Autonomous Dock Loading with AMT Guidance Switching in Trailers

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Solution Overview

Problem

Existing robotic material handling systems for loading and unloading trailers at dock stations are complex, costly, prone to errors, and require human intervention due to trailer creep and weight-related safety issues, leading to inefficiencies and potential dangers.

Innovation Solution

An autonomous dock station system utilizing an automated material lift truck (AMT) with sensors and guidance systems to autonomously load and unload trailers, minimizing human intervention and trailer creep, and optimizing pallet placement within the trailer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If forklift trucks are used to load and unload trailers, then material handling can be performed, but trailer creep occurs and safety risks increase

Engineering Contradiction:

Improvematerial handling capabilityVSAvoidtrailer creep and safety risks

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical forklift system with an automated robotic system that uses sensors, guidance systems, and automated control to perform material handling. This substitution eliminates the manual operation issues causing trailer creep while maintaining material handling capability through automated pallet manipulation mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The automated system performs material handling autonomously without human intervention during the loading/unloading process. The robotic platform navigates independently, detects pallet positions, and executes manipulation tasks automatically, making the system self-sufficient and eliminating safety risks associated with human operators near moving trailers.

Inventive Principle:

Principle #25Self-service

2Extent of automation

If complex robotic systems with multiple sensors and algorithms are used, then automation capability increases, but system complexity and cost increase

Engineering Contradiction:

Improveautonomous operation capabilityVSAvoidsystem complexity and cost

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The patent divides the automated material handling system into distinct functional modules: a robotic platform for navigation, a manipulation system for pallet handling, and a control system with sensors and guidance. This segmentation allows each component to be optimized independently and simplifies the overall system architecture while maintaining high automation capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The robotic platform is designed to perform multiple functions including navigation to the trailer, pallet detection, pallet manipulation, and autonomous return to the loading dock. This multi-functionality reduces the need for separate specialized systems, thereby decreasing overall system complexity and cost while maintaining extensive automation capability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If existing robotic systems operate around other machinery and human operators, then material handling can be performed, but errors increase and human assistance is required

Engineering Contradiction:

Improvematerial handling throughputVSAvoidsystem error rate and need for human assistance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system is designed to operate autonomously in the cargo space without requiring human operators nearby. The robotic platform independently navigates, detects obstacles using sensors, manipulates pallets, and returns to the loading dock automatically. This self-sufficient operation eliminates errors caused by human intervention and enables continuous productivity without safety interruptions.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent introduces an automated control system with sensors and guidance algorithms as an intermediary between the robotic platform and the environment. This intermediary processes sensor data, makes navigation and manipulation decisions, and coordinates system actions, thereby eliminating the need for human operators and reducing error rates while maintaining high productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20250361103A1Systems and methods for automated loading and unloading at a dock station

Publication Date: 2025.11.27 ASSA ABLOY ENTRANCE SYST AB

AI summary

An autonomous dock station system having an automated material lift truck (AMT), a pallet conveyor, and a facility guidance system can automatically load and/or unload a trailer at a dock station. The autonomous dock station system can coordinate these components according to a workflow procedure. In some embodiments, the workflow procedure can begin with the pallet conveyor supplying a loaded pallet to a specified position. The AMT, initially guided by fixed guidance elements of the facility guidance system, can lift the pallet off the conveyor and transport it to a trailer entrance where the AMT switches from the facility guidance system to a trailer guidance system. The AMT can then carry the pallet to an unloading position, move the pallet to one side of the trailer as needed, unload the pallet and return to the pallet conveyor. The workflow procedure can repeat until the trailer is full.