AUTONOMOUS MOBILE ROBOT FOR TRANSPORTING MATERIAL IN A MANUFACTURING ENVIRONMENT

Abstract

An autonomous mobile robot that transports material in a manufacturing environment includes a chassis comprising a main body that defines two opposite sides, a front, a back, and a bottom facing the terrain the robot traverses. The main body defines two or more channels arranged along its underside, each shaped to accommodate an arm of a lifting mechanism. The autonomous mobile robot also includes a track drive system comprising two drive units, each mounted on one of the two opposite sides of the chassis. Each drive unit includes a track, a pair of driven wheels, and one or more idler wheels positioned between the pair of driven wheels, with the track engaging with the pair of driven wheels and the idler wheel.

Description

INITIATIONThe present disclosure relates to an autonomous mobile robot for transporting material in a manufacturing environment.Autonomous mobile robots are mobile systems that navigate along a fixed, predefined path and react to uncontrolled environments without physical or electromechanical guidance and also without restriction of movement. According to one implementation, an autonomous mobile robot may be deployed to transport materials within a manufacturing environment. Specifically, the autonomous mobile robot can transport materials from storage or receipt locations to an order fill or use destination within a manufacturing facility.Although autonomous mobile robots fulfil their intended purpose of transporting materials, there are several challenges facing them in a manufacturing environment. Current autonomous mobile robots include, for example, wheels or casters that sometimes have problems in crossing rough terrain. In particular, features such as cracks, holes, pits, and uneven junctions along the floor of a manufacturing facility create difficulties when an autonomous mobile robot attempts to traverse the terrain. Further, various items commonly found in a manufacturing facility, such as bolts, nails, and nuts, may fall on the ground and tend to stick in the wheels of an autonomous mobile robot, which may prevent forward movement. The autonomous mobile robot may be returning and attempting to continue the forward travel, but this may be particularly difficult because the autonomous mobile robot does not know which specific object prevents the forward travel. In addition, many autonomous mobile robots have low ground clearance. While low ride height results in a lower overall height, low ride height results in lower terrain variation to which an autonomous mobile robot can adapt.In addition to the aforementioned challenges, it should also be noted that current autonomous mobile robots are not easily moved when not powered due to both electrical or hardware problems and during maintenance. Moreover, there are not many convenient options for removing an immobilized autonomous mobile robot from the bottom of the manufacturing facility. Indeed, depending on the problem, it may sometimes take hours or even days to repair or service an autonomous mobile robot.Autonomous mobile robots may also include numerous wires and controllers attached to a central chassis / frame. The numerous wires and controllers are highly integrated and may cause problems during manufacture and maintenance because it is not efficient to replace only some components without disassembling much of the autonomous mobile robot. Furthermore, many current autonomous mobile robots have a footprint that is smaller than the material cart they are transporting. These differences in size can cause problems during computer vision during navigation. Many autonomous mobile robots also require lifting mechanisms that are connected to trolley or racks. As a result, the docking and docking procedure between the autonomous mobile robot and the trolley or stand requires precise alignment, and can become time consuming.Thus, while current autonomous mobile robots fulfil their intended purpose, there is a need in the art for an autonomous mobile robot that overcomes the above-mentioned problems.US 2023 / 0 025 818 A1 discloses an autonomous mobile robot that transports material in an industrial environment. The autonomous mobile robot includes a chassis including a main body defining two opposing sides, a front side, a back side, and a bottom side facing the ground that the autonomous mobile robot crosses. The autonomous mobile robot also has a wheel drive system with two wheels on opposite sides. Further, the main body defines two channels that are disposed along the bottom of the main body and that are each shaped to receive an arm of a lifting mechanism. EP 3 760 481 A1 describes an autonomous mobile robot for material transport comprising a chassis having a main body defining two opposite sides, a front side, a