1A, IB, 2A and 2B illustrating an example first alignment operation.
[0042] FIG. 13A-13B are side views of the loading dock 100 of FIGS. 1 A, IB. 2A and 2B illustrating an example second alignment operation. [0043] FIGS. 14A-14Q are perspective views of the example loading dock 100 of FIGS. 1A, IB, 2A and 2B and the example ATLS 102 at different operational positions of an example loading operation.
[0044] In general, the same reference numbers will be used throughout the drawing(s) and accompanying written description to refer to the same or like parts. The figures are not to scale. As used in this patent, stating that any part (e.g., a layer, film, area, region, or plate) is in any way on (e.g., positioned on, located on, disposed on, or formed on, etc.) another part, indicates that the referenced part is either in contact with the other part, or that the referenced part is above the other part with one or more intermediate part(s) located therebetween.
DETAILED DESCRIPTION
[0045] Warehouses employ loading docks for loading and/or unloading goods between the loading docks and vehicles. Automatic Trailer Loading Systems (ATLS), also known as slug loaders, are advanced technologies designed to automate loading trailers or containers with goods or cargo. Slug loading systems include various components such as conveyors, sensors, and/or control systems. Goods and/or cargo placed on a conveyor of an ATLS in the order that will best use the trailer's interior space (e.g., cube).
[0046] Example methods, apparatus, and articles of manufacture disclosed herein provide automated trailer loading systems for positioning cargo or goods within a trailer or container. Additionally, example automated trailer loading systems disclosed herein significantly reduce a footprint/space required inside a loading dock compared to traditional automated trailer loading systems that take up as much as sixty feet in length (e.g., per dock door or loading bay of a loading dock) inside the loading dock or warehouse due to the fact that those other systems stage/load entire trailers at once as opposed to incrementally loading a trailer as the systems disclosed herein. Thus, example automated trailer loading systems disclosed herein do not require stage loading an entire load of a trailer and/or do not require moving an entire load into a trailer at once or simultaneously. Instead, loading can be staged or performed in intervals. By precisely arranging the goods or cargo within the trailer, these systems can increase (e.g., maximize) a load capacity and/or reduce (e.g., minimize) wasted space, which can lead to significant cost savings and increased productivity. Additionally, slug loading systems offer improved safety and reduced risk of damage to the goods or cargo. One or more sensors and/or control systems can be employed to improve (e.g., ensure precise) handling and/or placement of the cargo in the vehicle.
[0047] Example automated trailer loading systems disclosed herein employ a cart for supporting and/or moving goods within the trailer or container. Example, automated trailer loading systems disclosed herein employ a drive system that can roll up to a stored position. For instance, example drive systems disclosed herein can at least partially wind or roll up underneath a frame of the ATLS and/or underneath an upper surface of a floor of a loading dock (e.g., a warehouse). For example, at least a portion of a drive system of an example automated trailer loading system disclosed herein can store within a spiral track of the automated trailer loading system (e.g., a frame of the ATLS) positioned in a pit area of a loading dock and/or underneath a floor of a loading dock or w arehouse.
[0048] Material handling equipment (e.g., a forklift) initially loads a cart of the ATLS from one end of the frame and the cart is moved or pushed into a loading area of a trailer or container via a drive system. After the cart is fully extended into the vehicle (e.g., a total extension of approximately between 53 feet and 70 feet), the example cart of example automated trailer loading system disclosed herein is retracted to a staging position within the tailer and adjacent the frame. Guide doors of example ATLS disclosed herein move from a guiding position (e.g., a vertical position) to a staging or operating position (e.g., a horizontal position), wherein the material handling equipment loads the guide doors with additional cargo from the one end of the frame. The guide doors move or transfer the cargo to the cart, and the drive system extends to push the cart and the transferred cargo within the trailer. Example conveyors disclosed herein can be driven via one or more motors and/or transmission systems. Some example conveyors disclosed herein employ one or more push/pull chain and sprocket systems. For example, to retract the cart, the cart rolls into a large coil in a spiral track located in a cavity of the frame of the ATLS that is positioned in the building. In some examples, a drive system or drive beam (e.g., a chain) of an example automated trailer loading system can be approximately between 50 feet and 80 feet in length when fully extended (e.g., fully flat, or completely unwound). However, when w ound or stored (e.g., within a spiral track underneath a platform floor), example drive systems or drive beams disclosed herein can be approximately between 10 feet and 30 feet in length.
[0049] FIG. 1A is a perspective view of an example loading bay 101 of an example loading dock 100 implemented with an example automated trailer loading system (ATLS) 102 in accordance with teachings disclosed herein. FIG. IB is another perspective view of the example loading bay 101 show n from an exterior of the example loading dock 100. Referring to FIGS. 1A and IB. the loading bay 101 of the illustrated example can be a warehouse, cargo transport unit, and/or loading structure. The loading bay 101 of the illustrated example includes a dock w all 104 defining a doorway 106 leading to a platform 108 (e.g., the doorw ay 106 allows access between an interior of the loading bay 101 and an exterior of the loading bay 101). The example ATLS 102 of the of the illustrated example is positioned in the loading dock 100 at least partially extending underneath a floor 110 of the loading dock 100 adjacent the platform 108. For example, the ATLS 102 of the illustrated example is at least partially positioned in an opening or pit 112 formed in the platform and/or floor 110. For example, the ATLS 102 is positioned in the pit 112 and is offset relative to an exterior or dock face 114 of the dock wall 104. In some examples, the pit 112 can have a depth of between 2 feet and 10 feet. The ATLS 102 loads cargo inside a cargo area 116 of a trailer or vehicle 118. As described in greater detail below, the ATLS 102 moves into and out of the cargo area 116 of the vehicle 118 during a loading/unloading operation. While only one loading bay 101 is illustrated in FIGS. 1A and IB, in some examples, the loading dock 100 of the illustrated example has a plurality of loading bays positioned adjacent relative to one another. In some such examples, each loading bay 101 of an example loading dock can include an ATLS 102 disclosed herein.
[0050] FIG. 2A is a perspective top view of the example ATLS 102 of FIG. 1 A and FIG. IB. FIG. 2B is an exploded view of the ATLS 102 of FIG. 2A. Referring to FIGS. 2A and 2B, the ATLS 102 of the illustrated example includes a frame assembly 202, a cart 204 (e.g., a shuttle), and guide doors 206. Specifically, the ATLS 102 of the illustrated example includes a first guide door 206a positioned adjacent or on a first side 208 of the frame assembly 202 and a second side door 206b positioned adjacent or on a second side 210 of the frame assembly 202 (e.g., opposite the first side 208). The frame assembly 202 includes an inner platform 212 (e.g., a rear platform) adjacent a rear side or rear end 214 of the frame assembly 202 and a transition platform 216 (e.g., a front platform) positioned adjacent a front side or front end 218 of the frame assembly 202. The inner platform 212 of the illustrated example can be used to transition cargo from the floor 110 (FIG. 1A) onto the cart 204 and/or the guide doors 206, as described in greater detail below. The transition platform 216 provides a pathway or transition for the cart 204 to enable the cart 204 to move between the frame assembly 202 and the cargo area 116 of the vehicle 1 18 (FIG. 1 A). The inner platform 212 of the illustrated example includes a plurality of rollers 212a to facilitate transfer or cargo from the interior of the warehouse onto the ATLS 102. In some examples, the inner platform 212 includes a conveyor or belt to move the cargo to the ATLS 102. In some examples, the inner platform 212 is a smooth, flat, non-movable surface. In some examples, the rollers 212a are substantially similar or identical to upper rollers 804 of FIG. 8 A.
[0051] The frame assembly 202 of the illustrated example mounts or couples the ATLS 102 to the pit 112 of the loading dock 100. In the illustrated example, the frame assembly 202 has a rectangular shape. However, in some examples, the frame assembly 202 can have a square shape and/or any other suitable shape. The frame assembly 202 of the illustrated example includes a movable frame 220 and a fixed frame 222 (e.g., a support structure). The fixed frame 222 mounts the movable frame 220 to the loading dock 100. The fixed frame 222 of the illustrated example includes a plurality of beams 224 (e g., steel beams). The beams 224 are fastened or welded to each other to define a rectangular shape. Specifically, the beams 224 of the fixed frame 222 define a cavity 222a (e g., a space or volume) to receive at least a portion of the movable frame 220.
[0052] The movable frame 220 can move relative to the fixed frame 222 to enable alignment of the cart 204 (e.g.. and the transition platform 216 and/or the inner platform 212) relative to the cargo area 116 of the vehicle 118. For example, the ATLS 102 of the illustrated example can move in a plurality of different positions (e.g., six-degrees of freedom) to align (e.g., coaxially align) the cart 204 relative to the cargo area 116 of the vehicle 118 prior to performing a loading/unloading operation. Specifically, the movable frame 220 can move relative to the fixed frame 222 and/or the loading dock 100. In other words, the fixed frame 222 is fixed relative to the loading dock 100 and the movable frame 220 can move relative to the loading dock 100. The ATLS 102 of the illustrated example can move vertically (e.g., up and down), laterally (e.g., sideways) in a direction between side walls of the doorway 106, and/or in a skewed or angular direction where the front end 218 of the movable frame 220 can be move relative to the rear end 214 of the movable frame 220, and/or the rear end 214 of the movable frame 220 can move laterally relative to the front end 218.
[0053] To move the ATLS 102 in a vertical direction, the ATLS 102 of the illustrated example includes a first alignment system 226 (e.g.. a vertical alignment system). The first alignment system 226 includes a plurality of vertical actuators 228 (e.g., linear actuators). Specifically, the vertical actuators 228 are coupled to the movable frame 220. For example, the vertical actuators 228 of the illustrated example are positioned in respective comers 230 (e.g., four comers) of the frame assembly 202.
[0054] For example, FIG. 2C is a perspective view of the example vertical actuator 228 of FIGS. 2 A and 2B. FIG. 2D is a perspective, cutaway view of the example vertical actuator 228 of FIG. 2C. The vertical actuator 228 of the illustrated example includes an actuator end 228a (e.g., a piston) and a cylinder 228b (e.g., a base). The cylinder 228b of the actuator is coupled to a housing 260 (e.g., a mounting bracket). In the illustrated example, the housing 260 encloses or encompasses the cylinder 228b of the vertical actuator 228. The actuator end 228a (e.g.. a piston) of the vertical actuators 228 is coupled (e.g.. fixed) to a bracket 233 of the movable frame 220 and the cylinder 228b of the vertical actuators 228 is coupled or mounted (e.g., fixed to) to the housing 260. Specifically, the base 260 that slidably couples within pockets 231 formed in respective comers 230 of the movable frame 220. Each of the pockets 231 has an area or opening (e.g.. a perimeter) that is larger than an area or perimeter of the base 260. For example, the vertical actuators 228 (e.g., the base 260) are slidably coupled to the respective pockets 231. Thus, the vertical actuators 228 can move with the movable frame 220 laterally or sideways and can cause the movable frame 220 to move vertically. When moving sideways or laterally, the housing 260 of the illustrated example can move relative to the fixed frame 222. Specifically, the housing 260 has a bottom surface 260a that engages a pit floor. To facilitate movement of the vertical actuator 228 (e.g., reduce friction) laterally or sideways, the housing 260 of the illustrated example includes a glide pad 328 (FIG. 3 J, rollers, bearings, etc.) on the bottom surface 260a of the housing 260.
