Load handling device

Abstract

There is disclosed a robotic load handling device (100) comprising a pair of forks. The forks may be inserted into the interior of a platform, such as a pallet (200), such that the platform, and any load received thereon, may be lifted and moved. The ends of the forks may be shaped and / or configured such that they may be inserted into a platform which has been wrapped to restrain items received on the platform. The ends of the forks may move the wrap and / or the ends of the forks may pierce or puncture the wrap to enable the insertion of the forks.

Description

[0001] 726 EP - Porter Fork Tips

[0002] LOAD HANDLING DEVICE

[0003] The disclosure relates to a load handling device, and in particular to an autonomous vehicle which can lift and move pallets, for example within a storage facility.

[0004] Background

[0005] A robotic vehicle (e.g., a robotic truck) can include forks (also referred to as tynes or tines) to enable the vehicle to pick up and move object(s) (e.g., a pallet) in an environment such as a warehouse.

[0006] A platform such as a pallet may be used in a warehouse to support goods and to enable the goods to be carried from one location to another while on the platform. The platform includes opening(s) or slot(s) to facilitate lifting of the platform by a vehicle such as a forklift truck. Platforms can vary in size, shape, weight, form factor, etc. The variance in the size and design of a platform can cause problems with the lifting and movement of such platforms.

[0007] Figure 1 shows a schematic depiction of a robotic vehicle 100 which comprises a body 120 in which are housed multiple components used in the operation of the vehicle, for example control electronics, a drive module which can be controlled by the control electronics to control the movement of the robotic vehicle and other actions of the robotic vehicle. The robotic vehicle further comprises a platform support area 130 which is located at the rear of the robotic vehicle. The robotic vehicle further comprises a lifting shuttle 136 which is coupled to a first fork 132 and second fork 134. In operation, the lifting shuttle can be advanced from the body of the robotic vehicle, such that the first fork 132 and the second fork 134 are advanced from underneath the platform support area 130. The first fork and the second fork may be inserted into the interior of a platform (for example a pallet) such that that the platform may be lifted from the surface in which it is resting (for example the floor) to a height which is above that of the platform support area 130. The robotic vehicle may then advance such that the platform can be lowered onto the platform support area 130 and such that the lifting shuttle 136 is received within the body of the robotic vehicle.

[0008] An example of such a robotic vehicle is disclosed in the Applicant’s co-pending international patent application W02024 / 240940. The body of the robotic vehicle may comprise a first sensor 137 and a second sensor 138 arranged such that the first and second sensors can726 EP - Porter Fork Tips

[0009] view a platform, such as a pallet, as the platform support area 130 of the robotic vehicle is manoeuvred when approaching a platform.

[0010] The pallet 200 shown in Figure 1 comprises a plurality of upper deck boards 202 on which a load may be received. The pallet also comprises a plurality of lower deck boards 204 which are in contact with the ground (or the surface upon which the pallet is resting). The upper deck boards 202 and the lower deck boards 204 are connected by a number of stringers, in this example two external stringers 208, which are located at the edge of the pallet, and one internal stringer 206. The combination of the upper deck boards, lower deck boards and the stringers define apertures 210 on opposed faces of the pallet into which the forks of a robotic vehicle can be inserted.

[0011] The pallet described above with reference to Figure 1 is known as a stringer pallet. In an alternative arrangement, the pallet may be a type of pallet known as a block pallet, in which the stringers are replaced with a number of blocks that connect the upper deck boards to the lower deck boards. Typically, a block pallet comprises nine blocks, with one block being received at substantially the same position as the ends and the midpoint of each of the three stringers shown in Figures 1 and 2. Some types of pallets do not comprise lower deck boards such that the pallet rests on the floor on the stringers (or a combination of stringers and blocks).

[0012] The Applicant’s co-pending application W02026 / 022401, the contents of which are hereby incorporated by reference, discloses a robotic vehicle in which the forks of the robotic vehicle comprise sensors. The sensors detect the presence of pallet structures (for example lower deck boards, internal stringers etc) and by determining the position of these elements it is possible to determine the type of pallet. Once the pallet has been identified then it is possible to insert the forks a pre-determined distance within the pallet prior to lifting the pallet. Furthermore, the position and orientation of a robotic vehicle relative to a platform, for example a pallet, can be determined. This information may then be used to control the movement of the robotic vehicle such that the forks of the robotic vehicle are substantially perpendicular to the leading edge of the pallet when they are inserted into the apertures 210 of the pallet. The movement of the robotic vehicle may be controlled such that each fork of the robotic vehicle is inserted into substantially the centre of the respective pallet aperture.

