JP-7855827-B2 - Recognition-based robotic operating system and method for robotic truck unloaders for unloading/spreading products from trailers and containers.

JP7855827B2JP 7855827 B2JP7855827 B2JP 7855827B2JP-7855827-B2

Inventors

クリスウェル、ティム
ウィアー、ジャストリー
クリスウェル、アレックス
ドリオティス、パブロス
ラジャン、サマルト
ミドルトン、マシュー

Assignees

ダイフクイントラロジスティクスアメリカコーポレーション
株式会社ダイフク

Dates

Publication Date: 20260511
Application Date: 20220926
Priority Date: 20210924

Claims (9)

A robotic truck unloader for unloading/spreading multiple products, Structure of a mobile base having first and second ends; A drive subassembly connected to the mobile base, the drive subassembly including a plurality of wheels for steering and driving the mobile base; A transport subassembly is disposed on the mobile base, and the transport subassembly includes a powered transport path configured to transport the plurality of products between the first and second ends; An industrial robot is disposed near the second end of the mobile base, the industrial robot is configured to process the plurality of products, and the industrial robot has a robot-reachable space; A swivel forward conveyor is disposed at the second end of the moving base, the swivel forward conveyor has an integrated deck conveyor unit, the deck conveyor unit is configured to transport the plurality of products to the transport subassembly, the swivel forward conveyor is configured to process the plurality of products, and the swivel forward conveyor has a deck reachable space; camera; A control subassembly is arranged to communicate with the industrial robot, the slewing forward conveyor, and the camera, the control subassembly coordinates the selective joint movement of the industrial robot, the control subassembly coordinates the selective joint movement of the slewing forward conveyor; and the control subassembly includes a memory accessible from the processor, the memory being used by the processor when executed: A model is constructed from multiple data images collected by the aforementioned camera, and the model is a representation of at least one physical environment, which is the industrial robot and the rotating forward conveyor, and the physical environment includes the aforementioned multiple products. Specify a search operation within the model to identify the foreground wall (W). In order to identify the candidate product contact surface belonging to at least one candidate product of the plurality of products, a search operation within the foreground wall (W) is specified. Using one of the aforementioned industrial robots and the aforementioned forward-rotating conveyor, a removal operation is specified to unload the multiple products. The processor includes an executable instruction that specifies a search operation within the rotating forward conveyor in order to identify a product being processed located on the rotating forward conveyor, and specifies an automatic error handling operation in response to the product being processed being located on the rotating forward conveyor. Equipped with , The aforementioned forward-rotating conveyor further: A frame fixed to the second end of the movable base, the frame being inflexible; A planar extension blade comprising a rear portion connected to the frame, and a front portion extending for a certain length from the rear portion along the transverse axis AT between the first and second sides; The planar extension blade bends around the horizontal axis AT in response to the application of pressure . A robotic truck unloader equipped with the following features .
A robotic truck unloader for unloading/spreading multiple products, Structure of a mobile base having first and second ends; A drive subassembly connected to the mobile base, the drive subassembly including a plurality of wheels for steering and driving the mobile base; A transport subassembly is disposed on the mobile base, and the transport subassembly includes a powered transport path configured to transport the plurality of products between the first and second ends; An industrial robot is disposed near the second end of the mobile base, the industrial robot is configured to process the plurality of products, and the industrial robot has a robot-reachable space; A swivel forward conveyor is disposed at the second end of the moving base, the swivel forward conveyor has an integrated deck conveyor unit, the deck conveyor unit is configured to transport the plurality of products to the transport subassembly, the swivel forward conveyor is configured to process the plurality of products, and the swivel forward conveyor has a deck reachable space; Camera; A control subassembly is arranged to communicate with the industrial robot, the slewing forward conveyor, and the camera, the control subassembly coordinates the selective joint movement of the industrial robot, and the control subassembly coordinates the selective joint movement of the slewing forward conveyor; and The control subassembly includes memory accessible from the processor, and the memory is accessed by the processor when executed: A model is constructed from multiple data images collected by the aforementioned camera, and the model is a representation of at least one physical environment, which is the industrial robot and the rotating forward conveyor, and the physical environment includes the aforementioned multiple products. Specify a search operation within the model to identify the foreground wall (W). In order to identify the candidate product contact surface belonging to at least one candidate product of the plurality of products, a search operation within the foreground wall (W) is specified. Using one of the aforementioned industrial robots and the aforementioned forward-rotating conveyor, a removal operation is specified to unload the multiple products. In order to identify the product being processed located on the rotating forward conveyor, a search operation within the rotating forward conveyor is specified, and Depending on when the product being processed is positioned on the rotating forward conveyor, an automatic error handling operation is specified. Including processor-executable instructions, Equipped with, The aforementioned automatic error handling operation further includes vibration of the rotating forward conveyor beneath the product being processed by the robotic track unloader.
A robotic truck unloader for unloading/spreading multiple products, Structure of a mobile base having first and second ends; A drive subassembly connected to the mobile base, the drive subassembly including a plurality of wheels for steering and driving the mobile base; A transport subassembly is disposed on the mobile base, and the transport subassembly includes a powered transport path configured to transport the plurality of products between the first and second ends; An industrial robot is disposed near the second end of the mobile base, the industrial robot is configured to process the plurality of products, and the industrial robot has a robot-reachable space; A swivel forward conveyor is disposed at the second end of the moving base, the swivel forward conveyor has an integrated deck conveyor unit, the deck conveyor unit is configured to transport the plurality of products to the transport subassembly, the swivel forward conveyor is configured to process the plurality of products, and the swivel forward conveyor has a deck reachable space; Camera; A control subassembly is arranged to communicate with the industrial robot, the slewing forward conveyor, and the camera, the control subassembly coordinates the selective joint movement of the industrial robot, and the control subassembly coordinates the selective joint movement of the slewing forward conveyor; and The control subassembly includes memory accessible from the processor, and the memory is accessed by the processor when executed: A model is constructed from multiple data images collected by the aforementioned camera, and the model is a representation of at least one physical environment, which is the industrial robot and the rotating forward conveyor, and the physical environment includes the aforementioned multiple products. Specify a search operation within the model to identify the foreground wall (W). In order to identify the candidate product contact surface belonging to at least one candidate product of the plurality of products, a search operation within the foreground wall (W) is specified. Using one of the aforementioned industrial robots and the aforementioned forward-rotating conveyor, a removal operation is specified to unload the multiple products. In order to identify the product being processed located on the rotating forward conveyor, a search operation within the rotating forward conveyor is specified, and Depending on when the product being processed is positioned on the rotating forward conveyor, an automatic error handling operation is specified. Including processor-executable instructions, Equipped with, The aforementioned automatic error handling operation further includes a robotic track unloader, which includes the industrial robot that processes the product being processed on the rotating forward conveyor.
The robotic track unloader according to any one of claims 1 to 3 , wherein the rotating forward conveyor further includes first and second wings, respectively, located laterally along the rotating forward conveyor.
The robotic track unloader according to any one of claims 1 to 3 , wherein the swivel forward conveyor is fixedly attached to the robotic track unloader for swivel, extension, and retraction relative to the robotic track unloader, respectively.
The robotic track unloader according to any one of claims 1 to 3 , wherein the rotating forward conveyor further comprises a plurality of lateral skirt plates for guiding the plurality of products onto the deck conveyor unit.
The robotic track unloader according to claim 1 , wherein the planar extension blade further includes a spring steel.
The robotic truck unloader according to claim 1 , wherein the planar extension blade further comprises ultra-high molecular weight polyethylene.
The robotic track unloader according to claim 1 , wherein the planar extension blade bends about the horizontal axis AT in response to the application of pressure to conform to the shape of the object to which the pressure is applied.

