vehicle

Abstract

A controller for an autonomous guided vehicle (AGV) is provided such that the AGV can be operated in a semi-autonomous mode when coupled to the AGV controller. In this semi-autonomous mode, an operator has access to all of the AGV's functions through the AGV controller. The AGV controller can be detached from the AGV, allowing the AGV to return to autonomous operation.

Description

[Technical Field]

[0001] The present disclosure relates to vehicles, and more particularly to semi-autonomous guided vehicles that may be operated in storage facilities such as warehouses or fulfillment centers. [Background technology]

[0002] There is a trend toward using automated storage and retrieval systems (ASRS) to provide products to customers who order them online. ASRSs can be used to store products so they can then be packaged and shipped to customers. An example of such an ASRS is disclosed in the applicant's patent application WO 2015 / 019055. The level of automation within an ASRS can be increased through the use of robotic picking arms, such as those disclosed in WO 2023 / 285487. Another role for automation is the use of autonomous vehicles, such as those disclosed by the applicant's co-pending application GB 2217719.0 relating to an autonomous pallet mover. It has been observed that there are situations where such autonomous vehicles result in reduced efficiency, such as in limited space and when many pallets are tightly packed together. Summary of the Invention

[0003] According to a first aspect of the present disclosure, there is provided a controller for an autonomous guided vehicle, the controller comprising a coupling configured to couple, in use, to the autonomous vehicle and an interface for controlling operation of the autonomous vehicle. The controller may further comprise rolling means. The controller may comprise drive means operable to actuate the rolling means. The controller may further comprise a wireless network interface.

[0004] According to a second aspect of the present disclosure, there is provided a semi-autonomous vehicle comprising an autonomous guided vehicle and a controller for the autonomous guided vehicle as described above, wherein the autonomous guided vehicle comprises an aperture configured to receive a coupling of the controller such that, in use, the controller interface is used to control the autonomous guided vehicle.

[0005] Providing such an AGV controller allows an operator to control the AGV in environments where it has been observed that AGVs may experience difficulties, such as confined spaces where multiple pallets are densely packed together and / or located next to walls or other structures, allowing for more efficient operation of the vehicle.

[0006] The autonomous guided vehicle may include a control system such that, in use, the control system is responsive to control signals generated by the controller interface. The autonomous guided vehicle may include a drive system such that, in use, the drive system is actuated in response to control signals generated by the controller interface. The autonomous guided vehicle may also include a forklift mechanism such that, in use, the forklift mechanism is actuated in response to control signals generated by the controller interface.

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

[0008] In step d), the autonomous guided vehicle may deliver the load to the first predetermined location. The method may include the further step of e) the autonomous guided vehicle depositing the load at the first predetermined location and then traveling to a second predetermined location. In step b), the semi-autonomous vehicle may be controlled to navigate the semi-autonomous vehicle to a storage location to retrieve the load.

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

[0010] Segregating storage facilities into such zones helps separate AGVs from human operators. Such separation may allow AGVs to operate at increased speeds, leading to increased system efficiency, as the risk of collision with human operators is reduced. Such separation should also increase the welfare of human operators.

[0011] A transfer location may be defined adjacent to the first zone and the second zone. The storage facility may include a physical barrier to separate the first zone from the second zone. The physical barrier may include one or more apertures through which an autonomous guided vehicle or semi-autonomous vehicle may pass. A transfer location may be defined adjacent to one or each of the barrier apertures. The first direction may be contiguous with the second direction. Alternatively, the first zone may have an area that overlaps with the second zone.

[0012] Further features and aspects of the present invention will become apparent from the following detailed description of illustrative embodiments which proceeds with reference to the drawings. [Brief explanation of the drawings]

[0013] [Figure 1]1 shows a schematic diagram of a controller for an autonomous guided vehicle approaching an autonomous guided vehicle. [Figure 2] 1 shows a schematic diagram of an autonomous guided vehicle when coupled to a controller. [Figure 3] 10 shows a schematic diagram of a further example of a controller for an autonomous guided vehicle approaching an autonomous guided vehicle. [Figure 4] 4 shows a schematic diagram of an autonomous guided vehicle when coupled to the controller shown in FIG. 3. [Figure 5] 1 shows a schematic diagram of a storage facility in which a controller for autonomous guided vehicles and AGVs may be used. [Figure 6] 1 shows a schematic diagram of a further example of a storage facility in which a controller for autonomous guided vehicles and AGVs may be used. [Figure 7] FIG. 1 shows a flowchart illustrating the operation of an autonomous guided vehicle using an AGV controller. [Figure 8] 1 shows a schematic diagram of a first example of an autonomous pallet mover approaching a pallet. [Figure 9a] FIG. 9 is a schematic diagram of the autonomous pallet mover of FIG. 8. [Figure 9b] FIG. 9 is a schematic diagram of the autonomous pallet mover of FIG. 8. [Figure 9c] FIG. 9 is a schematic diagram of the autonomous pallet mover of FIG. 8. [Figure 9d] FIG. 9 is a schematic diagram of the autonomous pallet mover of FIG. 8. [Figure 9e] FIG. 9 is a schematic diagram of the autonomous pallet mover of FIG. 8. [Figure 9f] FIG. 9 is a schematic diagram of the autonomous pallet mover of FIG. 8. [Figure 9g] FIG. 9 is a schematic diagram of the autonomous pallet mover of FIG. 8. [Figure 10] FIG. 1 is a schematic diagram of a second example of an autonomous pallet mover. [Figure 11a] FIG. 11 is a schematic diagram of the autonomous pallet mover of FIG. 10. [Figure 11b] FIG. 11 is a schematic diagram of the autonomous pallet mover of FIG. 10. [Figure 11c] FIG. 11 is a schematic diagram of the autonomous pallet mover of FIG. 10. [Figure 12] FIG. 1 is a block diagram showing the main components of an autonomous pallet mover. [Figure 13] FIG. 10 is a flow diagram illustrating example steps taken by an autonomous pallet mover when engaging a pallet. [Figure 14(a)-(e)] 5 is a schematic diagram illustrating steps performed by an autonomous pallet mover according to a second example. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0014] FIG. 1 shows a schematic diagram of a controller 200 for an autonomous guided vehicle 1. In the example shown in FIG. 1, the autonomous guided vehicle (hereinafter AGV) is equipped with multiple forks 4 and is designed to lift and move a pallet 20. As will become apparent from the discussion below, the exact nature of the AGV is not important to this disclosure. The AGV 1 is capable of sliding the multiple forks 4 into the body of the pallet 20, lifting the pallet, moving the pallet to a particular location, and then placing the pallet at that location. The structure and function of the AGV are described below with reference to FIGS. 8-14.

