Modular cross-docking system

• US 9,457,970 B1
• Filed: 07/06/2015
• Issued: 10/04/2016
• Est. Priority Date: 03/30/2015
• Status: Active Grant

• Current Assignee: Boston Dynamics, Inc. (SoftBank Group Corp.)
• Original Assignee: Google Inc. (Alphabet Inc.)
• Inventors: Nusser, Stefan, Zevenbergen, John, Straszheim, Troy
• Primary Examiner(s): Randazzo, Thomas
• Application Number:
  US14/792,534
• Time in Patent Office: 456 Days
• US Class Current: 1/1
• CPC Class Codes: B25J 5/007 mounted on wheels
• CPC Class Codes: B25J 9/0093 co-operating with conveyor means
• CPC Class Codes: B60P 1/38 forming the main load-transporting element or part thereof B60P1/365 takes precedence
• CPC Class Codes: B60P 1/48 using pivoted arms raisable above load-transporting element for refuse collecting vehicles B65F3/041; load engaging elements B66C1/00 - B66C3/00
• CPC Class Codes: B60P 1/6409 details, accessories, auxiliary devices
• CPC Class Codes: B62D 63/08 Component parts or accessories
• CPC Class Codes: B65G 15/22 comprising a series of co-operating units
• CPC Class Codes: B65G 2203/041 Camera
• CPC Class Codes: B65G 47/52 Devices for transferring articles or materials between conveyors i.e. discharging or feeding devices loading or unloading by means not incorporated in, or not operatively associated with, conveyors B65G65/00; transfer of workpieces during metal rolling B21B41/00
• CPC Class Codes: B65G 47/905 Control arrangements
• CPC Class Codes: B65G 61/00 Use of pick-up or transfer devices or of manipulators for stacking or de-stacking articles not otherwise provided for
• CPC Class Codes: B65G 67/02 Loading or unloading land vehicles

Abstract

An example system includes a plurality of trailers arranged such that a given trailer of the plurality is connected to at least one other trailer of the plurality, where the plurality of trailers includes a plurality of respective conveyance systems to transport objects between connected trailers. The system further includes a control system configured to cause a conveyance system of a first trailer of the plurality to move at least one object to the first trailer from a first external trailer, cause respective conveyance systems of one or more trailers of the plurality to transport the at least one object from the first trailer of the plurality to a second trailer of the plurality that is connected to a second external trailer, and cause a conveyance system of the second trailer of the plurality to move the at least one object to the second external trailer.

Claims

1. A system, comprising:

a plurality of trailers arranged such that a given trailer of the plurality is connected to at least one other trailer of the plurality, wherein the plurality of trailers comprises a plurality of respective conveyance systems to transport objects between connected trailers; and

a control system configured to;

cause a conveyance system of a first trailer of the plurality to move at least one object to the first trailer from a first external trailer that is connected to the first trailer;

cause respective conveyance systems of one or more trailers of the plurality to transport the at least one object from the first trailer of the plurality to a second trailer of the plurality that is connected to a second external trailer; and

cause a conveyance system of the second trailer of the plurality to move the at least one object to the second external trailer.

2. The system of claim 1, wherein the plurality of trailers comprises a modular cross-docking system, wherein each trailer of the plurality is configured to perform at least one respective dedicated function to effectuate operation of the modular cross-docking system.

3. The system of claim 2, wherein each trailer of the plurality comprises at least one particular respective component to perform the at least one respective dedicated function, wherein the at least one particular respective component comprises at least one of a robotic truck loader, a sorting conveyor, a sorting robot, and a palletizing robot.

4. The system of claim 1, wherein:

the first trailer of the plurality comprises a first robotic manipulator that is configured to move the at least one object from the first external trailer to the first trailer of the plurality; and

the second trailer of the plurality comprises a second robotic manipulator that is configured to move the at least one object from the second trailer of the plurality to the second external trailer.

5. The system of claim 1, wherein a trailer of the plurality comprises an enclosed, rectangular container with at least one openable surface for connection to another trailer of the plurality.

6. The system of claim 1, wherein the one or more trailers of the plurality comprise a sorting trailer, wherein the sorting trailer comprises one or more conveyors configured to transport a given object to a particular one of at least two trailers of the plurality that are connected to the sorting trailer.

7. The system of claim 6, wherein the sorting trailer comprises at least a first side door for connection to a first trailer of the plurality and a second side door for connection to a second trailer of the plurality.

8. The system of claim 6, wherein the one or more conveyors in the sorting trailer comprise at least:

a first conveyor positioned at a first height that is configured to direct one or more objects toward a first end of the sorting trailer; and

a second conveyor positioned at a second height that is configured to simultaneously direct one or more other objects toward a second end of the sorting trailer that is opposite the first end.

9. The system of claim 6, wherein the sorting trailer further comprises a sorting robotic manipulator configured to move the given object to a particular conveyor of the one or more conveyors in order to direct the given object to the particular one of the at least two trailers of the plurality that are connected to the sorting trailer.

10. The system of claim 1, wherein the one or more trailers of the plurality comprise a palletizing trailer, wherein the palletizing trailer comprises a palletizing robotic manipulator configured to form a pallet comprising a plurality of objects including the at least one object to transport to the second external trailer.

11. The system of claim 1, wherein the control system is further configured to:

cause a conveyance system of a third trailer of the plurality to move at least one additional object to the third trailer from a third external trailer that is connected to the third trailer of the plurality;

cause respective conveyance systems of one or more trailers of the plurality to transport the at least one additional object from the third trailer of the plurality to the second trailer of the plurality; and

cause the conveyance system of the second trailer of the plurality to move the at least one additional object to the second external trailer.

