Autonomous mobile vehicle and method of operating the same

Abstract

An autonomous mobile vehicle system (100) includes a machine (106) that processes parts at different locations within a facility (104), a docking station (114) within the facility, an autonomous mobile vehicle (102) movable between the machine and the docking station within the facility, and a system control module (110) for guiding the autonomous mobile vehicle between the machine and the docking station within the facility. The system control module includes a system communication module (160) communicatively coupled to the autonomous mobile vehicle. The system control module includes a system controller (170) that includes one or more processors (180) configured to control the operation of the autonomous mobile vehicle.

Description

Technical Field

[0001] The subject matter herein relates generally to automated guided vehicle systems. Background Art

[0002] AGVs (Automatic Guided Vehicles) are becoming increasingly popular in production facilities to automatically transport parts and materials from one location to another. It is difficult to determine the number of AGVs to use in a specific facility. Providing too many AGVs can lead to increased costs and excessive idle time for the AGVs. Providing too few AGVs can lead to downtime for machines within the facility or insufficient charging of the AGVs, which can deteriorate the AGV's batteries. In addition, it is difficult to determine the facility layout effectively.

[0003] The problem to be solved is to provide a cost effective and reliable autonomous mobile vehicle and method of operating an autonomous mobile vehicle. Summary of the invention

[0004] The above problems are solved by an autonomous mobile vehicle system having: a machine that processes parts at different locations within a facility; a docking station within the facility; an autonomous mobile vehicle movable between the machine and the docking station within the facility; and a system control module for guiding the autonomous mobile vehicle between the machine and the docking station within the facility. The system control module includes a system communication module communicatively coupled to the autonomous mobile vehicle. The system control module includes a system controller, which includes: one or more processors configured to determine a completion time of a machine process of a first machine among the machines; one or more processors configured to determine a travel time of the autonomous mobile vehicle to the first machine; one or more processors configured to send a request to the autonomous mobile vehicle and place the request in a queue of the autonomous mobile vehicle based on the completion time of the machine process of the first machine and the travel time of the autonomous mobile vehicle to the first machine; one or more processors configured to determine whether the request from the first machine has a higher priority than other requests in the queue, wherein if the request from the first machine has a higher priority, the system controller sends the autonomous mobile vehicle to the first machine; one or more processors configured to determine whether the request from the first machine has a shorter estimated completion time than requests from other machines, wherein if the request from the first machine has a shorter completion time, the system controller sends the autonomous mobile vehicle to the first machine, and wherein if the request from the first machine does not have a shorter completion time, the system controller sends the autonomous mobile vehicle to the machine with the shortest completion time. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Figure 1is a schematic diagram of an autonomous mobile vehicle system according to an exemplary embodiment.

[0006] Figure 2 is a top perspective view of a system control module according to an exemplary embodiment.

[0007] Figure 3 is a front perspective view of an autonomous mobile vehicle according to an exemplary embodiment.

[0008] Figure 4 is a flow chart illustrating a method of operating an autonomous mobile vehicle between machines in a logistics facility.

[0009] Figure 5 is a flow chart illustrating a method of operating an autonomous mobile vehicle between machines in a logistics facility.

[0010] Figure 6 is a schematic diagram of an autonomous mobile vehicle system for use in a first layout of a logistics facility according to an exemplary embodiment.

[0011] Figure 7 is a schematic diagram of an autonomous mobile vehicle system for use in a second layout of a logistics facility that is different than the first layout.

[0012] Figure 8 is a schematic diagram of an autonomous mobile vehicle system for use in a third layout of a logistics facility that is different from the first layout.

[0013] Fig. 9 is a flow chart illustrating a method for planning the operation of an autonomous mobile vehicle between machines in a logistics facility.

[0014] Fig.10 is a graph illustrating utilization of a suboptimal logistics facility layout according to an exemplary embodiment.

[0015] Fig.11 is a graph illustrating utilization rates of an optimal logistics facility layout according to an exemplary embodiment. DETAILED DESCRIPTION

[0016] Figure 1is a schematic diagram of an autonomous mobile vehicle system 100 according to an exemplary embodiment. The autonomous mobile vehicle system 100 is used to control the movement of a mobile robot or autonomous mobile vehicle 102 within a logistics facility 104 such as a warehouse, a distribution center, and a manufacturing facility, a retail facility, etc. The autonomous mobile vehicle 102 is used for part picking and part drop-off within the logistics facility 104. For example, the autonomous mobile vehicle 102 is used to pick up parts from one or more processing machines 106 (e.g., manufacturing machines, storage bins, etc.), and the autonomous mobile vehicle 102 is used to drop off parts at other machines (e.g., other manufacturing machines, storage bins, etc.). The autonomous mobile vehicle 102 can be used to move parts to a lathe machine, a cleaning machine, an inspection machine, or other manufacturing machines.

[0017] In an exemplary embodiment, the autonomous mobile vehicle system 100 includes a system control module 110 located within a logistics facility 104, such as within a location or room containing one or more machines 106. The system control module 110 is communicatively coupled to the machines 106, such as via 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 handling within the logistics facility 104, such as movement of parts between machines 106 using the autonomous mobile vehicles 102. The autonomous mobile vehicles 102 autonomously transport parts from one location to another, such as between machines 106, based on control signals received from the system control module 110.

