Method for logistics and handling of assembly material

Abstract

ASSEMBLY MATERIAL LOGISTICS SYSTEM AND METHODS. System devices and methods for logistical handling and transfer of consumable assembly components and materials to support assembly or manufacturing operations. Through the use of a transport vehicle with first and second container supports, the method allows, in a component storage area and an assembly area, the transport vehicle to engage or pick up a full or empty container and unengage or deposit a full or empty container. In an alternative example, two separate transport vehicles can move in a coordinated manner together to engage or pick up a full or empty container and unengage or deposit a full or empty container in the component storage area or assembly area.

Description

1 / 42 METHOD FOR LOGISTICS AND HANDLING OF ASSEMBLY MATERIAL CROSS-REFERENCE TO RELATED REQUESTS TECHNICAL FIELD

[001] This disclosure refers to methods and devices useful for materials handling and logistics to support product manufacturing and assembly operations. FUNDAMENTALS

[002] Modern manufacturing and assembly facilities employ sophisticated and highly automated equipment and processes to increase efficiency and final product yield to meet the growing demands of customers and end consumers. The adoption of on-demand material supply, manufacturing, and assembly processes requires industrial facilities to be flexible in the products that can be produced, while minimizing the storage or warehousing of basic materials used in the manufacturing and assembly of the products.

[003] As the speed and volume of product production increase through automation, so does the supply of raw materials used to support manufacturing and assembly processes. This creates challenges for manufacturers to logistically move individual components and raw materials from a parts storage area in the facility to the assembly lines for use in the assembly process. Conventional facilities have used manually operated forklift devices to move large crates or pallets containing consumable raw materials and shelves containing components from a parts storage area in the assembly facility to the assembly line for use. Petition 870230085842, dated 09 / 27 / 2023, page 8 / 61 2 / 42

[004] When a component crate or shelf is empty on the assembly line, a forklift must be sent to the assembly line to retrieve the empty crate and transfer it to another area of ​​the facility, for example, to be sent back to the parts manufacturer to be replenished. The same forklift, or another, must then move to the parts storage area to retrieve a full crate or shelf and transfer it to the assembly line to replace the empty crate or shelf that has just been removed. This added time for a transfer device capable of only transporting and / or handling one container at a time is time-consuming and inefficient. To meet assembly demand, more forklifts are needed, which increases traffic in the production area.

[005] Other challenges for manufacturers and assemblers lie in minimizing the assembly plant space required to assemble products. In conventional facilities, crates of raw materials, for example, individual components or mechanical fasteners used in the assembly of the final product, were positioned in large quantities adjacent to the assembly station or cell and consumed during the assembly process. This storage of excess components and raw materials in the assembly area creates congestion for the movement of equipment and personnel in the assembly area and occupies unnecessary space. More modern facilities minimize the storage of components and raw materials next to the assembly line, but then suffer from disadvantages of conventional devices such as forklifts and slow supply. Petition 870230085842, dated 09 / 27 / 2023, page 9 / 61 3 / 42 unidirectional loading of full shelves and removal of empty shelves from the assembly line, which can slow down production.

[006] Improvements in logistics supply and material transfer are needed to support modern, automated, high-volume production processes. SUMMARY

[007] Enhanced methods and system devices for the logistical handling of component transfers and consumable assembly materials to support assembly or manufacturing operations in a high-volume manufacturing or assembly facility are disclosed in this document. In an exemplary application, the methods and systems are useful in a high-volume production passenger vehicle assembly facility. The disclosed methods and system devices are equally useful in other applications where rapid supply and transfer of materials used to support product manufacturing and assembly are required.

[008] In one example of the invention, an assembly plant is provided with a component storage area where components and consumable materials are temporarily stored on a storage shelf or other area suitable for the specific components. An exemplary storage shelf positions or presents a container of components in a shelving aisle for transfer to an assembly area. The storage area is logistically positioned upstream of an assembly area where Petition 870230085842, dated 09 / 27 / 2023, page 10 / 61 4 / 42 Individual components and consumable materials are used in an assembly operation to produce a predetermined product.

[009] A transport vehicle is positioned in and moves reciprocally along a materials aisle between the storage area and the assembly area. When positioned in the storage area, the transport vehicle engages to transport a full component container from the shelving aisle and secures the full component container to the transport vehicle for transfer to the assembly area. While in the storage area, the transport vehicle also deposits an empty component container in the storage area that was removed and transferred from the assembly area.

[010] After securing the full component container to the transport vehicle and depositing the empty container in the storage area, the transport vehicle moves along a material aisle towards the assembly area. Once the transport vehicle is positioned in the assembly area, the transport vehicle removes an empty component container from the assembly area shelving aisle and replaces it in the assembly shelving aisle with the full component container on board. The empty container is delivered by the transport vehicle to the storage area for deposit and attachment of another full component container.

[011] In one example, the transport vehicle includes a first component container support and a second component container support that is operable independently of the first container support. This Petition 870230085842, dated 09 / 27 / 2023, page 11 / 61 5 / 42 allows a single transport vehicle to pick up and drop off two component containers in a storage or assembly area. In another example, two transport vehicles, each with a single container holder, are coordinated to work and travel as a pair to achieve the dual action or activity described for a transport vehicle with a first container holder and a second container holder.

[012] In one example, the transport vehicle is driven, navigated and operated autonomously either through pre-programmed instructions in the transport vehicle's control system or through receiving wireless data signal streams from a central or local control system. In another example, the transport vehicle is semi-autonomous or operated manually by an onboard operator.

[013] The disclosed transport vehicle and facility usage method provides many advantages over conventional state-of-the-art material handling and transfer processes and devices. The method allows for the dual action or activity of a single transport vehicle (collecting full containers and delivering empty containers to the storage area and collecting empty containers and delivering full containers to the assembly area). While moving between the storage area and the assembly area, the transport vehicle is always performing productive work – whether transferring a full component container or an empty component container. This further provides an increase in productivity through the faster and more efficient supply of materials to support production, in addition to Petition 870230085842, dated 09 / 27 / 2023, page 12 / 61 6 / 42 reduce the area occupied or the space required for supplying necessary components in assembly and storage areas.

[014] These and other aspects of this disclosure are disclosed in the detailed description of the embodiments below, in the appended claims and in the appended figures. BRIEF DESCRIPTION OF THE DRAWINGS

[015] The invention is best understood from the detailed description that follows when read in conjunction with the accompanying drawings. It should be noted that, in accordance with common practice, the various features of the drawings are not to scale. On the contrary, the dimensions of the various features are arbitrarily enlarged or reduced for clarity.

[016] FIG. 1 is a left front perspective view of an example of an assembly installation that includes an assembly line of the present invention.

[017] FIG. 2 is a schematic top view of the example in FIG. 1.

[018] FIG. 3 is a schematic top view of an alternative example of FIG. 1.

[019] FIG. 4A is a left front perspective view of an example of a component container transport vehicle in a non-extended position.

[020] FIG. 4B is a left front perspective view of the component container transport vehicle in FIG. 4A with one of the container supports in a raised and extended position.

[021] FIG. 5 is a left front perspective view of an example of a component container shelf in a useful storage area with the present Petition 870230085842, dated 09 / 27 / 2023, p. 13 / 61 7 / 42 invention.

[022] FIG. 6 is a left front perspective view of an alternative example of a component container shelf in a useful storage area with the present invention.

[023] FIG. 7 is a schematic top view of an assembly area showing a transport vehicle in an assembly area in a first position removing an empty container and a second indexed position depositing a full container in its place.

[024] FIGS. 8A-8C are schematic side views of alternative positions of a component container transport vehicle engaging, securing and depositing a component container.

