CARGO TRANSPORT SYSTEM
20230105528 · 2023-04-06
Inventors
- Ross Wehner (Bouulder, CO, US)
- Ryan Marsini (Frederick, CO, US)
- Ryan Delgizzi (Arvada, CO, US)
- Mark Gordon (Lafayette, CO, US)
- Jesse Weifenbach (Thornton, CO, US)
- David Regan (Arvada, CO, US)
Cpc classification
B62D55/065
PERFORMING OPERATIONS; TRANSPORTING
B60P1/267
PERFORMING OPERATIONS; TRANSPORTING
B66F9/07577
PERFORMING OPERATIONS; TRANSPORTING
B66F9/0755
PERFORMING OPERATIONS; TRANSPORTING
B66F9/10
PERFORMING OPERATIONS; TRANSPORTING
B66F9/19
PERFORMING OPERATIONS; TRANSPORTING
International classification
B60P1/36
PERFORMING OPERATIONS; TRANSPORTING
B66F9/06
PERFORMING OPERATIONS; TRANSPORTING
B66F9/075
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A cargo transport system is provided that has an ability to move cargo in an autonomous or semi-autonomous manner, using a compact lift vehicle capable of lifting relatively heavy objects. The system includes a cargo loading system, a sensor suite coupled with a controller, dunnage detection, cross-decking capability, cargo stacking capability, autonomous navigation, tip detection and prevention, or any combinations thereof. The system may include a fork assembly coupled with a mast and movable in a vertical direction relative to the mast. Further, the mast may be coupled with a platform or deck and movable in a horizontal direction relative to the platform, to allow the fork assembly to be lowered below a top plane of the platform when the mast is at a forward location relative to the platform. The controller and sensor suite and may provide for autonomous or semi-autonomous control and movement of the cargo transport system.
Claims
1. A cargo transport apparatus, comprising: a vehicle chassis; a mast coupled with the vehicle chassis; and a fork assembly movably coupled with the mast, the mast configured to raise and lower the fork assembly, and the fork assembly including at least a first powered roller assembly mounted on at least a first fork of the fork assembly, wherein the first powered roller assembly moves cargo on the fork assembly away from or toward the mast.
2. The cargo transport apparatus of claim 1, wherein the fork assembly comprises: the first powered roller assembly mounted on the first fork of the fork assembly, and a second powered roller assembly mounted on a second fork of the fork assembly, wherein the first and second powered roller assemblies move cargo on the fork assembly away from or toward the mast.
3. The cargo transport apparatus of claim 2, wherein each of the first powered roller assembly and the second powered roller assembly comprise: a drive motor; and a conveyer chain coupled with the drive motor and a plurality of pads.
4. The cargo transport apparatus of claim 3, wherein the plurality of pads are mounted on an exterior side of the conveyer chain, and wherein the conveyer chain is mounted on the respective fork between a first end of the respective fork adjacent to the mast and a second end of the respective fork away from the mast.
5. The cargo transport apparatus of claim 4, wherein: the plurality of pads on the conveyer chain are configured to contact the cargo on the fork assembly and, when the drive motor is actuated, move the cargo on the fork assembly away from or toward the mast.
6. The cargo transport apparatus of claim 1, further comprising: a controller coupled with the fork assembly that controls movement of the cargo on the fork assembly away from or toward the mast.
7. The cargo transport apparatus of claim 1, further comprising: a release assembly coupled with the first powered roller assembly, the release assembly having a first position that secures the first powered roller assembly to the first fork and a second position that releases the first powered roller assembly from the first fork to allow for removal of the first powered roller assembly from the first fork.
8. The cargo transport apparatus of claim 1, wherein the first powered roller assembly is configured to load and unload cargo onto and off of the first fork when the cargo transport apparatus operates in a cross-decking or cross-loading operation for cargo handling onto and off of a raised surface.
9. The cargo transport apparatus of claim 8, wherein the raised surface is associated with an aircraft or warehouse conveyer system.
10. The cargo transport apparatus of claim 8, further comprising: a controller coupled with at least the first powered roller assembly and one or more sensors coupled with the first fork, the controller configured to activate the first powered roller assembly when the one or more sensors indicate the first fork is located at a proper position for the cross-decking or cross-loading operation.