rear side and a bottom side facing the floor which the robot crosses. In addition, the autonomous mobile robot has a crawler drive system having two crawlers on opposite sides each including a crawler, a pair of drive wheels, and pulleys disposed between the drive wheels.SUMMARYIt is an object of the invention to provide an improved mobile robot.To achieve the object, a mobile robot having the features of claim 1 is provided. Advantageous embodiments of the invention can be taken from the dependent claims, the description and the drawings.In several aspects, an autonomous mobile robot is disclosed that transports material in a manufacturing environment. The autonomous mobile robot includes a chassis including a main body defining two opposing sides, a front side, a back side, and a bottom side facing a terrain that the autonomous mobile robot traverses. The main body defines two or more channels that are disposed along the bottom of the main body and that are each shaped to receive an arm of a lifting mechanism. The autonomous mobile robot also includes a track drive system including two drive systems each mounted on one of two opposing sides of the chassis. Each drive system includes a track chain, a pair of driven wheels, and one or more idler wheels disposed between the pair of driven wheels, the track chain engaging the pair of driven wheels and the idler wheel. The autonomous mobile robot further includes a pallet seated on a top surface of a support plate seated on a top surface of the main body, the pallet including a main body defining a wing and a plurality of openings distributed in a grid pattern along the wing. The plurality of apertures of the pallet are specifically dimensioned to receive rack systems.In another aspect, each channel of the chassis extends from the front to the rear of the chassis.In yet another aspect, a clearance between the underside along one of the channels of the chassis and the terrain traversed by the autonomous mobile robot is measured.In one aspect, the autonomous mobile robot further includes two motors and two gears, each of the two motors corresponding to and driving one of the driving systems, and the two gears are directly connected to each of the two motors.In another aspect, the two or more channels are load-bearing members of the chassis.In yet another aspect, the autonomous mobile robot further includes two or more cameras, wherein a first camera is disposed along the front of the chassis and a second camera is disposed along the rear of the chassis.In one aspect, the autonomous mobile robot includes a LiDAR sensor disposed on each of the two opposing sides, the front side and the back side of the chassis.In another aspect, a first height measured between the terrain and one of the two or more cameras is greater than a second height measured between one of the LiDAR sensors and the terrain.In yet another aspect, the main body of the chassis defines one or more cavities.According to an aspect, the autonomous mobile robot further includes a support plate seated on an upper surface of the main body of the chassis to cover the one or more cavities.In one aspect, the track of the track drive system includes an inner surface and an outer surface.In another aspect, the inner surface of the track includes a plurality of inner teeth that engage corresponding teeth disposed about the pair of driven wheels, the outer surface of the track including a plurality of outer teeth.An example autonomous mobile robot transports material in a manufacturing environment. The autonomous mobile robot includes a chassis including a main body defining two opposing sides, a front side, a back side, and a bottom side facing a terrain that the autonomous mobile robot traverses. The main body defines two or more channels disposed along the underside of the main body and each shaped to receive an arm of a lifting mechanism, each channel of the chassis extending from the front to the rear of the chassis. The autonomous mobile robot also includes a track drive system including two drive systems each mounted on one of two opposing sides of the chassis. Each drive system includes a track chain including an inner surface including a plurality of inner teeth and an outer surface including a plurality of outer teeth, a pair of driven wheels including respective teeth, the plurality of inner teeth of the track chain engaging the respective teeth disposed about the pair of driven wheels, and one or more idler wheels disposed between the pair of driven wheels, the track chain engaging the pair of driven wheels and the idler wheel.The example autonomous mobile robot further includes two or more cameras, a first camera disposed along the front of the chassis and a second camera disposed along the rear of the chassis, and a LiDAR sensor disposed on each of the two opposing sides, the front