Recognition-based robotic operating system and method for robotic truck unloaders for unloading / spreading products from trailers and containers.

Abstract

A robotic truck unloader (10) for unloading / unloading products, such as boxes or cases, from trailers and containers is disclosed. In one embodiment, a moving base (50) structure provides a support framework for a drive subassembly (52), a transport subassembly (54), an industrial robot (40), a swiveling front conveyor (42), a distance measurement subassembly, and a control subassembly (62). The control subassembly (62) coordinates the operation of the drive subassembly (52) and the moving and swiveling front conveyor (42) through selective articulation of the industrial robot (40) based on a perception-based robotic manipulation system. The robotic truck unloader (10) utilizes the industrial robot (40) and the swiveling front conveyor (42) to perform pick and scoop operations. Automatic error handling is also provided.

Description

Technical Field

[0001] The present invention generally relates to machines for processing products, and more specifically to an automated unloading and unpacking recognition-based robot operation system and method that employs a robotic truck unloader designed to unload and unpack products such as packages or boxes from trailers and containers.

Background Art

[0002] Loading docks and loading bays are commonly found in large commercial and industrial buildings and provide arrival and departure locations for large loads carried or removed by trucks and vans. As an example, a truck can reverse into a loading bay such that the bumper of the loading bay contacts the bumper on the trailer, creating a gap between the loading bay and the truck. A dock leveler or dock plate bridges the gap between the truck and the warehouse, providing a fixed substantially horizontal surface. Next, powered moving equipment such as a forklift or conveyor belt is utilized to transport the load from the warehouse to the truck. Next, the load within the truck is removed by human labor. This is particularly applicable to the unloading of products such as boxes or cases from trucks or cargo containers. These systems are designed to minimize the use of human labor both to maximize the amount of load being unloaded and to protect employees and extend their lifespan. However, it has been found that reducing human labor is difficult. This is because the configuration and size of boxes in a truck or cargo container cannot be easily predicted in advance. Thus, there remains a need for an improved truck unloading system that further reduces the use of human labor when unloading or unpacking products such as cases and boxes from trailers and containers.

Summary of the Invention

[0003] It would be beneficial to realize systems and methods for automated unloading and unpacking of products such as parcels or boxes that enable complete unloading from trailers or containers with minimal or no human labor, thereby minimizing the time and human capital required for unloading from trucks. It is also desirable to enable robotic computer-based solutions to address this problem, particularly the recognition challenge, by rapidly unloading and retrieving parcels and boxes of varying sizes from trailers and similar containers. To better address one or more of these concerns, a robotic truck unloader for unloading / unpacking products such as boxes or cases from trailers and containers is disclosed in one embodiment. The mobile base structure provides a support framework for a drive subassembly, a transport subassembly, an industrial robot, a slewing forward conveyor, a distance measuring subassembly which may include, for example, a camera, and a control subassembly. The control subassembly coordinates the operation of the drive subassembly and the slewing forward conveyor, and the operation of the drive subassembly, based on a recognition-based robotic operating system, through selective articulation of the industrial robot. The robotic track unloader uses an industrial robot and a rotating forward conveyor to perform picking and scooping operations. Automatic error handling is also provided.

[0004] In one embodiment, a robotic track unloader for unloading / spreading products includes a mobile base structure to which a drive subassembly and a transport subassembly are fixed. An industrial robot and a slewing forward conveyor are arranged on the mobile base. A control subassembly is arranged to communicate with the industrial robot, the slewing forward conveyor and a perception subsystem in order to coordinate the movement of the industrial robot and the slewing forward conveyor by their respective selective joint movements. The control subassembly, which includes memory with processor-executable instructions accessible from the processor, enables the perception subsystem to construct a searchable space from data collected from the environment. The searchable space is searched to determine the contact surface of candidate products. The robotic track unloader then specifies a removal operation to unload the products by a picking and scooping operation using the industrial robot and the slewing forward conveyor. The picking portion of the picking and scooping operation may include, for example, grasping and pulling. The robotic track unloader also performs automatic error handling by searching the rotating forward conveyor to identify products still being processed that remain on the conveyor, and then processing those products.

[0005] In another embodiment, a robotic track unloader for unloading / spreading products includes a mobile base structure to which a drive subassembly and a transport subassembly are fixed. A slewing forward conveyor having a frame is disposed on the mobile base and configured to process products. The slewing forward conveyor includes a deck conveyor unit integrated within the frame. A planar extension blade indicating the rear portion is connected to the frame. The planar extension blade may have a forward portion extending for a certain length from the rear portion along a transverse axis between first and second sides. The planar extension blade bends about the transverse axis in response to applied pressure. A control subassembly may be arranged to communicate with the slewing forward conveyor and a perception subsystem to coordinate the movement of the industrial robot and the slewing forward conveyor by their respective selective articulations. The control subassembly, including a memory with processor-executable instructions accessible from the processor, enables the robotic track unloader to construct a searchable space from data images collected from a camera, search the searchable space to determine candidate product contact surfaces, and specify removal operations to unload multiple products using the slewing forward conveyor.

[0006] In a further embodiment, a robotic track unloader for unloading / spreading products includes a mobile base structure on which a drive subassembly and a transport subassembly are fixed. An industrial robot and a slewing forward conveyor are arranged on the mobile base. A control subassembly may be arranged to communicate with the industrial robot, the slewing forward conveyor and a perception subsystem in order to coordinate the movement of the industrial robot and the slewing forward conveyor by selective joint movements of each. As previously mentioned, the control subassembly includes a memory with processor-executable instructions accessible from the processor, enabling the robotic track unloader to construct a searchable space from data images collected by a distance measuring subassembly. The searchable space is explored to determine the contact surface of a candidate product. The robotic track unloader may then specify a removal operation in which the industrial robot clears a portion of the product from the foreground wall and then scoops up the product. More specifically, the robotic track unloader may specify a removal operation to unload the product using a selection and scooping operation with an industrial robot and a slewing forward conveyor, by then specifying a selection operation using an industrial robot, followed by two scooping operations using a slewing forward conveyor: a shallow scoop and a deep scoop. Generally, the industrial robot begins clearing the upper part of the product, and the slewing forward conveyor begins clearing the lower part of the product.

[0007] In a further embodiment, a robotic track unloader for unloading / spreading products includes a mobile base structure on which a drive subassembly and a transport subassembly are fixed. An industrial robot and a slewing forward conveyor are mounted on the mobile base. As in the previous description, a control subassembly may be configured to communicate with the industrial robot, the slewing forward conveyor and a perception subsystem in order to coordinate the movement of the industrial robot and the slewing forward conveyor by their respective selective joint movements. A control subassembly including memory with processor-executable instructions accessible from the processor enables the robotic track unloader to construct a searchable space from data images collected by a camera. The searchable space includes a foreground wall. The searchable space is explored to determine candidate product contact surfaces having a specific relationship with respect to the foreground wall. The robotic track unloader then specifies a removal operation to unload the products by picking and scooping operations using the industrial robot and the slewing forward conveyor.

[0008] Therefore, these systems and methods utilizing the robotic truck unloader maximize the volume of products and cargo unloaded while minimizing the use of human labor for both protecting and extending the lifespan of employees. These and other aspects of the invention will be made clearer and more apparent with reference to the embodiments described hereafter. [Brief explanation of the drawing]

[0009] For a more complete understanding of the features and advantages of the present invention, a detailed description of the invention is provided herein, along with the accompanying diagrams in which corresponding numbers in different figures refer to corresponding parts.

