System and method for docking automated guided vehicle to material handling vehicle

Abstract

A material handling vehicle may include a vertically movable platform including an operator cabin and a load deck, and a coupling mechanism for securing an automated guided vehicle to the load deck. In some examples, the coupling mechanism secures the automated guided vehicle to the load deck such that vertical movement of the load deck causes corresponding vertical movement of the automated guided vehicle. The invention also relates to a method of docking an automated guided vehicle to a material handling vehicle.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 555,297, filed February 19, 2024, the entire contents of which are incorporated herein by reference. Background Art

[0002] Automated guided vehicles (AGVs) can be used in warehouse environments to assist operators with order picking operations. For example, AGVs can provide operators with route guidance, optimization, or other efficiency-enhancing benefits. However, AGVs are typically limited to low-level order picking. Therefore, higher-level order picking operations cannot take advantage of the efficiency-enhancing benefits of AGVs. Summary of the Invention

[0003] In one aspect, the present disclosure describes a material handling vehicle. The material handling vehicle includes a vertically movable platform comprising an operator cabin and a load deck, and a connection mechanism for securing an automated guided vehicle to the load deck. The connection mechanism secures the automated guided vehicle to the load deck such that vertical movement of the load deck causes corresponding vertical movement of the automated guided vehicle.

[0004] In another aspect, the present disclosure describes a method for docking an automated guided vehicle to a material handling vehicle. The method includes identifying the material handling vehicle via the automated guided vehicle, initiating docking of the automated guided vehicle to the material handling vehicle by guiding the automated guided vehicle onto a load deck of the material handling vehicle, and securing the automated guided vehicle to the load deck of the material handling vehicle via a connection mechanism secured to the load deck. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the embodiments of the present invention:

[0006] Figure 1 is a schematic diagram of a material handling vehicle according to aspects of the present disclosure.

[0007] Figure 2 According to aspects of the present disclosure, a load deck is included. Figure 1 A perspective view of a portion of a material handling vehicle.

[0008] Figure 3 According to aspects of the present disclosure, Figure 2 An overhead view of the load deck of a material handling truck.

[0009] Figure 4 According to aspects of the present disclosure, Figure 2 Bottom perspective view of a material handling truck with a load deck.

[0010] Figure 5 Another example of a vehicle including a load deck according to aspects of the present disclosure is Figure 1 A side view of another example of a material handling vehicle.

[0011] Figure 6 According to aspects of the present disclosure, Figure 5 Side view of the load deck of a material handling truck.

[0012] Figure 7 According to aspects of the present disclosure, Figure 6 An overhead view of the load deck of a material handling truck.

[0013] Figure 8 According to aspects of the present disclosure, Figure 1 A perspective view of an automated guided vehicle used with a material handling vehicle.

[0014] Figure 9 According to aspects of the present disclosure Figure 8 Front view of an automated guided vehicle.

[0015] Figure 10 is fixed to the Figure 1 Material handling vehicles Figure 8 Bottom view of the automated guided vehicle.

[0016] Figure 11 According to aspects of the present disclosure Figure 10 A partial cross-sectional view of the connection mechanism.

[0017] Figure 12 According to aspects of the present disclosure, Figure 8 The automated guided vehicle is fixed to Figure 1 A bottom view of another example of a connection mechanism for a material handling vehicle.

[0018] Figure 13 According to aspects of the present disclosure, Figure 8 The automated guided vehicle is fixed to Figure 1 A partial side view of yet another example of a connection mechanism for a material handling vehicle.

[0019] Figure 14 According to aspects of the present disclosure Figure 1 Front view of the platform of a material handling truck.

[0020] Figure 15 According to aspects of the present disclosure Figure 8 Automated guided vehicles and Figure 1 Schematic diagram of sensor integration between material handling vehicles.

[0021] Figure 16According to aspects of the present disclosure, Figure 8 Automated guided vehicles and Figure 1 Flowchart of the order picking process for a material handling truck.

[0022] Figure 17 According to aspects of the present disclosure Figure 8 The automated guided vehicle docks to Figure 1 Flowchart of the docking process of a material handling vehicle.

[0023] Figure 18 According to aspects of the present disclosure Figure 8 Automated guided vehicles and Figure 1 Flowchart of the undocking process of a material handling vehicle.

[0024] Figure 19 According to aspects of the present invention, Figure 8 Automated guided vehicles and Figure 1 A flow chart of another example docking process for docking a material handling vehicle.

[0025] Figure 20 yes Figure 1 Material handling vehicles and Figure 8 Schematic diagram of an automated guided vehicle performing the pickup / unloading process. DETAILED DESCRIPTION

[0026] The following discussion is provided to enable those skilled in the art to make and use the embodiments of the present invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art given the benefit of this disclosure, and the principles herein may be applied to other embodiments and applications without departing from the embodiments of the present invention. Therefore, the embodiments of the present invention are not intended to be limited to the embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein.

[0027] The following detailed description should be read with reference to the accompanying drawings, in which like elements in different figures have like reference numerals. The drawings, which are not necessarily drawn to scale, illustrate selected embodiments and are not intended to limit the scope of embodiments of the invention. Those skilled in the art will recognize that the examples provided herein have many useful alternatives and that they fall within the scope of embodiments of the invention.

