SMART MOUNTING SYSTEM AND METHOD

Abstract

The system comprises: at least one transport vehicle (20) configured for operation on a route; a mounting plate (40) configured to carry a payload; a linkage (60) connecting the mounting plate (40) to the at least one transport vehicle (20); a sensor configured to determine a position of the linkage (60); and at least one controller (68) configured to modify the operation of the at least one transport vehicle (20) in response to a change in the position of the linkage (60); wherein the mounting plate (40) includes a linkage system (70) configured to align the mounting plate (40) with a second mounting plate (42) in one of several alternative orientations.

Description

INTRODUCTION The present invention relates in general to the transport of payloads, e.g. by the use of automated vehicles, and relates in particular to an intelligent support for the movement of objects by automated vehicles while simultaneously correcting imbalances that would otherwise be transferred to the payload. In a wide variety of operations in logistics, manufacturing, and general material handling, payloads, which can include materials and objects, need to be moved from one place to another. Automated guided vehicles (AGVs) have been used to move things automatically with limited or no direct human guidance. AGVs can follow a predefined route, for example, by following a wire or tape embedded in the floor, or they can be pre-programmed to follow a route. Typically, an AGV performs its assigned tasks independently. To increase effectiveness and / or efficiency, greater flexibility and payload-moving capabilities are sought, for example, through AGV-like devices. US 2017 / 0313303A1 describes an arrangement and method for optimizing the load position with respect to a plurality of transport vehicles, comprising at least one master vehicle and at least one slave vehicle. US 2016 / 0167888A1 describes a mobile robotic device with a conveyor belt configured to connect to another conveyor belt of a second mobile robotic device. In this way, the mobile robotic devices can provide integrated, flexible conveyor belts and have the ability to connect conveyor belts to form a complete conveyor belt of any shape and size. US 2020 / 0081455A1 describes methods and systems for transporting an object using multiple transport vehicles. A transport vehicle may be autonomous and have one or more wheels extending from a body and engaging the ground surface. A method may include providing a destination for the object to the multiple transport vehicles, the multiple transport vehicles determining a route to the destination, dividing the route into one or more route segments for the multiple transport vehicles, and a first of the transport vehicles encountering an obstacle while traveling along one of the route segments, and transmitting the location of the obstacle from the first transport vehicle to at least one second of the transport vehicles. A second of the transport vehicles may, based on the provided location, modify at least one of the route segments to circumvent the obstacle. The object of the invention is to provide systems and methods that enable more effective and efficient material / object movement by transport vehicles, such as AGVs. This object is achieved by the features of independent claims 1 and 7. DESCRIPTION According to the invention, systems and methods for determining and correcting autonomous transport imbalances are provided. At least one transport vehicle operates along a route. To transport a payload, a mounting plate is coupled to the transport vehicle via a connection. A sensor determines the position of the connection. At least one controller modifies the operation of the transport vehicle in response to a change in the position of the connection in order to correct imbalances. The mounting plate includes a connection system for aligning the mounting plate with a second mounting plate in one of several alternative orientations. In other embodiments, the linking system includes tabs and slots. In additional embodiments, the mounting plate includes a pressure sensor. The controller uses a signal from the pressure sensor to determine whether the payload is loaded correctly. In additional versions, the mounting plate includes a locator to position the payload on the mounting plate. The pressure sensor is positioned on the locator. In additional versions, the mounting plate includes a series of distance sensors to detect the proximity of obstacles around the mounting plate. In additional embodiments, the mounting plate includes an electrical connector for coupling with an adjacent mounting plate. In other embodiments, the control system calculates a positional error of the mounting plate. In additional embodiments, the control system generates a motion control signal from the transport vehicle to minimize the positioning error. In other embodiments, the control system changes the speed of the transport vehicle based on the positional error. According to the invention, a method comprises operating a transport vehicle along a track; coupling a mounting plate to the transport vehicle by means of a connection; carrying a payload on the mounting plate; determining the position of the connection by means of a sensor; and modifying the operation of the transport vehicle in response to a change in the position of the connection. The mounting