[0010] [Figure 1A] This is a side view having a partial cross-section of an embodiment of an automated truck unloader in a first operational configuration that utilizes a recognition-based robotic operating system to unload products from a truck trailer, as taught herein. [Figure 1B]This is a side view having a partial cross-section of one embodiment of the automatic track unloader shown in Figure 1A in the second operational configuration. [Figure 1C] This is a side view having a partial cross-section of one embodiment of the automatic track unloader shown in Figures 1A and 1B in the third operational configuration. [Figure 1D] Figures 1A, 1B, and 1C show a side view with a partial cross-section of one embodiment of the automatic track unloader illustrated in the fourth operational configuration. [Figure 2A] Figures 1A to 1D are right side views of the automatic track unloader. [Figure 2B] Figures 1A to 1D are left side views of the automatic track unloader shown. [Figure 2C] Figures 1A to 1D are forward perspective views of the automatic track unloader, in which the swivel forward conveyor articulates in a first position, which may be, for example, a low or lowest position. [Figure 2D] Figures 1A to 1D are forward perspective views of the automatic track unloader, where the rotating forward conveyor articulates in the second position. [Figure 2E] Figures 1A to 1D are top views of the automatic track unloader. [Figure 2F] Figures 1A to 1D are bottom views of the automatic track unloader. [Figure 2G] Figures 1A to 1D are rearward perspective views of the automatic track unloader, where the swivel forward conveyor articulates, for example, at a low position. [Figure 2H] Figures 1A to 1D are rearward perspective views of the automatic track unloader, where the swivel forward conveyor articulates, for example, at a high position. [Figure 3A] This is a front-top perspective view of one embodiment of a swivel forward conveyor that forms part of an automatic track unloader. [Figure 3B] Figure 3A is a lower perspective view of the rotating forward conveyor. [Figure 4]It is a side view of a part of a swivel front conveyor shown in FIGS. 3A and 3B in the first operation embodiment. [Figure 5] It is a front perspective view of a swivel front conveyor shown in FIGS. 3A and 3B in the second operation embodiment. [Figure 6] It is a front perspective view of a swivel front conveyor shown in FIGS. 3A and 3B in an alternative operation embodiment. [Figure 7] It is a front perspective view of a swivel front conveyor shown in FIGS. 3A and 3B in a further alternative operation embodiment. [Figure 8] It is a functional block diagram of one embodiment of a robot track unloader. [Figure 9] It is a functional block diagram of one embodiment of a robot track unloader in additional detail. [Figure 10] It is a functional block diagram of one embodiment of a robot controller forming part of a robot track unloader. [Figure 11] It is a schematic diagram of one embodiment of a recognition-based robot operation system in the first operation embodiment. [Figure 12] It is a schematic diagram of one embodiment of a recognition-based robot operation system in the second operation embodiment. [Figure 13] It is a schematic diagram of one embodiment of a recognition-based robot operation system in the third operation embodiment. [Figure 14] It is a schematic diagram of one embodiment of a recognition-based robot operation system in the fourth operation embodiment. [Figure 15] It is a flowchart illustrating one embodiment of a method for recognition-based robot operation. [Figure 16] It is a flowchart illustrating one embodiment of a method for recognition-based robot operation of a product. [Figure 17] It is a flowchart illustrating one operation implementation of a robot track unloader for unloading a product.

Best Mode for Carrying Out the Invention

[0011] While various embodiments of the present invention are described in detail below, it should be understood that the present invention provides many applicable inventive ideas that can be embodied in a wide variety of specific contexts. The specific embodiments described herein are merely illustrative of specific methods of creating and using the present invention and do not define the scope of the invention.

[0012] Referring first to Figure 1A, an automated robotic truck unloader, which may be referred to as a robotic truck unloader, is schematically shown and is generally designated 10. This robotic truck unloader 10 is used in systems and methods for automated truck unloading of trailers, containers and the like. However, it should be understood that much of the concepts and teachings presented herein are applicable to systems and methods for automated truck loading and consolidation. A semi-trailer truck 12 having a driver's cab 14 is towing a trailer 16 having an internal end wall 18, two side walls (unnumbered), a floor 22, a ceiling 24, and a rear access opening 26 accessible due to an opening door. The bumper 28 of the trailer 16 is retracted to the loading bay 30 of the loading dock 32, thereby the bumper 28 contacts the bumper 34 of the loading bay 30. A dock plate 36 bridges the gap between the floor 22 and the deck 38 of the loading dock 32.

[0013] As will be described in more detail below, under the supervision of navigation and recognition functions which may include information from one or more distance measuring subassemblies or other components of the robotic track unloader 10, the robotic track unloader 10 automatically maneuvers and drives into the trailer 16 to a position as close as possible to the front wall of the product W, and uses the industrial robot 40 and the swivel forward conveyor 42 to perform picking and scooping parcel processing operations. The robotic track unloader 10 operates independently of the operator, who is only required for certain types of troubleshooting, maintenance, and similar purposes. To handle the flow of product 46, a retractable conveyor unit 48 is connected to the robotic track unloader 10, and the retractable conveyor unit 48 is appropriately adjustable and readjustable in the trailer 16 as the robotic track unloader 10 moves forward and backward in the trailer 16. Product flow 46, which is in the form of standard cases, boxes, bags, or parcels 46a-46h of any size, is supplied by the robotic truck unloader as it is removed, as indicated by arrow A1. Although parcels 46a-46h are shown as product flow 46, it should be understood that the types of products that may be included in product flow 46 are not limited. In particular, the robotic truck unloader 10 has already unloaded boxes 46a-46c and others, such as products 46 near the inner end 18 and those at the intersection with the floor 22. As shown, the robotic truck unloader 10 is unloading parcels 46d, 46e, 46f, and 46g, followed by parcel 46h and other products 46. The robotic truck unloader 10 alternates between unloading the product 46 and driving it forward to generate more opportunities to grip the product 46 between the inner end 18 and the robotic truck unloader 10 until the trailer 16 has at least partially unloaded the product 46, and in most cases until it is empty.

[0014] Referring here to Figures 1A to 1D, as described, the robotic track unloader 10 uses the industrial robot 40 and the slewing forward conveyor 42 to perform the picking and scooping parcel processing operations. In Figure 1A, the robotic track unloader 10 is positioned and then specifies a removal operation to unload the products using a picking operation with the industrial robot 40, first picking up product 46, which includes parcels 46d, 46e, and 46f placed on the foreground product wall W of product 46. Although a single picking operation is illustrated in this example, it should be understood that any number of picking operations may be used.

[0015] The picking operation may include grasping product 46 and pulling product 46 away from the foreground product wall W. As part of the picking operation, parcels 46d, 46e fall onto the swivel forward conveyor 42 above the retracted forward area E in front of the foreground product wall W. That is, as is best seen in Figure 1B, following the picking operation by the industrial robot 40, the robotic track unloader 10 uses the swivel forward conveyor 42 to receive the products for transport away from the trailer 16. As shown in Figure 1C, the remaining products 46g are then scooped up, as indicated by arrow A2. The picking and scooping operations transport parcels 46a-46g to the expandable conveyor unit 48 via transport for further processing. As is best seen in Figure 1D, during one or more subsequent picking operations, parcel 46h remains stationary on the swivel forward conveyor 42. In the execution of automatic error handling, the robot track unloader 10 detects a parcel 46h that is not moving on the rotating forward conveyor 42 and performs an automatic error handling operation by readjusting the position of the industrial robot 40 (indicated by reference numeral R) to release the parcel 46h as shown.

[0016] Figures 2A to 2H illustrate the robotic track unloader 10 in more detail. The mobile base 50 supports the drive subassembly 52, the transport subassembly 54, the industrial robot 40, the slewing forward conveyor 42, the position adjustment subassembly 58, the safety subsystem 60, and the control subassembly 62, which interconnects the drive subassembly 52, the transport subassembly 54, the industrial robot 40, the slewing forward conveyor 42, the position adjustment subassembly 58, and the safety subsystem 60. The mobile base 50 includes a front end 64 and a rear end 66, as well as sides 68, 70, a surface 72, and a chassis 74.

[0017] The drive subassembly 52 is coupled to the chassis 74 of the mobile base 50, providing mobility. As will be described in more detail below, drive wheel assemblies 76 and 78 are located on the chassis 74 closer to the sides 68 and 70, respectively. A general-purpose wheel assembly 80 is located on the chassis 74 closer to the rear end 66, centered between the sides 68 and 70, respectively. Auxiliary front wheels 82 and 84 are located under the swivel forward conveyor 42. The wheel assemblies 76, 78, 80, 82, and 84 together provide forward and reverse drive and steering, and in some embodiments, traverse drive and steering. Motor assemblies 86 and 88 may also be located on the chassis 74 closer to the intersection of the end 64 and the side 68, and closer to the intersection of the end 66 and the side 70, respectively. As suggested, in forward or reverse driving and steering operations, such as moving in or out of the trailer 16, the drive wheel assemblies 76, 78 and the general-purpose wheel assembly 80 are actuated to contact the deck 38 of the loading dock 32 or the floor 22 of the trailer 16, and the motor assemblies 86, 88 provide power to them. Although the robotic truck unloader 10 is described in relation to unloading and unpacking, it should be understood that some of the teachings presented herein with respect to the robotic truck unloader 10 may also be used for loading and consolidating products, including boxes and cases, into the trailer.

[0018] The transport subassembly 54 is positioned on the surface 72 of the mobile base 50 and provides a powered transport path 90 capable of measuring, separating, transporting, and stacking boxes, parcels, and other products 46 from the front end 64 to the rear end 66 near the industrial robot 40, as required by the application and work assignment of the robotic track unloader 10. As shown, the powered transport path 90 includes a powered roller conveyor 92, which has roller elements and is sandwiched by lateral skirt plates 94, 96 to guide the products 46 as they are transported from the industrial robot 40 and the slewing forward conveyor 42 to a downstream location. The transport subassembly 54 and the expandable conveyor unit 48 may also be equipped with a series of end stop photo eyes to regulate the speed of the automatic flow of products through the expandable conveyor unit 42 and the transport subassembly 54, respectively. Such an implementation provides a stable and continuous flow of products, maintains proper separation of boxes or products, and prevents unnecessary gaps between products and product congestion and blockages.