[0013] By controlling the movement of the forks in accordance with the type of pallet, it is possible to avoid the forks of the robotic vehicle being inserted such that they protrude beyond the726 EP - Porter Fork Tips

[0014] opposed face of the pallet . Thus, it is possible to lift a pallet without the forks interfering with an adjacent pallet, even if the two pallets are in contact.

[0015] Summary

[0016] According to a first aspect of the present disclosure, there is provided a robotic vehicle comprising: a body; a drive means configured, in use, to move the robotic vehicle; and a lifting shuttle comprising an actuator, a first fork and a second fork; the robotic vehicle being configured to lift a platform with the first and second forks, the platform comprising: a) one or more apertures to receive the first and second forks of the robotic vehicles; b) one or more layers of material wrapped around a payload received on the platform such that the material covers the one or more platform apertures; wherein the distal end of the first and second forks are configured to pierce and / or move the one or more layers of material covering the one or more platform apertures such that the first and second forks are inserted into the interior of the platform.

[0017] Such a robotic vehicle is able to operate autonomously as the configuration of the distal ends of the forks enables the forks to be inserted into the pallet, even if the pallet apertures are blocked, either entirely or in part. For a robotic vehicle with conventional fork ends the layer(s) of wrapping may prevent the forks from penetrating the wrapping, requiring an operator to intervene and to cut the wrapping with a knife or other tool. The configuration of the distal ends of the forks reduces the force that is required for the forks to be inserted into the interior of the pallet.

[0018] In one example, the distal end of the first and second forks may comprise a plurality of serrations configured to pierce the one or more layers of material received on the platform. Alternatively, or in addition, the distal end of the first and second forks may comprise one or more spikes configured to pierce the one or more layers of material received on the platform.

[0019] In one example, the distal end of the first and second forks may be profiled so as to lift the one or more layers of material received on the platform. The height of the distal end of the first and second forks may increase from a minimum value to a maximum value.

[0020] It should be understood that the distal end of the first and second forks may be configured to both pierce and move the wrapping. The movement of the wrapping may be upwards (or726 EP - Porter Fork Tips

[0021] downwards) to permit the ingress of the forks into the platform. In a further variant, the distal end of the first and second forks may be configured to push the wrapping into the interior of the platform such that the increase in tension in the wrapping assists in the piercing (or puncturing) of the wrapping.

[0022] According to a second aspect of the present disclosure, there is provided a method of operating a robotic vehicle, the robotic vehicle comprising a body, a drive means configured, in use, to move the robotic vehicle, and a lifting shuttle comprising an actuator, a first fork and a second fork, the robotic vehicle being configured to lift a platform with the first and second forks, the platform comprising one or more apertures to receive the first and second forks of the robotic vehicles; and one or more layers of material wrapped around a payload received on the platform such that the material covers the one or more platform apertures; the method comprising: the robotic vehicle extending a first fork and a second fork from a body of the robotic vehicle into the one or more platform apertures, the distal end of the first and second forks piercing and / or moving the one or more layers of material covering the one or more platform apertures such that the first and second forks are inserted into the interior of the platform.

[0023] Brief description of the drawings

[0024] Embodiments of the invention will now be described byway of example only with reference to the accompanying drawings, in which like reference numbers designate the same or corresponding parts, and in which:

[0025] Figure 1 shows a schematic depiction of a robotic vehicle co-located with a platform; Figure 2 shows a schematic depiction of a first example of a fork end according to the present disclosure;

[0026] Figure 3 shows a schematic depiction of a robotic vehicle comprising the first example of the fork ends;

[0027] Figure 4 shows a schematic depiction of a second example of a fork end according to the present disclosure;

[0028] Figure 5 shows a schematic depiction of a third example of a fork end according to the present disclosure;

[0029] Figure 6 shows a schematic depiction of a fourth example of a fork end according to the present disclosure;726 EP - Porter Fork Tips

[0030] Figure 7 shows a schematic depiction of a fifth example of a fork end according to the present disclosure;

[0031] Figure 8 shows a schematic depiction of further aspects of the robotic vehicle; and Figure 9 shows a schematic depiction of a computer device which may be comprised within the robotic vehicle.

