Autonomous mobile vehicle

Abstract

An autonomous mobile vehicle (102) includes an automated guided vehicle (AGV) (200), a platform assembly (300) coupled to the AGV, and a collaborative manipulator (400) mounted to a support plate (320) of the platform assembly. A safety sensor (500) is coupled to the collaborative manipulator and includes a first proximity sensor (502) and a second proximity sensor (504), the first proximity sensor being fixed relative to the support plate, the second proximity sensor (504) being coupled to the collaborative manipulator proximate a gripper (414) of the collaborative manipulator and movable with an arm (412) of the collaborative manipulator. The safety sensor determines when the gripper is in a home position proximate the support plate by detecting a proximity of the second proximity sensor to the first proximity sensor.

Description

TECHNICAL FIELD

[0001] The subject matter herein relates generally to autonomous mobile vehicles. BACKGROUND

[0002] AGVs (Automated Guided Vehicles) are becoming more popular in production facilities to autonomously transport parts and materials from one location to another. Production facilities utilizing AGVs typically include a central operator station where an operator handles requests and dispatches AGVs to perform tasks. Such systems typically involve a great deal of human intervention in the control of the AGVs. Some known production environments have implemented automation where a process machine directly communicates with the AGVs to handle requests without human intervention. However, it has proven difficult to implement central control of the AGVs. It is difficult to determine the priority of machine requests, as well as efficient routing and scheduling of the AGVs.

[0003] During use, the AGVs autonomously navigate from point to point and transport materials. However, conventional systems typically require human assistance to load and unload materials from the AGVs. Some known AGVs include a collaborative manipulator, such as a robotic arm, mounted on top of the AGV to manipulate the materials. However, such robotic arms have independent control that is not controlled by the AGV. The mounting and integration of the robotic arm with the AGV is very expensive and is unit specific.

[0004] A problem to be solved is to provide an autonomous mobile vehicle having a modular platform for use with various types of AGVs and various types of collaborative manipulators. SUMMARY

[0005] The above problem is solved by an autonomous mobile vehicle having an automated guided vehicle (AGV) having a base, an electric motor coupled to the base, a wheel driven by the electric motor to move the AGV, a battery coupled to the electric motor to power the electric motor, and an AGV controller to control movement of the AGV. A platform assembly is coupled to the base of the AGV and moves with the AGV. The platform assembly includes a frame holding a collaborative manipulator controller. A collaborative manipulator is operably coupled to the frame. The collaborative manipulator has an arm and a gripper at a distal end of the arm operable to manipulate a part. The collaborative manipulator is operably coupled to the collaborative manipulator controller to control operation of the collaborative manipulator. A safety sensor is coupled to the collaborative manipulator and includes a first proximity sensor and a second proximity sensor. The first proximity sensor is fixed relative to a support plate. The second proximity sensor is coupled to the collaborative manipulator proximate the gripper and is movable with the arm and the gripper. The safety sensor determines when the gripper is in a home position proximate the support plate by detecting a proximity of the second proximity sensor to the first proximity sensor. BRIEF DESCRIPTION OF DRAWINGS

[0006] Figure 1 is a schematic diagram of an autonomous mobile vehicle system according to an example embodiment.

[0007] Figure 2 is an elevational perspective view of an autonomous mobile vehicle according to an example embodiment.

[0008] Figure 3 is a close-up view of a portion of an autonomous mobile vehicle according to an example embodiment, showing a safety sensor coupled to a co-manipulator.

[0009] Figure 4 is a side view of an autonomous mobile vehicle according to an example embodiment, showing a co-manipulator in a home position.

[0010] Figure 5 is an end view of an autonomous mobile vehicle according to an example embodiment, showing a co-manipulator in a home position.

[0011] Figure 6 is a side view of an autonomous mobile vehicle according to an example embodiment, showing a co-manipulator in an upwardly extended position.

[0012] Figure 7 is an end view of an autonomous mobile vehicle according to an example embodiment, showing a co-manipulator in an upwardly extended position.

[0013] Figure 8 is a side view of an autonomous mobile vehicle according to an example embodiment, showing a co-manipulator in a forwardly extended position.

