AGV Pallet Placement Control for Tight Truck Loading
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Solution Overview
Problem
Current automated systems for loading and unloading palletized goods into trucks or containers face challenges with precision and efficiency, particularly when entering from the rear side, as they often require specialized equipment and infrastructure, and struggle with tight placement of pallets next to each other, leading to issues like pallets getting stuck and incomplete loading/unloading tasks.
Innovation Solution
An automated method and apparatus using an AGV or AMR equipped with sensors and computing hardware to navigate and map the operating area, generate loading patterns, and adjust trajectories for precise placement of pallets without the need for special equipment or infrastructure modifications, allowing for autonomous rear-end loading and unloading of palletized goods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated systems use specialized equipment with tilt and side-shift mechanisms to load pallets, then loading precision is improved, but device complexity and infrastructure requirements increase
Solution Approach 1:
The patent replaces complex mechanical tilt and side-shift mechanisms with a sensor-based control system. Sensors detect pallet positions and the system automatically adjusts the forklift's approach angle and position to achieve precise loading without requiring specialized mechanical equipment.
Solution Approach 2:
The system uses sensors mounted on the forklift itself to detect pallet positions and automatically calculate the optimal approach trajectory. The forklift autonomously adjusts its own position and angle based on sensor feedback, eliminating the need for external specialized equipment.
2Productivity
If pallets are placed tightly next to each other to maximize space utilization, then productivity is improved, but reliability decreases due to pallets getting stuck
Solution Approach 1:
Sensors continuously monitor pallet positions during loading and provide feedback to the control system. When a pallet is detected to be improperly positioned or at risk of getting stuck, the system automatically adjusts the placement trajectory to ensure proper positioning while maintaining tight spacing.
Solution Approach 2:
The system performs preliminary detection of pallet positions and calculates the optimal approach trajectory before actual placement. This preliminary action prevents pallets from getting stuck by ensuring proper positioning from the start, allowing tight spacing to be maintained safely.
3Adaptability or versatility
If manual loading methods are used to handle improper load formation, then adaptability is improved, but productivity decreases due to required corrections
Solution Approach 1:
The sensor system automatically detects improper load formation and calculates correction trajectories without human intervention. The forklift autonomously performs multiple placement attempts with adjusted trajectories until the load is properly formed, eliminating the need for manual corrections while maintaining adaptability.
Solution Approach 2:
The system continuously monitors load formation during the loading process and provides real-time feedback to adjust placement trajectories. When improper formation is detected, the system automatically makes corrections by recalculating the approach angle and position, maintaining both adaptability and productivity.
4Difficulty of detecting and measuring
If current or pressure sensors are used to detect load contact, then measurement capability is improved, but measurement precision is insufficient for tight pallet placement
Solution Approach 1:
The patent replaces current and pressure sensors with optical or proximity sensors that directly measure pallet positions. These sensors provide precise positional data without relying on indirect measurements through current or pressure changes, enabling accurate detection even in tight spacing scenarios.
Data Source
AI summary
A method for controlling an automatic guided vehicle (AGV) to transport at least two loads from a load picking-up area to an operating area in which the at least two loads are to be placed in corresponding loading areas is provided. This method can comprise the steps of moving the AGV in the operating area to map virtual boundaries in the operating area within which the at least two loads are to be placed in the corresponding loading areas, generating a loading pattern for placing the at least two loads in the corresponding loading areas within the virtual boundaries in the operating area and generating travel trajectories which the AGV has to travel with each of the at least two loads to place the at least two loads in the corresponding loading areas. If the first load in the corresponding loading area does not correspond to the loading pattern in such a manner that the at least one further load is able to be placed according to the loading pattern, correcting the position and/or orientation of the first load in such a manner that the at least one further load is able to be placed according to the loading pattern.