[0018] In an exemplary embodiment, autonomous mobile vehicle system 100 includes an operator station 112 for managing and controlling autonomous mobile vehicle system 100. Operator station 112 is communicatively coupled to system control module 110 to monitor and / or control the operation of system control module 110. Operator station 112 is communicatively coupled to autonomous mobile vehicle 102 to monitor and / or control autonomous mobile vehicle 102. For example, operator station 112 may be wirelessly coupled to autonomous mobile vehicle 102.

[0019] In an exemplary embodiment, the autonomous mobile vehicle system 100 includes a docking station 114 for the autonomous mobile vehicle 102. The docking station 114 can be used to store and / or charge the autonomous mobile vehicle 102. In an exemplary embodiment, the autonomous mobile vehicle 102 returns to the docking station 114 after performing one or more tasks to charge the autonomous mobile vehicle 102. In various embodiments, the autonomous mobile vehicle 102 may require approximately 50% of the charging time and 50% of the operating time. In various other embodiments, the autonomous mobile vehicle 102 may require less charging time, such as approximately 25% or 33% of the charging time relative to the operating time. In various embodiments, the autonomous mobile vehicle system 100 can utilize multiple autonomous mobile vehicles 102 to ensure that the autonomous mobile vehicles 102 are fully charged and available at all times. The autonomous mobile vehicle system 100 may include a planning module for determining a required number of autonomous mobile vehicles 102 required for a particular layout of the logistics facility 104, for example based on the number of machines 106, processing times of the machines, physical layout of the machines 106, travel times of the autonomous mobile vehicles 102 between machines, waiting times of the autonomous mobile vehicles 102 at the machines during processing, charging times of the autonomous mobile vehicles 102, etc. The autonomous mobile vehicle system 100 may determine the required number of autonomous mobile vehicles 102 required based on simulated utilization of the autonomous mobile vehicles 102 during a planning mode of the planning module. The planning module may perform multiple iterations of the facility layout to determine which iterative layouts have relatively optimized layouts.

[0020] The autonomous mobile vehicle 102 autonomously navigates from point to point within the logistics facility 104, such as to pick up parts, drop off parts, inventory parts, or return to the docking station 114. For example, the autonomous mobile vehicle 102 moves along one or more paths through the logistics facility 104 between the docking station 114 and the machine 106.

[0021] In an exemplary embodiment, the autonomous mobile vehicle 102 includes an automated guided vehicle (AGV) 200, a platform assembly 300 mounted to the AGV 200, and a collaborative manipulator 400 mounted to the platform assembly 300. The AGV 200 is used to move the autonomous mobile vehicle 102 around the logistics facility 104. The collaborative manipulator 400 is used to manipulate parts at the machine 106. For example, in various embodiments, the collaborative manipulator 400 may include a mechanical arm and / or a gripper and / or a conveyor. Other types of part manipulators may be used in alternative embodiments. The platform assembly 300 provides mechanical and electrical connections between the AGV 200 and the collaborative manipulator 400. The platform assembly 300 may be modular and / or expandable for mounting to different types of AGVs 200 and / or for mounting different types of collaborative manipulators 400. An AGV controller 202 is provided to control the AGV 200. Although housed in the AGV 200, the AGV controller 202 forms part of the control system of the autonomous mobile vehicle system 100, such as part of the system control module 110. A collaborative manipulator controller 402 is provided for controlling the collaborative manipulator 400. Although housed in the platform assembly 300, the collaborative manipulator controller 402 forms part of the control system of the autonomous mobile vehicle system 100, such as part of the system control module 110. In various embodiments, the AGV controller 202 and the collaborative manipulator controller 402 may be integrated into a single controller for the autonomous mobile vehicle 102.

[0022] In alternative embodiments, other types of autonomous mobile vehicles 102 may be used. For example, autonomous mobile vehicles 102 may be provided without cooperating manipulators 400 and / or platform assembly 300. Autonomous mobile vehicles 102 may alternatively be manually loaded and unloaded at various machines.

[0023] Figure 2 1 is a top perspective view of a system control module 110 according to an exemplary embodiment. The system control module 110 holds a plurality of system components. In various embodiments, the system control module 110 includes one or more substrates 150, such as circuit boards, for the system components. The system control module 110 may include one or more connectors 152 that are coupled to the substrate 150 to establish an electrical connection with the system control module 110. The connector 152 may be a power connector and / or a data communication connector. Power lines and / or data communication lines may extend from the connector 152. The system control module 110 may include one or more I / O modules 154 coupled to the substrate 150. The I / O modules 154 may be electrically connected to other components of the autonomous mobile vehicle system 100, such as the machine 106 ( Figure 1In various other embodiments, the system control module 110 may communicate with the machine 106 via wireless data communications rather than via hard wiring.

[0024] The system control module 110 includes a communication module 160 coupled to the base plate 150. The communication module 160 is configured to communicate wirelessly with other components of the autonomous mobile vehicle system 100, such as the autonomous mobile vehicle 102 ( Figure 1 shown) and / or system control module 110 ( Figure 1 ) and / or machine 106. The communication module 160 is capable of sending and receiving signals. In an exemplary embodiment, the communication module 160 is electrically connected to an antenna 162, such as an omnidirectional antenna. The communication module 160 is configured to communicate via one or more wireless networking protocols, such as a Wi-Fi communication protocol. The communication module 160 may use other wireless forms of communication, such as cellular data communications. In various embodiments, the communication module 160 communicates with the autonomous mobile vehicle 102 and other components within the system 100 via the Modbus TCP protocol; however, in alternative embodiments, the communication module 160 may communicate via other communication protocols.