[0014] Figure 9 is an end view of an autonomous mobile vehicle according to an example embodiment, showing a co-manipulator in a forwardly extended position.

[0015] Figure 10 is a side view of an autonomous mobile vehicle according to an example embodiment, showing a co-manipulator in a laterally extended position.

[0016] Figure 11 is an end view of an autonomous mobile vehicle according to an example embodiment, showing a co-manipulator in a laterally extended position.

[0017] Figure 12 is a flowchart of a method of operating an autonomous mobile vehicle according to an example embodiment. DETAILED DESCRIPTION

[0018] Figure 1is a schematic diagram of an autonomous mobile vehicle system 100 according to an example embodiment. The autonomous mobile vehicle system 100 is used to control movement of mobile robots or autonomous mobile vehicles 102 in a logistics facility 104, such as a warehouse, distribution center, manufacturing plant, retail plant, etc. The autonomous mobile vehicles 102 are used for part picking and part put down within the logistics facility 104. For example, the autonomous mobile vehicles 102 are used to pick parts from one or more machines 106, such as manufacturing machines, bins, etc., and the autonomous mobile vehicles 102 are used to put down parts at other machines, such as other manufacturing machines, bins, etc.

[0019] In an example embodiment, the autonomous mobile vehicle system 100 includes a system control module 110 located within the logistics facility 104. The system control module 110 is communicatively coupled to the machines 106, such as through a wired connection or a wireless connection. The system control module 110 is communicatively coupled to a plurality of autonomous mobile vehicles 102 to control part processing within the logistics facility 104, such as moving parts between machines 106 using the autonomous mobile vehicles 102. The autonomous mobile vehicles 102 autonomously transport parts from one location to another location, such as between machines 106, based on control signals received from the system control module 110.

[0020] In an example embodiment, the autonomous mobile vehicle system 100 includes a docking station 112 for the autonomous mobile vehicles 102. The docking station 112 can be used to store or charge the autonomous mobile vehicles 102. In an example embodiment, the autonomous mobile vehicles 102 return to the docking station 112 to recharge the autonomous mobile vehicles 102 after performing one or more operations.

[0021] Autonomous mobile vehicle 102 navigates autonomously from point to point within logistics facility 104, for example, to pick up parts, drop off parts, inventory parts, or return to docking station 112. For example, autonomous mobile vehicle 102 moves through logistics facility 104 along one or more paths between docking station 112 and machine 106. Autonomous mobile vehicle 102 includes an automated guided vehicle (AGV) 200, a platform assembly 300 mounted to AGV 200, a collaborative manipulator 400 mounted to platform assembly 300, and a safety sensor 500 for detecting a position of collaborative manipulator 400. AGV 200 is used to move autonomous mobile vehicle 102 around logistics facility 104. Collaborative manipulator 400 is used to manipulate parts at machine 106. For example, in various embodiments, collaborative manipulator 400 can include a robotic arm and / or a gripper and / or a conveyor. In alternative embodiments, other types of part handlers can be used. Platform assembly 300 provides mechanical and electrical connections between AGV 200 and collaborative manipulator 400. Platform assembly 300 can be modular and / or scalable to be mounted to different types of AGV 200 and / or to mount different types of collaborative manipulator 400. AGV 200 includes an AGV controller 202 for controlling operation of AGV 200. Platform assembly 300 includes a collaborative manipulator controller 402 for collaborative manipulator 400.

[0022] Safety sensor 500 is used to ensure that collaborative manipulator 400 is in a safe position when moving around logistics facility 104. For example, safety sensor 500 detects that collaborative manipulator 400 is present in a home position (e.g., within a footprint of platform assembly 300, near platform assembly 300), thereby allowing normal operation of AGV 200. When collaborative manipulator 400 is in a safe position, AGV 200 is able to move around logistics facility 104. However, when collaborative manipulator 400 is extended and moved out of the home position, collaborative manipulator 400 is in an unsafe position. When in the unsafe position, safety sensor 500 is unable to detect collaborative manipulator 400. Because it can be unsafe to move autonomous mobile vehicle 102 when collaborative manipulator 400 is in the unsafe position, AGV 200 and / or collaborative manipulator 400 are shut down from moving.