Description

The present invention generally relates to a machine for processing products, and more specifically, to an automated recognition-based robotic operating system and method for unloading and unpacking products, such as parcels or boxes, from trailers and containers, employing a robotic truck unloader designed for unloading and unpacking. Loading docks and loading bays are commonly found in large commercial and industrial buildings and provide arrival and departure areas for large cargo transported by trucks and vans. For example, a truck may back into a loading bay so that the loading bay's bumper contacts the bumper on the trailer, creating a gap between the loading bay and the truck. A dock leveler or dock plate bridges the gap between the truck and the warehouse, providing a fixed, substantially horizontal surface. The cargo is then transported from the warehouse to the truck using powered moving equipment such as forklifts or conveyor belts. The cargo is then removed from the truck by human labor. This is particularly true for unloading products such as boxes or cases from trucks or cargo containers. These systems are designed to maximize the amount of cargo unloaded while minimizing the use of human labor, both to protect employees and extend their lifespan. However, reducing human labor has proven difficult. This is because the configuration and size of boxes in trucks or cargo containers cannot be easily predicted in advance. Therefore, there remains a need for improved truck unloading systems that further reduce the use of human labor when unloading or spreading products such as cases and boxes from trailers and containers. It would be beneficial to realize systems and methods for automated unloading and unpacking of products such as parcels or boxes that enable complete unloading from trailers or containers with minimal or no human labor, thereby minimizing the time and human capital required for unloading from trucks. It is also desirable to enable robotic computer-based solutions to address this problem, particularly the recognition challenge, by rapidly unloading and retrieving parcels and boxes of varying sizes from trailers and similar containers. To better address one or more of these concerns, a robotic truck unloader for unloading/unpacking products such as boxes or cases from trailers and containers is disclosed in one embodiment. The mobile base structure provides a support framework for a drive subassembly, a transport subassembly, an industrial robot, a slewing forward conveyor, a distance measuring subassembly which may include, for example, a camera, and a control subassembly. The control subassembly coordinates the operation of the drive subassembly and the slewing forward conveyor, as well as the operation of the drive subassembly, through selective articulation of the industrial robot, based on a recognition-based robotic operating system. The robotic track unloader utilizes an industrial robot and a rotating forward conveyor to perform picking and scooping operations. Automatic error handling is also provided. In one embodiment, a robotic track unloader for unloading/spreading products includes a mobile base structure on which a drive subassembly and a transport subassembly are fixed. An industrial robot and a slewing forward conveyor are arranged on the mobile base. A control subassembly is arranged to communicate with the industrial robot, the slewing forward conveyor and a perception subsystem in order to coordinate the movement of the industrial robot and the slewing forward conveyor by selective joint movements of each. The control subassembly, which includes memory with processor-executable instructions accessible from the processor, enables the perception subsystem to construct a searchable space from data collected from the environment. The searchable space is searched to determine the contact surface of candidate products. The robotic track unloader then specifies a removal operation to unload the products by picking and scooping operations using the industrial robot and the slewing forward conveyor. The picking portion of the picking and scooping operation may include, for example, grasping and pulling. The robotic track unloader also performs automatic error handling by searching the rotating forward conveyor to identify any remaining products in the process that are still positioned on it, and then proceeding to process those products. In another embodiment, a robotic track unloader for unloading/spreading products includes a mobile base structure to which a drive subassembly and a transport subassembly are fixed. A slewing forward conveyor having a frame is disposed on the mobile base and configured to process products. The slewing forward conveyor includes a deck conveyor unit integrated within the frame. A planar extension blade indicating the rear portion is connected to the frame. The planar extension blade may have a forward portion extending for a certain length f