[0032] Detailed description

[0033] Figure 2 shows a schematic depiction of a first example of a fork end 300 according to the present disclosure. The fork end comprises a profiled region 302 which extends diagonally downwards from the top face 303 of the fork to the bottom of the fork 301. The fork end also comprises a serrated region 304 which extends along at least a substantial portion of the leading edge of the profiled region. In the example shown in Figure 2, the serrated region extends across the entire extent of the leading edge of the profiled region, although it should be understood that this is not essential.

[0034] In use, it is commonplace for boxes, cartons or other types of containers received on pallets (or similar platforms) to be secured using a plastic wrap (or a wrap formed from another material). The wrap ensures that the boxes remain in place and on the pallet. Typically the wrap extends downwards such that it partially or entirely covers the pallet apertures 210, to secure the payload (boxes, cartons, etc.) to the pallet. The wrap may be provided in a single layer but it is typically applied in multiple layers such that the payload can be held in place on the pallet. Often the wrap is transparent such that bar codes, QR codes or other labels are visible through the wrap and can be scanned or read. When using conventional hand pallet trucks, an operator may use a knife to puncture or slash the wrap which covers the pallet apertures such that the forks may be inserted. Alternatively, the operator may apply sufficient force to the pallet truck such that the forks are forced through the wrap and into the interior of the pallet.

[0035] The combination of the profiled region and the serrated edge of the fork end 300 has been found to be effective as being repeatedly insertable into apertures of wrapped (or partially wrapped) pallets. The profiled region is effective at lifting the wrap when the aperture is only partially covered by the wrap such that the fork can be inserted without the wrap being punctured or cut (or with limited puncturing or cutting). The serrated region is effective at puncturing (or piercing) the wrap when the majority (or all) of the aperture is covered by the726 EP - Porter Fork Tips

[0036] wrap. Figure 3 shows a schematic depiction of a partial view of a robotic vehicle which comprises first and second forks which both comprise the profiled region 302 and the serrated region 304 discussed above with reference to Figure 2.

[0037] In use, the first and second forks of the robotic vehicle are shaped and / or configured such that the distal end of the first and second forks lift and / or pierce the wrap which is provided on a pallet (or similar platform). The robotic vehicle will determine the location and the orientation of the pallet and then navigate towards the pallet such that the forks of the robotic vehicle are substantially perpendicular to the leading edge of the pallet and that the forks are aligned such that they can be inserted into the pallet apertures (for example, in accordance with the disclosure of EP24386124.2.

[0038] The forks can then be inserted into the interior of the pallet. The distal end of the first and second forks will lift and or pierce the wrap present on the pallet such that the forks are inserted into the interior of the pallet. Once the forks have been inserted an appropriate distance into the pallet then the pallet may be lifted and the pallet moved relative to the robotic vehicle such that the pallet is received on the platform support area of the robotic vehicle. The robotic vehicle may then move to a further location such that, for example, the pallet may be deposited or some or all of the contents of the pallet may be unloaded from the pallet.

[0039] Figure 4 shows a schematic depiction of a second example of a fork end 300a according to the present disclosure in which the fork end comprises a substantially rectangular end face 305. The end face of the fork may have an essentially identical profile as the rest of the fork. Some or all of the upper edge 304 of the end face of the fork may comprise a serrated region 304.

[0040] Figure 5 shows a schematic depiction of a third example of a fork end 300b according to the present disclosure in which the end face of the fork comprises an upwardly sloping profiled region 307. The end face may also comprise a prow 306, which may be located at (or near to) the centre of the end face. The prow may be inclined downwards from the top face 303 of the fork.

[0041] Figure 6 shows a schematic depiction of a fourth example of a fork end 300c according to the present disclosure in which the end face of the fork comprises a profiled snout 308, which is tapered inwards from the outside faces of the fork. The snout may also taper vertically, that726 EP - Porter Fork Tips

[0042] is in respect to the top face 303 of the fork and the bottom of the fork 301. In one example, the centre of the snout may be centrally located relative to the centre of the fork end. The fork may also comprise a spike 310 received at the end of the profiled snout.

[0043] Figure 7 shows a schematic depiction of a fifth example of a fork end 300d according to the present disclosure in which the end face of the fork comprises a downwardly profiled top face 312 and two inwardly profiled side faces 314 and 316. The downwardly profiled top face and the inwardly profiled side faces meet so as to define a rectangular aperture 318. One or more of the leading edges of the rectangular aperture may comprise a serrated region 320. Furthermore, the upper edge of one or both of the inwardly profiled side faces may comprise a serrated region 320.

[0044] Under testing, the first example described above with reference to Figure 2 was the only fork end which punctured the wrap film on all occasions when the wrap covered the entirety of the pallet aperture. When the wrap partially covered the pallet aperture the profiled region of the fork end pushed the wrap upwards consistently such that the forks could be inserted using significantly less force than was required for the other fork end designs.