[0019] The industrial robot 40 is positioned at the front end 64 and is adapted to provide selective articulation of the end effector 100 between the powered transport path 90 and the reachable space 102, thereby enabling the industrial robot 40 to operate to process the product 46 in the reachable space 102. In one embodiment, the end effector 100 includes a gripper arm 104 adapted for manipulating the product and a grappling plate 106 fixed to a support frame 108 for attachment to the industrial robot 40 at a joint 110 that provides a sufficient range of motion. In some embodiments, the mechanical design of the end effector 100 with the support frame 108 is angled so that the industrial robot 40 may have a reach that can be optimized based on the orientation of the tool.

[0020] Multiple suction cups 112 are associated with the surface 114 of the grappa plate 106. A bulkhead fitting 116 secures multiple spring-loaded plungers 112 to the back side 118 of the grappa plate 106. Additionally, a vacuum manifold 120 on the back side 118 provides air communication with the spring-loaded plungers 112. Suction cups 122 are mounted on the surface 114 closest to the spring-loaded plungers 112. During operation, the vacuum is activated and operates in the presence of the product 46 by a flow restrictor. Depending on the presence of objects such as parcels 46d, 46e, the vacuum manifold 120 provides vacuum force to grip the objects via the suction cups 122. This configuration allows the end effector to handle parcels with uneven surfaces and varying sizes.

[0021] However, it should be understood that any type of end effector 100 may be used with the industrial robot 40, and the selection of the end effector 100 will depend on the product 46 and the application of the particular robotic track unloader 10. For example, a gripper arm 104 having a single grappa plate 106 is preferred for unloading and spreading boxes 46a to 46h using a picker method. However, it should be understood that the product 46 may be any type of goods, such as other cased or uncased objects that require unloading.

[0022] In one implementation, the industrial robot 40 includes seven segments 130, 132, 134, 136, 138, 140, and 142 connected by six joints 150, 152, 154, 156, 158, and 160, and is given movement by selective joint motion with six degrees of freedom. More specifically, as is best seen in Figures 2C and 2D, the referenced reachable space 102 is defined by the movement of the industrial robot 40 providing rotation around six axes, including rotational movement of the entire industrial robot 40 around the main vertical axis; rotational movement of segment 160 having a tower structure around the transverse axis to provide extension and retraction of segment 132 having a boom arm, for example; rotational movement of the boom arm around the transverse axis to provide raising and lowering of the boom arm; and selective rotational movement around three wrist axes.

[0023] A distance measuring subassembly 170, positioned at the front end 64 of the mobile base 50, measures distance and determines the presence of non-machine objects in the detection space located in front of the front end 64. In one embodiment, the detection space and the reachable space 132 overlap at least partially. The distance measuring subassembly 170 assists the robot track unloader 10 with respect to forward, backward, and lateral movement, and, but is not limited to, the industrial robot 40 in operating to raise and lower the slewing forward conveyor 42. Furthermore, the distance measuring subassembly 170 assists with the coordination and operation of the industrial robot 40 and the slewing forward conveyor 42. The distance and measurement information collected by the distance measuring subassembly 170 is provided to the control subassembly 62.

[0024] The distance measuring subassembly 170 may be a laser rangefinder operating on the basis or principle of time-of-flight measurement, or a camera or camera system operating on the principle of adaptive depth. However, it should be understood that other types of distance measurement are within the teachings of the present invention. For example, but not limited to, the distance measuring subassembly 170 may include navigation-based and recognition-based functions. More specifically, the distance measuring subassembly 170 may include a laser rangefinder, a camera, an ultrasonic measuring device, an inclinometer, and combinations thereof. It should be understood that the location and number of elements in the distance measuring subassembly 170 may vary and are not limited to. For example, but not limited to, distance measuring subassemblies 172, 174 may also be provided, similar to the distance measuring subassembly 170, but disposed on the sides 68, 70, or elsewhere, respectively. In one embodiment, each of the distance measuring subassemblies 172, 174 may include a detection space (not shown) to provide measurement and distance information to the control subassembly 62 during the lateral movement of the robot track unloader 10.

[0025] The safety subsystem 60 is distributed and mounted on the mobile base 50. The safety subsystem 60 may include a light tower 180 that provides the operator with rapid indication of the current status of the robotic truck unloader 10, and a wireless operator alert system that contacts the operator's smart device via a wireless network. It may also include a handrail 182 around the operator platform 44 to provide additional safety to the operator. Emergency buttons, such as an emergency stop button 184, may be placed throughout the robotic truck unloader 10 to provide instantaneous and immediate power down. A rear safety scanner 190 may be used to protect the robotic truck unloader 10, persons, and products during collisions with obstacles. The power panel 192 and user interface 194 are appropriately positioned so as not to interfere with the safe operation of the robotic truck unloader 10. It should be understood that other safety features may be integrated into the robotic truck unloader 10. As an example, but not limited to, some embodiments may include side and rear safety bumpers with detectors that detect the presence of an object and trigger an automatic power down during a collision. As a further example, deployable or fixed safety ladders 198, 200 may be located at either end of the operator platform 44, if required by the specific design and application of the robotic truck unloader 10.

[0026] The control subassembly 62, also distributed and mounted on the mobile base 50, may include a control station 210 having a user interface 212 located near the rear end 66 of the operator platform 44. As described, the drive subassembly 52, transport subassembly 54, industrial robot 40, slewing forward conveyor 42, position adjustment subassembly 58, and safety subassembly 60 are interconnected and communicate with the control subassembly 62 via a network of concealed cables and wires. This configuration allows the control subassembly 62 to coordinate the manual and automatic operation of the robotic track unloader 10.

[0027] The main frame 220 is constructed from welded steel tubing, including tubular sections that provide a rectangular framework. With regard to the operation of the drive subassembly 52 in conjunction with the mobile base 50, the drive wheel assemblies 76, 78 and the general-purpose wheel assembly 80 provide longitudinal mobility for the robotic track unloader 10. In addition to providing forward and reverse functionality, in one embodiment, the drive subassembly 52 may provide a lateral drive system, enabling the entire robotic track unloader 10 to move perpendicularly to a fixed object at a trailer or loading dock 32 or other location. In some other embodiments, the robotic track unloader 10 may be fixed to a static platform that can move laterally between adjacent dock doors.

[0028] Referring here to Figures 3A, 3B, 4, and 5, the swivel forward conveyor 42 is positioned at the front end 64 of the mobile base 50. The swivel forward conveyor 42 has an integrated deck conveyor unit 230 for processing products 46 and transporting them to a transport subassembly 54. As shown, the swivel forward conveyor includes a frame 232 that may be inflexible, fixed to the mobile base 50 together with an actuating subassembly 234 for each of the swivel, extension, and retraction relative to the robotic track unloader 10, as indicated by the deck reachable space 236. For example, the actuating subassembly 234 may include a hydraulic subassembly or a servo-driven linear actuator subassembly having mechanical couplings. Side skirt plates 238, 240 guide the products 46 onto and through the deck conveyor unit 230. In one implementation, the lateral skirt plates 238, 240 may be at least partially independently deployable around the swivel forward conveyor to contact the ground in order to improve receiving and scooping operations. The lateral rollers 242, 244 also assist in taking in and guiding the product 46.

[0029] In one embodiment, the swivel forward conveyor 42 includes a planar extension blade 250 that forms a rear portion 252 connected to a frame 232. The transverse axis A between sides 258, 260 T Along the rear portion 252, the front portion 254 extends for a certain length. The planar extension blade 250 may include, for example, spring steel or ultra-high molecular weight polyethylene. The planar extension blade 250 may include a flexible material that provides resistance to abrasion, impact, and chemicals. The planar extension blade 250 may have a spatula shape for fitting between the product 46 and the floor FL, or it may have a pallet knife shape for fitting between the product 46 and the floor FL.

[0030] In some embodiments, the long planar blade 250 includes multiple blade segments such as blade segments 262, 264, 266, 268, 270, 272, 274, 276, 278, and 280. However, it should be understood that the number of blade segments may vary depending on the application, if any is required. Additionally, in one embodiment, the long planar blade 250 or its blade segments 262-280 may be removed and replaced. As is best seen in Figure 4, the planar extension blade 250 moves along the horizontal axis A in response to the application of pressure. T It bends around and conforms to the shape of an object, such as a floor level (FL), to which pressure is applied.