[025] FIG. 9 is a left front perspective view of an alternative example of a component container transport vehicle in FIG. 4A.

[026] FIG. 10 is a right front perspective view of an alternative example of a component transport vehicle in FIG. 4A.

[027] FIG. 10A is a right front perspective view of an alternative example of a component transport vehicle in FIG. 4A.

[028] FIG. 11A is a left front perspective view of an alternative example of a component transport vehicle in FIG. 4A.

[029] FIG. 11B is a left front perspective view of an alternative example of a component transport vehicle in FIG. 11A.

[030] FIG. 11C is a front perspective view. Petition 870230085842, dated 09 / 27 / 2023, page 14 / 61 8 / 42 left of an alternative example of a component transport vehicle in FIG. 11A.

[031] FIG. 12 is a schematic front view of an alternative example of the use of a component container transport vehicle.

[032] FIG. 13 is a schematic illustration of an example of a useful control system with the present invention.

[033] FIG. 14 is a schematic diagram of an example of an assembly logistics monitoring system shown with the example in FIG. 1.

[034] FIG. 15 is a schematic flowchart of an example of a method of the present invention. DETAILED DESCRIPTION

[035] With reference to FIGS. 1-15, examples of an assembly material logistics system and methods are shown. In an exemplary application, the system and methods are useful in high-volume vehicle assembly plants. It is understood that the invention has many other applications for the assembly and manufacture of other products, including, but not limited to, consumer products and other commercial and industrial applications.

[036] With reference to FIG. 1, an example of a floor plan layout of a vehicle assembly plant 12 is shown for use in assembling passenger vehicle bodies or blank body structures. This example includes the assembly of sheet metal passenger vehicle bodies after the transmission, suspension and interior components have been connected to the vehicle body. Petition 870230085842, dated 09 / 27 / 2023, page 15 / 61 9 / 42

[037] With reference to FIG. 1, exemplary installation 12 and system and methods 10 include a market component and container storage area 20 and an assembly area 24 discussed and illustrated below. In exemplary installation 12 of FIG. 1, the assembly area 24 includes a plurality of assembly lines 24 (an assembly line 26 shown) which includes a travel path 30 in which a product, for example, a vehicle body, is progressively assembled in a series of sequentially positioned assembly cells 34. Each assembly cell 34 includes one or more assembly operations, for example, welding of a component or sub-assembly to the progressively constructed vehicle body by a plurality of programmable multi-axis robots. Although FIG.1. Showing the market storage area 20 in a relatively close position, substantially linearly aligned and upstream of the assembly area 24, it is understood that the storage area 20 and the assembly area 24 may be in different locations and orientations relative to each other within the facility 12 to, for example, accommodate the occupied floor area of ​​the existing building of the facility 12 and existing structures. Other locations and configurations of the system 10, facility 12, storage area 20 and assembly area 24 may be used to suit the specific application known to those skilled in the art.

[038] With reference to illustrative FIGS. 1 and 2, the system and methods 10 use one or more and, in some examples, a plurality of vehicles for transporting containers of Petition 870230085842, dated 09 / 27 / 2023, page 16 / 61 10 / 42 components 40 for engaging and transporting filled component containers 44 from storage area 20 to assembly area 24 and returning empty component containers 44 to storage area 20 as described and illustrated below. In the exemplary system and methods 10, reference to component containers 44 includes open or partially or fully closed containers, crates, pallets, platforms, component racks, conveyors and other structures for supporting and / or containing components. Reference to components includes individual components or parts, sub-assembled components, consumable assembly materials and / or other items used directly in the assembly process or used indirectly by the equipment or operators to support assembly operations. It is understood that containers may contain a single component or part, or multiple components.It is understood that consumable assembly materials may include a wide range of materials used in the assembly process, for example, fasteners, adhesives, paints, seals, lubricants, other fluids, and other items used directly in the assembly process to meet the specific application and / or known to those skilled in the art. Consumable assembly materials may also include materials that are used by equipment or operators to support or maintain the assembly process and / or assembly equipment, including water, lubricants, consumable welding or joining materials, and other physical items and fluids used in assembly processes known to those skilled in the art. Containers may be full, partially full, or empty / depleted. Petition 870230085842, dated 09 / 27 / 2023, page 17 / 61 11 / 42 components. As used in this document, a full component container may be any of the containers described, including one or more of any of the components described. As used in this document, an empty or depleted component container may be any of the containers described that is empty or depleted of any of the components described, or depleted to such an extent that the exemplary production process specifies that the container is effectively empty and / or in need of replacement. As used in this document, the term container may refer to a container of components (full or empty) or just to a component itself (e.g., where a container is not required for storage, transport, or assembly of the component).

[039] As best seen in FIGS. 1 and 2, the exemplary system and methods 10 includes a material aisle 50, a shelving aisle or component container 56, and a pedestrian aisle 60 as generally shown. In the examples shown, and as described and illustrated in more detail below, the shelving aisle 56 is an aisle, path, or area in which component containers 44 are positioned and temporarily stored in storage area 20 and assembly area 24 within the reach or engageable extension of transport vehicles 40 positioned in and mobile along the material aisle 50. As best seen in FIGS. 1 and 2, in a preferred, but not exclusive, example, the shelving aisle 56 extends in a direction from the x-coordinate 64 of storage area 20 through at least a portion of assembly area 24, directly adjacent to Petition 870230085842, dated 09 / 27 / 2023, p. 18 / 61 12 / 42 assembly cells 34. In the preferred example, the shelving aisle 56 is continuous and / or substantially linear from storage area 20 to assembly area 24. In one example, the shelving aisle 56 is substantially parallel to the path 30 of the assembly line 26.

[040] With reference to FIGS. 1 and 2, exemplary material aisle 50 is a corridor, path, or area positioned directly adjacent to and substantially parallel to the shelving aisle 56, extending in the x-coordinate direction 64. As discussed and illustrated further below, material aisle 50 is wide enough to allow transport vehicles 40 to move along the path between storage area 20 and assembly area 24. In the example shown, material aisle 50 is substantially straight or linear and aligned with shelving aisle 56. In one example, the width of material aisle 50 in the y-coordinate direction 66 is just wide enough to accommodate a single transport vehicle 40 (not wide enough for two transport vehicles side-by-side) to minimize the footprint of the facility 12.In another example (not shown), material aisle 50 is wide enough to allow two or more transport vehicles 40 to move side-by-side in the 66 y direction to, for example, navigate and travel around other transport vehicles 40 positioned in material aisle 50.

[041] The exemplary system and method 10 further includes a pedestrian corridor 60 for use in enabling operators and technical personnel to walk or move along the storage area 20 and assembly area 24 without Petition 870230085842, dated 09 / 27 / 2023, page 19 / 61 13 / 42 prevent the movement of transport vehicles 40 that move along the material corridor 50. In one example (not shown), the pedestrian corridor 60 is not included in the system 10. In another example (not shown), the corridor 60 may be used for other purposes known to those skilled in the art.

[042] With reference to FIG. 3, an alternative example of system and methods 10 and installation 12 is shown. In the example, storage area 20 is positioned towards an upstream end of assembly area 24, as generally shown. Material aisle 50, shelving aisle 56 and pedestrian aisle 60 are positioned on either side of assembly area 24. This example allows component containers 44 to be transported and positioned on both opposite sides of assembly area 24 as generally shown. It is understood that alternative constructions, positions, configurations and / or orientations of installation 12, storage area 20, assembly area 24, material aisle 50, shelving aisle 56 and pedestrian aisle 60 may be used to meet the application and performance requirements of installation 12 and product production as known to those skilled in the art.