[0055] In operation, the first alignment system 226 can move the movable frame 220 in a first vertical direction 232 (e.g., an upward direction in the orientation of FIGS. 2A and 2B) and a second vertical direction 234 (e.g., a downward direction in the orientation of FIGS. 2A and 2B), and/or can tilt the front end 218 of the frame assembly 202 relative to the rear end 214 in the longitudinal and/or horizontal directions. For example, extension of the vertical actuators 228 causes the movable frame 220 to move (e.g., lift) away from the fixed frame 222 and retraction of the vertical actuators 228 causes the movable frame 220 to move toward the fixed frame 222. Thus, the actuator end 228a can move the movable frame 220 relative to the fixed frame 222 and/or the housing 260 in the vertical directions 232. 234. For example. FIG. 2D shows the actuator end 228a at different stroke positions 262. 264, and 266. Each of the vertical actuators 228 can be operated independently and can cause a respective one of the comers 230 to move relative to another respective one of the comers 230. Thus, respective ones of the corners 230 of the movable frame 220 can be positioned at different heights (e.g., vertical heights or stroke positions). The first alignment system 226 can be employed to adjust a height (e.g., a vertical height) and/or a slope (e.g., a tilt or vertical angle) of the ATLS 102 between the front end 218 and the rear end 214 of the movable frame 220. For example, the vertical actuators 228 adjacent the front end 218 of the ATLS 102 can be actuated or extended to a length greater than a length or extension of the vertical actuators 228 adjacent the rear end 214 of the ATLS 102 to tilt or slope the cart 204 downwardly in a direction between the front end 218 and the rear end 214. Likewise, the vertical actuators 228 adjacent the front end 218 of the ATLS 102 can be actuated or retracted to a length that is less than a length or extension of the vertical actuators 228 adjacent the rear end 214 of the ATLS 102 to tilt or slope the cart 204 upwardly in a direction between the front end 218 and the rear end 214 The first alignment system 226 of the illustrated example includes four vertical actuators. However, in some examples, the first alignment system 226 can include one actuator, two actuators, six actuators and/or any number of actuators.
[0056] FIG. 2E is a side view' of the example ATLS 102 of the illustrated example shown in an example vertically displaced position 270. In the illustrated example of FIG. 2E, the front end 218 of the frame assembly 202 is raised relative to the rear end 214 such that the front end is sloped or angled relative to the rear end 214 in the longitudinal direction of the ATLS 102. For example, in the illustrated example of FIG. 2E, the actuator ends 228a of the vertical actuators 228 associated with or adjacent the front end 218 are raised or extended to a position (e.g., a stroke position) that is greater than a position (e.g., stroke position) of the vertical actuators 228 associated with the rear end 214 of the ATLS 102. As shown in FIG. 2E, the pockets 231 associated with the vertical actuators 228 adjacent the front end 218 move with the movable frame 220 in an upward direction in the orientation of FIG. 2E and the housing 260 remains stationary. Additionally, the pockets 231 associated with the vertical actuators 228 adjacent the rear end 214 of the movable frame 220 are located at approximately a mid-point of a height (e.g., a vertical height) of the housing 260. Thus, the pockets 231 do not interfere with vertical movement of the movable frame 220 and/or the vertical actuators 228, but enable the vertical actuators 228 move laterally or sideways via a second alignment system 236 (e.g.. a lateral alignment system). As a result, in the illustrated example of FIG. 2E, the front end 218 to be at a higher elevation than the rear end 214 of the ATLS 102. In some examples, the vertical actuators 228 associated with the rear end 214 can be moved to a position (e.g., a stroke position) that is greater than a position (e.g., a stroke position) of the vertical actuators 228 associated with the front end 218 to enable the rear end 214 to be at a higher elevation in the vertical direction than an elevation of the front end 218. In some examples, the vertical actuators 228 can each be actuated to different vertical positions (e.g., stroke positions) to orient the movable frame 220 to any desired position. In some examples, the vertical actuators 228 associated with the first side 208 of the movable frame 220 can be actuated to a different position (e.g., a stroke position) than the vertical actuators 228 associated with the second side 210 of the movable frame 220 to affect a tilt orientation of the movable frame 220 between the first side 208 of the movable frame 220 and the second side of the movable frame 220.
[0057] In some examples, vertical alignment system can include a plurality of pivotal links adjacent respective ones of the corners of the frame assembly 202. Each of the links includes a first arm, a second arm. and a hinge. The first arm is coupled (e.g., fastened, welded, or otherw ise fixed) to the first frame portion at a first end of the first arm and a second end of the first arm opposite the first end is coupled to the hinge. Similarly, the second arm is coupled (e.g., fastened, welded, or otherwise fixed) to the second frame portion at a third end of the second arm and a fourth end of the second arm opposite the first end is coupled to the hinge. Thus, the first arm is coupled to the second arm via the hinge. The hinge enables the first arm to move (e.g., vertically) relative to the second arm. To enable movement of the first frame portion (e.g., the first arm) relative to the second frame portion (e.g., the second arm), each of the pivotal links includes an actuator. The actuator includes a first end coupled to the first frame portion of the first arm of the pivotal link and a second end coupled to the second frame portion. Thus, extension of the actuator causes the first frame portion to move away from the second frame portion and retraction of the actuator causes the first frame portion to move toward the second frame portion.
[0058] To move the ATLS 102 in a first direction or laterally (e.g., a horizontal direction between side walls of the doorway 106) and/or in an angular position (e.g., movement of the front edge relative to the rear edge of the frame), the ATLS 102 of the illustrated example includes a second alignment system 236 (e.g., a lateral alignment system). The second alignment system 236 of the illustrated example includes a first lateral actuator 238 (e.g.. a first actuator or front end drive) and a second lateral actuator 240 (e.g., a second actuator or a rear end drive). The first lateral actuator 238 and the second lateral actuator 240 can be operated independently of each other. The second alignment system 236 of the illustrated example includes two lateral actuators. However, in some examples, the second alignment system 236 can include one actuator, three actuators, six actuators and/or any number of actuators.
[0059] FIG. 3 A is a top view of the example ATLS 102 in an example first lateral position 301 (e.g., an initial or centered position). FIG. 3B is a side view of the example ATLS 102 of FIG. 3 A. FIG. 3C . FIG. 3C is a bottom view of the example frame assembly 202 and the second alignment system 236 of the ATLS 102 of FIGS. 3A. FIG. 3D is a top view of the example ATLS 102 in an example second lateral position 303 (e.g.. a first skewed position). FIG. 3E is a side view of the example ATLS 102 of FIG. 3D. FIG. 3F is a bottom view of FIG. 3D. FIG. 3G is a top view of the example ATLS 102 in an example third lateral position 305 (e.g., a second skewed position). FIG. 3H is a side view of the example ATLS 102 of FIG. 3G. FIG. 31 is a bottom view of FIG. 3G.
[0060] The frame assembly 202 of the illustrated example is coupled to and/or movable by the alignment system 200. For example, the first lateral actuator 238 adjusts the front end 218 of the ATLS 102 (e.g., the movable frame 220) relative to the rear end 214 and the second lateral actuator 240 adjusts the rear end 214 of the ATLS 102 (e.g., the movable frame 220) relative to the front end 218. In the illustrated example, the first lateral actuator 238 and the second lateral actuator 240 are linear actuators. The first lateral actuator 238 of the illustrated example is coupled to the movable frame 220 and the fixed frame 222. For example, a first end 302 (e.g., a piston end) of the first lateral actuator 238 is coupled (e.g., fixed to) a front end 304 of the movable frame 220 (e.g., via a mounting bracket) and a second end 306 (e.g., a cylinder end) of the first lateral actuator 238 is coupled (e.g.. mounted) adjacent to a front end 308 of the fixed frame 222 (e.g., via a mounting bracket). Similarly, the second lateral actuator 240 of the illustrated example is coupled to the movable frame 220 and the fixed frame 222. For example, a first end 310 (e.g., a piston end) of the second lateral actuator 240 is coupled (e.g., fixed to) a rear end 312 of the movable frame 220 (e.g., via a mounting bracket) and a second end 314 (e.g., a cylinder end) of the second lateral actuator 240 is coupled (e.g., mounted) adjacent to a rear edge 316 of the fixed frame 222 (e.g., via a mounting bracket).
[0061] As shown in the example of FIGS. 3A-3I, the first and second lateral actuators 238, 240 can move or actuate (e.g., independently or in coordination) to modify a positioning of the movable frame 220 relative to a reference (e.g., a reference line 318 corresponding to a position of the vehicle 1 18). The second alignment system 236 can be employed to move the front end 304 and/or the rear end 312 in a first lateral direction 320 and/or a second lateral direction 322 to angle the movable frame 220 and, thus, position the ATLS 102 (e.g., the cart 204), in alignment with respect to a vehicle or trailer (e.g., the vehicle 118). Additionally, the second alignment system 236 can be employed to move the front end 304 and the rear end 312 (e.g., simultaneously or a same distance) in a first lateral direction 320 (e.g. an upward direction in the orientation of FIG. 3C) and a second lateral direction 322 (e.g. a downw ard direction in the orientation of FIG. 3C) opposite the first lateral direction 320 to offset a lateral position of the movable frame 220 relative to the reference line 318 and/or the fixed frame 222 (e.g., to position the ATLS 102 (e.g.. the cart 204) in alignment with respect to the vehicle 118). For example, the ATLS 102 can move laterally in the first lateral direction 320 and the second lateral direction 322 based on coordinated movements of the first and second lateral actuators 238, 240 (e.g., simultaneous movement or movement of a same stroke length of the first and second lateral actuators 238. 240 in extension or retraction). Further, the ATLS 102 can rotate in a first angular direction 324 (e.g., a clockwise direction in the orientation of FIGS. 3C and 3F) based on an extension of the first lateral actuator 238 and/or retraction of the second lateral actuator 240. The ATLS 102 can rotate in a second angular direction 326 (e.g., a counterclockwise direction in the orientation of FIG. 3C) based on a retraction of the first lateral actuator 238 and/or extension of the second lateral actuator 240.
[0062] For example, in FIGS. 3A-3C, the first lateral actuator 238 and the second lateral actuator 240 are positioned at similar or identical stroke length positions to cause the movable frame 220 to move to the first lateral position 301. In the first lateral position 301, the front end 304 of the movable frame 220 is parallel or aligned with the front end 308 of the fixed frame 222, and the rear end 312 of the movable frame 220 is parallel or aligned with the rear edge 316 of the fixed frame 222. In the first lateral position 301, the front end 308 of the movable frame 220 and the rear end 312 of the movable frame 220 are central located relative to the first side 208 and the second side 210 of the frame assembly 202.
[0063] In FIGS. 3D-3F, in the second lateral position 303, the first lateral actuator 238 and the second lateral actuator 240 are positioned at different stroke positions such that the first lateral actuator 238 is at a first stroke position that is less than a second stroke position of the second lateral actuator 240. In the second lateral position 303, the front end 304 of the movable frame 220 is angled or non-parallel (e.g., skewed) relative to the front end 308 of the fixed frame 222, and the rear end 312 of the movable frame 220 is angled or non-parallel (e.g., skewed) relative to the rear edge 316 of the fixed frame 222 such that the rear end 312 is closer to the second side 210 of the fixed frame 222 than the first side 208 of the fixed frame 222.
[0064] In FIGS. 3G-3I, in the third lateral position 305, the first lateral actuator 238 and the second lateral actuator 240 are positioned at different stroke positions such that the first lateral actuator 238 is at a first stroke position that is greater than a second stroke position of the second lateral actuator 240. In the third lateral position 305, the front end 304 of the movable frame 220 is angled or non-parallel (e.g., skewed) relative to the front end 308 of the fixed frame 222, and the rear end 312 of the movable frame 220 is angled or non-parallel (e.g., skewed) relative to the rear edge 316 of the fixed frame 222 such that the rear end 312 is closer to the first side 208 of the fixed frame 222 than the second side 210 of the fixed frame 222.