[0023] Figure 2 is a front perspective view of autonomous mobile vehicle 102 according to an example embodiment. Figure 2 Platform assembly 300 mounted to AGV 200 is shown and collaborative manipulator 400 mounted to platform assembly 300 is shown. Safety sensor 500 is mounted to platform assembly 300 and / or collaborative manipulator 400. Safety sensor determines a position of collaborative manipulator 400 relative to platform assembly 300, for example, to determine whether collaborative manipulator 400 is in a safe position or an unsafe position.

[0024] The AGV 200 includes a base 210 that houses a motor 212 and wheels 214 that are driven by the motor 212 to move the AGV 200. The base 210 has a footprint (e.g., length and width) and other components of the AGV 200 are contained within the footprint of the base 210. The AGV 200 includes a battery 216 that is coupled to the motor 212 to power the motor 212. In an example embodiment, an AGV controller 202 controls the movement of the AGV 200. The AGV controller 202 is operably coupled to the motor 212. The AGV controller 202 controls the operation of the motor 212 to move the AGV 200. The AGV controller 202 can control the ON / OFF mode of the motor 212, can control the speed of operation of the motor 212, can control the direction of operation of the motor 212, etc. For example, during a normal mode of operation, the AGV controller 202 can allow the motor 212 to be on, can control the speed of the motor 212, and can control the direction of the motor 212 to allow the AGV 200 to move around the logistics facility 104. During a safety mode, the AGV controller 202 can turn off the motor 212 and limit the operation of the motor 212 to limit the movement of the AGV 200. For example, it can be unsafe to move the autonomous mobile vehicle 102 around the logistics facility 104 when the collaborative manipulator 400 is in the extended position. Thus, the AGV controller 202 can change to a safety mode to stop the movement of the AGV 200 when the collaborative manipulator 400 is in the extended position (e.g., the safety sensor 500 does not detect the collaborative manipulator in the home position). The AGV controller 202 is communicatively coupled to the system control module 110 (as shown in FIG. 1) to receive control signals to operate the AGV 200. For example, the AGV controller 202 can receive route information to guide the AGV 200 along a particular path, such as between the docking station 112 and the machines 106, 108 (as shown in FIG. 1). The AGV controller 202 can receive information instructing the AGV 200 to move forward, move backward, and / or turn right or left to control the movement of the AGV 200. Figure 1 Figure 1

[0025] ​​The platform assembly 300 includes a frame 310 having walls 312 that enclose a cavity 314. The walls 312 extend between a top 316 and a bottom 318 of the frame 310. The bottom 318 of the frame 310 is mounted to the base 210 of the AGV 200. The frame 310 has a footprint (e.g., length and width), and other components of the platform assembly 300 are contained within the footprint of the frame 310. The bottom 318 can define the footprint. However, the top 316 or another location of the frame 310 can define the maximum dimensions of the platform assembly 300, and thus the footprint. In various embodiments, the footprint of the platform assembly 300 can be less than the footprint of the AGV 200; however, in other various embodiments, the footprint of the platform assembly 300 can be equal to or greater than the footprint of the AGV 200. The platform assembly 300 moves with the AGV 200. In an example embodiment, the platform assembly 300 includes a button 306 on one of the walls 312, which can be used to reset operations or stop the operation of the AGV 200 and / or the collaborative manipulator 400. Optionally, one or more of the walls 312 can include vents that circulate air through the cavity 314.

[0026] The platform assembly 300 includes a support plate 320 at the top 316. The support plate 320 supports the collaborative manipulator 400. For example, the collaborative manipulator 400 can be mounted directly to the support plate 320, such as using fasteners. In an example embodiment, the support plate 320 includes a plurality of mounting locations for mounting the collaborative manipulator 400 at different locations on the support plate 320 and / or for mounting different types of collaborative manipulators on the support plate 320. In an example embodiment, the platform assembly 300 includes a part holder 322 at the top of the support plate 320. The part holder 322 can include rails or walls that form a space to receive and hold parts on the support plate 320 during transport, such as between machines 106. In the illustrated embodiment, the part holder 322 is located near a front 324 of the platform assembly 300. However, the part holder 322 can be located at other locations, such as near a back 326 of the platform assembly 300 or a side 328 of the platform assembly 300.