[043] With reference to FIGS. 4A and 4B, an example of an autonomous transport vehicle 40 operable for engaging, transporting and depositing component containers 44 along the material aisle 50 is shown. The exemplary transport vehicle 40 includes a body or housing 70 which includes a rigid internal load-bearing structure (not shown). The transport vehicle 40 Petition 870230085842, dated 09 / 27 / 2023, page 20 / 61 14 / 42 includes an onboard control system 74 which includes the components generally shown and described further below in FIG. 13. The control system 74 controls the internal operations of the transport vehicle 40, movement or propulsion and navigation along the travel path 52 in the material corridor 50 as described and illustrated below.

[044] The body 70 of the transport vehicle 40 includes one or more motorized wheels 80 used to propel the transport vehicle 40 along the predetermined travel path 52. Each motorized wheel 80 is engaged to a wheel drive device, for example, an electric motor drive 308 (shown schematically in FIG. 13) which is in communication with the control system 74 to selectively provide drive motion to predetermined wheels 80. In one example, one or more wheels 80 may be omnidirectional wheels that allow the transport vehicle 40 to rotate around a vertical geometric axis or z-coordinate direction 90, move laterally in a horizontal direction or y-coordinate direction 66 transverse to the x-coordinate direction 64, or other complex movements, for example along a curved path. One or more wheels 80 may be intermediate wheels. The actuators 308 are powered by a power source 316 (FIG.13), for example, a rechargeable battery. Other energy sources 316 and control and drive mechanisms known to those skilled in the art may be used.

[045] In the example of FIGS. 4A, B, the transport vehicle 40 is driven autonomously and guided by navigation through the use of a navigation and communication system of Petition 870230085842, dated 09 / 27 / 2023, page 21 / 61 15 / 42 wireless digital data, which includes a transmitting / receiving antenna 84, 314 and one or more sensors 86, 306 (see FIG. 13). In one example, the transport vehicle 40 includes onboard software and instructions programmed into the onboard control system 74 that allow the vehicle to move autonomously (without direct personnel involvement or intervention) along the material aisle 50 and selectively engage and deposit component containers 44 as generally described in this document to support assembly operations. In another example, better seen in FIG. 14, each transport vehicle 40 directly receives, in real time, wireless digital data signals transmitted from a local 92 or central control system 92A, which is processed by the vehicle 40's onboard control system 74, which is used to move and navigate the vehicle 40 through predetermined movements and operations as generally described in this document.

[046] It is understood that any of the transport vehicles 40 described herein may be configured to be semi-autonomous in operation. For example, as shown in FIGS. 10A and 11C, vehicle 40 may be configured to support a human operator on board the body 70 to supervise and / or manually operate certain functions of vehicle 40 as described in this document. As used in this document, autonomous and semi-autonomous operation is collectively referred to as autonomous unless expressly identified. In an alternative example that may also be configured the same as or similar to FIGS. 10A and 11C, transport vehicle 40 may be a manually operated device in which the functions, movement and navigation Petition 870230085842, dated 09 / 27 / 2023, page 22 / 61 16 / 42 are controlled by an operator or technician.

[047] In an example or mode of operation as best seen in FIGS. 1 and 2, the transport vehicle 40 is generally limited to linear and straight movement along the travel path 52 in the direction of the x-coordinate 64 in the material aisle 50 between the storage area 20 and the assembly area 24. It is understood that an alternative mode of operation or movement may allow the vehicle 40 to move omnidirectionally, laterally, curvilinearly and / or negotiate curves like a conventional manually operated forklift, for example, to move out of or away from material aisle 50 for maintenance, reloading, reprogramming or other activities known to those skilled in the art. In an example where the installation 12 is not configured in a generally straight linear manner, as shown in FIG.1. The 40 transport vehicles are operable to move along alternative routes to suit the specific orientation of the facility 12 and production operations.

[048] Still referring to the example in FIG. 4A, a first or vertical drive device 94 is used to selectively raise and lower, along a vertical direction or the z-coordinate 90, a first container support 110 relative to the body 70. In the example in FIG. 4A, the first or vertical drive 94 includes a first vertical guide 100 rigidly connected to the body structure 70 and a second vertical guide 104 engaged with the first vertical guide 100 and movable vertically in the z-direction 90 relative to it. The engagement of the second vertical guide 104 with the first vertical guide 100 can be done Petition 870230085842, dated 09 / 27 / 2023, p. 23 / 61 17 / 42 by one of many conventional ways, for example, rollers, complementary gears, shelf and pinion and other devices known to those skilled in the art. In one example, a rotary gear is connected to a first vertical guide 100 (or to the body 70) and to an electric motor drive 308 in communication with the control system 74 to selectively activate and deactivate the motor to move the second vertical guide 104 up and down in the vertical or z 90 direction, relative to the body 70. Encoders and / or other sensors in communication with the control system 74 can be used to determine and monitor the position and movement of the first vertical drive device 94 and the individual parts.

[049] The exemplary transport vehicle 40 further includes a first component container support 110 and a second component container support 114 positioned on an opposite side of the body 70, as shown in general. With reference only to the first component container support 110 for ease of description, the first support 110 (or alternatively the body 70) includes a second or horizontal drive device 120 operable to selectively move the first support 110, or parts thereof, laterally along the y-coordinate direction 66 relative to the body 70. In one example, the y-coordinate direction 66 is substantially horizontal and transverse to the x-coordinate direction 64. The second drive 120 may include identical or similar components described for vertical drive 94, or other devices known to those skilled in the art. Petition 870230085842, dated 09 / 27 / 2023, page 24 / 61 18 / 42

[050] The first exemplary vehicle support 110 additionally includes a rear plate structure 124 rigidly engaged with the second drive 120 and a pair of forks 130 connected to the rear plate 124. The rear plate 124 is engaged with the second drive 120 to selectively move the first support 110 along the y direction 66 relative to the body 70 as described below and illustrated. It is understood that different constructions and configurations of the first support 110 may be used to suit the specific application as is known to those skilled in the art.

[051] In one example, the forks 130 are similar to traditional forklift forks useful for engaging pallets and industrial conveyor racks with corresponding openings. It is understood that an alternative to the forks 130 or other structures connected to the forks 130, such as accessories or other tools (for example, as shown in FIG. 10 described below) may be used to suit the specific component container 44 or component to be engaged and transported by the transport vehicle 40. In the illustrative FIG. 4A, the second support 114 is constructed similarly to the first support 110. It is understood that the first support 110 and the second support 114 may have different constructions or configurations from each other in a given transport vehicle 40.

[052] In the exemplary vehicle 40 as shown and as further described below and illustrated in FIG. 4B, both the first 110 and the second support 114 are capable of raising and lowering selectively and independently along the z 90 direction and extending in the y 66 direction. In a Petition 870230085842, dated 09 / 27 / 2023, page 25 / 61 19 / 42 example, both the first 110 and the second 114 supports are oriented, or open, to only one side of the body 70 (towards the shelving aisle 56 as shown). In one example (not shown), one of the first 110 or second 114 supports may be oriented 180 degrees around the z 90 direction and extend to the opposite side of the body 70 (opposite to the direction of the other support). This would provide flexibility to accommodate storage shelves or shelving aisles 56 positioned on either side of the material aisle 50, or for example, in a storage area configured alternatively with component shelves on either side of a material aisle 50. Alternative constructions, configurations and orientations of the first 110 and second 114 supports, and transport vehicle 40, may be used to suit the specific container 44 and / or application as known to those in the art.

