Material handling apparatus and methods of using the same

Abstract

A material handling apparatus is provided, including a base, a drive system, a housing, a material support frame, and a material handling device. The drive system is connected to the base to move the base in at least one direction of motion. The housing includes one or more components of a control system, wherein the control system is operable to control the drive system to selectively move the base in the at least one direction of motion. The material support frame is supported by the base along the second side of the base, wherein material is stored within the material support frame. The material handling device is attached to the base between the housing and the material support frame. The material handling device includes a moveable arm and a material support assembly at an end of the moveable arm, the material support assembly being moveable with the moveable arm.

Description

MATERIAL HANDLING APPARATUS AND METHODS OF USING THE SAMECROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and benefit of U.S. Provisional Patent Application No. 63 / 635,858, filed April 18, 2024, and U.S. Provisional Patent Application No. 63 / 519,521, filed August 14, 2023, each of which are hereby incorporated by reference in their entirety.DISCUSSION OF ART

[0002] The field of the disclosure relates generally to a material handling apparatus, and, more particularly, to an apparatus to handle, transport, and place material, such as a construction pile.

[0003] Piles are commonly used in the construction of clean energy resources, such as to mount solar panels across a solar field. However, the placing of piles during construction of the solar field can be an arduous and inefficient process, often requiring manual handling and placement of the piles at pile locations across the solar field. Alternatively, large and heavy machinery may be used to transport the piles, which may damage the surface of the solar field during construction.

[0004] Thus, there is a need for a material handling apparatus that reduces the manual handling of piles and facilitates increasing the efficiency of pile transport and placement.SUMMARY

[0005] In an embodiment, a material handling apparatus is provided. The material handling apparatus includes a base having a first side and a second side, each of the first and second sides extending along a base axis, a drive system connected to the base to move the base in at least one direction of motion, and a housing supported by the base along the first side of the base. The housing includes one or more components of a control system, wherein the control system is operable to control the drive system to selectively move the base in the at least one direction of motion. The material handling apparatus also includes a material support frame supported by the base along the second side of the base, wherein material is stored within the material support frame, and a material handling device attached to the base between the housing and the material support frame. The material handling device includes a moveable arm and a material support assembly at an end of the moveable arm, the material support assembly beingmoveable with the moveable arm. The control system is operable to move the material handling device to locate the moveable arm above the material support frame between the first and second ends of the material support frame and position the material support assembly outwards of the material support frame to place material engaged by the material support assembly and removed from the material support frame on a placement surface. The material handling device determines a next material to be removed from the material support frame by detecting material in an uppermost position within the material support frame.

[0006] In another embodiment, a method for placing material using an automated material handling apparatus is provided. The material handling apparatus includes a material support frame and a material handling device. The method includes loading material into the material support frame, locating a material support assembly of the material handling device above the material support frame between first and second ends of the material support frame, and locating material within the material support frame using the material handling device. The material may be located by detecting material in at least one of an uppermost position and an outermost position within the material support frame. The method also includes engaging material located for removal within the material support frame by the material support assembly, removing material engaged by the material support assembly from the material support frame, and placing material removed from the material support frame on a placement surface using the material handling device.

[0007] In still another embodiment, a control system for an automated material handling apparatus is provided. The material handling apparatus includes a material support frame having first and second frame ends being oriented to support material and a material handling device having a moveable arm and a material support assembly at an end of the moveable arm. The control system includes a controller, the controller including a processor and a memory device, the memory device storing instructions that are executed by the processor. The processor is caused to move the material handling apparatus, via a drive system, to a first location on a placement surface for placement of material, locate material within the material support frame by locating the moveable arm of the material handling device above the material support frame between the first and second ends of the material support frame, remove material from the material support frame by engaging material with the material support assembly at the end of the moveable arm of the material handling device, place material removed from the material support frame on the placement surface, via the material handling device, bypositioning the material support assembly outwards of the material support frame to place material on the placement surface, and move the material handling apparatus, via the drive system, from the first location to a second location on the placement surface for further placement of material.

[0008] In yet another embodiment, a material handling apparatus is provided. The material handling apparatus includes a base having a first side and a second side, each of the first and second sides extending along a base axis, a drive system connected to the base to move the base in at least one direction of motion, and a housing supported by the base along the first side of the base. The housing includes one or more components of a control system, wherein the control system is operable to control the drive system to selectively move the base in the at least one direction of motion. The material handling apparatus also includes a material support frame supported by the base along the second side of the base, wherein material is stored within the material support frame. The material support frame includes first and second frame ends, and first and second longitudinal frame members perpendicular to the first and second frame ends. A length of the material support frame extends between the first and second frame ends, a width of the material support frame extends perpendicular to the length between the first and second longitudinal frame members, and a height of the material support frame extends upwards and perpendicular to the length. The first and second frame ends have vertical support members oriented to secure material along the length of the material support frame. The material handling apparatus further includes a material handling device attached to the base between the housing and the material support frame. The material handling device includes a moveable arm and a material support assembly at an end of the moveable arm, the material support assembly being moveable with the moveable arm. The control system is operable to move the material handling device to locate the moveable arm above the material support frame between the first and second frame ends of the material support frame and position the material support assembly outwards of the material support frame to place material engaged by the material support assembly and removed from the material support frame on a placement surface.

[0009] In still another embodiment, a material handling apparatus is provided. The material handling apparatus includes a base having a first side and a second side, each of the first and second sides extending along a base axis, a drive system connected to the base to move the base in at least one direction of motion, the drive system including a pair of tracks eachextending along one of the first and second sides of the base, and a housing supported by the base along the first side of the base. The housing includes one or more components of a control system. The control system is operable to control the drive system to selectively move the base in the at least one direction of motion. The material handling apparatus also includes a removeable material support frame securable to the base along the second side of the base, wherein material is stored within the material support frame. The material support frame includes first and second frame ends and first and second longitudinal frame members perpendicular to the first and second frame ends. The material handling apparatus further includes a material handling device attached to the base between the housing and the material support frame. The material handling device includes a moveable arm and a material support assembly at an end of the moveable arm, the material support assembly being moveable with the moveable arm. The material handling apparatus may be configured for compact travel in a stow configuration, the stow configuration comprising the material handling device positioned such that an entirety of the material support assembly is between the first and second sides of the base.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 A is a perspective view of a material handling apparatus.

[0011] FIG. IB is a front view of the material handling apparatus shown in FIG. 1 A.

[0012] FIG. 1C is another perspective view of the material handling apparatus shown in FIG. 1 A, including alternate positioning of the arm.

[0013] FIG. 2 is a top view of the material handling apparatus shown in FIG. 1C.

[0014] FIG. 3 is a perspective view of an embodiment of a material support frame for use with a material handling apparatus.

[0015] FIG. 4 is a perspective view of the embodiment of the material support frame shown in FIG. 3, including material within the material support frame.

[0016] FIG. 5 is a perspective view of a material handling apparatus with a material support frame removed from a base of the material handling apparatus.

[0017] FIG. 6A is a front view of an embodiment of an arm for use with a material handling apparatus.

[0018] FIG. 6B is a detailed view of an embodiment of a material support assembly for use with an arm of a material handling apparatus.

[0019] FIG. 7 is a perspective view of another embodiment of an arm for use with a material handling apparatus.

[0020] FIG. 8A is a front view of a material handling apparatus including the embodiment of the arm shown in FIG. 7.

[0021] FIG. 8B is a detailed view of another embodiment of a material support assembly for use with an arm of a material handling apparatus.

[0022] FIG. 9 is a back view of a material handling apparatus including the embodiment of the arm shown in FIG. 7, the arm being used to place material in a first orientation.

[0023] FIG. 10 is a back view of a material handling apparatus including the embodiment of the arm shown in FIG. 7, the arm being used to place material in a second orientation.

[0024] FIGS. 11 A and 1 IB are perspective views of a material handling apparatus including the embodiment of the arm shown in FIG. 7, the arm being used to place material in two embodiments of a third orientation.

[0025] FIGS. 12A, 12B, and 12C are views of an embodiment of a material support assembly for use with an arm of a material handling apparatus.

[0026] FIGS. 13A and 13B are views of another embodiment of a material support assembly for use with an arm of a material handling apparatus.

[0027] FIGS. 14A, 14B, and 14C are views of yet another embodiment of a material support assembly for use with an arm of a material handling apparatus, including an alternate gripper embodiment.

[0028] FIGS. 15A and 15B are views of the embodiment of the material support assembly for use with an arm of a material handling apparatus, including an alternate gripper embodiment.

[0029] FIG. 16 is a perspective view of one embodiment of a stow configuration of a material handling apparatus.

[0030] FIG. 17A is a front view of another embodiment of the stow configuration of a material handling apparatus.

[0031] FIG. 17B is a top view of the embodiment of the stow configuration shown in FIG.17 A.

[0032] FIG. 18A is a front view of yet another embodiment of the stow configuration of a material handling apparatus.

[0033] FIG. 18B is a top view of the embodiment of the stow configuration shown in FIG.18 A.

[0034] FIG. 19A is a perspective view of another embodiment of a material support assembly for use with an arm of a material handling apparatus.

[0035] FIG. 19B is a detailed view of the embodiment of the material support assembly shown in FIG. 19 A.

[0036] FIG. 20 is a schematic of a control system for use with a material handling apparatus.

[0037] FIG. 21A is a detailed view of a material support assembly for use with an arm of a material handling apparatus.

[0038] FIG. 2 IB is a back view of a material handling apparatus including a material support assembly for use with an arm of a material handling apparatus.

[0039] FIG. 22 is a flowchart of a method for placing material using a material handling apparatus.

[0040] FIG. 23 is a perspective view of another embodiment of a material support frame for use with a material handling apparatus.