[0028] Before any embodiments of the present invention are described in detail, it should be understood that the present invention is not limited to its application to the structural details and component arrangements described in the following description or shown in the accompanying drawings. The present invention is capable of other embodiments and can be practiced or implemented in various ways. Moreover, it should be understood that the words and terms used herein are for descriptive purposes and are not to be considered as limiting. As used herein, "includes," "comprising," or "having" and variations thereof are meant to include the items listed thereafter and their equivalents as well as additional items. Unless otherwise specified or limited, the terms "mounted," "connected," "supported," and "coupled" and variations thereof are used broadly and include direct and indirect mounting, connection, support, and coupling. Further, "connected" and "coupled" are not limited to physical or mechanical connections or couplings.

[0029] It should be understood that material handling vehicles are designed in various categories and configurations to perform various tasks. It will be apparent to those skilled in the art that the present disclosure is not limited to any particular material handling vehicle and that various other types of material handling vehicle categories and configurations may also be provided, including, for example, lift trucks, forklifts, reach trucks, SWING trucks, and other similar vehicle types. Vehicles, turret trucks, side loaders, counterbalanced forklifts, pallet stacking trucks, material pickers, transtackers, tractors, and manned trucks are typically found in warehouses, factories, freight yards, and generally where pallets, large packages, or stacks of goods need to be transported from one location to another. The various systems and methods disclosed herein are suitable for any operator-controlled, pedestrian-controlled, remotely-controlled, and autonomously-controlled material handling vehicles. In addition, the present disclosure is not limited to the use of material handling vehicles. Instead, the present disclosure can be provided for other types of vehicles, such as automobiles, buses, trains, tractor trailers, farm vehicles, factory vehicles, and the like.

[0030] It should be noted that the various material handling vehicles (MHVs) listed above can perform a variety of load handling operations. For example, the material handling vehicle and / or the load handling portion of the material handling vehicle (e.g., forks, mast, and / or fork carrier, etc.) can be operated to traverse (e.g., move the forks up to a full load depth), tilt, reach (e.g., move the forks up to a partially loaded depth), rotate, drive (e.g., move the material handling vehicle V), travel (e.g., move the material handling vehicle), and / or any combination thereof to perform load handling functions.

[0031] It should also be noted that various government agencies, laws, rules, and regulations impose training requirements on certain types of vehicles. For example, OSHA imposes an obligation on employers to train and supervise operators of various types of material handling vehicles. Recertification is also required every three years. In some cases, operators should be provided with refresher training on relevant topics when necessary. In all cases, the operator maintains control of the material handling vehicle during the performance of any action. In addition, the warehouse manager maintains control of a fleet of material handling vehicles within the warehouse environment. The training and supervision of the operators provided by the warehouse manager primarily requires appropriate operating time, mainly including the operator maintaining control of the material handling vehicle, paying attention to the operating environment, and always keeping a lock on the direction of travel.

[0032] In some examples, a material handling vehicle may include a vertically movable platform that includes a load deck configured to receive and retain an automated guided vehicle. In some examples, the load deck can secure the automated guided vehicle to the material handling vehicle. For example, the load deck can include a series of slots configured to receive and retain one or more wheels of the automated guided vehicle. In another example, the load deck can be segmented, wherein a second segment is configured to move from a position parallel to a first segment to a position perpendicular to the first segment to retain the automated guided vehicle. In other examples, the automated guided vehicle can be secured to the platform via one or more forks extending from the platform. For example, one or more forks of the material handling vehicle can include a connecting mechanism that is configured to receive and retain a portion of the automated guided vehicle to secure the automated guided vehicle to the material handling vehicle. Thus, the automated guided vehicle can be raised or lowered along with the platform (e.g., to allow the automated guided vehicle to reach items above floor level). In another example, the automated guided vehicle can be raised or lowered along with the platform to allow the automated guided vehicle to be delivered to another floor or level of a warehouse or other facility. For example, an AGV can dock to a material handling vehicle, which can then lift the AGV to a desired level (e.g., mezzanine, second floor, etc.), after which the AGV can undock and resume the picking process.

[0033] In another example, when the AGV is docked to the material handling vehicle, it can engage with the platform's communication port (wired or wireless). For example, the communication port can allow the AGV to utilize one or more sensors or cameras of the material handling vehicle to autonomously guide the material handling vehicle via the AGV's guidance system. In other words, via the communication port, the AGV can autonomously guide the material handling vehicle according to the AGV's route planning system. Thus, the material handling vehicle can benefit from the AGV's efficient route planning, while the AGV can benefit from the material handling vehicle's above-floor reach.

[0034] Figure 1An example of a material handling vehicle 100 is shown. The material handling vehicle 100 includes a tractor unit 105 and a vertically retractable mast 110 mounted relative to the tractor unit 105. The mast 110 includes a fixed mast section 115 and a retractable mast section 120, with a vertically movable platform 125 attached to the retractable mast section 120. In some examples, the retractable mast section 120 raises and lowers the platform 125.

[0035] In some examples of the material handling vehicle 100, the platform 125 includes an operator cabin 130, which may also be referred to as an operator station. The operator cabin 130 includes an operator platform 135 on which the operator sits or stands, and an operator console 140 for operating the material handling vehicle 100 (including operating the platform functions). The console 140 includes controls for controlling the vehicle's steering and speed, and controls for controlling the raising and lowering of the platform 125 and the operation of one or more forks 145, which may be referred to as platform forks. The operator cabin 130 may also include lights and one or more displays for displaying operational data. In other examples, the material handling vehicle 100 may include a fixed operator cabin on the tractor unit 105 (i.e., the operator does not travel up or down with the platform), or may not include a designated operator cabin, such as when the operator does not stand on the material handling vehicle 100, but instead walks alongside the vehicle and controls the vehicle using a joystick.

