Material handling automation system using portable transfer module

• US 5,202,832 A
• Filed: 01/29/1991
• Issued: 04/13/1993
• Est. Priority Date: 01/29/1991
• Status: Expired due to Fees

• Current Assignee: RR Donnelley & Sons Company
• Original Assignee: RR Donnelley & Sons Company
• Inventors: Lisy, Donald J.
• Primary Examiner(s): Lall, Parshotam S.
• Assistant Examiner(s): ZANELLI, MICHAEL J
• Application Number:
  US07/647,146
• Time in Patent Office: 805 Days
• Field of Search: 364/424.01, 364/424.02, 364/444, 364/449, 364/456, 364/460, 364/443, 318/587, 180/167, 180/168, 180/169, 414/351, 414/352, 414/374, 414/279, 356/1
• US Class Current: 701/24
• CPC Class Codes: B65G 2209/06 Use of order trucks
• CPC Class Codes: G05D 1/0236 in combination with a laser lasers per se H01S
• CPC Class Codes: G05D 1/0242 using non-visible light signals, e.g. IR or UV signals
• CPC Class Codes: G05D 1/0246 using a video camera in combination with image processing means
• CPC Class Codes: G05D 1/0255 using acoustic signals, e.g. ultra-sonic singals sonar systems designed for anti-collision purposes G01S15/93
• 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 1/028 using a RF signal

Abstract

A warehouse material handling automation system is disclosed which includes a portable module (22) with which to load and unload material onto and off of an automatic guided vehicle (14). The system operates such that the automatic guided vehicle (14) can calculate its position relative to a destination and follow a route to the destination. In addition, the system operates even when the portable module (22) is displaced or moved from its original position to establish a new destination.

Claims

1. A portable material handling module for transferring materials between an automatic guided vehicle which is not preprogrammed to follow a predetermined route and a truck, said module comprising:

a platform having a top surface approximating the height of a top surface of a corresponding platform on said automatic guided vehicle; and

means for transmitting a signal indicative of an exact position of said module for assisting said automatic guided vehicle in being directed to travel along a route in real time for alignment of said vehicle with said module located at or near any selected destination irrespective of any predetermined module location.

2. The module as in claim 1 wherein said module further comprises an electrically powered conveyor on said top surface of said platform, said automatic guided vehicle also having a conveyor on a top surface or a corresponding platform for transferring materials between said module and said automatic guided vehicle.

3. The module as in claim 1 wherein said module further comprises means for transmitting information on whether said module is carrying material.

4. The module as in claim 3 wherein said means for transmitting information comprises a radio frequency transceiver and antenna.

5. The module as in claim 1 wherein said module further comprises at least one target for identification by a scanning device on said automatic guided vehicle.

6. The module as in claim 1 further comprising means for sensing the proximity of an approaching automatic guided vehicle to facilitate docking.

7. A portable module for transferring materials between an automatic guided vehicle and a truck, said module comprising:

a platform having a top surface approximating the height of a top surface of a corresponding platform on said automatic guided vehicle; and

means for transmitting a signal indicative of an exact position of said module for assisting said automatic guided vehicle in travelling along a route to said module at any selected destination;

said module further comprising a computer for processing information on said exact position of said module at said selected destination and said module still further comprising a radio frequency receiver/transmitter for transmitting said signal indicative of said exact position of said module at said selected destination to and receiving a signal from a central system control computer.

8. A portable module for transferring material between an automatic guided vehicle and a truck, said module comprising:

a platform having a top surface approximating the height of a top surface of a corresponding platform on said automatic guided vehicle; and

means for transmitting a signal indicative of an exact position of said module for assisting said automatic guided vehicle in travelling along a route to said module at any selected destination;

said module further comprising a rotating scanning device.

9. A portable module for transferring material between an automatic guided vehicle and a truck, said module comprising:

a platform having a top surface approximating the height of a top surface of a corresponding platform on said automatic guided vehicle; and

means for transmitting a signal indicative of an exact position of said module for assisting said automatic guided vehicle in travelling along a route to said module at any selected destination;

said module further comprising an elongated member extending upwards from said platform of said module, said elongated member having at least one target for identification by a scanning device on said automatic guided vehicle at or near the top thereof, said elongated member also having a rotating scanning device at or near the top thereof, and a radio frequency antenna attached to and extending past the top of said elongated member.

10. A portable module for transferring material between an automatic guided vehicle and a truck, said module comprising:

a platform having a top surface approximating the height of a top surface of a corresponding platform on said automatic guided vehicle; and

means for transmitting a signal indicative of an exact position of said module for assisting said automatic guided vehicle in travelling along a route to said module at any selected destination;

said module further comprising a base having means for accommodating engagement by a fork lift truck for transportation of said module.