[0025] In an exemplary embodiment, the system control module 110 includes a system controller 170 for processing control schemes for the autonomous mobile vehicle system 100. The system controller 170 receives inputs from the operator station 112, the machine 106, the docking station 114, and the autonomous mobile vehicle 102, and generates outputs to the operator station 112, the machine 106, the docking station 114, and the autonomous mobile vehicle 102. The system controller 170 guides the autonomous mobile vehicle 102 between the various machines 106 and the docking station 114 within the autonomous mobile vehicle system 100. For example, the system controller 170 may receive inputs from the machine 106 requesting a part pick-up or a part delivery. The system controller 170 determines which autonomous mobile vehicle 102 will perform various tasks and provides guidance and / or route planning to the autonomous mobile vehicles 102 within the logistics facility 104 according to the control scheme to pick up parts and / or drop off parts. The inputs and outputs are received and / or sent via the I / O module 154 and / or the communication module 160.

[0026] The system controller 170 includes electronic components, such as one or more processors 180, memory, etc., for data processing and controlling components of the autonomous mobile vehicle system 100. In an exemplary embodiment, the system controller 170 includes logic software that receives input, prioritizes requests from machines 106, sends control signals to the autonomous vehicle 102, receives location and task information from the autonomous vehicle 102, prioritizes control functions of the autonomous mobile vehicle 102, sends confirmation signals to the machine 106 and / or the autonomous mobile vehicle 102, etc. The system controller 170 can continuously monitor input requests from the machine 106. The system controller 170 sends pick-up and delivery requests to the autonomous mobile vehicle 102 based on the priority assigned to the machine 106. When the autonomous mobile vehicle 102 completes the pick-up and drop-off task, the system controller 170 sends a confirmation signal to the machine 106.

[0027] In an exemplary embodiment, the system control module 110 includes a human machine interface (HMI) 172 that is communicatively coupled to the system controller 170 and / or the communication module 160. The HMI 172 may provide a log or status of inputs and outputs to and from the system control module 110 for a user to view. The HMI 172 receives inputs from an operator of the system control module 110. The HMI 172 includes a display 174 and an input 176. For example, the input 176 may be a button, a dial, a keypad, a keyboard, etc. Alternatively, the display 174 may be a touch screen with digital inputs on the display 174. In an exemplary embodiment, the HMI is a remote control device that is removable from the system control module 110. In various embodiments, a user may connect to and / or monitor one or more autonomous mobile vehicles 102 via the HMI 172. A user may remotely control the autonomous mobile vehicles 102 through the HMI 172.

[0028] Figure 3 is a front perspective view of autonomous mobile vehicle 102 according to an exemplary embodiment. Figure 3 The platform assembly 300 is shown mounted to the AGV 200 , and the cooperating manipulator 400 is shown mounted to the platform assembly 300 .

[0029] 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 AGV 200 includes a battery 216 that is coupled to the motor 212 to power the motor 212. In an exemplary embodiment, the AGV 200 includes an AGV controller 202 for controlling 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 is communicatively coupled to the system control module 110 (e.g., Figure 1 ) to receive control signals for operating the AGV 200. For example, the AGV controller 202 may receive route information to guide the AGV 200 along a particular path (e.g., between the docking station 114 and the machine 106). Figure 1 AGV controller 202 may receive information instructing AGV 200 to stop, move forward, move backward, and / or turn right or left to control the movement of AGV 200.

[0030] The AGV controller 202 includes electronic components, such as one or more processors, memory, etc., for data processing and control of components of the AGV 200. In an exemplary embodiment, the AGV controller 202 includes logic software that receives input, receives location and task information, maps routes between locations, plans movements, prioritizes requests, prioritizes control functions, sends confirmation signals, etc. The AGV controller 202 may receive input from the system controller 170 or other components.

[0031] The platform assembly 300 includes a frame 310 having walls 312 surrounding 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 platform assembly 300 moves with the AGV 200. In an exemplary embodiment, the platform assembly 300 includes an emergency stop button 306 on one of the walls 312, which can be used to stop the operation of the AGV 200 and / or the cooperative manipulator 400. Optionally, one or more of the walls 312 may include vents for circulating air through the cavity 314.

[0032] The platform assembly 300 includes a support plate 320 at the top 316. The support plate 320 supports the cooperative manipulator 400. For example, the cooperative manipulator 400 can be directly mounted to the support plate 320, such as using fasteners. In an exemplary embodiment, the support plate 320 includes a plurality of mounting locations for mounting the cooperative manipulator 400 at different locations on the support plate 320 and / or for mounting different types of cooperative manipulators on the support plate 320. For example, the support plate 320 can include different hole patterns at different mounting locations for receiving different types of cooperative manipulators 400. In an exemplary embodiment, the platform assembly 300 includes a part holder 322 at the top of the support plate 320. The part holder 322 may include a track or a wall that forms a space to receive and hold parts on the support plate 320 during transportation (e.g., between machines 106). In the illustrated embodiment, the part holder 322 is located near the front 324 of the platform assembly 300. However, the part holder 322 may be located in other locations, such as near a rear 326 of the platform assembly 300 and / or a side 328 of the platform assembly 300 .