[0036] Figure 2-4 Some examples of material handling vehicles 100 are shown, including a platform 125 with a load deck 205 to hold and secure an automated guided vehicle 210. As previously described, the automated guided vehicle 210 can be raised or lowered with the platform 125 (including the load deck 205) to allow the automated guided vehicle 210 to reach items above floor level. In another example, the automated guided vehicle 210 can be raised or lowered with the platform 125 to allow the automated guided vehicle 210 to be delivered to another layer or level of a warehouse or other facility. For example, the automated guided vehicle 210 can be docked to the material handling vehicle 100 (e.g., via the load deck 205), and then the material handling vehicle 100 can lift the automated guided vehicle 210 to a desired layer (e.g., a mezzanine, the second floor, etc.), and then the automated guided vehicle 210 can be detached from the docking and resume the picking process.

[0037] In some examples, the automated guided vehicle 210 can include a chassis 215 and one or more storage containers 220. For example, the chassis 215 can include a powertrain, a guidance, navigation, and control system, one or more cameras, and one or more sensors to control the operation of the automated guided vehicle 210. Accordingly, the storage container 220 can be in the form of a basket, a rack, or any other known storage system. In some examples, an operator can place the picked items in the storage container 220 during the picking operation. For example, the operator can be on the operator platform 135 and operate the material handling vehicle 100 via the control console 140 according to instructions from the warehouse management system or the automated guided vehicle 210. Therefore, the operator can benefit from the route planning of the automated guided vehicle 210, which can improve overall order picking efficiency and reduce overall downtime.

[0038] In some examples, to secure the AGV 210 to the material handling vehicle 100, the AGV 210 can traverse onto the load deck 205 such that one or more wheels 405, 410 of the chassis 215 slide into or engage one or more slots 310, 315 defined by the floor 305 of the load deck 205. Thus, when the platform 125 is raised, the AGV 210 is secured to the platform 125 (e.g., the load deck 205) via engagement between the wheels 405, 410 and the slots 310, 315. However, when the platform 125 is lowered, the wheels 405, 410 contact the warehouse floor before the load deck 205, which can apply force to the AGV 210 to dislodge the wheels 405, 410 from the slots 310, 315.

[0039] In some examples, the load deck 205 can include a pair of opposing side walls 415 extending upward from the floor 305 of the load deck 205. In some examples, the side walls 415 can include an angled upper surface 425 extending from the first end 430 of the load deck 205 to the end wall 420 of the load deck 205. It should be understood that in other examples, the side walls 415 can define other shapes, such as rectangular, polygonal, or other shapes. The end wall 420 of the load deck 205 can separate the load deck 205 from the operator platform 135 of the platform 125. In some examples, the end wall 420 can include one or more mechanical or electrical connectors to integrate the automated guided vehicle 210 into the material handling vehicle 100 (e.g., for integration between the control system of the material handling vehicle 100 and the control system of the automated guided vehicle 210).

[0040] Figure 5 and 6Another example of a material handling vehicle 100 including a load deck 505 is shown. In some examples, the load deck 505 can define a segmented body having a first section 510 and a second section 515. In some examples, the second section 515 can be configured to rotate as indicated by arrow 605 to form a stop for the load deck 505. It should be understood that the second section 515 can be rotated from the first position 500 (e.g., as shown in FIG. 5 ). Figure 5 ) moves to a second position 600 (e.g., as shown Figure 6 as shown) to keep the automated guided vehicle 210 on the load deck 505.

[0041] In an example use case, the automated guided vehicle 210 can travel onto the load deck 505, which can include an angled surface 525 to facilitate guiding the automated guided vehicle 210 onto the load deck 505. In some examples, the automated guided vehicle 210 continues to advance on the load deck 505 until the automated guided vehicle 210 reaches the end wall 530 of the load deck 505. Once the automated guided vehicle 210 reaches the end wall 530, the second segment 515 can rotate to the second position 600 to secure the automated guided vehicle 210 to the load deck 505. In some examples, once the automated guided vehicle 210 engages (e.g., contacts) the end wall 530, the second segment 515 can automatically move from the first position 500 to the second position 600. In another example, the second segment 515 can move from the first position 500 to the second position 600, for example, upon actuation of a switch or button by an operator.

[0042] like Figure 7 As shown, the load deck 505 includes a width 705, which can correspond to the width of the operator platform 135. In some examples, the width 705 can be sized to allow a pair of automated guided vehicles 210 to fit on the load deck 505. In other examples, the width 705 of the load deck 505 can be sized to accommodate only a single automated guided vehicle 210 or more than a pair of automated guided vehicles 210.

[0043] Figure 8 and 9An example of a chassis 215 of an automated guided vehicle 210 is shown. The chassis 215 may include a load surface 805 that can receive and hold one or more storage containers 220. Accordingly, the chassis 215 may include a body that can house the internal components of the chassis 215 (e.g., one or more sensors, one or more cameras, guidance, navigation and control systems, powertrain systems, etc.). In some examples, the chassis 215 may include a fork receptacle 810 defining an opening 815. The opening 815 is configured to receive the forks 145 of the material handling vehicle 100 to secure the automated guided vehicle 210 to the material handling vehicle 100. In addition, the fork receptacle 810 may include a pair of openings 815 disposed on each end of the chassis 215. Thus, the fork receptacle 810 can assist in aligning the automated guided vehicle 210 on the forks 145 of the material handling vehicle 100.

