Proportional position-sensing system for an automatic guided vehicle

• US 5,187,664 A
• Filed: 11/27/1990
• Issued: 02/16/1993
• Est. Priority Date: 11/27/1990
• Status: Expired due to Fees

• Current Assignee: HK Systems Incorporated (KION GROUP AG)
• Original Assignee: Eaton-Kenway Incorporated
• Inventors: Whatcott, Gary L., Yardley, James V., Schutten, Herman P., Petersen, John A. M.
• Primary Examiner(s): Black, Thomas G.
• Application Number:
  US07/618,793
• Time in Patent Office: 812 Days
• Field of Search: 364/424.02, 364/424.01, 180/167-169, 318/568.12, 318/587
• US Class Current: 701/23
• CPC Class Codes: G05D 1/0261 using magnetic plots
• CPC Class Codes: G05D 1/0265 using buried wires
• CPC Class Codes: G05D 1/027 comprising intertial navigation means, e.g. azimuth detector inertial navigation G01C21/16; inertial navigation combined with non-inertial navigation instruments G01C21/165
• CPC Class Codes: G05D 1/0272 comprising means for registering the travel distance, e.g. revolutions of wheels measuring distance traversed on the ground by vehicles, e.g. using odometers G01C22/00
• CPC Class Codes: G05D 1/0274 using mapping information stored in a memory device navigation using map-matching G01C21/30

Abstract

Apparatus for detecting and controlling the position of an automatic guided vehicle to enable precise positioning of the vehicle at a predetermined place such as a load pickup/delivery terminal. In one embodiment a mat having a passive short-circuited loop of wire embedded in it is positioned on the floor at the terminal. On the vehicle an oscillator and a transmitting antenna provide a primary magnetic field that excited the loop in the mat whenever the vehicle is in the terminal, inducing current in the loop. The current in the loop produces a secondary magnetic field having a predetermined spatial pattern. Receiving antennas on the vehicle detect the secondary magnetic field. Prior knowledge of the spatial pattern enables onboard electronic apparatus to ascertain the position of the vehicle relative to the mat. Both transverse and longitudinal position can be detected and controlled. The same on-board apparatus enables the vehicle to follow an energized guidewire in the floor between terminals. The vehicle can also navigate by dead reckoning between terminals.

Claims

1. Position-sensing apparatus for an automatic guided vehicle that is controlled by command signals and position feedback signals comprising:

electrical conductor means at the floor for providing a time-varying magnetic field that extends up to the vehicle;

magnetic sensing means on the vehicle having first and second coils for sensing said magnetic field to produce first and second electrical output signals respectively from said coils;

said coils being spaced apart in the direction in which the position of the vehicle is to be measured;

said coils having axes that are horizontal and disposed in the direction in which the position of the vehicle is to be measured;

signal processing means connected for processing said first and second output signals and for outputting the resulting processed signals to be available as position feedback signals;

said apparatus further comprises means for processing signals emanating from two differing types of electrical conductor means at the floor, namely passive loop conductor means and active guide-wire conductor means;

wherein said signal-processing means comprise means for connecting said first output signal to at least two separate channels for processing, and further comprise means for connecting said second output signal to at least two separate channels for processing;

said apparatus further comprises means for selectively being responsive to signals from said passive loop conductor means and from said active guide-wire conductor means, including means for processing said signals from said passive loop conductor means, including (a) one of said two separate channels for processing said first output signal and (b) one of said two separate channels for processing said second output signal;

said means for selectively being responsive further comprising means for processing said signals from said active guide-wire conductor means, including (c) the other one of said two separate channels for processing said first output signal and (d) the other one of said two separate channels for processing said second output signal.

2. Apparatus as in claim 1 and wherein said signal processing means comprises conditioning means connected for processing said first and second coil output signals, including means for amplifying, attenuating, bandpass filtering, lead-lag compensating them.