[0041] FIG. 24 is a detailed perspective view of the embodiment of the gripper of the material support assembly for use with the material handling apparatus shown in FIG. IB.

[0042] FIG 25 is a perspective view of a material handling apparatus.

[0043] FIG. 26 is a perspective view of another embodiment of a material support frame for use with a material handling apparatus.

[0044] FIG. 27 is a front view of an arm of the material handling apparatus shown in FIG.25.DETAILED DESCRIPTION

[0045] There is a need for a material handling apparatus that reduces the manual handling of piles and facilitates increasing the efficiency of pile transport and placement. Specifically, there is a need for a material handling apparatus that may be at least partly autonomously controlled by a control system to handle and place piles.

[0046] When introducing elements of various embodiments disclosed herein, the articles “a”, “an”, “the”, and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0047] Unless otherwise indicated, approximating language, such as “generally”, “substantially”, and “about”, as used herein indicates that the term so modified may apply to only an approximate degree, as would be recognized by one of ordinary skill in the art, rather than to an absolute or perfect degree. Accordingly, a value modified by a term or terms such as “about”, “approximately”, and “substantially” is not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Additionally, unless otherwise indicated, the terms “first”, “second”, etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, for example, a “second” item does not require or preclude the existence of, for example, a “first” or lower-numbered item or a “third” or higher-numbered item.

[0048] FIGS. 1 A, IB, and 1C are views of a material handling apparatus 100 (e.g., a material transporter). The material handling apparatus 100 includes a base 102, a drive system 104, and a control system 106 (shown in FIG. 20). The base 102 may include one or more base components welded together to form a mainframe of the material handling apparatus 100. The material handling apparatus 100 also includes a material handling device 108 to handle and place material, and a material support frame 110 to transport material. The material handling apparatus 100 may be used to handle, transport, and place piles for construction of a solar field, including a plurality of solar panels each at a solar panel mount location across the solar field. For example, the material support frame 110 may transport the piles as the material handlingapparatus 100 moves between pile locations across the solar field, and the material handling device 108 may handle and place the piles from within the material support frame 110 onto the solar field at each solar panel mount location. The material handling device 108 includes an arm 105 coupled to the base 102 and a material support assembly 107 coupled to a free end 109 of the arm 105. The material support assembly 107 includes one or more grippers 130 to handle material from the material support frame 110 (e.g., engage material within the material support frame 110).

[0049] The base 102 is oriented along a base axis 111, with a first base side 112 and a second base side 114 opposite the first base side 112. The first base side 112 and the second base side 114 each extend parallel to the base axis 111. The material support frame 110 is supported by the base 102 and may be oriented along a side of the base 102, such as, for example, the second base side 114 along a frame axis 115 parallel to the base axis 111. Additionally, a housing 116 is supported by the base 102 and may also be oriented along a side of the base 102, such as, for example, the first base side 112 along a housing axis 117 parallel to the base axis 111. The housing 116 may include one or more components of the control system 106 (shown in FIG. 20), in addition to an engine (not shown), one or more hydraulic pumps (not shown), a cooling system (not shown), and / or a battery (not shown). The material handling device 108 is coupled to the base 102 and may be positioned between the material support frame 110 and the housing 116. Although the material handling device 108 is illustrated as equally spaced between the first base side 112 and the second base side 114, this is meant to be illustrative only and is not intended to be limiting.

[0050] The drive system 104 is coupled to the base 102 and is operable to move the base 102 in at least one direction of motion. The drive system 104 may include one or more tracks 118 to move the base 102 on a surface. The control system 106 (shown in FIG. 20) is communicatively coupled to the drive system 104 to control the drive system 104, in that the control system 106 may control the drive system 104 to selectively move the base 102 to transport and place piles across a solar field at solar panel mount locations.

[0051] The drive system 104 may be similar or substantially similar to a drive system used for a pile driver apparatus. For example, the drive system 104 may include one or more hydraulic motors powered by an engine. Although two of the tracks 118 are illustrated in the Figures, one on each side of the base 102 (e.g., along the first base side 112 and the second base side 114), this is meant to be illustrative only and is not intended to be limiting. The drivesystem 104 may include any number of tracks 118 positioned at any location across a bottom side of the base 102. Additionally, the drive system 104 may include tracks 118 of varying sizes and / or shapes, and is not limited to including tracks 118 with an oblong oval shape that extends under an entirety of a length of the base 102.

[0052] Material Support Frame

[0053] The material support frame 110 holds and transports material to be handled by the material handling apparatus 100. FIGS. 1A and IB illustrate the material handling apparatus 100 in a base configuration, with the material handling device 108 extending upwards (e.g., away from the base 102) such that the material support assembly 107 is positioned above the material support frame 110. Material may be loaded into the material support frame 110 when the material handling apparatus 100 is in the base configuration. Additionally, the material support frame 110 may be loaded onto and off the base 102 when the material handling apparatus 100 is in the base configuration.

[0054] FIG. 1C illustrates the material handling apparatus 100 during operation, with the material handling device 108 extending outwards of the material support frame 110 to place material removed from the material support frame 110 onto a surface beneath the material handling apparatus 100. The material handling device 108 may remove a pile from the material support frame 110 using the material support assembly 107 and move the pile outwards of the material support frame 110 to be placed on the ground proximate the second base side 114, such as on the solar field at a solar panel mount location. Although the material handling device 108 is illustrated as equally spaced along a frame length parallel to the base axis 111 (e.g., between the ends of the material support frame 110), this is meant to be illustrative only and is not intended to be limiting.

[0055] FIG. 2 is a top view of the material handling apparatus 100 during operation, with the material handling device 108 extending outwards of the material support frame 110 to place material removed from the material support frame 110 onto the surface beneath the material handling apparatus 100 proximate the second base side 114. In some embodiments, the material may be placed on the surface proximate the second base side 114 oriented substantially parallel to the base axis 111. In other embodiments, the material may be placed on the surface proximate the second base side 114 at an angle relative to the base axis 111.

[0056] FIG. 3 is a perspective view of an embodiment of the material support frame 110 for use with a material handling apparatus, such as the material handling apparatus 100. The material support frame 110 includes a pair of longitudinal frame members 302 and a pair of lateral frame gates 304. When the material support frame 110 is placed onto the material handling apparatus 100, the longitudinal frame members 302 extend parallel to the base axis 111. Each of the longitudinal frame members 302 extend perpendicular to each of the lateral frame gates 304 to form a rectangular pen oriented to hold material, the material support frame 110 being defined by a frame length 307, a frame width 309, and a frame height 311. In some embodiments, the longitudinal frame members 302 may be approximately 30” to 31” above the placement surface below the track 118 when the material support frame 110 is mounted on the base 102 of the material handling apparatus 100.

[0057] The lateral frame gates 304 have a frame gate height 303 that extends upwards (e.g., away from the base 102 when the material support frame 110 is placed onto the material handling apparatus 100) along the frame height 311. Each of the lateral frame gates 304 includes a pair of lateral gate end members 306, a first lateral gate end member 306a extending between the longitudinal frame members 302 on a shared plane (e.g., along the frame width 309) to form the rectangular pen shape of the material support frame 110 and a second lateral gate end member 306b positioned upwards of, and extending parallel to, the first lateral gate end member 306a.

[0058] Additionally, each of the lateral frame gates 304 include one or more gate members 305 that extend upwards (e.g., away from the base 102 when the material support frame 110 is placed onto the material handling apparatus 100) along the frame gate height 303 to serve as the ends of the material support frame 110. In some embodiments, each of the lateral frame gates 304 may include a plurality of gate members 305. For example, the plurality of gate members 305 may be spaced evenly along the frame width 309. In other embodiments, the gate member 305 may be in the form of a plate that covers the lateral frame gates 304. For example, the gate member 305 may cover a portion of the lateral frame gate 304 or the entirety of the lateral frame gate 304. The lateral frame gates 304 are oriented to secure material in the material support frame 110 along the frame length 307 to facilitate minimizing movement of the material in relation to the frame length 307 during operation of the material handling apparatus 100.

[0059] The material support frame 110 also includes one or more stationary vertical frame members 308 and one or more moveable vertical frame members 310. The stationary vertical frame members 308 and the moveable vertical frame members 310 extend upwards (e.g., away from the base 102 when the material support frame 110 is placed onto the material handling apparatus 100) along the frame height 311 to serve as the sides of the material support frame 110. The stationary vertical frame members 308 and the moveable vertical frame members 310 are oriented to secure material in the material support frame 110 along the frame width 309 to facilitate minimizing movement of the material in relation to the frame width 309 during operation of the material handling apparatus 100.

[0060] The material support frame 110 also includes one or more nesting members 312 and one or more hollow members 314. The nesting members 312 and the hollow members 314 extend between the longitudinal frame members 302 on a shared plane (e.g., along the frame width 309) to serve as the bottom of the material support frame 110. The nesting members 312 and the hollow members 314 are oriented to secure material in the material support frame 110 along the frame height 311.

[0061] The nesting members 312 are positioned between the lateral frame gates 304 (e.g., along the frame length 307) to align with corresponding nesting features on the base 102 of the material handling apparatus 100 (such as the base nesting member 140 shown in FIG. 5) to facilitate proper positioning of the material support frame 110 when placed onto the base 102. The hollow members 314 are also positioned between the lateral frame gates 304 (e.g., along the frame length 307) to align with tines of a lifting machine, such as, but not limited to, a forklift or a telehandler, to facilitate lifting the material support frame 110 independently of the material handling apparatus 100. For example, the tines of the lifting machine may be inserted into cavities of the hollow members 314 to lift the material support frame 110 onto, off of, or in relation to the base 102 of the material handling apparatus 100.