[0033] In an exemplary embodiment, the collaborative manipulator 400 includes a mounting base 410 that is mounted to the support plate 320, for example, using fasteners. In the illustrated embodiment, the collaborative manipulator 400 is mounted proximate to the rear 326 of the platform assembly 300. In alternative embodiments, other mounting locations are also possible. The mounting base 410 fixes the collaborative manipulator 400 relative to the platform assembly 300. In an exemplary embodiment, the collaborative manipulator 400 includes an arm 412 and a gripper 414 at the end of the arm 412, which is used to pick up parts and move 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. Other types of robotic arms can be used in alternative embodiments. In other various embodiments, other types of part manipulators can be utilized in addition to the gripper 414 and / or the arm 412. For example, the collaborative manipulator 400 can include a conveyor, a stack indicator, or other types of manipulators.

[0034] In an exemplary embodiment, the platform assembly 300 includes a remote control device 340 that can be removably coupled to the frame 310. The remote control device 340 defines a human-machine interface for the platform assembly 300, such as for controlling the AGV 200 and / or the collaborative manipulator 400 (both in FIG. Figure 3102). Remote control device 340 may be communicatively coupled to AGV controller 202 and / or collaborative manipulator controller 402. Remote control device 340 receives input from an operator to monitor and / or control autonomous mobile vehicle 102. In an exemplary embodiment, remote control device 340 is communicatively coupled to system control module 110 and / or operator station 112 (both at Figure 1 340 to remotely monitor and / or control autonomous mobile vehicle 102 via remote control device 340. In an exemplary embodiment, remote control device 340 includes display 344 and input 346 for receiving input directly from an operator. For example, input 346 may be a button, a dial, a keypad, a keyboard, etc. Alternatively, display 344 may be a touch screen with digital input on display 344. In various embodiments, remote control device 340 may be a tablet computer.

[0035] The cooperative controller 402 includes a communication module 350 configured to communicate wirelessly with other components of the autonomous mobile vehicle system 100, such as the system control module 110 ( Figure 1 The communication module 160 (shown) Figure 1 shown) and / or operator station 112 ( Figure 1 ) and / or remote control device 340. In an exemplary embodiment, communication module 350 includes an antenna, such as an omnidirectional antenna. Communication module 350 is configured to communicate via one or more wireless networking protocols, such as a Wi-Fi communication protocol. Communication module 350 may use other wireless forms of communication, such as cellular data communications. Control signals received at communication module 350 are used to control collaborative manipulator 400, such as to move arm 412 and / or gripper 414.

[0036] The collaborative controller 402 includes electronic components, such as one or more processors, memory, etc., for data processing and controlling components of the collaborative manipulator 400. In an exemplary embodiment, the collaborative controller 402 includes logic software that receives inputs, receives position and task information, prioritizes requests, plans movements, prioritizes control functions, sends confirmation signals, etc.

[0037] Figure 41 is a flow chart illustrating a method of operating a system control module 110 to control (multiple) autonomous mobile vehicles 102 between machines 106 of a logistics facility 104. In various embodiments, the method is used to control the movement of one or more autonomous mobile vehicles 102 between machines 106. In various embodiments, the method is used to prioritize requests from machines 106 and control autonomous mobile vehicles 102 between machines 106. In various embodiments, the method is used to plan and control the operation of the autonomous mobile vehicle system 100 to optimize the production of the logistics facility 104.

[0038] At 450, the method includes determining a completion time of a machine process for a first machine in machines 106. The completion time may be based on a start time of the machine process. In an exemplary embodiment, system control module 110 includes system controller 170, which includes one or more processors 180 configured to determine a completion time of a machine process for a first machine in machines 106. At 452, the method includes determining a travel time of autonomous mobile vehicle 102 to the first machine. The travel time is based on a position of autonomous mobile vehicle 102 relative to the first machine. For example, the travel time may be based on a travel distance along a particular route to the first machine. In an exemplary embodiment, system control module 110 includes system controller 170, which includes one or more processors 180 configured to determine a travel time of autonomous mobile vehicle 102 to the first machine.

[0039] At 454, the method includes sending a request to the autonomous mobile vehicle 102 based on the completion time of the machine process of the first machine and based on the travel time of the autonomous mobile vehicle 102 to the first machine. The request may be placed in a queue of the autonomous mobile vehicle 102. In an exemplary embodiment, the request is sent when the completion time of the first machine is less than the travel time of the autonomous mobile vehicle 102 to the first machine. The request may be sent only when the autonomous mobile vehicle 102 is available, such as when the autonomous mobile vehicle 102 is fully charged. The request may be sent to a plurality of autonomous mobile vehicles 102, and the request may be accepted by the autonomous mobile vehicle 102 having the shortest travel time or the shortest fulfillment time based on the task queue of the autonomous mobile vehicle 102. In an exemplary embodiment, the system control module 110 includes a system controller 170, and the system controller 170 includes one or more processors 180, and the processor 180 is configured to send the request to the autonomous mobile vehicle 102 and place the request in a queue of the autonomous mobile vehicle 102 based on the completion time of the machine process of the first machine and the travel time of the autonomous mobile vehicle 102 to the first machine.

[0040] At 456, the method includes determining whether the request from the first machine has a higher priority than other requests in the queue. In an exemplary embodiment, if the request from the first machine has a higher priority, autonomous mobile vehicle 102 is sent to the first machine. If the request from the first machine has a lower priority, autonomous mobile vehicle 102 places the request in a queue. In an exemplary embodiment, system control module 110 includes system controller 170, system controller 170 includes one or more processors 180, processor 180 is configured to determine whether the request from the first machine has a higher priority than other requests in the queue, wherein if the request from the first machine has a higher priority, system controller 170 sends autonomous mobile vehicle 102 to the first machine.