[0031] In one embodiment, the swivel forward conveyor 42 has sensors 282, 284 that identify products being processed that are located on the swivel forward conveyor 42 for extended periods. In other embodiments, it should be understood that the sensors for detecting products being processed are partially or fully integrated into, for example, a position adjustment subassembly 58 or a distance measuring subassembly 170. Such products being processed may become immobile and unable to move from the deck conveyor unit 230 to the transport subassembly 54. An automatic error handling operation occurs to release the products being processed by vibrations of the swivel forward conveyor 42 beneath the products being processed, or of the industrial robot 40 processing the products being processed on the swivel forward conveyor 42, or a combination thereof. Vibrations may include, for example, alternating movement of the deck conveyor unit 230, or vertical movement of the swivel forward conveyor 42, or a combination thereof. In the embodiment shown in Figure 5, conveyor units 286-292 alternately move forward and backward as indicated by arrows M1, M2, M3, and M4.

[0032] Figure 6 illustrates a further embodiment of an automatic error handling operation to address a product in processing that may become immobile and unable to move from the deck conveyor unit 230 to the transport subassembly 54. As shown, the wings 300, 302, located laterally on the swivel forward conveyor 42, can be flipped as indicated by arrow F. When a product such as product 46 becomes immobile, the wings, such as wing 302, can be activated to process the product 46 and ensure that the product 46 is continuously transported on the swivel forward conveyor 42. Furthermore, in many cases, the entrance to the trailer may be narrower than the interior of the trailer. In these cases, when the robotic truck unloader 10 enters or exits the trailer, the wings 300, 302 can be flipped inward and upward. Inside the trailer, the wings 300, 302 can be deployed to improve the reach of the swivel forward conveyor 42.

[0033] Referring here to Figure 7, a further embodiment of an automatic error handling operation for dealing with a product in processing that may become immobile and unable to move from the deck conveyor unit 230 to the transport subassembly 54 is shown. In this embodiment, an industrial robot 40 that processes the product in processing may be used to clear the error by contacting the product 46. As previously mentioned, different end effectors 100 may be used. As shown, to process the product when the product is a bag such as the product shown in Figure 7, a plurality of pins 310 are associated with the surface 114 of the grappa plate 106.

[0034] Figure 8 illustrates one embodiment of the robotic track unloader 10, schematically showing a computer-based architecture including a processor 350 connected to a bus 352 in which transmitter / receiver circuits 354, outputs 356, inputs 358, memory 360, and storage 362 are interconnected. In one embodiment, a control subassembly 62 includes memory 360 accessible from the processor 350. Furthermore, the control subassembly 62 includes, and may include, a perception subsystem which, in some embodiments, provides software to analyze raw data and provide meaningful information to the rest of the robotic track unloader 10. Memory 360 includes processor-executable instructions that, when executed, cause the processor 350 to execute instructions for unloading or unloading products 46, such as parcels or other objects.

[0035] For example, but not limited to, the memory may include a first processor-executable instruction specifying the removal of a product utilizing an industrial robot and / or a slewing forward conveyor. The processor-executable instruction causes the processor to construct a model from multiple data images collected from a distance measuring subassembly 170 which may include one or more sensors or cameras. The model is a representation of at least one physical environment of the industrial robot and the slewing forward conveyor. The physical environment includes the product. The processor-executable instruction causes the processor to specify a search operation within the model to identify a foreground wall, and then a search operation within the foreground wall to identify a candidate product contact surface belonging to at least one candidate product of the multiple products. As a result, based on the location of the foreground wall of product W, it may proceed to perform a selection operation or to move the robot track unloader 10 for repositioning.

[0036] The processor-executable instructions may then cause the processor to specify a removal operation to unload multiple products using at least one of an industrial robot and a swivel forward conveyor. In one implementation, these processor-executable instructions may cause the processor to specify a removal operation to select a product that may contain multiple packages at the candidate product contact surface using an industrial robot. The packages are then received by the swivel forward conveyor. In another implementation, these processor-executable instructions may specify multiple scoop-up removal operations using the swivel forward conveyor, such as specifying deep scoop-up removal operations and shallow scoop-up removal operations. The scoop-up removal operations may be specified to occur in a retracted forward area below the candidate product contact surface.

[0037] Next, a search operation is specified to identify the product being processed located on the rotating forward conveyor, and an automatic error handling operation is specified depending on whether the product being processed is located on the rotating forward conveyor. The automatic error handling operation may include, for example, vibration of the rotating forward conveyor beneath the product being processed, or vibration of the industrial robot processing the product on the rotating forward conveyor.

[0038] For example, but not limited to, the memory may include a second processor-executable instruction directed to construct a 3D model from multiple first data images collected by a camera. The 3D model is a representation of the physical environment of an industrial robot and a slewing forward conveyor, including the product. The instruction also causes the processor to convert the multiple 3D data images captured by the distance measuring subassembly 170 into a partial 3D model subject to filtering, and to provide the filtered 3D model. Next, a search operation may be specified within the 3D model to identify foreground walls belonging to the product. In accordance with this search operation, the processor-executable instruction may specify another search operation to identify candidate product contact surfaces on the foreground walls that may belong to one or more candidate products of the product. More specifically with respect to candidate product contact surfaces, the instruction causes the processor to identify segmented planes in the 3D voxel model using planar segmentation with weighted surface area, which may result in a T-shaped candidate product surface located offset below the top of the foreground wall in one embodiment or prioritization. In one embodiment, the candidate product contact surface spans multiple candidate product packages. Further instructions to be executed include removal operations to calculate instructions for unloading candidate products and for removing candidate products using industrial robots and slewing forward conveyors.

[0039] By utilizing these various commands, the robotic track unloader may specify a first removal operation to remove a first portion of the product within the upper section of the foreground wall W using an industrial robot, so that the product is grasped and pulled by an industrial robot and received by a swivel forward conveyor. Once received by the swivel forward conveyor, downstream transport may begin. The robotic track unloader may also specify a second removal operation following the first removal operation to scoop up a second portion of the product within the lower section using the swivel forward conveyor. Such operations, utilizing the navigation and recognition capabilities of the robotic track unloader, may continue until all products have been removed. Additionally, error handling operations are performed as needed and when necessary.

[0040] Figure 9 illustrates one embodiment of the robot track unloader 10 and its associated control signals, which can be extended across the computer architecture shown, for example, in Figure 8. The components shown coordinate the various functions and operations of the robot track unloader 10. The user interface 194, the operating environment database 370, the programmable logic controller 372, the robot controller 374, the slewing forward conveyor controller 375, and the distance measuring subassemblies 170, 172, 174 are interconnected, depending on the number employed. As shown, the camera 377 is associated with the distance measuring subassembly 170 and may have a variable position. That is, the location of the distance measuring subassembly 170 may vary, and its components, such as the camera, may be located in different places on the robot track unloader 10, including, for example, the industrial robot 40. The drive subassembly 52, the transport subassembly 54 represented by the control 376 for the conveyor / elevator, and the safety controller 378 are connected to the programmable logic controller 372. Finally, the industrial robot 40 and the slewing forward conveyor 42 are connected to the robot controller 374. In one implementation, the user interface 212, the operating environment database 370, and the programmable logic controller 372 are part of the control subassembly 62, and the robot controller 374 forms part of the industrial robot 40, the slewing forward conveyor 40, or a combination of both. The safety controller 358 is included in the safety subsystem 60 and provides operation to the above components of this subsystem.

[0041] The user interface 212 provides user control and interaction with the robotic track unloader 10. The user interface 212 may utilize icons in conjunction with labels and / or text to provide navigation and a complete representation of available information and actions for the operator. In addition to loading operations, user interaction may relate to maintenance, repair, and other routine actions to keep the robotic track unloader 10 running in sequence or to prevent malfunctions.

[0042] The motion data environment database 370 includes data on the reachable space 102 of the industrial robot 40, the reachable space 236 of the slewing forward conveyor 42, selection method data, grasping method data, pulling method data, receiving method data, and scooping method data. Product information and information on the standard size of the trailer are not required but may be provided. The systems and methods presented herein relating to a robotic truck unloader utilize the navigation and recognition-based technologies presented herein to enable grasping and pulling products such as parcels regardless of the location of individual instances of the product and regardless of prior knowledge of the environment (e.g., truck dimensions).

[0043] If stored, product information is stored in the operational data environment database 350 and can be obtained by the transport subassembly 54 as previously described, or by a combination thereof. As an example, Tables I and II present exemplary examples of the types of trailer data that the automated track unloader 10 can utilize in determining position and placing products. However, it should be understood that the robotic track unloader presented herein can operate with or without pre-loading information such as the trailer data presented in Tables I and II. Table I: Trailer Dimensions [Table 1] Table II: Trailer Dimensions (continued) [Table 2] The programmable logic controller 372 coordinates the overall operation and switches between various operating modes, including manual and automatic. The programmable logic controller 372 also provides the high level of calculation and coordination required during automatic operation for various items.

[0044] The robot controller 374 controls the movement of the industrial robot 40 through built-in inputs and outputs wired to the industrial robot 40. The programmable logic controller 372 controls the movement of the slewing forward conveyor 42 through built-in inputs and outputs wired to it. While a specific architecture for controlling the robot track unloader 10 is presented, it should be understood that other architectures are also within the teachings of the present invention. For example, any combination of hardware, software, and firmware may be employed. As a further example, the control distribution may differ from that presented herein.

