Carrier

Abstract

A controller for an automated guided vehicle (AGV) is provided such that the AGV can operate in a semi-automatic mode when coupled to the AGV controller. In this semi-automatic mode, an operator can access all functions of the AGV through the AGV controller. The AGV controller can be detached from the AGV, and the AGV can be restored to automatic operation.

Description

[0001] The present disclosure relates to a vehicle, and more particularly to a semi - automatic guided vehicle that can operate in storage facilities such as warehouses or distribution centers. Background Art

[0002] There is a trend to use an Automated Storage and Retrieval System (ASRS) to provide goods to customers who order products online. The ASRS can be used to store products for subsequent packing and shipping to customers. An embodiment of such an ASRS is disclosed in the applicant's patent application WO2015 / 019055. By using a robotic picking arm (such as that disclosed in WO2023 / 285487), the level of automation within the ASRS can be increased. Another aspect of automation is the use of an automated vehicle, such as the automated vehicle disclosed in the applicant's co - pending application GB2217719.0, which relates to an automated pallet mover. It has been observed that the efficiency of such an automated vehicle can be reduced in situations where, for example, many pallets are closely stacked together (such as in a restricted space). Summary of the Invention

[0003] According to a first aspect of the present disclosure, there is provided a controller for an automated guided vehicle, the controller including a coupling portion configured to be coupled to the automated vehicle in use and an interface for controlling the operation of the automated vehicle. The controller may further include a roll device. The controller may include a drive device operable to actuate the roll device. The controller may further include a wireless network interface.

[0004] According to a second aspect of the present disclosure, there is provided a semi - automatic vehicle including an automated guided vehicle and a controller for the automated guided vehicle as described above, wherein the automated guided vehicle includes a hole configured to receive the coupling portion of the controller so that, in use, the controller interface is used to control the automated guided vehicle.

[0005] Providing such an AGV controller enables an operator to control the AGV so as to achieve more efficient vehicle operation in environments where it has been observed that the AGV may face difficulties, such as in restricted spaces where multiple pallets are closely arranged and / or located close to walls or other structures.

[0006] The automated guided vehicle may include a control system so that, in use, the control system responds to control signals generated by the controller interface. The automated guided vehicle may include a drive system so that, in use, the drive system is actuated in response to control signals generated by the controller interface. The automated guided vehicle may further include a fork - lift mechanism so that, in use, the fork - lift mechanism is actuated in response to control signals generated by the controller interface.

[0007] According to a third aspect of the present disclosure, a method for operating an automated guided vehicle within a storage facility is provided, the method comprising the steps of: a) coupling a controller for the automated guided vehicle to the automated guided vehicle to form a semi-automated vehicle; b) controlling the semi-automated vehicle to perform a task via the controller; c) decoupling the controller from the semi-automated vehicle; d) the automated guided vehicle automatically moving to a first predetermined position within the storage facility.

[0008] In step d), the automated guided vehicle may transport a load to the first predetermined position. The method may further comprise the step of: e) the automated guided vehicle placing the load at the first predetermined position and subsequently moving to a second predetermined position. In step b), the semi-automated vehicle may be controlled to move the semi-automated vehicle to a storage location to retrieve the load.

[0009] According to a fourth aspect of the present disclosure, a storage facility comprising a first zone and a second zone is provided, wherein the first zone is reserved for use by one or more automated guided vehicles, and the second zone is reserved for use by one or more controllers for automated guided vehicles and one or more semi-automated vehicles as described above.

[0010] Dividing the storage facility into such zones helps to separate the automated guided vehicles from human operators. Due to the reduced risk of collision with human operators, such separation may enable the automated guided vehicles to operate at higher speeds, thereby improving system efficiency. Such separation also keeps human operators safer and healthier.

[0011] A handover location may be defined adjacent to the first and second zones. The storage facility may include a physical barrier to separate the first zone from the second zone. The physical barrier may include one or more holes through which the automated guided vehicle or semi-automated vehicle may pass. The handover location may be defined adjacent to one or each of the barrier holes. The first zone may be connected to the second zone. Alternatively, the first zone may have an overlapping area with the second zone. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Further features of the present invention will be elucidated by the following detailed description of specific embodiments taken in conjunction with the drawings. Among them: Figure 1 A schematic diagram showing a controller for an automated guided vehicle approaching the automated guided vehicle is shown; Figure 2 A schematic diagram showing the automated guided vehicle when coupled to the controller is shown; Figure 3 A schematic diagram showing a further embodiment of a controller for an automated guided vehicle approaching the automated guided vehicle is shown; Figure 4 Shows Figure 3Schematic diagram of an automated guided vehicle when coupled to a controller; Figure 5 Schematic diagram showing a storage facility that can use an automated guided vehicle and a controller for an AGV; Figure 6 Schematic diagram showing a further embodiment of a storage facility that can use an automated guided vehicle and a controller for an AGV; Figure 7 Flowchart showing the operation of an automated guided vehicle with an AGV controller; Figure 8 Schematic diagram showing a first embodiment of an automatic pallet mover approaching a pallet; Figures 9(a) to 9(g) are Figure 8 schematic diagrams of an automatic pallet mover; Figure 10 Schematic diagram of a second embodiment of an automatic pallet mover; Figures 11(a) to 11(c) are Figure 10 schematic diagrams of an automatic pallet mover; Figure 12 Block diagram showing the main components of an automatic pallet mover; Figure 13 Flowchart showing an embodiment of the steps performed by an automatic pallet mover when engaging with a pallet; and Figure 14 (a) to 14(e) are schematic diagrams showing the steps performed by an automatic pallet mover according to a second embodiment. Detailed Description

[0013] Figure 1 Schematic diagram showing a controller 200 for an automated guided vehicle 1. In Figure 1 the embodiment shown, the automated guided vehicle (hereinafter referred to as AGV) includes a plurality of forks 4 and is designed to lift and move a pallet 20. As will be discussed below, the exact type of AGV is not critical to this disclosure. The AGV 1 is capable of sliding a plurality of forks 4 into the body of the pallet 20, lifting the pallet, moving the pallet to a specific location, and placing the pallet at that location. The structure and function of the AGV are described below with reference to Figures 8 to 14 description of the AGV.