[0044] like Figure 10 and 11 As shown, the material handling vehicle 100 can include a connection mechanism 1005 disposed on the underside 1020 of each fork 145. In some examples, the connection mechanism 1005 can engage and retain the cross member 1010 of the chassis 215 to secure the automated guided vehicle 210 to the material handling vehicle 100. The connection mechanism 1005 can include a mounting shaft 1105 to secure the connection mechanism 1005 to the fork 145. In some examples, the connection mechanism 1005 can be pivotally secured to the fork 145. In some examples, the connection mechanism 1005 includes a body 1110 having an angled nose 1115. The angled nose 1115 can cause rotational movement of the connection mechanism 1005 via engagement between the cross member 1010 of the chassis 215 and the angled nose 1115.

[0045] In some examples, as the chassis 215 moves along the forks 145, the cross member 1010 can contact the angled nose 1115 of the connection mechanism 1005, which can cause rotational movement of the body 1110 via the mounting shaft 1105. In some examples, the body 1110 includes a cutout 1120 defined by one or more walls 1125. The cutout 1120 can be sized to receive and retain the cross member 1010 to secure the automated guided vehicle 210 to the material handling vehicle 100. For example, once the cross member 1010 reaches the cutout 1120, the cross member 1010 can fall into the cutout 1120 of the connection mechanism 1005. Additionally, the connection mechanism 1005 can include a biasing element to bias the connection mechanism into a closed position (e.g., where the connection mechanism is arranged parallel to the forks 145). In some examples, to release cross member 1010 from connection mechanism 1005 , an operator may actuate a switch or button, which may cause rotation of connection mechanism 1005 and release cross member 1010 from cutout 1120 .

[0046] Figure 12 Another example of a connection mechanism 1200 for securing an automated guided vehicle 210 to a material handling vehicle 100 is shown. In some examples, the chassis 215 of the automated guided vehicle 210 can include one or more locking pawls 1205 secured to an underside 1225 of the chassis 215. In some examples, the locking pawls 1205 can be unidirectional (e.g., only allowing movement in a single direction), such that the fork 145 can be inserted through an opening 1230 defined by the locking pawl 1205 in a first direction, indicated by arrow 1215, but cannot be removed from the opening 1230 defined by the locking pawl 1205 in a second, opposite direction, indicated by arrow 1220. Thus, the automated guided vehicle 210 can be secured to the material handling vehicle 100 via engagement between the locking pawls 1205 and one or more surfaces of the fork. The surface can be a side 1210 or multiple sides 1210 of the fork 145. In another example, the automated guided vehicle 210 can be secured to the material handling vehicle 100 using only a single locking pawl 1205. For example, the fork 145 can be inserted through the opening defined by the locking pawl 1205 in a first direction, but cannot be removed from the opening defined by the locking pawl in a second, opposite direction. In some examples, the fork 145 can be retained between (e.g., sandwiched between) the sidewall of the chassis 215 and the locking pawl 1205. Thus, the automated guided vehicle 210 can be secured to the material handling vehicle 100 via engagement between the locking pawl 1205 and the surface of the fork.

[0047] Figure 13 Another example of a connection mechanism 1300 for securing the automated guided vehicle 210 to the material handling vehicle 100 is shown. Figure 13 In the example shown, the locking pawl 1205 can engage a surface of the fork. For example, instead of engaging the side 1210 of the fork 145, the locking pawl 1205 can engage the upper surface 1305, the lower surface 1310, or both the upper and lower surfaces 1305, 1310 of the fork 145. Similarly, if only a single pawl 1205 is used, the fork can be constrained between a surface (e.g., the bottom surface) of the chassis 215 and the pawl 1205. In some examples, to release the fork 145 from the locking pawl 1205 (e.g., to remove the automated guided vehicle 210 from engagement with the material handling vehicle 100), the operator can actuate a switch or button, which can release the locking pawl 1205 and allow the fork 145 to move through the opening 1230 of the locking pawl 1205 in the direction indicated by the arrow 1220.

[0048] Watch Now Figure 14, shows an example of the platform 125 of the material handling vehicle 100. In some examples, the platform 125 can include a communication port 1405, a charging port 1410, and one or more fiducial markers (e.g., an April tag 1415, a barcode, a Quick Response (QR) code, an ArUco marker, a WhyCon marker, a WhyCode marker, etc.) disposed at the intersection between the load deck and the operator platform to facilitate connection between the automated guided vehicle 210 and the material handling vehicle 100. For example, the communication port 1405 can be used to facilitate communication between the automated guided vehicle 210 and the material handling vehicle 100 (e.g., between one or more sensors or cameras of the automated guided vehicle 210 and the material handling vehicle 100, the guidance, navigation, and control systems of the automated guided vehicle 210 and the material handling vehicle 100, etc.). In another example, when the AGV 210 is docked to the material handling vehicle 100, the AGV 210 can exchange the last known location of the AGV 210, which can facilitate tracking of the AGV 210 or the material handling vehicle 100. In another example, the charging port 1410 can facilitate charging the AGV 210 while it is docked or connected to the material handling vehicle 100. To facilitate accurate docking of the AGV 210 to the material handling vehicle 100, the AGV 210 can utilize one or more fiducial markers (e.g., April tags 1415, bar codes, Quick Response (QR) codes, ArUco markers, WhyCon markers, WhyCode markers, etc.) disposed on the platform 125 to guide the AGV 210 to the load deck 205 or the fork 145 (e.g., with an interface connection mechanism).