[0027] In example embodiments, the co-manipulator 400 includes a mounting base 410 mounted to the support plate 320, for example using fasteners. In the illustrated embodiment, the co-manipulator 400 is mounted to the platform assembly 300 near the rear portion 326. In alternative embodiments, other mounting locations are possible. The mounting base 410 fixes the co-manipulator 400 relative to the platform assembly 300. In example embodiments, the co-manipulator 400 includes an arm 412 and a gripper 414 at a distal end of the arm 412 for picking up parts and moving the parts to or from the part holder 322. In various embodiments, the arm 412 can be a four-axis manipulator arm or a six-axis manipulator arm. In alternative embodiments, other types of robotic arms can be used. In other various embodiments, other types of part handlers can be used instead of the gripper 414 and / or the arm 412. For example, the co-manipulator 400 can include a conveyor, a stack light, or other types of manipulators.

[0028] A safety sensor 500 is coupled to the platform assembly 300 and / or the co- manipulator 400. The safety sensor 500 determines (e.g., senses) when the gripper 414 of the co-manipulator 400 is in the home position. In example embodiments, the safety sensor 500 includes a proximity sensor for detecting the presence of an object or target or sensor component within a predetermined range or target area. When the presence of such an object or target or sensor component is not detected, the safety sensor determines that the gripper 414 is outside the home position, and thus the co-manipulator is in an extended and unsafe position. In example embodiments, the safety sensor 500 includes a first proximity sensor 502 and a second proximity sensor 504. In alternative embodiments, the safety sensor 500 can include additional sensor elements. The first proximity sensor 502 is fixed relative to the support plate 320. For example, the first proximity sensor 502 can be coupled to the support plate 320 or the mounting base 410 of the co-manipulator 400. The first proximity sensor 502 can be positioned near the home position of the gripper 414 and senses the presence of the second proximity sensor 504 and thus the gripper 414 in the home position. The second proximity sensor 504 is movable relative to the support plate 320 and the first proximity sensor 502. For example, the second proximity sensor 504 can be coupled to the co-manipulator 400 and movable with the co-manipulator 400. In various embodiments, the second proximity sensor 504 can be positioned near the gripper 414, for example mounted directly to the gripper 414 or to the arm 412 near the distal end 413 of the gripper 414.

[0029] Figure 3is a close-up view of a portion of the autonomous mobile vehicle 102 according to example embodiments, showing a safety sensor 500 coupled to the co-manipulator 400. A first proximity sensor 502 is shown coupled to the mounting base 410 and fixed relative to the support plate 320. The first proximity sensor 502 is located proximate to the support plate 320. The first proximity sensor 502 can be located proximate to the part holder 322. The first proximity sensor 502 does not move when the co-manipulator 400 moves. A second proximity sensor 504 is shown coupled to the gripper 414. The second proximity sensor 504 can move with the gripper 414 relative to the support plate 320 and the first proximity sensor 502. Other mounting locations are possible in alternative embodiments.

[0030] In example embodiments, the first proximity sensor 502 is a sensing element and the second proximity sensor 504 is a target element. In various embodiments, the first proximity sensor 502 can be a transmitter, a receiver, or a transceiver. The first proximity sensor 502 can be a non-contact sensor. In various embodiments, the first proximity sensor 502 is an RF sensor element. The first proximity sensor 502 can be an inductive sensor, a capacitive sensor, a photoelectric sensor, a through-beam sensor, a backscatter sensor, an ultrasonic sensor, or the like. The first proximity sensor 502 is configured to sense the presence or absence of the second proximity sensor 504 within a target zone 506 of the first proximity sensor 502. The target zone 506 is a zone within a predetermined distance of the first proximity sensor 502. The target zone 506 can be directional or omnidirectional relative to the first proximity sensor 502. The second proximity sensor 504 can be a non-contact sensor. In various embodiments, the second proximity sensor 504 can be magnetic or non-magnetic.