[0045] In one operational embodiment, the programmable logic controller 372 accesses the dimensions of the trailer 16 from the operational environment database 372. The operator is indicated, via the user interface 212, by what type of trailer has arrived at the docking bay 30. Alternatively, the distance measuring subassembly 170 is operable to detect this information. The distance measuring subassemblies 170, 172, and 174 relay distance and position data to the programmable logic controller 352, which uses this information to send control signals to the robot controller 374, the drive subassembly 52, the controller 372, and the safety controller 378. Additionally, the programmable logic controller 372 receives control signals from each of these components, which are inputs to the behavioral process. The programmable logic controller 352 provides the operator with periodic updates and status information via the user interface 194.

[0046] Figure 10 illustrates one embodiment of a robot controller 372 that forms part of a robot track unloader 10. The essence of the robot controller 372 is a robot system or control program 380 that controls an industrial robot 40 and a slewing forward conveyor 42. The control program 380 may be operated by an operator, or automatically by an operation service 382 that communicates with a user interface 194 that receives input data (and, where appropriate, provides commands) from an operating environment database 350 and a programmable logic controller 372 via a driver 384. It should be understood that the independence of the robot controller 374 can vary. In one implementation, the robot controller 374 may be under the control of the programmable logic controller 374. In another implementation, as shown, the robot controller 374 may be more autonomous and include features such as direct connection to the user interface 194.

[0047] In one embodiment, a separate data processing layer is provided between the driver 384 and the control program 380 in the form of a frame program 386 that controls the movement of the robot, and a unit 388 for automation or event control policies or behavior selection based on the resulting states and signals. The user application program, event control policy selection and sensor program in the frame program 386 may be programmed by the operator and directed by a robot program 390 that monitors the balance and implementation of manual and automatic control of the industrial robot.

[0048] Figure 11 illustrates one embodiment of a recognition-based robot operation system, where the products include various boxes stacked in a physical environment and labeled 46i, 46j, 46k, 46l, 46m, 46n, 46o, 46p, 46r, 46s, 46t, 46u, 46x, 46y, 46z, 47a (Figure 14), and 47b (Figure 14). In terms of operation, generally, the robot track unloader 10 selects products 46 by using an industrial robot 40 to grasp the packages and pull them onto a swivel forward conveyor 42, which provides further outward transport and transport to downstream systems such as the retractable conveyor units shown in Figures 1A-1D, via the robot track unloader 10.

[0049] More specifically, in one embodiment, the operator positions the robotic track unloader 10, which has an industrial robot 40 and a slewing forward conveyor 42, near the trailer opening 46 by positioning the robotic track unloader 10 using a programmable logic controller and a distance measuring subassembly 170. The robotic track unloader 10 first captures multiple data images of the product 46, which are represented by multiple 3D data images 400. The multiple 3D data images 400 are then converted into a composite 3D model 402, and then into a filtered 3D model 404. In some embodiments, the multiple 3D data images capture the entire scene. Product identification 406 identifies the foreground wall W corresponding to the physical packages 46l, 46m, 46n, 46r, 46s, 46t, 46x, 46t and 46z. In some implementations, the foreground wall W is divided into an upper portion U and a lower portion L. The upper section U corresponds to packages 46l, 46m, 46r, 46s, 46x, and 46y. The lower section L corresponds to packages 46n, 46t, and 46z. In some implementations, the upper section U contains products that do not directly contact the floor FL, and the lower section L contains products that directly contact the floor FL.

[0050] Product dimensioning 408 occurs to identify candidate product contact surfaces T, which may take the form of a capital "T" based on prioritization and correspond to parcels 46r, 46s, 46x, and 46l. In some embodiments, the candidate product surfaces T are located within the upper portion P. As part of these operations, candidate contact surfaces are generated and evaluated for their likelihood of successful selection. Candidates may then be prioritized based on spatial distribution to optimize product throughput, which may take the form of a capital "T". In this example, the resulting candidates correspond to parcels 46r, 46s, 46x, and 46y. The industrial robot 40 is then given a command to remove parcels 46r, 46s, 46x, and 46y from the stack of products 46. As shown in Figure 11, the industrial robot 40 can utilize the conformability of the end effector to grasp parcels of different dimensions having non-uniform surfaces. The industrial robot 40 then pulls the packages 46r, 46s, 46x, and 46y from the stack of products 46 onto the swivel forward conveyor 42, which receives the packages 46r, 46s, 46x, and 46y. The robot track unloader 10 may repeat the picking process as needed, utilizing the grasping and pulling process of the industrial robot 40, until the area above the swivel forward conveyor 42 is empty.

[0051] Referring now to Figure 12, continuing from the machine operation sequence presented in Figure 11, parcels 46r, 46s, 46x, and 46y are picked up by the industrial robot 40 onto the swivel forward conveyor 42 using a grasping and pulling technique indicated by arrow A3, and move downstream as indicated by arrow A4. The swivel forward conveyor 42 receives parcels 46r, 46s, 46x, and 46y. Such an operation is represented by operation 410, where articulation in the swivel forward conveyor 42 may include scooping. Next, when a specified height of parcels has been reduced, such as when parcels of the lower rows of the first few rows remain in the lower section L (e.g., parcels 46n, 46t, and 46z remain), the robot track unloader 10 may then articulate the swivel forward conveyor 42 to scoop up for the remaining parcels, if necessary. The lower portion L, from which the upper portion U has been removed, can be considered an evacuated front area below the candidate product contact surface T, which is scooped up by the swivel forward conveyor 42. It should be understood that more than one scooping operation may be employed. Furthermore, scooping operations of different depths, such as shallow and deep, may be utilized.

[0052] Referring now to Figure 13, following the machine operation sequence presented in Figures 11 and 12, in this example, before scooping up the remaining product 46 on the lower portion L, the robot track unloader 10, in operation 412, utilizes automatic error handling to detect that the parcel 46s is not moving and is not progressing through the conveyor on the swivel forward conveyor 42, as indicated by the letter S. The automatic error handling function of the robot track unloader 10 can then use wings 300, 302, particularly wing 302, to reposition the parcel 46s so that it can continue moving downstream through the conveyor. Alternatively, the automatic error handling function of the robot track unloader 10 can then cause the industrial robot 40 to reposition, as indicated by repositioning R, to engage with the parcel 46s on the swivel forward conveyor 42 so that it can continue moving downstream through the conveyor. However, in some implementations, as a further addition or alternative, it should be understood that the automatic error handling function of the robotic track unloader 10 may cause the parcels 46s to vibrate on the swivel forward conveyor 42. Such vibrations may be caused by moving the swivel forward conveyor 42 up and down, or by alternating directional movements of the conveyor units of the swivel forward conveyor 42. As shown in Figure 14, once the parcels 46s are released by the automatic error handling, the robotic track unloader 10 uses this downstream transport, represented by arrows A5 and A6, to scoop up the remaining products 46 on the lower portion L, including parcels 46n, 46t, and 46z. In one embodiment, the swivel forward conveyor 42 of the robotic track unloader 10 moves forward with a driven scoop to engage with the products 46 on the lower portion L. Subsequently, the robotic track unloader 10 may be repositioned, and following necessary navigation and recognition operations, the industrial robot 40 may perform picking, including grasping and pulling, and the swivel forward conveyor 42 that transports the picked products then performs a series of scooping operations. Such a sequence of machine operations, as shown in Figures 9-12, may continue until the end of the trailer is detected by the recognition system of the robotic track unloader 10.

[0053] Figure 15 illustrates one embodiment of a method for recognition-based robot operation. In some embodiments, in block 420, a distance measuring subassembly captures data from different viewpoints of the product. More specifically, 3D data images are collected from the distance measuring subassembly, and in block 422, a coordinate transformation occurs. In one embodiment, the coordinates observed by the distance measuring subassembly, which may include one or more cameras, are transformed into a reference frame in order to perform product actions, such as picking up a box, including grasping and pulling, using the recognition data. As an example, but not limited to, the following coordinate systems may be defined: • The camera coordinate system {c} in which the RGB-D point cloud data is originally represented. • Robot coordinate system {r} located at the base of the manipulator In some embodiments, a homogeneous transformation matrix from the camera to the robot coordinate system is defined for the distance measurement subassembly, which can be obtained using a hand-eye calibration procedure or other preferred calibration procedure. For example, such a calibration procedure may be performed offline when the distance measurement subassembly is installed or maintained, and the resulting transformation is stored for future use. The point cp originally represented in the camera coordinate system can then be transformed to the robot base using Equation 1.