plate includes a connection system for aligning the mounting plate with a second mounting plate in one of several alternative orientations. In additional embodiments, a method includes forming the connection system in the form of tabs and slots. In additional embodiments, a method includes using a signal from a pressure sensor to determine whether the payload is loaded correctly. In additional embodiments, a method includes locating the payload on the mounting plate using the locator, wherein the pressure sensor is positioned on the locator. In additional embodiments, a method includes the use of distance sensors to determine the proximity of obstacles around the mounting plate. In further embodiments, a method comprises coupling the mounting plate to an adjacent mounting plate by means of an electrical connector. In further embodiments, a method includes calculating a positioning error of the mounting plate. In one example, a method includes generating a motion control signal of the transport vehicle to minimize the position error; and changing the speed of the transport vehicle based on the position error. In several further embodiments, a mounting system comprises two or more autonomous transport vehicles, each having a connection that couples a mounting plate to the autonomous transport vehicle. Each mounting plate contains a set of sensors for detecting observable conditions with respect to the mounting plate. A connection system aligns the mounting plates in one of several alternative orientations. A controller modifies the operation of the autonomous transport vehicles in response to a change in the position of at least one of the first and second connections in order to correct imbalances. BRIEF DESCRIPTION OF THE DRAWINGS The exemplary embodiments are described below in conjunction with the following drawing figures, where identical numbers denote identical elements, and where: Fig. 1 schematically shows a swarm of autonomous transport vehicles with mounting systems, including mounting plates, carrying a payload, according to various embodiments; Fig. 2 is a schematic top view of the autonomous transport vehicles of Fig. 1, with the mounting plates and payload omitted for clarity; Fig. 3 is a schematic top view of the mounting plates of Fig. 1 without a payload, according to various embodiments; Fig. 4 is a schematic section through line 4-4 indicated in Fig. 3, according to various embodiments; Fig. 5 is a schematic section through line 5-5 indicated in Fig. 3, according to various embodiments; Fig. 6 is a schematic top view of a group of reconfigurable mounting plates, according to various embodiments; Fig.Figure 7 schematically shows a top view of an autonomous transport vehicle with a mounting plate and an intermediately positioned, repositionable linkage, according to various embodiments; Figure 8 is a schematic bottom view of a mounting plate showing details of a sensor unit, according to various embodiments; Figure 9 is a schematic top view of a mounting plate showing details of a sensor unit, according to various embodiments; Figure 10 is a schematic side view of a mounting plate showing details of a sensor unit, according to various embodiments; Figure 11 is a schematic end view of a mounting plate showing details of a sensor unit, according to various embodiments; Figure 12 is a control system diagram for the mounting system of Figure 1, according to various embodiments; and Figure 13 is a schematic diagram of the mounting system of Figure 1, according to various embodiments.13 a flowchart of a method for controlling linkage connections for an AMR, according to various embodiments. DETAILED DESCRIPTION The following detailed description discloses exemplary embodiments which are not intended to limit the application and its uses. Furthermore, there is no intention to be bound by any express or implied theory presented in the preceding technical field, background information, brief description, or detailed description below.In the form used herein, the term module refers to any hardware, software, firmware, electronic control component, processing logic and / or processor device, individually or in any combination, including but not limited to: application-specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated or group) and memory executing one or more software or firmware programs, a combinational logic circuit and / or other suitable components providing the described functionality. Embodiments of the present invention can be described herein in the form of functional and / or logical block components and various processing steps. It should be noted that such block components can be implemented by any number of hardware, software, and / or firmware components configured to perform the specified functions. For example, an embodiment of the present invention may employ various integrated circuit components, such as memory elements, digital signal processing elements, logic elements, lookup tables, or the like, which can perform a variety of functions under the control of one or more microprocessors or other control devices.Furthermore, those skilled in the art will recognize that embodiments of the present invention can be practiced in conjunction with any number of control systems and that the vehicle system described here is only an exemplary embodiment of the present invention. For the sake of brevity, conventional techniques relating