[0041] At 458, the method includes determining whether the request from the first machine has a shorter estimated time to complete than requests from other machines. In an exemplary embodiment, if the request from the first machine has a shorter time to complete, the autonomous mobile vehicle is sent to the first machine. If the request from the first machine does not have a shorter time to complete, the autonomous mobile vehicle is sent to the machine with the shortest time to complete. In an exemplary embodiment, system control module 110 includes system controller 170, which includes one or more processors 180, which are configured to determine whether the request from the first machine has a shorter estimated time to complete than requests from other machines, wherein if the request from the first machine has a shorter time to complete, the system controller 170 sends autonomous mobile vehicle 102 to the first machine, and if the request from the first machine does not have a shorter time to complete, the system controller 170 sends autonomous mobile vehicle 102 to the machine with the shortest time to complete.

[0042] At 460, the method includes determining a completion time of a machine process for a second machine in machines 106. The completion time may be based on a start time of the machine process. At 462, the method includes determining a travel time for autonomous mobile vehicle 102 to the second machine. The travel time is based on a position of autonomous mobile vehicle 102 relative to the second machine. For example, the travel time may be based on a travel distance along a particular route to the second machine. Steps 460, 462 may occur before or after steps 450, 452, or may occur simultaneously with steps 450, 452.

[0043] At 464, the method includes sending a request to the autonomous mobile vehicle 102 based on the completion time of the machine processing of the second machine and based on the travel time of the autonomous mobile vehicle 102 to the second machine. The request may be placed in a queue of the autonomous mobile vehicles 102. In an exemplary embodiment, the request is sent when the completion time of the second machine is less than the travel time of the autonomous mobile vehicle 102 to the second machine. The request may be sent only when the autonomous mobile vehicle 102 is available, such as when the autonomous mobile vehicle 102 is fully charged. The request may be sent to a plurality of autonomous mobile vehicles 102, and the request may be accepted by the autonomous mobile vehicle 102 having the shortest travel time or the shortest fulfillment time based on the task queue of the autonomous mobile vehicles 102.

[0044] At 466, the method includes determining whether the request from the second machine has a higher priority than other requests in the queue. In an exemplary embodiment, if the request from the second machine has a higher priority, autonomous mobile vehicle 102 is sent to the second machine. If the request from the second machine has a lower priority, autonomous mobile vehicle 102 places the request in the queue.

[0045] At 468, the method includes determining whether the request from the second machine has a shorter estimated time to completion than requests from other machines, such as the first machine or other machines. In an exemplary embodiment, if the request from the second machine has a shorter time to completion, autonomous mobile vehicle 102 is sent to the second machine. If the request from the second machine does not have a shorter time to completion, the autonomous mobile vehicle is sent to the machine with the shortest time to completion.

[0046] Figure 5 is a flow chart of a method of operating autonomous mobile vehicle 102 according to an exemplary embodiment. System control module 110 may perform one or more of various steps to complete Figure 4 In various embodiments, the method is used to control the movement of one or more autonomous mobile vehicles 102 between machines 106. In various embodiments, the method is used to prioritize requests from machines 106 and control autonomous mobile vehicles 102 between machines 106. In various embodiments, the method is used to plan and control the operation of the autonomous mobile vehicle system 100 to optimize the production of the logistics facility 104.

[0047] In 502, the system control module 110 initiates a control operation. For example, the system control module 110 may initiate a control operation when the machine 106 is started, or the system control module 110 may initiate a control operation at a predetermined time (e.g., periodically). In 504, the system control module 110 determines a completion time for the machine 106. For example, the completion time may be based on a start time of a machine process. In 506, the system control module 110 determines whether the estimated completion time is longer than a drive time from the autonomous mobile vehicle 102 to the machine 106. If the estimated completion time is longer than the drive time, the system control module 110 enters a feedback loop to return to step 504. If the estimated completion time is shorter than the drive time, the control operation continues to step 508.

[0048] In 508, the system control module 110 issues a request for processing, such as for part picking. The request may be sent from the system control module 110, or may be sent from the machine 106. In 510, the system control module 110 determines if any autonomous mobile vehicle 102 is available. If no autonomous mobile vehicle 102 is available, the system control module 110 enters a feedback loop in 512 and waits from the next available autonomous mobile vehicle 102. When an autonomous mobile vehicle 102 is available, in 514, the system control module 110 sends a request to the autonomous mobile vehicle 102. In 516, the autonomous mobile vehicle 102 receives the request and adds the request to a queue.

[0049] At 518, system control module 110 determines whether there are any other requests in the queue of autonomous mobile vehicles 102. Such a determination may be made by system controller 170 or by a controller on autonomous mobile vehicle 102 (e.g., AGV controller 202 or collaborative manipulator controller 402). If there are no other requests in the queue, control continues to step 520. At 520, autonomous mobile vehicle 102 is sent to machine 106.

[0050] At 518, if there are other requests in the queue, control continues to step 522. At 522, system control module 110 determines whether the current request has a higher priority than the other requests in the queue. If the current request has the highest priority, control continues to step 520 and autonomous mobile vehicle 102 is sent to the machine. If the current request does not have a higher priority, control continues to step 524.

