Automated bed-loaded container unloader and method

An automated unloading apparatus, system and method for use with a container having a plurality of items located on a base belt. The apparatus includes a ramp, a conveyor, and a spooling roller. The configured to pass under the base belt. The conveyor is conveyor configured to remove a first item from the plurality of items. The spooling roller is configured to wind the base belt around itself and by doing so, move the automated unloading apparatus into the interior of the container.

TECHNICAL FIELD

The present disclosure is directed, in general, to mail and parcel processing techniques.

BACKGROUND OF THE DISCLOSURE

Improved and more efficient systems for unloading items from a container or trailer are desirable.

SUMMARY OF THE DISCLOSURE

Various disclosed embodiments include an automated unloading apparatus for use with a container having a plurality of items located on a base belt. The automated unloading apparatus includes a ramp configured to pass under the base belt, a conveyor configured to remove a first item from the plurality of items, a spooling roller configured to wind the base belt around itself and by doing so, move the automated unloading apparatus into the interior of the container. In some implementations, the spooling roller acts as a tensioning mechanism for the base belt and move the ramp under the first item. In some implementations, the automated unloading apparatus includes a plurality of guide wheels configured to controllably extend from each side of the conveyor to respective sides of the container. In some implementations, the ramp is further configured to controllably expand to substantially an entire width of the container. In some implementations, the automated unloading apparatus is substantially stationary during an unloading process and moves into the interior of the container by relative motion of the container. In some implementations, the ramp is further configured to pass under a plurality of side belts. In some implementations, the automated unloading apparatus includes a plurality of guide wheels configured to controllably extend from each side of the conveyor to act as a positioning mechanism for the automated unloading apparatus. In some implementations, the automated unloading apparatus includes a retraction roller system configured to retract the automated unloading apparatus from the container.

In another embodiment, an automated unloading system for use with a container having a plurality of items located on a base belt includes an operator console, a controller, and an automated unloading apparatus. The controller is communicatively coupled to the operator console and the automated unloading apparatus is communicatively coupled to the controller. The automated unloading apparatus includes a ramp configured to pass under the base belt, a conveyor configured to remove a first item from the plurality of items, and a spooling roller configured to wind the base belt around itself and by doing so, move the automated unloading apparatus into the interior of the container. The controller is configured to control operation of the automated unloading apparatus in response to an operator action at the operator console.

In still another embodiment, a method of unloading items from a container having a plurality of items located on a base belt includes moving a ramp of an automated unloading apparatus under the base belt and a first item of the plurality of items. The method also includes removing the first item from the plurality of items using a conveyor of the automated unloading apparatus. The method also includes moving the automated unloading apparatus into the container by winding the base belt around a spooling roller.

DETAILED DESCRIPTION

In an effort to increase load density and reduce transportation cost, the trucking industry may use a practice called “bed-loading”. A trailer may be loaded with items of a broad range of sizes, weights, and shapes. Sacks and items having extreme aspect ratios or weights are typically bed-loaded last in a separate area of the trailer or box bed. On a full trailer, such extreme pieces may be located near the trailer door and would be the first items unloaded.

Manually unloading a bed-loaded trailer can be a grueling job that may be performed at extreme temperatures with relatively low pay. A person unloading standard packages with the aid of an extendible conveyor may achieve sustained rates in the range of 1,000 pieces per hour (1K PPH). Sacks and items of irregular size/shape are typically unloaded at rates much less than standard packages. Such reduced rates are often 200-500 PPH, depending on weight, shape, door configuration, and other factors. The time required to load or unload a trailer directly affects dock door utilization/productivity and therefore facility size. Problems have arisen with previous attempts to automated trailer unloading, including solution cost, cube loss, trailer fleet modification, throughput, staffing, package size/type/formats, loading constraints/configuration, package damage, ease of operation/automation, cost to maintain and ease of retrofitting existing loading dock facilities.

Various disclosed embodiments include unloading items from a trailer or other container generally without operator intervention. A nose ramp of an automated unloading apparatus is moved under a base belt in the trailer and under a first item of a plurality of items in the trailer. As the ramp continues advancing, the item is moved onto a conveyor, which is adapted to carry the item out of the trailer. A stack control curtain maintains the remaining items in a stack or pile during and after removal of the first item. A tensioning mechanism maintains a desired tension on the base belt as the ramp moves under the base belt and the first item.