[053] As used in this document, similar reference numbers refer to similarly constructed or functional structures. Similar reference numbers followed by a character refer to a similar device or base part, but with alternative construction and / or function. With reference to FIGS. 9, 10 and 10A, alternative transport vehicles 40A, 40B and 40C are shown, which include first 110 and second 114 supports. With reference to FIG. 9, the exemplary alternative transport vehicle 40A is configured to be an autonomous driving and navigation device, as generally described above for transport vehicle 40 (FIG. 4A). The exemplary transport vehicle 40A includes a body 70A configured Petition 870230085842, dated 09 / 27 / 2023, p. 26 / 61 Alternatively, the 20 / 42 control system has a 74 control system, a first or vertical drive device 94A, a second or horizontal drive device 120A, and first 110A and second 114A supports as generally shown. The 40A transport vehicle is configured with 130 forks as described for the 40 transport vehicle.

[054] With reference to FIG. 10, the alternative and exemplary transport vehicle 40B is configured to be an autonomous driving and navigation device, as generally described for the transport vehicle 40, as described above. The exemplary transport vehicle 40B includes an alternatively configured body 70B, control system 74, first or vertical drive device 94B, second or horizontal drive device 120B and first 110B and second 114B supports as generally shown. The first 110B and second 114B supports of the transport vehicle 40B are alternatively configured with tools or accessories 130A then traditional forks 130. In one example, the tool 130A is specifically configured to engage and support a specific container or component 44.In one example, the first 110B and second 114B supports of the transport vehicle 40B, or a portion thereof, are extendable along the y direction 66 to both opposite sides of the body 70B to, for example, engage and deposit containers 44 in storage areas 20 and assembly areas 24 positioned on both sides of a material aisle 50. The transport vehicle 40B may also include semi-autonomous operation and functions that are supervised by an onboard operator, as described alternatively for. Petition 870230085842, dated 09 / 27 / 2023, page 27 / 61 21 / 42 the transport vehicle 40.

[055] With reference to FIG. 10A, the alternative and exemplary transport vehicle 40C is configured to be a manually operated and navigated device as generally described above. The exemplary transport vehicle 40C includes an alternatively configured body 70C, control system 74, first or vertical drive device 94C, second or horizontal drive device 120C and first 110C and second 114C supports as generally shown. The transport vehicle 40C is configured with forks 130 as described for the transport vehicle 40. In the example, an operator can manually drive, navigate and operate the drives 94B, 120B to engage and deposit containers 44 in the storage areas 20 and assembly areas 24 as generally described for the transport vehicle 40.The 40C transport vehicle may also include semi-autonomous operation and functions that are supervised by an onboard operator, as described alternatively for the 40 transport vehicle.

[056] With reference to FIGS. 11A, 11B and 11C, alternative transport vehicles 40D, 40E and 40F are shown which include a single first support 110. As noted below, in an example of system and method 10, a pair of transport vehicles, for example 40D, can operate collectively and coordinately together to obtain the benefits of engaging, transporting and depositing containers 44 as described for transport vehicle 40. With reference to FIG. 11A, the exemplary alternative transport vehicle 40D is configured to be a device of Petition 870230085842, dated 09 / 27 / 2023, page 28 / 61 22 / 42 autonomous driving and navigation as generally described above for transport vehicle 40. The exemplary transport vehicle 40D includes an alternatively configured body 70D, control system 74, first or vertical drive device 94D, second or horizontal drive device 120D and first support 110D as generally shown. The transport vehicle 40A is configured with forks 130 as described for transport vehicle 40.

[057] With reference to FIG. 11B, the alternative and exemplary transport vehicle 40E is configured to be an autonomous driving and navigation device, as generally described for the transport vehicle 40, as described above. The exemplary transport vehicle 40E includes an alternatively configured body 70E, control system 74, first or vertical drive device 94E, second or horizontal drive device 120E and first support 110E as generally shown. The transport vehicle 40A is configured with forks 130 as generally described for the transport vehicle 40.

[058] With reference to FIG. 11C, the alternative and exemplary transport vehicle 40F is configured to be a manually operated and navigated device as generally described above. The exemplary transport vehicle 40F includes an alternatively configured body 70F, control system 74, first or vertical drive device 94F, second or horizontal drive device 120F and a first support 110F as generally shown. The transport vehicle 40F is configured Petition 870230085842, dated 09 / 27 / 2023, page 29 / 61 23 / 42 with 130 forks as described for the transport vehicle 40. In the example, an operator can drive, navigate, and manually operate units 94F, 120F to engage and deposit containers 44 in storage areas 20 and assembly areas 24 as generally described for the transport vehicle 40. The transport vehicle 40F may also include semi-autonomous operation and functions that are supervised by an onboard operator, as alternatively described for the transport vehicle 40. It is understood that the alternative transport devices 40B-40F can be alternatively structured, configured, and functioned to suit the specific application, as is known to those skilled in the art.

[059] With reference to FIGS. 1, 5 and 6, alternative examples of market storage area or storage area 20 are shown. In the example of FIG. 5, a large component container area 140 which includes a large component shelf 144, useful for storing and queuing a plurality of large component containers 44 (all containers generally referred to as 44). Large component containers 44 are generally useful for storing larger components which, for example, are normally housed in custom storage shelves or conveyors (containers), for example, passenger vehicle door panels or vehicle body subassemblies. Other large components may be stored in large component containers 44.

[060] In the example, storage shelf 144 includes a load-bearing structure that includes supports Petition 870230085842, dated 09 / 27 / 2023, pp. 30 / 61 24 / 42 vertical and shelving units 146 dividing shelving unit 144 into a plurality of compartments 148 extending from a display row(s) and column(s) 150 positioned in the shelving aisle 56 and directly adjacent to the material aisle 50. In the large shelving unit 144 example, each compartment 148 includes a width 154 and sufficient height for the passage of large component containers 44 through the container supports 110, 114 of the transport vehicle 40, or portions thereof, such as forks 130 for engaging the component containers 44 as discussed and illustrated below.

[061] In an exemplary storage area 20, using large component shelving 144 as an example, large component shelving 144 includes separate and predetermined areas, or selected compartments 148, for temporary storage of full containers 44 intended for transport to the assembly area 24, and separate predetermined compartments 148 for empty containers 44 that have been returned from the assembly area 24 for replenishment. Large component shelving 144 may include devices that automatically or manually move or queue the containers on the shelving to, for example, automatically advance a full container 44 to the presentation queue 150 for engagement by a transport vehicle 40. One or more sensors may be used to detect and monitor the positions of the containers 44 on the respective component shelving and / or compartments 148.In one example, the sensors can send signals to a local control system 92 and / or central system 92A to actively monitor and / or coordinate activity with them. Petition 870230085842, dated 09 / 27 / 2023, pp. 31 / 61 25 / 42 transport vehicles 40 and other system equipment 10. Other devices and methods for the logistical management of full containers 44 and empty containers 44, known to those skilled in the art, may be used to suit the specific application.

[062] With reference to FIG. 6, an alternative example of a large component shelf 144A is shown with an alternatively configured transport vehicle 40 (see FIG. 10). It is understood that large component shelves 144 can be alternatively constructed or configured to suit specific containers 44 and applications as known to those skilled in the art.

[063] With reference to FIGS. 1 and 2, in an example of storage area 20, additional or alternative storage areas 20 are included in addition to the large component area 140. In one example, additional storage areas, for example, a small container or consumable materials area 160, include a small container shelf 164 for smaller component containers 44. Each additional or alternative storage area 160 is positioned adjacent to the material aisle 50, thus presenting or positioning the specific component container 44 in the shelving aisle 56 in a presentation row 150 so as to be reachable and engageable by the transport vehicle 40 moving in the material aisle 50, as described for the large component area 140 and the large parts shelf 144.It is understood that some containers 44, and their respective storage areas, may not require vertical and / or three-dimensional shelves, such as. Petition 870230085842, dated 09 / 27 / 2023, pp. 32 / 61 26 / 42 container shelves 144 and 164. Some containers 44, and / or their respective components, may be positioned on conventional pallets and / or supported on the facility floor, for example, industrial adhesive drums. Additional or alternative storage areas may employ similar or alternative devices and processes to logistically manage full and empty containers, as described above. Although alternative storage areas 140 and 160 are shown close to each other upstream of assembly area 24, it is understood that the different storage areas 140 and 160 may be positioned in separate and remote areas of the facility 12 in relation to each other and / or assembly area 24.

