ROBOTIC CARTON UNLOADER

• US 20140341694A1
• Filed: 05/16/2014
• Published: 11/20/2014
• Est. Priority Date: 05/17/2013
• Status: Active Grant

• Current Assignee: Intelligrated Headquarters LLC (Honeywell International Inc.)
• Original Assignee: Intelligrated Headquarters LLC (Honeywell International Inc.)
• Inventors: Girtman, Michael, Wicks, Matthew
• Granted Patent: US 9,969,573 B2
• Time in Patent Office: Days
• US Class Current: 414/796.5
• CPC Class Codes: B25J 11/00 Manipulators not otherwise provided for
• CPC Class Codes: B25J 15/10 with three or more finger members B25J15/0009 takes precedence
• CPC Class Codes: B25J 9/0093 co-operating with conveyor means
• CPC Class Codes: B65G 59/02 De-stacking from the top of the stack
• CPC Class Codes: B65G 67/24 Unloading land vehicles

Abstract

A robotic carton unloader for automatic unloading of cartons from a carton pile stacked within a trailer. In various embodiments, a robotic carton unloader may comprise a conveyor system, a manipulator movably attached to an end of a robotic positioner and configured to dislodge one or more cartons from a carton pile; and a frame comprising a bumper configured to be pressed against the carton pile below one or more cartons being dislodged from the carton pile by the manipulator to stabilize the carton pile below the one or more cartons being dislodged; and a shelf configured to catch the one or more cartons dislodged from the carton pile and guide the one or more cartons dislodged from the carton pile onto the conveyor system.

Claims

1. A robotic carton unloader for unloading a carton pile, comprising:

a conveyor system;

a manipulator movably attached to an end of a robotic positioner and configured to dislodge one or more cartons from the carton pile; and

a frame, comprising;

a bumper configured to be pressed against the carton pile below the one or more cartons being dislodged from the carton pile by the manipulator to stabilize the carton pile below the one or more cartons being dislodged; and

a shelf configured to catch the one or more cartons dislodged from the carton pile and guide the one or more cartons dislodged from the carton pile onto the conveyor system.

2. The robotic carton unloader of claim 1, wherein the one or more cartons comprises a plurality of cartons.

3. The robotic carton unloader of claim 2, further comprising a frame lift connected to the frame and configured to raise and lower the frame.

4. The robotic carton unloader of claim 3, further comprising a control and visualization system connected to the conveyor system, the manipulator, the robotic positioner, and the frame lift, wherein the control and visualization system is configured to automatically control the conveyor system, the manipulator, the robotic positioner, and the frame lift to unload the carton pile.

5. The robotic carton unloader of claim 1, wherein the bumper comprises a cover over a rigid core.

6. The robotic carton unloader of claim 4, wherein the cover is an elastomer.

7. The robotic carton unloader of claim 1, wherein the bumper comprises a roller rotatable over a rigid core.

8. The robotic carton unloader of claim 1, wherein the shelf is curved.

9. The robotic carton unloader of claim 1, wherein the shelf is configured to decelerate the one or more cartons dislodged from the carton pile.

10. The robotic carton unloader of claim 1, wherein the manipulator includes at least one actuatable element configured to draw the one or more cartons toward the shelf to dislodge the one or more cartons from the carton pile when actuated.

11. The robotic carton unloader of claim 10, wherein the at least one actuatable element is two or more actuatable elements.

12. The robotic carton unloader of claim 10, wherein the actuatable element is a claw.

13. The robotic carton unloader of claim 10, further comprising a control and visualization system connected to the conveyor system, the manipulator, and the robotic positioner, wherein the control and visualization system is configured to automatically control the conveyor system, the manipulator, and the robotic positioner to unload the carton pile.

14. The robotic carton unloader of claim 13, further comprising a carton sensor connected to the control and visualization system and configured to detect a distance from the bumper to the carton pile.

15. The robotic carton unloader of claim 13, further comprising a carton sensor connected to the control and visualization system and configured to detect contact of the bumper with the carton pile.

16. The robotic carton unloader of claim 1, wherein the carton pile is a carton pile stacked within a trailer.

17. The robotic carton unloader of claim 16, further comprising:

a mobile body; and

a drive system attached to the mobile body, the drive system including a plurality of wheels for driving and steering the mobile body,

wherein the conveyor system, the manipulator, the robotic positioner, and the frame are coupled to the mobile body.