FIG. 1depicts a block diagram of a data processing system100in which an embodiment can be implemented, for example as a control system for a mechanism as described below, and can be configured to perform processes as described herein. The data processing system depicted includes a processor102connected to a level two cache/bridge104, which is connected in turn to a local system bus106. Local system bus106may be, for example, a peripheral component interconnect (PCI) architecture bus. Also connected to local system bus in the depicted example are a main memory108and a graphics adapter110. The graphics adapter110may be connected to display111.

Other peripherals, such as local area network (LAN)/Wide Area Network/Wireless (e.g. WiFi) adapter112, may also be connected to local system bus106. Expansion bus interface114connects local system bus106to input/output (I/O) bus116. I/O bus116is connected to keyboard/mouse adapter118, disk controller120, and I/O adapter122. Disk controller120can be connected to a storage126, which can be any suitable machine usable or machine readable storage medium, including but not limited to nonvolatile, hard-coded type mediums such as read only memories (ROMs) or erasable, electrically programmable read only memories (EEPROMs), magnetic tape storage, and user-recordable type mediums such as floppy disks, hard disk drives and compact disk read only memories (CD-ROMs) or digital versatile disks (DVDs), and other known optical, electrical, or magnetic storage devices.

I/O adapter122can be connected to mail processing and imaging devices128, as described herein, to image, scan, transport, label, address process, sort, and otherwise processes the mail pieces in accordance with the various embodiments described herein.

Also connected to I/O bus116in the example shown is audio adapter124, to which speakers (not shown) may be connected for playing sounds. Keyboard/mouse adapter118provides a connection for a pointing device (not shown), such as a mouse, trackball, trackpointer, etc.

Those of ordinary skill in the art will appreciate that the hardware depicted inFIG. 1may vary for particular implementations. For example, other peripheral devices, such as an optical disk drive and the like, also may be used in addition or in place of the hardware depicted. The depicted example is provided for the purpose of explanation only and is not meant to imply architectural limitations with respect to the present disclosure.

LAN/WAN/Wireless adapter112can be connected to a network130(not a part of data processing system100), which can be any public or private data processing system network or combination of networks, as known to those of skill in the art, including the Internet. LAN/WAN/Wireless adapter112can also communicate with packages as described herein, and perform other data processing system or server processes described herein. Data processing system100can communicate over network130with one or more server systems140, which are also not part of data processing system100, but can be implemented, for example, as separate data processing systems100. A server system140can be, for example, a central server system at a central mail processing facility.

FIG. 2depicts a schematic view of an automatic unloader200according to the present disclosure. A trailer202is positioned adjacent to a loading dock204and a dock door area206for unloading. Within the trailer202are loaded items208, which are to be unloaded by the automatic unloader200. The items208are positioned on top of a base belt210, a first end of which is attached to the trailer at an attachment point212. A second end of the base belt210(opposite to the first end) may be raised to a first transit position214to provide supported to stacked items during transit to help prevent stack collapse. The second end of the base belt210may alternately be placed in a second transit position (not shown inFIG. 2) on the floor of the trailer202, where the base belt210may be rolled or gathered during transit. From either the first or second transit position, to initiate unloading of the trailer202, the second end of the base belt210is brought generally along the path indicated by the arrow216to be attached to the automatic unloader200, as described in greater detail below.

The unloader200is positioned at the open door of the trailer202by an operator at an operator console218. The operator may use a video camera (not shown inFIG. 2) that is mounted to the unloader200or to the loading dock204and presents the operator with a view of the unloader200and the trailer202. The unloader includes a positioning mechanism220, which is remotely operated by the operator to position the unloader200at the entrance to the trailer202. The positioning mechanism220may be a motorized caster or other mechanism suitable for positioning the unloader200relative to the trailer202prior to initiating an unloading process or during the unloading process. The positioning mechanism220is operable to position the unloader200at least along a longitudinal axis of the trailer202or horizontally relative to the trailer202. In some embodiments, the unloader200is substantially the same width as the interior of the trailer202, such that the unloader200substantially fills the trailer202from one sidewall to the other sidewall.