11. The module as in claim 10 wherein said engagement accommodating means comprises recesses in said base for receiving protruding forks of said fork lift truck.

12. A portable module for transferring material between an automatic guided vehicle and a truck, said module comprising:

a platform having a top surface approximating the height of a top surface of a corresponding platform on said automatic guided vehicle; and

means for transmitting a signal indicative of an exact position of said module for assisting said automatic guided vehicle in travelling along a route to said module at any selected destination;

said platform having a concave surface on at least two opposite sides of said platform for engagement by a roll grab truck for transportation of said module.

13. A material handling automation system comprising:

at least one automatic guided vehicle for transporting material which is not preprogrammed to follow a predetermined route;

means for determining a position of said vehicle relative to any selected destination;

at least one portable material handling module at or near said selected destination with which said vehicle can align irrespective of any predetermined module location;

means for determining an exact position for said module at or near said selected destination at least at frequent time intervals;

means for determining a route for said vehicle to travel and directing said vehicle to said exact position for said module in real time for alignment of said vehicle with said module at or near said selected destination;

means for controlling said automatic guided vehicle to move on said route; and

means for transferring material between said module and said vehicle when said vehicle is aligned with said module at said exact position.

14. The material handling automation system as in claim 13 further comprising means for transmitting signals between said vehicle and said selected destination at least at frequent time intervals, said signal transmitting means including a scanner on said vehicle and said vehicle position determining means including a computer on said vehicle, said computer triangulating said position of said vehicle responsive to said laser scanning at least one bar code affixed to said module and at least two bar coded targets at fixed points independent of said vehicle and said module.

15. The material handling automation system as in claim 13 wherein said vehicle and said module have cooperative means for sensing alignment at said destination.

16. The material handling automation system as in claim 13 wherein said vehicle further comprises a platform having a powered conveyor on a top surface thereof.

17. The material handling automation system as in claim 16 wherein said module further comprises a platform having a powered conveyor on a top surface thereof, said conveyor of said module corresponding in height and being synchronized with said conveyor on said vehicle.

18. The material handling automation system as in claim 17 wherein said powered conveyors are bi-directional.

19. A material handling automation system comprising:

at least one automatic guided vehicle for transporting material;

means for determining a position of said vehicle relative to any selected destination;

at least one portable module with which said vehicle can align at said selected destination;

means for determining an exact position for said module at said selected destination at least at frequent time intervals;

means for determining a route for said vehicle to travel to said exact position for said module for alignment at said selected destination;

means for controlling said automatic guided vehicle to move on said route; and

means for transferring material between said module and said vehicle when said vehicle is aligned with said module at said selected destination;

said vehicle further comprising a platform having a powered conveyor on a top surface thereof, said module further comprising a platform having a powered conveyor on a top surface thereof, said conveyor on said module corresponding in height and being synchronized with said conveyor on said vehicle;

said module position determining means including a radio frequency transmitter and said module further comprises;

means for sensing proximity of said vehicle to said module;

means for transporting said module from said selected destination to a new destination; and

means for transmitting a signal indicative of position.

20. The material handling automation system as in claim 19 wherein said module further comprises an elongated member extending upwards from said platform of said module, at least one bar code target at or near the top of said elongated member, a rotating laser scanner at or near the top of said elongated member and a radio frequency antenna attached to and extending past the top of said elongated member.

21. A system for automating the transportation of rolls of paper in a printing plant comprising:

at least one automatic guided vehicle which is not preprogrammed to follow a predetermined route, said vehicle having a platform with a top surface for carrying rolls of paper and having means for determining a position of said vehicle relative to any selected destination, said vehicle further having means for transmitting said position of said vehicle by signal at frequent time intervals;

at least one portable material handling module at or near said selected destination with which said vehicle can align irrespective of any predetermined module location, said module having a platform with a top surface at the same height as said top surface of said platform on said vehicle, said top surface of said platform on said module also being aligned for carrying rolls of paper;

an electrically powered conveyor on said top surface of said vehicle and a corresponding electrically powered conveyor on said top surface of said module for transferring material between said module and said vehicle;

means for receiving said signal from said vehicle for determining an exact position of said vehicle;

means for determining said exact position for said module at said selected destination at frequent time intervals;

means for determining a route for said vehicle and directing said vehicle to travel to said exact position for said module in real time for alignment of said vehicle with said module at said selected destination; and

means for controlling said vehicle to move on said route.