[0014] The AGV additionally includes a hole 50 configured to engage with a coupling portion 220 of the AGV controller 200. The AGV controller 200 further includes an interface 210 and a roll device 230. In operation, the AGV controller can be manually maneuvered to a position adjacent to the AGV, and the coupling portion 220 of the AGV controller can be inserted into the AGV hole 50. The coupling of the AGV controller to the AGV overrides the automatic functions of the AGV, enabling an operator to operate the AGV through manipulation of the controller interface 210. For ease of operation, the controller interface can be similar to the interfaces of conventional manual vehicles such as carts or pallet lifters that can be seen in storage facilities. When coupled together, the AGV and the AGV controller can be regarded as a semi-automatic guided vehicle 201 (hereinafter referred to as SAGV).

[0015] In Figure 1 and Figure 2 the illustrated embodiment, the controller interface includes a joystick 212 and a plurality of triggers 214. Figure 3 and Figure 4 A second embodiment of the AGV controller is shown, where the AGV interface 210 includes a steering wheel 216. It should be understood that the AGV interface 210 can include further controls, actuators, etc. These can be physical controls such as switches, tuning knobs, etc., and / or can include graphical user interface elements on a touch screen that can be selected and / or activated by an operator.

[0016] Figure 5 A schematic diagram of a storage facility 400 is shown, where AGV 1, AGV controller 200, and SAGV 201 are used to transport pallets. The storage facility includes a manual operation area 410, an automatic operation area 420, and a plurality of storage areas 430. The plurality of storage areas 430 can be located within the manual operation area 410, or alternatively, the plurality of storage areas 430 can be adjacent to the manual operation area 410 to enable access to the plurality of storage areas from the manual operation area.

[0017] From Figure 5It can be seen that there is an overlapping part between the manual operation area 410 and the automatic operation area 420. It should be understood that in an alternative configuration, the manual operation area and the automatic operation area can be connected. In use, the central computing system 450 instructs one of the plurality of AGVs 1 to move from its current position (which may be within the automatic operation area) to a position within the manual area. In one embodiment, the AGV will move to the edge of the manual area so that the operator can move the AGV controller to a position adjacent to the AGV. The AGV controller can then cooperate with the AGV to form a SAGV. The operator can then move the SAGV to one of the plurality of storage areas and manipulate the SAGV to lift and retrieve the pallet stored in the storage area.

[0018] The operator can then move the SAGV to the automatic operation area and disconnect the AGV controller from the AGV. The AGV can then perform one or more automatic actions. For example, the central computing system can transfer the position in the automatic operation area to the AGV. The AGV will then automatically move to this position. This position can be adjacent to one of the plurality of stations 422 located in the automatic operation area. The station can be a tipping station for unloading product items from the pallet so that they can be introduced into the automated storage and retrieval system. This tipping function can be performed by a human operator, a robotic picking arm, or both in cooperation. Once all the product items have been removed from the pallet, the AGV can place the empty pallet at the pallet storage location. Once the AGV has placed the pallet, it can return to the manual area so that the AGV can be attached to more AGV controllers to complete more tasks.

[0019] In an alternative arrangement, the AGV can place the loaded pallet near one of the plurality of stations 422 and then return to the manual area to complete more tasks as a SAGV. Another AGV can automatically retrieve the empty pallet from a position near one of the plurality of stations and then place it at the pallet storage location.

[0020] In use, the central computing system can instruct one of the plurality of AGVs to move to one of a number of predetermined handover positions so that the operator can couple the AGV controller to this AGV. Similarly, the central computing system can send a message to the operator to instruct the operator to move to one of the handover positions where the AGV may be waiting to be coupled to the AGV controller. Once the SAGV has been loaded with a pallet from a truck trailer, the operator can move the SAGV to the nearest handover position and then remove the AGV controller, causing the AGV to alternate to automatic operation. In an alternative scenario, the central computing system can send an instruction to the operator to instruct the operator to move the SAGV to a designated handover position and then remove the AGV controller from the AGV.

[0021] Figure 6 shows a schematic diagram of a further embodiment of the storage facility described above with reference to Figure 5 In this embodiment, a plurality of storage areas 430 include a plurality of truck trailers. The truck trailers typically contain a plurality of closely stacked pallets, each pallet storing boxes or containers of product items. It has been found that due to the close stacking of the pallets and the limited space inside the truck trailers, it is difficult for an AGV to efficiently remove the pallets from such positions. Figure 6 Also depicted is the use of a physical barrier 415, which provides a separation between the manual operation area and the automatic operation area. The physical barrier 415 may include a gap 417 through which the AGV can pass. One or more than one predetermined handover location may be defined at or near the barrier gap 417.