[0062] The material support frame 110 also includes one or more bottom plates 315. The bottom plates 315 are positioned between the lateral frame gates 304 (e.g., along the frame length 307), extending between the longitudinal frame members 302, and are oriented to secure material in the material support frame 110 and facilitate minimizing movement of the material in relation to the frame width 309 during operation of the material handling apparatus 100. For example, the bottom plates 315 may prevent shifting of material proximate the bottom plates 315, which may be a first row of material within the material support frame 110. In someembodiments, a plurality of shapes and / or sizes of the bottom plates 315 may be available for selection, such that the bottom plate 315 is removable to select a shape of the bottom plate 315 that depends on the loading order of the material into the material support frame 110. That is, differently shaped alternative plates of the bottom plate 315 may be used to accommodate specific material locations and / or differently sized material along the bottom row of material loaded into the material support frame 110 to facilitate securing the material along the frame width 309.

[0063] FIG. 4 is a perspective view of material within the material support frame 110. The frame length 307 of the material support frame 110 may be adjustable to accommodate material of varying lengths, such as, but not limited to, a material length between 10 feet (10’) and 25 feet (25’), such as, but not limited to, a length of 10’, 12’, 15’, 20’, and / or 25’. For example, the frame length 307 may extend from a first frame length 307a to a second frame length 307b, the second frame length 307b being a maximum frame length that extends from a first longitudinal frame member end 316 to a second longitudinal frame member end 318. In some embodiments, the lateral frame gates 304 may be positioned along the longitudinal frame members 302 such that the frame length 307 does not extend out to the first longitudinal frame member end 316 and / or the second longitudinal frame member end 318, with the frame length 307 being less than the second frame length 307b.

[0064] The frame width 309 of the material support frame 110 may also be adjustable to accommodate material of varying widths and / or varying amounts of material. For example, the frame width 309 may extend from a first frame width 309a to a second frame width 309b, the second frame width 309b being a maximum frame width. The first frame width 309a extends between the longitudinal frame members 302, such that the material is held between the stationary vertical frame members 308 on opposing sides of the pen. The second frame width 309b extends past the longitudinal frame members 302 on one side of the pen, such that the material is held between the stationary vertical frame members 308 on one side of the pen and the moveable vertical frame members 310 on the opposing side of the pen.

[0065] Material may be loaded into the material support frame 110 when the material support frame 110 is positioned on the base 102 and / or when the material support frame 110 is independent of the material handling apparatus 100 (such as when the material support frame 110 is positioned on a ground surface). In the base configuration of the material handling apparatus 100, the material handling device 108 is oriented such that the material supportassembly 107 is positioned above the material support frame 110 to provide clearance space for loading material into the material support frame 110 and / or loading the material support frame 110 already loaded with material onto the base 102.

[0066] In some embodiments, material may be placed individually into the material support frame 110, such as individual piles being placed into the material support frame 110 one at a time. Material placed individually may be loaded into the material support frame 110 in an order. In other embodiments, material may be placed as a bundle into the material support frame 110, such as piles secured together being placed into the material support frame 110 as a bundle. In still other embodiments, a plurality of material support frames 110 may be concurrently loaded with material to be interchangeably lifted onto the base 102 once one of the material support frames 110 is emptied of material. For example, the plurality of material support frames 110 may include varying measurements of the frame length 307 and / or the frame width 309 to accommodate varying material sizes and / or material amounts.

[0067] In some embodiments, the material support frame 110 may be removeable from the base 102. In other embodiments, the material support frame 110 may not be removeable from the base 102, such that the material support frame 110 is intended to remain on the base 102.

[0068] The material support frame 110 is oriented such that material will be in a predictable location within the material support frame 110 relative to the material handling device 108 for handling and placement of the material. For example, the material being secured along the frame length 307 and / or the frame width 309 by the lateral frame gates 304, the stationary vertical frame members 308, the moveable vertical frame members 310, and / or the bottom plates 315 may be positioned within the material support frame 110 such that the control system 106 (shown in FIG. 20) may control the material handling device 108 to locate, pick up, and / or handle the material held by the material support frame 110. That is, the material may be positioned within the material support frame 110 to facilitate accurate handling and placement of the material onto a placement surface by the control system 106 based on how the material is secured within the material support frame 110 by the lateral frame gates 304, the stationary vertical frame members 308, the moveable vertical frame members 310, and / or the bottom plates 315.

[0069] Material may have a material orientation within the material support frame 110 relative to the vertical axis 606 and / or the horizontal axis 608. That is, material within thematerial support frame 110 may be positioned at an angle from the vertical axis 606 and / or the horizontal axis 608. Additionally, material may have a material configuration within the material support frame 110. That is, material within the material support frame 110 may be positioned in a “H” configuration (e.g., a first configuration of material) with the material height perpendicular to the base 102 or in an “I” configuration (e.g., a second configuration of material) with the material height parallel to the base 102.

[0070] FIG. 5 is a perspective view of the material handling apparatus 100 with a material support frame (such as the material support frame 110) removed from the base 102. The base 102 includes one or more base nesting members 140 positioned to align with the one or more nesting members of the material support frame (such as the nesting members 312 of the material support frame 110) to facilitate proper positioning of the material support frame 110 when placed onto the base 102 of the material handling apparatus 100.

[0071] The base 102 also includes one or more frame pins 142 to secure the material support frame 110 onto the base 102. The frame pins 142 may be positioned at the comers of the rectangle pen shape of the material support frame 110, as shown in FIG. 5. However, this positioning of the frame pins 142 is illustrative and is not intended to be limiting. The frame pins 142 may include an engagement mechanism 144 that transitions the frame pins 142 between an unengaged configuration, in which the engagement mechanism 144 is withdrawn into a pin housing 146, and an engaged configuration, in which the engagement mechanism 144 extends outwards from the pin housing 146 and towards an interior of the base 102 to secure the material support frame 110 to the base 102. In some embodiments, the frame pins 142 may be spring loaded.

[0072] Referring now to FIG. 25, in another embodiment, the base 102 includes locking features other than the one or more frame pins 142 of FIG. 5 for securing the material support frame 110 onto the base 102 of the material handling apparatus 100. For example, the base 102 may include first and second slides 134a, 134b that may be secured to the base 102. The slides 134a, 134b may be moved by actuators (such as the actuator 135 shown in FIG. 25) to secure the material support frame 110.

[0073] As an alternative to, or in addition to, the slides 134a, 135b, the base 102 may include one or more hook elements 137 for securing the material support frame 110 onto the base 102 of the material handling apparatus 100. The hook elements 137 may be caused to pivot by anactuator 138. It should be noted that while both the slides 134a, 134b and the hook elements 137 are shown in FIG. 25, the slides 134a, 134b and the hook elements 137 are generally alternatives to each other and the base 102 typically includes only one type of locking feature (i.e., the slides 134 or the hook elements 137). Referring now to FIG. 26, the material support frame 110 may have corresponding features that cooperate with the slides 134a, 134b and / or the hook elements 137. For example, the material support frame 110 may include locking bars 139a, 139b that mate with the slides 134 and / or the hook elements 139. Additionally, the material support frame 110 may include length extension members 141 for securing longer lengths of material.

[0074] Material Handling Device

[0075] The arm 105 of the material handling device 108 is coupled to an arm base 602 and includes one or more arm members 604. The arm members 604 are pivotally coupled such that the general outline shape of the arm 105 may be varied to manipulate the position of the material support assembly 107, and thus the material handled by the material handling device 108.

[0076] FIG. 6A is a front view of the material handling apparatus 100, including a first embodiment of the arm 105 of the material handling device 108. The arm 105 may include a first arm member 604a, a second arm member 604b, and a third arm member 604c. FIG. 6B is a detailed view of an embodiment of the material support assembly 107 coupled to the arm 105. As illustrated in FIG. 6 A, the first arm member 604a of the first embodiment of the arm 105 may be a linkage that includes an outer first arm member 604aa and an inner first arm member 604ab, with the first arm members 604aa and 604ab, the second arm member 604b, and the third arm member 604c forming a four-bar linkage.

[0077] The outer first arm member 604aa may include an actuator 605 to move the first arm member 604a in relation to a vertical axis 606. The vertical axis 606 is perpendicular to a horizontal axis 608. The first arm member 604a may be at an angle a in relation to the vertical axis 606 and the control system 106 (shown in FIG. 20) may move the arm 105 such that the angle a increases or decreases as the first arm member 604a is moved. The arm base 602 is pivotally coupled to the base 102 of the material handling apparatus 100, such that the arm 105 may be rotated about the vertical axis 606. In some embodiments, the coupling of the arm base602 to the base 102 may include a slewing ring for rotation of the arm base 602 about the vertical axis 606.

[0078] The outer first arm member 604aa may include an actuator 605 to move the first arm member 604a in relation to a vertical axis 606. The vertical axis 606 is perpendicular to a horizontal axis 608. The first arm member 604a may be at an angle a in relation to the vertical axis 606 and the control system 106 (shown in FIG. 20) may move the arm 105 such that the angle a increases or decreases as the first arm member 604a is moved. The arm base 602 is pivotally coupled to the base 102 of the material handling apparatus 100, such that the arm 105 may be rotated about the vertical axis 606. In some embodiments, the coupling of the arm base 602 to the base 102 may include a slewing ring for rotation of the arm base 602 about the vertical axis 606.

[0079] Additionally, as illustrated in FIG. 6A, the third arm member 604c of the first embodiment of the arm 105 is fixedly coupled to the second arm member 604b. The third arm member 604c extends from a third arm member end 610 to the free end 109 of the arm 105. The third arm member 604c may be coupled to the second arm member 604b between the third arm member end 610 and the free end 109 of the arm 105. The third arm member 604c may be at an angle y in relation to the second arm member 604b and the control system 106 (shown in FIG. 20) may move the arm 105 with the angle y remaining the same as the third arm member 604c and / or the first arm member 604a is moved. Additionally, the control system 106 (shown in FIG. 20) may control the first arm member 604a and / or the third arm member 604c to position the material support assembly 107 for handling of material within the material support frame 110.