[0051] At 524, system control module 110 determines the estimated completion time from the other machines 106. At 526, system control module 110 determines whether the estimated completion time of the current request is shorter than the estimated completion time from the other machines 106. If the estimated completion time of the current request is shorter than the estimated completion time of the other machines, control continues to step 520 and autonomous mobile vehicle 102 is sent to the machine. If the estimated completion time of the current request is longer than the estimated completion time of the other machines, control continues to step 528. At 528, autonomous mobile vehicle 102 is sent to the machine with the shortest completion time.

[0052] Figure 6 is a schematic diagram of an autonomous mobile vehicle system 100 used in a first layout of a logistics facility 104 according to an exemplary embodiment. Figure 7 is a schematic diagram of autonomous mobile vehicle system 100 used in a second configuration of logistics facility 104 that is different than the first configuration. Figure 8 is a schematic diagram of an automated moving vehicle system 100 for use in a third configuration of a logistics facility 104 that is different than the first and second configurations. Figure 6 , 7 8 show various machines 106 with various layouts. For example, in the illustrated embodiment, the machines 106 include a docking station 114, various processing machines 115 (e.g., a lathe) for forming parts, a tumbler 116, a cleaning station 117, and an inspection station 118. During the manufacturing process, parts are formed by the processing machines 115, and the formed parts are then transported to the tumbler 116 for final processing and then transported to the cleaning station 117 and the inspection station 118. Because the tumbler 116 receives parts from all of the various processing machines in different batches, the tumbler 116 is a critical machine that forms a bottleneck in the production volume of parts during manufacturing. The workflow to and from the critical machines (e.g., the tumbler 116) is important and can therefore be prioritized. Figure 7 Shown with Figure 6 Compared to the docking station 114 at the improved position, the utilization rate of the autonomous mobile vehicle 102 is improved. Figure 7 In the layout shown, Figure 6 The docking station 114 is located closer to the handler 115 and closer to the diverter 116 than in the illustrated arrangement. Figure 8 Shown with Figure 6 and Figure 7 Compared to one of machines 106 (e.g., steering machine 116) in an improved position, the utilization of autonomous mobile vehicle 102 can be improved. Figure 8 In the layout shown, Figure 6 and Figure 7Compared to the illustrated arrangement, the diverter 115 is closer to the docking station 114 and closer to the cleaning station 117 .

[0053] In an exemplary embodiment, the autonomous mobile vehicle system 100 includes a planning module, such as at the operator station 112 ( Figure 1 104). The planning module is configured to simulate various layouts of the logistics facility 104. For example, the planning module may allow an operator to simulate different locations of one or more machines 106 to determine the utilization of the autonomous mobile vehicles 102 based on the simulated layout. The planning module may be used to determine different utilizations of the autonomous mobile vehicles 102 based on the number of autonomous mobile vehicles 102 utilized. The planning module may be used to determine the appropriate number of autonomous mobile vehicles 102 to be used within a given layout based on the determined utilization of the autonomous mobile vehicles 102.

[0054] The planning module determines the distances between the various machines along a predetermined route or path. The planning module determines the travel time of the autonomous mobile vehicle 102 between the various machines 106. The planning module determines the completion time of the various machine processes of the various machines. The planning module determines the processing time of the autonomous mobile vehicle 102 at the various machines 106, such as the loading time or unloading time of the parts. The planning module determines the priority arrangement of the processing tasks. The planning module determines the utilization of the autonomous mobile vehicle 102 based on the simulated workflow. In an exemplary embodiment, the simulated workflow is within a predetermined time period, such as a 24-hour time period. The planning module compares the utilization of the autonomous mobile vehicle 102 based on various layouts to determine which facility layout has the highest utilization to plan the optimal facility layout.

[0055] Fig. 9 1 is a flow chart illustrating a method for planning the operation of (multiple) autonomous mobile vehicles 102 between machines 106 of a logistics facility 104. The method may be executed by a system control module 110 as a planning tool. In various embodiments, the method is used to determine the utilization of autonomous mobile vehicles 102 in various different layouts of a logistics facility 104. The method may be used to determine the appropriate number of autonomous mobile vehicles 102 to be used within a given layout based on the determined utilization of autonomous mobile vehicles 102. The method may be used to plan an optimized logistics facility layout.

[0056] In 600, the method includes determining a first completion time for machine processing of a machine in a first simulated logistics facility layout, in which, for example: the docking station 114 is placed in a first simulated position, the diverter 116 is placed in a first simulated position, the processing machine 115 is placed in a first simulated position, etc. The completion time can be based on the average time to complete a specific task. For example, each processing machine 115 can have a predetermined completion time based on the type of parts being manufactured, the number of parts being manufactured in each batch, etc. Each processing machine 115 can have a different average completion time (for example, one or more machines can manufacture 15 parts per part in 7 minutes, with a total completion time of 105 minutes, one or more other machines can manufacture 50 parts per part in 6 minutes, with a total completion time of 300 minutes, etc.). The processing machine 115 can operate in parallel, each operating at the same time and having overlapping completion times. The processing machine 115 can have a storage area that allows part storage, so that the autonomous mobile vehicle 102 does not need to pick up the parts just when the processing machine is processing the next batch of parts. In various embodiments, the diverter 116 can have an average completion time of approximately 10 minutes. The cleaning station 117 may have an average completion time of approximately 8 minutes. The inspection station 118 may have an average completion time of approximately 6 minutes. In various embodiments, the turner 116 may be the critical processing machine because it has the longest average completion time in the inline portion of the manufacturing operation. However, in alternative embodiments, the cleaning station 117 or the inspection station 118 may have a longer average completion time, resulting in the cleaning station 117 or the inspection station being the critical processing machine.