[0031] Figure 4 is a side view of the autonomous mobile vehicle 102 according to example embodiments, showing the co-manipulator 400 in a retracted position. Figure 5 is an end view of the autonomous mobile vehicle 102 according to example embodiments, showing the co-manipulator 400 in a retracted position. Figure 6 is a side view of the autonomous mobile vehicle 102 according to example embodiments, showing the co-manipulator 400 in an extended position (e.g., upwardly extended position). Figure 7 is an end view of the autonomous mobile vehicle 102 according to example embodiments, showing the co-manipulator 400 in an extended position (e.g., upwardly extended position). Figure 8 is a side view of the autonomous mobile vehicle 102 according to example embodiments, showing the co-manipulator 400 in an extended position (e.g., forwardly extended position). Figure 9This is an end view of an autonomous mobile vehicle 102 according to an exemplary embodiment, showing the cooperative manipulator 400 in an extended position (e.g., a forward-extended position). Figure 10 This is a side view of an autonomous mobile vehicle 102 according to an exemplary embodiment, showing the cooperative manipulator 400 in an extended position (e.g., a lateral extended position). Figure 11 This is an end view of an autonomous mobile vehicle 102 according to an exemplary embodiment, showing the cooperative manipulator 400 in an extended position (e.g., a lateral extended position).

[0032] During use, the cooperative manipulator 400 moves from its original position ( Figure 4 and Figure 5 The gripper 414 and arm 412 move to various extended positions, such as for picking up and placing parts onto and from machine 106. In the extended position, the gripper 414 and arm 412 move away from support plate 320. Operating the autonomous moving vehicle 102 may be unsafe when the gripper 414 and arm 412 are in the extended position. The gripper 414 and arm 412 can be located in various extended positions outside the coverage area of ​​platform assembly 300 (see, for example...). Figures 8-11 For example, gripper 414 and arm 412 can be located in front of or behind platform assembly 300. Figures 8-9 ) and / or gripper 414 and arm 412 may be located in platform assembly 300 ( Figures 10-11 The gripper 414 and arm 412 can be located in various extended positions outside the coverage area of ​​the platform assembly 300 (see, for example, Figures 6-7 ).

[0033] The safety sensor 500 is used to detect when the collaborative manipulator 400 is in the home position and when the collaborative manipulator 400 is away from the home position and thus in the extended position. In the home position, the second proximity sensor 504 is within the target zone 506 near the first proximity sensor 502. In an example embodiment, when the collaborative manipulator 400 is in the home position, it is safe to operate the AGV 200 and move the autonomous mobile vehicle 102 around the logistics facility 104. For example, the gripper 414 and arm 412 are within the footprint of the platform assembly 300. However, in the extended position, the second proximity sensor 504 is outside the target zone 506 away from the first proximity sensor 502. In an example embodiment, when the AGV 200 attempts to move and the collaborative manipulator 400 is in the extended position, the autonomous mobile vehicle 102 is shut down. In the extended position, it can be unsafe to move the autonomous mobile vehicle 102. For example, if the autonomous mobile vehicle 102 is to hit one of the machines 106 or other structures within the logistics facility 104, the collaborative manipulator 400 can be damaged. Additionally, when the collaborative manipulator 400 is in the extended position, the collaborative manipulator 400 can damage the machines 106 or other structures within the logistics facility 104 or can injure personnel within the logistics facility 104.

[0034] Figure 12 is a flowchart of a method of operating an autonomous mobile vehicle 102 according to an example embodiment. At 600, a safety check is initiated. The safety check can be initiated manually, for example by turning on the autonomous mobile vehicle 102 or by pressing a button on the autonomous mobile vehicle 102. The safety check can be initiated automatically, for example a routine safety check performed periodically by the autonomous mobile vehicle 102 when the autonomous mobile vehicle 102 is running. For example, the safety check can be performed every M seconds, or multiple times per second, for example every N milliseconds.