[0080] In some embodiments, as shown in FIG. 6A, the fixed coupling between the second arm member 604b and the third arm member 604c allows the third arm member 604c to remain in a vertical orientation (e.g., parallel to the vertical axis 606) as the arm 105 is moved. In other embodiments, a length of the outer first arm member 604aa and / or the inner first arm member 604ab may be varied to change the orientation of the third arm member 604c so that it is not parallel to the vertical axis 606. That is, the length of the outer first arm member 604aa and / or the inner first arm member 604ab may differ from the lengths as shown in FIG. 6A. Regardless of the length of the first arm member 604a, the linkages created by the first arm members 604aa and 604ab, the second arm member 604b, and / or the third arm member 604c allow the arm 105 and the material support assembly 107 to move in a predictable arc.

[0081] The third arm member 604c may include an extension assembly 612 to vary a third arm member length 614 measured from the third arm member end 610 to the free end 109 of the arm 105. The control system 106 (shown in FIG. 20) may control the extension assembly 612 to position the material support assembly 107 in relation to the free end 109 of the arm 105 for handling of material within the material support frame 110. The extension assembly may include a linear actuator and a telescoping assembly that includes an inner tube that slides within an outer tube as the linear actuator is actuated to move the material support assembly 107 in relation to the free end 109 of the arm 105.

[0082] Referring now to FIG. 27, another embodiment of the third arm member 604c of the arm 105 of the material handling apparatus 100 includes an extension assembly 612 that varies the third arm member length. The extension assembly 612 includes a linear actuator 615 and two telescoping assemblies. Each telescoping assembly includes an inner tube 619 that slides within an outer tube 621 as the linear actuator 615 is actuated (with a single inner tube being shown in the embodiment of FIG. 6A). The linear actuator 615 is disposed between the two telescoping assemblies.

[0083] FIG. 7 is a perspective view of a second embodiment of the arm 105 of the material handling device 108. FIG. 8A is a front view of the material handling apparatus 100, including the second embodiment of the arm 105. FIG. 8B is a detailed view of an embodiment of the material support assembly 107 coupled to the arm 105. The second embodiment of the arm 105 includes a first arm member 654a and a second arm member 654b. As illustrated in FIG. 8 A, the first arm member 654a of the second embodiment of the arm 105 may include an actuator 655 to move the first arm member 654a in relation to the vertical axis 606. The first arm member 654a may include a lower first arm member portion 656 and an upper first arm member portion 658. The lower first arm member portion 656 may be at an angle a in relation to the vertical axis 606 and the control system 106 (shown in FIG. 20) may move the arm 105 such that the angle a increases or decreases as the first arm member 654a is moved.

[0084] As illustrated in FIG. 8A, the first arm member 654a of the second embodiment of the arm 105 is pivotally coupled to the second arm member 654b. The first arm member 654a may include an actuator 657 to move the second arm member 654b in relation to the first arm member 654a. The second arm member 654b may be at the angle y in relation to the upper first arm member portion 658 of the first arm member 654a and the control system 106 (shown in FIG. 20) may move the arm 105 such that the angle y increases or decreases as the second armmember 654b is moved. The control system 106 (shown in FIG. 20) may control the first arm member 654a and / or the second arm member 654b of the second embodiment of the arm 105 to position the material support assembly 107 for handling of material within the material support frame 110.

[0085] FIGS. 9 and 10 are back views of the material handling apparatus 100. The arm 105 may include an actuator 661 for changing a tilt angle P of the material support assembly 107. The tilt angle P may be changed to deliver the material in a specific configuration, such as a “H” configuration (FIG. 9) or an “I” configuration (FIG. 10). The control system 106 (shown in FIG. 20) may control the arm 105 to move along a predetermined path for handling and placing material. For example, the arm 105 may be moved between the base configuration, with the arm 105 positioned such that the material support assembly 107 is positioned above the material support frame 110 (not shown for the embodiment of the arm 105 illustrated in FIG. 7, but similar to as shown in FIG. IB), and a placement configuration, with the arm 105 extending outwards of the material support frame 110 (as shown in FIGS. 9 and 10) to place material from the material support frame 110 onto a placement surface 860 proximate the material handling apparatus 100.

[0086] As shown in FIG. 7, material handled by the material handling device 108 may include a material length 702, a material width 704, and a material height 706. The arm 105 and the material support assembly 107 may be moved and positioned to place material on the placement surface 860 in various orientations. As shown in FIG. 9, material may be placed in a first orientation with the material width 704 and the material length 702 substantially parallel to the placement surface 860 in a “H” configuration. As shown in FIG. 10, material may also be placed in a second orientation with the material height 706 and the material length 702 substantially parallel to the placement surface 860 in an “I” configuration. The material may be placed in the first orientation or the second orientation irrespective of how the material is oriented in the material support frame 110.

[0087] FIG. 13 A is a perspective view of the second embodiment of the material support assembly 107 including one or more mechanical grippers 130a. The material support assembly 107 may change the angular position of the material by operating the actuator 151. The material support assembly 107 is pivotally coupled to a leg 153 of the arm 105. The leg 153 includes a mounting plate 155 that is pivotally attached to a yoke 157 of the material support assembly 107 such that the material support assembly 107 pivots about axis Al 07 relative to the arm105. As shown in FIG. 13 A, in some embodiments, axis Al 07 may be substantially parallel to the vertical axis 606 and substantially perpendicular to the horizontal axis 608. In other embodiments, axis Al 07 may be at an angle relative to the vertical axis 606 and / or the horizontal axis 608. The control system 106 may control actuation of actuator 151 for pivotal rotation of the material support assembly 107 about axis Al 07. The actuator 151 is pivotally mounted at a first end to an extended portion 161 of the mounting plate 155 and a second end of the actuator 151 is pivotally mounted to a yoke mounting plate 159 of the yoke 157.

[0088] FIGS. 11 A and 1 IB are perspective views of the material handling apparatus 100. As shown in FIGS. 11A and 11B, material may be placed in embodiments of a third orientation with the material width 704 and the material height 706 substantially parallel to the placement surface 860 (not shown) below the material handling apparatus 100. As shown in FIG. 11 A, material may be placed in a first embodiment of the third orientation with the material height 706 substantially parallel to the base axis 111. As shown in FIG. 11B, material may also be placed in a second embodiment of the third orientation with the material width 704 substantially parallel to the base axis 111. The material may be placed in either embodiment of the third orientation irrespective of how the material is oriented in the material support frame 110.

[0089] Similar to the arm 105 shown in FIGS. 6A and 6B, FIGS. 7-12 illustrate another configuration of the arm 105 where the material support assembly 107 is coupled to the free end 109 of the arm 105 (e.g., to a free end of the third arm member 604c or the second arm member 654b) such that movement of the arm 105 and / or the material support assembly 107 may orient the material support assembly 107 to handle material in the material support frame 110. The material support assembly 107 may include a support member 132 (shown in FIGS. 12-15, 19A, and 19B) coupled to the one or more grippers 130, with the support member 132 in pivotal connection with the free end 109 of the arm 105. The material support assembly 107 is pivotally coupled to the free end 109 of the arm 105 at a pivot point 802 (shown in FIGS. 12, 13, 15, and 19A). In embodiments in which the orientation assembly 818 is a controllable actuator, the control system 106 (shown in FIG. 20) may move the material support assembly 107 in relation to the pivot point 802 to position the material support assembly 107 for handling of material within the material support frame 110.

[0090] FIG. 24 is a perspective view of the gripper 130 of FIGS. 1A-1C, 6A, and 6B. The gripper 103 include an actuator 120 and a gripper frame 128. The actuator 120 extends and retracts to move a gripper jaw 122. The gripper jaw 122 has slides 124 that slide within a track126 of the gripper frame 128. The actuator 120 is mounted to the gripper frame 128 at a first end 172 of the actuator 120 and is mounted to the gripper jaw 122 at a second end 174 of the actuator 120. Gripper plates 129 are removably fastened to the gripper jaw 122 and the gripper frame 128 to pinch material upon extension of the actuator 120.

[0091] FIG. 12A is a perspective view, and FIGS. 12B and 12C are side views, of another embodiment of the material support assembly 107 including an embodiment of the gripper 130, specifically including one or more mechanical grippers 130a. As shown in FIG. 12B, the material support assembly 107 may be moved such that a gripper orientation 804 of the one of more grippers 130, extending parallel to a length 806 of the gripper 130, is oriented parallel to the horizontal axis 608. As shown in FIG. 12C, the material support assembly 107 may be moved such that the gripper orientation 804 of the one of more grippers 130 is oriented parallel to the vertical axis 606.

[0092] As shown in FIG. 12A-12C, the material support assembly 107 includes an actuator 881. Operation of the actuator 881 causes rotation about pivot axis Y107 which changes the orientation of the grippers 130. A first end of the actuator 881 is attached to the yoke 157. A second end of the actuator 881 is attached to a mounting arm 883 of the support member 132.

[0093] The mechanical grippers 130a include a pair of gripping members 808, a gripping surface 810 coupled to a free end of each of the gripping members 808, and a gripping mechanism 812. The gripping surfaces 810 may include a textured surface 814. The control system 106 (shown in FIG. 20) may control an actuator 885 (FIGS. 12A and 12B) coupled to the gripping mechanism 812 to move the gripping members 808 such that the gripping surfaces 810 are brought together to engage with and handle material. As shown in FIGS. 12B and 12C, the gripping members 808 may be moved to bring together the gripping surfaces 810 around an extending edge 816 of the material such that movement of the material support assembly 107 also moves the material engaged by the gripping surfaces 810. The material support assembly 107 may be moved such that the gripping surfaces 810 engage with the extending edge 816 of material in various orientations. For example, as shown in FIG. 12B, the gripping surfaces 810 may engage with the extending edge 816 of material with the material height 706 oriented parallel to the horizontal axis 608. Additionally, for example, as shown in FIG. 12C, the gripping surfaces 810 may engage with the extending edge 816 of material with the material width 704 oriented parallel to the horizontal axis 608.