[0065] The operating limits of the first lateral actuator 238 and the second lateral actuator 240 define a lateral operating limit and/or an angular operating limit of the ATLS 102. For example, the ATLS 102 is laterally movable between a full extension position or stroke of the first and second lateral actuators 238, 240 and a full retraction position or stroke of the first and second lateral actuators 238, 240. Thus, the lateral operating limit of the ATLS 102 can be defined by a maximum length of the first and second lateral actuators 238, 240 (at full extension stroke) and a minimum length of the first and second lateral actuators 238, 240 (at full retraction stroke). Further, the ATLS 102 can rotate in the first angular direction 324 (e.g., a clockwise direction in the orientation of FIGS. 3C and 3F) between a full retraction position or stroke of the second lateral actuator 240 and a full extension position or stroke of the first lateral actuator 238. Additionally, the ATLS 102 can rotate in the second angular direction 326 (e.g.. a counterclockwise direction in the orientation of FIG. 3C) between a full retraction position or stroke of the first lateral actuator 238 and a full extension position or stroke of the second lateral actuator 240. Thus, the angular operating limit of the ATLS 102 can be defined by a maximum clockwise rotation and a maximum counterclockwise rotation. As such, the second alignment system 236 is limited from rotating or translating the ATLS 102 beyond the extension/retraction capabilities of the first and second lateral actuators 238, 240 (as defined by the lateral operating limit and the angular operating limit).
[0066] FIG. 3J is an enlarged, partial perspective view of the example second alignment system 236 of FIGS. 3A-3I. To reduce friction and/or facilitate movement of the front end 304 of the movable frame 220 and/or the rear end 312 of the movable frame 220 in the first lateral direction 320 and/or the second lateral direction 322, the second alignment system 236 of the illustrated example includes glide pads 328. The glide pads 328 are coupled to the vertical actuators 228. In some examples, the glide pads 328 can be coupled to the movable frame 220. Specifically, the glide pads 328 of the illustrated example are coupled or positioned at each comer of the movable frame 220 (e.g.. via the vertical actuators 228). In the illustrated example, the glide pads 328 include a plurality of rollers 330 that engage a floor (e.g., the floor of the pit) to facilitate movement of the movable frame 220 in the first and second lateral directions 320, 322. In some examples, the rollers can be wheels, balls, spheres and/or any other suitable rollers for reducing friction.
[0067] FIG. 4A is a perspective top view of the example ATLS 102 of FIGS. IA-IB and 2A-2B. FIG. 4B is a perspective bottom view of the example ATLS 102 of FIG. 4A. The movable frame 220 of the illustrated example includes a first frame portion 402 (e.g., an upper frame portion) and a second frame portion 404 (e.g., a lower frame portion) spaced from the first frame portion 402. The movable frame 220 defines a cavity’ 406 between the first frame portion 402 and the second frame portion 404.
[0068] To move the cart 204 relative to the frame assembly 202 (e.g., relative to the movable frame 220), the ATLS 102 of the illustrated example includes a cart drive system 408. Specifically, the cart 204 is coupled (e.g., tethered) to the frame assembly 202 via the cart drive system 408. The cart drive system 408 moves the cart 204 into and out of the cargo area 116 of the vehicle 118 during a loading/unloading operation. In particular, the cart drive system 408 of the illustrated example moves the cart 204 in a linear direction relative to (e.g., away from and/or towards) the frame assembly 202. For example, the cart drive system 408 of the illustrated example moves the cart 204 in a first linear direction 410 (e.g.. a forward direction) and a second linear direction 412 (e.g., a rearward direction) opposite the first linear direction 410 in the orientation of FIGS. 4 A and 4B.
[0069] The cart drive system 408 of the illustrated example includes a track 414, a drive beam 416, and a motor 418. The track 414 houses or receives the drive beam 416 (e.g., contains or confines the drive beam 416 when the cart drive system 408 and/or the cart 204 are in a stored position). In other words, when the drive beam 416 is in a stored configuration 420 (e.g., a fully stored position), at least a portion of the drive beam 416 is stored within a perimeter and/or volume (e.g.. the cavity’ 406) of the movable frame 220. At least some of the drive beam 416 is hidden from view in the stored configuration 420 because the track 414 stores the drive beam 41 in a loop (e g., harbored in the track 414) beneath the platform 1 11 8 and/or an upper surface 422 of the first frame portion 402. In an extended configuration, the drive beam 416 is positioned above the platform 108 and/or on top of or above the upper surface 422 of the first frame portion 402. The drive beam 416 is flat or straight in the extended configuration.
[0070] The track 414 of the illustrated example is positioned underneath the cart 204. Specifically, the track 414 is positioned (e.g., within the cavity 406 or space) between the first frame portion 402 and the second frame portion 404. Specifically, the track 414 is positioned between the first side 208 of the frame assembly 202 (e.g., the first frame portion 402) and a second side 210 of the frame assembly 202 and positioned between the first frame portion 402 and the second frame portion 404. In other words, the track 414 is at least positioned partially underneath the first frame portion 402. A portion of the track 414 extends from underneath the first frame portion 402 and toward the upper surface 422 of the first frame portion 402 adjacent a rear edge 424 of the first frame portion 402 opposite a front end 426. The track 414 is positioned along a longitudinal or center axis 428 of the movable frame 220 and/or the cart 204. However, in some examples, the track 414 of the illustrated example includes a first track provided adjacent the first side 208 of the frame assembly 202 and a second track provided adjacent the second side 210 of the frame assembly 202. In some examples, the ATLS 102 can include a plurality of drive systems and/or tracks positioned between the first side 208 and the second side 210 of the frame assembly 202. For instance, the ATLS 102 can include a first track positioned along the center axis 428 of the frame assembly 202 (e.g., as shown in FIG. 4 A), a second track positioned along the first side 208 of the frame assembly 202 and a third track positioned along the second side 210 of the frame assembly 202.
[0071] The track 414 of the illustrated example is a housing 430 having a first track side wall 432 and a second track side wall 434 spaced from the first track side wall 432 by a thickness T. The first track side wall 432 and the second track side wall 434 define a cavity 436 within which the drive beam 416 is positioned and/or stored. Specifically, the housing 430 is coupled or fixed to the first frame portion 402. For instance, a first edge 438 (e.g., a first longitudinal edge) of the track 414 (e.g., of each of the track side walls 432, 434) is coupled to the first frame portion 402 and a second edge 440 (e.g., a second longitudinal edge) of the track 414 (e.g., of each of the track side walls 432, 434) is suspended or projects the first frame portion 402. Alternatively, the second edge 440 (e.g.. a second longitudinal edge) of the track 414 (e.g.. of each of the track side walls 432, 434) is coupled to the second frame portion 404 and the first edge 438 protrudes or projects from the second frame portion 404. [0072] FIG. 5A is a cross-sectional side view of the ATLS 102 of FIG. 4A and 4B. FIG. 5B is a perspective view of the example track 414 of FIGS. 4A and 4B. FIG. 5C is a perspective view of a first end cap 502 of the track 414 of FIGS. 4A and 4B. FIG. 5D is a perspective view of a first side wall 504 of the track 414 of FIGS. 4A and 4B. FIG. 5E is a perspective view of a second end cap 506 of the track 414 of FIGS. 4A and 4B. FIGS. 5C-5E illustrate the first track side wall 432 of the track 414 of FIGS. 4A and 4B. The second track side wall 434 of the track 414 is a mirror image of the first track side wall 432 of the track 414 of FIGS. 4A and 4B.
[0073] The track 414 of the illustrated example has a spiral, oval or serpentine shape or pathway 500. For example, the track 414 includes a plurality of channels 508 having an oblong shape formed and/or supported by the housing 430 to form the serpentine pathway. To provide the track 414, the first end cap 502 couples to a front edge 511 of the first side wall 504 and the second end cap 506 couples to a rear edge 512 of the first side wall 504. The first end cap 502, the first side wall 504 and the second end cap 506 define the channels 508 that align to define respective track portions 510. For example, the first end cap 502 includes a plurality of curved channels 508a, the first side wall 504 includes a plurality of straight channels 508b, and the second end cap 506 includes a plurality7 of curved channels 508c. The second end cap 506 includes an outlet 508d that is positioned adjacent to the upper surface 422 of the first frame portion 402. The first end cap 502 provides the outlet 508d of the track 414 that enables the drive beam 416 to move above (e.g., on top of) the first frame portion 402 (e.g., from underneath the first frame portion 402). The channels 508 (e.g., grooves, slots, recesses, etc.) can be provided (e.g., cut, grooved, extruded, etc.) in the first side wall 504, the first end cap 502 and the second end cap 506. In some examples, the first end cap 502, the second end cap 506 and the first side wall 504 can be integrally formed as a single piece or structure.
[0074] The track 414 of the illustrated example includes a plurality of track portions 510 (e.g., vertically spaced track portions, loops, channels, etc.). In the illustrated example, the track 414 includes a first track portion 510a, a second track portion 510b. a third track portion 510c, a fourth track portion 51 Od and a fifth track portion 51 Oe. The track portions 51 Oa-51 Oe receive the drive beam 416 to enable the drive beam 416 to w ind or collapse in a serpentine pattern when the drive beam 416 is in a stored position. For instance, in the stored position, the drive beam 416 is positioned within the track portions 510a-510e of the track 414 of the ATLS 102 (e.g.. defined by the housing 430). For example, the drive beam 416 of the illustrated example is snaked or wounded underneath the first frame portion 402 via the track 414. The track 414 (e.g., the vertically separated channels 510a-510e) keeps the drive beam 416 from intertangling or interwinding. During a loading operation, the drive beam 416 extends (e.g., unfolds or unrolls) from the track 414 and moves into the cargo area 116 of the vehicle 118. The track 414 maintains an orientation of the drive beam 416 during deployment.
[0075] FIG. 6A is a perspective view of the drive beam 416 of FIGS. 4A-4B. FIG. 6B is a partial, enlarged portion of the drive beam 416 of FIG. 4A. The drive beam 416 of FIGS. 6A and 6B is shown in a coiled or stored configuration 600. The drive beam 416 of the illustrated example is foldable, deflectable, or bendable. In this manner, the drive beam 416 of the illustrated example can roll up, wind, coil or otherwise fold to the stored configuration 600 (e.g.. as shown in FIG. 5 A). For instance, the drive beam 416 is a continuous drive beam having a length between a leading end 602 (e.g., edge) and a trailing end 604 (e.g., edge). To move the drive beam 416 to the stored configuration 600, the trailing edge or end 604 of the drive beam 416 snakes around the channels 508 of the track 414 in the curved or serpentine pattern and the leading end 602 is positioned adjacent the outlet 508d. For example, the drive beam 416 of the illustrated example can be folded into loops 606a-e that correspond with respective ones of the track portions 510a-d of FIGS. 5A-5E. For example, a first loop 606a is positioned in the first track portion 510a. a second loop 606b is positioned in the second track portion 510b, a third loop 606c is positioned in the third track portion 510c, a fourth loop 606d is positioned in the fourth track portion 510d and a fifth loop 606e is positioned in the fifth track portion 510e. When moved to an extended position, the drive beam 416 exits the track 414 and extends in a substantially straight configuration. The drive beam 416 of the illustrated example can have a total extended length of approximately between 65 feet and 75 feet (e.g., 70 feet). The platform 108 and/or the ATLS 102 can have a length of approximately between 5 feet and 20 feet (e.g., 15 feet). Thus, the drive beam 416 can be configured to accommodate a cargo bed (e.g., the cargo area 116) having a length of approximately 53 feet.
[0076] The drive beam 416 of the illustrated example includes a plurality of drive beam links 608 that interconnect to provide a continuous drive beam and enable the drive beam 416 to roll or bend about the track 414 when the drive beam 416 moves to the stored configuration 600. The drive beam 416 of the illustrated example includes a drive chain 610 (e.g., a roller chain, a chain, etc.) and a cover 612. The drive chain 610 interacts or interfaces with the cart drive system 408 and the cover 612 interacts or interfaces with the track 414. To drive (e.g., push or pull) the drive beam 416 along the track 414, the drive beam 416 of the illustrated example includes a plurality of rollers 614. The drive beam 41 includes a cable carrier channel 616 provided by the cover 612. The cable carrier channel 616 can cany' one or more power cords, communication cables, and/or other cords or cables of the ATLS 102.