[0049] like Figure 15As shown, the automated guided vehicle 210 can communicate with one or more sensors or cameras 1505 of the material handling vehicle 100 via a communication link 1510. In some examples, the communication link 1510 can be a wired communication link. In another example, the communication link 1510 can be a wireless communication link. For example, when the automated guided vehicle 210 is docked to the material handling vehicle 100, the automated guided vehicle 210 can communicate with the sensors or cameras 1505 of the material handling vehicle 100 via the communication port 1405. In another example, the automated guided vehicle 210 can utilize the one or more sensors or cameras 1505 of the material handling vehicle 100 in combination with the internal guidance, navigation, and control systems of the automated guided vehicle 210 to control the movement or operation of the material handling vehicle 100. In other words, the connection between the material handling vehicle 100 and the automated guided vehicle 210 can transition the material handling vehicle 100 from operator control to autonomous control or control by the automated guided vehicle 210. As a result, the material handling vehicle 100 can benefit from the route planning system of the automated guided vehicle 210. Similarly, in some examples, when an automated guided vehicle is docked to a material handling vehicle, the material handling vehicle may communicate with one or more sensors or cameras of the automated guided vehicle via a communication link (eg, a communication port).

[0050] Figure 16 An example of a picking process utilizing an automated guided vehicle 210 and a material handling vehicle 100 is shown. At stage 1605, a warehouse management system may receive a pick request corresponding to an item within the warehouse. At stage 1610, the pick request may pass through a pick optimization engine that may organize the pick request based on item type, item location (e.g., region), or other characteristics. At stage 1615, the optimized pick request may be transmitted or uploaded to one or more automated guided vehicles 210.

[0051] Upon receiving the pick request, the automated guided vehicle 210 may determine whether the automated guided vehicle 210 is currently connected to the material handling vehicle 100 (at stage 1620). If the automated guided vehicle 210 is connected to the material handling vehicle 100, then at stage 1640, the operator may guide the material handling vehicle 100 (including the automated guided vehicle 210) to the pick location. In another example, the automated guided vehicle 210 may interact with the material handling vehicle 100 (e.g., via the sensors or camera 1505 discussed above) to autonomously guide the material handling vehicle 100 to the pick location at stage 1645. In either case, once the pick location is reached, at stage 1660, the operator may complete the pick process. However, if, at stage 1620, the automated guided vehicle 210 is not connected to the material handling vehicle 100, then at stage 1625, the automated guided vehicle 210 may determine whether the requested pick is at or above floor level.

[0052] If the requested pick is at floor level (e.g., as determined by the automated guided vehicle 210, a warehouse management system, etc.), the automated guided vehicle 210 can autonomously drive to a predetermined rendezvous point at stage 1650. At stage 1655, an operator (e.g., a picker without the material handling vehicle 100) can rendezvous with the automated guided vehicle 210 at the rendezvous point. Once the picker and the automated guided vehicle 210 have rendezvoused, at stage 1645, the automated guided vehicle 210 can guide the picker to the pick location. Thereafter, at stage 1660, the picker can complete the picking process.

[0053] Accordingly, if the requested pick at stage 1625 is above floor level (e.g., as determined by the automated guided vehicle 210, a warehouse management system, etc.), then at stage 1630 the automated guided vehicle 210 may autonomously drive to a rendezvous point to rendezvous with the operator and the material handling vehicle 100 at stage 1635. In some examples, when the operator rendezvouses with the automated guided vehicle 210, the automated guided vehicle may dock with the material handling vehicle 100. Thereafter, at stage 1640, the operator may drive the material handling vehicle 100, including the automated guided vehicle 210, to the pick location 21 indicated by the automated guided vehicle. Once at the pick location, the operator may complete the pick using the material handling vehicle 100 and the automated guided vehicle 210 at stage 1660.

[0054] After the pick is complete, it can be determined (e.g., via the automated guided vehicle 210, the warehouse management system, etc.) whether the next pick location can be most efficiently performed using the same material handling vehicle 100 (e.g., based on predetermined area boundaries, etc.). If the pick is performed using the same vehicle (e.g., the host), the automated guided vehicle 210 can assist the operator in guiding the material handling vehicle 100 and the automated guided vehicle 210 to the next pick location. Accordingly, at stage 1665, if the next pick is not performed by the same material handling vehicle 100 (determined by the automated guided vehicle, the warehouse management system, etc.), the automated guided vehicle 210 returns to stage 1625 as previously described.

[0055] Figure 17An example of a docking process between an automated guided vehicle 210 and a material handling vehicle 100 is shown. At stage 1705, the automated guided vehicle 210 may identify the material handling vehicle 100. For example, the automated guided vehicle 210 may identify the material handling vehicle 100 via one or more fiducial markers (e.g., an April tag 1415, a barcode, a Quick Response (QR) code, an ArUco marker, a WhyCon marker, a WhyCode marker, etc.) disposed on the platform 125 of the material handling vehicle 100. At stage 1710, the automated guided vehicle 210 may begin docking with the material handling vehicle 100. For example, the automated guided vehicle 210 may drive onto the load deck 205 of the material handling vehicle 100. In another example, the automated guided vehicle 210 may engage the forks 145 of the material handling vehicle 100, as previously described. At stage 1715, the automated guided vehicle 210 (or material handling vehicle) may determine whether the automated guided vehicle 210 is fully docked with the material handling vehicle 100 (e.g., whether the automated guided vehicle 210 has contacted the communication port 1405). If it is determined that the automated guided vehicle 210 is fully docked with the material handling vehicle 100, the material handling vehicle 100 may lock the automated guided vehicle 210 in place via the connection mechanism. At stage 1725, the operator may drive the automated guided vehicle 210 and the material handling vehicle 100 to the pickup location.