3. Apparatus as in claim 2 and wherein said conditioning means comprises separate third conditioning means for said first signal, and fourth conditioning means for said second signal, said third and fourth conditioning means having separate outputs;

and said apparatus further comprises means for combining said outputs of said third and fourth conditioning means.

4. Apparatus as in claim 3 and wherein said means for combining said outputs of said third and fourth conditioning means also comprises means for combining said command signals with said outputs.

5. Position-sensing apparatus for an automatic guided vehicle that is controlled by command signals and position feedback signals comprising:

electrical conductor means at the floor for providing a time-varying magnetic field that extends up to the vehicle;

magnetic sensing means on the vehicle having first and second coils for sensing said magnetic field to produce first and second electrical output signals respectively from said coils;

said coils being spaced apart in the direction in which the position of the vehicle is to be measured;

said coils having axes that are horizontal and disposed in the direction in which the position of the vehicle is to be measured;

signal processing means connected for processing said first and second output signals and for outputting the resulting processed signals to be available as position feedback signals;

means for connecting said resulting processed signals to serve as feedback signals by closing a position feedback loop including;

means for combining said resulting processed signals with command signals for control of the vehicle;

a main guidance system for generally navigating the vehicle when it is not at a terminal;

a general vehicle guidance system for guiding the vehicle when the vehicle is not at a terminal;

said main guidance system comprising navigation means for recognizing when the vehicle is at a terminal and for providing a change command thereupon for the vehicle to be controlled by said position-sensing apparatus in response to said command signals and said position feedback signals;

switching means on the vehicle receiving said change command, for enabling control of the vehicle by position-sensing apparatus in response to said command signals and said position feedback signals instead of by said general vehicle guidance system while the vehicle is at a terminal.

6. Apparatus as in claim 5 and further comprising means for transferring control of the vehicle when it leaves a terminal, from said position-sensing apparatus to said general vehicle guidance system, wherein:

said main guidance system further comprises navigation and guidance means for recognizing when the vehicle is leaving a terminal and for providing a resumption command thereupon for the vehicle to be controlled by said general vehicle guidance system;

switching means on the vehicle receiving said resumption command, for enabling control of the vehicle by said general vehicle guidance system instead of by the position-sensing apparatus when the vehicle leaves a terminal.

7. Apparatus as in claim 5 and wherein:

said magnetic sensing means comprises a magnetic antenna having a unitary core on which both of said two spaced-apart coils are disposed, and

said coils are connected at a common ground and oriented so that said first and second output signals are additive when the coils sense said magnetic field.

8. Apparatus as in claim 7 and wherein said unitary core comprises a ferrite rod core.

9. Guidance apparatus for use with a vehicle that must be capable of being guided between terminals in a hybrid installation both (a) by self contained navigation and guidance and (b) by following a conductively energized guide wire at the floor, comprising:

transmitting means for inductively exciting a conductor at the floor at a terminal for terminal positioning of the vehicle;

receiving apparatus on the vehicle comprising means used in common for both (1) receiving position information from said inductively excited conductor at the floor at a terminal, and (2) receiving position information from said conductively energized guide wire at the floor between terminals;

whereby in said hybrid installation said vehicle is able to operate between terminals (a) by self contained navigation and guidance and also (b) by following said conductively energized guide wire, and is able also (c) to follow an inductively excited conductor and utilize said receiving means in common for receiving position information at a terminal.

10. Guidance apparatus as in claim 9 and further comprising:

means for storing data serving as a route map of route segments including data as to what route segments have guide wires;

means for tracking the vehicle'"'"'s position on said map.