[0022] Figure 7 shows a flow chart, where in step S700, an AGV controller is attached to the AGV to form an SAGV. Subsequently, before the SAGV is moved to the automatic zone (S720), the SAGV is used to perform a task (S710, such as retrieving a load from a storage location). The operator then detaches the AGV controller, returning the AGV to autonomous operation. Subsequently, before returning to the manual zone (S750), the AGV will automatically perform a task (S740, such as moving a pallet to a station for dumping operations). Once the AGV has returned to the manual zone, it can be attached to the controller, causing the method to return to step S700. It should be understood that the AGV can repeat this method multiple times until there are no more loads in the storage area. If the AGV determines that its battery level is insufficient to perform the next iteration of the method, the AGV can pause the implementation of the method after step S740. The AGV can then move to a charging station and resume execution of the method from step S750 after it is fully charged (or reaches an appropriate level of charge).

[0023] Figures 1 to 4The AGV controller shown can take a variety of forms. For example, the AGV controller can be unpowered, such that an operator must manually move the SAGV. In an alternative, the connection between the AGV controller and the AGV can enable the control system of the AGV to actuate the drive assembly and / or the forklift mechanism of the AGV in response to an action by the operator on the AGV interface 210. Additionally, or as a further alternative, the AGV controller can include a drive device (such as one or more electric motors) for driving the roll device 230 of the AGV controller, such that the roll device assists or replaces the manual labor of the operator. The AGV controller can include a power source (such as a battery), or the power for the drive device of the AGV controller can be supplied by the AGV. The AGV controller can include a platform 250 on which an operator can stand when operating the SAGV (or when the AGV controller is capable of driving the movement). When the AGV controller is manually moved, the platform 250 can be folded up so as not to be in the way (for example, folded to a vertical orientation, as Figure 4 shown).

[0024] The coupling between the AGV controller and the AGV can be only a mechanical coupling. As an alternative, the coupling can be an electromechanical coupling, such that manipulation of the AGV controller interface 210 by the operator causes one or more drive assemblies, forklift mechanisms, or other subsystems of the AGV to be actuated. If the coupling is only a mechanical coupling, a wireless connection can be established between the AGV controller and the AGV, such that movement of the AGV controller causes elements of the AGV to be actuated. The AGV elements can be directly controlled by the AGV controller interface, or the movement of the AGV controller interface can be an input to the AGV control elements, which then control the AGV elements accordingly. The AGV controller can include a display screen, which can be used to provide feedback to the operator regarding the status and operation of the AGV controller (or regarding the SAGV when the AGV controller is attached to the AGV). The display screen can be used to display messages transmitted by a central computing system. It will be understood that in such a case, the AGV controller will include a wireless network interface (such as WiFi) in order to be able to communicate with the central computing system. Additionally, or as an alternative, messages can be sent to an operator device (such as a handheld device, smartwatch, etc.) to indicate to the operator the destination of the AGV controller (or SAGV). The AGV controller can include mounting means for securing a handheld device (such as a smartphone or tablet) such that the operator can view the device while operating the AGV controller (or SAGV).

[0025] Figures 1 to 4An embodiment of the type of controller interface that can be used is shown. It should be understood that other forms of controller interfaces are also feasible. It is generally considered beneficial to make the controller interface very similar to the interface of a commonly used manual load carrier so that the operator can more efficiently transition from a traditional carrier to the SAGV of the present disclosure. It should be understood that in an alternative, the controller interface may include a trackball or a joystick as a substitute for the Figures 1 to 4 controller interface shown, or as a supplement to these controller interfaces. Additionally, or as a further alternative, an AGV controller display screen or a graphical user interface similar to a display screen can be used to provide part or all of the controller interface.

[0026] It should be understood that although the following discussion describes an AGV that moves pallets, it should be understood that the concept of an ABV controller that can be coupled to an AGV to provide a semi-automatic guided vehicle can be applied to various types of AGVs, regardless of their functions.

[0027] Figure 8 An embodiment of an automated guided vehicle 1 operating as an AGV is shown, which includes a body 2. The body 2 includes a drive assembly (not shown) for moving the AGV on the floor, a steering mechanism (not shown) for maneuvering the AGV 1, and a lifting mechanism (not shown) for raising and lowering a plurality of forks 4 extending from the body 2. In Figure 8 the specific embodiment shown, the AGV 1 includes two forks defining a left fork 6 and a right fork 8. A first set of wheels 10 and a second set of wheels 12 are mounted to the left fork 6 and the right fork 8. That is, half of the wheels of the first set of wheels 10 and the second set of wheels 12 are mounted to the left fork 6, and the other half of the wheels of the first set of wheels 10 and the second set of wheels 12 are mounted to the right fork 8. For ease of illustration, each set of wheels in the first set of wheels 10 and the second set of wheels 12 includes a first wheel 14 and a second wheel 16. The first wheel 14 and the second wheel 16 of each set of wheels in the first set of wheels 10 and the second set of wheels 12 are shown as being mounted to the left fork 6 and the right fork 8 of the AGV 1, respectively.