[0015] The AGV additionally comprises an aperture 50 configured to engage with a coupling 220 of the AGV controller 200. The AGV controller 200 further comprises an interface 210 and a rolling means 230. During operation, the AGV controller can be manually maneuvered into a position adjacent to the AGV, and the AGV controller coupling 220 can be inserted into the AGV aperture 50. Coupling the AGV controller and the AGV disables the AGV's autonomous functions, so that the AGV can be operated by an operator through manipulation of the controller interface 210. For ease of operation, the controller interface may resemble the interface of a conventional manual vehicle, such as a hand truck or pallet lifter, such as may be found in a storage facility. When coupled together, the AGV and AGV controller can be considered a semi-autonomous guided vehicle 201 (hereinafter, SAGV).

[0016] 1 and 2, the controller interface includes a yoke 212 and a plurality of triggers 214. Figures 3 and 4 show a second example of an AGV controller in which the AGV interface 210 includes a steering wheel 216. It should be understood that the AGV interface 210 may include additional controls, actuators, etc. These may be physical controls such as switches, dials, etc., and / or may include GUI elements on a touchscreen that can be selected and / or activated by an operator.

[0017] 5 shows a schematic diagram of a storage facility 400 in which AGV 1, AGV controller 200, and SAGV 201 are used to transport pallets. The storage facility includes a manual driving area 410, an autonomous driving area 420, and multiple storage areas 430. The multiple storage areas 430 may be located within the manual driving area 410, or alternatively, the multiple storage areas 430 may be located adjacent to the manual driving area 410 such that the multiple storage areas can be accessed from the manual driving area.

[0018] From FIG. 5, it can be seen that there is an overlap between the manual driving area 410 and the autonomous driving area 420. It should be understood that in an alternative configuration, the manual driving area and the autonomous driving area may be contiguous. In use, the central computing system 450 commands one of the AGVs 1 to move from its current location (likely within the autonomous driving area) to a location within the manual zone. In one example, the AGV will move to the edge of the manual zone so that an operator can move the AGV controller to a position adjacent to the AGV. The AGV controller may then be mated to the AGV to form a SAGV. The operator can then move the SAGV to one of a number of storage areas and operate the SAGV to pick up and retrieve pallets stored within the storage area.

[0019] The operator can then move the SAGV to the edge of the autonomous driving area and disengage the AGV controller from the AGV. The AGV can then perform one or more autonomous actions. For example, the central computing system can communicate a location in the autonomous driving area to the AGV. The AGV will then autonomously move to this location. This location can be adjacent to one of multiple stations 422 located within the autonomous driving area. The station can be a decant station used to decant product items from a pallet so that they can be introduced into an automated storage and retrieval system. This decant function can be performed by a human operator, a robotic picking arm, or a combination of the two. Once all of the product items have been removed from the pallet, the AGV can place the empty pallet in a pallet storage location. After the AGV disposes of the pallet, the AGV can return to the manual zone so that the AGV can be attached to an additional AGV controller to complete additional tasks.

[0020] In an alternative configuration, the AGV may deposit a loaded pallet adjacent to one of the stations 422 and then return to the manual zone to complete further tasks as a SAGV. An additional AGV may be used autonomously to retrieve empty pallets from a location adjacent to one of the stations and then place them in a pallet storage location.

[0021] During use, the central computing system may command one of the AGVs to move to one of several predetermined transfer locations so that an operator can couple the AGV controller to the AGV. Similarly, the central computing system may send a message to an operator instructing the operator to move to one of the transfer locations where an AGV may be waiting to couple the AGV controller to the AGV. Once the SAGV is loaded with a pallet from one of the truck trailers, the operator may move the SAGV to the nearest transfer location before removing the AGV controller and handing the AGV over to autonomous operation. Alternatively, the central computing system may send a message to an operator instructing the operator to move the SAGV to a designated transfer location before removing the AGV controller from the AGV.