to signal processing, data transmission, signaling, control, and other functional aspects of the systems (and the individual operating components of the systems) are not described in detail here. Furthermore, the connecting lines shown in the various figures are intended to represent exemplary functional relationships and / or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may exist in an embodiment of the present invention. As described herein, the disclosed system and method implementations offer greater flexibility for the deployment of cost-effective and / or generic autonomous transport vehicles, such as AGVs and autonomous mobile robots (AMRs), in a wide range of applications, both individually and in swarms. The AGVs / AMRs used may have limited computing power, while the capabilities of the disclosed support systems can correct imbalances to safely move payloads of various configurations. For example, one or more support plates are reconfigurable to support different types of payloads. Sensors / encoders provide information about the relative positions / angles between the autonomous transport vehicles and their associated support plates, which is used to dynamically adjust the operation of the autonomous transport vehicles to compensate for variations during operation and prevent damage to the payload.In some embodiments, the individual relative positions / angles of the mounting plates can be modified to further correct imbalances or compensate for fluctuations. In a variety of embodiments, the mounting plates can incorporate distance / proximity sensors to determine the presence of obstacles and / or distances to loading or processing locations. The mounting plates can also include some type of load sensor to verify the correct loading of the payload and / or to balance loads for stable transport. The mounting plates can be modular and can be connected to other mounting plates in any number of configurations to provide a flexible and scalable platform for accommodating various payloads. One embodiment, as shown in Fig. 1, can comprise a number of autonomous transport vehicles 20, 22, 24 that cooperate. Example transport vehicles can generally be autonomous in their mission, e.g., to travel a route between different locations while transporting the payload. In various embodiments, an autonomous transport vehicle 20, 22, 24 can operate alone to fulfill a mission or be grouped with a number of other autonomous transport vehicles 20, 22, 24 in a swarm that can be formed in real time according to the requirements of a particular mission. In several embodiments, parameters such as size, shape, payload weight, and / or location position(s) can be used to determine a swarm footprint, the number of autonomous transport vehicles required for the mission, and / or the positioning of the autonomous transport vehicles relative to each other.The autonomous transport vehicles 20, 22, 24, etc., can navigate autonomously through the mission and communicate with each other and with other devices. The mounting plate systems and procedures described herein can be used with various autonomous transport vehicles, including those described in US 2020 / 0081455A1, which is expressly incorporated herein by reference. Referring to Fig. 2 together with Fig. 1, each autonomous transport vehicle 20, 22, 24 includes a number of wheels 26 for driving on a surface, such as a floor 28. In the present embodiment, the autonomous transport vehicles 20, 22, 24 form a swarm 36 of three. It should be understood that in various embodiments, a swarm can contain any number of autonomous transport vehicles 20, 22, 24 suitable for transporting the payload of a particular mission. As the swarm 36 moves across the floor 28 or any other surface it traverses, positional or formational deviations may occur between the individual autonomous transport vehicles 20, 22, 24, for example, due to imperfect operation, uneven spots on the floor 28, cornering, or other factors. As described here, the autonomous transport vehicles 20, 22, 24 each carry a mounting system 30, 32 respectively.34, which offers a number of advantages, including helping to compensate for fluctuations in order to maintain a consistent support system for the payload. As described herein, advantages can arise such that the payload is protected and transported safely. Each of the support systems 30, 32, 34 is flexible, e.g., by incorporating a support plate 40, 42, or 44, respectively, which can be tailored to the payload being transported, and each can have aspects that vary between the different autonomous transport vehicles 20, 22, 24 to which it is connected. In the present embodiment, the swarm 36 is configured to support, for example, an axle assembly 48 for a vehicle (not shown), with the support system 32 being constructed differently from the support systems 30, 34 in order to conform to the shape of the axle assembly 48.For example, the mounting system 32 includes a mount 52, which is constructed differently from the mounts 50, 54. Each unit also includes a connection 60, 62, 64 between a respective autonomous transport vehicle 20, 22, 24 and its respective mounting plate 40, 42, 44, which, as described below, is dynamic. It includes at least one controller 68, which serves as an interface and for controlling various aspects and functions, including those of the mounting systems 30, 32, 34. The controller(s) 68 can