[0056] Figure 18 An example of a detachment process between an automated guided vehicle (AGV) 210 and a material handling vehicle (MT) 100 is shown. At stage 1805, the AGV 210 may notify the operator of a detachment request. For example, the AGV 210 may notify the operator via a display on the control console 140. In addition, the AGV 210 may notify the operator of a position to detach the AGV 210. At stage 1810, the operator may drive the material handling vehicle (MT) 100, including the AGV 210, to the indicated detachment position and lower the AGV 210 to the floor (e.g., by lowering the gantry 120). At stage 1815, the AGV 210 may determine whether the AGV 210 is positioned at the desired drop-off position and at floor level. If the AGV 210 is lowered and in the desired drop-off position, the material handling vehicle 100 may unlock the AGV 210 from the material handling vehicle 100. For example, the material handling vehicle 100 may release the connection mechanism or lower the second section 515, as previously described. At stage 1825, the automated guided vehicle 210 may leave the material handling vehicle 100 and autonomously drive to a predetermined rendezvous point.

[0057] Figure 19An alternative docking process between an automated guided vehicle 210 and a material handling vehicle 100 is shown. At stage 1905, the automated guided vehicle 210 may identify the material handling vehicle 100. For example, the automated guided vehicle 210 may identify the material handling vehicle 100 (e.g., via one or more cameras or other sensors on the automated guided vehicle) via one or more fiducial markers (e.g., an April tag 1415, a barcode, a Quick Response (QR) code, an ArUco marker, a WhyCon marker, a WhyCode marker, etc.) disposed on the platform 125 of the material handling vehicle 100. At stage 1910, the automated guided vehicle 210 may begin docking with the material handling vehicle 100. For example, the automated guided vehicle 210 may begin advancing onto the load deck (e.g., the forks 145) of the material handling vehicle 100. At stage 1915, the automated guided vehicle 210 may determine whether the automated guided vehicle 210 is fully docked with the material handling vehicle 100. For example, the automated guided vehicle 210 may be fully docked when contacting the operator platform 135. If it is determined that the automated guided vehicle 210 is fully docked to the material handling vehicle 100, the material handling vehicle 100 may lock the automated guided vehicle 210 in place via the connection mechanism previously described.

[0058] In some examples, once the automated guided vehicle 210 is docked to the material handling vehicle 100, the automated guided vehicle 210 may determine whether the material handling vehicle 100 includes a communication port 1405 at stage 1925. In some examples, if the vehicle does not include a communication port 1405, the operator may guide the material handling vehicle 100 and the automated guided vehicle 210 to the pickup location at stage 1930. However, if the vehicle includes a communication port, then at stage 1935, the automated guided vehicle 210 may engage with (e.g., access data from) one or more sensors or cameras disposed throughout the material handling vehicle 100 and modify the motion model of the automated guided vehicle 210 to match the model of the material handling vehicle 100. Thereafter, at stage 1940, the automated guided vehicle 210 may guide the material handling vehicle 100 via autonomous operation. In another example, if the vehicles do include communication ports, the interface between the automated guided vehicle 210 and the material handling vehicle 100 can allow the material handling vehicle to interface with (e.g., access data from) one or more sensors or cameras disposed throughout the automated guided vehicle 210.

[0059] Figure 20An example of a multi-level (e.g., multi-layer) docking / undocking process is shown for docking or undocking an automated guided vehicle 210 using a material handling vehicle 100 with a platform 125. In one example, a material handling vehicle 100 can dock with an automated guided vehicle 210 at a first rendezvous location 2005 in a warehouse or facility (e.g., on a first level 2010, on a first shelf, etc.). For example, the automated guided vehicle 210 can travel to the rendezvous location 2005 to rendezvous with an operator and the material handling vehicle 100.

[0060] In one example, the automated guided vehicle 210 can be docked to the material handling vehicle 100 via the platform 125 at a rendezvous location 2005, as previously described. Once the automated guided vehicle 210 is docked to the material handling vehicle 100, the material handling vehicle can move (e.g., raise or lower) the automated guided vehicle 210 via the platform 125, as indicated by arrow 2025. For example, the material handling vehicle 100 can raise the automated guided vehicle 210 to a second level 2020 of a warehouse or facility (e.g., a second level shelf, a mezzanine, etc.). Once at the second level 2020, the automated guided vehicle 210 can be undocked from the platform 125 of the material handling vehicle 100 at a second rendezvous location 2015.

[0061] It should be understood that in some examples, the material handling vehicle 100 can thus be used to transport the automated guided vehicle 210 between levels of a warehouse or facility. For example, the material handling vehicle 100 can dock with the automated guided vehicle 210 at a rendezvous location on a first level and undock from the automated guided vehicle 210 at a second rendezvous location on a second, different level.

[0062] In some embodiments, the apparatus or system disclosed herein can be utilized, manufactured, or installed using methods embodying various aspects of the present invention. Accordingly, any description herein of a particular feature, capability, or intended purpose of an apparatus or system is generally intended to include methods for disclosing methods of using such apparatus to achieve the intended purpose, methods for implementing such capabilities by other methods, methods for manufacturing components related to such apparatus or system (or apparatus or system as a whole), and methods for installing disclosed (or other known) components to support such purposes or capabilities. Similarly, unless otherwise indicated or limited, discussion herein of any method for manufacturing or using a particular apparatus or system (including installing the apparatus or system) is intended to inherently include the features and implemented capabilities utilized by such apparatus or system as embodiments of the present disclosure.