[0077] The drive chain 416 of the illustrated example includes a plurality of chain links 618 and the cover 612 of the illustrated example includes a plurality of cover links 620. A respective one 618a of the chain links 618 and a respective one 620a of the cover links 620 provides a respective one 608a of the drive beam links 608. Each of the chain links 618 are pivotally coupled and/or interconnected to provide a continuous drive chain and each of the cover links 620 are pivotally coupled and/or interconnected to provide a continuous cover. Specifically, a respective one 620a of the cover links 620 is coupled to and/or houses a respective one 618a of the chain links 618. In particular, respective ones of the cover links 620 encase, encompass, or surround respective ones of the chain links 618.
[0078] Each of the cover links 620 of the illustrated example includes a first link side wall 622, a second link side wall 624 spaced from the first link side wall 622, and a plate 626 coupling the first link side wall 622 and the second link side wall 624. The plate 626 is coupled to the first link side wall 622 and the second link side wall 624 via fasteners 628 (e.g., screws). However, in some examples, the plate 626 can be coupled to the first and second link side walls 622, 624 via welding and/or any other suitable fastener. Each of the cover links 620 of the illustrated example also includes a first plate side wall 630 extending from a first side of the plate 626 and/or adjacent the first link side wall 622 and a second plate side wall 632 extending from a second side of the plate 626 and/or adjacent the second link side wall 624. The plate 626, the first plate side wall 630 and the second plate side wall 632 define a channel portion 616a of the cable carrier channel 616. Additionally, each of the cover links 620 of the illustrated example includes a first roller 614a coupled to the first link side wall 622 and a second roller 614b coupled to the second link side wall 624. The first roller 614a projects in a direction away from the first link side wall 622 and the second roller 614b projects in a direction away from the second link side wall 624. Thus, the cover links 620 (e.g., and the drive chain 618) move within the cavity' 436 (FIG. 4B) formed between the first track side wall 432 of the track 414 and the second track side wall 434 of the track 414, with the first roller 614a interfacing with (e.g., engaging) the channels 508 of the first track side wall 432 of the track 414 and second roller 614b interfacing with (e.g., engaging) the channels 508 of the second track side wall 434 of the track 414. The cover links 620 can couple to the chain links 618 via a fastener, welding, and/or any other suitable fastener(s).
[0079] Additionally, the cover 612 provides rigidity to the drive beam 416 when in an extended position. To provide rigidity to the drive beam 416 when in an extended position, the drive beam 416 (e.g., the cover links 620) of the illustrated example interlock via locking features. For example, each of the first link side wall 622 and the second link side wall 624 include a tab or lip 638 projecting from a front edge of the cover links 620 and a groove or shoulder 640 formed on a rear edge of the cover links 620. In operation, the lip 638 of the first one 608a of the drive beam links 608 engages (e.g., is received by) the shoulder 640 of a second one 608b of the drive beam links 608 (e.g., immediately) adjacent (e.g., in front of) the first one 608a of the drive beam links 608. The lips 638 and the shoulders 640 of adjacent ones of the drive beam links 608 disengage or move away from each other to enable the drive beam 416 to bend in a first direction 644 (e.g., a downward direction). However, the lips 638 and the shoulders 640 of adjacent ones of the drive beam links 608 engage to prevent the drive beam 416 from bending or flexing in a second direction 646 (e.g., an upward direction) opposite the first direction 644. An upward flex of the drive beam 416 (e.g., in the second direction 646) is limited by interference provided between respective ones of the lips 638 of the cover links 620 touching or engaging respective ones of the shoulders 640 of adjacent ones of the cover links 620. Additionally, when the drive beam 416 is on a flat surface, the lips 638 engage or interact with the shoulders 640 to provide a rigid drive beam. Specifically, the ground or surface on which the drive beam 416 moves prevents rotation of the drive beam in the first direction 644 and the locking interface (e.g.. provided by the lips 638 and the shoulders 640) prevents rotation of the drive beam 416 in the second direction 646, thereby providing a rigid characteristic to the drive beam 416. Thus, when the drive beam 416 is in a flat position or a pushing configuration (e.g., an extended position), the cover links 620 prevent pivotal movement of the drive beam links 608 in the second direction 646 (e.g., a collapsed configuration). However, when the drive beam 416 is not supported on a flat surface and/or bends out of alignment in the first direction 644 (e.g., a downward rotation in the orientation of FIGS. 6A-6B), adjacent drive beam links 608 can rotate or pivot relative to each other and the drive beam 416 can bend or collapse to the stored configuration 600. Thus, when the drive beam 416 moves through the channels 508 of the track 414, the drive beam 416 and/or the drive beam links 608 can pivot relative to each other to enable the drive beam 416 to move (e.g., snake) along the track 414 to the stored configuration
600.
[0080] FIG. 7A is a perspective rear view of the ATLS 102 of FIGS. 1A, IB, 2A and 2B. FIG. 7B is an enlarged, partial view of the ATLS 102 of FIG. 7A. FIG. 7C is a partial cross-sectional view of the cart drive system 408 of FIG. 7A. The drive beam 416 of the illustrated example is coupled or tethered to the cart 204. Specifically, the drive beam 416 of the illustrated example is coupled (e g., fixed or fastened) to a rear end or rear edge 702 of the cart 204 via a bracket 704. The bracket 704 includes a first flange 704a to couple to a first side of the drive beam 416 and a second flange 704b to couple to a second side of the drive beam 416. For example, a chain link 706 of the leading end 602 of the drive beam 416 of the drive beam 416 can be coupled to the bracket 704 via a locking pin. In some examples, the drive beam 416 can be welded to the bracket 704.
[0081] To drive the drive beam 416 of the illustrated example between the stored configuration 600 and an extended configuration, the ATLS 102 of the illustrated example includes the motor 418. The motor 418 is mounted or coupled to the second frame portion 404 adjacent to the rear end 214 of the frame assembly 202. The motor 418 of the illustrated example is coupled to the drive beam 416 via a transmission 708. The transmission 708 of the illustrated example includes a drive belt 710, a plurality of gears and/or sprockets 712, and a drive shaft 714 to operatively couple an output shaft 716 of the motor 418 and the drive beam 416. The drive shaft 714 includes a first gear or sprocket 712a to interface with the drive belt 710 and a second gear 712b to interface with the drive chain 618. As shown in FIG. 7C, the second gear 712b includes teeth 718 that engage with the chain links 618 to push or pull the drive beam 416 relative to the track 414. Rotation of the output shaft 716 in a first rotational direction 720 about an axis of rotation 724 via the first motor causes the drive beam 416 to retract to the stored configuration 600 and rotation of the output shaft 716 in a second rotational direction 722 opposite the first rotational direction 720 about the axis of rotation 724 via the motor 418 causes the drive beam 416 to move to an extended or operational position.
[0082] FIGS. 8A-8G are various views of the cart 204 or FIGS. 2A and 2B. FIG. 8A is a perspective top view of the cart 204. FIG. 8B is an enlarged, partial view of the cart 204 of FIG. 8A. FIG. 8C is another enlarged, partial view of the cart 204 of FIGS. 8A and 8B. FIG. 8D is an alternative roller disclosed herein. FIG. 8E is a partial, rear perspective view of the cart 204 of FIGS. 8A and 8B. FIG. 8F is a perspective bottom view of the cart 204 of FIGS. 8A and 8B. FIG. 8G is a partial perspective view of the cart 204 of FIG. 8F.
[0083] The cart 204 of the illustrated example includes a cart frame 802, a plurality of surface or upper rollers 804 (e.g., anti-friction rollers) and a plurality of lower rollers 806 (e.g., anti-friction rollers). The cart frame 802 includes a plurality of longitudinal beams 808 for rotatably coupling the upper rollers 804 and/or the lower rollers 806 to the cart frame 802 and a plurality7 of braces 810 extending between and/or coupled to adjacent ones of the longitudinal beams 808 to support and/or reinforce the longitudinal beams 808. The cart frame 802 is tethered to the movable frame 220 via the drive beam 416. In other words, the cart frame 802 and/or the cart 204 is coupled to the movable frame 220 only via the drive beam 416.
[0084] To reduce friction between a cargo load and an upper surface 811 of the cart 204 and improve or facilitate removal of a load position on the cart 204 when the cart 204 moves relative to the frame assembly 202, the cart 204 of the illustrated example includes the upper rollers 804. The upper rollers 804 facilitate positioning (e.g., receiving and/or removal) of a load on the cart 204. To improve or facilitate movement of the cart 204 relative to the platform 108 and/or the cargo area 116 of the vehicle 118, the cart 204 of the illustrated example includes the lower rollers 806 (FIGS. 8F and 8G). The lower rollers 806 reduce friction between a ground floor (e.g., a support floor, a floor of the vehicle) when the cart 204 moves (e.g., slides) on surfaces. The upper rollers 804 can extend below the upper surface 811 of the cart 204. However, the upper rollers 804 do not engage a ground surface on which the cart 204 traverses during a loading/unloading operation.
[0085] In the illustrated example, the upper rollers 804 include a first set 804a of upper rollers 804 (e.g., rotatably coupled between a first pair of longitudinal beams 808), a second set 804b of upper rollers 804 (e.g., rotatably coupled between a second pair of longitudinal beams 808), a third set 804c of upper rollers 804 (e.g., rotatably coupled between a third pair of longitudinal beams 808). and a fourth set 804d of upper rollers 804 (e.g., rotatably coupled between a fourth pair of longitudinal beams 808). The cart 204 of the illustrated example includes strips or covers 812 to cover gaps 814 formed between the longitudinal beams 808.
[0086] The upper rollers 804 of the illustrated example includes one or more drive rollers 816 and a plurality of follower rollers 818. The drive rollers 816 of the illustrated example drive or cause rotation of the follower rollers 818. The upper rollers 804 are rotatably coupled to (e g., journaled at) adjacent ones of the longitudinal beams 808. The upper rollers 804 of the illustrated example include rotational axes 819 that are non-parallel (e.g., perpendicular) relative to a longitudinal axis 820 and/or a direction of movement 822 of the cart 204. In this manner, the upper rollers 804 rotate in a first rotational direction 824 to move a cargo load in a direction from the rear edge 702 of the cart toward a front edge 827 of the cart 204. The drive rollers 816 can be controlled by a control system 1114 (e.g., programmable circuitry) and/or can be manually operated during a loading/unloading operation.
[0087] The drive rollers 816 of the illustrated example include a motor (e.g., contained within the roller) that rotates an output shaft of the drive rollers 816. To drive the follower rollers 818. the drive rollers 816 and the follower rollers 818 are operatively coupled via a roller transmission 830 (FIGS. 8B and 8C). The roller transmission 830 of the illustrated example includes a plurality of belts 832 and a plurality' of pulleys 834. A belt 832 interconnects or couples to pulleys of adjacent upper rollers 804. An output shaft of each of the upper rollers 804 includes a pulley 834 to receive the belt 832 (e.g.. a belt-driven pulley system or transmission). Thus, rotation of a drive roller 816a operatively coupled to a follower roller 818a via the roller transmission 830 causes rotation of the follower roller 818a. Additionally, the upper rollers 804 have the same diameter. However, in some examples, the drive rollers 816 can have a diameter that is different than (e.g. , greater than or less than) a diameter of the follower rollers 818. Also, any ratio of drive rollers to follower rollers can be used.
[0088] The lower rollers 806 of the illustrated example are coupled to a bracket 840 and protrude below the upper rollers 804. The lower rollers 806 do not engage the upper rollers 804. In other words, the lower rollers 806 do not interfere with the upper rollers 804 during operation. The lower rollers 806 have a diameter that is smaller than a diameter of the upper rollers 804.