also control various aspects of one or more of the autonomous transport vehicles 20, 22, 24. In several embodiments, each autonomous transport vehicle 20, 22, 24 can have a separate controller (not shown). When operating in a swarm 36, one autonomous transport vehicle 20, 22, 24 can act as a lead vehicle for coordinating the control. In several embodiments, the controller(s) 68 can be a series of controllers, one of which is supported by each of the mounting plates 40, 42, 44.In several additional embodiments, the controller(s) 68 can be a plug-and-play unit that is coupled to one of the mounting plates 40, 42, 44 during setup. In several additional embodiments, the controller(s) 68 can be remotely controlled and coupled to the swarm 36 wirelessly or by other means. Aspects of the controller(s) are described below. Referring to Fig. 3, one embodiment of the mounting plates 40, 42, 44 shows that each has a connection system 70, 72, 74 by which the mounting plates 40, 42, 44 can interlock in various configurations. The connection systems 70, 72, 74 enable the mounting plates 40, 42, 44 to interlock in different configurations and to easily separate from one another after completion of an operation. For example, at the beginning of an operation, the autonomous transport vehicles 20, 22, 24, which are connected to the mounting plates 40, 42, 44, can drive towards each other and interlock in a configuration suitable for the payload. As part of the connection systems 70, 72, 74, the tabs 80 of the mounting plate 40 engage in the slots 92 of the mounting plate 42. Furthermore, the tabs 82 of the mounting plate 42 engage in the slots 90 of the mounting plate 40 and in the slots 94 of the mounting plate 44.Additionally, the tabs 84 of the mounting plate 44 engage in the slots 92 of the mounting plate 42. The connection systems 70, 72, 74 assist in aligning the mounting plates 40, 42, 44, but in this embodiment, they do not lock the mounting plates 40, 42, 44 together. Accordingly, the mounting plates 40, 42, 44 can easily separate after completion of the mission, and the associated autonomous transport vehicles 20, 22, 24 can detach and operate independently to reach their next mission. The mounting plates 40, 42, 44 contain a series of locators 100, 102, 104 for setting up brackets tailored to different payloads. The locators 100, 102, 104 can have various shapes such as pins, holes, slots, etc., and can be distributed across the top or other surfaces of the mounting plates 40, 42, 44 as required. The mounting plates 40, 42, 44 can also include electrical connectors 106, 108 for the automatic coupling of electrical features when the mounting plates 40, 42, 44 are assembled at the start of an operation. With further reference to Fig. 4, the pressure sensors 110, 112 are associated with the localizers 104 as an example to determine the load on the payload as described below. Furthermore, as shown in Fig. 5, the sensors, such as encoders 114, 116, 118, are each positioned next to a corresponding connection 60, 62, 64 to measure the position and inclination of the mounting plates 40, 42, 44 relative to their respective autonomous transport vehicle 20, 22, 24, as described in more detail below. The encoders 114, 116, 118 can be embedded in their respective mounting plates 40, 42, 44 or mounted in another way to determine the relative position and inclination. In a number of embodiments, the encoders 114, 116, 118 can be any sensor that converts position and / or angle changes into electronic signals in real time. As shown in Fig. 6, the mounting plates 110, 112, 114 are configured with the connection systems 116, 118, 120, which allow for greater flexibility in their relative positioning. In this example, each mounting plate has tabs and slots on each side and at each end. For example, mounting plate 110 has tabs and / or slots on side 122 and side 124. Furthermore, mounting plate 110 has tabs and / or slots on side 126 and side 128. Mounting plates 112 and 114 are similarly configured. Consequently, the mounting plates 110, 112, 114 can interlock on one or both sides and / or ends. It should be noted that, while the current example includes mounting plates of a generally rectangular shape, other embodiments may include mounting plates of any other shape, such as polygonal, rounded, curved, etc., depending on the payloads to be transported.Additionally, while tabs and slots are included in this example, other shapes can be used for the connection systems, such as straight edges or features that are rounded, bent, angled, etc., as is suitable for the detachable alignment of the mounting plates 110, 112, 114 to accommodate the intended payloads. As schematically illustrated in Fig. 7, a linkage connection system 130 is shown, which can be used for the connections 60, 62, 64. The linkage connection system 130 in this example offers flexibility and extended possibilities for the connection between the autonomous transport vehicle 132 and the mounting plate 134. The linkage connection system 130 includes a connection 136, which provides a number of degrees of freedom between the mounting plate 134 and the autonomous transport vehicle 132. The connection 136 can be configured as a hinge, ball joint, universal joint, or other mechanism to allow pivoting and / or rotation of the mounting plate 134 relative to the autonomous transport vehicle 132. In several embodiments, the