[0022] FIG. 6 shows a schematic diagram of a further example of a storage facility such as that described above with reference to FIG. 5. In this example, the multiple storage areas 430 comprise multiple truck trailers. It is common for the truck trailers to hold multiple closely spaced pallets, each storing a box or container of product items. The tight packing of the pallets, along with the limited space inside the truck trailer, has proven difficult for an AGV to efficiently retrieve pallets from such locations. FIG. 6 also illustrates the use of a physical barrier 415 to provide separation between the manual and autonomous driving areas. The physical barrier 415 may include a gap 417 through which the AGV can pass. One or more predetermined handover locations may be defined at or near the barrier gap 417.

[0023] FIG. 7 shows a flowchart diagram in which, in step S700, an AGV controller is attached to an AGV to form an SAGV. The SAGV is then used to perform a task (S710, e.g., retrieving load from a storage location) before the SAGV is moved to an autonomous zone (S720). The operator would then remove the AGV controller and return the AGV to autonomous operation. The AGV would then autonomously perform a task (S740, e.g., moving a pallet to a station for a decant activity) before returning to the manual zone (S750). Once the AGV returns to the manual zone, the AGV may be attached to the controller, so that the method returns to step S700. It should be understood that the AGV may repeat multiple instances of the method until there is no more load in the storage area(s). The AGV may pause execution of the method after step S740 if the AGV determines that it has insufficient battery charge to perform further instances of the method. The AGV may then travel to a recharging station and then restart the method at step S750 once the AGV is fully recharged (or until an adequate charge level is achieved).

[0024] The AGV controller shown in FIGS. 1-4 can take a wide variety of forms. For example, the AGV controller may not have a motive force such that an operator must manually move the SAGV. Alternatively, a connection between the AGV controller and the AGV may cause the AGV's control system to operate the AGV's drive assembly and / or forklift mechanism in response to an operator's actions on the AGV interface 210. Additionally or as a further alternative, the AGV controller may include drive means (e.g., one or more electric motors) operable to drive the AGV controller's rolling means 230, so that the rolling means supplements or replaces the operator's physical efforts. The AGV controller may include a power source, such as a battery, or power for the AGV controller drive means may be supplied from the AGV. The AGV controller may include a platform 250 on which an operator can stand when operating the SAGV (or the AGV controller when the AGV controller is capable of powered movement). The platform 250 can be folded out of the way (e.g., into a vertical orientation as shown in FIG. 4) when the AGV controller is being manually moved.

[0025] The coupling between the AGV controller and the AGV may be purely mechanical. Alternatively, the coupling may be electromechanical, such that manipulation of the AGV controller interface 210 by an operator actuates one or more of the AGV's drive assembly, forklift mechanism, or other subsystems. If the coupling is purely mechanical, a wireless connection may be made between the AGV controller and the AGV, such that movement of the AGV controller actuates elements of the AGV. The AGV elements may be directly controlled by the AGV controller interface, or movement of the AGV controller interface may be input to the AGV control elements, which then control the AGV elements accordingly. The AGV controller may include a display screen that may be used to provide feedback to the operator regarding the status and operation of the AGV controller (or SAGV, when the AGV controller is attached to the AGV). The display screen may be used to display messages sent by a central computing system. In such cases, it will be understood that the AGV controller includes a wireless network interface, such as WiFi, to enable communication with the central computing system. Additionally or alternatively, messages may be sent to an operator device, e.g., a handheld device, a smartwatch, etc., to instruct the operator on the destination of the AGV controller (or SAGV). The AGV controller may include a stationary device capable of holding a handheld device, e.g., a smartphone or tablet computer, so that the operator can view the device while operating the AGV controller (or SAGV).

[0026] 1-4 show examples of types of controller interfaces that may be used. It should be understood that other forms of controller interfaces are possible. To enable an operator to efficiently transition from a conventional vehicle to the SAGV of the present disclosure, it is believed to be beneficial for the controller interface to closely resemble the interfaces of commonly used manual load-bearing vehicles. Alternatively, it should be understood that the controller interface may comprise a trackball or joystick, either in place of or as an extension of the controller interfaces shown in FIGS. 1-4. Additionally or as a further alternative, some or all of the controller interface may be provided using a graphical user interface on an AGV controller display screen or similar display screen.

[0027] While the following discussion describes a pallet-moving AGV, it will be appreciated that the concept of an AGV controller that can be coupled to an AGV to provide a semi-autonomous guided vehicle is applicable to all types of AGVs, regardless of their function.

[0028] An example of an autonomous guided vehicle 1 operating as an AGV is shown in FIG. 8 and includes a body 2 including a drive assembly (not shown) for moving the AGV across a floor, a steering mechanism (not shown) for steering the AGV 1, and a lift mechanism (not shown) for raising and lowering a plurality of forks 4 extending from the body 2. In the particular example shown in FIG. 8, the AGV 1 includes two forks defining a left fork 6 and a right fork 8. A first set of wheels 10 and a second set of wheels 12 are mounted to the left fork 6 and the right fork 8, respectively, in the sense that half of the wheels of the first set of wheels 10 and the second set of wheels 12 are mounted to the left fork 6, and the other half of the wheels of the first set of wheels 10 and the second set of wheels 12 are mounted to the right fork 8. For ease of explanation, each of the first and second sets of wheels 10, 12 includes a first wheel 14 and a second wheel 16. A first wheel 14 and a second wheel 16 of each of the first and second sets of wheels 10,12 are shown mounted to respective left and right forks 6,8 of the AGV 1.