[0028] While the first set of wheels 10 and the second set of wheels 12 are shown as being rotatably mounted inside the forks 4, the present invention also permits the first set of wheels 10 and the second set of wheels 12 to be rotatably mounted to the plurality of forks 4 in other ways such that the plurality of forks 4 can move on the floor. The number of forks is not limited to two, but may include any number of forks, such as a pallet mover 3 with three forks. To be able to move in the vertical direction, each of the first set of wheels 10 and the second set of wheels 12 may be pivotally mounted to the plurality of forks 4. For example, each of the first set of wheels 10 and the second set of wheels 12 may be mounted to a rod (not shown) that is pivotally mounted to the plurality of forks 4 and is telescopic in the vertical direction so that each wheel retracts towards the inside of its respective fork and thus disengages from the floor, and so that each wheel extends towards the outside of its respective fork in the deployed position and thus engages the floor. However, the present invention also permits each of the first set of wheels 10 and the second set of wheels 12 to be mounted in other ways to effect vertical movement relative to the plurality of forks 4. An actuation mechanism (not shown) coupled to the first set of wheels 10 and the second set of wheels 12 is configured to independently move each of the first set of wheels and the second set of wheels in the vertical direction. More details of the actuation mechanism are discussed below.

[0029] A lifting mechanism (not shown) for raising and lowering the plurality of forks is connected to the plurality of forks. Various lifting mechanisms known in the art may be used to raise and lower the plurality of forks. This includes but is not limited to hydraulic pumps, electric motors, etc. Generally, the plurality of forks are connected to a frame to form the body of the AGV, and the lifting mechanism is connected to the plurality of forks and the frame such that the lifting mechanism is configured to raise and lower the frame and the plurality of forks. The lifting mechanism may cooperate with the first set of wheels or the second set of wheels to raise or lower the plurality of forks. For example, the plurality of forks may be raised by lowering the first set of wheels or the second set of wheels. The first set of wheels may be mounted on a rod attached to a link that is connected to a rod attached to a hydraulic pump in the body of the AGV to lower the first set of wheels or the second set of wheels to raise the plurality of forks. Since the first set of wheels may be primarily load-bearing wheels, the plurality of forks may be raised by lowering the first set of wheels. The lower the first set of wheels are relative to the plurality of forks, the higher the plurality of forks are raised. Alternatively, the lifting mechanism for raising the plurality of forks may be separate from the first set of wheels and the second set of wheels. However, the first set of wheels or the second set of wheels will lower as the plurality of forks are raised. When the plurality of forks are in the raised position, a locking mechanism locks the first set of wheels or the second set of wheels in the lowered position to lift a pallet engaged with the plurality of forks off the ground.

[0030] A drive assembly (not shown) including one or more drive wheels drives the AGV on the floor. The drive assembly includes a drive mechanism, such as a drive motor, for driving one or more drive wheels to rotate about a drive axis. The drive assembly is located at the rear of the AGV within the body. The drive wheels for driving the AGV on the floor can be connected to a steering mechanism (not shown) for maneuvering the AGV on the floor. The steering mechanism can be configured to rotate one or more of the drive wheels about a steering axis that is substantially perpendicular to its drive axis to change the direction of the AGV on the floor. Various steering mechanisms known in the art can be used to change the direction of the AGV. This includes but is not limited to a steering drive unit coupled to one or more drive wheels and configured to rotate one or more of the drive wheels about the steering axis. For example, the body of the AGV can include caster wheels located at the four corners of the body of the AGV. The drive wheels and the steering wheels drive the body of the AGV and change the direction of the body of the AGV, respectively. The steering mechanism can be separate from the drive assembly, that is, separate steering wheels can be used to change the direction of the AGV, and it is independent of the drive assembly driving the AGV.

[0031] The AGV includes a guidance system (not shown) that is coupled to the drive assembly and the steering mechanism to control the movement of the AGV in the workplace. The guidance system can include but is not limited to electromagnetic guidance, laser guidance, tape guidance, odometer guidance, inertial guidance, or alternative guidance. For example, a laser guidance system uses special markers sensed by the AGV and used to control its travel. The guidance system is controlled by a control system that includes a controller (such as a processor) and a memory storage device for storing instructions that are executed by the controller to control the operation of the AGV. The memory storage device can be any storage device known in the art, including but not limited to RAM, computer-readable media, magnetic storage media, optical storage media, or other electronic storage media that can be used to store data and accessed by the controller. Controlling the operation of the AGV includes but is not limited to: controlling the drive assembly and the steering mechanism in response to signals from the guidance system to control the travel of the AGV; controlling the vertical movement of a first set of wheels and a second set of wheels mounted to a plurality of forks to engage with a pallet; and controlling a lifting mechanism to raise and lower the pallet.

[0032] To engage a plurality of fork portions 4 with the pallet 18, a control system cooperating with an actuation mechanism and a drive mechanism is configured to move the AGV so as to fully engage with the pallet. The expression "fully" engaging the plurality of fork portions with the pallet is used to describe a state in which the plurality of fork portions are inserted into the pallet such that the pallet can be lifted off the ground. The actuation mechanism may include linear actuators to move each of a first set of wheels and a second set of wheels in a vertical direction via one or more linkages. The control system may be configured to actuate the actuation mechanism to independently move the first set of wheels and the second set of wheels in the vertical direction. For example, the actuation mechanism may include a first linear actuator for raising and lowering the first set of wheels and a second linear actuator for raising and lowering the second set of wheels. To independently move the first set of wheels and the second set of wheels in the vertical direction, the control system may be configured to independently actuate the first linear actuator to extend or retract the first set of wheels and independently actuate the second linear actuator to extend or retract the second set of wheels. Alternatively or in combination with the linear actuators, the actuation mechanism may include a cam mechanism including one or more cams and cam followers, and the cam followers may move along one or more cams to move the cam followers from a raised position that retracts the first set and / or the second set of wheels to a lowered position that extends the first set and / or the second set of wheels.