[0054] Formula 1: rp=crH*cp In block 424, the 3D data images are stitched together to form a 3D model that may be a partial model and, in one implementation, a partial 3D point cloud data model. In block 426, asymmetric areas are filtered out in the 3D model to generate a world spatial model. Asymmetric areas may include side walls, ceilings, floors, and conveyor planes that can be constructed by two 3D data points provided by the PLC. In block 428, a region-based segmentation algorithm is employed to identify foreground walls. In block 430, various spatial metrics are calculated to determine whether the position of the rotating forward conveyor should be moved to expose more walls, or whether the current walls have disappeared. In decision block 432, if the walls have disappeared and no candidate selection is possible, the method proceeds to block 452 (described below) to communicate to the programmable logic controller that there are no valid candidates in the block.

[0055] In block 434, applicable filters are applied before a valid set of candidates is determined. Candidate product contact surfaces may belong to at least one candidate product and are calculated using the sliding window method described in block 436. In block 436, the application of filters generates a set of candidate contact surfaces using a sliding window method that can extract contact surfaces based on a dynamically generated grid structure. Subsequently, in block 438, each candidate is evaluated for surface quality and the likelihood of successful extraction based on spatial and geometric features. The candidate products are then ranked in block 440 based on their spatial distribution and in block 442 based on the number of previous trials in that region.

[0056] In block 444, the optimal candidate is selected, which may include the removal of the product by a selection action, including grasping and pulling by an industrial robot, followed by receiving by a swivel forward conveyor, which is simulated in block 446 before interference checking is performed in block 448. In block 450, it is determined whether the swivel forward conveyor position requires modification for subsequent selection cycles. In block 452, a command is sent to the programmable logic controller to control the end effector of the industrial robot to remove the product, which may be a box or parcel as mentioned. This command may additionally include instructions to adjust the swivel forward conveyor position or to perform one or more scoops to remove the remaining product. In block 454, automatic error handling is performed if necessary.

[0057] Figure 16 illustrates one embodiment of a method for recognition-based optimal conveyor positioning. In some embodiments, in block 460, a distance measuring subassembly captures data from different viewpoints of the product, including 3D data images. In block 462, a coordinate transformation occurs. In one embodiment, the coordinates observed by the camera are transformed into a reference frame in order to perform box-selection actions, including grasping and pulling, using the recognition data. As an example, but not limited to, the following coordinate systems may be defined: • The camera coordinate system {c} in which the RGB-D point cloud data is originally represented. • Robot coordinate system {r} located at the base of the manipulator A homogeneous transformation matrix crH from the camera to the robot coordinate system is defined, which can be obtained using a hand-eye calibration procedure. This can be performed offline when the distance measurement subassembly includes a camera mounted on the system, and the resulting transformation is stored for future use. The point cp originally represented in the camera coordinate system can then be transformed to the robot base using Equation 1.

[0058] Formula 1: rp=crH*cp In block 464, the 3D data images are stitched together to form a 3D model that can be a partial model and, in one implementation, a partial 3D point cloud data model. In block 466, to generate a world spatial model, asymmetric areas are filtered out in the 3D model. As an example, but not limited to, asymmetric areas may include side walls, ceilings, floors, and conveyor planes, which can be constructed from two 3D data points provided by the PLC. In block 468, a region-based segmentation algorithm is employed to identify foreground walls. Next, in block 470, the symmetric subregions are calculated using various spatial metrics that can determine the best 3D points of our remaining partial 3D point cloud model. The conveyor position is determined.

[0059] Figure 17 illustrates one operational implementation of a robotic truck unloader that unloads products from, for example, a truck or container. The method begins in block 500 before proceeding to block 502, where the robotic truck unloader is positioned near the unloading door of the truck or container containing the products. In this step, the operator moves the robotic truck unloader near the unloading door and ensures that the robotic truck unloader is ready to operate, including the functioning of safety systems. In block 504, the robotic truck unloader is positioned near the products, and, for example, a programmable logic controller 372 and a distance measuring subassembly 170 work together to guide the robotic truck unloader to a specified distance from the products. In block 506, a 3D model is constructed from the loaded products and the surrounding environment, as described, for example, in Figures 12 and 13.

[0060] In block 508, a transport subassembly, which may include an outward-facing conveyor providing a powered transport path, is appropriately positioned to process the product based on data collected by generating a 3D model. In block 510, the industrial robot of the robotic track unloader is also appropriately positioned to process the product based on data collected by generating a recognition-based model. In block 512, the industrial robot grasps the product, and in block 514, the industrial robot pulls the product onto the swivel forward conveyor to transport it to the transport subassembly. In determination block 516, if the area being grasped and pulled by the industrial robot is empty, the method proceeds to block 518. On the other hand, if the space with the product on the swivel forward conveyor is not empty, the grasping and pulling actions described in blocks 512 and 514 are repeated. That is, generally, in some embodiments, the method recaptures data after all selections and then determines that it is empty when the swivel forward conveyor is appropriately lowered to accommodate the selections. When a threshold is reached, a scooping occurs.

[0061] In block 518, the slewing forward conveyor is positioned by articulating it downwards to a specified height corresponding to the remaining products. In block 520, the slewing forward conveyor performs scooping by driving the unit forward to position its long blades under the products and scoop them up. In decision block 522, if the space that the slewing forward conveyor was scooping up is empty, the method proceeds to decision block 524; otherwise, the articulation and scooping operations of blocks 518 and 520 are repeated. In decision block 524, if there are products remaining to be unloaded, the method returns to block 504. On the other hand, if the products are to be unloaded, the method ends in block 526, where the robotic truck unloader may exit the trailer or container. As previously mentioned, the systems and methods presented herein relating to a robotic track unloader utilize the navigation and recognition-based technologies presented herein to enable the grasping and pulling of products such as parcels, regardless of the location of individual instances of the product and regardless of prior knowledge of the environment (e.g., truck dimensions). The product is grasped by an industrial robot and pulled onto a swivel forward conveyor and transport subassembly for further transport. To limit the distance traveled for outward transport to various downstream systems, the movement and articulation of the swivel forward conveyor allow the robotic track unloader to approach the location of the product.

[0062] Unless otherwise specified, the order in which the methods and process flows described herein are performed or executed is not essential. That is, unless otherwise specified, the elements of the methods and process flows may be performed in any order, and the methods may include more or fewer elements than those disclosed herein. For example, performing or executing a particular element before, simultaneously with, or after another element is assumed to be all possible execution orders.