[0029] Although the first and second sets of wheels 10, 12 are shown rotatably mounted inside the forks 4, other means for rotatably mounting the first and second sets of wheels 10, 12 to the forks 4 to allow the forks 4 to move across a floor are acceptable within the present invention. The number of forks is not limited to two and can include any number of forks, for example, a pallet moving device having three forks. Each wheel of the first and second sets of wheels 10, 12 can be pivotally mounted to the forks 4 to allow vertical movement. For example, each wheel of the first and second sets of wheels 10, 12 can be mounted to a lever (not shown) pivotally mounted to the forks 4 that retracts vertically to retract each wheel toward the inside of its respective fork, thereby disengaging from the floor, and extends outward from its respective fork to engage the floor in the deployed position. However, other means for mounting each set of wheels of the first and second sets 10, 12 to allow vertical movement relative to the forks 4 are acceptable within the present invention. An actuation mechanism (not shown) coupled to the first and second sets of wheels 10, 12 is configured to move each of the first and second sets of wheels independently in a vertical direction, further details of the actuation mechanism are discussed below.

[0030] A lift mechanism (not shown) is connected to the forks for raising and lowering the forks. Various lift mechanisms commonly known in the art can be used to raise and lower the forks. These include, but are not limited to, hydraulic pumps, electric motors, etc. Typically, the forks are connected to a frame forming the body of the AGV, and a lift mechanism is connected to the forks and the frame such that the lift mechanism is configured to raise and lower the frame and the forks. The lift mechanism can cooperate with the first or second set of wheels to raise or lower the forks. For example, the forks can be raised by lowering the first or second set of wheels. The first set of wheels can be mounted on a lever attached to a linkage that leads to a lever attached to a hydraulic pump in the body of the AGV, which lowers the first or second set of wheels to raise the forks. Because the first set of wheels can be primarily load-bearing wheels, the first set of wheels can be lowered to raise the forks. The lower the first set of wheels relative to the forks, the higher the forks can be raised. Alternatively, the lift mechanism for raising the forks may be separate from the first and second sets of wheels, but the first or second sets of wheels lower as the forks are raised. The locking mechanism locks the first or second sets of wheels in a lowered position when the forks are in the raised position so as to raise a pallet engaged with the forks from the ground.

[0031] A drive assembly (not shown) including one or more drive wheels propels the AGV on the floor. The drive assembly includes a drive mechanism, e.g., a drive motor, for driving the rotation of the one or more drive wheels about a drive axis. The drive assembly is located at the rear of the AGV within the body. The drive wheels for propelling the AGV on the floor may be connected to a steering mechanism (not shown) for maneuvering the AGV on the floor. The steering mechanism may be configured to rotate one or more of the drive wheels about a steering axis substantially perpendicular to the drive axis to change the direction of the AGV on the floor. Various steering mechanisms known in the art may be used to change the direction of the AGV. These include, but are not limited to, a steering drive unit coupled to one or more drive wheels configured to rotate one or more of the drive wheels about a steering axis. For example, the body of the AGV may include swivel casters located at the four corners of the body of the AGV. The drive wheels and steering wheels propel and change the direction of the body of the AGV, respectively. The steering mechanism may be separate from the drive assembly in the sense that a separate steering wheel may be used to change the direction of the AGV independent of the propulsion of the AGV by the drive assembly.

[0032] The AGV includes a guidance system (not shown) coupled to the drive assembly and steering mechanism to control the AGV's movement on the worksite. The guidance system may include, but is not limited to, wire guidance, laser guidance, magnetic tape guidance, odometry guidance, inertial guidance, or optional guidance. For example, a laser guidance system uses special markers that the AGV senses and uses to control its movement. The guidance system is controlled by a control system including a controller, e.g., a processor, and a memory storage device for storing instructions executed by the controller to control the operation of the AGV. The memory storage device may be any storage device commonly known in the art, including, but not limited to, RAM, computer-readable media, magnetic storage media, optical storage media, or other electronic storage media used to store data and accessible by the controller. Controlling the operation of the AGV includes, but is not limited to, controlling the drive assembly and steering mechanism in response to signals from the guidance system to control the movement of the AGV, controlling the vertical movement of first and second sets of wheels mounted on a plurality of forks to engage a pallet, and controlling a lift mechanism to raise and lower the pallet.