11. Transverse-position-sensing apparatus for an automatic guided vehicle that is controlled by command signals and position feedback signals, said vehicle having a longitudinal axis of travel, comprising:

electrical conductor means at the floor for providing a time-varying magnetic field that extends up to the vehicle;

magnetic sensing means on the vehicle having first and second coils spaced apart for sensing said magnetic field to produce first and second electrical output signals respectively from said coils;

said coils being spaced apart in a direction in which the position of the vehicle is to be measured, namely a direction transverse to the longitudinal axis of the vehicle;

said coils having axes that are horizontal and in a transverse direction, for sensing said magnetic field when said longitudinal axis is in a direction having a component parallel to said electrical conductor means;

signal processing means connected for processing said first and second coil output signals and for outputting the resulting processed signals to be available as transverse-position feedback signals;

second receiving means on said vehicle spaced longitudinally from said first receiving means and responsive to said time-varying magnetic field that extends up to the vehicle, for providing a second signal;

wherein said second receiving means comprises means for providing information as to the position of the vehicle'"'"'s second receiving means along a direction line crossing said electrical conductor means;

means for subtracting said first and second signals and for ascertaining therefrom the heading of said vehicle relative to the direction of said electrical conductor means.

12. Apparatus as in claim 11 and further comprising:

means for providing command information to said vehicle determinative of the desired position and heading of the vehicle relative to said electrical conductor means;

means for controlling the movement of said vehicle to position the vehicle in accordance with said information as to desired position and heading and information as to the vehicle'"'"'s present position and heading obtained from said first and second receiving means.

13. Apparatus for use with an automatic guided vehicle that has a longitudinal axis and that moves about with respect to a reference frame, comprising:

transmitting means on the vehicle for providing a time-varying primary magnetic field;

passive loop means on said reference frame, receiving said primary magnetic field to induce a current in said passive loop means, for producing a secondary magnetic field having a predetermined spatial pattern relative to said reference frame, said loop means having a longitudinal axis;

first receiving means on the vehicle receiving at least said secondary magnetic field for providing a first signal responsive to said secondary magnetic field;

signal processing means receiving said first signal for processing it to provide a processed signal having information as to said vehicle'"'"'s position relative to a desired position.

14. Apparatus as in claim 13 and wherein said passive loop means on said reference frame is manually portable and placeable without change to a supporting floor to provide a temporary path where there is no other reference frame magnetic field means.

15. Apparatus as in claim 13 and wherein said passive loop means comprises an electrical conductor having two ends connected together and having at least one turn.

16. Apparatus as in claim 13 and wherein said passive loop means comprises a skewed-figure-8 shape of conductive loop having segments disposed as follows:

a central conductive segment that extends generally longitudinally;

a crossing segment that crosses said center segment;

said center segment having a portion longitudinally forward of said crossing segment and a portion longitudinally rearward of said crossing segment;

said crossing segment having a portion on a first side of said center segment and a portion on a second side of said center segment;

a forward loop configuration located forward of said crossing segment and on a first side of said center segment, wherein said forward portion of said center segment and said portion of said crossing segment on said first side of said center segment are component segments of said forward loop configuration;

a rearward loop configuration located rearward of said crossing segment and on a second side of said center segment, wherein said rearward portion of said center segment and said portion of said crossing segment on said second side of said center segment are component segments of said rearward loop configuration;

said forward and rearward loop configurations being in series electrically.

17. Apparatus as in claim 13 and wherein:

said passive loop means comprises both longitudinal segments and segments transverse to the longitudinal segments and said vehicle has a longitudinal axis of travel;

said first receiving means on the vehicle comprises means for receiving signals from both longitudinal and transverse segments of said passive loop means; and

said signal processing means comprises means for receiving signals from said first receiving means and for providing information as to the position of the vehicle in directions both along said longitudinal axis and transverse thereto.

18. Apparatus as in claim 13 and further comprising means for combining said processed signal as feedback with said command signals for control of the vehicle.

19. Apparatus as in claim 13 and further comprising:

means for providing command information to said vehicle determinative of the desired position of the vehicle relative to said reference frame;

means for controlling the movement of said vehicle in response to said information as to desired position and said information as to the vehicle'"'"'s present position obtained from said processed signal, to achieve said desired position.

