System and method for automated truck loading

• US 8,562,277 B2
• Filed: 05/23/2008
• Issued: 10/22/2013
• Est. Priority Date: 05/23/2007
• Status: Active Grant

• Current Assignee: Daifuku Intralogistics America Corporation
• Original Assignee: Wynright Corporation (Daifuku Company Limited)
• Inventors: Criswell, Tim
• Primary Examiner(s): Rodriguez, Saul
• Assistant Examiner(s): MYERS, GLENN F
• Application Number:
  US12/126,463
• Publication Number:
  US 20090110522A1
• Time in Patent Office: 1,978 Days
• Field of Search: 414/334, 414/335, 414/349, 414/351, 414/352, 414/353, 414/679, 414/398, 180/24.01, 180/211, 105/177, 105/185, 305/15, 280/3, 280/270, 280/278, 280/418, 280/422, 280/442, 280/443, 280/472, 280/475, 280/491.1, 280/100, 280/103, 280/124.11, 280/124.116, 280/124.113, 280/124.125, 198/302, 198/306, 198/310, 198/313
• US Class Current: 414/398
• CPC Class Codes: B25J 9/0093 co-operating with conveyor means
• CPC Class Codes: B65G 47/902 provided with drive systems incorporating rotary and rectilinear movements
• CPC Class Codes: B65G 47/905 Control arrangements
• CPC Class Codes: B65G 67/08 using endless conveyors

Abstract

An automatic case loader for loading product in a trailer is disclosed. A mobile base structure provides a support framework for a drive subassembly, conveyance subassembly, an industrial robot, a distance measurement sensor, and a control subassembly. Under the operation of the control subassembly, product advances through a powered transportation path to an industrial robot which places the product within the trailer. The control subassembly coordinates the selective articulated movement of the industrial robot and the activation of the drive subassembly based upon the distance measurement sensor detecting objects within a detection space, dimensions of the trailer provided to the control subassembly, and dimensions of the product provided to the control subassembly.

Claims

1. An automatic case loader for loading product in a trailer, the automatic case loader comprising:

a mobile base having first and second ends and having first and second sides;

a drive subassembly coupled to the mobile base, the drive subassembly including a plurality of wheels for steering and driving the mobile base;

the drive subassembly including a universal wheel assembly between the first and second sides and configured to provide steering and driving of forward, reverse, and transverse directions;

the drive subassembly including a first retractable wheel assembly configured to provide forward and reverse steering and driving and a second retractable wheel assembly configured to provide transverse steering and driving, the second retractable wheel assembly being orthogonally oriented to the first retractable wheel assembly,

whereby in a forward/reverse drive and steering operation, the universal wheel assembly and the first retractable wheel assembly are actuated while the second retractable wheel assembly is withdrawn,

whereby in a traverse drive and steering operation, the universal wheel assembly and the second retractable wheel assembly are actuated while the first retractable wheel assembly is withdrawn;

a conveyance subassembly disposed on the mobile base, the conveyance subassembly including a powered transportation path operable for transporting product from the first end to the second end;

an industrial robot disposed at the second end of the mobile base, the industrial robot providing selective articulated movement of an end effector between the powered transportation path and a reachable space such that the industrial robot is operable to place the product in the reachable space;

a distance measurement sensor disposed at the second end, the distance measurement sensor for determining presence of objects within a detection space, wherein the detection space and the reachable space at least partially overlap; and

a control subassembly mounted to the mobile base, the control subassembly being in communication with the drive subassembly, the industrial robot, and the distance measurement sensor, the control subassembly coordinating the selective articulated movement of the industrial robot and the activation of the drive subassembly based upon the distance measurement sensor detecting objects within the detection space, dimensions of the trailer provided to the control subassembly, and dimensions of the product provided to the control subassembly.