[0033] To engage the forks 4 with the pallet 18, a control system cooperating with the actuation mechanism and the drive mechanism is configured to move the AGV to fully engage the pallet. The term "fully" engage the forks with the pallet is used to describe a condition in which the forks are inserted into the pallet so that the pallet can be lifted off the floor. The actuation mechanism may include a linear actuator for vertically moving each of the first and second sets of wheels via one or more linkages. The control system may be configured to operate the actuation mechanism to independently move the first and second sets of wheels vertically. For example, the actuation mechanism may include a first linear actuator for raising and lowering the first set of wheels and a second linear actuator for raising and lowering the second set of wheels. To independently move the first and second sets of wheels vertically, the control system may be configured to independently operate the first linear actuator to deploy or retract the first set of wheels and the second linear actuator to deploy or retract the second set of wheels. Alternatively, or in combination with the linear actuator, the actuation mechanism may comprise a cam mechanism comprising one or more cams and a cam follower movable along the one or more cams to move the cam follower from a raised position that stores the first and / or second set of wheels and a lowered position that deploys the first and / or second set of wheels.

[0034] 9a-9g are schematic diagrams illustrating the stages of engagement of the forks 4 with a pallet 18. The engagement operation involves independently retracting and deploying the first and second sets of wheels 10, 12 in a predetermined sequence in conjunction with driving the AGV 1 toward the pallet 18. This operation begins with retracting the first set of wheels 10 (i.e., the front set of wheels) proximate the distal ends of the forks 4 to allow the fronts of the forks 4 to be inserted into openings provided by the space between the upper deck 20 and lower deck 22 of the pallet 18. In FIG. 9b, the AGV 1 moves a first distance L1 toward the pallet 18 so that the fronts of the forks 4 clear planks or runners 24 in the lower deck 22 of the pallet 18. The first distance depends on the spacing between the first set of wheels 10 and the second set of wheels 12. In this particular example, the first distance L1 is sufficient for the second set of wheels 12 proximal to the body 2 of the AGV 1 to step over a single plank 24 in the lower deck 22 of the pallet 18 without physically climbing over or bumping over the single plank, as shown in FIG. 9b. The first distance L1 may be a predetermined distance applicable to the type of pallet stored in a memory storage device and may depend on the width of the one or more planks 24 in the lower deck 22 of the pallet 18. Once the AGV 1 moves the first distance L1 toward the pallet 18 so that the front ends of the multiple forks 4 enter the pallet 18, the engagement operation proceeds to deploy the first set of wheels 10 to engage the floor and then retract the second set of wheels 12, as shown in FIG. 9c. Deploying the first set of wheels 10 before retracting the second set of wheels 12 maintains the stability of the AGV 1 and prevents the AGV 1 from tipping as the second set of wheels 12 is retracted. This allows the AGV 1 to move a second distance L2 toward the pallet 18 to further insert the forks 4 into the pallet 18, as shown in Figure 9d. Like the first distance, the second distance may be a predetermined distance applicable to the type of pallet stored in the memory storage device.The predetermined sequence of operations—(i) retracting the first set of wheels, (ii) moving the AGV a first distance toward the pallet, (iii) deploying the first set of wheels and retracting the second set of wheels, and (iv) moving the AGV a second distance toward the pallet—is repeated when the AGV clears a second plank in the lower deck of the pallet, as shown in FIGS. 9e and 9f. Because there are typically three planks or runners 24 in the lower deck of the pallet, once the first and second sets of wheels clear the first and second planks, the forks are considered fully engaged with the pallet, as shown in FIG. 9f. Once the forks are fully engaged with the pallet, the next operation would be to lift the pallet 18 off the floor, as shown in FIG. 9g, so that the pallet 18 can be moved across the floor. Lifting the pallet 18 involves lowering or deploying the first set of wheels 10 relative to the forks 4 by an actuation mechanism such that the forks 4 are elevated. Alternatively, the forks can be elevated separately, lowering the first set of wheels 10 to engage the floor. A locking mechanism (not shown) locks the first set of wheels in a lowered or extended position to lift the pallet engaged with the plurality of forks from the floor.

[0035] The first set of wheels 10 proximal to the distal ends of the plurality of forks 4 are load-bearing wheels because they bear the weight of the pallet 18 and any load placed on the pallet when it is lifted off the ground. The second set of wheels 12 proximal to the body 2 of the AGV 1 act as balance wheels to prevent the AGV 1 from tipping when the first set of wheels 10 is retracted. This allows the first and second sets of wheels 10, 12 to clear one or more planks 24 in the lower deck 22 of the pallet 18, as shown in FIGS. 9(a-g). The spacing between the first set of wheels 10 and the second set of wheels 12 depends on the number of planks 24 in the lower deck of the pallet 18 and the number of movements required for the first and second sets of wheels 10, 12 to clear one or more planks 24 in the lower deck of the pallet when fully engaging the pallet.

[0036] In a second example of the AGV 101, as shown in Figure 10, the spacing S between the first set of wheels 110 and the second set of wheels 112 is such that the multiple forks 104 fully engage the pallet 18 in fewer movements than in the example shown in Figure 8. Compared to the first example shown in Figures 9a-g, which requires multiple movements of the first and second sets of wheels 10, 12 to fully engage the pallet 18, in the second example shown in Figure 10, a single movement is required for the AGV 101 to move toward the pallet 18 a first distance L1 corresponding to the distance the first set of wheels 110 clears two planks 24 in the lower deck 22 of the pallet 18; i.e., the first distance L1 corresponds to the spacing between the two planks 24 in the lower deck of the pallet, including the width of the two planks. 11(a-c) begins with retracting the first set of wheels 110 so that they clear a first plank on the periphery of the pallet 18 and inserting the forks into the pallet. Because the spacing between the first set of wheels and the second set of wheels is large enough to clear or step over two spaced apart planks in the lower deck of the pallet, the forks 104 can be further inserted into the pallet to step over two planks in the lower deck of the pallet in a single moving motion.