[064] With reference to FIGS. 1 and 2, the system and methods 10 includes an assembly area 24 with one or more assembly lines 26 and sequentially positioned assembly cells 34 as described above (one assembly line 26 and two assembly cells 34 shown in FIGS. 1 and 2). In the exemplary assembly area 24, the shelving aisle 56 extends in at least part and, in the example shown, extends throughout the assembly area 24. In one example, the shelving aisle 56 extends substantially linearly in a straight line from the storage area 20 through the assembly area 24 as generally shown. In one example, the shelving aisle is continuous. In the example described and shown, the shelving aisle 56 is positioned directly adjacent and parallel to the material aisle 50 and is further positioned adjacent to or in communication with each assembly cell 34.

[065] With reference to FIG. 3, an assembly area Petition 870230085842, dated 09 / 27 / 2023, pp. 33 / 61 Alternative 24A is shown where aisles 50, 56, and 60 are positioned on either side of an assembly line 26 as described above. It is understood that additional assembly lines 26 may be used in system and method 10. It is further understood that the assembly area 24, the assembly cells 34, and the shelving aisle 56 may have alternative constructions, configurations, and / or orientations to suit specific installation and production processes, as known to those skilled in the art.

[066] With reference to FIGS. 1, 7, 8A-C and 16, system and methods 10 includes method 200 for assembly material logistics and handling. As described above, method 200 can be used in a manufacturing or assembly facility and is specifically, but not exclusively, useful in high-volume assembly facilities. There are many other applications where product packaging and / or distribution logistics require temporary storage and transfer of components, packaging and containers to another area of ​​a facility for further processing (collectively referred to as assembly material logistics).

[067] In one example, method 200 is useful in installation 12, which has exemplary storage area 20; assembly area 24; one or more, or a plurality of transport vehicles 40; a material aisle 50; shelving aisle 56; and pedestrian aisle 60 as described and illustrated above and below. In an exemplary step 205, a component transport vehicle 40 is positioned in a material aisle 50 adjacent to a shelving aisle 56. The shelving aisle 56 extends through Petition 870230085842, dated 09 / 27 / 2023, pp. 34 / 61 28 / 42 at least a portion of the storage area 20 and a portion of the assembly area 24 as described and illustrated above. In a preferred exemplary step 205, the transport vehicle 40 includes a first container support 110 and a second container support 114 as generally shown in FIGS. 4A, B. It is understood that alternatively configured transport vehicles 40 may be used which include a first 110 and second 114 supports, for example, those illustrated in FIGS. 9, 10 and 10A, as well as in FIGS. 11A-11C, and others not illustrated may be used.

[068] In exemplary step 205, in a common installation condition 12 where the assembly area 24 and the assembly line 26 are in operation and there is an empty container 44 needing replacement, the transport vehicle 40 is moved along the material aisle 50 to a position in the storage area 20 to engage a full container 44, for example positioned on a large storage shelf 144 (see FIGS. 1 and 5). In an example where the transport vehicle 40 is autonomous, the movement of the transport vehicle 40 is autonomous and positioned in a compartment 148 of a predetermined shelf 144 that includes a full container 44 of the correct component to replace the empty container 44 in the assembly area 24.

[069] As generally described above, the transport vehicle 40 may include pre-programmed instructions stored in a data memory storage device 304 in the control unit 74 in order to direct the movement of the actuators 308 that drive or propel the wheels 80 to move to the predetermined location or Petition 870230085842, dated 09 / 27 / 2023, pp. 35 / 61 29 / 42 shelf compartment 146 in storage area 20. Upon receiving a wireless or other signal from a local control system 92 or central system 92A, the vehicle control system 74 accesses and executes pre-programmed instructions stored in memory via the controller processor 310 to execute the instructions and move the vehicle to the predetermined compartment 148. Sensors 86, 306 on board the transport vehicle 40, in communication with the control system 74, can assist in navigating and positioning the transport vehicle 40 in the predetermined position in storage area 20 relative to the large shelf 144 and / or compartment 148.Additional or alternative sensors (not shown) in storage area 20 and / or large shelf 144, communicating with local control systems 92 and / or central systems 92A, and / or the transport vehicle control system 74, can also be used to positively and accurately position the transport vehicle 40 in relation to compartment 148 and / or the correct full container 44 to be attached and transported.

[070] In an alternative example described above, the transport vehicle 40 may receive real-time wireless transmission data signals from the local control system 92 and / or central system 92A which provides the predetermined location(s) in storage area 20, movement of the transport vehicle 40 along the material aisle 50 and navigation along the material aisle 50. In an alternative example of step 205, where the transport vehicle 40 is semi-autonomous or manually operated, an individual operator may propel, navigate and / or Petition 870230085842, dated 09 / 27 / 2023, pp. 36 / 61 30 / 42 Manually position the transport vehicle 40 to the predetermined position in the storage area 20.

[071] As best seen in FIGS. 7 and 8, and in the production start example, exemplary method step 210A involves transport vehicle 40 engaging a predetermined full container 44 which includes the correct components to replace the empty container 44 in the assembly area. In this example, transport vehicle 40 is positioned to engage a full container 44 from a predetermined compartment 148 of the large parts shelf 144. In the example shown in FIG. 7, the first support of transport vehicle 110 is positioned directly adjacent to and aligned with the x direction 64 and the z direction 90, a previously positioned full container 44 in the shelf aisle 56 and presentation line 150 within the reach or extension of the first support 110 along the y direction 66.

[072] In a better example seen in FIGS. 8A and 4B, a portion of the first support 110 of the transport vehicle is extended outwards in the y 66 direction towards the large shelf 144 and full container 44 to engage the full container 44. In the example described above, the horizontal or second drive 120 can be used to extend or retract the first (or second 114) support 110 in the y 66 direction. As described above, the vertical or first drive 94 can then be used to engage and lift or vertically raise the full container from the shelf 146 in the z 90 direction, thus engaging and supporting the full container 44 as seen in FIG. 8A. The activation of the second 120 and first 94 drive units is Petition 870230085842, dated 09 / 27 / 2023, pp. 37 / 61 31 / 42 controlled by the on-board control system 74 in one of the ways described above (pre-programmed instructions or transmitted data signals). One or more sensors 86, 306 on the transport vehicle 40 and / or large shelf 144 can be used to positively identify the engagement of the first support 110 with the full container 44. The exemplary step 210 is also applicable to the use of the second support 114 of the transport vehicle 40 in the same way.

[073] As best seen in FIG. 8B, once the full container 44 has been engaged in the shelf aisle 56 by the first support 110, the second drive 120 is activated to retract the first support 110 along the y direction 66 to position the engaged full container 44 in a safe position on board the transport vehicle 44 for further transport. When the engaged full container is in a high position or row on the large shelf 144, the first drive 94 would be lowered in the z direction 90 to the safe position as shown in FIG. 8B. One or more sensors 86, 308 can be used to identify or confirm that the full container 44 is located in the safe position.In an alternative example (not shown), where two full containers 44 are needed to support production at this stage of production, for example, shift start, the positioning described above of the transport vehicle 74 and the coupling with a second full container 44 can be carried out with the second support 114 in the same manner. In a normal production operation described, a single full container 44 will be coupled to storage area 20 as described. As further described below, an empty container. Petition 870230085842, dated 09 / 27 / 2023, pp. 38 / 61 32 / 42 on board the transport vehicle can be deposited in the shelving aisle 56 on the large shelf 144 before the transport vehicle moves towards the assembly area 24.

