AGV Cart Gripper Alignment Using Optical Coupling Feedback
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Solution Overview
Problem
Existing gripping systems for autonomous guided vehicles (AGVs) face challenges in precise alignment and secure coupling with carts, leading to inefficient docking, increased wear, and potential loss of carts during transport, with no safe indication of correct alignment or decoupling.
Innovation Solution
A gripping system for AGVs featuring a pivotally attached arm with adjustable height and sensors to ensure correct alignment and secure coupling, including sensors to confirm proper engagement and disengagement, and proximity sensors for obstacle detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a commercial hitch and ball mounting system is used for cart coupling, then the system is simple to implement, but the positioning precision and coupling reliability deteriorate due to inability to ensure precise alignment
Solution Approach 1:
The patent replaces the mechanical alignment process with an optical measurement system. A camera captures images of alignment markers on the cart, and image processing algorithms calculate the precise position and orientation of the cart relative to the AGV. This substitution of mechanical alignment with optical measurement resolves the contradiction by achieving high positioning precision without compromising implementation simplicity.
2Reliability
If multiple docking attempts are made to achieve correct alignment, then the coupling reliability improves, but the time consumption and productivity deteriorate
Solution Approach 1:
The system performs preliminary alignment measurement before the actual docking action. The camera and image processing system determine the correct docking position in advance, allowing the AGV to adjust its position and orientation before engagement. This preliminary action ensures correct alignment on the first attempt, eliminating the need for multiple docking attempts and thereby improving productivity while maintaining coupling reliability.
3Reliability
If docking is performed at slow speed to ensure precision, then the coupling reliability improves, but the operation speed deteriorates
Solution Approach 1:
The patent replaces speed-dependent mechanical alignment with optical measurement and calculation. The camera-based system can accurately measure alignment at higher speeds because it relies on image processing rather than slow mechanical adjustment. This allows the AGV to dock at higher speeds while maintaining coupling reliability, resolving the contradiction between speed and reliability.
4Device complexity
If no alignment indication system is provided, then the device complexity is reduced, but the operational safety deteriorates due to inability to confirm correct alignment
Solution Approach 1:
The system implements feedback by providing real-time alignment indication to the operator through visual signals (e.g., LED indicators showing correct alignment status). The image processing system continuously monitors the relative position of alignment markers and provides feedback on whether the AGV is correctly aligned with the cart. This feedback mechanism enhances operational safety without significantly increasing system complexity, as it utilizes the existing camera and processing system.
5Device complexity
If a rigid fixed mounting system is used for the gripper, then the structural simplicity is improved, but the adaptability to various cart types deteriorates
Solution Approach 1:
The patent introduces dynamic adjustability to the gripper mounting system. The gripper can be positioned at different locations on the AGV and adjusted in orientation to accommodate various cart types and coupling configurations. This dynamic positioning capability, controlled by the image processing system, allows a single gripper structure to adapt to multiple cart types, resolving the contradiction between structural simplicity and adaptability.
Data Source
AI summary
A gripping system for an autonomous guided vehicle (AGV) and such AGV are disclosed herein. The gripping system for automated gripping and pulling/pushing a cart comprises a unique gripping end effector ensuring controlled steering of the cart while allowing rolling of the cart relative to the body of the AGV. The end effector comprises means for indication of state of connection between the cart and the gripping system, ensuring a reliable, safe and efficient cart gripping and pulling operation.