[0035] At 602, the autonomous mobile vehicle 102 determines whether the AGV 200 is moving or whether the AGV 200 is stationary (not moving). In an example embodiment, the AGV controller 202 controls and monitors the operation of the AGV 200, for example the operation of the electric motor 212 of the AGV 200. For example, the AGV controller 202 can control the supply of power to the electric motor 212. When power is supplied to the electric motor 212, the AGV 200 moves. When power is not supplied to the electric motor 212, the AGV 200 is stationary. If the AGV 200 is stationary, the autonomous mobile vehicle 102 can be operated in a mounted state. The collaborative manipulator 400 can be operated when the autonomous mobile vehicle 102 is in a safe state. When operated in the safe state, the collaborative manipulator 400 can be used to pick and place parts.

[0036] If the AGV 200 is stationary, at 604, the autonomous mobile vehicle 102 determines whether the collaborative manipulator 400 is in a safe position. The autonomous mobile vehicle 102 can continuously or periodically determine the position of the collaborative manipulator 400. In various embodiments, if the AGV 200 receives a move command, the autonomous mobile vehicle 102 can determine whether the collaborative manipulator 400 is in a safe position before allowing the AGV 200 to move. In an exemplary embodiment, the safety sensor 500 determines whether the collaborative manipulator 400 is in a home position. For example, the safety sensor 500 determines whether the gripper 414 is within a certain proximity or range of the safety sensor 500. The safety sensor 500 determines whether the second proximity sensor 504 is within a certain proximity or range of the first proximity sensor 502. When the presence of the second proximity sensor 504 is detected, the safety sensor 500 determines that the collaborative manipulator 400 is in the home position, and thus, in a safe position. For example, the gripper 414 and the arm 412 are within the footprint of the platform assembly 300 in a collapsed or merged state. When the absence of the second proximity sensor 504 is detected (e.g., the second proximity sensor is not detected), the safety sensor 500 determines that the collaborative manipulator 400 is in an extended position, and thus, in an unsafe position. For example, the gripper 414 and / or the arm 412 can be positioned outside of the footprint of the platform assembly 300, and thus, can be damaged or damage other components or injure personnel if the AGV 200 moves. In an exemplary embodiment, the safety sensor 500 determines whether the gripper 414 and the arm 412 are within the footprint of the platform assembly 300. If the gripper 414 and the arm 412 are within the footprint of the platform assembly, the safety sensor 500 determines that the collaborative manipulator 400 is in a safe position (e.g., in the home position). For example, the safety sensor 500 can include proximity sensors to determine the position of the gripper 414 and the arm 412 relative to the safety sensor 500 and / or the overall structure of the AGV 200. The safe position determination is made when the gripper 414 and the arm 412 are in a safe position, as detected by the safety sensor 500. The safety sensor 500 can generate a safe position signal when the gripper 414 and the arm 412 are in a safe position. The safe position signal can be sent to the AGV controller 202 to control other operations of the AGV 200. If the gripper 414 and the arm 412 are outside of the footprint of the platform assembly, the safety sensor 500 determines that the collaborative manipulator 400 is in an unsafe position (e.g., in an extended position). For example, if the position of the gripper 414 and the arm 412 are outside (e.g., beyond) a safe proximity or distance of the proximity sensor, the safety sensor 500 determines that the collaborative manipulator 400 is in an unsafe position. The safety sensor 500 can generate an unsafe position signal when the gripper 414 and the arm 412 are in an unsafe position.The unsafe position signal can be sent to the AGV controller 202 to limit or reduce other operations of the AGV 200. For example, the AGV 200 cannot move when the gripper 414 and arm 412 are in an unsafe position.

[0037] If the AGV 200 is stationary and the collaborative manipulator 400 is in a safe position, at 606, the autonomous mobile vehicle 102 operates in the installed state. The autonomous mobile vehicle 102 can continue to operate and perform tasks or routines in the queue. For example, the collaborative manipulator 400 can be operated when the autonomous mobile vehicle 102 is in a safe state. The collaborative manipulator 400 can be used to pick and place parts when operating in the safe state.