[074] As described above, it is understood that steps 205 and 210A can be used when the filled container 44 is stored in a different way in the storage area 20, for example, shelves or containers 44 configured differently. It is further understood that different engagement devices and mechanisms can be used by the transport vehicle 40 and first 110 and second 114 supports to physically engage the filled container 44 other than forks 130 to suit the specific application and container 44. For example, auxiliary devices fed into the first support 110 can act to physically grip the container 44, for example, opposing compressive grippers (not shown).

[075] With reference to FIGS. 1 and 2, and the exemplary production condition described, in exemplary step 215, the transport vehicle and the full container on board 44 are moved or propelled towards the assembly area 24 along the travel path 52 along the material corridor 50. In exemplary step 220, the transport vehicle 40 is autonomously propelled and navigated from the storage area 20 to a predetermined position in the assembly area 24 where the empty container 44 that needs to be replaced is positioned. The positioning and alignment of the transport vehicle 44 in the x 64 and z 90 directions is achieved in the manner described above for the storage area 20. Petition 870230085842, dated 09 / 27 / 2023, pp. 39 / 61 33 / 42

[076] As best seen in FIG. 7, in exemplary step 225A with the transport vehicle in the first position, the second empty support 114 is positioned in alignment with the empty container 44, as shown in general. As similarly described above for step 210A, a portion of the second support 114 is extended in the y direction 66 towards the shelf aisle 56 to engage the empty container 44 and is then retracted to a safe position in the manner described above for storage area 20 (FIGS. 8A and 8B). With both the empty container 44 and the full container 44 supported and on board, the transport vehicle 40 is then quickly indexed or moved along the travel path 52 slightly downstream to a second position to align the first support 110 and the full container 44 in the predetermined position to deposit the full container 44 in the shelving aisle of the assembly area 56 (FIG.8C) to replace the newly removed empty container 44. In exemplary step 225B, the transport vehicle 40 extends the first support 110 in the y direction 66 to deposit the full container 44 in the shelf aisle 56 of the assembly area 24 to replace the empty container 44 in a manner similar to that described above, except that the first drive 94 is lowered in the z direction 90 to deposit the full container 44 in the shelf aisle of the assembly area 56 so as to disengage the first support 110 from the full container 44.

[077] In an alternative step 225 (not shown), the filled container 44 can be placed in a different position in the shelving aisle of the assembly area 56 Petition 870230085842, dated 09 / 27 / 2023, pp. 40 / 61 34 / 42 from where the described empty container 44 was positioned. For example, the transport vehicle 40 may first deposit the full container 44 in an alternatively predetermined available space in the shelving aisle of the assembly area 56 and subsequently index or move to align the second support 114 with the empty container 44 and engage and secure the empty container 44 in the manner described. In an alternative step 225 (not shown), the transport vehicle, without a full container on board 44, may be used to engage separate empty containers 44 with both the first 110 and second 114 supports and transport them to storage area 20 or another predetermined area and position for further processing. Other alternative uses and method steps 225 may be used to meet specific application and production requirements known to those skilled in the art.

[078] As soon as the full container 40 is deposited in the shelving aisle 56 of the assembly area 20, the first support 110 and the attached empty container 44 are returned to the safe position (FIG. 8B). In the exemplary step 230, the transport vehicle 40 and the empty container on board 44 are autonomously propelled and navigated back to the storage area 20 to a predetermined position in the manner described above. With the empty container 44 on board, the transport vehicle is still performing the work (transporting the empty container 44), so there are no empty runs with the transport vehicle 40, thus increasing the efficiency of use of the transport vehicle 40 and decreasing the time spent supplying full containers 44 and removing empty containers 44, to support the Petition 870230085842, dated 09 / 27 / 2023, pp. 41 / 61 35 / 42 production assembly process.

[079] As best seen in FIG. 15, as soon as the transport vehicle 40 with the empty container 44 on board is positioned back in the storage area 20 (step 205), in exemplary step 210B, the transport vehicle 40 is positioned in a predetermined position aligned with the storage compartment 148 of the large shelf 144 designated for empty containers 44. The transport vehicle 40 deposits the empty container 44 in the shelf aisle 56 of the predetermined and designated storage area 20 for empty containers 44 in the manner of depositing full containers described in the assembly area 24 (second position of FIG. 7, FIG. 8C). In a similar manner to that described above for the assembly area of ​​FIG.7, the transport vehicle 40 is then quickly moved or indexed along the travel path 52 in the material aisle 50 to a predetermined position aligned with a large shelf compartment 148 to engage a full container 44. In step 210A described above, the transport vehicle 40 engages a full container 44 for transport to the assembly area in the manner described above (FIG. 8A). The process repeats as the transport vehicle engages and deposits full or empty containers in storage areas 20 and assembly areas 24 and moves reciprocally between storage areas 20 and assembly areas 24 carrying a full or empty container 44 to support the production process as determined by the local control systems 92 and / or central 92A. In an alternative example of steps 210A and B as described, it is further understood that before depositing the empty container. Petition 870230085842, dated 09 / 27 / 2023, pp. 42 / 61 36 / 42 on shelf 144, transport vehicle 40 can first attach the full container 44 from shelf 144 and then later deposit the empty container 44 onto shelf 144 before moving back to assembly area 24 to replace an empty container 44 with the attached full container 44.

[080] In an exemplary alternative method 200 wherein the transport vehicle 40B includes a single first support 110 (FIGS. 11A-C), two transport vehicles 40 (40D-F) can be used in a coordinated and / or synchronous manner to achieve the same methods and efficiencies of engaging a container and depositing a container 44 described above in the storage areas 20 and assembly areas 24 using a single transport vehicle with first 110 and second 114 supports. In one example, a pair of transport vehicles 40D is pre-programmed with instructions or wireless data signals transmitted in the manner described above, to move effectively along the material aisle 50 and operate in a coordinated and / or synchronous manner to engage and deposit containers 44 in the storage areas 20 and assembly areas 24 in the ways described.Other uses of multiple 40D-F transport vehicles to achieve the described advantages and efficiencies known to those skilled in the art may be employed.

[081] With reference to FIG. 12, an alternative application of the transport vehicle 40 and method is shown in combination with continuous conveyors 176 that load / unload respective full containers 44 (“F”) and empty containers 44 (“E”) from the transport vehicle 40 to a transfer device (“FL”). Petition 870230085842, dated 09 / 27 / 2023, pp. 43 / 61 37 / 42 for subsequent transport or processing. It is understood that other devices besides continuous conveyors 176 may be used in combination with transport vehicles 40, to meet specific application and production needs, as known to those skilled in the art.

[082] It is understood for method 200 that additional method steps, or removal of method steps, and / or execution of the steps described in a different order, at different times, or simultaneously in time, may be used to suit specific application and production performance requirements as by those skilled in the art.

[083] The exemplary method 200, and specifically, but not exclusively, steps 210A, B and 225A, B, provide significant advantages over previous systems and methods. Conventional transport vehicles 40 with single supports, for example, a common forklift, present significant disadvantages when an empty container requires replacement with a full container. The use of conventional forklifts and similar material handling devices requires multiple and separate actions (lowering the transported full container; picking up, moving and then lowering the removed empty container; then picking up / retrieving, moving and depositing the full container in its place and then picking up / retrieving the removed empty container for transport).This use of a single conventional forklift requires even more transport operations by a single forklift (removing the empty container, depositing the empty container in a storage area, and then retrieving and moving the full container). Petition 870230085842, dated 09 / 27 / 2023, pp. 44 / 61 38 / 42 Alternatively, several conventional forklifts are needed to perform the separate actions to reduce the disadvantages and inefficiencies described. This conventional system, devices, and methods are time-consuming and inefficient. The example of the present invention, as described with first 110 and second 114 supports, and simple indexing in the mounting areas 24 or storage areas 20, provides a quick replacement of the empty container and a much faster and more efficient solution. Advantages are further achieved on the container storage area side where empty containers are deposited and full containers are hooked up.

