Rover Conveyor Synchronization for Misaligned Truck Loading
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Solution Overview
Problem
Existing robotic truck loading systems face challenges in coordinating the operation of telescopically extending conveyors with robotic loaders to prevent package dropping and equipment damage during loading and unloading, especially in scenarios where the trailer is misaligned or has varying vertical clearance.
Innovation Solution
A robotic truck loading system that includes a rover and extendable conveyor pair, controlled by a computer vision system and sensors, which maintains synchronized and relative positions and orientations to ensure continuous and automated transfer of packages without human intervention, adapting to trailer misalignments and varying conveyor dynamics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the robot advances into the truck to retrieve packages, then the unloading capability is improved, but the risk of package dropping and equipment damage increases if the conveyor is not properly coordinated
Solution Approach 1:
The system uses sensors to detect the robot's position and the conveyor's extension state, feeding this information back to the control system which coordinates their movements to maintain proper alignment and prevent package dropping
Solution Approach 2:
The robot and extendable conveyor are controlled as an integrated system with coordinated movement, where the conveyor extension is synchronized with robot positioning to ensure continuous package transfer without interruption or damage
2Length of moving object
If the extendable conveyor is advanced behind the robot, then the robot can reach further into the truck, but the system complexity increases due to coordination requirements
Solution Approach 1:
The control system serves multiple functions by simultaneously managing robot movement, conveyor extension, and synchronization, reducing the need for separate dedicated control mechanisms for each component
3Productivity
If the robot backs out of the truck to create space for loading, then the loading capability is improved, but the conveyor must also be backed out simultaneously which reduces operational flexibility
Solution Approach 1:
The system dynamically adjusts the coordination between robot and conveyor based on operational mode (loading vs. unloading), allowing flexible adaptation to different task requirements while maintaining proper synchronization to prevent package dropping
4Ease of operation
If the system operates without coordination between robot and conveyor, then the operational simplicity is improved, but package dropping and equipment damage occur
Solution Approach 1:
The system uses sensors and control algorithms to automatically detect and correct misalignment between the robot and conveyor, enabling self-regulation that maintains safe operation without requiring complex manual coordination
Data Source
AI summary
A robotic loading/unloading system is disclosed. In various embodiments, sensor data is received via a communication interface. The sensor data is used to determine a position and orientation of an extendable conveyor relative to a robotic loader comprising one or more robotic arms mounted on a robotically controlled rover. The determined position and orientation of the extendable conveyor relative to the robotic loader are used to control one or both of the extendable conveyor and the robotic loader to place the extendable conveyor and robotic loader to position a distal end of the extendable conveyor within reach of the one or more robotic arms at a location within a work area from which one or more pick or placement locations within the work area are within reach of at least one of the one or more robotic arms.