[0045] Modifications and Variations

[0046] It should be understood that the present disclosure encompasses numerous fork end designs, and is not limited to those examples described above with reference to Figures 2 and 4-6.

[0047] It should also be understood that the individual features described in respect of those examples described above with reference to Figures 2 and 4-6 should be regarded as being separable and not being inextricably linked.

[0048] For example, the first exemplary fork end shown in Figure 2 could be modified such that it featured solely the profiled region and did not comprise a serrated region. The second example shown in Figure 4 could be modified to comprise additional serrated regions, for example on one or both of the vertical edges of the end face, and / or on the lower horizontal edge of the end face. These additional serrated regions may extend across some or all of the respective edges and / or they may comprise non-continuous regions of the edge (or edges).726 EP - Porter Fork Tips

[0049] The third example shown in Figure 5 could be modified such that the prow was not inclined with respect to the upper face 303 of the fork, i.e.such that the point of the prow was level with the upper face of the fork. The fork end could be configured such that the prow was located at the bottom of the fork. In such a case, the prow could be inclined such that it is above the level of the bottom of the fork (that is, in a manner that is the reverse shown in Figure 5 where the prow is inclined below the top of the fork. In other variants, the fork end could comprise multiple prows, with one or more prows associated with the upper face and / or the bottom of the fork. It should be understood that serrated regions could be formed on part, or all, of one or more of the prows.

[0050] The fourth example shown in Figure 6 could be modified such that the fork end comprised multiple snouts. Some or all of the diagonal edges defining the one or more snouts may comprise serrated regions. These serrated regions may extend along some or all of the length of the diagonal edges. Some of the serrated edges may be non-continuous.

[0051] The fifth example shown in Figure 7 such that one or either side wall or the top wall may comprise additional projections. These projections may form a grid of edges rather than the rectangular aperture 318 shown in Figure 7. Some or all of these edges may comprise serrations. Some form of prow (see Figure 5), snout (see Figure 6) or spike(s) (see Figure 6) may be located on the upper face of the downwardly profiled top face 312 so as to increase the probability of puncturing or piercing the wrap.

[0052] Although not described above with reference to Figures 2 & 3-7, the fork ends may comprise one or more sharp edges, which are configured to puncture or cut the wrap on the pallet. For example, a serrated region of a fork end may be replaced with a sharp edge. Such a modification is not preferred due to the increased risk of injury to an operative that may be working in the same space in which the robotic vehicle operates. It has been found that a serrated edge can cut a typical wrap material when relatively low forces are applied by the robotic vehicle. It has also been found that these forces are inadequate to cause such a serrated edge to lacerate human skin.

[0053] Figure 9 shows a schematic depiction of further aspects of the robotic vehicle that are not described above with reference to Figure 1. The example robotic vehicle 100 comprises a body 120, processor circuitry 105 to control the operations of the robotic vehicle and a drive means 123. The drive means may comprise one or more motors (e.g. electric motor(s) and / or726 EP - Porter Fork Tips

[0054] other drive mechanism(s)) to cause movement of the body 120 via the wheel(s) of the robotic vehicle 100. The robotic vehicle may further comprise a power source 121 which provides power to the drive means 123 and the processor circuitry 105. The power source may be rechargeable and may comprise one or more batteries.

[0055] The processor circuitry 105 may comprise motor control circuitry 103 (e.g. hardware and / or software components) to control, for example, the speed of the robotic vehicle 100. One or more components of the motor control circuitry 103 can be implemented by processor circuitry 105 of the vehicle 100. The robotic vehicle 100 can include an autonomous vehicle. The robotic vehicle 100 comprises vehicle control circuitry 107 to control movement of the autonomous or self-driving robotic vehicle 100. One or more components of vehicle control circuitry 107 can be implemented by the processor circuitry 105 of the robotic vehicle 100, processor circuitry of another user device, a remote computing system and / or cloud-based services. The robotic vehicle 100 can move to a location in a storage environment without or with limited user input control during movement of the vehicle 100. The lifting control circuitry 111 controls the lateral movement of the forks (for example, into and out of the interior of a platform) and the vertical movement of the forks to lift or lower the forks (and a platform received on the forks).