[0038] If the AGV 200 is stationary and the collaborative manipulator 400 is in an unsafe position, at 608, the autonomous mobile vehicle 102 operates in the installed state. The autonomous mobile vehicle 102 can continue to operate and perform tasks or routines in the queue. For example, the collaborative manipulator 400 can be operated when the AGV 200 is stationary due to the autonomous mobile vehicle 102 being in a safe state. The collaborative manipulator 400 can be used to pick and place parts when operating in the safe state. The collaborative manipulator 400 can be moved to an unsafe position when the AGV 200 is stationary and thus in a safe state.

[0039] When the AGV 200 moves, at 610, the autonomous mobile vehicle 102 can continuously or periodically determine that the co-manipulator 400 is in a safe position. In an example embodiment, the safety sensor 500 determines whether the co-manipulator 400 is in the home position. For example, the safety sensor 500 determines whether the gripper 414 is within a certain proximity or range of the safety sensor 500. The safety sensor 500 determines whether the second proximity sensor 504 is within a certain proximity or range of the first proximity sensor 502. When the presence of the second proximity sensor 504 is detected, the safety sensor 500 determines that the co-manipulator 400 is in the home position, and thus, in a safe position. For example, the gripper 414 and the arm 412 are within the footprint of the platform assembly 300 in the retracted or collapsed state. When the absence of the second proximity sensor 504 is detected (e.g., the second proximity sensor is not detected), the safety sensor 500 determines that the co-manipulator 400 is in the extended position, and thus, in an unsafe position. For example, the gripper 414 and / or the arm 412 can be positioned outside of the footprint of the platform assembly 300, and thus, can be damaged or damage other components or injure personnel if the AGV 200 moves. In an example embodiment, the safety sensor 500 determines whether the gripper 414 and the arm 412 are within the footprint of the platform assembly 300. If the gripper 414 and the arm 412 are within the footprint of the platform assembly, the safety sensor 500 determines that the co-manipulator 400 is in a safe position (e.g., in the home position). If the gripper 414 and the arm 412 are outside of the footprint of the platform assembly, the safety sensor 500 determines that the co-manipulator 400 is in an unsafe position (e.g., in the extended position).

[0040] If the AGV 200 moves and the co-manipulator 400 is in a safe position (e.g., the home position), at 612, the autonomous mobile vehicle 102 operates in a safe state. The autonomous mobile vehicle 102 can continue to operate and perform tasks or routines in the queue. For example, the AGV 200 can operate to move parts between machines or to move to a docking station.

[0041] If the AGV 200 is moving and the collaborative manipulator 400 is in an unsafe position, at 614, the autonomous mobile vehicle 102 is in an unsafe state. If it is determined that the collaborative manipulator 400 is in an unsafe position, the AGV 200 needs to be shut down or powered off to stop. If the AGV 200 is to move and the collaborative manipulator 400 is in an extended state, the collaborative manipulator 400 can be damaged or can damage other parts or injure personnel. For example, the collaborative manipulator 400 can hit one of the machines 106 or other structures within the logistics facility 104, which can damage the collaborative manipulator 400. When the AGV 200 is moving and the collaborative manipulator 400 is in an extended position, the collaborative manipulator 400 can damage the machines 106 or other structures within the logistics facility 104, or can injure personnel within the logistics facility 104. When it is determined that the collaborative manipulator 400 is in an unsafe position, an unsafe position signal is sent to the AGV controller 202 to shut off power or otherwise cause the AGV 200 to stop moving. In the unsafe state, the autonomous mobile vehicle 102 is shut down and inoperable. In the unsafe state, the AGV 200 is shut down and stationary. Power is disconnected from the electric motor 212 so that the AGV 200 cannot move. In the unsafe state, the collaborative manipulator 400 is shut down and stationary. Power is disconnected from the collaborative manipulator so that the arm 412 and the gripper 414 cannot move. If the unsafe signal is received, an operator can manually shut off power to the electric motor 212, either through the AGV 200 itself or from a remote control location.

[0042] After the autonomous mobile vehicle 102 is shut down, at 616, the autonomous mobile vehicle 102 is reset. In an example embodiment, the autonomous mobile vehicle 102 is manually reset. For example, the collaborative manipulator 400 is manually reset by moving the collaborative manipulator 400 to a home position. The arm 412 and the gripper 414 can be moved to a collapsed or merged position close to the support plate 320 within the footprint of the platform assembly 300. The autonomous mobile vehicle 102 can be reset by pressing a reset button on the autonomous mobile vehicle 102.