11. The cargo transport apparatus of claim 10, wherein the controller autonomously activates the first powered roller assembly to move the cargo onto or off of the first fork when the one or more sensors indicate the first fork is located at the proper position for the cross-decking or cross-loading operation.
12. The cargo transport apparatus of claim 1, further comprising: a platform coupled with the vehicle chassis, wherein the mast is movably coupled with the platform to move the fork assembly between a forward location at which the fork assembly is movable above or below a top plane of the platform and a rearward location at which the fork assembly is movable above the top plane.
13. The cargo transport apparatus of claim 1, further comprising: one or more propulsion units coupled with the vehicle chassis, each of the one or more propulsion units coupled with a power source, one or more sensors, and a controller to control operation of the one or more propulsion units.
14. The cargo transport apparatus of claim 1, further comprising: a controller coupled with at least the first powered roller assembly and one or more sensors coupled with the first fork, the controller configured to weigh the cargo and control operation of one or more forklift or drivetrain propulsion units.
15. The cargo transport apparatus of claim 14, wherein: the controller is further configured to capture a cargo unique identifier code and to communicate logistics data to an operator or system mainframe.
16. A method for transporting cargo using a cargo transport apparatus, comprising: identifying cargo that is to be transported using the cargo transport apparatus, wherein the cargo transport apparatus is adapted to transport the cargo from a first location to a second location; aligning a fork assembly of the cargo transport apparatus relative to the cargo, when the cargo is at the first location, to a position in which the cargo can be moved onto the fork assembly; activating, responsive to the aligning the fork assembly relative to the cargo, a powered roller assembly coupled with the fork assembly to move the cargo onto the fork assembly; lifting the cargo using the fork assembly; moving the cargo to the second location.
17. The method of claim 16, further comprising: lowering the cargo at the second location, using the fork assembly, to a surface associated with the second location; activating, responsive to the lowering the cargo to the surface, the powered roller assembly to move the cargo off of the fork assembly and onto the surface.
18. The method of claim 17, further comprising: monitoring, while moving the cargo off of the fork assembly, one or more sensors coupled with the fork assembly; determining, based on the monitoring, that the cargo is off of the fork assembly; and deactivating the powered roller assembly.
19. The method of claim 18, wherein the one or more sensors include one or more inertial sensors, one or more pressure sensors, one or more distance sensors, one or more optical sensors, one or more tilt sensors, one or more compression state sensors associated with a suspension of the cargo transport apparatus, or any combinations thereof.
20. The method of claim 18, wherein the one or more sensors include pressure sensors located at a distal end, away from a vehicle chassis of the cargo transport apparatus, of one or more forks of the fork assembly.
21. The method of claim 18, wherein the determining, and the deactivating are performed autonomously by a controller coupled with the powered roller assembly based at least in part on the monitoring of the one or more sensors.
22. The method of claim 16, wherein the activating the powered roller assembly to move the cargo onto the fork assembly comprises: autonomously activating, by a controller coupled with the cargo transport apparatus, the powered roller assembly based at least in part on one or more sensors of the fork assembly indicating that the cargo can be moved onto the fork assembly.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0022] This description provides examples, and is not intended to limit the scope, applicability or configuration of the invention. Rather, the ensuing description will provide those skilled in the art with an enabling description for implementing embodiments of the invention. Various changes may be made in the function and arrangement of elements. Thus, various implementations of techniques and components as discussed herein may omit, substitute, or add various procedures or components as appropriate. For instance, aspects and elements described with respect to certain examples may be combined in various other examples. It should also be appreciated that the following systems, devices, and components may individually or collectively be components of a larger system, wherein other procedures may take precedence over or otherwise modify their application.
[0023] Various examples disclosed herein provide a cargo transport system that is self-propelled and interacts with one or more control systems. The cargo transport system of various aspects is a self-propelled cargo transport system vehicle (e.g., using an electric motor, internal combustion engine, fuel cell, or any combinations thereof) that is designed to move cargo in various different settings autonomously, semi-autonomously, or teleoperatively (e.g., by remote control). In some cases, the cargo transport system may use hydraulic propulsion with a hybrid electric and gasoline or diesel engine providing power to a hydraulic system. In some cases, the cargo transport system may use an all-electric propulsion system in which one or more electric motors are powered by a rechargeable battery, an on-board generator, or combinations thereof. In some cases, the cargo transport system maintains compatibility with one or more different military cargo transports (e.g., aircraft, ship, vehicle, etc.) such as, for example, current military CH-53 and V-22 aircraft. In other examples, the system may be compatible other aircraft such as military C-17, C-130, or Boeing 747 aircraft, or may be compatible with commercial Boeing 737, 747, 757, or 767 aircraft, Airbus A300 aircraft, or McDonnell Douglas MD-11-type aircraft. Further, the cargo transport system may be compatible with ground-based transports (e.g., cargo trucks, trailers, shipping containers, etc.) or maritime-based transports (e.g., military or commercial maritime vessels). Such systems provide a compact vehicle with an advanced ability to autonomously or semi-autonomously move cargo in congested, dynamic, environments of warehouses, aircraft decks, shipboards, outdoor settings, landing zones, airports, and the like, with relatively little operator involvement.