[0094] FIG. 13 A is a perspective view, and FIG. 13B is a side view, of another embodiment of the material support assembly 107 including one or more mechanical grippers 130a. The control system 106 (shown in FIG. 20) may move the embodiment of the material support assembly 107 shown in FIGS. 13A and 13B in relation to the horizontal axis 608, using an orientation assembly 818, to position the material support assembly 107 for handling of material. The control system 106 (shown in FIG. 20) may also move the embodiment of the material support assembly 107 shown in FIGS. 13A and 13B in relation to the vertical axis 606 and / or the axis Al 07, using the yoke 157. The orientation assembly 818 is coupled between the arm 105, proximate the free end 109 of the arm, and the support member 132, and is oriented at an angle such that extension and / or contraction of the orientation assembly 818 may move the material support assembly 107 in relation to the horizontal axis 608. In some embodiments, the orientation assembly 818 may include one or more spring-loaded cylinders (e.g., one or two cylinders) to bias the support member 132 to a center position while allowing for adjustment of the orientation of the support member 132 for pickup and placement of material.

[0095] FIG. 14A is a perspective view, and FIGS. 14B and 14C are side views, of the first embodiment of the material support assembly 107 including another embodiment of the gripper 130, specifically including one or more magnetic grippers 130b. The magnetic grippers 130b include a gripper housing 820, a gripper pin 822, and a magnetic gripping surface 824 coupled to an end of the gripper pin 822. The gripper pin 822 extends through the gripper housing 820, such that the gripper pin 822 may be extended out of an end of the gripper housing 820 to move the magnetic gripping surface 824 in relation to an end 825 of the gripper housing 820. The magnetic grippers 130b within each pair also include a rotation stop 826 that extends away from the gripper housing 820 towards the magnetic gripping surface 824 to prevent rotation of the gripper 130b. The extension length of the grippers 130b may be adjusted by rotating a nut on the free end of the gripper pin 822. By adjusting the extension length of the gripper pin 822, the magnetic gripping surface 824 may be moved in relation to the end 825 of the gripper housing 820.

[0096] The embodiment of the material support assembly 107 may include pairs of the magnetic grippers 130b positioned along the support member 132, oriented such that the gripper orientations 804 of the magnetic grippers 130b of each pair are substantially perpendicular to facilitate engaging two edges of the material being handled by the material support assembly 107. For example, as shown in FIG. 14B, one of the magnetic grippingsurfaces 824 may engage the material along the material width 704, and the other of the magnetic gripping surface 824 may engage the material along the material height 706, with the material oriented with the material width 704 parallel to the horizontal axis 608. Additionally, for example, as shown in FIG. 14C, one of the magnetic gripping surfaces 824 may engage the material along the material height 706, and the other of the magnetic gripping surface 824 may engage the material along the material width 704, with the material oriented with the material height 706 parallel to the horizontal axis 608.

[0097] FIG. 15A is a perspective view, and FIG. 15B is a side view, of the second embodiment of the material support assembly 107 including one or more magnetic grippers 130b. The second embodiment of the material support assembly 107 includes magnetic grippers 130b positioned along the support member 132, oriented such that the gripper orientation 804 of the magnetic grippers 130b facilitates engagement of each of the magnetic gripping surface 824 with a shared edge of the material being handled by the material support assembly 107. For example, as shown in FIG. 15B, the magnetic gripping surfaces 824 may engage the material along the material width 704 with the material oriented such that the material width 704 is parallel to the horizontal axis 608. Additionally, the magnetic gripping surface 824 may engage the material along the material height 706 with the material oriented such that the material height 706 is parallel to the horizontal axis 608.

[0098] Each embodiment of the material support assembly 107 may be used with each embodiment of the arm 105. That is, although specific embodiments of the material support assembly 107 are shown as coupled to specific embodiments of the arm 105 in FIGS. 1 and 5- 15, this is meant to be illustrative only and is not intended to be limiting. Additionally, the embodiment of the material support assembly 107 may be changed during operation of the material handling device 108. For example, the material support assembly 107 may be removable from the free end 109 of the arm 105 such that the embodiment of the material support assembly 107 may be changed to facilitate improved handling of material depending on the type of material and / or the type of gripper (including, but not limited to, a mechanical gripper, a magnetic gripper, and / or a vacuum gripper), in addition to simplified repair and / or replacement of the material support assembly 107.

[0099] FIG. 16 is a perspective view of the material handling apparatus 100 in one embodiment of a stow configuration. In the stow configuration, elements of the material handling apparatus 100 may be positioned more compactly to facilitate increasing a number ofthe material handling apparatus 100 that can fit in a shipping container and / or within a specified space. For example, the material handling apparatus 100 in the stow configuration may fit within a standard shipping container door opening with dimensions of a total height of less than 89 inches and a total width of less than 90 inches. Additionally, for example, the material handling apparatus 100 in the stow configuration may fit within a high cube shipping container with dimensions of a total height of less than 101 inches and a total width of less than 90 inches. Furthermore, for example, the material handling apparatus 100 in the stow configuration may fit within a standard shipping container with dimensions of a total height of less than 89 inches and a total width of less than 88 inches.

[0100] As shown in FIG. 16, one embodiment of the stow configuration includes the material handling device 108 positioned with the arm 105 oriented along the base axis 111 (specifically, the first arm member 604a) such that the material support assembly 107 is extended past an edge 178 of the base 102 and positioned below a plane of the base 102, such as between the tracks 118. The apparatus 100 may include various position sensors (e.g., proximity sensors) that sense whether the arm 105 is in a stow configuration for transport or the base configuration for operation.

[0101] FIG. 17A is a front view, and FIG. 17B is a top view, of the material handling apparatus 100 in another embodiment of the stow configuration. As shown in FIGS. 17A and 17B, the material handling device 108 may be positioned with the arm 105 (specifically, the first arm member 604a of the arm 105) extending along, and oriented at an angle G from, the base axis 111 such that the material support assembly 107 is extended past the edge 178 of the base 102 and positioned below a plane of the base 102. The angle G may be such that the material support assembly 107 is not between the tracks 118.

[0102] FIG. 18A is a front view, and FIG. 18B is a top view, of the material handling apparatus 100 in yet another embodiment of the stow configuration. As shown in FIGS. 18A and 18B, the material handling device 108 may be positioned with the arm 105 (specifically, the first arm member 604a) extending along, and oriented at an angle cp from, the base axis 111 such that an entirety of the material support assembly 107 is between the first base side 112 and the second base side 114 of the base 102. The angle cp may be such that the material support assembly 107 is not between the tracks 118.

[0103] FIG. 19A a perspective view of a third embodiment of the material support assembly 107 including a linkage assembly 320. FIG. 19B is a detailed view of the linkage assembly 320. The linkage assembly 320 allows for lateral movement of the gripper portion of the material support assembly 107 when engaging with material to facilitate reduced motion of adjacent material in the material support frame 110. The linkage assembly 320 includes a top member 322, a bottom member 324, and one or more linkages 326. The top member 322 may be coupled to or incorporated into the support member 132. The bottom member 324 may be coupled to or incorporated into the gripper 130. Each of the linkages 326 are pivotally attached to the top member 322 at one end and the bottom member 324 at the opposite end.

[0104] The linkage assembly 320 includes a spring 328 positioned between a pair of slotted plates 330, the slotted plates 330 having a slot 332. The slot 332 facilitates lateral movement of the gripper 130 within a known range of motion and the spring 328 biases the position of the gripper 130 such that it may be predicted by the control system 106 (shown in FIG. 20). The gripper 130 may move laterally with the extension and / or contraction of the spring 328 until a bolt 334 extending between the slots 332 of the pair of slotted plates 330 reaches an end of the slot 332. The range of motion of the gripper 130 as allowed by the linkage assembly 320 may bias the gripper 130 towards the arm base 602 (not shown in FIGS. 19A and 19B) of the material handling device 108. When the gripper 130 engages material and lifts said material away from contact with surrounding material in the material support frame 110, the linkage assembly 320 may bias the gripper 130 towards the base 102.

[0105] Control System

[0106] FIG. 20 is a schematic of the control system 106 for use with a material handling apparatus, such as the material handling apparatus 100. The control system 106 includes a controller 910 in communication with the material handling device 108, the drive system 104, and a plurality of sensors. The controller 910 includes a memory 912 and a processor 914. The memory 912 may be any device allowing information such as executable instructions and / or data to be stored and retrieved. The processor 914 may include one or more processing units to retrieve and execute instructions and / or data stored by the memory 912.

[0107] The control system 106 may use signals received from the plurality of sensors to control the material handling apparatus 100. The plurality of sensors may include, but is not limited to, one or more positioning sensors 916, one or more material positioning sensors 918,one or more material orientation sensors 920, and / or one or more pressure sensors 922. The control system 106 may also use signals received from a server 924. The server 924 may be in communication with a computing device 926, such as, but not limited to, a user computing device.