[0057] In 602, the method includes determining a first total driving distance of the autonomous mobile vehicle 102 using the machine 106 in the first simulated logistics facility layout. The total driving distance can be based on the number of trips made by the autonomous mobile vehicle 102 between each of the various machines 106 within a predetermined amount of time, such as within a 24-hour period. The total driving distance is based on the location of the machine 106 within the simulated logistics facility layout. The total driving distance is based on the priority arrangement of performing processing within a predetermined time period (e.g., within a 24-hour period). The total driving distance is based on the location of the docking station 114 within the layout, because the autonomous mobile vehicle 102 can return to the docking station when charging is required or when the autonomous mobile vehicle 102 is idle (e.g., when there are no tasks in the queue).

[0058] At 604, the method includes determining a first travel time for the autonomous mobile vehicle 102 when the machines 106 are in the first simulated logistics facility layout. The travel time is based on a travel distance between the machines 106. The travel time is based on a speed of the autonomous mobile vehicle 102.

[0059] In 606, the method includes determining a first docking time of the autonomous mobile vehicle 102 in the docking station 114 in the first simulated logistics facility layout. The first docking time is the total time spent in the docking station 114 within a predetermined time period (e.g., a 24-hour time period). The first docking time is based on priority scheduling, and therefore based on the order in which the processing is performed within the predetermined time period (e.g., a 24-hour time period). The first docking time is based on the location of the machine 106, and therefore based on the travel time to return to the docking station 114 for each docking action. The planning module is able to determine whether sufficient charging time is provided for the autonomous mobile vehicle 102 within 24 hours. For example, in various embodiments, the autonomous mobile vehicle 102 may require approximately 50% of the charging time relative to the use time. In various other embodiments, the autonomous mobile vehicle 102 may require less charging time, such as 25% of the charging time with 75% of the use time. If insufficient charging time is allowed based on the layout, the planning module can determine that a specific layout requires additional autonomous mobile vehicles 102.

[0060] At 608, the method includes determining a utilization rate of a first autonomous mobile vehicle in a first simulated logistics facility layout. The utilization rate may be based on completion time, travel time, docking time, etc. The utilization rate may be based on processing time of the autonomous mobile vehicle 102 on various machines, such as loading time or unloading time. The utilization rate may be the percentage of time that the autonomous mobile vehicle 102 is used to perform a task. The utilization rate may be the inverse of the docking time.

[0061] In 700, the method includes determining a second completion time for a machine process of the machine 106 in a second simulated logistics facility layout, in which, for example, the docking station 114 is placed in a second simulated position, the diverter 116 is placed in a second simulated position, the processing machine 115 is placed in a second simulated position, etc. Some positions may be the same as those in the first layout. For example, the position of the docking station 114 may be different, or the position of the diverter 116 may be different, or the position of another machine may be different. The completion time may be based on an average time to complete a particular task.

[0062] At 702, the method includes determining a second total travel distance of the autonomous mobile vehicle 102 while the machine 106 is in a second simulated logistics facility layout. The total travel distance may be based on the number of trips made by the autonomous mobile vehicle 102 between each of the various machines 106 within a predetermined amount of time, such as within a 24-hour period. The total travel distance is based on the location of the machine 106 within the simulated logistics facility layout. The total travel distance is based on a priority schedule for performing processing within a predetermined time period (e.g., within a 24-hour period). The total travel distance is based on the location of the docking station 114 within the layout, because the autonomous mobile vehicle 102 can return to the docking station when charging is required or when the autonomous mobile vehicle 102 is idle (e.g., when there are no tasks in the queue).

[0063] At 704, the method includes determining a second travel time for the autonomous mobile vehicle 102 while the machines 106 are in the second simulated logistics facility layout. The travel time is based on a travel distance between the machines 106. The travel time is based on a speed of the autonomous mobile vehicle 102.

[0064] At 706, the method includes determining a second docking time of the autonomous mobile vehicle 102 in the docking station 114 in the second simulated logistics facility layout. The second docking time is the total time spent in the docking station 114 within a predetermined time period (e.g., a 24-hour time period). The second docking time is based on the priority schedule, and therefore based on the order in which the processes are performed within the predetermined time period (e.g., a 24-hour time period). The second docking time is based on the location of the machine 106, and therefore based on the travel time to return to the docking station 114 for each docking action.

[0065] At 708, the method includes determining a second autonomous mobile vehicle utilization rate in a second simulated logistics facility layout. The utilization rate may be based on completion time, travel time, docking time, etc. The utilization rate may be based on the processing time of the autonomous mobile vehicle 102 on various machines, such as loading time or unloading time. The utilization rate may be the percentage of time that the autonomous mobile vehicle 102 is used to perform a task. The utilization rate may be the inverse of the docking time.

[0066] In 800, the method includes comparing the utilization of the first autonomous mobile vehicle and the utilization of the second autonomous mobile vehicle. The planning module can determine which utilization is the highest and which utilization is the lowest. The planning module can determine that the logistics facility layout with a lower utilization is the best (between the selected number) because the lower utilization corresponds to the autonomous mobile vehicle 102 with less usage to perform tasks. In this way, in the logistics facility layout with a lower utilization, the autonomous mobile vehicle 102 can have more charging time. In a layout where the docking station 114 is located closer to a key processing machine (e.g., a steering machine 116), the utilization may be lower because less time is spent between the docking station 114 and the key processing machine. In a layout where the docking station 114 is positioned closer to a large number of machines 106, the utilization may be lower. For example, if the machines 106 are gathered in one area, it may be beneficial to position the docking station 114 near the area.