[0033] Figures 9a to 9g is a schematic diagram showing the stages of engagement of a plurality of fork portions 4 with the pallet 18. The engagement operation includes independently retracting and extending a first set of wheels 10 and a second set of wheels 12 in a predetermined order while driving the AGV 1 towards the pallet 18. This operation begins by retracting the first set of wheels 10 (i.e., the front set of wheels) near the distal end of the plurality of fork portions 4 to allow the front insertion opening of the plurality of fork portions 4 to be provided with an opening by the space between the upper deck 20 and the lower deck 22 of the pallet. In Figure 9b AGV 1 moves a first distance L1 towards the pallet 18 such that the front portion of the plurality of fork portions 4 clears the board or slat 24 in the lower deck 22 of the pallet 18. The first distance depends on the spacing between the first set of wheels 10 and the second set of wheels 12. In this particular embodiment, the first distance is sufficient to span a single board 24 in the lower deck 22 of the pallet 18 while the second set of wheels 12 near the body 2 of the AGV 1 does not physically roll over or hit the single board, as Figure 9b shown. The first distance L1 may be a predetermined distance applicable to the pallet type stored in a memory storage device and may depend on the width of one or more boards 24 in the lower deck 22 of the pallet 18. Once the AGV 1 has moved the first distance L1 towards the pallet 18 such that the front portion of the plurality of fork portions 4 enters the pallet 18, the engagement operation continues: in as Figure 2Before retracting the second set of wheels 12 shown in c, the first set of wheels 10 is deployed to engage the floor. Deploying the first set of wheels 10 before retracting the second set of wheels 12 maintains the stability of the AGV 1 and prevents it from tilting when the second set of wheels 12 is retracted. As Figure 9d shown, this enables the AGV 1 to move a second distance L2 towards the pallet 18 and enables the plurality of forks 4 to be further inserted into the pallet 18. Similar to the first distance, the second distance can be a predetermined distance applicable to the pallet type stored in the memory storage device. The predetermined order of operations is: (i) retract the first set of wheels; (ii) move the AGV a first distance towards the pallet; (iii) deploy the first set of wheels and retract the second set of wheels; (iii) move the AGV a second distance towards the pallet; repeat the operations when crossing the second board in the lower board of the pallet as shown in Figure 9e and Figure 9f shown. Since there are usually three boards or slats 24 in the lower board of the pallet, once the first set of wheels and the second set of wheels have crossed the first board and the second board, the plurality of forks are considered to be fully engaged with the pallet, as shown in Figure 2 f. Once the plurality of forks are fully engaged with the pallet, the next operation is to lift the pallet 18 off the ground as shown in Figure 9g shown so that it can be moved on the floor. Lifting the pallet 18 includes lowering or deploying the first set of wheels 10 relative to the plurality of forks by means of an actuating mechanism so that the plurality of forks 4 are lifted. Alternatively, the plurality of forks are individually lifted, causing the first set of wheels 10 to lower in order to engage the floor. A locking mechanism (not shown) locks the first set of wheels in the lowered position or the deployed position in order to lift the pallet engaged with the plurality of forks off the floor.

[0034] The first set of wheels 10 near the distal end of the plurality of forks 4 are load-bearing wheels because these wheels carry the weight of the pallet 18 and any load on the pallet when lifting the pallet off the ground. The second set of wheels 12 near the body 2 of the AGV 1 act as balance wheels to prevent the AGV 1 from tilting when the first set of wheels 10 is retracted. This enables the first set of wheels 10 and the second set of wheels 12 to cross one or more boards 24 in the lower board 22 of the pallet 18 as shown in Figure 2 (a to g). The spacing between the first set of wheels 10 and the second set of wheels 12 depends on the number of boards 24 in the lower board of the pallet 18 and the number of operations required for the first set of wheels 10 and the second set of wheels 12 to cross one or more boards 24 in the lower board of the pallet when fully engaged with the pallet.

[0035] In a second embodiment of the AGV 101, as shown in Figure 10 shown, the spacing S between the first set of wheels 110 and the second set of wheels 112 enables the plurality of forks 104 to be in a state such that Figure 8The embodiment shown requires fewer operation times to fully engage with the pallet 18. Compared with Figure 9a the first embodiment shown, which requires multiple movements of the first set of wheels 10 and the second set of wheels 12 to fully engage with the pallet 18, in Figure 10 the second embodiment shown, the AGV 1 only needs a single operation of moving a first distance L1 towards the pallet 18. The first distance L1 corresponds to the distance that the first set of wheels 110 spans two plates 24 in the lower deck 22 of the pallet 18, that is, the first distance L1 corresponds to the spacing (including the widths of the two plates) between two plates 24 in the lower deck of the pallet. Therefore, as Figure 4 shown in (a and b), the process of fully engaging with the pallet starts with retracting the first set of wheels 110 so that they cross the first plate at the outer periphery of the pallet 18 and inserting a plurality of forks into the pallet. Since the spacing between the first set of wheels and the second set of wheels is large enough to cross or span two spaced-apart plates in the lower deck of the pallet, the plurality of forks 104 can be further inserted into the pallet, thereby spanning two plates in the lower deck of the pallet in a single movement operation.