[0089] To facilitate movement of the cart 204 within the cargo area 1 16 of the vehicle 118 and/or to facilitate loading/unloading of cargo or goods, the cart 204 of the illustrated example includes a lead-in ramp 844 (e.g., a guide ramp, a leading edge, a ramp, a lip, etc.). The lead-in ramp 844 is tapered to facilitate removal of a load (e.g., enables pallets on the cart 204 to slide off smoothly) from the cart 204 when the load is delivered into the vehicle 118 (e.g., pallets are deposited into the cargo area 116) and the cart 204 of the ATLS 102 is extracted (e.g., removed or retracted) from the vehicle 118.
[0090] Additionally, to guide the cart 204 within the cargo area 116 of the vehicle 118. the cart 204 of the illustrated example includes guide rollers 846. The guide rollers 846 are positioned adjacent to the front edge 827 of the cart frame 802 and aft of the lead-in ramp 844. The guide rollers 846 each have a rotational axis 848 that is non-parallel (e.g., perpendicular) relative to the rotational axes 819 of the upper rollers 804. In some examples, the guide rollers 846 can be mounted at an angle such that the rotational axes 848 of the guide rollers 846 are angled (e.g., non-perpendicular) relative to the rotational axes 819 of the upper rollers 804. The guide rollers 846 are coupled to the cart 204 via brackets 850. The guide rollers 846 of the illustrated example include a first guide roller 846a positioned on a first side of the cart 204 and a second guide roller 846b positioned on a second side of the cart 204 opposite the first side.
[0091] FIG. 8G is a side view of another example roller 890 that can be used with the ATLS 102 disclosed herein. The roller 890 of the illustrated example includes a housing 892 that houses a ball 894 (e.g., a sphere). The ball 894 can rotate in any direction within the housing 892. The roller 890 of FIG. 8D can be used in lieu of and/or in addition to, for example, the guide rollers 846, the lower rollers 806, the pad 328, and/or can be coupled underneath the lead-in lip 826.
[0092] FIG. 9A is a perspective view of the ATLS 102 of FIGS. 2A and 2B with the guide doors 206 shown in an example guide position 900. FIG. 9B is another perspective view of the ATLS 102 of FIGS. 2A and 2B with the guide doors 206 shown in an example transfer position 902.
[0093] The guide doors 206 are movable between the guide position 900 at which the guide doors 206 are positioned perpendicular relative to the upper surface 422 of the frame assembly 202 and the transfer position 902 at which the guide doors 206 are substantially parallel relative to the upper surface 422 of the frame assembly 202. In other words, in the guide position 900. the guide doors 206 are in an upright position (e.g., a vertical position). In the guide position 900, the guide doors 206 can flank cargo positioned on the cart 204. In the transfer position 902, the guide doors 206 are in a lower or flat position (e.g., a horizontal position). In other words, the guide doors 206 are folded or positioned on top of the upper surface 422 of the movable frame 220. In the transfer position 902. the guide doors 206 enable transfer of cargo from the rear end 214 of the frame assembly 202 to the front end 218 of the frame assembly 202 (e.g., and onto the cart 204).
[0094] The guide doors 206 include a first guide door 904 (e.g., a panel) pivotally coupled to the first side 208 of the frame assembly 202 and a second guide door 906 (e.g., a panel) pivotally coupled to the second side 210 of the frame assembly 202. The first guide door 904 pivots about a first pivot axis 904a and the second guide door 906 pivots about a second pivot axis 906a. The first pivot axis 904a and the second pivot axis 906a are substantially parallel relative to the center axis 428 of the frame assembly 202.
[0095] To pivotally couple the guide doors 206 relative to the frame assembly 202, the ATLS 102 of the illustrated example includes a guide door drive system 908. The guide door drive system 908 of the illustrated example includes a plurality of actuators 910. The actuators 910 includes a first set 910a of actuators 910 to operate the first guide door 904 and a second set 910b of the actuators 910 to operate the second guide door 906. Specifically, a first end 912 (e.g., a piston end) of each actuator 910 is coupled to a respective one of the guide doors 206 and a second end 914 (e.g.. a cylinder end) of each actuator 910 is coupled to the frame assembly 202 (e.g., the second frame portion 404 of the movable frame 220). Thus, movement of the actuators 910 from a retracted position to an extended position causes the guide doors 206 to rotate about the respective pivot axes 904a, 906a from the guide position 900 to the transfer position 902 and movement of the actuators 910 from an extended position to a retracted position causes the guide doors 206 to pivot about the respective pivot axes 904a, 906a from the transfer position 902 to the guide position 900.
[0096] To facilitate transfer of cargo across the guide doors 206 when the guide doors 206 are in the transfer position 902, the guide doors 206 of the illustrated example include a plurality of guide door rollers 916. The guide door rollers 916 of the illustrated example include can include one or more drive rollers, one or more driven rollers, and/or a mix of drive rollers and follower rollers. Each of the guide doors 206 includes a guide door frame 918 including beams 920 to rotatably couple the guide door rollers 916 (e.g., substantially similar to the cart frame 802). The guide door rollers 916 of the guide doors 206 include rotational axes that are substantially parallel relative to the rotational axes 819 (FIGS. 8A-8F) of the upper rollers 804 of the cart 204 when the guide doors 206 are in the transfer position 902. The guide doors 206 can be structured or configured substantially similar to the cart 204 and/or the guide door rollers 916 of the guide doors 206 can be structured or configured substantially similar to the upper rollers 804 of the cart 204. In other words, one or more of the guide door rollers 916 can be tethered via a transmission (e.g., a belt-pulley transmission of FIGS. 8A-8F) to operatively couple two or more other ones of the guide door rollers 916.
[0097] The guide doors 206 each have a width that provide a gap 922 between respective inner edges 924 of the guide doors 206 to receive the drive beam 416 therebetween when the guide doors 206 are in the transfer position 902. In the transfer position 902, the guide doors 206 are pivoted downward on top of and/or above the first frame portion 402 of the movable frame 220 when the cart 204 is removed or positioned away from the first frame portion 402. For example, in the transfer position 902, a front edge 920a of the guide doors 206 can be positioned adjacent the rear edge 702 of the cart 204 (e.g., the cart 204 is positioned in the cargo area 116 adjacent the guide doors ). Additionally, the guide door rollers 916 and/or the guide door frame 918 are above an uppermost surface of the drive beam 41 . Thus, the guide doors 206 do not interfere with the cart drive system 408 and/or the drive beam 416 when the guide doors 206 are in the transfer position 902.
[0098] FIG. 10A is a partial perspective front view of the example ATLS 102 of FIGS. 1, 2A and 2B with an example sensor assembly 1000 of an example scanner system shown in an example stowed position 1002. FIG. 10B is a partial perspective front view of the example ATLS 102 of FIG. 10A with the example sensor assembly 1000 of the example scanner system shown in an example scanning position 1004. FIG. 10C is a front view of the example sensor assembly 1000 of FIG. 10B.
[0099] Referring to FIGS. 10A-10C, the example sensor assembly 1000 of the example ATLS 102 is provided (e.g., housed) within the transition platform 216. Thus, the sensor assembly 1000 of the illustrated example is positioned adjacent the front end 218 of the ATLS 102. The sensor assembly 1000 includes an arm 1006 and a sensor 1008 carried by the arm 1006. In the stowed position 1002 of FIG. 10A, the arm 1006 (e.g., an outer surface 1010 of the arm 1006 is flush mounted with the upper surface 422 of the first frame portion 402 of the movable frame 220. Thus, in the stowed position 1002, the sensor 1008 is hidden from view and/or is positioned underneath the first frame portion 402 of the movable frame 220. In particular, the example arm 1006 may be a portion of the first frame portion 402 of the movable frame 220 of the ATLS 102. The arm 1006 can be built or integrated with the first frame portion 402 of the movable frame 220 of the ATLS 102. The sensor 1008 can be stowed underneath or below the cart 204 and/or flush mounted relative to a travel path of the cart 204 of the ATLS 102 after a scanning operation so that the sensor assembly 1000 does not interfere with a loading/unloading operation.
[00100] The sensor 1008 is positioned on a distal end of the arm 1006 (e.g., support arm, lever arm, elongated arm, etc.). The sensor 1008 of the illustrated example includes a first sensor 1008a and a second sensor 1008b. In some examples, the first sensor 1008a performs a first scan (e.g., a horizontal scan) of the cargo area 11 and the second sensor 1008b performs a second scan (e.g., a vertical scan) of the cargo area 1 16. Referring to FIGS. 10B-10C, the example arm 1006 is pivotable (e.g., rotatable) about an axis 1012 defined by a hinge 1014. As shown in FIG. 10C, the sensor assembly 1000 includes an example sensor actuator 1016 to rotate (e.g.. push/pull on) the arm 1006 about the hinge 1014 to adjust a position of the sensor assembly 1000 between the stowed position 1002 and the scanning position 1004. The ATLS 102 can include a control system 1114 (e.g., programmable circuitry) that commands the sensor actuator 1016 to pivot the arm 1006 between the stowed position 1002 and the scanning position 1004. The sensor 1008 may be a two dimensional (2D) LIDAR sensor, a three- dimensional (3D) LIDAR sensor, a camera, etc. For example, the sensor assembly 1000 can employ time of flight technology to scan the cargo area 116 and determine information regarding a position of the vehicle relative to a reference (e.g. a longitudinal axis of the ATLS 102), a length of the cargo area 116, a lateral position of the vehicle 118 relative to the reference, an angular position of the vehicle 1 18 relative to the reference and/or any other information. A control system (e.g., processor circuitry, programmable circuitry, programmable logic controllers, etc.) of the ATLS 102 receives and/or processes data (e.g., feedback signals) from the sensors 1008a and 1008b to determine information regarding the cargo area 116 and/or an orientation of the vehicle 118 relative to the ATLS 102 and/or the loading dock 100.
[00101] FIG. 11A-11C are schematic illustrations of the ATLS 102 of FIGS. 1 A, 2B, 2A and 2B in an example scanning operation. FIGS. 11 A is a side view of the example loading dock 100 with the vehicle 118 parked at the loading dock 100 and the ATLS 102 performing an example scanning operation 1100. FIG. 1 IB is a partial perspective view of the ATLS 102 and the loading dock 100 of FIG. 11 A. FIG. 11C is another perspective view of FIGS. 11A and 1 IB showing the cargo area 116 of the vehicle 118.
[00102] During a scanning operation 1100, the sensor assembly 1000 moves from the stowed position 1002 to the scanning position 1004 via the sensor actuator 1016. With the arm 1006 positioned in the example scanning position 1004 (e.g., an upright position), the example sensors 1008 projects one or more beams 1102, 1104 (e.g., laser beams) to perform the scanning operation 1100. In the illustrated example, the first sensor 1008a performs a scan (e.g., a two-dimensional scan) in a first direction (e.g., a horizontal direction or between the inner side walls 1106 of the vehicle 118) and the second sensor 1008b performs a scan in a second direction (e.g., a vertical direction or between an upper roof surface 1108 and a floor 1110) different than the first direction (e.g., perpendicular relative to the first direction). [00103] To determine information regarding the cargo area 1 16 and/or the vehicle 118 relative to the loading dock 100, the ATLS 102 of the illustrated example includes a control system. For example, the control system 1114 receives and/or processes signals (e.g., feedback signals) from the sensor 1008 to determine information regarding the cargo area 1 16 and/or the vehicle 118 including, but not limited to, a vehicle reference 1116 of the vehicle 118, a width of an opening of the vehicle 118 (e.g., between the inner side walls 1106), a height of the opening of the vehicle 118, a depth or length of the cargo area 116, obstructions within the cargo area 116, an orientation of the vehicle 118 relative to areference of the ATLS 102 and/or the doorway 106, a vertical position of the ATLS 102 relative to the vehicle 118 (e.g., the floor 11 10 of the cargo area 116), and/or other information regarding a position of the vehicle 1 18 relative to the loading dock 100 and/or information regarding the cargo area 116. In some examples, the sensor assembly 1000 can detect and/or determine positional information associated with the cargo area 116. the vehicle 118, and/or the ATLS 102. For example, the sensor 1008 can determine positional information of the inner side walls 1106, the floor 1110 and/or the upper roof surface 1108 of the vehicle 118, an end wall 1112 of the vehicle 118, a length of the vehicle 118 and/or any other information relating to the vehicle 118. In the illustrated example, the control system 1114 determines the vehicle reference 1 116 for adjusting the ATLS 102 relative to the vehicle reference 1116. The control system 1 114 can determine a lateral position of the vehicle reference 1116 and/or an angular slope 1118 of the vehicle reference 1116 relative to horizontal 1120. In other words, the vehicle reference 1116 is a central or longitudinal axis of the cargo area 116 and/or the vehicle 118 (e g., the trailer) when parked on a driveway 1122 of the loading dock 100 and restrained (e.g., by a vehicle restraint) for a loading operation.