[0024] As mentioned above, various aspects are described herein with respect to specific mechanical designs compatible with current military cargo transports. However, as will be readily apparent to those of skill in the art, the cargo transport system as discussed herein may be used in numerous other commercial, industrial, and military settings having different cargo handling specifications. In some cases, the cargo transport system utilizes a tracked propulsion system to provide vehicle motion in space constrained environments that may be unimproved to provide off-road capable cargo transport in unimproved environments, in addition to supporting the ability to load/unload cargo aircraft. The system, in some examples, may be used in a variety of situations that require moving heavy loads, such as delivery of cargo to remote locations, for transportation of supplies (water, food, etc.), or for construction to move around heavy building components, to name but a few examples. Further, the cargo transport system may also provide the ability to navigate indoor or outdoor environments, or both. For example, the cargo transport system may provide for autonomous or semi-autonomous movement of cargo through indoor/outdoor thresholds of warehouses, and autonomous or semi-autonomous movement of cargo between disparate warehouse buildings.
[0025] To operate autonomously and safely, the cargo transport system of various aspects utilizes a suite of sensors to detect its surroundings to include detection of obstacles (to include people, vehicles, boxes, walls, etc.), perform collision avoidance of obstacles, and determine its location indoors, outdoors, and within a cargo transport. Such sensors may include, for example, positioning sensors, Global Positioning System (GPS) sensors, inertial measurement units (IMUs), proximity detectors, cameras, stereographic imaging sensors, ultrasonic sensors, 3D flash LIDAR systems, LIDAR systems, and 3D Time of Flight (TOF) cameras, to name a few. As used herein, the term dense 3D sensor units may be used to refer to units that may provide data that may be used for 3D sensing around a cargo system, such as stereographic imaging sensors, ultrasonic sensors, 3D flash LIDAR, LIDAR, radar, and cameras coupled with image processing and recognition, for example. Further, aspects discussed herein may also have cargo detection and identification sensors, such as sensors (e.g., optical, radar, and ultrasonic sensors or rangefinders, etc.) that are located at the tip of each fork and/or adjacent to a mast that may be used to detect fork and vehicle location relative to cargo or dunnage.
[0026] With reference now to
[0027] While various examples illustrated and discussed herein show four tracked propulsion units 310, in some cases, the system may be constructed with only two propulsion units if desired, with more than four propulsion units, with wheels rather than tracks (with some or all of the wheels or tracks powered). Cargo 505 may be palletized cargo such as illustrated in
[0028] As shown in
[0029] Each propulsion unit 310, in some examples, may include a motor, suspension, a hydraulic system used to propel, raise, and lower the chassis, and a controller to control operation of the unit. In some examples, each propulsion unit may include a suspension spring (e.g., one or more coil springs, leaf springs, torsion springs, or any combinations thereof) for shock absorption and a hydraulic cylinder to provide height manipulation. In some examples, the system uses motor controllers (e.g., CANopen controllers) to communicate between each propulsion unit controller and a master computing system. The motors in some examples may be driven by a fully hydraulic system, or electrically using a battery system (e.g., a 48 V rechargeable battery system) and/or generator (e.g., internal combustion engine, fuel cell, photovoltaic system, etc.). The controller at each propulsion unit may respond to speed and torque commands from the master computing system or master controller and power the drive motors responsive to the commands. The propulsion units 310 may be mounted to the side or the bottom of the chassis using bolts, and each propulsion unit 310 may include an emergency stop button. In some examples, one or more of the propulsion units 310 may include sensors for use in control operations, such as positioning sensors, rotational sensors, speed sensors, encoders, and the like.