12. The system of claim 1, further comprising a control trailer that is unconnected to the plurality of trailers, wherein the control trailer comprises a control system and a network communication system, wherein the control system is configured to use the network communication system to communicate instructions to respective local control systems of the plurality of trailers to enable synchronized autonomous operation of at least one mechanically operable device in each of the plurality of trailers.

13. The system of claim 1, wherein the control system is further configured to provide instructions to move the plurality of trailers in order to position the plurality of trailers within a lot before the first external trailer is connected to the first trailer of the plurality.

14. The system of claim 1, wherein a trailer of the plurality comprises:

at least one front leg positioned at a front end of the trailer, wherein the at least one front leg has an adjustable height to a ground surface in order to align the front end of the trailer with a front-connected trailer; and

at least one back leg positioned at a back end of the trailer, wherein the at least one back leg has an adjustable height to a ground surface in order to align the back end of the trailer with a back-connected trailer.

15. The system of claim 14, wherein:

the at least one front leg comprises a front left leg positioned at a left side of the front end of the trailer and a front right leg positioned at a right side of the front end of the trailer;

the at least one back leg comprises a back left leg positioned at a left side of the back end of the trailer and a back right leg positioned at a right side of the back end of the trailer; and

each of the front left leg, the front right leg, the back left leg, and the back right leg has an independently adjustable respective height to the ground surface in order to align the trailer with the front-connected trailer and the back-connected trailer.

16. A method, comprising:

moving, by a conveyance system of a first trailer of a plurality of connected trailers, at least one object to the first trailer of the plurality from a first external trailer that is connected to the first trailer of the plurality;

transporting, by respective conveyance systems of one or more trailers of the plurality of connected trailers, the at least one object from the first trailer of the plurality to a second trailer of the plurality that is connected to a second external trailer; and

moving, by a conveyance system of the second trailer of the plurality, the at least one object from the second trailer of the plurality to the second external trailer.

17. The method of claim 16, further comprising:

moving the at least one object to the first trailer of the plurality from the first external trailer with a first robotic manipulator fixed within the first trailer of the plurality; and

moving the at least one object from the second trailer of the plurality to the second external trailer with a second robotic manipulator fixed within the second trailer of the plurality.

18. The method of claim 16, wherein the plurality of connected trailers comprises a sorting trailer comprising one or more sorting conveyors, the method further comprising:

transporting, by at least one of the one or more sorting conveyors, a given object of the at least one object to a particular one of at least two trailers of the plurality that are connected to the sorting trailer.

19. A control system, comprising:

at least one processor; and

data storage comprising instructions executable by the at least one processor to the cause the control system to perform functions comprising;

identifying at least one object within a first external trailer for transport to a second external trailer;

causing a conveyance system of a first trailer of a plurality of connected trailers to move the at least one object to the first trailer of the plurality from the first external trailer, wherein the first external trailer is connected to the first trailer of the plurality;

causing respective conveyance systems of one or more trailers of the plurality of connected trailers to transport the at least one object from the first trailer of the plurality to a second trailer of the plurality that is connected to the second external trailer; and

causing a conveyance system of the second trailer of the plurality to move the at least one object from the second trailer of the plurality to the second external trailer.

20. The control system of claim 19, the functions further comprising:

identifying at least one additional object within the first external trailer for transport to a third external trailer;

causing the conveyance system of the first trailer of the plurality to move the at least one additional object to the first trailer of the plurality from the first external trailer;

causing respective conveyance systems of one or more trailers of the plurality of connected trailers to transport the at least one additional object from the first trailer of the plurality to a third trailer of the plurality that is connected to the third external trailer; and

causing a conveyance system of the third trailer of the plurality to move the at least one additional object from the third trailer of the plurality to the third external trailer.

21. The control system of claim 19, the functions further comprising:

causing a plurality of trailers to undergo respective movements within a lot in order to connect the plurality of trailers before the first external trailer is connected to the first trailer of the plurality.

22. The control system of claim 19, the functions further comprising:

identifying one or more additional external trailers expected to arrive at the lot; and

causing at least some of the plurality of connected trailers to undergo respective movements in order to reposition the plurality of connected trailers within the lot to accommodate the one or more additional external trailers.

23. The control system of claim 19, the functions further comprising:

identifying at least one function to be performed on one or more objects to be transported between a particular external trailer and the system of connected trailers; and

causing at least some of the plurality of connected trailers to undergo respective movements in order to position a particular trailer of the plurality to enable connection between the particular trailer of the plurality and the particular external trailer, wherein the particular trailer of the plurality comprises at least one component configured to perform the at least one function.

24. The control system of claim 19, the functions further comprising:

determining a number of incoming external trailers expected to arrive at the lot within a particular time period;

based on the number of incoming external trailers, determining one or more trailers of the plurality to make available for connection to respective external trailers, wherein each of the one or more trailers of the plurality comprises a robotic truck unloader; and

causing at least some of the plurality of connected trailers to undergo respective movements in order to position the one or more trailers of the plurality to allow for connection between the one or more trailers of the plurality and respective external trailers.

25. The control system of claim 19, the functions further comprising:

receiving an indication of a system failure in a particular trailer of the plurality of connected trailers;

redirecting the at least object through the plurality of connected trailers in order to avoid passing through the particular trailer.

26. The control system of claim 19, the functions further comprising:

identifying a particular trailer to be a bottleneck that is causing reduced overall throughput of the plurality of connected trailers;

causing at least some of the plurality of connected trailers to undergo respective movements in order to reduce a number of objects passing through the particular trailer.