20. Apparatus as in claim 13 where in said desired position comprises an offset lateral to the longitudinal axis of said loop.

21. Apparatus as in claim 13 and wherein;

said transmitting means on the vehicle for providing a primary magnetic field comprises magnetic coil means;

said passive loop means for receiving said primary magnetic field and providing a secondary magnetic field comprises two series-connected loops of electrical current conductor disposed side-by-side transversely to said longitudinal axis.

22. Apparatus as in claim 13 and wherein said transmitting means on the vehicle comprises:

oscillator means for providing an alternating electrical current;

electromagnet means receiving said alternating electrical current, for providing, in proximity to said electromagnet means, said time-varying primary magnetic field.

23. Apparatus as in claim 13 and wherein:

said vehicle has a general direction of forward and backward travel and a longitudinal axis in that general direction of travel, and has a lateral direction transverse to that direction of travel;

said transmitting means comprises two magnetic core means, each encircled by at least one current-conductive coil for producing portions of said primary magnetic field;

said two core means being spaced apart transversely on said vehicle;

said loop means comprises two side-by-side loops, each having an outwardly disposed conductor segment, wherein said two outwardly disposed conductor segments are spaced apart transversely by such an amount as to enable simultaneous coupling of each of said loops with at least one of said transmitting core means.

24. Apparatus as in claim 13 and further comprising:

means controlling the movement of said vehicle for positioning the vehicle in response to said processed signal having information as to said vehicle'"'"'s position.

25. Apparatus as in claim 13 and wherein said first receiving means on the vehicle comprises:

means that receives both signals due to said primary magnetic field received directly from said transmitting means, and signals received via said passive loop means; and

,

means for substantially disregarding signals due to said primary magnetic field and for utilizing said signals due to said secondary magnetic field.

26. Apparatus as in claim 13 and wherein:

said first receiving means on the vehicle receiving said secondary magnetic field is so located as simultaneously to receive also said primary magnetic field, and to provide a total electrical signal accordingly, having components of signal in response to both said primary and secondary magnetic fields;

said first receiving means further comprises means for rectifying said total signal;

said first receiving means further comprises means for subtracting out a DC bias approximately corresponding to said component of signal produced in response to said primary magnetic field.

27. Apparatus as in claim 13 and wherein:

said first receiving means on the vehicle receiving said secondary magnetic field is so located as simultaneously to receive also said primary magnetic field, and to provide a total electrical signal accordingly, having AC components of signal in response to both said primary and secondary magnetic fields;

said first receiving means comprising AC means for biasing out said component of signal produced in response to said primary magnetic field, said AC means for biasing out comprising;

phase-locked loop means for locking onto said total electrical signal and providing an AC output;

initialization means for setting the level of AC output of said phase-locked loop means to equal said primary magnetic field component of AC signal when the vehicle is away from said passive loop means;

means for maintaining constant said set level of output of said phase-locked loop means thereafter;

means for subtracting said set level from the total signal subsequently received by said first receiving means.

28. Apparatus as in claim 27 and wherein said phase-locked loop means comprises:

means for sensing the output level of said AC output of said phase-locked loop and for providing a DC gain-control signal accordingly;

means responsive to said DC gain-control signal to control the amplitude of said AC output of said phase-locked loop to be substantially constant at said level set during initialization.

29. Apparatus as in claim 13 and wherein said first receiving means receives an AC component of magnetic field directly from said transmitting means and an AC component of magnetic field from said passive loop, and said receiving means comprises:

two magnetic receiving coils; and

only one phase-locked loop, tracking the phase of only one of said two receiving coils; and

wherein the AC output of said phase-locked loop is subtracted from the signals of both of said coils for biasing out the portion of the magnetic field that is received directly from the transmitting means.

30. Apparatus as in claim 13 and wherein said transmitting means comprises magnetic core means encircled by at least one current-conductive coil for producing a magnetic field when said coil is energized by current.