[0056] It will be understood that a robotic vehicle according to the present disclosure may comprise one or more computing devices, for example for instantiating the processor circuitry 105. Figure 9 shows a schematic depiction of a computer device 900 that may include a central processing unit (“CPU”) 902 connected to a storage unit 914 and to a random access memory 906. The CPU 902 may process an operating system 901 , application program 903, and data 923. The operating system 901, application program 903, and data 923 may be stored in storage unit 914 and loaded into memory 906, as may be required. Computer device 900 may further include a graphics processing unit (GPU) 922 which is operatively connected to CPU 902 and to memory 906 to offload intensive image processing calculations from CPU 902 and run these calculations in parallel with CPU 902. The computing device may further comprise a network interface 911 , for example a WiFi interface or a cellular interface (for example, an interface using LTE technology), to communicate with a warehouse management system and / or other systems operating in the storage environment in which the robotic vehicle operates. The computer device 900 may receive data from one or more sensors 935. These sensors may generate data that is used to determine the location and / or orientation of a platform to be lifted, such that the movement of the robotic vehicle can be controlled to enable726 EP - Porter Fork Tips

[0057] efficient movement of the platform. The sensors located in the forks may be used to determine the position of the forks within the platform and / or to determine the type of platform being lifted. Computer code for execution by the CPI may be provided on some form of physical media, for example, DVD, CD-ROM, USB memory stick, etc. or may be downloaded from a server to which the computer device 900 can connect to.

[0058] In one respect, there is disclosed a robotic load handling device comprising a pair of forks. The forks may be inserted into the interior of a platform, such as a pallet, such that the platform, and any load received thereon, may be lifted and moved. The ends of the forks may be shaped and / or configured such that they may be inserted into a platform which has been wrapped to restrain items received on the platform. The ends of the forks may move the wrap and / or the ends of the forks may pierce or puncture the wrap to enable the insertion of the forks.

Claims

726 EP - Porter Fork TipsCLAIMS1. A robotic vehicle comprising:a body;a drive means configured, in use, to move the robotic vehicle; anda lifting shuttle comprising an actuator, a first fork and a second fork;the robotic vehicle being configured to lift a platform with the first and second forks, the platform comprising:a) one or more apertures to receive the first and second forks of the robotic vehicles;b) one or more layers of material wrapped around a payload received on the platform such that the material covers the one or more platform apertures;wherein the distal end of the first and second forks are configured to pierce and / or move the one or more layers of material covering the one or more platform apertures such that the first and second forks are inserted into the interior of the platform.

2. A robotic vehicle according to claim 1, wherein the distal end of the first and second forks comprise a plurality of serrations configured to pierce the one or more layers of material covering the one or more platform apertures.

3. A robotic vehicle according to claim 1 or claim 2, wherein the distal end of the first and second forks comprise one or more spikes configured to pierce the one or more layers of material covering the one or more platform apertures.

4. A robotic vehicle according to any of claims 1 to 3, wherein the distal end of the first and second forks are profiled so as to lift the one or more layers of material covering the one or more platform apertures.

5. A robotic vehicle according to claim 4, wherein the height of the distal end of the first and second forks increases from a minimum value to a maximum value.

6. A robotic vehicle according to any preceding claim, wherein the robotic vehicle further comprises one or more optical sensors and a processor circuit, the processor circuit being configured to: cause the one or more optical sensors to illuminate the platform; receive data726 EP - Porter Fork Tipsfrom the one or more optical sensors; and process the received data to determine the position and orientation of the platform relative to the robotic vehicle.

7. A robotic vehicle according to any preceding claim, wherein the first fork comprises one or more sensors and the second fork comprises one or more sensors; wherein when at least a portion of the first and second forks have been inserted into the interior of the platform the robotic vehicle is configured to, in accordance with the data received from the one or more sensors of the first fork and / or the one or more sensors of the second fork:determine the location and / or size of one or more platform elements; andidentify the type of platform in accordance with the determination of the one or more platform elements.

8. A method of operating a robotic vehicle, the robotic vehicle comprising a body, a drive means configured, in use, to move the robotic vehicle, and a lifting shuttle comprising an actuator, a first fork and a second fork, the robotic vehicle being configured to lift a platform with the first and second forks, the platform comprising one or more apertures to receive the first and second forks of the robotic vehicles; and one or more layers of material wrapped around a payload received on the platform such that the material covers the one or more platform apertures; the method comprising:the robotic vehicle extending a first fork and a second fork from a body of the robotic vehicle into the one or more platform apertures, the distal end of the first and second forks piercing and / or moving the one or more layers of material covering the one or more platform apertures such that the first and second forks are inserted into the interior of the platform.

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