Autonomous Robot Force Feedback Detection for Container Jams
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Solution Overview
Problem
Fulfillment centers face inefficiencies in processing orders due to complications in product retrieval, sorting, and packaging, particularly when items are not in the same location or require transfer between facilities, leading to bottlenecks and increased handling times.
Innovation Solution
Implementing foldable containers with automated force feedback detection for autonomous robots that allow both manual and robotic handling, ensuring ergonomic interaction and preventing jams during transport, while optimizing order consolidation and sorting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If autonomous robots transport containers manually, then handling flexibility is improved, but ergonomic risks and handling time increase
Solution Approach 1:
The system enables autonomous robots to self-regulate their interaction with containers through force feedback detection. The robot independently detects when manual interaction is needed and automatically adjusts its behavior, eliminating the need for continuous human monitoring while maintaining ergonomic handling.
Solution Approach 2:
Force feedback sensors provide real-time information about manual interaction forces applied to containers by humans. This feedback loop allows the robot to detect ergonomic risks and adjust its control accordingly, preventing both injury and handling delays.
2Reliability
If autonomous robots maintain continuous control of containers, then transport reliability is improved, but jam occurrence increases during manual interaction
Solution Approach 1:
The system proactively detects force feedback indicating impending manual interaction before a jam can occur. By anticipating the need for human intervention and preparing to release control, the system prevents jams rather than reacting to them after they occur.
Solution Approach 2:
Real-time force feedback detection allows the robot to sense when a human is approaching or touching the container. This continuous monitoring enables the robot to adjust its control in advance, maintaining reliability while preventing harmful jams during manual interaction.
3Ease of operation
If force feedback detection is implemented, then ergonomic safety is improved, but system complexity increases
Solution Approach 1:
The system replaces complex mechanical safety monitoring systems with force feedback sensors that provide ergonomic safety through simpler electronic detection. The sensors measure forces directly, eliminating the need for complex mechanical interlocks or multiple safety systems.
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
Improves throughput and efficiency in fulfillment centers by enabling seamless handling of containers across facilities, reducing processing time, and enhancing ergonomics for human-robot interaction.
Implementation Method 1
a sensor (e.g., a load cell) of the autonomous robot may be configured to detect a change in weight distribution
Data Source
AI summary
Systems and methods are disclosed for automated force feedback detection for autonomous robots transporting containers. In one embodiment, an example mobile robot is configured to transport a container. The mobile robot can include a first sensor, a second sensor, a motor, and a controller. The controller may be configured to determine that the container is loaded, determine, using at least one of the first sensor and the second sensor, that a first change in load distribution along a first axis satisfies a threshold, determine that the first change in load distribution has persisted for a first length of time, and cause the motor to be disabled.