[00104] FIGS. 12A-12B are top views of the loading dock 100 of FIGS. 1A, IB, 2A and 2B illustrating an example lateral alignment operation 1200. FIG. 12A is a top view of the example ATLS 102 in an example first lateral position 1202 (e.g., an initial or reference position) relative to the example vehicle 118. FIG. 12B is a top view of the example ATLS 102 in an example second lateral position 1204 (e.g., an adjusted lateral position) relative to the vehicle 118. The sensor assembly 1000 is in the scanning operation 1100 to scan the cargo area 116 of the vehicle 118 (e.g., via the sensor 1008).
[00105] To adjust the ATLS 102 relative to the vehicle 118, the ATLS control system determines the vehicle reference 1116 (e.g., a longitudinal axis or reference) of the vehicle 1 18 relative to (e.g., compared to) an ATLS reference 1208 (e.g., a longitudinal axis) of the ATLS 102. Referring to FIG. 12 A, the control system 1 1 14 determines that the ATLS reference 1208 is misaligned (e.g., is not axially or coaxially aligned) relative to the vehicle reference 1116. For example, the ATLS 102 (e.g., the ATLS reference 1208) is skewed, off- center, angled, tilted, offset, etc. relative to the vehicle 1 18 (e.g., the vehicle reference 1116) in a horizontal or angular direction in the orientation of FIGS. 12A and 12B. In some examples, the misalignment between the ATLS 102 and the vehicle 118 can limit or prohibit deployment of the cart 204 of the ATLS 102. For example, if the cart 204 were to deploy and/or extend into the vehicle 118 while the ATLS 120 is misaligned relative to the vehicle 118, the cart 204 can contact/intersect one of the inner side walls 1106.
[00106] FIG. 12B shows the ATLS 102 in an adjusted position (e.g., the second lateral position 1204) after a lateral and/or angular adjustment of the ATLS 102 relative to the vehicle 118 (e.g., the vehicle reference 1116) (e.g., from the first lateral position 1202 of FIG. 12A). Thus, the control system 1114 adjusts a lateral position of the ATLS 102 (e.g.. to adjust for misalignment of the ATLS 102 relative to the vehicle 118 shown in FIG. 12A). For example, the control system 1114 of the ATLS 102 can determine a lateral and/or angular offset of the ATLS 102 (e.g., in a horizontal plane) relative to the vehicle reference 1116 and, in turn, move the ATLS 102 to align (e.g., axially align) the ATLS reference 1208 with the vehicle reference 1116 of the vehicle 1 18 (e.g., in the horizontal plane). In other words, the ATLS reference 1208 can be adjusted to be parallel relative to the vehicle reference 1116 laterally or in the orientation of FIGS. 12A and 12B (e.g., the horizontal plane). Adjustment(s) can be made via the second alignment system 236 described in connection with FIGS. 3A-3C. For example, in the example of FIG. 12B, the second alignment system 236 can be employed to move the rear end 312 of the ATLS 102 in the first lateral direction 320 by extending the first end 310 (e.g., the piston end) of the second lateral actuator 240 to move the rear end 312 of the movable frame 220 relative to (e.g., in an upward direction in the orientation of FIG. 12B relative to) the front end 304 of the movable frame 220 and, thus, change an angular position of the ATLS reference 1208 (e.g., in the horizontal plane in the orientation of FIGS. 12A and 12B). Additionally, if the ATLS reference 1208 is not axially aligned with the vehicle reference 1116 of the vehicle 118 after movement of the rear end 312 (e.g., the ATLS reference 1208 is laterally offset relative to the vehicle reference 1116 in the horizontal plane), the movable frame 220 can be moved in the first lateral direction 320 or the second lateral direction 322 via the second alignment system 236 by actuating (e.g., extending or retracting) the first lateral actuator 238 and the second lateral actuator 240 to the same stroke position (e.g., simultaneously or sequentially). As such, the adjusted position of the ATLS 102 is aligned (e.g., axially aligned) with the vehicle reference 1116 corresponding to a position of the vehicle 118.
[00107] FIG. 13A-13B are side views of the loading dock 100 of FIGS. 1, 2 A and 2B illustrating an example vertical alignment operation 1300. FIG. 13A is a side view of the example ATLS 102 in an example first vertical position 1302 (e.g., an initial or reference position) relative to the example vehicle 118. FIG. 13B is a side view of the example ATLS 102 in an example second vertical position 1304 (e.g., an adjusted vertical position) relative to the vehicle 118. The sensor assembly 1000 is in the scanning operation 1 100 to scan the cargo area 116 of the vehicle 118 (e.g., via the sensor 1008).
[00108] To adjust the ATLS 102 relative to the vehicle 118 in the vertical directions 232, 234, the control system 1114 determines the angular slope 1118 of the vehicle reference 1116 (e.g., a slope of the longitudinal axis or reference) relative to horizontal 1120. In other words, the control system 11 14 uses data from the sensor assembly 1000 (e.g., feedback signals) to determine a slop of the vehicle 118 and/or the cargo area 116 relative to horizontal 1120. Referring to FIG. 13A, in the first vertical position 1302, the vehicle reference 1116 is misaligned relative to the ATLS reference 1208 in the vertical plane or direction. For example, the vehicle 118 (e.g., the vehicle reference 1116) is tilted, sloped or slanted relative to the ATLS reference 1208. In some examples, the vertical misalignment between the ATLS 102 and the vehicle 118 can limit or prohibit deployment of the cart 204 of the ATLS 102.
[00109] FIG. 13B shows the ATLS 102 in a vertically adjusted position (e.g., the second vertical position 1304) after a vertical adjustment of the ATLS 102 relative to the vehicle 1 18 (e g., relative to the vehicle reference 1116 ofthe vehicle 1 18) from the first vertical position 1302 shown in FIG. 13A (e.g., the second lateral position 1204 of FIG. 12B). Thus, the control system 1114 adjusts a vertical position of the ATLS 102 (e.g., to adjust for misalignment of the ATLS 102 relative to the vehicle 118 in the vertical direction shown in FIG. 13 AB). As such, the adjusted position (e.g., the second vertical position 1304) of the ATLS 102 of FIG. 13B is aligned (e.g., coaxially aligned) with the vehicle reference 1116 corresponding to a position of the vehicle 118.
[00110] For example, the control system 1114 of the ATLS 102 can determine a vertical offset of the ATLS 102 (e.g., in a vertical plane) relative to the vehicle reference 1116 and, in turn, move the ATLS 102 to align (e.g., coaxially align) the ATLS reference 1208 with the vehicle reference 1116 (e.g., in the vertical plane). Adjustment(s) can be made via the first alignment system 226 described in connection with FIGS. 2A-2B. For example, in FIG. 13B, the first alignment system 226 can be employed to move the front end 304 of the movable frame 220 in the first vertical direction 232 (e.g., upward in the orientation of FIG. 13B) by extending the vertical actuators 228 adjacent the front end 218 of the frame assembly 202 to a first stroke position and/or move the rear end 312 of the movable frame 220 in the second vertical direction 234 (e.g., a downward direction in the orientation of FIG. 13B) by retracting the vertical actuators 228 adjacent the rear end 214 of the frame assembly 202 to a second stroke position less than the first stroke position and, thus, change an vertical position of the ATLS reference 1208 (e.g., in the vertical plane in the orientation of FIGS. 13A and 13B). Thus, the ATLS reference 1208 can be moved angularly (e.g., tilted) in a longitudinal direction to align with (e.g., match) the slope or angle of the vehicle reference 1116. The movable frame 220 can be moved to adjust a longitudinal slope of the ATLS 102 between the front end 304 and the rear end 312 of the movable frame 220 (e.g., as shown in FIG. 13B) and/or can be moved to adjust a lateral slop of the ATLS 102 between the first side 208 and the second side 210 of the movable frame 220.
[00111] Thus, the ATLS 102 (e.g., the movable frame 220) of the illustrated example can be adjusted or moved in different degrees of freedom (e.g., six degrees of freedom) to coaxially align the ATLS reference 1208 relative to the vehicle reference 1116 and/or move the ATLS 102 in parallel alignment with the cargo area 116. In other words, the ATLS 102 can be adjusted via the movable frame 220 such that the cart 204 is parallel relative to floor 1110 of the cargo area 116. Specifically, the upper surface 422 of the movable frame 220 is adjusted via the control system 1114 to be substantially parallel (e.g., within a threshold limit) relative to the floor 1110 of the cargo area 116. In this manner, the cart 204 is positioned substantially parallel relative to the floor 1110 and can traverse between the movable frame 220 and the floor 1110 efficiently. To enable and/or achieve different (e.g., six) degrees of freedom of movement, each of the vertical actuators 228 of the first alignment system 226 and each of the lateral actuators 238, 240 of the second alignment system 236 can move to different stroke positions and/or operate independently of each other.
[00112] FIGS. 14A-14Q are perspective views of the example loading dock 100 of FIGS. 1, 2A and 2B and the example ATLS 102 at different positions 1400-1436 of an example loading operation. The loading operation commences after tire control system 1114 aligns the ATLS 102 relative to the vehicle reference 11 16 so that the cart 204 is substantially parallel relative to the floor 1110 of the cargo area 116 (e.g., the position of the ATLS 102 of FIG. 13B). During a loading operation, the sensor assembly 1000 is moved to the stowed position 1002 via the sensor actuator 1016 as shown in FIG. 10A.
[00113] Referring to FIG. 14A, at an example first position 1400, the cart 204 is in an initial or stored position 1438 (e.g., a home or stored position) when the drive beam 416 is in the stored configuration 600. Additionally, the guide doors 206 are in the guide position 900 (e.g., a vertical orientation). In the guide position 900. the guide doors 206 flank the cart 204. Thus, the cart 204 is positioned on the movable frame 220 between the first guide door 904 and the second guide door 906. With the cart 204 in the stored position 1438 and the guide doors 206 in the guide position 900, a first cargo 1442a (e.g., a first portion of a total cargo load) can be loaded on the cart 204 (e.g., via a material handling equipment or forktruck). In particular, the first cargo 1442a fits within a perimeter of the cart 204. Specifically, the first cargo 1442a is loaded on the cart 204 via the inner platform 212. The rollers 212a of the inner platform 212 transfers the cargo on the cart 204.