[0067] Fig.10 is a graph illustrating utilization of a suboptimal logistics facility layout according to an exemplary embodiment. Fig.11 is a diagram showing an optimal logistics facility layout according to an exemplary embodiment (e.g., Fig.10 Graphs of utilization of the layout shown compared to an improved layout). The terms "optimal" and "suboptimal" are used as relative terms for comparison. For example, there may be other logistics facility layouts that were not simulated but would result in improved utilization. These graphs illustrate the utilization of various facility layouts and are compared to determine which facility layout has higher utilization. The graphs compare travel distance, travel time, idle time, etc. to determine utilization.

[0068] In the illustrated embodiment, corresponding to Fig.10 The logistics facility layout of the diagram in has a total of 12.4986 hours in docking station 114 and 11.5014 hours in operation, which corresponds to a utilization of 47.9224. In contrast, Fig.11 The total time that the logistics facility layout corresponding to the graph in FIG. 1 is in docking station 114 is 11.9604 hours, and the time in operation is 12.0396 hours, which corresponds to a utilization rate of 50.1652. Fig.11 The corresponding logistics facility layout in the chart increases utilization by 2% (47.9224 vs. 50.1652).

[0069] CROSS-REFERENCE TO RELATED APPLICATIONS

[0070] This application claims priority to U.S. Provisional Application No. 62 / 923,899, filed on October 21, 2019, entitled “AUTONOMOUS MOBILE VEHICLE AND METHOD OF OPERATING THE AUTONOMOUS MOBILE VEHICLE,” which is incorporated herein by reference in its entirety.

Claims

1. An autonomous mobile vehicle system (100), comprising: machines (106) for processing parts located at various locations within the facility (104); a docking station (114) within said facility; an autonomous mobile vehicle (102) capable of moving between the machine and the docking station within the facility; a system control module (110) for guiding the autonomous mobile vehicle between the machine and the docking station within the facility, the system control module comprising a system communication module (160) communicatively coupled to the autonomous mobile vehicle, the system control module comprising a system controller (170), the system controller comprising: one or more processors (180) configured to determine a completion time of a machine process of a first one of the machines; one or more processors configured to determine a travel time for the autonomous mobile vehicle to the first machine; one or more processors configured to send a request to the autonomous mobile vehicle and place the request in a queue of the autonomous mobile vehicle based on a completion time of a machine process of the first machine and a travel time of the autonomous mobile vehicle to the first machine; one or more processors configured to determine whether the request from the first machine has a higher priority than other requests in the queue, wherein the system controller sends the autonomous mobile vehicle to the first machine if the request from the first machine has a higher priority; one or more processors configured to determine whether the request from the first machine has a shorter estimated completion time than requests from other machines, wherein if the request from the first machine has a shorter completion time, the system controller sends the autonomous mobile vehicle to the first machine, and wherein if the request from the first machine does not have a shorter completion time, the system controller sends the autonomous mobile vehicle to the machine with the shortest completion time; and A planning module is provided for planning and improving the layout of the facility (104) and determining the required number of the autonomous mobile vehicles (102) required for the layout of the facility (104).

2. The autonomous mobile vehicle system (100) according to claim 1, wherein: The system controller (170) sends a request when the completion time of the first machine is less than the travel time of the autonomous mobile vehicle to the first machine.

3. The autonomous mobile vehicle system (100) according to claim 1, wherein: The system controller (170) includes one or more processors (180) configured to determine whether the autonomous mobile vehicle (102) is available, and if the autonomous mobile vehicle is available, the system controller sends a request.

4. The autonomous mobile vehicle system (100) according to claim 1, wherein: The system controller (170) includes one or more processors (180) configured to determine whether the autonomous mobile vehicle (102) is sufficiently charged.

5. The autonomous mobile vehicle system (100) according to claim 1, wherein: The system controller (170) includes one or more processors (180) configured to determine whether the autonomous mobile vehicle (102) has other requests in a queue, wherein if the autonomous mobile vehicle does not have other requests in the queue, the system controller sends the autonomous mobile vehicle to the first machine.

6. The autonomous mobile vehicle system (100) according to claim 1, wherein: The system controller (170) comprises: One or more processors (180) configured to determine a completion time of a machine process of a second one of the machines (106); one or more processors configured to determine a travel time from the autonomous mobile vehicle to the second machine; one or more processors configured to send a request to the autonomous mobile vehicle and place the request in a queue of the autonomous mobile vehicle based on a completion time of a machine process of the second machine and a travel time of the autonomous mobile vehicle to the second machine; one or more processors configured to determine whether the request from the second machine has a higher priority than other requests in the queue, wherein if the request from the second machine has a higher priority, sending the autonomous mobile vehicle to the second machine; and One or more processors configured to determine whether the request from the second machine has a shorter estimated completion time than requests from other machines, wherein if the request from the second machine has a shorter completion time, the autonomous mobile vehicle is sent to the second machine, and wherein if the request from the second machine does not have a shorter completion time, the autonomous mobile vehicle is sent to the machine with the shortest completion time.

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