and the rear of the chassis.The main body of the chassis may define one or more cavities.The autonomous mobile robot may further include a support plate seated on an upper surface of the main body of the chassis to cover the one or more cavities.The autonomous mobile robot may further include a pallet seated on the top of the support plate.Another example autonomous mobile robot transports material in a manufacturing environment. The autonomous mobile robot includes a chassis including a main body defining one or more cavities, a top, two opposing sides, a front, a back, and a bottom facing a terrain that the autonomous mobile robot traverses. The main body defines two or more channels disposed along the underside of the main body and each shaped to receive an arm of a lifting mechanism, each channel of the chassis extending from the front to the rear of the chassis. The autonomous mobile robot also includes a support plate seated on an upper surface of the chassis main body to cover the one or more cavities. The autonomous mobile robot also includes a pallet seated on top of the support plate. The autonomous mobile robot also includes a track drive system including two drive systems each mounted on one of two opposing sides of the chassis. Each drive system includes a track chain including an inner surface including a plurality of inner teeth and an outer surface including a plurality of outer teeth, a pair of driven wheels having respective teeth, the plurality of inner teeth of the track chain engaging the respective teeth disposed about the pair of driven wheels, and one or more idler wheels disposed between the pair of driven wheels, the track chain engaging the pair of driven wheels and the idler wheel.Further areas of applicability will become apparent from the description provided herein. It should be appreciated that the description and specific examples are provided for purposes of illustration only and are not intended to limit the scope of the disclosure.BRIEF DESCRIPTION OF THE DRAWINGSThe drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way; it shows: FIG. 1 is a perspective view of the disclosed autonomous mobile robot including a track chain drive system, a chassis, multiple perception sensors, and a pallet, according to an example embodiment; FIG. 2A is an arrangement view of the autonomous mobile robot shown in FIG. 1, according to an exemplary embodiment; FIG. 2B illustrates the chassis with two motors and a transmission located within the cavities of the chassis visible, according to an exemplary embodiment; FIG. 3 is a side view of the autonomous mobile robot showing one of the drive systems that are part of the crawler drive system according to an exemplary embodiment; FIG. 4 is an enlarged view of one of the crawlers shown in FIG. 3 according to an exemplary embodiment; FIG. 5 is a front view of the autonomous mobile robot according to an exemplary embodiment; FIG. 6 is a bottom view of the autonomous mobile robot showing the bottom of the chassis and two channels according to an exemplary embodiment; and FIG. 7 is a perspective view of a prior art forklift including a pair of arms corresponding to the two channels of the chassis shown in FIG. 6.DETAILED DESCRIPTIONThe following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.A perspective view of the disclosed autonomous mobile robot 10 is illustrated in FIG. 1. The autonomous mobile robot 10 navigates and responds to uncontrolled events within a manufacturing environment without requiring external intervention during materials shipping. FIG. 2A is an arrangement view of the autonomous mobile robot shown in FIG. 1. In FIGS. 1 and 2A, the autonomous mobile robot 10 includes a track chain drive system 20, a chassis 22, a support plate 24, a pallet 26, and a housing 28 (seen in FIG. 2A ) that contains one or more rechargeable battery modules (the one or more rechargeable battery modules not visible in the figures).More specifically, in FIG. 2A, the chassis 22 includes a main body 40 defining one or more cavities 42 shaped to contain multiple electrical components, such as the housing 28 containing the one or more battery modules, multiple sensing sensors 44, and one or more controllers 46. As seen in FIG. 2A, the housing 28 containing the one or more rechargeable battery modules is positioned within a central region 48 of the one or more cavities 42 of the chassis 22. The one or more rechargeable battery modules may include, for example, lead-acid or lithium-ion batteries and provide the electrical power required to operate the autonomous mobile robot 10. The support plate 24 is a guard plate that sits on a top 82 of the main body 40 of the chassis 22 and covers the one or more cavities 42 of the chassis 22. The one or more controllers 46 are electronically in communication with the track chain drive system 