[00114] FIG. 14B illustrates the ATLS 102 at an example second position 1402. To move or carry the first cargo 1442a into the cargo area 116 via the cart 204, the ATLS 102 employs the cart drive system 408. Specifically, the ATLS 102 causes the motor 418 to rotate in the second rotational direction 722. As a result, an exposed portion 1444 of the drive beam 416 exits the track 414 and pushes the cart 204 (e.g., and the first cargo 1442a) inside the cargo area 116 of the vehicle 118. As noted in FIGS. 6A-6B and 7A-7C, the exposed portion 1444 of the drive beam 416 interlocks to provide a rigid structure or push bar when the drive beam 416 exits the track 414. Thus, a non-exposed portion 1448 of the drive beam 416 remaining in the track 414 can bend or curve (e.g., a non-locked condition) to snake or move around the channels 508 of the track 414 as the drive beam 416 exits the track 414. As the exposed portion 1444 of the drive beam 416 traverses the floor 1110. the floor 1110 prevents the exposed portion 1444 of the drive beam 416 from bending or flexing in the first direction 644 (FIG. 6B) (e.g., a downward direction) and the locking features (e.g., the lips 638 and the shoulders 640) prevent the exposed portion 1444 of the drive beam 416 from bending or flexing in the second direction 646 (FIG. 6B)(e.g., an upward direction). Thus, the exposed portion 1444 of the drive beam 416 remains substantially flat (e.g., and rigid) as the drive beam 416 traverses the floor 11 10. [00115] The lead-in ramp 844 of the cart 204 facilitates transition of the cart 204 from the movable frame 220 onto the floor 1110 of the cargo area 116. Additionally, the guide rollers 846 of the cart 204 help maintain alignment between the vehicle reference 1116 and the ATLS reference 1208. Moreover, the lower rollers 806 of the cart 204 reduce friction between the cart 204 and the floor 1110 when the cart drive system 408 moves the cart 204 and the first cargo 1442a into the cargo area 116. Specifically, as described below, the cart 204 moves from the stored position 1438 towards an extended position or drop-off position 1440 (FIG. 14D) adjacent to the end wall 1112 of the cargo area 116. During an extension of the cart drive system 408 and/or when pushing the cart 204 into the cargo area 116 toward the end wall 1 112, the upper rollers 804 of the cart 204 do not rotate.
[00116] Additionally, after the cart 204 advances into the cargo area 116 and/or is removed from the movable frame 220. the ATLS 102 (e.g., via the actuators 910) causes the guide doors 206 to rotate (e.g.. about the respective pivot axes 904a, 906a) from the guide position 900 to the transfer position 902 via the guide door drive system 908. In other words, the guide doors 206 are positioned flat or parallel on (e.g., directly on top of) the upper surface 422 of the movable frame 220. The rollers 212a of the inner platform 212 transfers the cargo on the guide doors 206 when the guide doors 206 are in the flat position.
[00117] FIG. 14C illustrates the ATLS 102 at an example third position 1404. In the third position 1404, the cart drive system 408 continues to advance or cany7 the first cargo 1442a toward the end wall 1112 of the cargo area 116. Additionally, with the guide doors 206 in the transfer position 902, a second cargo 1442b (e.g., a second portion of the total cargo load) can be positioned on the guide doors 206 (e.g., as the cart 204 is transferring the first cargo 1442a into the cargo area 116). The guide doors 206 or the second cargo 1442b do not interfere with the drive beam 416 as the cart drive system 408 advances the cart 204 because the drive beam 416 is positioned between the inner edges 924 of the guide doors 206 and the guide doors 206 and/or the guide door rollers 916 extend above the drive beam 416. Thus, the drive beam 416 is positioned underneath an upper most surface of the guide door rollers 916 and/or a lowermost surface of a pallet 1455 carrying the second cargo 1442b. Thus, loading of cargo onto the guide doors 206 does not interfere with the winding or unwinding of the drive beam 416 relative to the track 414.
[00118] FIG. 14D illustrates the ATLS 102 at an example fourth position 1406. At the fourth position 1406, the cart drive system 408 moves the cart 204 and the first cargo 1442a to a first position or the drop-off position 1440 adjacent the end wall 1 112. In other words, the drive beam 416 is fully exposed and/or in an extended position (e.g., 48-53 feet) and traverses a length L (e.g., a total length or total longitudinal length) of the cargo area 116. At the drop-off position 1440, a gap (G) is provided between the first cargo 1442a and the end wall 1112. For example, the gap (G) is provided by the lead-in ramp 844. The gap (G) can be, for example, one inch, two inches, five inches and/or any other suitable distance (e.g., a length of the lead-in ramp 844). The gap (G) provides space to enable the second cargo 1442b to move in the first linear direction 410 when the second cargo 1442b is removed from the cart 204. In some examples, the lead-in ramp 844 engages the end wall 1112. With the first cargo 1442a and the cart 204 positioned adjacent the end wall 11 12 at the drop-off position 1440, the upper rollers 804 of the cart 204 are operated to rotate in the first rotational direction 824. Thus, as the upper rollers 804 rotate in the first rotational direction 824 the upper rollers 804 cause the first cargo 1442a to move in the first linear direction 410 to transfer off or from the cart 204 onto the floor 1110 of the cargo area 116, the cart drive system 408 is commanded to move the cart 204 in the second linear direction 412. In other words, the cart drive system 408 is commanded to operate in the first rotational direction 720 to retract the exposed portion 1444 of the drive beam 416 within the track 414 and move the cart 204 in the second linear direction 412 toward the ATLS 102. In some examples, the cart 204 can move in the second linear direction 412 as the upper rollers 804 rotate in the first rotational direction 824. Thus, as the upper rollers 804 rotate in the first rotational direction 824 and the cart 204 is pulled away from the end wall 1112 and toward the ATLS 102 simultaneously to remove the first cargo 1442a from the cart 204. Thus, the upper rollers 804 cause the first cargo 1442a to transfer off or from the cart 204 in the first linear direction 410 onto the floor 1110 of the cargo area 116 as the cart 204 retracts in the second linear direction 412.
[00119] FIG. 14E illustrates the ATLS 102 in an example fourth position 1408. The cart 204 is freed of the first cargo 1442a and retracts toward the doorway 106 and/or the ATLS 102 in the second linear direction 412 as the motor 418 rotates in the first rotational direction 720. Additionally, the exposed portion 1444 of the drive beam 416 winds within the track 414 toward the stored configuration 600 as the cart 204 retracts or moves toward the ATLS 102.
[00120] FIG. 14F illustrates the example ATLS 102 in an example fifth position 1410. At the fifth position 1410, the cart 204 moves to a staging position 1454 adjacent to the frame assembly 202 and/or the guide doors 206. In other words, the cart 204 is not positioned on the guide doors 206, but the rear edge 702 of the cart 204 is positioned adjacent to the guide doors 206. In other words, in the staging position 1452, a portion of the cart 204 overlaps or spans across an interface or gap between the vehicle 118 and the dock wall 104. For instance, at least a portion of the cart 204 overlaps the opening of the vehicle 118 and the opening of the doorway 106 and is positioned on the movable frame 220 (e.g., the transition platform 216). In some examples, in the staging position 1454, the rear edge 702 of the cart 204 abuts or engages (e.g., directly engages) the front edge 920a of the guide doors 206. In the illustrated example, the guide doors 206 have a slightly larger elevation (e.g., a taller vertical profile) than the cart 204 to facilitate transfer of cargo between the guide doors 206 and the cart 204.
[00121] FIG. 14G illustrates the ATLS 102 in an example sixth position 1412. At the sixth position 1412, the second cargo 1442b transfers from the guide doors 206 to the cart 204. To transfer (e.g., hand-off) the second cargo 1442b from the guide doors 206, the guide door rollers 916 rotate in the first rotational direction 824, which causes the second cargo 1442b to transfer, move or otherwise slide from the guide doors 206 to the cart 204 in the first linear direction 410 (e.g., a forward direction). Additionally, in some examples, the upper rollers 804 of the cart 204 can be rotated in the first rotational direction 824 to facilitate transfer of the second cargo 1442b from the guide doors 206 to the cart 204. In some examples, operation of the guide door rollers 916 and/or the upper rollers 804 can be sequentially or simultaneously.
[00122] FIG. 14H illustrates the ATLS 102 in an example seventh position 1414. To move the second cargo 1442b into the cargo area 116 adjacent to the first cargo 1442a, the cart drive system 408 activates by rotating the motor 418 in the second rotational direction 722. Rotating the cart drive system 408 in the second rotational direction 722 causes the drive beam 416 to unwind from the track 414 and move (e.g., push) the cart 204 in the first linear direction 410 away from the guide doors 206 and toward the first cargo 1442a. In some examples, the cart drive system 408 moves the cart 204 to another drop-off position 1456 that provides a gap (G) between the first cargo 1442a and the second cargo 1442b. To remove the second cargo 1442b from the cart 204, the upper rollers 804 are driven in the first rotational direction 824 and the cart 204 is driven in the second linear direction 412, causing the second cargo 1442b to move off of the upper surface 811 of the cart 204. As a result, the second cargo 1442b moves against the first cargo 1442a, thereby removing the gap (G) between the first cargo 1442a and the second cargo 1442b. [00123] FIG. 141 illustrates the ATLS 102 in an example eighth position 1416. After the second cargo 1442b is removed from the cart 204, the cart drive system 408 continues to move the cart 204 in the second linear direction 412 toward the ATLS 102 and towards the staging position 1454.
[00124] FIG. 14J illustrates the ATLS 102 in an example ninth position 1418. In the ninth position 1418, the cart 204 is returned to the staging position 1454 and a third cargo 1442c is positioned on the guide doors 206.
[00125] FIG. 14K illustrates the ATLS 102 in an example tenth position 1420, at which the third cargo 1442c is transferred to the cart 204 while the cart 204 is at the staging position 1454. To transfer the third cargo 1442c, the guide door rollers 916 are rotated in the first rotational direction 824 to cause the third cargo 1442c to transfer, slide or move onto the cart 204 and off the guide doors 206.
[00126] FIG. 14L illustrates the ATLS 102 in an example eleventh position 1422. At the eleventh position 1422, the cart 204 is driven in the first linear direction 410 to another drop-off position 1458 that provides the gap (G) between the second cargo 1442b and the third cargo 1442c. The upper rollers 804 of the cart 204 are rotated in the first rotational direction 824 and the cart is driven in the second linear direction 412 to remove the third cargo 1442c from the cart 204 in the first linear direction 410 (e.g., thereby reducing or eliminating the gap (G)) and onto the floor 1110 of the cargo area 116 adj acent to the second cargo 1442b.
[00127] FIG. 14M illustrates the ATLS 102 in an example twelfth position 1424. In FIG. 14M, a fourth cargo 1442d has been positioned in the cargo area 116 by moving the cart 204 to the staging position 1454. transferring the fourth cargo 1442d on the cart 204. moving the cart 204 to a drop-off position, rotating the upper rollers 804 of the cart in the first rotational direction 824 and moving the cart 204 in the second linear direction 412 to the staging position 1454 to receive a fifth cargo 1442e.
[00128] FIG. 14N illustrates the ATLS 102 in an example thirteenth position 1426, which illustrates the fifth cargo 1442e transferred from the guide doors 206 onto the cart 204 while the cart 204 is in the staging position 1454.
[00129] FIG. 140 illustrates the ATLS 102 in an example fourteenth position 1428. At the fourteenth position 1428. when the last cargo load is in on the cart 204 and in the cargo area 116, the guide doors 206 are moved to the guide position 900. For example, the actuators 910 are actuated to pivot the guide doors 206 about the pivot axes 904a, 904b to the guide position 900. In the guide position 900, the cart 204 has access to the upper surface 422 of the frame assembly 202. Additionally, to move the fifth cargo 1442e onto the floor 1110 of the cargo area 116, the upper rollers 804 are activated to rotate in the first rotational direction 824 to move the fifth cargo 1442e from the upper surface 811 of the cart 204 and onto the floor 1110.
[00130] FIG. 14P illustrates the ATLS 102 in an example fifteenth position 1430. In FIG. 14P, the cart 204 moves to the initial or stored position 1446 via the cart drive system 408. For example, the cart drive system 408 is operated to rotate in the first rotational direction 720 to move the cart 204 in the second linear direction 412 (e.g., a rearward direction) on the upper surface 422 of the movable frame 220. In other words, the drive beam 416 is retracted to the stored configuration 600 (e g., a fully retracted position).
[00131] FIG. 14Q illustrates the ATLS 102 in an example sixteenth position 1432, at which the vehicle 118 left the loading dock 100.