[0037] To fully engage the pallet 18, the first set of wheels 110 are deployed, as shown in FIG. 11b, and the second set of wheels 112 are retracted, allowing the AGV to move closer, a second distance L2, toward the pallet 18, as shown in FIG. 11c. Once the forks are fully engaged with the pallet, the forks 104 may be raised to lift the pallet off the floor. Raising the forks can be accompanied by lowering or deploying the first set of wheels 110. Alternatively, the forks are independently raised and lowered to engage the first set of wheels 110. A locking mechanism (not shown) locks the first set of wheels in the lowered position to lift the pallet engaged with the forks off the floor.

[0038] The spacing S between the first set of wheels and the second set of wheels can be changed by changing the position of the first set of wheels 10, 110 relative to the second set of wheels 12, 112. The closer the second set of wheels 12, 112 can be to the body 2, 102 of the AGV 1, 101 without tilting the AGV when the first set of wheels 10, 110 is retracted, the greater the spacing between the first set of wheels and the second set of wheels. Typically, the spacing S between the first set of wheels and the second set of wheels must exceed 100 cm in order for the first set of wheels 110 to step over two planks in the lower deck of the pallet in a single movement.

[0039] To automate the independent movement of the first and second sets of wheels when engaging with a pallet as shown in FIGS. 8 and 10 , the AGV 1, 101 includes one or more proximity sensors for detecting the presence of a nearby obstacle or object, in this case, one or more planks in the lower deck of the pallet. Examples of proximity sensors for detecting the presence of an object include, but are not limited to, a LiDAR sensor with a laser beam source and an optical receiver, and an ultrasonic sensor. Another example of detecting the presence of a nearby object is the use of one or more cameras or depth cameras to visualize the presence of nearby objects or obstacles. The proximity sensor or camera may be mounted on the forks, particularly on the distal end of one or more of the forks. Alternatively, the proximity sensor or camera may be mounted on the body of the AGV. A control system is coupled to the proximity sensor and / or camera and configured to independently retract or deploy the first and second sets of wheels in response to one or more signals from the proximity sensor and / or camera.

[0040] FIG. 12 is a simplified block diagram 30 illustrating the major components of an AGV for engaging a pallet, and FIG. 13 is a flow diagram 1300 illustrating example steps an AGV performs when engaging a pallet. The major components of an AGV for engaging a pallet can be summarized in FIG. 12 to include an actuation mechanism 38 configured to move first and second sets of wheels vertically, a proximity sensor 44 for sensing nearby objects, a drive assembly 40 for steering the AGV, and a forklift mechanism 42 for raising and lowering the plurality of forks. Each of the components for engaging a pallet is controlled by a control system 32 including a controller 34, e.g., a processor, and a memory storage device 36 for storing instructions to be executed by the controller 34. For example, the instructions include actuating the actuation mechanism 38 to independently move the first and second sets of wheels vertically in response to one or more signals from the proximity sensor 44. In addition to these components, the AGV may further include a battery (or some other power source) for powering the different components discussed above with reference to FIG. 5. The AGV will be equipped with an interface so that the battery can be recharged or hot swapped to allow continued AGV operation. The AGV will further be equipped with a wireless interface to allow it to receive data from a central computing system and send data, e.g., status messages, data logs, etc., back to the central computing system.

[0041] The steps in engaging a plurality of forks with a pallet can be summarized in flowchart 1300, shown in FIG. 13 in conjunction with FIG. 12. The process begins with a proximity sensor detecting the presence of a plank in the lower deck of the pallet S1304 (S1302). In response to detecting the presence of the plank, the controller 34 activates the actuation mechanism 38 to retract a first set of wheels and deploy a second set of wheels S1306. This allows the AGV to move a first distance toward the pallet as the first set of wheels clears the plank S1308. However, if the AGV does not detect the presence of a pallet, the AGV is instructed to continue moving until the pallet is detected S1316. To fully engage the pallet, the controller 34 activates the actuation mechanism 38 to deploy the first set of wheels and retract the second set of wheels, allowing the second set of wheels to clear the plank as the AGV moves a second distance toward the pallet S1312.

[0042] Depending on the spacing between the first set of wheels and the second set of wheels, the next step is determining whether the forks have fully engaged with the pallet S1314. If the spacing between the first set of wheels and the second set of wheels is relatively small (see FIG. 8), the first set of wheels and the second set of wheels may need to step over two planks in two sets of motions or steps (e.g., four motions) to fully engage the pallet. After stepping over the first plank of the pallet, the controller 34, responsive to one or more signals from the proximity sensor 44, is configured to actuate the actuation mechanism 38 to independently move the first and second sets of wheels to step over a second plank in the lower deck of the pallet. One set of motions or steps for stepping over one or more planks in the lower deck of the pallet may involve: i) retracting a first set of wheels and deploying a second set of wheels; ii) moving the AGV a first distance to insert a portion of the plurality of forks into the pallet and overstep a first plank in the lower deck of the pallet; iii) deploying a first set of wheels and retracting a second set of wheels to stabilize the plurality of forks; iv) moving the AGV a second distance to insert an increased portion of the plurality of forks into the pallet;

