Fork-Tine Payload Sensing to Prevent AMR Pushing and Dragging
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Solution Overview
Problem
Conventional autonomous mobile robots (AMRs) face challenges in accurately determining whether a payload is being properly engaged or disengaged, especially when payloads are at varying heights, as existing sensors are obstructed by the payload during engagement or disengagement.
Innovation Solution
The implementation of a payload monitoring system on the AMR, which includes at least one carriage sensor positioned to acquire position data of the payload relative to the fork tines, and a computer program to process this data and determine if the payload is being properly engaged or disengaged, preventing pushing or dragging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sensors are used to detect payload position, then the system is simple, but the sensor view is blocked by the payload during engagement and disengagement
Solution Approach 1:
The patent introduces an intermediary sensor system consisting of multiple sensors positioned at different locations (including carriage-mounted sensors and fixed infrastructure sensors) that can detect payload position through or around the payload itself, rather than requiring a direct line-of-sight view that gets blocked during engagement operations
2Measurement precision
If a single paddle switch is used to detect payload engagement, then the device complexity is low, but it cannot determine whether pushing or dragging is occurring
Solution Approach 1:
The patent segments the detection function into multiple independent sensors positioned at different locations (e.g., before the payload, after the payload, and on the carriage), each providing specific measurement data. This segmentation allows the system to detect not only engagement status but also the direction and nature of forces applied during engagement and disengagement operations
Solution Approach 2:
The patent transitions from a single-point detection approach to multi-dimensional detection by positioning sensors in different spatial locations and measuring multiple parameters (position, velocity, acceleration) simultaneously, enabling comprehensive analysis of engagement dynamics
3Adaptability or versatility
If payloads are handled at various heights, then the system versatility is improved, but the risk of payload dropping increases
Solution Approach 1:
The patent implements continuous feedback monitoring through multiple sensors that track payload position, carriage position, and engagement status in real-time. The system provides feedback signals to the control logic, which can detect abnormal conditions (such as unexpected payload movement or loss of engagement) and respond by alerting operators or initiating safety protocols to prevent payload dropping
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 enables continuous estimation of the payload position and provides discrete outputs to ensure proper engagement or disengagement, preventing accidents such as payload dropping or improper handling, even when payloads are at elevated heights.
Implementation Method 1
at least one sensor positioned on the robot to acquire position data indicating a position of a payload relative to fork tines of the robot
Data Source
AI summary
In accordance with one aspect of the inventive concepts, provided is an autonomous mobile robot, comprising: at least one processor in communication with at least one computer memory device; at least one sensor positioned on the robot to acquire data indicating a position of a payload along fork tines of the robot, the data comprising at least one of discrete and continuous measurements; and a payload monitoring system comprising computer program code executable by the at least one processor to monitor one of pushing and dragging of the payload based on the data. A corresponding method is also provided.