[00132] The control system 1114 of the example ATLS 102 can control the different drive systems to perform an alignment operation (e.g., as shown in FIGS. 12A-12B and BABB) and the loading operation shown in FIGS. 14A-14Q. For example, the control system 1114 of the illustrated example can receive signals or information (e.g., data, feedback signals, etc.) from the sensor assembly 1000 to perform an alignment operation and operate the first alignment system 226 and/or the second alignment system 236 to align the ATLS reference 1208 relative to vehicle reference 1116 to establish a parallel or substantially parallel (e.g., within between one degree and ten degrees of parallel) relationship between the floor 1110 of the cargo area 116 and the cart 204 and/or the movable frame 220 of the frame assembly 202.
[00133] Additionally, the control system 1114 can receive information (e.g., data, feedback signals, etc.) from one or more sensors (e.g., a proximity sensor, an encoder, a weight sensor, etc.) to perform the loading operation of FIGS. 14A-14Q. For example, a proximity sensor can be provided adjacent a forward edge of the lead-in ramp 844 to determine when a drop-off location has been reached by sensing the end wall 1112 and/or a cargo positioned in the cargo area 116. In some examples, a sensor can be positioned adjacent the doorway 106 to detect the cart 204 in the staging position 1454. In some examples, an encoder can be used to detect or determine a position of the drive beam 416 as it moves between the stored configuration 600 and an extended position (e.g., the fourth position 1406). Based on information received by the one or more sensors, the control system 1114 can operate the motor 418, the actuators 910, the upper rollers 804 and/or the guide door rollers 916 (e.g., and/or provide a fully automated loading operation).
[00134] “Including’" and “comprising” (and all forms and tenses thereof) are used herein to be open ended terms. Thus, whenever a claim employs any form of “include” or “comprise” (e.g., comprises, includes, comprising, including, having, etc.) as a preamble or within a claim recitation of any kind, it is to be understood that additional elements, terms, etc., may be present without falling outside the scope of the corresponding claim or recitation. As used herein, when the phrase “at least” is used as the transition term in, for example, a preamble of a claim, it is open-ended in the same manner as the term “comprising” and “including” are open ended. The term “and/or” when used, for example, in a form such as A, B, and/or C refers to any combination or subset of A, B, C such as (1) A alone, (2) B alone, (3) C alone, (4) A with B, (5) A with C, (6) B with C, or (7) A with B and with C. As used herein in the context of describing structures, components, items, objects and/or things, the phrase “at least one of A and B” is intended to refer to implementations including any of (1) at least one A, (2) at least one B, or (3) at least one A and at least one B. Similarly, as used herein in the context of describing structures, components, items, objects and/or things, the phrase “at least one of A or B” is intended to refer to implementations including any of (1) at least one A, (2) at least one B, or (3) at least one A and at least one B. As used herein in the context of describing the performance or execution of processes, instructions, actions, activities, etc., the phrase “at least one of A and B” is intended to refer to implementations including any of (1) at least one A, (2) at least one B, or (3) at least one A and at least one B. Similarly, as used herein in the context of describing the performance or execution of processes, instructions, actions, activities, etc., the phrase “at least one of A or B” is intended to refer to implementations including any of (1) at least one A, (2) at least one B, or (3) at least one A and at least one B.
[00135] As used herein, singular references (e.g., “a”, “an”, “first”, “second"’, etc.) do not exclude a plurality. The term “a” or “an” object, as used herein, refers to one or more of that object. The terms “a” (or “an”), "‘one or more”, and “at least one” are used interchangeably herein. Furthermore, although individually listed, a plurality of means, elements, or actions may be implemented by, e.g., the same entity or object. Additionally, although individual features may be included in different examples or claims, these may possibly be combined, and the inclusion in different examples or claims does not imply that a combination of features is not feasible and/or advantageous. [00136] As used herein, unless otherwise stated, the term “above” describes the relationship of two parts relative to Earth. A first part is above a second part, if the second part has at least one part between Earth and the first part. Likewise, as used herein, a first part is “below” a second part when the first part is closer to the Earth than the second part. As noted above, a first part can be above or below a second part with one or more of: other parts therebetween, without other parts therebetween, with the first and second parts touching, or without the first and second parts being in direct contact with one another.
[00137] As used in this patent, stating that any part (e.g., a layer, film, area, region, or plate) is in any way on (e.g.. positioned on, located on, disposed on, or formed on, etc.) another part, indicates that the referenced part is either in contact with the other part, or that the referenced part is above the other part with one or more intermediate part(s) located therebetween.
[00138] As used herein, connection references (e.g., attached, coupled, connected, and joined) may include intermediate members between the elements referenced by the connection reference and/or relative movement between those elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and/or in fixed relation to each other. As used herein, stating that any part is in “contact” with another part is defined to mean that there is no intermediate part between the two parts.
[00139] Unless specifically stated otherwise, descriptors such as “first,” “second,” “third,” etc., are used herein without imputing or otherwise indicating any meaning of priority, physical order, arrangement in a list, and/or ordering in any way. but are merely used as labels and/or arbitrary names to distinguish elements for ease of understanding the disclosed examples. In some examples, the descriptor “first” may be used to refer to an element in the detailed description, while the same element may be referred to in a claim with a different descriptor such as “second” or “third.” In such instances, it should be understood that such descriptors are used merely for identifying those elements distinctly within the context of the discussion (e.g., within a claim) in which the elements might, for example, otherwise share a same name.
[00140] As used herein, “substantially,” “approximately” and “about” modify their subjects/values to recognize the potential presence of variations that occur in real w orld applications. For example, “substantially,” “approximately” and “about” may modify dimensions that may not be exact due to manufacturing tolerances and/or other real world imperfections as will be understood by persons of ordinary skill in the art. For example, “substantially,” “approximately” and “about” may indicate such dimensions may be within a tolerance range of +/- 10% unless otherwise specified herein.
[00141] As used herein, the phrase “in communication.” including variations thereof, encompasses direct communication and/or indirect communication through one or more intermediary components, and does not require direct physical (e.g., wired) communication and/or constant communication, but rather additionally includes selective communication at periodic intervals, scheduled intervals, aperiodic intervals, and/or one-time events.
[00142] As used herein, “programmable circuitry” is defined to include (i) one or more special purpose electncal circuits (e.g., an application specific circuit (ASIC)) structured to perform specific operation(s) and including one or more semiconductor-based logic devices (e.g., electrical hardware implemented by one or more transistors), and/or (ii) one or more general purpose semiconductor-based electrical circuits programmable with instructions to perform specific functions(s) and/or operation(s) and including one or more semiconductorbased logic devices (e.g., electrical hardware implemented by one or more transistors). Examples of programmable circuitry include programmable microprocessors such as Central Processor Units (CPUs) that may execute first instructions to perform one or more operations and/or functions, Field Programmable Gate Arrays (FPGAs) that may be programmed with second instructions to cause configuration and/or structuring of the FPGAs to instantiate one or more operations and/or functions corresponding to the first instructions, Graphics Processor Units (GPUs) that may execute first instructions to perform one or more operations and/or functions, Digital Signal Processors (DSPs) that may execute first instructions to perform one or more operations and/or functions, XPUs, Network Processing Units (NPUs) one or more microcontrollers that may execute first instmctions to perform one or more operations and/or functions and/or integrated circuits such as Application Specific Integrated Circuits (ASICs). For example, an XPU may be implemented by a heterogeneous computing system including multiple types of programmable circuitry (e.g., one or more FPGAs, one or more CPUs, one or more GPUs, one or more NPUs, one or more DSPs, etc., and/or any combination(s) thereof), and orchestration technology (e.g., application programming interface(s) (API(s)) that may assign computing task(s) to whichever one(s) of the multiple types of programmable circuitry is/are suited and available to perform the computing task(s).
[00143] The following claims are hereby incorporated into this Detailed Description by this reference. Although certain examples, methods, apparatus, and articles of manufacture have been disclosed herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all systems, methods, apparatus, and articles of manufacture fairly falling within the scope of the claims of this patent.

Claims

What Is Claimed Is:
1. An automated trailer loading system (ATLS) comprising: a frame defining a cavity; a track at least partially in the cavity of the frame; a cart movable relative to the frame between an extended position and a retracted position; and a drive beam movable within the track between an extended position and a retracted position, the drive beam to at least one of push or pull the cart, the drive beam to at least partially bend when in the retracted position.
2. The ATLS of claim 1, wherein the track includes a first wall, a second wall spaced from the first wall and an end cap at respective first ends of the first wall and the second wall.
3. The ATLS of claim 2, wherein the end cap includes an opening in communication with an upper surface of the frame.
4. The ATLS of claim 1, wherein the track at least partially overlaps a longitudinal axis of the frame.
5. The ATLS of claim 4, wherein the cart is tethered to the frame via the drive beam.
6. The ATLS of claim 1, wherein the drive beam includes a chain and a cover.
7. The ATLS of claim 1, wherein the drive beam includes a plurality of links that interlock when the drive beam is deployed to provide rigidity to move the cart.
8. The ATLS of claim 7, wherein the links unlock when the drive beam retracts into the track.
9. The ATLS of claim 8, wherein the track includes a curved portion that cause the links to bend and unlock relative to each other when the drive beam is moved to a retracted position within the track.
10. The ATLS of claim 6, wherein the drive beam includes rollers journalled at lateral edges of the drive beam, the rollers to engage the track to guide the drive beam when the drive beam moves between the retracted position and the extended position.
11. The ATLS of claim 1, wherein the frame is to move in at least six degrees of movement.
12. The ATLS of claim 1, wherein the frame includes a movable frame to move in at least one of a first direction, a second direction different than the first direction, or a third direction different than the first direction and the second direction.
13. The ATLS of claim 1, further including guide doors pivotally coupled to the frame, the guide doors movable between a guide position and a transfer position.
14. The ATLS of claim 13, wherein the guide doors are in the guide position when the cart is on the frame, the guide doors are in the transfer position during a loading/unloading operation of a vehicle.
15. The ATLS of claim 1, wherein a frame of the cart is only coupled to the frame via the drive beam.
16. An automated trailer loading system (ATLS) comprising: a frame having a fixed frame portion and a movable frame portion; a first alignment system to move the movable frame portion in a first direction; a second alignment system to move the movable frame portion in a second direction, the second direction being orthogonal relative to the first direction; and a cart movable relative to the frame between an extended position and a retracted position.
17. The ATLS of claim 16, further including a drive beam movable between an extended position and a retracted position, the drive beam to at least one of push or pull the cart, the drive beam to at least partially bend when in the retracted position.
18. The ATLS of claim 16, wherein the first alignment system includes a first plurality7 of actuators to move the movable frame portion relative to the fixed frame portion in a sideways direction, the second alignment system includes a second plurality of actuators to move the movable frame portion relative to the fixed frame portion in a vertical direction.
19. An automated trailer loading system (ATLS) comprising: a frame; a track; a cart movable relative to the frame between an extended position and a retracted position; a drive beam movable relative to the track between an extended position and a retracted position, the drive beam to move the cart between the extended position and the retracted position, the drive beam to at least partially bend when in the retracted position; and an alignment system to the frame in a plurality of different positions to align the cart relative to a cargo area of a vehicle 118 prior to performing a loading/ unloading operation.
20. The ATLS of claim 19, wherein the cart includes a cart frame having a plurality of surface rollers and a plurality of lower rollers, the cart tethered to the drive beam.
PCT/US2025/033040 2024-06-11 2025-06-10 Automated trailer loading systems and related methods Pending WO2025259692A1 (en)

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US202463658783P 2024-06-11 2024-06-11
US202463658779P 2024-06-11 2024-06-11
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US63/658,783 2024-06-11
US63/658,777 2024-06-11
US63/658,779 2024-06-11
US202563755896P 2025-02-07 2025-02-07
US63/755,896 2025-02-07

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PCT/US2025/033040 Pending WO2025259692A1 (en) 2024-06-11 2025-06-10 Automated trailer loading systems and related methods
PCT/US2025/033038 Pending WO2025259690A1 (en) 2024-06-11 2025-06-10 Methods and apparatus to adjust a position of an automated trailer loading system
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