[0036] To fully engage with the pallet 18, as Figure 4 shown in b, the first set of wheels 110 is expanded and the second set of wheels 112 is retracted to allow the AGV to move a second distance L2 closer to the pallet 18, as Figure 4 shown in c. Once the plurality of forks are fully engaged with the pallet, the plurality of forks 104 can be lifted to lift the pallet off the floor. Lifting the plurality of forks may include lowering or expanding the first set of wheels 110. Alternatively, the plurality of forks are individually lifted, causing the first set of wheels 110 to lower in order to engage with the floor. A locking mechanism (not shown) locks the first set of wheels in the lowered position in order to lift the pallet engaged with the plurality of forks off the floor.

[0037] The spacing S between the first set of wheels and the second set of wheels can be changed by changing the positions of the first set of wheels 10, 110 relative to the second set of wheels 12, 112. Without causing the AGV to tilt when the first set of wheels 10, 110 retract, the closer the second set of wheels 12, 112 are to the main bodies 2, 102 of the AGV 1, 101, the larger the spacing between the first set of wheels and the second set of wheels. Generally, the spacing S between the first set of wheels and the second set of wheels must exceed 100 cm so that the first set of wheels 110 can span two plates in the lower deck of the pallet in a single movement operation.

[0038] To be in with Figure 8 and Figure 10Automating the independent movement of a first set of wheels and a second set of wheels when engaging a pallet shown, AGV 1, 101 includes one or more proximity sensors to sense the presence of nearby obstacles or objects, in this case, the obstacle or object being one or more plates in the lower deck of the pallet. Examples of proximity sensors for sensing the presence of an object include, but are not limited to, lidar sensors including a laser beam source and a light receiver, and ultrasonic sensors. Other examples of sensing the presence of nearby objects are using one or more cameras or depth cameras to visualize the presence of nearby objects or obstacles. The proximity sensor or camera can be mounted to a plurality of forks, specifically, at the distal end of one or more of the plurality of forks. Alternatively, the proximity sensor or camera can be mounted to the body of the AGV. The control system is coupled to the proximity sensor and / or camera and is configured to independently contract or expand the first set of wheels and the second set of wheels in response to one or more signals from the proximity sensor and / or camera.

[0039] Figure 12 is simplified block diagram 30, which shows the main components of the AGV for engaging a pallet. Figure 13 is block diagram 1300, which shows an embodiment of the steps performed by the AGV when engaging a pallet. In Figure 12 this case, the main components of the AGV for engaging a pallet can be summarized as including: an actuating mechanism 38 configured to move the first set of wheels and the second set of wheels in a vertical direction, a proximity sensor 44 for sensing nearby objects, a drive assembly 40 for maneuvering the AGV, and a fork lift mechanism 42 for raising and lowering a plurality of forks. Each component for engaging a pallet is controlled by a control system 32, which includes a controller 34 (e.g., a processor) and a memory storage device 36 for storing instructions executed by the controller 34. For example, the instructions include actuating the actuating mechanism 38 in response to one or more signals from the proximity sensor 44 to independently move the first set of wheels and the second set of wheels in a vertical direction. In addition to these components, the AGV will further include a battery (or other power source) to power the different components referred to Figure 5 above. The AGV will include an interface so that the battery can be recharged or the battery is hot-swappable to ensure continuous operation of the AGV. The AGV further includes a wireless interface to enable it to receive data from a central computing system and send data back to the central computing system, such as status messages, data logs, etc.

[0040] The steps of engaging a plurality of forks with a pallet can be summarized in combination with Figure 12 of Figure 13In the flowchart 1300 shown, the process starts at S1302, where a proximity sensor detects the presence of a board in the lower deck of the pallet at S1304. In response to detecting the presence of the board, the controller 34 actuates the actuation mechanism 38 to retract the first set of wheels and deploy the second set of wheels at S1306. This enables the AGV to move a first distance towards the pallet as the first set of wheels straddle the board at S1308. However, if the AGV does not detect the presence of the pallet, the AGV is instructed to continue moving at S1316 until the pallet is detected. To fully engage with the pallet, the controller 34 actuates the actuation mechanism 38 to deploy the first set of wheels and retract the second set of wheels, thereby allowing the second set of wheels to straddle the board as the AGV moves a second distance towards the pallet at S1312.

[0041] Depending on the spacing between the first set of wheels and the second set of wheels, the next step is to determine whether the plurality of forks are fully engaged with the pallet at S1314. In the case where the spacing between the first set of wheels and the second set of wheels is relatively small (see Figure 8 ), the first set of wheels and the second set of wheels must straddle two boards through multiple operations or procedures of both sets to fully engage with the pallet. After straddling the first board of the pallet, in response to one or more signals from the proximity sensor 44, the controller 34 is configured to actuate the actuation mechanism 38 to independently move the first set of wheels and the second set of wheels to straddle the second board in the lower deck of the pallet. A set of operations or procedures for straddling one or more boards in the lower deck of the pallet may include: i) Retract the first set of wheels and deploy the second set of wheels; ii) Move the AGV a first distance to insert a portion of the plurality of forks into the pallet and straddle the first board in the lower deck of the pallet; iii) Deploy the second set of wheels and retract the first set of wheels to stabilize the plurality of forks; iv) Move the AGV a second distance to insert more portions of the plurality of forks into the pallet; Since the spacing between the first set of wheels and the second set of wheels is relatively small, the above operations (i) to (iv) are repeated to straddle the second board in the lower deck of the pallet. In as Figure 10When the distance between the first set of wheels and the second set of wheels shown is relatively large, after crossing two boards in the lower layer of the pallet through a set of operations ((i) to (iv)), that is, when the plurality of fork portions move a first distance and a second distance, the plurality of fork portions are fully engaged with the pallet. When approaching the pallet, the first set of wheels and the second set of wheels may already be deployed. In this case, since the second set of wheels is already deployed, step (i) may include retracting the first set of wheels to cross the boards in the lower layer of the pallet. Data related to the type of the plurality of fork portions (including the distance between the first set of wheels and the second set of wheels) is stored in the memory storage device 36. The controller cooperating with the memory storage device is capable of determining the type of the plurality of fork portions when the plurality of fork portions are engaged with the pallet.