[084] With reference to FIGS. 13 and 14, an example of a control system 300 is illustrated for serving as a transport vehicle control system 74 and a local and / or central control system 92A (collectively referred to as control system 300). With reference to FIG. 13, the exemplary control system 300 includes a computing device, or several computing devices, working cooperatively. The exemplary control system computing device 300 includes common hardware components, which include, but are not limited to, a central processing unit (CPU) 302, a data memory storage device 304, one or more controllers (which include, but are not limited to, programmable logic controllers (PLCs)) 310, input / output devices 312, a transmitter and receiver 314 for sending and receiving wireless data signals, actuators 308 (e.g., electric motors), and sensors 86, 306.These hardware components are in signal communication. Petition 870230085842, dated 09 / 27 / 2023, pp. 45 / 61 39 / 42 data are transmitted between each other, either through hardwired connections or wireless communication protocols, via a bus 320 or other suitable hardware. Other hardware components, including additional input and output devices 312, may be used to suit the specific application and performance specifications known to those skilled in the art. Examples of input devices include, but are not limited to, touch-sensitive display devices, keyboard image devices, and other devices that generate computer-interpretable signals in response to user interaction. Examples of output devices include, but are not limited to, display screens, loudspeakers, warning lights, and other audio or visually perceptible devices. The control system 300 is powered by the power supply 312, for example, a rechargeable battery or electrical power supplied to the facility 12.

[085] The exemplary processor 302 can be any type of device that is capable of processing, calculating, or manipulating information, which includes, but is not limited to, digital information, that is currently known or may be developed in the future. An example of a processor is a conventional central processing unit (CPU).

[086] The exemplary data memory storage device 304 may include devices that store information, including but not limited to digital information, for immediate or future use by the processor 302. Examples of memory storage devices include either or both of the access memory devices. Petition 870230085842, dated 09 / 27 / 2023, pp. 46 / 61 Randomized memory (RAM) or read-only memory (ROM) can be stored in 40 / 42 random number storage (RAM). The memory storage device 304 can store information, such as program instructions that can be executed by the processor 302, and data that is stored and retrieved by the processor 302. Additionally, parts of the operating system for the computing device and other applications can be stored in the data memory storage device 304. Non-limiting examples of memory storage devices 304 include a hard disk drive or a solid-state drive. Alternatively, parts of the stored information can be stored in the cloud (remote storage devices or data centers) and selectively retrieved via wireless protocols.

[087] An example of a system control system 300 includes a suitable software operating system and pre-programmed software to perform predetermined actions, functions, or operations of the system 10 described in this document. The operating system and software may be stored in the data memory storage device 304 and processed and executed by the processor 302 via the controller 310 and actuators 308.

[088] With reference to FIGS. 13 and 14, in one example, system 10, or components thereof, for example, transport vehicles 40, may receive operational instructions and commands via data signals transmitted wirelessly in real time from the local control system 92 or central control system 92A, or other local or central control systems. Examples of communication networks that may be in use in the installation 12 may include, but are not limited to, networks of Petition 870230085842, dated 09 / 27 / 2023, pp. 47 / 61 41 / 42 large area network (LAN) or a campus area network (CAN). Examples of wireless communication networks, systems, and protocols usable with system 10 include wireless routers for communication based on the IEEE 802.11 standard (also known as Wi-Fi). Other wireless communication protocols, for example, Bluetooth, may be used. In certain applications, other wired communication systems and components for communication based on the IEEE 802.3 standard (also known as Ethernet) may be used. Other forms of communication networks, wired and wireless communication protocols, systems, and devices known to those skilled in the art may be used.

[089] The autonomous or self-driving mode of operation of transport vehicles 40 described above can be achieved through the use of one or a plurality of sensors 86, 306 on board the device 40, for example, omnidirectional LIDAR (image, detection and light ranging), on-board processing of sensor data received by the transport vehicle 40 and on-board execution of commands via the on-board control system 74 and actuators 308 to navigate and move the vehicle 40 along a travel path 52. Other types and forms of sensors 86, 306, and positional monitoring and navigation systems may be used, including, but not limited to, global positioning satellite systems (GPS), triangular positioning devices, ultrasonic sensors, laser sensor systems, radar, proximity sensors and / or visual imaging devices or systems known to those skilled in the art.As noted, instructions and commands for guiding the movement and navigation of each vehicle (40) can be received. Petition 870230085842, dated 09 / 27 / 2023, pages 48 / 61 42 / 42 alternatively or in combination by the respective vehicle 40 of a local and / or central control system 92A for execution by the respective vehicle 40 or through pre-programmed instructions stored in the memory data storage device 304 in the control system 74 of the transport vehicle. Other hardware, software and communication devices and protocols of the control system 300 may be used to suit the system and methods 10 and specific application, as known to those skilled in the art.

[090] Although the invention has been described in relation to certain embodiments, it should be understood that the invention is not limited to the embodiments disclosed, but, on the contrary, is intended to cover various equivalent modifications and arrangements included in the scope of the appended claims, the scope of which should be given the broadest interpretation so as to encompass all equivalent modifications and structures permitted by law. Petition 870230085842, dated 09 / 27 / 2023, pp. 49 / 61

Claims

1 / 11 CLAIMS 1. A method for logistics and handling of assembly material, characterized in that it comprises: selectively positioning a component transport vehicle along a material aisle in at least one of a component storage area or a component assembly area, the storage area being positioned outside and away from the assembly area, the material aisle being positioned adjacent to a component shelving aisle and extending in a direction of the x-coordinate; the transport vehicle: initially, engages for transport in the storage area a selected plurality of full component containers positioned in the component shelving aisle and deposits in the component shelving aisle in the storage area an empty component container engaged and transported from the assembly area;and subsequently, it engages for transport in the assembly area a selection of a plurality of empty component containers positioned in the component shelving aisle in the assembly area and deposits in the component shelving aisle of the assembly area a full component container that has been engaged and transported from the storage area; and selectively and reciprocally moves the transport vehicle, including at least one of the full component container engaged or the empty component container engaged, along the material aisle between the storage area and the assembly area.

2. Method according to claim 1, characterized in that the step of engaging to transport the selected component from among a plurality of full or empty component containers further comprises: extending a portion of the transport vehicle in a y-coordinate direction in the shelving aisle to engage the respective selected full or empty component container, the y-coordinate direction being transverse to the x-coordinate direction; and retracting the portion of the transport vehicle and the respective engaged full or empty component container in the y-coordinate direction from the shelving aisle to the material aisle to a fixed position on the transport vehicle before moving the transport vehicle between the storage area and the assembly area.

3. Method for logistics and handling of assembly material, characterized in that it comprises: selectively positioning a component transport vehicle positioned along a material aisle in at least one of a component storage area or a component assembly area, the material aisle positioned adjacent to a component shelving aisle and extending in an x-coordinate direction, the transport vehicle including a first component container holder and a second component container holder, the second container holder being operable independently of the first container holder;whereby the transport vehicle: initially, engages for transport in the storage area via the first container support a selected container from a plurality of full component containers positioned in the component shelving aisle and deposits via the second container support in the component shelving aisle in the storage area an empty component container transported from the assembly area; and subsequently, engages with the second container support for transport in the assembly area a selected container from a plurality of empty component containers positioned in a predetermined position in the component shelving aisle in the assembly area and deposits with the first container support the transported full component container in the predetermined position in the shelving aisle of the assembly area;and move, selectively and reciprocally, the transport vehicle including at least one of the attached full component container or the attached empty component container along the material aisle between the storage area and the assembly area.