[0063] While the present invention has been described with reference to exemplary embodiments, the above description is not intended to be construed as limiting the invention. Various improvements and combinations of other embodiments in addition to the exemplary embodiments of the present invention will be apparent to those skilled in the art by reference to the description. Accordingly, the appended claims are intended to encompass any such improvements or embodiments. (Other possible items) (Item 1) A robotic truck unloader (10) for unloading / spreading multiple products (46), Structure of a mobile base (50) having first and second ends (64, 66); A drive subassembly (52) is connected to the mobile base (50), the drive subassembly (52) includes a plurality of wheels for steering and driving the mobile base (50); A transport subassembly (54) is disposed on the mobile base (50), and the transport subassembly (54) includes a powered transport path (90) configured to transport the plurality of products (46) between the first end and the second end (64, 66); An industrial robot (40) is disposed near the second end (66) of the mobile base (50), the industrial robot (40) is configured to process the plurality of products (46), and the industrial robot (40) has a robot-reachable space (102); A swivel forward conveyor (42) is disposed at the second end (66) of the mobile base (50), the swivel forward conveyor (42) has an integrated deck conveyor unit (230), the deck conveyor unit (230) is configured to transport the plurality of products (46) to the transport subassembly (54), the swivel forward conveyor (42) is configured to process the plurality of products (46), and the deck (38) has a deck reachable space (236); Camera (377); A control subassembly (62) is arranged to communicate with the industrial robot (40), the swivel forward conveyor (42), and the camera (377), the control subassembly (62) coordinates the selective joint movement of the industrial robot (40), and the control subassembly (62) coordinates the selective joint movement of the swivel forward conveyor (42); and The control subassembly (62) includes a memory (360) accessible from the processor (350), and the memory (360) is accessed by the processor (350) when executed: A model (402) is constructed from multiple data images (400) collected by the camera (377), the model (402) being a representation of at least one physical environment of the industrial robot (40) and the rotating forward conveyor (42), the physical environment including the multiple products (46), To identify the foreground wall (W), specify a search operation within the model (402). In order to identify the candidate product contact surface belonging to at least one of the plurality of products (46), a search operation within the foreground wall (W) is specified. Using one of the industrial robot (40) and the rotating forward conveyor (42), a removal operation is specified to unload the multiple products (46). In order to identify the product being processed located on the rotating forward conveyor (42), a search operation within the rotating forward conveyor (42) is specified, and When the product being processed is positioned on the rotating forward conveyor (42), an automatic error handling operation is specified. Including processor-executable instructions, A robotic truck unloader (10) equipped with [a specific feature]. (Item 2) The robotic track unloader (10) according to item 1 further includes first and second wings (300, 302) located laterally along the rotating forward conveyor (42). (Item 3) A robotic truck unloader (10) for unloading / spreading multiple products (46): Structure of a mobile base (50) having first and second ends (64, 66); A drive subassembly (52) is connected to the mobile base (50), the drive subassembly (52) includes a plurality of wheels for steering and driving the mobile base (50); A transport subassembly (54) is disposed on the mobile base (50), and the transport subassembly (54) includes a powered transport path (90) configured to transport the plurality of products (46) between the first and second ends; A swivel forward conveyor (42) having a frame disposed at the second end (66) of the moving base (50), the swivel forward conveyor (42) having a deck conveyor unit (230) integrated within the frame, the deck conveyor unit (230) configured to transport the plurality of products (46) to the transport subassembly (54), the swivel forward conveyor (42) configured to process the plurality of products (46), and the deck (38) having a deck reachable space (236); A planar extension blade (250) is provided, which represents the rear portion connected to the frame, and the planar extension blade (250) has a front portion that extends for a certain length from the rear portion along the transverse axis between the first and second sides (300, 302); The planar extension blade (250) bends around the transverse axis in response to the application of pressure; Camera (377); A control subassembly (62) is arranged to communicate with the swivel forward conveyor (42) and the camera (377), the control subassembly (62) coordinates the movement of the swivel forward conveyor (42) by selective joint movement; and The control subassembly (62) includes a memory (360) accessible from the processor (350), and the memory (360) is accessed by the processor (350) when executed: A model is constructed from multiple data images collected by the camera (377), the model being a representation of at least one physical environment of an industrial robot (40) and a rotating forward conveyor (42), the physical environment including the multiple products (46), and The system is configured to perform a removal operation to unload the multiple products (46) using the aforementioned rotating forward conveyor (42). Including processor-executable instructions, A robotic truck unloader (10) equipped with [a specific feature]. (Item 4) The robotic track unloader (10) described in item 3 further includes a spatula shape that fits between the product and the floor, wherein the planar extension blade (250) also includes a spatula shape that fits between the product and the floor. (Item 5) A robotic truck unloader (10) for unloading / spreading multiple products (46): Mobile base (50); An industrial robot (40) is disposed on the mobile base (50), the industrial robot (40) is configured to select the plurality of products (46), and the industrial robot (40) has a robot-reachable space (102); A rotating forward conveyor (42) is installed on the moving base (50), and the rotating forward conveyor (42) is configured to scoop up the plurality of products (46); Camera (377); A control subassembly (62) is arranged to communicate with the industrial robot (40), the swivel forward conveyor (42), and the camera (377), the control subassembly (62) coordinates the selective joint movement of the industrial robot (40), and the control subassembly (62) coordinates the selective joint movement of the swivel forward conveyor (42); and The control subassembly (62) includes a memory (360) accessible from the processor (350), and the memory (360) is accessed by the processor (350) when executed: A model is constructed from multiple data images collected by the camera (377), the model being a representation of at least one physical environment of the industrial robot (40) and the rotating forward conveyor (42), the physical environment including the multiple products (46), Specify a search operation within the model to identify the foreground wall (W). A search operation within the foreground wall (W) is specified to identify a candidate product contact surface belonging to at least one of the plurality of products (46), wherein the candidate product contact surface is offset from the top of the foreground wall (W). On the contact surface of the candidate product, the industrial robot (40) is instructed to perform a first removal operation in order to select the plurality of products (46), and Following the first removal operation, a second removal operation is specified in order to scoop up the plurality of products (46) using the rotating forward conveyor (42). Includes processor-executable instructions; A robotic truck unloader (10) equipped with [a specific feature]. (Item 6) When executed, the processor executable instruction causes the processor (350) to specify a second removal operation to scoop up the plurality of products (46) using the rotating forward conveyor (42) following the first removal operation, when executed, the processor (350) is: The robotic track unloader (10) described in item 5 further includes a processor-executable instruction specifying a second removal operation to scoop up the plurality of products (46) using the rotating forward conveyor (42) in the retracted forward area, the retracted forward area being below the candidate product contact surface. (Item 7) A robotic truck unloader (10) for unloading / spreading multiple products (46): Structure of a mobile base (50) having first and second ends (64, 66); A drive subassembly (52) is connected to the mobile base (50), the drive subassembly (52) includes a plurality of wheels for steering and driving the mobile base (50); A transport subassembly (54) is disposed on the mobile base (50), and the transport subassembly (54) includes a powered transport path (90) configured to transport the plurality of products (46) between the first and second ends; A swivel forward conveyor (42) is disposed at the second end (66) of the mobile base (50), a deck conveyor unit (230) is integrated into the swivel forward conveyor (42), the deck conveyor unit (230) is configured to transport the plurality of products (46) to the transport subassembly (54), and the swivel forward conveyor (42) is configured to process the plurality of products (46); The deck conveyor unit (230) includes a plurality of conveyor subassemblies; A plurality of lateral skirt plates are arranged on the rotating forward conveyor (42), and the plurality of lateral skirt plates are configured to guide the plurality of products (46) through the deck conveyor unit (230); Multiple sensors positioned to monitor the aforementioned rotating forward conveyor (42); The swivel forward conveyor (42), the deck conveyor unit (230), and the control subassembly (62) arranged to communicate with the plurality of sensors, the control subassembly (62) coordinating the selective articulation movement of the swivel forward conveyor (42), and the control subassembly (62) coordinating the selective operation of each of the plurality of conveyor subassemblies of the deck conveyor unit (230); and The control subassembly (62) includes a memory (360) accessible from the processor (350), and when executed, the memory (360) is provided to the processor (350): In order to identify the product being processed located on the rotating forward conveyor (42), the multiple sensors are used to specify a search operation within the rotating forward conveyor (42), and Depending on the position of the product being processed on the rotating forward conveyor (42), an automatic error handling operation is specified, and the automatic error handling operation includes the selective operation of each of the plurality of conveyor subassemblies of the deck conveyor unit (230). Including processor-executable instructions, A robotic truck unloader (10) equipped with [a specific feature]. (Item 8) The aforementioned rotating forward conveyor (42) further: A frame fixed to the second end (66) of the movable base (50), the frame being inflexible; A planar extension blade (250) comprising a rear portion connected to the frame and a front portion extending for a certain length from the rear portion along the transverse axis between the first and second sides; The planar extension blade (250) bends around the horizontal axis in response to the application of pressure. A robotic truck unloader (10) as described in item 7, comprising: (Item 9) A robotic truck unloader (10) for unloading / spreading multiple products (46): Structure of a mobile base (50) having first and second ends (64, 66); A drive subassembly (52) is connected to the mobile base (50), the drive subassembly (52) includes a plurality of wheels for steering and driving the mobile base (50); A transport subassembly (54) is disposed on the mobile base (50), and the transport subassembly (54) includes a powered transport path (90) configured to transport the plurality of products (46) between the first and second ends; An industrial robot (40) is disposed near the second end (66) of the mobile base (50), the industrial robot (40) is configured to process the plurality of products (46), and the industrial robot (40) has a robot-reachable space (102); Camera (377); A rotating forward conveyor (42) is disposed at the second end (66) of the moving base (50), the rotating forward conveyor (42) has an integrated deck conveyor unit (230), the deck conveyor unit (230) is configured to transport the plurality of products (46) to the transport subassembly (54), and the rotating forward conveyor (42) is configured to process the plurality of products (46); The deck conveyor unit (230) includes a plurality of conveyor subassemblies; A control subassembly (62) is arranged to communicate with the industrial robot (40), the camera (377), the swivel forward conveyor (42), and the deck conveyor unit (230). The control subassembly (62) coordinates the selective joint movement of the industrial robot (40), the selective joint movement of the swivel forward conveyor (42), and the selective operation of each of the plurality of conveyor subassemblies of the deck conveyor unit (230). The control subassembly (62) includes a memory (360) accessible to the processor (350), and when executed, the memory (360) is provided to the processor (350): In order to identify the product being processed located on the rotating forward conveyor (42), a search operation within the rotating forward conveyor (42) is specified via the camera (377), and Depending on the position of the product being processed on the rotating forward conveyor (42), an automatic error handling operation is specified, and the automatic error handling operation includes selective processing of the product being processed on the rotating forward conveyor (42) via the industrial robot (40). Including processor-executable instructions, A robotic truck unloader (10) equipped with [a specific feature]. (Item 10) The aforementioned rotating forward conveyor (42) further: A frame fixed to the second end (66) of the movable base (50), the frame being inflexible; A planar extension blade (250) comprising a rear portion connected to the frame and a front portion extending for a certain length from the rear portion along the transverse axis between the first and second sides; The planar extension blade (250) bends around the horizontal axis in response to the application of pressure. A robotic truck unloader (10) as described in item 9, comprising: (Item 11) A robotic truck unloader (10) for unloading / spreading multiple products (46): base; An industrial robot (40) is disposed on the base, the industrial robot (40) is configured to select the plurality of products (46), and the industrial robot (40) has a robot-reachable space (102); A rotating forward conveyor (42) is disposed on the base, and the rotating forward conveyor (42) is configured to scoop up the plurality of products (46); Camera (377); A control subassembly (62) is arranged to communicate with the industrial robot (40), the swivel forward conveyor (42), and the camera (377), the control subassembly (62) coordinates the movement of the industrial robot (40) by selective joint movements, the control subassembly (62) coordinates the movement of the swivel forward conveyor (42) by selective joint movements, and The control subassembly (62) includes a memory (360) accessible from the processor (350), and when executed, the memory (360) is provided to the processor (350): A model is constructed from multiple data images collected by the camera (377), the model being a representation of at least one physical environment of the industrial robot (40) and the rotating forward conveyor (42), the physical environment including the multiple products (46), To identify the foreground wall (W), a search operation is specified within the model, wherein the foreground wall (W) has an upper portion having product instances that do not directly contact the floor, and the foreground wall (W) has a lower portion having product instances of the plurality of products (46) that directly contact the floor. Using the industrial robot (40), a first removal operation is specified to remove the first portion of the plurality of products (46) within the upper portion, and Following the first removal operation, a second removal operation is specified using the rotating forward conveyor (42) to scoop up the second portion of the plurality of products (46) in the lower part. Including processor-executable instructions, A robotic truck unloader (10) equipped with [a specific feature]. (Item 12) The memory (360) further, when executed, to the processor (350): Following the second removal operation, a third removal operation is specified in order to scoop up the plurality of products (46) using the rotating forward conveyor (42). Including processor-executable instructions, Robot truck unloader (10) as described in item 11.