[0108] The controller 910 may receive positioning data as related to the material handling apparatus 100 from the one or more positioning sensors 916. The one or more positioning sensors 916 may include one or more angular position sensors, one or more linear variable differential transformer (LVDT) sensors, one or more proximity sensors, one or more magnetic position sensors, one or more linear position sensors, and / or any other sensors known in the art that facilitate the collection of positioning data as related to the various elements of the material handling apparatus 100. For example, one or more positioning sensors 916 may be oriented on the arm 105 of the material handling device 108 to determine the position and / or orientation of the arm 105 in space, and / or relative to the base 102, the material support frame 110, and / or material within the material support frame 110. Additionally, for example, one or more positioning sensors 916 may be oriented on the material support assembly 107 to determine the position and / or orientation of the material support assembly 107 in space, and / or relative to the base 102, the arm 105, the material support frame 110, material within the material support frame 110, and / or the placement surface 860.

[0109] In some embodiments, two or more positioning sensors 916 may be oriented on the arm 105 of the material handling device 108. The controller 910 may use the data from the two or more positioning sensors 916 oriented on the arm 105 to calibrate the positioning of the arm 105 and the material support assembly 107 at the free end 109 of the arm 105. The two or more positioning sensors 916 may include one or more rotary position sensors.

[0110] The controller 910 may receive material positioning data as related to material being handled by the material handling apparatus 100 from the one or more material positioning sensors 918. The one or more material positioning sensors 918 may include one or more infrared sensors, one or more proximity sensors, one or more ultrasonic sensors, one or more laser sensors, and / or any other sensors known in the art that facilitate the collection of material positioning data as related to the material being handled by the material handling apparatus 100. For example, one or more material positioning sensors 918 may be oriented on the material support assembly 107 to determine the position of material within the material support frame110, such as a material height and / or a material position relative to the sides of the material support frame 110 that form the rectangular pen.

[0111] FIG. 21 A is a detailed view of an embodiment of the material support assembly 107 including one or more material positioning sensors 918. The one or more material positioning sensors 918 oriented on the material support assembly 107 may scan in a horizontal plane across the frame width 309 of the material support frame 110, parallel to the horizontal axis 608, to determine an uppermost and outermost material position. For example, as shown in FIG. 21 A, the material support assembly 107 may be positioned to orient the material positioning sensor 918 to scan in a sensor scan direction 930 parallel to and / or angled relative to a horizontal plane parallel to the horizontal axis 608. The material support assembly 107 may include two positioning sensors 918 that are mounted across from each other toward the far ends of the gripper frame (which assists with angle calculation). The positioning sensors 918 may be disposed below or within a sensor housing 699 (FIG. 27) (e.g., for protection from the elements such as rain). In some embodiments, the sensor scan direction 930 may be angled 1 to 2 degrees above a horizontal plane parallel to the horizontal axis 608 (such that the scan direction is slightly upward).

[0112] The one or more material positioning sensors 918 may detect the uppermost material in the material support frame 110 (e.g., material in a position in the material support frame 110 that is highest within the material support frame 110 as measured from the base 102 along the vertical axis 606) by starting to scan from above the material support frame 110 as the material support assembly 107 is lowered towards the base 102. Additionally, the material positioning sensors 918 may detect the outermost material in the material support frame 110 (e.g., material in a position in the material support frame 110 that is outermost within the material support frame 110 as measured from the second base side 114 along the horizontal axis 608) by starting to scan from a first frame side 932 proximate the second base side 114 of the base 102 as the material support assembly 107 is moved towards a second frame side 934 opposite the first frame side 932 and proximate the arm base 602 (not shown in FIG. 21A). The scan by the material positioning sensor 918 may determine a horizontal distance from the material support assembly 107 and the second frame side 934 of the material support frame 110 and / or an angle from a horizontal axis of the scan and an uppermost edge of the outermost material. In some embodiments, the sensor scan may be in the form of a triangle, such as for an ultrasonic sensor,as shown in FIG. 21 A. In other embodiments, the sensor scan may be in the form of a line, such as for a laser sensor, or in any other sensor scan shape.

[0113] The controller 910 may control the material support assembly 107 based on data received from the one or more material positioning sensors 918 and / or the one or more positioning sensors 916. For example, when the material support assembly 107 is positioned such that the gripper 130 is proximate the next material to be handled by the material support assembly 107, the controller 910 may control the operation of the gripper 130 (such as by controlling the gripping mechanism 812) and engage the next material.

[0114] The controller 910 may receive material orientation data as related to material being handled by the material handling apparatus 100 from the one or more material orientation sensors 920. The one or more material orientation sensors 920 may include one or more infrared sensors, one or more angular position sensors, one or more magnetic position sensors, and / or any other sensors known in the art that facilitate the collection of orientation data as related to the material to be handled by the material handling apparatus 100. For example, one or more material orientation sensors 920 may be oriented on the arm 105 and / or the material support assembly 107 of the material handling device 108 to determine the orientation and / or angle of material within the material support frame 110. As the material handling apparatus 100 is operated, the orientation of material within the material support frame 110 may change, such as moving from parallel to the base axis 111 of the base 102 to an angle relative to the base axis 111. The one or more material orientation sensors 920 may determine how the next material to be handled by the material support assembly 107 is positioned (e.g., whether the next material to be engaged by the gripper 130 is parallel to the base axis 111 or at an angle relative to the base axis 111) to orient and position the material support assembly 107 as needed to engage the next material.

[0115] The controller 910 may receive pressure data as related to the material handling apparatus 100 from the one or more pressure sensors 922. The one or more pressure sensors 922 may include one or more pressure transducers and / or any other sensors known in the art that facilitate the collection of pressure data as related to the various elements of the material handling apparatus 100. For example, one or more pressure sensors 922 may be oriented on the material support assembly 107 to determine the pressure applied by the one or more grippers 130 when engaging material. Additionally, for example, one or more pressure sensors 922 may be oriented on the material handling device 108 to collect pressure information as related to thevarious actuators used to move and position the arm 105 and / or one or more members of the arm 105. The material handling apparatus 100 may include bump bars and / or an object detection systems (e.g., one or more cameras and / or lidar) to sense nearby objects.

[0116] FIG. 21B is a back view of the material handling apparatus 100 including an embodiment of the material support assembly 107 including one or more positioning sensors 916 and one or more material positioning sensors 918. Similar to the disclosure pertinent to FIG. 21 A, the one or more material positioning sensors 918 oriented on the material support assembly 107 may scan in a horizontal plane across the frame width 309 of the material support frame 110, parallel to the horizontal axis 608, to determine an uppermost and outermost material position. The one or more positioning sensors 916 oriented on the material support assembly 107 may scan in a vertical plane down towards the placement surface 860 to determine a proximity of the material support assembly 107 to the placement surface 860. For example, as shown in FIG. 2 IB, the material support assembly 107 may be positioned to orient one or more of the positioning sensors 916 to scan in a sensor scan direction 930 in a vertical plane parallel to the vertical axis 606.

[0117] The one or more positioning sensors 916 may detect the placement surface 860 to determine a proximity of the material support assembly 107 to the placement surface 860 for placing material removed from the material support frame 110 and engaged by the material support assembly 107 onto the placement surface 860. The scan by the positioning sensors 916 may determine a vertical distance from the material support assembly 107 to the placement surface 860. For example, the positioning sensors 916 may detect the placement surface 860 being lower and / or higher than the surface directly below the tracks of the drive system 104. Thus, the positioning sensors 916 may facilitate improved placement of material onto the placement surface 860 for uneven ground, to minimize releasing the material from too high of a height or hitting the placement surface 860 in trying to release the material from too low of a height. In some embodiments, the sensor scan may be in the form of a triangle, such as for an ultrasonic sensor, as shown in FIG. 2 IB. In other embodiments, the sensor scan may be in the form of a line, such as for a laser sensor, or in any other sensor scan shape.

[0118] As seen in FIG. 21 A, the one or more positioning sensors 916 may also be oriented on the material support assembly 107 to scan in a vertical plane downwards towards the material support frame 110 to determine a proximity of the material support assembly 107 to material within the material support frame 110. For example, the material support assembly107 may be positioned to orient one or more of the positioning sensors 916 to scan in a sensor scan direction 930 in a vertical plane parallel to the vertical axis 606.

[0119] The material handling apparatus 100 is configured for operation under active control by an operator (e.g., a user). Additionally, the material handling apparatus 100 may be configured for autonomous operation via the control system 106. For example, the controller 910 is configured to receive operating instructions from a user with active control of the material handling apparatus 100. Active control of the material handling apparatus 100 may be executed via a control unit 940 positioned on the material handling apparatus 100, such as on a surface of the housing 116 (shown in FIG. 1A). Active control of the material handling apparatus 100 may also be executed via the computing device 926 communicatively connected to the server 924. The computing device 926 may be a remote control unit.

[0120] Additionally, for example, the controller 910 may be configured to autonomously control one or more operations of the material handling apparatus 100. Autonomous control of the material handling apparatus 100 may be for automated operation, such that active control by the user is maintained throughout operation with limited control transferred to the controller 910 for a specific subset of operation functions. Additionally, autonomous control of the material handling apparatus 100 may be for semi -autonomous operation, such that a subset of operation functions may be controlled by the controller 910 and another subset of operation functions may be actively controlled by the user. As used herein, the term “autonomous” refers to the operation of a material handling apparatus based on at least one of the following levels, in no particular order. At level 1, the apparatus includes partial autonomation and partial manual operation of required tasks. In instances of partial automation, an operator still monitors operation and may take control at any time. At level 2, the material handling apparatus can detect its environment and perform most operational tasks, but operator intervention is still required in some instances. At level 3, the material handling apparatus has a high level of autonomation for all tasks under certain situations, typically within a geofenced area (e.g., a space), and operator intervention is an option but not required within the defined space. At level 4, operation of the material handling apparatus is fully automated with no human intervention required. Said differently, the apparatus performs all machine safety-critical and operational-critical functions related to its defined operations without operator interaction.