2. The automatic case loader as recited in claim 1, wherein the plurality of wheels further comprises a pair of front drive wheels disposed proximate to the second end, the pair of front drive wheels being powered by respective AC motors with double reduction gearboxes.

3. The automatic case loader as recited in claim 1, wherein the plurality of wheels further comprises a rear drive wheel disposed proximate to the first end, the rear drive wheel being powered by an AC motor with a reduction gearbox and mounted to a vertical axis to provide steering capability.

4. The automatic case loader as recited in claim 1, wherein the conveyance subassembly further comprises a conveyor having a telescoping conveyor interface for coupling the automatic case loader to a telescoping conveyor unit.

5. The automatic case loader as recited in claim 1, wherein the conveyance subassembly further comprises a powered roller conveyor.

6. The automatic case loader as recited in claim 1, wherein the industrial robot comprises seven segments joined by six joints to furnish selective articulated movement having six degrees of freedom.

7. The automatic case loader as recited in claim 1, wherein the end effector comprises a gripper arm adapted for manipulating product with opposing grapplers.

8. The automatic case loader as recited in claim 1, wherein the distance measurement sensor comprises a laser range finding apparatus operating on a time-of-flight measurement principle.

9. The automatic case loader as recited in claim 1, wherein the distance measurement sensor comprises a device selected from the group consisting of laser range finding apparatuses, ultrasonic measurement apparatuses, inclinometers, and combinations thereof.

10. The automatic case loader as recited in claim 1, wherein the dimensions of the trailer are programmed into the control subassembly.

11. The automatic case loader as recited in claim 1, wherein the dimensions of the product are programmed into the control subassembly.

12. The automatic case loader as recited in claim 1, wherein the conveyance subassembly further comprises a curtain for measuring with light the dimensions of the product and forwarding the measured dimensions to the control subassembly.

13. The automatic case loader as recited in claim 1, wherein the universal wheel assembly is centered between the first and second sides.

14. An automatic case loader for loading product in a trailer, the automatic case loader comprising:

a mobile base having first and second ends and having first and second sides;

a drive subassembly coupled to the mobile base, the drive subassembly including a plurality of wheels for steering and driving the mobile base;

the drive subassembly including a universal wheel assembly between the first and second sides and configured to provide steering and driving of forward, reverse, and transverse directions;

the drive subassembly including a first retractable wheel assembly configured to provide forward and reverse steering and driving and a second retractable wheel assembly configured to provide transverse steering and driving, the second retractable wheel assembly being orthogonally oriented to the first retractable wheel assembly,

whereby in a forward/reverse drive and steering operation, the universal wheel assembly and the first retractable wheel assembly are actuated while the second retractable wheel assembly is withdrawn,

whereby in a traverse drive and steering operation, the universal wheel assembly and the second retractable wheel assembly are actuated while the first retractable wheel assembly is withdrawn;

means for conveying product from the first end to the second end of the mobile base;

an industrial robot disposed at the second end of the mobile base, the industrial robot providing selective articulated movement of an end effector through a reachable space such that the industrial robot is operable to manipulate the product within the reachable space;

means for determining presence of objects within a detection space proximate to the second end of the mobile base, the detection space and the reachable space at least partially overlap; and

a control subassembly mounted to the mobile base, the control subassembly being in communication with the drive subassembly, the industrial robot, and the means for determining presence, the control subassembly coordinating the selective articulated movement of the industrial robot and the activation of the drive subassembly based upon the means for determining presence detecting objects within the detection space, dimensions of the trailer provided to the control subassembly, and dimensions of the product provided to the control subassembly.

15. The automatic case loader as recited in claim 14, wherein the dimensions of the trailer are programmed into the control subassembly.

16. The automatic case loader as recited in claim 14, wherein the dimensions of the product are programmed into the control subassembly.

17. The automatic case loader as recited in claim 14, wherein the means for conveying product further comprises a curtain for measuring with light the dimensions of the product and forwarding the measured dimensions to the control subassembly.