The unloader200also includes a stack control curtain222mounted to a positioning mechanism224. The operation of the stack control curtain222and the positioning mechanism224will be explained in greater detail with reference toFIGS. 5 and 6. The unloader200is coupled to an extendible conveyor226, which is operable to carry items unloaded by the unloader200from the trailer202. A sensor250may be mounted in a position that enables the sensor250to sense items on the unloader200or the extendible conveyor226. The sensor250is operable to sense a label, RFID tag, barcode, or other identifying feature of such items.

FIG. 3depicts an automated unloading system300according to the disclosure. Unloaders302,304,306and308according to the disclosure are controlled by a controller310. Each of the unloaders302-308may be positioned at each of four truck docks and operated to unload four trailers separately or concurrently. An operator may use an operator console312to control the unloaders302-308. The controller310may be communicatively coupled to a facility management system314. The controller310may receive address or identification information sensed from items unloaded by one or more of the unloaders302-308and send the information to the facility management system314(or other external system) for its use in routing the items to desired destinations.

While the operator console312, the controller310, and the facility management system314are depicted inFIG. 3as separate elements of the automated unloading system300, it will be understood that in other embodiments, this functionality of these elements may be provided in one or two elements. In some embodiments, the automated unloading system300also includes one or more sensors (not shown inFIG. 3) providing a view of one or more of the unloaders302-308and one or more corresponding trailers or other containers. In such embodiments, the controller310is further adapted to control an unloader positioning mechanism to position the unloader in a desired position relative to the trailer, prior to initiating an unloading process.

FIG. 4depicts a schematic detail view of the automatic unloader system200. The base belt210has been routed over a nose ramp404, between the nose ramp404and a nose conveyor406, through pinch rollers408, and coupled at coupling410to a tensioning roller412. The pinch rollers408and the tensioning roller412comprise a tensioning mechanism for the base belt210. The nose ramp405may pivot about a horizontal axis, as indicated by arrow405. The tensioning roller412maintains a desired tension Tbbon the base belt210via the coupling410. The unloader200moves itself forward under the base belt210and loaded items208by using the pinch rollers408to pull on the base belt210. In other embodiments, the unloader200moves itself forward using the positioning mechanism220and the tensioning roller412operates to maintain the base belt210taut over the nose ramp404. The tensioning roller412is mounted in a fixed position relative to the loading dock204, in order to maintain the tension Tbbon the base belt210regardless of movement of the unloader200.

The unloader200moves into the trailer along the trailer floor402, sliding the nose ramp404under a rearmost item of the items208. By sliding the nose ramp404under an item while the item remains on the base belt210, the unloader200reduces the possibility of the nose ramp404pushing the item into the trailer, rather than sliding it up onto the nose conveyor406. When moving forward, the unloader200moves at a speed Vrthat substantially matches a speed Vcof a transport belt of the nose conveyor406. In this way, the items208are transferred with substantially no relative motion from the base belt210to the nose conveyor406. Once on the nose conveyor406, a lowest, rearmost item of the items208is carried under the stack curtain222out of the trailer202along the nose conveyor406, onto the takeaway conveyor416, toward the extendible conveyor226. An upper portion of the transport belt of the nose conveyor406may be supported by a cushion414, to reduce impact forces on items that fall onto the nose conveyor from the items208.

Note that the descriptions herein of the unloader200moving into the trailer202(or other container) refers to a relative motion. In many implementations, the container is stationary and the unloader is in motion to move into the container. However, in other implementations, the unloader can be substantially or entirely stationary, while the container is moved onto it. In such cases, the unloader is still seen as moving into the container, in a relative sense, and so the descriptions herein are intended to apply to those cases as well.

As will be described in greater detail below, the stack curtain222may be moved toward and away from the items208in order to break the lowest, rearmost item free of any item resting upon it, to enable the item to be carried away by the nose conveyor406. The stack curtain222may be moved to a higher position above the nose conveyor406, to permit a larger item to pass under the stack curtain222. The stack curtain222may be positioned rearward along the nose conveyor, farther from the nose ramp404, in order to expose a larger portion of the nose conveyor406, to permit a larger item to rest entirely upon the nose conveyor406and be carried away. The unloader200is operable to remove a diversity of items208(e.g., packages, irregular shapes/weights, sacks, containers, rolling stock, pallets, etc.) from the trailer202or other container, whether the items208are arranged in orderly, segregated stacks or intermingled in disordered piles.