[0042] For the plurality of fork portions to be fully engaged with the pallet, the frequency required for the first set of wheels and the second set of wheels to cross one or more boards in the lower layer of the pallet depends on the interval S along the plurality of fork portions between the first set of wheels and the second set of wheels. The smaller the interval S between the first set of wheels and the second set of wheels, the more times the first set of wheels and the second set of wheels need to cross one or more boards in the lower layer of the pallet. In Figure 14 a to Figure 14 In the second embodiment of the AGV 301 shown in e, the second set of wheels 212 may be configured to be longitudinally telescopic along the plurality of fork portions 204 to change the interval between the first set of wheels 210 (not shown) and the second set of wheels 210, rather than telescoping in a substantially vertical direction as in the first embodiment of the present disclosure described above. As Figures 1 to 6 shown in Figure 14 (a), the second set of wheels 212 moves along the axis X-X, so that there is no longer a need to have a predetermined interval between the first set of wheels and the second set of wheels, and thus there is no longer a need for the second set of wheels 212 to cross one or more boards in the lower layer 22 of the pallet 18.

[0043] To ensure the stability of the AGV 201 when the first set of wheels 210 is retracted, the second set of wheels 212 remains in contact with the floor, but when approaching the lower layer 22 of the pallet 18, the second set of wheels 212 contracts longitudinally along the plurality of fork portions 204. Once inserted into the pallet 18, the lifting mechanism (not shown) is configured to extend or deploy the first set of wheels 210 in the vertical direction relative to the plurality of fork portions 204 to engage with the floor. Further extension of the first set of wheels 210 relative to the plurality of fork portions 204 will raise the plurality of fork portions 204 and the pallet supported by the plurality of fork portions. In Figure 14 the specific embodiment shown in e, the second set of wheels 212 is separated from the plurality of fork portions 204 to maintain the stability of the main body 202 of the AGV when the plurality of fork portions are raised. As Figure 14 a to Figure 14As shown in e, the second set of wheels 212 is mounted on a plurality of slats 216 such that the second set of wheels can be telescoped longitudinally parallel to the plurality of forks. The plurality of slats 216 are mounted to the body 202 of the AGV so that when the plurality of forks are raised, the second set of wheels 212 is separated from the plurality of forks as shown in Figure 14 e.

[0044] Similar to the first embodiment of the present invention, the first set of wheels 210 and the second set of wheels 212 can move independently relative to the plurality of forks 204. The independent movement of the first set of wheels and the second set of wheels can be controlled by the actuation mechanism described above. The second set of wheels 212 moves in the longitudinal direction from Figure 14 the forward position shown in (b) to Figure 14 the rearward position shown in (d) when the second set of wheels approaches the lower deck 22 of the pallet 18. Various ways can be used to move the second set of wheels 212 along the plurality of forks 204 in the longitudinal direction (substantially horizontal direction). One embodiment is that the second set of wheels 212 can be elastically biased in the forward direction by an elastic member (such as a spring) to be closer to the first set of wheels 210 in the stationary position, so as to improve the stability of the AGV 201 when the first set of wheels is vertically retracted into the plurality of forks 204 in the retracted configuration. The elastic member (not shown) is configured to retract the second set of wheels 212 away from the first set of wheels in the longitudinal direction when the bias of the elastic member is overcome. For example, the resilience of the elastic member can be selected such that the bias of the elastic member can be overcome by the drive assembly (such as a motor) of the AGV. The second set of wheels 212 is arranged to abut against the lower deck 22 of the pallet 18 when the plurality of forks 204 start to insert into the pallet (see Figure 14 c). Since the drive assembly moves the pallet 18 and the plurality of forks engage with the pallet, the bias is overcome. In Figure 14 (a) to Figure 14 (e) in the specific embodiment shown, the drive assembly includes drive wheels 214 that can rotate about a drive axis for driving the AGV to move on the floor. Merely driving the AGV towards the pallet is sufficient to overcome the bias of the second set of wheels, causing it to retract away from the first set of wheels as the plurality of forks gradually engage with the pallet (see Figure 14 d).

[0045] Each wheel in the second set of wheels can be mounted to a carriage that is movable in a longitudinal direction along its respective fork and is arranged to abut the lower deck when a plurality of forks enter the tray, rather than having the second set of wheels abut the lower deck of the tray. Using a carriage to carry each wheel in the second set of wheels reduces the risk of the second set of wheels rolling over one or more of the boards in the lower deck of the tray when a plurality of forks enter the tray. Alternatively, a drive mechanism responsive to signals from a suitable sensor, such as a proximity sensor, can be configured to gradually retract the second set of wheels as a plurality of forks gradually engage the tray. In all cases, the first set of wheels remains retracted until a plurality of forks are fully engaged with the tray.