20, the one or more battery modules, and the plurality of sensing sensors 44.The chassis 22 defines two opposing sides 50, a front side 52, and a rear side 54. The track chain drive system 20 includes two drive systems 56, each drive system 56 mounted to one of the two opposing sides 50 of the chassis 22. Each propulsion system 56 includes a track 60, a pair of driven wheels 62, and one or more idler wheels 64 disposed between the pair of driven wheels 62, FIG. 2B illustrates the chassis 22 with a plurality of the electrical components located within the one or more cavities 42 removed to more clearly show two motors 66, each motor 66 corresponding to and driving one of the propulsion systems 56. It should be appreciated that two transmissions 68 are each directly connected to one of the two motors 66, however only one of the transmissions 68 is visible in FIG. 2B. According to the embodiment shown, each motor 66 is positioned in alignment with the corresponding transmission 68.FIG. 3 is a side view of the autonomous mobile robot 10 illustrating one of the drive systems 56. The track 60 corresponding to each drive system 56 engages the respective driven wheels 62 and idler wheels 64. Referring to FIGS. 2B and 3, it is to be appreciated that each propulsion system 56 is operatively connected to one of the two motors 66 via a respective transmission 68, with each motor 66 driving a respective pair of driven wheels 62. Unlike existing designs, the autonomous mobile robot 10 does not include an integrated motor. In other words, the motors 66 are separated from the pair of driven wheels 62, which enables upgrading, repair, and maintenance of the motors 66 and the track drive system 20 without the need to disassemble the chassis 22. It should also be appreciated that the components of the track drive system 20, such as the track 60, the pair of driven wheels 62, and the one or more idler wheels 64, may also be easily replaced because they are separate components.FIG. 4 is an enlarged view of one of the tracks 60 of the track drive system 20. in FIGS. 2A and 4, each track 60 of the track drive system 20 includes an inner surface 70 and an outer surface 72. the inner surface 70 of each track 60 includes a plurality of inner teeth 74 that engage corresponding teeth (not visible in the figures) disposed about the pair of driven wheels 62. The outer surface 72 of each track 60 also includes a plurality of outer teeth 76. Although the figures illustrate the tracks 60 including the inner teeth 74 and the outer teeth 76, it should be appreciated that the figures are merely exemplary and the shape, geometry, and number of teeth may be changed depending on the specific requirements of a particular application. Further, in addition or as an alternative to the teeth 74, 76, the track 60 may also include other types of tread features.According to the embodiment shown in FIG. 4, the track 60 is a symmetrical double-sided belt, meaning that the plurality of inner teeth 74 disposed along the inner surface 70 of the track 60 are aligned with the plurality of outer teeth 76 disposed along the outer surface 72 of the track 60. However, it should be appreciated that, according to embodiments, the track 60 may include an offset arrangement between the plurality of inner teeth 74 disposed along the inner surface 70 of the track 60 and the plurality of outer teeth 76 disposed along the outer surface 72 of the track 60.It should be appreciated that the track drive system 20 results in improved mobility across the floor of a manufacturing facility because the problems such as dirt, bumps along the floor, and bumpy transitions are less important compared to other types of mobility systems such as wheels and casters. Furthermore, the track chain drive system 20 also results in increased ground clearance as compared to wheels and rollers. The track drive system 20, unlike wheels and rollers, can traverse various surfaces such as dirt, grass, sand, gravel, and concrete. The track drive system 20 may also traverse relatively large off-road gaps, such as railroad crossings and gaps created by a dock.FIG. 5 illustrates the front side 52 of the chassis 22, however, it should be appreciated that the rear side 54 of the chassis 22 includes the same configuration. The main body 40 of the chassis 22 defines a bottom 80 and a top 82, wherein the bottom 80 of the chassis 22 faces the terrain 92 that the autonomous mobile robot 10 traverses and the top 82 of the chassis 22 faces the support plate 24. FIG. 6 is a bottom view of the chassis 22 showing the bottom 80. In Figures 6 and 7, the main body 40 defines two or more channels 84 disposed along the underside 80 of the chassis 22 and each shaped to receive an arm 86 (shown in Figure 7) found on a load carriage 88 of a lift mechanism 90. Although FIG. 7 illustrates the lift mechanism 