31. A method for use in a guided vehicle for providing signals signifying the position of the vehicle relative to a stationary reference frame on the floor, comprising the steps of:

establishing a time-varying primary magnetic field that extends from the vehicle to the floor;

inducing a circulating electrical current in a conductive loop provided on the floor, by operation of said time-varying primary magnetic field;

said circulating electrical current producing a time-varying secondary magnetic field that extends from at least one segment of the loop to the vehicle, said secondary magnetic field having a field strength pattern whose shape varies in accordance with distance and direction from said segment;

inducing a second electrical current in at least one magnetic receiving antenna on the vehicle by operation of said secondary magnetic field, said second electrical current being dependent upon the secondary magnetic field strength at said magnetic receiving antenna;

processing said second electrical current to provide information as to the distance of said receiving antenna from said segment of said loop.

32. A method for initializing apparatus that is used for determining the position of an automatic guided vehicle that determines its position by measuring a secondary magnetic field component produced by an induced passive-loop current located off the vehicle, in the presence of a primary magnetic field component produced by an on-board transmitter, comprising:

measuring the total received magnetic field under conditions in which the vehicle is free of effects of magnetic fields originating from passive loops located off the vehicle;

providing a bias signal to be subtracted from the total received signal;

setting the bias signal to bias out the received primary magnetic field signal under said effect-free conditions;

maintaining substantially the same bias signal setting while magnetic field measurements are made under conditions having secondary-magnetic-field effects of a passive loop;

whereby the primary magnetic field signal remains biased out during measurements and the remaining signal represents only the induced secondary magnetic field component, which is thereby separately measurable.

33. A position-sensing apparatus for hybrid vehicles that are operable in areas of a reference frame having different types of guidance equipment on the floor, i.e., (a) passive loop type and/or (b) active guide-wire type, comprising:

command means for providing port and starboard command signals for directing the vehicle;

transmitting means on the vehicle for providing a time-varying primary magnetic field;

passive loop means on said reference frame, receiving said primary magnetic field to induce a current in said loop means, for producing a secondary magnetic field having a predetermined spatial patter relative to said reference frame;

said loop means having a longitudinal axis;

magnetic sensing means on the vehicle, having first and second coils for (a) receiving at least said secondary magnetic field for providing first and second signals respectively from said coils in response to said secondary magnetic field, said first and second coils functioning also for (b) receiving a magnetic field produced by an active guide wire at the floor that carries electrical current of a predetermined guide-wire frequency and for providing corresponding third and fourth electrical signals from said first and second coils respectively;

said first and second coils being spaced apart in the direction in which the position of the vehicle is to be measured;

said coils having axes that are horizontal and oriented in the direction in which the position of the vehicle is to be measured;

loop-signal-processing means connected for processing said first and second electrical signals and for outputting the resulting processed loop signals so as to be available as position feedback signals;

guide-wire-signal-processing means connected for processing said third and fourth electrical signals and for outputting the resulting processed guide-wire signals so as to be available as position feedback signals;

switchable circuit means for selectively enabling control of the system by guidance equipment on the floor of either (a) the passive loop type or (b) the active guidewire type; and

;

means for combining said first and second, and/or third and fourth feedback signals with said port and starboard command signals for controlling the vehicle.

34. Position-sensing apparatus as in claim 33 and wherein said means for combining comprises means for combining on an amplitude-difference basis so as to assign control to be of the passive loop type or the active guide-wire type, comprising:

switching means for stopping said first and second signal by turning off said transmitting means when control is assigned to be of said active-guide-wire type;

switchable attenuator means for switchably attenuating said third and fourth signal when control is assigned to be of said passive loop type.