[0063] Moreover, as used herein, unless otherwise limited or qualified, "or" refers to a non-exclusive list of components or operations that can represent any kind of combination, rather than an exclusive list of components that can only be substituted for each other. For example, a list of "A, B, or C" refers to the following options: A; B; C; A and B; A and C; B and C; and A, B, and C. Correspondingly, the term "or" as used herein is intended to refer to exclusive substitutions only when preceded by an exclusive term, such as "or," "one of," "only one of," or "exactly one of." For example, a list of "one of A, B, or C" refers to the following options: A, but not B and C; B, but not A and C; and C, but not A and B. A list preceded by "one or more" (and variations thereon), and including "or" to separate the listed elements, refers to one or more options of any one or all of the listed elements. For example, the phrases "one or more of A, B, or C" and "at least one of A, B, or C" refer to the following options: one or more A; one or more B; one or more C; one or more A and one or more B; one or more B and one or more C; one or more A and one or more C; and one or more A, one or more B, and one or more C. Similarly, preceding the word "plurality" (and variations thereon) and including "or" to separate listed elements refers to the option of multiple instances of any or all of the listed elements. For example, the phrases "plurality of A, B, or C" and "two or more of A, B, or C" refer to the following options: A and B; B and C; A and C; and A, B, and C.

[0064] As used herein, unless otherwise defined or limited, directional terminology is used to facilitate discussion with reference to a particular figure or example. For example, references to a downward (or other) direction or a top (or other) position may be used to discuss aspects of a particular example or figure, but do not necessarily require similar orientations or geometries in all installations or configurations.

[0065] Likewise, as used herein, unless otherwise limited or defined, the term "integral" and its derivatives (e.g., "integrally") describe an element that is manufactured as a single piece without the need for fasteners, adhesives, or the like to secure separate parts together. For example, an element that is stamped, cast, or otherwise molded as a single-piece component from a single piece of sheet metal or using a single die, without rivets, screws, or adhesives holding the separately formed pieces together, is a unitary (and integrally formed) element. In contrast, an element that is formed from multiple pieces that are initially formed separately and then subsequently joined together is not a unitary (or integrally formed) element.

[0066] In addition, unless otherwise specified or limited, the terms "about" and "approximately" used herein with respect to a reference value refer to a variation of ±15% or less from the reference value, including the endpoints of the range. Similarly, the term "substantially equal to" (etc.) used herein with respect to a reference value refers to a variation of less than ±30% from the reference value, including the endpoints. Where specified, the term "substantially" can specifically refer to a variation in a numerical direction relative to the reference value. For example, "substantially less than" a reference value (etc.) means a value that is reduced by 30% or more from the reference value, while "substantially greater than" a reference value (etc.) means a value that is increased by 30% or more from the reference value.

[0067] The previous description of the disclosed embodiments is provided to enable one skilled in the art to make or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art given the benefit of this disclosure, and the principles defined herein may be applied to other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0068] Additional Examples

[0069] Example 1. A material handling vehicle comprises: a vertically movable platform including an operator cabin, a load deck, and one or more forks extending outwardly from the vertically movable platform; and a connecting mechanism secured to an underside of the one or more forks, the connecting mechanism securing an automated guided vehicle to the load deck such that vertical movement of the load deck causes corresponding vertical movement of the automated guided vehicle.

[0070] Example 2. The material handling vehicle of Example 1, wherein the connecting mechanism is pivotally mounted to an underside of the one or more forks via a mounting shaft.

[0071] Example 3. The material handling vehicle of Example 2, wherein the connecting mechanism includes angled surfaces for guiding a cross member of the automated guided vehicle into a cutout of the connecting mechanism to retain the automated guided vehicle to the material handling vehicle.

[0072] Example 4. The material handling vehicle of any previous example, wherein the connection mechanism includes a locking pawl mounted to an underside of the automated guided vehicle.

[0073] Example 5. The material handling vehicle of Example 4, wherein the locking pawl engages a surface of the fork to secure the automated guided vehicle to the material handling vehicle.

[0074] Example 6. The material handling vehicle of any of the previous examples, wherein the load deck includes a series of slots for holding one or more wheels of an automated guided vehicle.

[0075] Example 7. The material handling vehicle of any previous example, wherein the load deck includes a first segment and a second segment, and wherein the second segment of the load deck rotates from a position parallel to the first segment to a position perpendicular to the second segment to retain the automated guided vehicle on the load deck.

[0076] Example 8. The material handling vehicle of any preceding example, wherein the vertically movable platform includes a communication port to facilitate communication between the automated guided vehicle and the material handling vehicle.

[0077] Example 9. The material handling vehicle of Example 8, wherein connecting the automated guided vehicle and the material handling vehicle via the communication port allows the automated guided vehicle to utilize one or more sensors of the material handling vehicle.

[0078] Example 10. The material handling vehicle of any preceding example, wherein the vertically movable platform includes a charging port.

[0079] Example 11. The material handling vehicle of any preceding example, wherein the vertically movable platform includes fiducial markings to guide engagement between the automated guided vehicle and the material handling vehicle.

[0080] Example 12. The material handling vehicle of Example 11, wherein the fiducial marker is one of: an April tag, a barcode, a Quick Response (QR) code, an ArUco marker, a WhyCon marker, or a WhyCode marker.

[0081] Example 13. A method of docking an automated guided vehicle to a material handling vehicle, the method comprising: identifying the material handling vehicle via a fiducial marker disposed on the material handling vehicle; initiating docking the automated guided vehicle to the material handling vehicle by guiding the automated guided vehicle onto a load deck of the material handling vehicle; and securing the automated guided vehicle to the load deck of the material handling vehicle via a connection mechanism secured to the load deck.

[0082] Example 14. The method of Example 13, wherein vertical movement of the load deck causes corresponding vertical movement of the automated guided vehicle when the automated guided vehicle is secured to the material handling vehicle.