FIG. 5depicts a schematic view of another automatic unloader500according to the present disclosure. The unloader500includes a segmented drive ramp502and a stack control curtain mechanism504. The stack control curtain mechanism504includes a cushioned stack control curtain506and one or more actuators508adapted to change a configuration of the stack control curtain506relative to items518. The actuators are operable to independently move the top and bottom of the stack control curtain506toward and away from the nose of the trailer202, as well as to vary a contour of the stack control curtain506using a roller510or other suitable actuator.

The segmented drive ramp502includes a nose conveyor512and ramping conveyor segments516. The nose conveyor512has a cam roller514, which rotates on a longitudinal axis that is not coincident with a geometric longitudinal axis of the roller514. As the cam roller514rotates, it raises and lowers an upper portion of a transport belt of the nose conveyor512. The cam roller514operates to jostle or otherwise disturb the items518positioned on the nose conveyor512, to facilitate removal of a lowest item by the nose conveyor512. The cushioned stack control curtain506, the nose conveyor512, and the ramping conveyor segments516manage stack decomposition and reduce free fall distance and impact force for the items518.

A ramping angle and terracing effect may be created by the ramping conveyor segments516. As the segmented drive ramp502advances deeper into the stack, the ramping conveyor segments516may be raised and controlled relative to raising the stack control curtain mechanism504to allow package flow between the surface of the segmented drive ramp502and the bottom edge of the cushioned stack control curtain506. As the segmented drive ramp502advances into the stack, items are removed at higher and higher levels. The conveyor segments516turn on and off to reduce forces between packages and to cancel relative motion between conveyor and package until drive forces are needed

The cam roller514is mounted below an upper portion of a transport belt of the nose conveyor512. Cam rollers may also be mounted below upper portions of one or more of the conveyor segments516to aid package flow. Pressure and coverage applied by the stack control curtain506to the stack is kept within an acceptable range by the actuators508to avoid package free fall while not inducing excessive forces or forces that might damage the items518. A variety of devices know in the art can sense and signal pressure levels. Pressures applied over a small area or at a single point are avoided by making the stack control curtain506from a thick cushioned and/or compliant material, such as laminated foam rubber.

FIG. 6depicts a detail schematic view of the stack control curtain mechanism504according to the disclosure. The stack control curtain506is moved into a desired configuration by the actuators508. As individual items are removed from the bottom of the stack or pile of items518, an internal void602may be created within the stack. Where the items are in an otherwise orderly stack or array, such a void may allow an item604to drop into the internal void, possibly damaging the item604or an item on which it lands, or creating a jam that prevents subsequent items518from being removed from the trailer202. Internal voids may create similar unloading problems is unordered piles of items518. Under control of the actuators508, the stack control curtain506is adapted to change configuration to prevent formation of internal voids in the stack or pile of items518.

FIG. 7depicts a schematic view of a ramping conveyor700according to the present disclosure. The ramping conveyor700includes a nose conveyor702and a variable incline angle conveyor704. The ramping conveyor700supports items on conveyor belts, rather than on underlying solid support structures. The nose conveyor702includes a cushioned cam roller706that raises and lowers an upper portion of the nose conveyor702, to break items loose from a stack or pile of items. A stack control curtain708restrains upper items of the stack or pile and allows single items to pass from the nose conveyor702to the variable incline angle conveyor704. As may be seen by comparing depicted positions of the stack control curtains222,506and708inFIGS. 2, 4, 5 and 7, a stack control curtain according to the disclosure may be moved to multiple desired positions above a nose conveyor and other conveyor segments of unloaders according to the disclosure.

The variable incline angle conveyor704may include raised cleats710to prevent items on the conveyor704from slipping back toward the trailer as an angle from the horizontal of the conveyor704is increased. The conveyor704may include a cushioned cam roller712to control clumping and spacing of items on the conveyor704. The conveyor704includes a roller714that may be raised and lowered to vary an angle from the horizontal of an upper portion of the variable incline angle conveyor704. The suspended belt of the conveyor704provides a forgiving surface for items that it transports, to reduce damage to the items. Similar results may be obtained through the use of foam cushions or air bladders beneath the upper portion of the conveyor704.