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[0033] At 1215, optionally, the vehicle may identify dunnage associated with the cargo. In some cases, LIDAR and optical inputs may be used to sense dunnage under palletized cargo with sufficient accuracy to enable the vehicle to autonomously pick-up cargo off of the dunnage. In some cases, sensors may be placed at the end of the forklift tines to locate the dunnage underneath pallets (e.g., distance rangefinders, optical sensors, etc.). Further, in some cases, the vehicle may also detect dunnage without cargo with sufficient accuracy to be able to autonomously drop cargo off on the dunnage in unloading operations. Additionally, in cases where a pallet has integrated dunnage (e.g., a standard cargo wooden pallet), or in cases where a container has integrated lift points (e.g., for fork placement at the top, bottom, or sides of the container), the vehicle may detect proper locations for placement of the fork tines. At 1220, the vehicle may determine routing and fork placement to lift cargo. At 1225, the vehicle may be positioned to approach the cargo and pick up the cargo. When dropping off the cargo, the vehicle may autonomously drive to the desired location and lower the cargo or otherwise place the cargo at the desired location. In some cases, such as illustrated in
[0034] As discussed herein, a cargo transport system may perform a number of functions that provide for efficient handling and movement of cargo, including sensing cargo with varying shape, size, and positioning to enable autonomous manipulation of cargo. The system may also sense an aircraft (or other cargo drop-off points) with sufficient accuracy to determine whether it is in the cross-decking configuration (for loading and unloading cargo only) or in the ramped position for driving into the aircraft. This ensures that the vehicle does not perform the wrong behavior and damage the aircraft or other cargo moving devices.
[0035] Vehicle height—which may be calculated with actuator position sensors, and/or using downward pointing LIDAR systems;
[0036] Motor speed—which may be calculated using encoders on the motor and/or freewheel;
[0037] Track angle—which may be calculated with data from one or more tilt sensors on the track of each propulsion unit, and/or through the use of encoders on a track bearing;
[0038] Vehicle orientation—which may be calculated based on data from tilt sensors, a GPS, and/or an IMU;
[0039] Vehicle speed—which may be calculated based on data from a ground speed sensor and/or encoders associated with each propulsion unit. In some examples, GPS data may also provide vehicle speed, and LIDAR also may provide speed data as well;
[0040] Vehicle location—which may be calculated based on GPS data and/or any of the other data as discussed above (and/or data from one or more other positioning systems);
[0041] Ramp detection of an aircraft or vehicle ramp, cargo bay, or cargo door—which may be calculated based on LIDAR data to detect ramp edges, and/or other imaging components such as cameras or time of flight cameras;
[0042] Collision detection—which may be determined based on LIDAR detection data, sonar, or cameras (time of flight cameras may also provide distance data to prevent collisions).
[0043] Cargo position detection—which may be calculated based on GPS data and/or any of the other data, as discussed above (and/or data from one or more other positioning systems);
[0044] Cargo weighing and stability detection—which may be calculated based on data from load cells, strain gauges, and/or any of the other data, as discussed above;
[0045] Powered forklift conveyor speed and position—which may be calculated based on data from encoders, proximity sensors, pressure sensors, and/or any of the other data, as discussed above;
[0046] Anti-tip system speed, position, and orientation—which may be calculated based on data from encoders, proximity sensors, pressure sensors, and/or any of the other data, as discussed above.
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[0048] It should be noted that the systems and devices discussed above are intended merely to be examples. It must be stressed that various embodiments may omit, substitute, or add various procedures or components as appropriate. For instance, it should be appreciated that, in alternative embodiments, features described with respect to certain embodiments may be combined in various other embodiments. Different aspects and elements of the embodiments may be combined in a similar manner. Also, it should be emphasized that technology evolves and, thus, many of the elements are exemplary in nature and should not be interpreted to limit the scope of the invention.
[0049] Specific details are given in the description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, well-known circuits, structures, and techniques have been shown without unnecessary detail in order to avoid obscuring the embodiments.
[0050] Having described several embodiments, it will be recognized by those of skill in the art that various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the invention. For example, the above elements may merely be a component of a larger system, wherein other rules may take precedence over or otherwise modify the application of the invention. Also, a number of steps may be undertaken before, during, or after the above elements are considered. Accordingly, the above description should not be taken as limiting the scope of the invention.