[0043] Because the spacing between the first set of wheels and the second set of wheels is relatively small, the above operations (i) to (iv) are repeated to clear the second plank in the lower deck of the pallet. As shown in FIG. 10 , when the spacing between the first set of wheels and the second set of wheels is relatively large, the forks fully engage with the pallet after clearing two planks in the lower deck of the pallet in one set of operations (i) to (iv), i.e., the movement of the forks along the first and second distances. When approaching the pallet, the first and second sets of wheels may already be deployed, in which case step (i) may involve retracting the first set of wheels when the second set of wheels is already deployed to clear the plank in the lower deck of the pallet. Data related to the type of the forks, including the spacing between the first and second sets of wheels, is stored in memory storage device 36. A controller in cooperation with the memory storage device is capable of determining the type of the forks when engaging the pallet.

[0044] The frequency with which the first and second sets of wheels must step over one or more planks in the lower deck of the pallet in order for the plurality of forks to fully engage the pallet will depend on the separation S between the first set of wheels and the second set of wheels along the plurality of forks. The closer the separation S between the first set of wheels and the second set of wheels, the more times the first and second sets of wheels will need to step over one or more planks in the lower deck of the pallet. In the second embodiment of the AGV 301 shown in FIGS. 14a-e, the second set of wheels 212 may be configured to be retractable longitudinally along the plurality of forks 204 to vary the separation between the first set of wheels 210 (not shown) and the second set of wheels 212, rather than substantially vertically as in the first embodiment of the invention discussed above with reference to FIGS. 1-6. As shown in FIG. 14(a), the second set of wheels 212 moves along axis XX, eliminating the need for a predetermined separation between the first set of wheels and the second set of wheels, and therefore eliminating the need for the second set of wheels 212 to step over one or more planks in the lower deck 22 of the pallet 18.

[0045] To ensure stability of the AGV 201 when the first set of wheels 210 is retracted, the second set of wheels 212 remains engaged with the floor but retracts longitudinally along the plurality of forks 204 as the second set of wheels 212 approaches the lower deck 22 of the pallet 18. When inserted into the pallet 18, a lift mechanism (not shown) is configured to vertically extend or deploy the first set of wheels 210 relative to the plurality of forks 204 to engage the floor. Further extension of the first set of wheels 210 relative to the plurality of forks 204 elevates the plurality of forks 204 and the pallet supported by the plurality of forks. In the particular example shown in FIG. 14e, the second set of wheels 212 separates from the plurality of forks 204 to maintain stability of the body of the AGV 201 when the plurality of forks 204 are raised. As shown in FIGS. 14a-e, the second set of wheels 212 is mounted on a plurality of runners 216 that allow the second set of wheels to be retracted longitudinally parallel to the plurality of forks. The runners 216 are mounted to the body 202 of the AGV such that when the forks are raised, the second set of wheels 212 separates from the forks, as shown in FIG. 14e.

[0046] Similar to the first embodiment of the present invention, the first and second sets of wheels 210, 212 may be independently movable relative to the plurality of forks 204. The independent movement of the first and second sets of wheels may be controlled by an actuation mechanism, as discussed above. As the second set of wheels 212 approaches the lower deck 22 of the pallet 18, longitudinal movement of the second set of wheels occurs from a forward position, as shown in FIG. 14(b), to a rearward position, as shown in FIG. 14(d). Various means may be used to move the second set of wheels 212 longitudinally (in a substantially horizontal direction) along the plurality of forks 204. In one example, the second set of wheels 212 may be resiliently biased forward by a resilient member (e.g., a spring) so that the second set of wheels 212 is closer to the first set of wheels 210 in a rest position, providing increased stability for the AGV 201 when the first set of wheels is in a vertically stored configuration within the plurality of forks 204. The elastic member (not shown) is configured to longitudinally retract the second set of wheels 212 away from the first set of wheels when the bias of the elastic member is overcome. For example, the elasticity of the elastic member can be selected such that the bias of the elastic member is overcome by the drive assembly (e.g., motor) of the AGV. The second set of wheels 212 is positioned to abut against the lower deck 22 of the pallet 18 when the forks 204 are initially inserted into the pallet (see FIG. 14c). This bias is overcome by the drive assembly moving the pallet 18 and engaging the forks with the pallet. In the particular example shown in FIGS. 14(a)-(e), the drive assembly includes a drive wheel 214 rotatable about a drive shaft for driving the movement of the AGV across the floor. The mere driving action of the AGV toward the pallet can be sufficient to overcome the bias of the second set of wheels and retract away from the first set of wheels as the forks progressively engage the pallet (see FIG. 14d).

[0047] Instead of the second set of wheels abutting the lower deck of the pallet, each wheel of the second set of wheels may be mounted on a cradle that is longitudinally movable along its respective fork and positioned to abut the lower deck as the forks enter the pallet. The use of a cradle to support each of the second set of wheels mitigates the risk of the second set of wheels climbing over one or more of the planks in the lower deck of the pallet as the forks enter the pallet. Alternatively, a drive mechanism responsive to signals from a suitable sensor (e.g., a proximity sensor) may be configured to progressively retract the second set of wheels as the forks progressively engage the pallet. In all cases, the first set of wheels remains retracted until the forks are fully engaged with the pallet.