connection 136 can be passive, move in response to applied forces, and be pre-tensioned, e.g., by spring action, to return to an initial position.In several other embodiments, an actuator 138 can be used to automatically and dynamically position the link 136 and can employ gears, belts, screws, linkages, electromagnetism, or other mechanisms to effect the movement. An encoder 140 provides a signal to determine the relative position and / or angle. In this embodiment, a second actuator 142 is included to vary the height of the mounting plate 134 relative to the autonomous transport vehicle 132. The encoder 140 can provide data on the relative height, or a separate sensor can be used. The linking system 130 enables real-time compensation of variables that may arise due to factors such as operating area fluctuations and formation deviations in the swarm 36.Compensation can be achieved by varying the operation of the autonomous transport vehicle 132 for correction and / or by actuating the connection 136. In a number of embodiments, active compensation enables the use of more cost-effective autonomous transport vehicles that can be built to less stringent specifications with less precise operating tolerances. With reference to Figures 8-11, a sensor unit 150 is shown for the mounting plate 152, the aspects of which are applicable to other mounting plates, such as mounting plates 40, 42, and 44. In Figure 8, the upper 154 of the mounting plate 152 is shown, which corresponds to the surface on which the payload is borne. Each localizer 156 is surrounded by a pressure sensor 158, which maps the pressure of the payload onto the mounting plate 152. Each localizer 156 defines a load zone through which the weight of the payload is transferred to the mounting plate 152. Any number of load zones can be included, so that in some embodiments the upper surface 154 of the mounting plate can be substantially covered with a pressure-sensitive film or layer for mapping the load onto the mounting plate 152.The expected pressure profile of a given payload can be predetermined for each mounting plate in the swarm based on factors such as weight, size / footprint, and localization scheme for a balanced load on the autonomous transport vehicles. In this embodiment, the pressure measurement signals from the pressure sensors 158 are used to verify the loaded position of the payload by comparing the predetermined pressure profile with the actual pressure profile determined by the pressure sensors 158. If deviations occur between the currently loaded payload positions, as reflected by the pressures and the predetermined profile, and if the deviations exceed a predefined specification / tolerance, the load is considered unbalanced.If an unbalanced load occurs, an alarm or other indicator can be issued to show that reloading is required, and / or the loaded swarm can be programmed not to move. As shown in Fig. 9, the base 160 of the mounting plate 152 is shown, corresponding to the surface facing the associated autonomous transport vehicle 20, 22, 24. In this embodiment, each of the connections 162, 164 for coupling with the autonomous transport vehicle 20, 22, 24 includes a sensor, which in this example is an encoder 166, 168. The encoders 166, 168 measure the position / angle of the mounting plate 152 relative to their respective autonomous transport vehicles 20, 22, 24 to enable control, maintain alignment between the various mounting plates in the given swarm, and limit stresses on the payload, as described below. Figure 10 shows side 170 of the mounting plate, which either fits with other mounting plates in the swarm or is located on the outside of the mounting plates in the swarm. Side 170 contains proximity sensors 172, 174, which can be embedded or plugged in as needed to detect the proximity of objects. The proximity sensors 172, 174 can be ultrasonic, electromagnetic, or of another type. In several embodiments, the proximity sensors 172, 174 are used to determine the proximity of other objects, such as other mounting plates during swarm formation, obstacles in the path, and / or structures at the target locations. Figure 11 illustrates the end 176 of the mounting plate 152, which similarly also contains the proximity sensors 178, 180.Furthermore, the end 176 includes a navigation sensor 182 for use by the associated autonomous transport vehicle 20, 22, 24 for self-navigation with LIDAR, RADAR, cameras, or other visual navigation devices that facilitate three-dimensional vision. The end 184 of the mounting plate 152 can be configured similarly to the end 176. General aspects of a control system 190 for the mounting system 30, 32, 34 are shown in Fig. 12. The control system 190 generally comprises the controller 68, the sensors 158, 166, 172 and 178, the actuators 138, 142 and other interface controller(s) 192. The controller 68 can receive various signals from the sensors 158, 166, 172 and 178, send control signals to the actuators 138, 142 and can form an interface with the other controller(s) 192, e.g. with the autonomous transport vehicles 20, 22, 24, other mounting plates and / or other. In several embodiments, other sensors may be included that detect observable conditions relating to the mounting plates 40, 42, 44 and / or the mounting systems 30, 32, 34.The controller 68 is communicatively coupled to receive input signals from the various sensors, which are configured to