[0121] An automated handling of material by the material handling device 108 may include the controller 910 receiving a command, via the control unit 940 and / or the computing device926 through the server 924, to start a material handling process. The material handling process may be paused or stopped at any time for automated operation of the material handling apparatus 100, such as if a hold and / or stop command is received by the controller 910 from the control unit 940 and / or the computing device 926 via the server 924. The material handling process may include the controller 910 receiving a command for the material handling device108 to be positioned such that the material support assembly 107 is above the material support frame 110 in a ready position for handling material in the material support frame 110. Positioning the material handling device 108 may include centering the position of the support member 132 of the material support assembly 107 between ends of the material support frame 110. Positioning the material handling device 108 may also include positioning the material support assembly 107 above the material support frame 110 in a scan initiation position proximate the second base side 114.

[0122] The material handling process may also include the controller 910 receiving a command from the one or more material positioning sensors 918 to actively scan across the material support frame 110 as the material support assembly 107 is moved vertically (e.g., parallel to the vertical axis 606) to determine an uppermost and outermost material location from which to start handling material.

[0123] If the one or more material positioning sensors 918 detect material in the material support frame 110, the material handling process may also include the controller 910 receiving a command for the material support assembly 107 to engage a next material in the material support frame 110. That is, the control system 106 may determine, based on the data and signals received, the material to be next handled and removed from the material support frame 110. For example, the controller 910 may control the material handling device 108 to position the material support assembly 107 proximate the next material to be handled in the material support frame 110 for the one or more grippers 130 to engage the next material. The command for the material support assembly 107 to engage material may include location data of the free end109 of the arm 105 in relation to the arm base 602.

[0124] If the one or more material positioning sensors 918 do not detect material in the material support frame 110, the material handling process may terminate and the controller 910 may receive a command for the material handling device 108 to be positioned in the base configuration (as shown in FIG. IB). Additionally, the controller 910 may receive a command-SO-for the material handling device 108 to be positioned in one of the embodiments of the stow configuration (as shown in FIGS. 16-18).

[0125] If the material support assembly 107 engages material in the material support frame 110, the material handling process may include the controller 910 receiving a command to operate the gripping mechanism 812 to apply adequate pressure to the material for engagement with the grippers 130 and / or receiving data to confirm the material was engaged, such as via pressure sensor readings on the one or more grippers 130. The material support assembly 107 may include proximity switches (e.g., a whisker switch or a non-contact sensor such as an ultrasonic sensor or a laser sensor) that detect if the material has been successfully secured by the grippers 130. The material handling process may also include the controller 910 receiving commands for the material handling device 108 to be positioned such that the material support assembly 107 is upwards of the material support frame 110 and for the material handling device 108 to be moved such that the material support assembly 107 has been extended past the second base side 114 (e.g., not sharing a vertical plane with the base 102 and / or the tracks 118). The material handling process may also include the controller 910 receiving a command to lower the material support assembly 107 until the one or more positioning sensors 916 detect proximity of the material support assembly 107 to the placement surface 860.

[0126] The material handling process may further include the controller 910 receiving a command to place the engaged material on the placement surface 860. Placing material on the placement surface 860 may include the controller 910 receiving orientation data to position and / or angle the material support assembly 107 for material placement. For example, the material, such as piles, may be placed horizontally, vertically, or at an angle on the placement surface 860 at each solar panel mount location. Placing material on the placement surface 860 may include the controller 910 receiving a command to release the one or more grippers 130 to release the engaged material. Following placement of material on the placement surface 860, the material handling process may continue for additional material in the material support frame 110 and / or end with a command for the material handling device 108 to be positioned in the base configuration (as shown in FIG. IB) or one of the embodiments of the stow configuration (as shown in FIGS. 16-18). The one or more commands received by the controller 910 may include data indicative of a site plan and / or as received from a positioning system (such as, but not limited to, a GPS).

[0127] Automated control of the drive system 104 of the material handling apparatus 100 may include the controller 910 receiving a command (e.g., a command from a remote / operator or from the autonomous control of the apparatus) to move the material handling apparatus 100 via the tracks 118 from one material placement location to another material placement location on the placement surface 860. For example, the material handling apparatus 100 may be moved by the controller 910 in a grid format between material placement locations (such as between solar panel mount locations) on the placement surface 860.

[0128] FIG. 22 is a flowchart of a method 900 for placing material using a material handling apparatus, such as the material handling apparatus 100. The method 900 includes loading 902 material into a material support frame (such as the material support frame 110) and locating 904 a material support assembly of a material handling device (such as the material support assembly 107 of the material handling device 108) above the material support frame between first and second ends of the material support frame. The method also includes removing 906 material from the material support frame using the material handling device, wherein the material may be removed in an order independent of how the material was loaded into the material support frame. The method further includes placing 908 material removed from the material support frame on a placement surface (such as the placement surface 860) using the material handling device.

[0129] FIG. 23 is a perspective view of another embodiment of the material support frame 110 for use with a material handling apparatus, such as the material handling apparatus 100. The embodiment of the material support frame 110 shown in FIG. 23 includes a panel 350. The panel 350 is positioned between stationary vertical frame members 308 along one side of the material support frame 110. The panel 350 is oriented to secure material in the material support frame 110 along the frame width 309 to facilitate minimizing movement of the material in relation to the frame width 309 during operation of the material handling apparatus 100. The panel 350 may include a plurality of subpanels welded together.

[0130] The panel 350 may include a mesh design such that the panel 350 is not completely solid, with the position of the panel 350 and / or the mesh design of the panel 350 serving as a fixed calibration point for one or more sensors. For example, one or more sensors of the material handling apparatus 100 may need to be calibrated to determine the positioning of the arm 105 and / or the material support assembly 107 of the material handling device 108 and facilitate accurate handling of material within the material support frame 110.

[0131] Referring to FIG. 26, other embodiments of the material support frame 110 may include the panel 350 to serve as a fixed calibration point. Alternatively or in addition, referring to FIG. 25, the frame of the material handling apparatus 100 may include a panel 370 to be used as a fixed calibration point. Generally, any component of the material handling apparatus 100 that has a known location (e.g., shield, hood, frame, track frame, and the like) may be used as a fixed calibration point.

[0132] A sensor (such as, but not limited to, a rotary sensor) may be positioned near a connection between the first arm member 604a of the first embodiment of the arm 105 to calibrate the positioning of the first arm member 604a, shown as one of the positioning sensors 916 in FIG. 6 A. For example, the actuator cylinder of the outer first arm member 604aa of the first arm member 604a may be retracted and then extended, with a position of the first arm member 604a being determined for each, to facilitate accurate calibration of the positioning of the arm 105. Additionally, or alternatively, a sensor (such as, but not limited to, a linear position sensor) may be positioned along an interior surface of the third arm member 604c of the first embodiment of the arm 105 to calibrate the positioning of the first arm member 604a, shown as one of the positioning sensors 916 in FIG. 6 A. For example, the actuator cylinder of the third arm member 604c may be retracted and then extended, with a position of the third arm member 604c being determined for each, to facilitate accurate calibration of the positioning of the arm 105.

[0133] Additionally, or alternatively, a sensor (such as, but not limited to, a rotary sensor) may be positioned at a connection between the free end 109 of the arm 105 and the material support assembly 107 to calibrate the positioning of the material support assembly 107 with reference to the panel 350 of the material support frame 110. For example, an actuator cylinder of the material support assembly 107 may be retracted and then extended, with a position and / or orientation of the material support assembly 107 being determined for each, to facilitate accurate calibration of the positioning of the material support assembly 107. Additionally, for example, the material support assembly 107 may be moved in relation to the material support frame 110 to determine a position and / or orientation of each material within the material support frame 110 to facilitate accurate calibration of the positioning of the material support assembly 107.

[0134] This written description uses examples to disclose the invention, including the best mode and to enable a person of ordinary skill in the relevant art to make and practice theinvention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims. Such other examples are within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. Aspects from the various embodiments described, as well as other known equivalents for each such aspects, can be mixed and matched by one of ordinary skill in the art to construct additional embodiments and techniques in accordance with principles of this application.

Claims

WHAT IS CLAIMED IS:

1. A material handling apparatus comprising: a base having a first side and a second side, each of the first and second sides extending along a base axis; a drive system connected to the base to move the base in at least one direction of motion; a housing supported by the base along the first side of the base, the housing comprising one or more components of a control system, wherein the control system is operable to control the drive system to selectively move the base in the at least one direction of motion; a material support frame supported by the base along the second side of the base, wherein material is stored within the material support frame; and a material handling device attached to the base between the housing and the material support frame, the material handling device comprising a moveable arm and a material support assembly at an end of the moveable arm, the material support assembly being moveable with the moveable arm, wherein the control system is operable to move the material handling device to locate the moveable arm above the material support frame between the first and second ends of the material support frame and position the material support assembly outwards of the material support frame to place material engaged by the material support assembly and removed from the material support frame on a placement surface, wherein the material handling device determines a next material to be removed from the material support frame by detecting material in an uppermost position within the material support frame.

2. The material handling apparatus of claim 1, wherein the material support assembly is moveable independent of the moveable arm.

3. The material handling apparatus of claim 1, wherein the moveable arm comprises a first member and a second member, the material support assembly being attached to the second member at the end of the moveable arm.

4. The material handling apparatus of claim 3, wherein the material support assembly is substantially perpendicular to the second member of the moveable arm.

5. The material handling apparatus of claim 1, wherein the material support frame and the housing are oriented parallel to the base axis.

6. The material handling apparatus of claim 1, wherein the material support frame is oriented parallel to the at least one direction of motion.

7. The material handling apparatus of claim 1, wherein the material support frame has a frame width and a frame height, and wherein at least one of the frame width and the frame height is adjustable.