35. Position-sensing apparatus as in claim 33 and wherein said means for differentiating between lateral-position-sensing signals of the passive loop control type and lateral-position-sensing signals of the active-guide-wire control type on an amplitude-difference basis comprises:

attenuator means for attenuating said third and fourth signals;

switching means for enabling and disabling said attenuating means;

control means for actuating said switching means to a condition of enabling said attenuating means to attenuate the active-guide-wire type of signals when the magnetic transmitting means is transmitting magnetic fields to said loop means.

36. Position-sensing apparatus as in claim 33 and further comprising:

switching means for turning said transmitting signal on and off;

computer control means for actuating said switching means to on and off states;

whereby said transmitter signal is on when said vehicle is relying on said passive loops for control and is off at other times.

37. Apparatus for sensing the position of a guided vehicle comprising:

current-conductive means at the floor for providing a magnetic field that extends to the vehicle, said magnetic field being in a field pattern that varies in accordance with distance form the current-conductive means;

magnetic field sensing means on the vehicle for sensing magnetic fields provided by said current-conductive means at the floor and providing signals accordingly;

signal-processing circuit means on the vehicle receiving said signals;

a first subchannel circuit means connected to receive signals from said signal-processing circuit means, for separating passive-loop lateral-positioning signals, when such signals are present, from other signals by attenuation of one of the signals;

second subchannel circuit means connected to receive signals from said signal-processing circuit means, for processing guide-wire-lateral-positioning signals when such signals are present, and for attenuating signals when the passive-lateral-positioning signals are present, separating said guide-wire and passive loop signals from each other on a basis of amplitude difference;

both of said subchannel circuit means having their outputs connected for communicating the position of the vehicle to other apparatus.

38. Apparatus for use with an automatic guided vehicle that moves about with respect to a reference frame comprising:

transmitting means on the vehicle for providing a time-varying primary magnetic field;

passive loop means on said reference frame, receiving said primary magnetic field to induce a current in said passive loop means for producing a secondary magnetic field having a predetermined spatial pattern relative to said reference frame;

receiving means on the vehicle receiving said primary and secondary magnetic fields for providing a total electrical signal in response thereto, having components of signal in response to both said primary and secondary magnetic fields;

signal processing means receiving said signal for processing it to provide a processed signal having information as to said vehicle'"'"'s position;

said receiving means further comprising automatic bias-setting means for compensating for said component of signal produced in response to said primary magnetic field, said automatic bias-setting means comprising;

subtraction means receiving said total electrical signal for subtracting out a bias signal and outputting a compensated signal;

means for commanding said automatic bias-setting means to set the bias while the vehicle is positioned remotely from said secondary magnetic field, whereby to sense only said component of signal response to said primary magnetic field;

an event counter capable of counting up or down depending upon a direction signal, and of providing a digital count;

means for producing countable event signals at time intervals that are controllable by a frequency-control signal, said countable event signals being connected, for counting, with said event counter;

means receiving said compensated signal for providing a frequency-control signal dependent upon the magnitude of said compensated signal, said frequency-control signal resulting in zero count frequency when said compensated signal is zero;

means for sensing the polarity of said compensated signal and providing said direction signal to said event counter to count up for one polarity and down for the other polarity of said compensated signal;

digital-to-analog conversion means for converting said digital count to an analog bias signal having such polarity as to drive said compensated signal to zero.

39. Means for providing a temporary traffic lane for an automatic guided vehicle that is controlled by command signals and position feedback signals from a guide wire at the floor, said providing means comprising:

at least one passive guide wire containing mat which when laid on the floor defines at least a portion of said lane;

at least one active guide wire loop;

means on the vehicle for inducing a sensible electrical signal in a passive guide wire when the vehicle is over the passive guide wire;

means for being selectively response to signals from said passive guide wire;

means for being selectively responsive to signals from said active guide wire;

means for causing the vehicle to transfer from a passive guide wire to an active guide wire and from an active guide wire to a passive guide wire.

40. Means according to claim 39 wherein said mat is portable and is manually positionable.