[0083] Example 15. The method of Example 14, wherein the vertical movement of the load deck transports the automated guided vehicle between a first level and a different second level of the facility.

[0084] Example 16. The method of Example 15, further comprising: docking the automated guided vehicle to the material handling vehicle at a first rendezvous location on the first level; and undocking the automated guided vehicle from the material handling vehicle at a second rendezvous location on the second level.

[0085] Example 17. The method of Examples 13 to 16, further comprising: guiding a cross member of the automated guided vehicle into a cutout of the connecting mechanism via an angled surface on one end of the connecting mechanism to secure the automated guided vehicle to the material handling vehicle.

[0086] Example 18. The method of Examples 13 to 17, further comprising: engaging a fork of the material handling vehicle with a locking pawl mounted to an underside of the automated guided vehicle such that the locking pawl contacts a surface of the fork to secure the automated guided vehicle to the material handling vehicle.

[0087] Example 19. The method of Examples 13 to 18, further comprising: when the automated guided vehicle is secured to the load deck of the material handling vehicle, connecting the automated guided vehicle to a communication port disposed on the load deck to allow the automated guided vehicle to utilize one or more sensors of the material handling vehicle.

[0088] Example 20. The method of Example 19, further comprising controlling, via the automated guided vehicle, one or more sensors of the material handling vehicle when the automated guided vehicle is connected to the communication port to allow the automated guided vehicle to guide movement of the material handling vehicle.

Claims

1. A material handling vehicle, comprising: a vertically movable platform comprising an operator cabin, a load deck, and one or more forks extending outwardly from the vertically movable platform; as well as A connecting mechanism is secured to an underside of the one or more forks, the connecting mechanism securing the automated guided vehicle to the load deck such that vertical movement of the load deck causes corresponding vertical movement of the automated guided vehicle.

2. The material handling vehicle according to claim 1, wherein: The connecting mechanism is pivotally mounted to the underside of the one or more forks via a mounting shaft.

3. The material handling vehicle according to claim 1, wherein: The connection mechanism includes angled surfaces for guiding a cross member of the automated guided vehicle into a cutout of the connection mechanism to retain the automated guided vehicle to the material handling vehicle.

4. The material handling vehicle according to claim 1, wherein: The connection mechanism includes a locking pawl mounted to an underside of the automated guided vehicle.

5. The material handling vehicle according to claim 4, wherein: The locking pawl engages a surface of the fork to secure the automated guided vehicle to the material handling vehicle.

6. The material handling vehicle according to claim 1, wherein: The load deck includes a series of slots for holding one or more wheels of the automated guided vehicle.

7. The material handling vehicle according to claim 1, wherein: The load deck includes a first section and a second section, and wherein the second section of the load deck is rotated from a position parallel to the first section to a position perpendicular to the second section to retain the automated guided vehicle on the load deck.

8. The material handling vehicle of claim 1, wherein: The vertically movable platform includes a communication port to facilitate communication between the automated guided vehicle and the material handling vehicle.

9. The material handling vehicle according to claim 8, wherein: Connecting the automated guided vehicle and the material handling vehicle via the communication port allows the automated guided vehicle to utilize one or more sensors of the material handling vehicle.

10. The material handling vehicle of claim 1, wherein: The vertically movable platform includes a charging port.

11. The material handling vehicle of claim 1, wherein: The vertically movable platform includes fiducial markings to guide engagement between the automated guided vehicle and the material handling vehicle.

12. The material handling vehicle of claim 11, wherein: The fiducial marker is one of the following: April Label; barcode; Quick Response (QR) codes; ArUco marking; WhyCon Marks; or WhyCode tag.

13. A method of docking an automated guided vehicle to a material handling vehicle, the method comprising: identifying the material handling vehicle via a fiducial marker disposed on the material handling vehicle; initiating docking of the automated guided vehicle to the material handling vehicle by guiding the automated guided vehicle onto a load deck of the material handling vehicle; as well as The automated guided vehicle is secured to the load deck of the material handling vehicle via a connection mechanism secured to the load deck.

14. The method according to claim 13, characterized in that When the automated guided vehicle is secured to the material handling vehicle, vertical movement of the load deck causes corresponding vertical movement of the automated guided vehicle.

15. The method according to claim 14, characterized in that Vertical movement of the load deck transports the automated guided vehicle between a first level and a different second level of a facility.

16. The method according to claim 15, characterized in that Also includes: docking the automated guided vehicle to the material handling vehicle at a first meeting location on the first level; as well as The automated guided vehicle is undocked from the material handling vehicle at a second meeting location on the second level.

17. The method according to claim 13, wherein Also includes: The automated guided vehicle is secured to the material handling vehicle by guiding a cross member of the automated guided vehicle into a cutout of the connecting mechanism via an angled surface on one end of the connecting mechanism.

18. The method according to claim 13, characterized in that Also includes: The forks of the material handling vehicle are engaged with locking pawls mounted to the underside of the automated guided vehicle so that the locking pawls contact surfaces of the forks to secure the automated guided vehicle to the material handling vehicle.

19. The method according to claim 13, wherein Also includes: When the automated guided vehicle is secured to the load deck of the material handling vehicle, the automated guided vehicle is connected to a communication port disposed on the load deck to allow the automated guided vehicle to utilize one or more sensors of the material handling vehicle.

20. The method according to claim 19, characterized in that Also includes: When the automated guided vehicle is connected to the communication port, one or more sensors of the material handling vehicle are controlled via the automated guided vehicle to allow the automated guided vehicle to guide movement of the material handling vehicle.

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