8. The material handling apparatus of claim 1, wherein the material support frame is removable from the base.

9. The material handling apparatus of claim 1, wherein the material support assembly of the material handling device comprises one or more gripping surfaces to engage material.

10. The material handling apparatus of claim 9, wherein the material support assembly comprises at least one of one or more magnets or one or more suction assemblies to engage material.

11. The material handling apparatus of claim 1, wherein the material handling device determines the next material to be removed from the material support frame by detecting material in the uppermost position and an outermost position within the material support frame.

12. The material handling apparatus of claim 1, wherein the material support frame has one or more bottom plates oriented to secure material in the material support frame, the one or more bottom plates comprising a top surface having one or more slots to receive an extending edge of material within the material support frame.

13. The material handling apparatus of claim 1, wherein the material is a pile that is intended to be driven into a ground surface for installation on a solar field.

14. The material handling apparatus of claim 1, wherein material may be transported in the material support frame in a first configuration with a material height substantially perpendicular to the base or a second configuration with the material height substantially parallel to the base.

15. The material handling apparatus of claim 14, wherein material may be placed onto the placement surface in the first configuration with the material height substantiallyperpendicular to the placement surface or the second configuration with the material height substantially parallel to the placement surface.

16. A method for placing material using an automated material handling apparatus, the material handling apparatus comprising a material support frame and a material handling device, the method comprising: loading material into the material support frame; locating a material support assembly of the material handling device above the material support frame between first and second ends of the material support frame; locating material within the material support frame using the material handling device, wherein the material may be located by detecting material in at least one of an uppermost position and an outermost position within the material support frame; engaging material located for removal within the material support frame by the material support assembly; removing material engaged by the material support assembly from the material support frame; and placing material removed from the material support frame on a placement surface using the material handling device.

17. The method of claim 16, wherein placing material removed from the material support frame comprises extending a moveable arm of the material handling device over the material support frame and positioning the material support assembly of the material handling device outwards of the material support frame.

18. The method of claim 16, wherein locating material within the material support frame comprises using one or more sensors to determine one or more of a material orientation or a material configuration of material within the material support frame.

19. The method of claim 18, wherein engaging material within the material support frame comprises positioning the material support assembly at an angle to match the material orientation of material within the material support frame.

20. The method of claim 16, wherein material is located, engaged by the material support assembly, removed from the material support frame, and placed on the placement surface until the material support frame is empty of material.

21. The method of claim 16, wherein placing material removed from the material support frame comprises placing material on the placement surface in a first configuration with a material height perpendicular to the placement surface or a second configuration with the material height parallel to the placement surface.

22. A control system for an automated material handling apparatus, the material handling apparatus comprising a material support frame having first and second frame ends being oriented to support material and a material handling device having a moveable arm and a material support assembly at an end of the moveable arm, the control system comprising a controller, the controller including a processor and a memory device, the memory device storing instructions that when executed by the processor cause the processor to: move the material handling apparatus, via a drive system, to a first location on a placement surface for placement of material; locate material within the material support frame by locating the moveable arm of the material handling device above the material support frame between the first and second ends of the material support frame; remove material from the material support frame by engaging material with the material support assembly at the end of the moveable arm of the material handling device; place material removed from the material support frame on the placement surface, via the material handling device, by positioning the material support assembly outwards of the material support frame to place material on the placement surface; and move the material handling apparatus, via the drive system, from the first location to a second location on the placement surface for further placement of material.

23. The control system of claim 22, wherein the control system further comprises one or more sensors mounted to the material handling apparatus, and wherein locating material within the material support frame comprises the one or more sensors detecting material in at least one of an uppermost position and an outermost position within the material support frame.

24. The control system of claim 22, wherein the control system further comprises one or more sensors mounted to the material handling apparatus, wherein removing material from the material support frame comprises the one or more sensors detecting a proximity of the material support assembly to material within the material support frame.

25. The control system of claim 22, wherein the control system further comprises one or more sensors mounted to the material handling apparatus, wherein placing material on the placement surface comprises the one or more sensors detecting a proximity of the material support assembly to the placement surface for placement on the placement surface.

26. The control system of claim 22, wherein removing material from the material support frame comprises detecting a material orientation of material within the material support frame and positioning the material support assembly at an angle to match the material orientation.

27. A material handling apparatus comprising: a base having a first side and a second side, each of the first and second sides extending along a base axis; a drive system connected to the base to move the base in at least one direction of motion; a housing supported by the base along the first side of the base, the housing comprising one or more components of a control system, wherein the control system is operable to control the drive system to selectively move the base in the at least one direction of motion; a material support frame supported by the base along the second side of the base, wherein material is stored within the material support frame, the material support frame comprising: first and second frame ends; and first and second longitudinal frame members perpendicular to the first and second frame ends, wherein a length of the material support frame extends between the first and second frame ends, a width of the material support frame extends perpendicular to the length between the first and second longitudinal frame members, and a height of the material support frame extends upwards and perpendicular to the length, wherein the first and second frame ends have vertical support members oriented to secure material along the length of the material support frame; and a material handling device attached to the base between the housing and the material support frame, the material handling device comprising a moveable arm and a material support assembly at an end of the moveable arm, the material support assembly being moveable with the moveable arm,wherein the control system is operable to move the material handling device to locate the moveable arm above the material support frame between the first and second frame ends of the material support frame and position the material support assembly outwards of the material support frame to place material engaged by the material support assembly and removed from the material support frame on a placement surface.

28. The material handling apparatus of claim 27, wherein the material support frame further comprises one or more vertical frame members extending along the height of the material support frame, the one or more vertical frame members being oriented to secure material along the width of the material support frame.

29. The material handling apparatus of claim 28, wherein at least one of the height and the width of the material support frame is adjustable.

30. The material handling apparatus of claim 29, wherein at least one of the one or more vertical frame members are moveable to adjust at least one of the height and the width of the material support frame.

31. The material handling apparatus of claim 27, wherein the material support frame and the housing are oriented parallel to the base axis.

32. The material handling apparatus of claim 27, wherein the material support frame is oriented parallel to the at least one direction of motion.

33. The material handling apparatus of claim 27, wherein the material handling device determines a next material to be removed from the material support frame by detecting material in at least one of an uppermost position and an outermost position within the material support frame.

34. The material handling apparatus of claim 27, wherein the material support frame further comprises one or more bottom plates extending between the first and second longitudinal frame members, the one or more bottom plates being oriented to secure material along the height of the material support frame.

35. The material handling apparatus of claim 34, wherein the one or more bottom plates comprise a top surface having one or more slots to receive an extending edge of material within the material support frame.

36. The material handling apparatus of claim 27, wherein the material is a pile that is intended to be driven into a ground surface for installation on a solar field.

37. The material handling apparatus of claim 27, wherein material may be transported in the material support frame in a first configuration with a material height substantially perpendicular to the base or a second configuration with the material height substantially parallel to the base.

38. The material handling apparatus of claim 37, wherein material may be placed onto the placement surface in the first configuration with the material height perpendicular to the placement surface or the second configuration with the material height parallel to the placement surface.

39. The material handling apparatus of claim 27, wherein the material support frame is removeable from the base.

40. The material handling apparatus of claim 39, wherein the material support frame is removably secured to the base by at least one of pins, slides, or hooks.

41. A material handling apparatus comprising: a base having a first side and a second side, each of the first and second sides extending along a base axis; a drive system connected to the base to move the base in at least one direction of motion, the drive system comprising a pair of tracks each extending along one of the first and second sides of the base; a housing supported by the base along the first side of the base, the housing comprising one or more components of a control system, wherein the control system is operable to control the drive system to selectively move the base in the at least one direction of motion; a removeable material support frame securable to the base along the second side of the base, wherein material is stored within the material support frame, the material support frame comprising first and second frame ends and first and second longitudinal frame members perpendicular to the first and second frame ends; anda material handling device attached to the base between the housing and the material support frame, the material handling device comprising a moveable arm and a material support assembly at an end of the moveable arm, the material support assembly being moveable with the moveable arm, wherein the material handling apparatus may be configured for compact travel in a stow configuration, the stow configuration comprising the material handling device positioned such that an entirety of the material support assembly is between the first and second sides of the base.

42. The material handling apparatus of claim 41, wherein the stow configuration comprises the moveable arm of the material handling device extending at an angle relative to the base axis.

43. The material handling apparatus of claim 41, wherein the stow configuration comprises the moveable arm of the material handling device extending along the base axis such that the entirety of the material support assembly is between the tracks of the drive system.

44. The material handling apparatus of claim 41, wherein the material support assembly is moveable independent of the moveable arm.

45. The material handling apparatus of claim 41, wherein the moveable arm comprises a first member and a second member, the material support assembly being attached to the second member at the end of the moveable arm, wherein the first member is located parallel to the base axis in the stow configuration.

46. The material handling apparatus of claim 41, wherein the material support assembly is substantially perpendicular to the second member of the moveable arm.

47. The material handling apparatus of claim 41 , wherein at least one of the housing and the material support frame is oriented parallel to the base axis.

48. The material handling apparatus of claim 41, wherein the material support frame is oriented parallel to the at least one direction of motion.

49. The material handling apparatus of claim 41, wherein disassembly of one or more of the base, the drive system, the housing, and the material handling device is not required for compact travel of the material handling apparatus in the stow configuration.

50. The material handling apparatus of claim 41, wherein the material handling apparatus in the stow configuration has a total height of less than 89 inches and a total width of less than 90 inches.

51. The material handling apparatus of claim 42, wherein the material handling apparatus in the stow configuration has a total height of less than 101 inches and a total width of less than 90 inches.

52. The material handling apparatus of claim 41, wherein the material handling apparatus in the stow configuration has a total height of less than 89 inches and a total width of less than 88 inches.

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