generate signals relative to different physical parameters. In general, the controller 68 can use the acquired values ​​to generate output signals for transmission to various controlled devices. The controller 68 can comprise any number of electronic control modules and is configured to receive information from various sources, process this information, and provide control signals / commands based on it to produce results such as the operation of the actuators 138, 142. In the illustrated embodiment, the controller 68 includes a processor 194 and a memory device 196 and may include or be coupled to a memory device 198.The processor 194 performs the computing and control functions of the controller 68 and can comprise any type of processor or multiple processors, individual integrated circuits, such as a microprocessor, or a suitable number of integrated circuits and / or printed circuit boards working together to perform the functions of a processor unit. During operation, the processor 194 executes one or more programs and can use data, each of which may be contained in the storage device 198, and as such, the processor 194 controls the general operation of the controller 68 in the execution of the processes described herein, including those shown below in conjunction with Fig. 13. The memory device 196 can be any type of suitable memory. For example, the memory device 196 can include volatile and non-volatile storage in read-only memory (ROM), random access memory (RAM), and keep-alive memory (KAM). KAM can include persistent or non-volatile memory that can be used to store various operating variables while the processor 194 is powered off. The memory device 196 can be implemented using any of the known memory devices, such as PROMs (programmable read-only memory), EPROMs (erasable PROMs), EEPROMs (electrically erasable PROMs), flash memory, or other electrical, magnetic, optical, or combined memory devices capable of storing data, some of which may be executable instructions used by the controller 68.In certain embodiments, the storage device 196 can be located on the same computer chip and / or co-located on the same computer chip as the processor 194. In the embodiment shown, the storage device 196 can store the aforementioned programs together with one or more stored data values, e.g., for short-term data access. The storage device 198 stores data, e.g., for long-term data access for use in the automatic control of the mounting system 30, 32, 34 and the associated systems. The storage device 198 can be any suitable type of storage device, including direct-access storage devices such as hard disk drives, flash systems, floppy disk drives, and optical disk drives. In an exemplary embodiment, the storage device 198 comprises a source from which the storage device 196 receives the programs that execute one or more embodiments of one or more processes of the present invention, such as the steps of the process (and all subprocesses thereof) described below, including below in conjunction with Fig. 13.In another exemplary embodiment, the programs can be stored directly in the storage device 196 and / or accessed from it in another way. The programs represent executable instructions used by the electronic controller 68 for information processing and for controlling the mounting system 30, 32, 34 and related systems. The instructions can contain one or more separate programs, each containing an ordered list of executable instructions for implementing logical functions. When executed by the processor 194, the instructions support the reception and processing of signals, e.g., from the various sensors, and the execution of logic, calculations, procedures, and / or algorithms for the automatic control of the components and systems of the mounting system 30, 32, 34.The processor 194 can generate control signals for automatic control based on logic, calculations, procedures, and / or algorithms. As can be estimated, the data storage device 198 can be part of the controller 68, separate from the controller 68, part of one or more other controllers, or part of multiple systems. The storage device 196 and the data storage device 198 work together with the processor 194 to access and use the programs and data. While the components are presented as part of the same system, it should be understood that these features can encompass multiple systems in certain embodiments. In several embodiments, the controller 68 and / or the controller(s) 192 can determine operational changes for the autonomous transport vehicles 20, 22, 24 in order to correct imbalances in their operation within the swarm 36. In several additional embodiments, the controller 68 can determine adjustments to the positioning of the mounting plates 40, 42, 44 relative to their respective autonomous transport vehicles 20, 22, 24, e.g., by using the input signals from the encoders 166, 168 and adjusting the actuators 138, 142. With reference to Fig. 13, a process 200 is additionally shown in the form of a flowchart, as it can be carried out by the controller 68 to maintain the positioning between the mounting plates 40, 42, 44 due to instabilities arising from fluctuations / imperfect operation of the autonomous transport vehicles 20, 22, 24. The process 200 begins, for example, when the swarm 36 is formed at the start of a mission.In process 200, the following parameters can be used, where: v is the current control