AMR Cart Docking With Robotic Arms and Reflective Orientation Sensing
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Solution Overview
Problem
Autonomous mobile robots (AMRs) face challenges in efficiently and safely docking with wheeled carts, particularly when carts are improperly parked or in difficult-to-reach locations, due to limitations in existing hooking mechanisms and sensor technologies, which affect speed, safety, and reliability.
Innovation Solution
The implementation of a cart coupling system with elongated gripping elements, robot arms equipped with gripper hands, and an orientation control system using reflector units and light sensors to accurately determine and adjust the AMR's orientation relative to the cart, enabling secure docking and handling in various conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hooking mechanism is used for docking, then the AMR can attach to the cart, but the docking speed decreases and the system becomes less adaptable to improperly parked carts
Solution Approach 1:
The patent replaces the fixed hooking mechanism with a dynamic robotic arm system that can actively adjust its position and orientation. The robotic arm includes multiple joints and actuators that enable real-time adaptation during the docking process, allowing the AMR to compensate for misaligned carts and achieve reliable attachment without requiring perfectly positioned docking points.
Solution Approach 2:
The system changes the operational parameters of the docking mechanism by using controllable robotic arms with adjustable degrees of freedom. Instead of a rigid fixed-position hook, the robotic arm can vary its position coordinates, orientation angles, and gripping force, enabling it to adapt to carts that are not perfectly parked while maintaining docking reliability.
2Measurement precision
If optical sensors are used for position estimation, then the AMR can detect the cart, but the computational resources required increase and the system becomes more complex
Solution Approach 1:
The patent replaces complex optical sensor systems with a simplified mechanical sensing approach. Instead of using computationally intensive cameras and image processing algorithms, the system employs direct mechanical feedback from the robotic arm's position sensors and encoders to determine relative position and orientation, significantly reducing computational requirements while maintaining adequate measurement precision.
Solution Approach 2:
The robotic arm itself acts as an intermediary between the AMR and the cart, providing direct tactile and positional feedback during the docking process. The arm's built-in sensors and actuators serve as the primary sensing mechanism, eliminating the need for separate complex optical sensor systems and their associated computational processing.
3Device complexity
If a fixed hooking mechanism is used, then the structure is simpler, but the adaptability to different cart positions and orientations is reduced
Solution Approach 1:
The patent transforms the static fixed hooking mechanism into a dynamic robotic arm system with multiple degrees of freedom. The robotic arm can actively change its configuration during docking, adapting to carts at various positions and orientations. This dynamic capability provides high adaptability while the modular design keeps the overall system complexity manageable.
Solution Approach 2:
The robotic arm docking system serves multiple functions: it can dock with properly parked carts, improperly parked carts, carts at various orientations, and even maneuver carts into oblique parking positions. This multi-functionality provides universal adaptability across different docking scenarios without requiring multiple specialized mechanisms.
4Device complexity
If the AMR uses basic compensatory controller for reverse movement, then the control is simpler, but the safety risk increases when carts are heavy or move unexpectedly
Solution Approach 1:
The patent implements a feedback-controlled robotic arm system that continuously monitors the cart's position, the arm's configuration, and external forces during reversing operations. Sensors detect unexpected cart movements or collisions, and the control system responds by adjusting the arm's position and gripping force, maintaining safety even with heavy or moving carts. This feedback mechanism provides reliable safety without requiring overly complex control architecture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances the speed, efficiency, and safety of AMR operations by allowing docking with improperly parked carts and navigating through oblique positions, reducing computational power requirements, and improving reliability in diverse lighting conditions.
Implementation Method 1
a reflector unit configured to selectively reflect light from a broadband light emitter at a specific narrowband wavelength
Data Source
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AI summary
The present invention is in the field of autonomous or automated mobile robots configured in particular for transport and logistics applications. In particular, present invention relates to systems for docking of such robots with wheeled carts. Also, the present invention relates to methods for operation of such robots.