Robotic Gladhand Connection Using 3D Occlusion Mapping
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Solution Overview
Problem
The manual connection and disconnection of electrical and pneumatic lines between truck tractors and trailers in the trucking industry is labor-intensive, and existing automated solutions fail to account for the variability in trailer geometry, leading to inefficiencies and potential collisions.
Innovation Solution
A system and method using a robotic manipulator on an autonomous vehicle (AV) truck that generates a 3D model of the trailer's free space through Obstacle Detection and Obstacle Avoidance (OD/OA), employing 3D sensors to create an occlusion map and guide the robotic arm to connect to the trailer's gladhand, with adaptive motion planning and calibration techniques to avoid collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual connection methods are used, then flexibility and adaptability to various trailer geometries are maintained, but labor intensity and time consumption increase significantly
Solution Approach 1:
The system enables automated self-service connection through robotic manipulators that autonomously perform the connection tasks. The robot navigates to the trailer, identifies gladhand locations using vision systems, and executes connections without human intervention, thereby reducing labor intensity while maintaining connection time within acceptable ranges
Solution Approach 2:
The patent replaces manual mechanical operations with an automated robotic system equipped with sensors, vision systems, and controlled manipulators. This substitution automates the connection process, reducing the need for manual labor while maintaining operational efficiency through programmed sequences and real-time adjustments
2Extent of automation
If existing automated solutions are used, then labor intensity is reduced, but reliability decreases due to failures to account for trailer geometry variability
Solution Approach 1:
The system employs dynamic adaptation to trailer geometry variability through real-time sensor data acquisition and vision-based identification of gladhand locations. The robotic manipulator adjusts its motion paths and connection parameters dynamically based on detected geometric variations, ensuring reliable connections across different trailer configurations
Solution Approach 2:
The patent utilizes parameter changes in the form of adaptive motion planning and calibration techniques. The system modifies connection parameters such as approach angles, speeds, and positions based on real-time geometric data, thereby maintaining high reliability despite variations in trailer geometry
3Productivity
If automated robotic manipulation is implemented, then productivity increases, but device complexity and risk of collisions increase
Solution Approach 1:
The system segments the complex automated connection task into distinct phases: navigation to the trailer, vision-based identification of gladhands, path planning, and execution of connection. This segmentation manages device complexity by breaking down the overall system into modular, independently controllable components while maintaining high productivity through coordinated operation
Data Source
AI summary
This invention provides a system and method for allowing motion of a robotic manipulator on an AV truck in connecting to a native gladhand on a trailer front that represents and constructs a model of this free space on-the-fly, in the manner of an Obstacle Detection and Obstacle Avoidance (OD/OA) system and process. A robotic arm on an AV truck is adapted to connect a pneumatic line to a gladhand on the trailer front. A first 3D sensor generates a pointcloud, and is located at an elevated position on the truck to image the trailer front. A second 3D sensor also generates pointclouds at during robot motion, located adjacent to an end of the robotic arm. An occlusion mapping process generates an occlusion map of the trailer front, and a map update process updates the occlusion map to add and remove voxels therefrom to allow safe guidance of the robot.