[0043] Cross Reference to Related Applications

[0044] This application claims priority to U.S. Provisional Application No. 62 / 923,877, filed October 21, 2019, entitled “AUTONOMOUS MOBILE VEHICLE,” which is incorporated by reference herein in its entirety.

Claims

1. An autonomous mobile vehicle (102), comprising: an automated guided vehicle (AGV) (200) having a base (210), an electric motor (212) coupled to the base, a wheel (214) driven by the electric motor to move the AGV, a battery (216) coupled to the electric motor to power the electric motor, and an AGV controller (202) to control movement of the AGV; a platform assembly (300) coupled to the base of the AGV and moving with the AGV, the platform assembly including a frame (310) having sides extending at a top and a bottom defining a footprint of the platform assembly, the platform assembly including a collaborative manipulator controller (402); a collaborative manipulator (400) operably coupled to the collaborative manipulator controller, the collaborative manipulator having a movable arm (412) and a gripper (414) at a distal end (413) of the arm operative to manipulate a part, the collaborative manipulator mounted to a support plate of the platform assembly at the top of the frame; and a safety sensor (500) including a first proximity sensor (502) and a second proximity sensor (504), wherein the first proximity sensor (502) is configured to sense a presence or an absence of the second proximity sensor (504) within a target zone (506) of the first proximity sensor (502), the target zone (506) being an area within a predetermined distance of the first proximity sensor (502), wherein the target zone (506) is located within the footprint of the platform assembly (300) and when the second proximity sensor (504) is located within the target zone, both the gripper (414) and the arm (412) are located within the footprint, the first proximity sensor is fixed relative to the frame at an original position at the top of the frame within the footprint away from the collaborative manipulator, the second proximity sensor is coupled to the collaborative manipulator near the gripper and movable with the arm and the gripper, the safety sensor determines when the gripper is located within the target zone relative to the frame by detecting a proximity of the second proximity sensor to the first proximity sensor fixed to the frame at the original position.

2. The autonomous mobile vehicle (102) of claim 1, wherein, if the AGV is moving and the safety sensor (500) does not detect the gripper (414) in the original position, the AGV (200) and the collaborative manipulator (400) are shut down.

3. The autonomous mobile vehicle (102) of claim 1, wherein the first proximity sensor (502) is coupled to one of a mounting base (410) of the co-manipulator (400) or a support plate (320) of the platform assembly (300) and is held in a fixed position relative to the support plate, and wherein the second proximity sensor (504) is coupled to one of the arm (412) or the gripper (414) and is movable relative to the support plate and relative to the first proximity sensor.

4. The autonomous mobile vehicle (102) of claim 1, wherein, The co-manipulator (400) is in a safe position when the safety sensor (500) detects the gripper (414) in the home position and is in an unsafe position when the safety sensor does not detect the gripper.

5. The autonomous mobile vehicle (102) of claim 4, wherein, The AGV (200) is inoperable when the co-manipulator (400) is in the unsafe position.

6. The autonomous mobile vehicle (102) of claim 4, wherein the AGV controller (202) determines whether the AGV (200) is moving, and if the AGV is moving and the co-manipulator (400) is in the unsafe position, the AGV controller shuts down the AGV.

7. The autonomous mobile vehicle (102) of claim 4, wherein the AGV controller (202) determines whether the AGV (200) is moving, and if the AGV is moving and the co-manipulator (400) is in the safe position, the AGV controller allows normal operation of the AGV.

8. The autonomous mobile vehicle (102) of claim 4, wherein the AGV controller (202) determines whether the AGV (200) is moving, and if the AGV is stationary, the co-manipulator controller (402) allows normal operation of the co-manipulator.

9. The autonomous mobile vehicle (102) of claim 1, wherein the first proximity sensor (502) is a non-contact sensor and the second proximity sensor (504) is a target sensor, the non-contact sensor determining proximity of the target sensor within a predetermined range of the non-contact sensor.

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