speed of the autonomous transport vehicle; θ is the current link encoder reading; F is the mounting plate coordinate frame; pfine is the position of an autonomous transport vehicle relative to the mounting plate frame; lfine is the position of an autonomous guide transport vehicle relative to the mounting plate frame; pfine is the current position of an autonomous transport vehicle relative to the guide robot frame; desfine is the desired position of the autonomous transport vehicle relative to the guide robot frame; and undfine is the positional error of an autonomous transport vehicle from its desired position. Process 200 continues and various sensor signals are read 204, including those from encoders 114, 116, 118, and other inputs are received, such as from the other controller(s) 192, like the speed of the autonomous transport vehicle 20, 22, 24. The position of the autonomous transport vehicle is calculated by the controller 68 within the frame of the mounting plate 40, 42, 44 based on the linkage kinematics 206, where pf = Link(θ). Each mounting plate 40, 42, 44 is transformed by the controller 68 from its respective mounting plate frame 208 into the frame of the autonomous guide transport vehicle using pl = (lpf) - 1 * pf. The current position error of the autonomous transport vehicle is calculated by the controller 68 210 using ep = despl - pl. The position error ep is transmitted to the control(s) 192 for motion control of the autonomous transport vehicle 20, 22, 24 212.The controller(s) 192, which controls the movement of the autonomous transport vehicle 20, 22, 24, can 214 generate a new vneu value of the motion control to minimize the position error ep towards zero. Process 200 continues and compares vneu with acceptable speeds to determine 216 whether it is within the limits. If determination 216 is positive, process 200 continues to determine 218 whether the position of the autonomous transport vehicle 20, 22, 24 has reached the destination. If determination 218 is positive, process 200 ends 220 until a new cycle is initiated. If determination 218 is negative, process 200 returns to step 204 and continues from there. Returning to step 216 if the determination is negative, swarm 36 is stopped for a certain time 222 to allow the swarm 36 formation to stabilize, and the process returns to step 204 and continues from there. The aforementioned embodiments enable systems and methods to autonomously transport payloads and to detect and correct imbalances. Imbalances can be corrected if they arise from imperfect operation of the autonomous transport vehicles or from other factors. These imbalance corrections ensure the safe transport of payloads, even when using conventional AGVs / AMRs with limited computing power.

Claims

System comprising: at least one transport vehicle (20) configured for operation on a route; a mounting plate (40) configured to carry a payload; a linkage (60) connecting the mounting plate (40) to the at least one transport vehicle (20); a sensor configured to determine a position of the linkage (60); and at least one controller (68) configured to modify the operation of the at least one transport vehicle (20) in response to a change in the position of the linkage (60); wherein the mounting plate (40) includes a linkage system (70) configured to align the mounting plate (40) with a second mounting plate (42) in one of several alternative orientations. System according to claim 1, wherein the connection system (70) comprises tabs (80) and slots (92). System according to claim 1, wherein the mounting plate (40) includes a pressure sensor (110), and wherein the at least one controller (68) is configured to determine, using a signal from the pressure sensor (110), whether the payload is loaded correctly. System according to claim 1, wherein the mounting plate (40) includes a number of distance sensors (172, 174) configured to detect the proximity of obstacles around the mounting plate (40). System according to claim 1, wherein the mounting plate (40) includes an electrical connector (106) configured to be coupled to an adjacent mounting plate (42). System according to claim 1, wherein the at least one controller (68) is configured to calculate a positional error of the mounting plate (40). The method comprises: operating at least one transport vehicle (20) on a track; coupling a mounting plate (40) to the at least one transport vehicle (20) by means of a connection (60); carrying a payload on the mounting plate (40); determining a position of the connection (60) by means of a sensor; and modifying the operation of the at least one transport vehicle (20) by means of at least one controller (68) in response to a change in the position of the connection (60); wherein the mounting plate (40) includes a connection system (70) configured to align the mounting plate (40) with a second mounting plate (42) in one of several alternative orientations. Method according to claim 7, comprising calculating a positioning error of the mounting plate (40) by the at least one control (68). The method of claim 8, comprising: generating a motion control signal of the at least one transport vehicle (20) by the at least one controller (68) to minimize the position error; and changing the speed of the at least one transport vehicle (20) by the at least one controller (68) based on the position error.

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