90 as a forklift, it should be appreciated that any other type of lift mechanism, such as a pallet truck, may also be used. According to the embodiment shown in FIGS. 6 and 7, two channels 84 are arranged along the bottom 80 of the main body 40 of the chassis 22, each channel 84 extending from the front 52 to the back 54 of the chassis 22.In Figs. 6 and 7, each channel 84 of the chassis 22 is shaped to receive one of the individual arms 86 of the lifting mechanism 90. It should be appreciated that the arms 86 of the lifting mechanism 90 are each disposed directly below one of the channels 84 of the chassis 22. Accordingly, the arms 86 are received by and abut a corresponding channel 84 of the chassis 22 of the autonomous mobile robot 10. The load carriage 88 of the lifting mechanism 90 is then lifted so that the lifting mechanism 90 can support and transport the autonomous mobile robot 10. Thus, it should be appreciated that the channels 84 are the load bearing elements of the chassis 22.In FIG. 5, a clearance 94 is measured between the underside 80 along the channel 84 of the chassis 22 and the terrain 92 that the autonomous mobile robot 10 is traversing. The space 94 is dimensioned to receive the arms 86 of the lift mechanism 90 (shown in Figure 7). It should be appreciated that the clearance 94 is greater than the clearance found in current designs that utilize other types of mobility systems, such as wheels and casters. If the autonomous mobile robot 10 is unable to move due to electrical or hardware problems or during maintenance, the autonomous mobile robot 10 may simply be lifted by the lifting mechanism 90 and transported to another area of the manufacturing facility for maintenance.Referring to FIGS. 1 and 2A, according to one embodiment, the plurality of perception sensors 44 include two or more cameras 96 and a LiDAR sensor 98 corresponding to the two opposing sides 50, the front 52, and the back 54 of the chassis 22. According to the non-limiting embodiment, as shown in FIGS. 1 and 2A, the autonomous mobile robot 10 includes a first camera 96 disposed along the front side 52 of the chassis and a second camera 96 disposed along the rear side 54 of the chassis 22, but it should be appreciated that additional cameras 96 may also be included. In FIG. 5, in one embodiment, the support plate 24 defines the openings 100 along the front and rear sides 52, 54 of the chassis 22 that receive the cameras 96. FIGS. 1 and 2A also illustrate a LiDAR sensor 98 disposed on each of the two opposing sides 50, the front side 52, and the back side 54 of the chassis 22. Therefore, the plurality of LiDAR sensors 98 may provide a substantial or near 360 degree view of the environment of the autonomous mobile robot 10 without blind spots.According to the embodiment shown in the figures, the two or more cameras 96 are elevated in position relative to the terrain 92 (FIG. 5 ) traversed by the autonomous mobile robot 10. That is, as seen in FIG. 5, a first height H 1 measured between the terrain 92 and one of the cameras 96 is greater than a second height H 2 measured between one of the LiDAR sensors 98 and the terrain 92. It should be appreciated that the near 360 degree view provided by the plurality of LiDAR sensors 98 and the image data captured by the elevated cameras 96 provide a wide field of view to the one or more controllers 46. The one or more controllers 46 may then navigate the autonomous mobile robot 10 within the manufacturing facility based on the perception data provided by the plurality of LiDAR sensors 98 and the cameras 96.In FIGS. 2A and 5, the pallet 26 sits on a top surface 102 of the support plate 24. the pallet 26 acts as a platform for storing materials that the autonomous mobile robot 10 transports through the manufacturing facility. Specifically in FIG. 2A, the pallet 26 includes a main body 104 defining a deck 106 and a plurality of apertures 108 distributed in a grid pattern along the deck 106. It should be appreciated that the plurality of apertures 108 of the pallet 26 are specifically dimensioned to receive existing rack systems. Therefore, the pallet 26 may be used to support a wide variety of materials on the deck 106. For example, the pallet 26 may be used to support items such as, but not limited to, a rack system, a container, a rotating sequencing kit, another pallet, or a robot.The disclosed autonomous mobile robot provides various technical effects and advantages generally with respect to the figures. Specifically, the autonomous mobile robot may be a dedicated material mover and container within a manufacturing environment. The pallet ensures that a wide variety of containers and racks can be used to transport materials. Accordingly, the autonomous mobile robot ensures that there is full-time knowledge of the location of the material because the material is always