[0046] Reference is now made to Figure 7 Figures (a to e) to illustrate the steps of engagement of a plurality of forks of the AGV 201 according to a second embodiment of the present invention with the tray 18. Figure 14 Figure (a) shows the positions of the first set of wheels 210 and the second set of wheels 212 relative to a plurality of forks 204 in a normal configuration, and shows that the first set of wheels 210 is in a retracted position and the second set of wheels 212 is in a forward position relative to the plurality of forks to maintain the stability of the AGV when the AGV moves on the floor. The second set of wheels 212 shown in the figure is mounted on a carriage that is movable in a longitudinal or axial direction (X-X). The drive wheels 214 are also shown mounted on the body 201 of the AGV 201 for moving the AGV. As Figure 14 shown in Figure (b), as a plurality of forks 204 enter the tray, the second set of wheels 212 approaches the lower deck 22 of the tray 18. Further movement of the AGV 201 towards the tray not only increases the portion of the plurality of forks entering the tray but also causes the second set of wheels 212 to abut the lower deck 22 of the tray 18. More specifically, as Figure 14 shown in Figure (c), it abuts the board in the lower deck of the tray. As Figure 14 shown in Figure (d), when a plurality of forks are driven into the tray, it causes the second set of wheels 212 to retract rearwardly away from the first set of wheels 210. As Figure 14 shown in Figure (e), once a plurality of forks have been fully engaged with the tray, the lifting mechanism is actuated to extend the first set of wheels 210 in the vertical direction to engage the floor, thereby stabilizing the AGV on the floor when the plurality of forks are lifted. Further extension or lowering of the first set of wheels raises the plurality of forks, thereby lifting the tray off the floor. Similar to the first embodiment of the AGV, the lifting mechanism can include one or more hydraulic pumps and / or electric motors that are coupled to the first set of wheels by one or more rods to raise or lower the plurality of forks.

[0047] It should be understood that, within the principles and scope of the present disclosure, those skilled in the art can make various changes, modifications, variations, and combinations to the details, materials, and arrangements of the parts and components described and shown for the purpose of illustrating the AGV controller described in this application.

[0048] According to one aspect, a controller for an automated guided vehicle (AGV) is provided such that the AGV can operate in a semi-automatic mode when coupled to the AGV controller. In this semi-automatic mode, an operator can access all functions of the AGV through the AGV controller. The AGV controller can be removed from the AGV, and the AGV can resume automatic operation.

Claims

1. A controller for an automated guided vehicle, the controller including a coupling configured to be coupled to the automated vehicle in use and an interface for controlling the operation of the automated vehicle.

2. The controller according to claim 1, wherein, The controller further includes a roll device.

3. The controller according to claim 2, wherein The controller further includes a drive device operable to actuate the roll device.

4. The controller according to any one of claims 1-3, wherein, The controller further includes a wireless network interface.

5. A semi-automatic vehicle, the semi-automatic vehicle comprising an automated guided vehicle and a controller for the automated guided vehicle according to any one of claims 1 to 4, wherein, The automated guided vehicle includes a hole configured to receive the coupling of the controller so that, in use, the controller interface is used to control the automated guided vehicle.

6. The semi-automatic vehicle according to claim 5, wherein, The automated guided vehicle further includes a control system so that, in use, the control system responds to control signals generated by the controller interface.

7. The semi-automatic vehicle according to claim 5 or claim 6, wherein, The automated guided vehicle further includes a drive system so that, in use, the drive system is actuated in response to control signals generated by the controller interface.

8. The semi-automatic vehicle according to any one of claims 5-7, wherein, The automated guided vehicle further includes a fork lift mechanism so that, in use, the fork lift mechanism is actuated in response to control signals generated by the controller interface.

9. A method of operating an automated guided vehicle within a storage facility, the method including the steps of: a) coupling a controller for an automated guided vehicle to the automated guided vehicle to form a semi-automated vehicle; b) controlling the semi-automated vehicle via the controller to perform a task; c) detaching the controller from the semi-automated vehicle; d) the automated guided vehicle automatically moving to a first predetermined position within the storage facility.

10. The method according to claim 9, wherein, In step d), the automated guided vehicle transports a load to the first predetermined position.

11. The method according to claim 10, wherein, The method includes a further step of: e) the automated guided vehicle placing the load at the first predetermined position and subsequently moving to a second predetermined position.

12. The method according to any one of claims 9 - 11, wherein, In step b), controlling the semi-automated vehicle to move the semi-automated vehicle to a storage location to retrieve a load.

13. A storage facility including a first zone and a second zone, wherein the first zone is reserved for use by one or more automated guided vehicles and the second zone is reserved for use by one or more controllers for automated guided vehicles according to any one of claims 1 - 4 and one or more semi-automated vehicles according to any one of claims 5 - 8.

14. The storage facility according to claim 13, wherein, The storage facility includes a physical barrier to separate the first zone from the second zone.

15. The storage facility according to claim 14, wherein, The physical barrier includes one or more holes through which an automated guided vehicle or a semi-automated vehicle can pass.

16. The storage facility according to claim 15, wherein, A handover position may be defined adjacent to one or each of the barrier holes.

17. The storage facility according to any one of claims 13-16, wherein The first zone is connected to the second zone.

18. The storage facility according to any one of claims 13 to 16, wherein, The first zone and the second zone have an overlapping area.

Images