[0048] The steps of engagement of the forks of an AGV 201 with a pallet 18 according to a second embodiment of the present invention can now be described with reference to FIGS. 14(a)-(e). The positions of the first set of wheels 210 and the second set of wheels 212 relative to the forks 204 in a normal configuration are shown in FIG. 14(a), which shows the first set of wheels 210 in a retracted position and the second set of wheels 212 in a forward position relative to the forks to maintain stability of the AGV as it moves across the floor. The second set of wheels 212 is shown mounted on a cradle that is movable in the longitudinal or axial direction X. Also shown are drive wheels 214 mounted on the body 202 of the AGV 201 for moving the AGV. The second set of wheels 212 approaches the lower deck 22 of the pallet 18 when the forks 204 enter the pallet as shown in FIG. 14(b). Further movement of the AGV 201 toward the pallet not only increases the percentage of the forks entering the pallet, but also forces the second set of wheels 212 against the lower deck 22 of the pallet 18, more specifically, against a plank in the lower deck of the pallet, as shown in FIG. 14(c). This causes the second set of wheels 212 to retract backward, away from the first set of wheels 210, as the forks are driven into the pallet, as shown in FIG. 14(d). Once the forks fully engage the pallet, as shown in FIG. 14(e), the lift mechanism is activated, extending the first set of wheels 210 vertically to engage the floor, stabilizing the AGV on the floor as the forks are raised. Further extension or lowering of the first set of wheels raises the forks, which in turn raises the pallet off the floor. As with the first embodiment of the AGV, the lift mechanism can include a hydraulic pump and / or an electric motor coupled to the first set of wheels by one or more levers to raise or lower the forks.

[0049] It will be understood that various changes, modifications, alterations, and combinations in the details, materials, and arrangements of parts and components described and illustrated to illustrate the AGV controller as described herein may be made by those skilled in the art within the principles and scope of the present disclosure.

[0050] According to an aspect, a controller for an autonomous guided vehicle (AGV) is provided such that the AGV can be operated in a semi-autonomous mode when coupled to the AGV controller. In this semi-autonomous mode, an operator has access to all of the AGV's functions through the AGV controller. The AGV controller can be detached from the AGV, allowing the AGV to return to autonomous operation.

Claims

1. 1. A controller for an autonomous guided vehicle, the controller comprising a coupling configured to couple, in use, to an autonomous vehicle and to an interface for controlling operation of the autonomous vehicle.

2. The controller of claim 1 , further comprising a rolling means.

3. The controller of claim 2 , wherein the controller further comprises a drive means operable to actuate the rolling means.

4. The controller of any one of claims 1 to 3, further comprising a wireless network interface.

5. 5. A semi-autonomous vehicle comprising an autonomous guided vehicle and a controller for an autonomous guided vehicle according to any one of claims 1 to 4, the autonomous guided vehicle comprising an aperture configured to receive the coupling of the controller such that, in use, the controller interface is used to control the autonomous guided vehicle.

6. 6. The semi-autonomous vehicle of claim 5, wherein the autonomous guided vehicle further comprises a control system such that, in use, the control system is responsive to control signals generated by the controller interface.

7. 7. The semi-autonomous vehicle of claim 5 or 6, wherein the autonomous guided vehicle further comprises a drive system such that, in use, the drive system is actuated in response to control signals generated by the controller interface.

8. 8. The semi-autonomous vehicle of any one of claims 5 to 7, wherein the autonomous guided vehicle further comprises a forklift mechanism such that, in use, the forklift mechanism is actuated in response to control signals generated by the controller interface.

9. 1. A method for operating an autonomous guided vehicle within a storage facility, the method comprising: a) coupling a controller for the autonomous guided vehicle to an autonomous guided vehicle to form a semi-autonomous vehicle; b) controlling the semi-autonomous vehicle via the controller to perform a task; c) decoupling the controller from the semi-autonomous vehicle; d) the autonomous guided vehicle autonomously traveling to a first predetermined location within the storage facility; A method comprising:

10. The method of claim 9 , wherein in step d), the autonomous guided vehicle delivers a load to the first predetermined location.

11. The method comprises:

11. The method of claim 10, comprising the further step of: e) the autonomous guided vehicle depositing the load at the first predetermined location and then traveling to a second predetermined location.

12. 12. The method according to any one of claims 9 to 11, wherein in step b) the semi-autonomous vehicle is controlled to drive the semi-autonomous vehicle to a storage location and retrieve the load.

13. 10. A storage facility comprising a first zone and a second zone, wherein the first zone is reserved for use by one or more autonomous guided vehicles and the second zone is reserved for use by one or more controllers for autonomous guided vehicles as claimed in any one of claims 1 to 4 and one or more semi-autonomous vehicles as claimed in any one of claims 5 to 8.

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

15. 15. The storage facility of claim 14, wherein the physical barrier comprises one or more apertures through which an autonomous guided vehicle or semi-autonomous vehicle may pass.

16. 16. The storage facility of claim 15, wherein a handover location may be defined adjacent one or each of the barrier apertures.

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

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

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