paired with the autonomous mobile robot. Furthermore, because the pallet is located at the top of or on the autonomous mobile robot, the autonomous mobile robot does not require docking to a carriage or a rack, which may result in an increased amount of time and interference problems between the robot and the carriage or the rack. If the autonomous mobile robot is unable to move due to electrical or hardware problems or during maintenance, a lifting mechanism such as a forklift may be used to transport the autonomous mobile robot to another area of the manufacturing facility for maintenance. The autonomous mobile robot also includes a track chain drive system that provides improved mobility over the floor of a manufacturing facility as compared to other types of mobility systems, such as wheels and casters.The controllers may refer to or be part of an electronic circuit, a combinational logic circuit, a field programmable gate array (FPGA), a processor (shared, dedicated, or group) that executes code, or a combination of some or all of the above, such as in a system on a chip. Additionally, the modules may be microprocessor-based, such as a computer having at least one processor, a memory (RAM and / or ROM), and associated input and output buses. The processor may operate under the control of an operating system residing in memory. The operating system may manage the computer resources such that computer program code embodied as one or more computer software applications, such as an application residing in memory, may include instructions executed by the processor. According to an alternative embodiment, the processor may execute the application directly, in which case the operating system may be omitted.

Claims

An autonomous mobile robot (10) that transports material in a manufacturing environment, the autonomous mobile robot (10) comprising: a chassis (22) including a main body (40) defining two opposing sides, a front side (52), a back side (54), and a bottom side (80) facing a terrain (92) that the autonomous mobile robot (10) traverses, the main body (40) defining two or more channels (84) disposed along the bottom side (80) of the main body (40) and each shaped to receive an arm (86) of a lifting mechanism (90); and a track drive system (20) including two drive systems (56) each mounted to one of the two opposing sides (50) of the chassis (22), each drive system (56) including: a track (60); a pair of driven wheels (62); and one or more idler wheels (64) disposed between the pair of driven wheels (62), the track (60) engaging the pair of driven wheels (62) and the idler wheel (64); wherein the autonomous mobile robot (10) further includes a pallet (26) seated on a top surface (102) of a support plate (24) seated on a top surface (82) of the main body (40), the pallet (26) including a main body (104) defining a support surface (106) and a plurality of openings (108) distributed in a grid pattern along the support surface (106), the plurality of openings (108) of the pallet (26) being specifically dimensioned to receive frame systems.The autonomous mobile robot (10) of claim 1, wherein each channel of the chassis (84) (22) extends from the front side (52) to the back side (54) of the chassis (22).The autonomous mobile robot (10) of claim 1, wherein a clearance (94) between the bottom surface (80) along one of the channels (84) of the chassis (22) and the terrain (92) that the autonomous mobile robot (10) crosses is measured.The autonomous mobile robot (10) of claim 1, further comprising two motors (66) and two gears (68), each of the two motors (66) corresponding to and driving one of the drive systems (56), and the two gears (68) each being directly connected to one of the two motors (66).The autonomous mobile robot (10) of claim 1, wherein the two or more channels (84) are load bearing members of the chassis (22).The autonomous mobile robot (10) of claim 1, further comprising two or more cameras (96), wherein a first camera (96) is disposed along the front side (52) of the chassis (22) and a second camera (96) is disposed along the back side (54) of the chassis (22).The autonomous mobile robot (10) of claim 6, further comprising a LiDAR sensor (98) disposed on each of the two opposing sides, the front side (52) and the back side (54) of the chassis (22).The autonomous mobile robot (10) of claim 7, wherein a first height measured between the terrain (92) and one of the two or more cameras (96) is greater than a second height measured between one of the LiDAR sensors (98) and the terrain (92).The autonomous mobile robot (10) of claim 1, wherein the main body (40) of the chassis (22) defines one or more cavities (42).The autonomous mobile robot (10) of claim 9, wherein the support plate (24) covers the one or more cavities (42).

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