Claims

1. A robotic truck unloader for unloading / spreading multiple products, Structure of a mobile base having first and second ends; A drive subassembly connected to the mobile base, the drive subassembly including a plurality of wheels for steering and driving the mobile base; A transport subassembly is disposed on the mobile base, and the transport subassembly includes a powered transport path configured to transport the plurality of products between the first and second ends; An industrial robot is disposed near the second end of the mobile base, the industrial robot is configured to process the plurality of products, and the industrial robot has a robot-reachable space; A swivel forward conveyor is disposed at the second end of the moving base, the swivel forward conveyor has an integrated deck conveyor unit, the deck conveyor unit is configured to transport the plurality of products to the transport subassembly, the swivel forward conveyor is configured to process the plurality of products, and the swivel forward conveyor has a deck reachable space; camera; A control subassembly is arranged to communicate with the industrial robot, the slewing forward conveyor, and the camera, the control subassembly coordinates the selective joint movement of the industrial robot, and the control subassembly coordinates the selective joint movement of the slewing forward conveyor; and The control subassembly includes memory accessible from the processor, and the memory is accessed by the processor when executed: A model is constructed from multiple data images collected by the aforementioned camera, and the model is a representation of at least one physical environment, which is the industrial robot and the rotating forward conveyor, and the physical environment includes the aforementioned multiple products. Specify a search operation within the model to identify the foreground wall (W). In order to identify the candidate product contact surface belonging to at least one candidate product of the plurality of products, a search operation within the foreground wall (W) is specified. Using one of the aforementioned industrial robots and the aforementioned forward-rotating conveyor, a removal operation is specified to unload the multiple products. In order to identify the product being processed located on the rotating forward conveyor, a search operation within the rotating forward conveyor is specified, and Depending on when the product being processed is positioned on the rotating forward conveyor, an automatic error handling operation is specified. Including processor-executable instructions, Equipped with, The aforementioned rotating forward conveyor further: A frame fixed to the second end of the movable base, the frame being inflexible; A planar extension blade comprising a rear portion connected to the frame, and a front portion extending for a certain length from the rear portion along the transverse axis AT between the first and second sides; The planar extension blade bends around the horizontal axis A t in response to the application of pressure. A robotic truck unloader equipped with the following features.

2. A robotic truck unloader for unloading / spreading multiple products, Structure of a mobile base having first and second ends; A drive subassembly connected to the mobile base, the drive subassembly including a plurality of wheels for steering and driving the mobile base; A transport subassembly is disposed on the mobile base, and the transport subassembly includes a powered transport path configured to transport the plurality of products between the first and second ends; An industrial robot is disposed near the second end of the mobile base, the industrial robot is configured to process the plurality of products, and the industrial robot has a robot-reachable space; A swivel forward conveyor is disposed at the second end of the moving base, the swivel forward conveyor has an integrated deck conveyor unit, the deck conveyor unit is configured to transport the plurality of products to the transport subassembly, the swivel forward conveyor is configured to process the plurality of products, and the swivel forward conveyor has a deck reachable space; camera; A control subassembly is arranged to communicate with the industrial robot, the slewing forward conveyor, and the camera, the control subassembly coordinates the selective joint movement of the industrial robot, and the control subassembly coordinates the selective joint movement of the slewing forward conveyor; and The control subassembly includes memory accessible from the processor, and the memory is accessed by the processor when executed: A model is constructed from multiple data images collected by the aforementioned camera, and the model is a representation of at least one physical environment, which is the industrial robot and the rotating forward conveyor, and the physical environment includes the aforementioned multiple products. Specify a search operation within the model to identify the foreground wall (W). In order to identify the candidate product contact surface belonging to at least one candidate product of the plurality of products, a search operation within the foreground wall (W) is specified. Using one of the aforementioned industrial robots and the aforementioned forward-rotating conveyor, a removal operation is specified to unload the multiple products. In order to identify the product being processed located on the rotating forward conveyor, a search operation within the rotating forward conveyor is specified, and Depending on when the product being processed is positioned on the rotating forward conveyor, an automatic error handling operation is specified. Including processor-executable instructions, Equipped with, The aforementioned automatic error handling operation further includes vibration of the rotating forward conveyor beneath the product being processed by the robotic track unloader.

3. A robotic truck unloader for unloading / spreading multiple products, Structure of a mobile base having first and second ends; A drive subassembly connected to the mobile base, the drive subassembly including a plurality of wheels for steering and driving the mobile base; A transport subassembly is disposed on the mobile base, and the transport subassembly includes a powered transport path configured to transport the plurality of products between the first and second ends; An industrial robot is disposed near the second end of the mobile base, the industrial robot is configured to process the plurality of products, and the industrial robot has a robot-reachable space; A swivel forward conveyor is disposed at the second end of the moving base, the swivel forward conveyor has an integrated deck conveyor unit, the deck conveyor unit is configured to transport the plurality of products to the transport subassembly, the swivel forward conveyor is configured to process the plurality of products, and the swivel forward conveyor has a deck reachable space; camera; A control subassembly is arranged to communicate with the industrial robot, the slewing forward conveyor, and the camera, the control subassembly coordinates the selective joint movement of the industrial robot, and the control subassembly coordinates the selective joint movement of the slewing forward conveyor; and The control subassembly includes memory accessible from the processor, and the memory is accessed by the processor when executed: A model is constructed from multiple data images collected by the aforementioned camera, and the model is a representation of at least one physical environment, which is the industrial robot and the rotating forward conveyor, and the physical environment includes the aforementioned multiple products. Specify a search operation within the model to identify the foreground wall (W). In order to identify the candidate product contact surface belonging to at least one candidate product of the plurality of products, a search operation within the foreground wall (W) is specified. Using one of the aforementioned industrial robots and the aforementioned forward-rotating conveyor, a removal operation is specified to unload the multiple products. In order to identify the product being processed located on the rotating forward conveyor, a search operation within the rotating forward conveyor is specified, and Depending on when the product being processed is positioned on the rotating forward conveyor, an automatic error handling operation is specified. Including processor-executable instructions, Equipped with, The aforementioned automatic error handling operation further includes a robotic track unloader, which includes the industrial robot that processes the product being processed on the rotating forward conveyor.

4. The robotic track unloader according to any one of claims 1 to 3, wherein the rotating forward conveyor further includes first and second wings, respectively, located laterally along the rotating forward conveyor.

5. The robotic track unloader according to any one of claims 1 to 3, wherein the swivel forward conveyor is fixedly attached to the robotic track unloader for swivel, extension, and retraction relative to the robotic track unloader, respectively.

6. The robotic track unloader according to any one of claims 1 to 3, wherein the rotating forward conveyor further comprises a plurality of lateral skirt plates for guiding the plurality of products onto the deck conveyor unit.

7. The robotic track unloader according to claim 1, wherein the planar extension blade further includes a spring steel.

8. The robotic truck unloader according to claim 1, wherein the planar extension blade further comprises ultra-high molecular weight polyethylene.

9. The planar extension blade, in response to the application of pressure, moves along the horizontal axis A Ｔ A robotic track unloader according to claim 1, which bends around and conforms to the shape of an object to which the pressure is applied.

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