4. Method according to claim 1, characterized in that the step of depositing the selected component from among a plurality of full component containers or empty component containers further comprises: extending a portion of the transport vehicle and the selected full component container or empty component container attached in a y-coordinate direction of the material aisle into the shelving aisle to disengage the respective selected full or empty component container, the y-coordinate direction being transverse to the x-coordinate direction; and retracting the portion of the transport vehicle in the y-direction of the shelving aisle into the material aisle before moving the transport vehicle between the storage area and the assembly area.

5. A method according to claim 3, characterized in that after the empty component container is coupled with the second container support and while the transport vehicle continues to couple the empty component container, the method further comprises the step of indexing the transport vehicle along the material aisle to align the first container support carrying the full container with the predetermined position to deposit the full container in the predetermined position in the shelving aisle of the assembly area vacated by the empty component container.

6. Method, according to claim 3, characterized in that engaging the empty component container to the second container support in the predetermined position occurs at a first moment and depositing the full component container in the predetermined position occurs at a second moment, the second moment later than the first moment. Petition 870230085842, dated 09 / 27 / 2023, pp. 53 / 61 5 / 11 7. Method, according to claim 3, characterized in that at least one of the transport vehicles that engages the full or empty component container, deposits the full or empty containers, or moves reciprocally along the material corridor, is driven autonomously.

8. Method for logistics and handling of assembly material, characterized in that it comprises: selectively positioning a component transport vehicle positioned along a material aisle in at least one of a component storage area or a component assembly area, the material aisle positioned adjacent to a component shelving aisle and extending in an x-coordinate direction, the transport vehicle including a first component container holder and a second component container holder, the second container holder being operable independently of the first container holder;the transport vehicle: initially, using the second container support, it deposits an empty component container transported from the assembly area into a predetermined first position in the shelving aisle of the storage area and, using the first container support, it engages for transport in the storage area a selected container from a plurality of full component containers positioned in a predetermined second position in the shelving aisle of the storage area; and Petition 870230085842, dated 09 / 27 / 2023, page 54 / 61 6 / 11, subsequently, using the second container support for transport in the assembly area, it engages a selected container from a plurality of empty component containers positioned in the component shelving aisle in the assembly area and, using the first container support, it deposits a fully engaged component container transported from the storage area;To move, selectively and reciprocally, the transport vehicle, including at least one of the attached full component container or the attached empty component container, along the material aisle between the storage area and the assembly area.

9. Method according to claim 8, characterized in that after depositing the empty component container with the second container support, the method further comprises the step of indexing the transport vehicle along the material aisle to align the first container support with the second predetermined position for engaging the filled container with the first container support.

10. Method, according to claim 1, characterized in that the transport vehicle comprises a first transport vehicle and a second transport vehicle, the second transport vehicle being operable independently of the first transport vehicle, the method further comprising: initially, coupling to transport the selected component from among the plurality of filled component containers in the shelf aisle of the area of ​​Petition 870230085842, dated 09 / 27 / 2023, page.55 / 61 7 / 11 storage by the first transport vehicle and deposit the empty component container transported from the assembly area onto the shelving aisle of the storage area by the second transport vehicle; and in the second moment, hitch up to transport the selected plurality of empty containers onto the shelving aisle of the assembly area by the second transport vehicle and deposit the full component container transported from the storage area onto the shelving aisle of the assembly area vacated by the empty component container transported by the first transport vehicle.

11. Method according to claim 10, characterized in that the first transport vehicle and the second transport vehicle move synchronously and in a coordinated manner along the material corridor between the storage area and the assembly area.

12. Method, according to claim 1, characterized in that after engaging and removing one selected from a plurality of empty component containers from a predetermined position in the shelving aisle of the assembly area, depositing the full container transported from the assembly area in the predetermined position in the shelving aisle of the assembly area vacated by the empty component container.

13. Method, according to claim 12, characterized in that at least one of the transport vehicles that engages the full or empty component container, deposits the full or empty containers, or moves reciprocally along the material aisle, is driven autonomously.

14. Method for logistics and handling of assembly material, characterized in that it comprises: storing a plurality of filled component containers positioned along a shelving aisle in a storage area extending in an x-coordinate direction, the first storage area positioned upstream of an assembly area; storing a plurality of empty component containers positioned along the shelving aisle in the assembly area extending in an x-coordinate direction; selectively positioning a component transport vehicle positioned along a material aisle in either the storage area or the assembly area, the transport vehicle having a first component holder and a second component holder, the material aisle positioned adjacent to the shelving aisle and extending in the x-coordinate direction;The transport vehicle: initially, it engages for transport via the first component container support a selected component from among the plurality of full component containers positioned in the shelving aisle of the storage area and deposits via the second component container support an empty component container transported from the assembly area into the shelving aisle of the storage area; and subsequently, it engages for transport via the second component container support a selected component from among the plurality of empty component containers positioned in the shelving aisle of the assembly area and deposits via the first component container support a full component container transported from the storage area into the shelving aisle of the assembly area;To move, selectively and reciprocally, the transport vehicle, including either the attached full component container or the attached empty component container, along the material aisle between the storage area and the assembly area.

15. Method according to claim 14, characterized in that the step of engaging for transport a selected container from among a plurality of full component containers or empty component containers further comprises: extending the respective first container support or second container support in a y-coordinate direction in the shelving aisle to engage the respective selected full or empty component container, the y-coordinate direction being transverse to the x-coordinate direction; and retracting the portion of the respective first container support or second container support and the respective engaged full or empty component container in the y-coordinate direction from the shelving aisle to the material aisle to a secure position in the transport vehicle before moving the transport vehicle between the storage area and the assembly area.

16. Method according to claim 15, characterized in that the step of engaging one selected from a plurality of filled component containers or empty component containers further comprises moving, respectively, the first container support or the second container support in a z-coordinate direction relative to the transport vehicle, the z-coordinate direction being transverse to the y-coordinate direction.

17. Method according to claim 14, characterized in that the step of depositing the selected one from among a plurality of full component containers or empty component containers further comprises: extending the respective first container support or the second container support and the engaged full component container or empty component container in a y-coordinate direction from the material aisle into the shelving aisle to disengage the respective selected full or empty component container, the y-coordinate direction being transverse to the x-coordinate direction; and retracting the respective first container support or the second container support in the y-direction from the shelving aisle to the material aisle before moving the transport vehicle between the storage area and the assembly area.

18. Method, according to claim 17, characterized in that the step of uncoupling a Petition 870230085842, dated 09 / 27 / 2023, page 59 / 61 11 / 11 selected from a plurality of full component containers or empty component containers further comprises moving a portion of the transport vehicle in a z-coordinate direction relative to the transport vehicle, the z-coordinate direction being transverse to the y-coordinate direction.

19. Method according to claim 14, characterized in that the step of selectively and reciprocally moving the transport vehicle between the storage area and the assembly area further comprises: Selectively and autonomously moving the transport vehicle along the material aisle between a plurality of predetermined positions in the storage area and a plurality of predetermined positions in the assembly area.

20. Method, according to claim 19, characterized in that the transport vehicle includes a control system for motorized propulsion and directional navigation, the method further comprising: receiving wireless data signals from at least one local or central control system for use by the transport vehicle to autonomously move the transport vehicle in a predetermined direction and navigate directionally along a predetermined travel path. Petition 870230085842, dated 09 / 27 / 2023, pp. 60 / 61

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