The conveyor704is generally inclined to cause layers of tall stacks of items to decompose due to gravity. This thinning of layers provides natural metering of package flow for easier hand off from discharge of the conveyor704to generally narrower downstream takeaway conveyors. At an opposite end of the conveyor704from the nose conveyor702, the angle is selectively changed to produce a wedge-like engagement of the nose conveyor702with items of the stack to facilitate stack decomposition and removal. Similar comments apply to the ramping segmented drive ramp502of the unloader500depicted inFIG. 5.

FIG. 8depicts a schematic view of another automatic unloader800according to the present disclosure. The unloader800includes a conveyor mechanism802, an item removal mechanism804, an upper stack control curtain806, and a lower stack control curtain810. The unloader800unloads items808from an upper portion of a stack or pile. The upper portion may be a top, or near the top, of the stack. The lower stack control curtain810passes over a nose ramp812, and is placed under tension to control a lower portion of the stack of items808. The item removal mechanism804pulls individual items from the top of the stack of items808over the nose ramp812and onto a nose conveyor814, which transports the items to a take-away conveyor816. The item removal mechanism804may be a vacuum head, a magnetic head, a hook, or other suitable mechanism for mechanically coupling to an item and pulling the item onto the nose conveyor814. The relative positions of the item removal mechanism804and the nose ramp812manages stack decomposition and minimizes free fall distance and resulting impact force. As the top of the stack of items808is cleared the conveyor mechanism802is lowered down the face of the stack. The lower stack control curtain810is kept taut to continue controlling the lower portion of the stack of items808. The item removal mechanism804is mechanically coupled to, and moves with, the conveyor mechanism802, as the conveyor mechanism802moves vertically along the stack of items808and horizontally into the trailer (or other container).

As the conveyor mechanism802is lowered down the face of the stack, the upper stack control curtain806is extended downward to further control the stack of items808by forming a barrier against items falling from the stack onto the nose ramp812. The upper stack control curtain806may be positioned farther forward than the lower stack control curtain810, to be positioned adjacent to, and control, a remaining upper portion of the stack of items808. When the conveyor mechanism802reaches the bottom of the stack of items808, the conveyor mechanism802advances to a face of the remaining portion of the stack of items808. The conveyor mechanism802is raised to the top, or near the top, of the stack and unloading by the item removal mechanism804resumes. As the conveyor mechanism802is raised, the lower stack control curtain810is extended to control the lower portion of the stack, and the upper stack control curtain806is retracted.

FIG. 9depicts a schematic view of another automatic unloader900according to the present disclosure. The unloader900includes a conveyor mechanism902, a vacuum head904, and an upper stack control curtain906. The conveyor mechanism902includes a nose ramp912, a nose conveyor914and a segmented take-away conveyor916. The nose conveyor914and/or some or all segments of the segmented take-away conveyor916may be cushioned, as described with reference to nose conveyor406shown inFIG. 4. The unloader900unloads items908from an upper portion of a stack or pile. The upper portion may be a top, or near the top, of the stack. Segments of the segmented take-away conveyor916are initially raised to a substantially vertical configuration to control a lower portion of the stack of items908.

The vacuum head904pulls individual items from the top of the stack of items908onto a currently uppermost segment of the segmented take-away conveyor916. The relative positions of the vacuum head904and the currently uppermost segment of the segmented take-away conveyor916manages stack decomposition and minimizes free fall distance and resulting impact force. As the top of the stack of items908is cleared segments of the segmented take-away conveyor916are repositioned to reduce the height of the segmented take-away conveyor916along the face of the stack. The remaining substantially vertical elements of the segmented take-away conveyor916control the lower portion of the stack of items908. The vacuum head904is mechanically coupled to, and moves with, the conveyor mechanism902, as the conveyor mechanism902moves horizontally into the trailer (or other container). The vacuum head904is coupled to the conveyor mechanism902by a linkage918that is operable to raise and lower the vacuum head904.

As the segments of the segmented take-away conveyor916are repositioned to reduce the height of the segmented take-away conveyor916along the face of the stack, the upper stack control curtain906is extended downward to further control the stack of items908by forming a barrier against items falling from the stack onto the segmented take-away conveyor916. The upper stack control curtain906may be positioned farther forward than the substantially vertical elements of the segmented take-away conveyor916, to be positioned adjacent to, and control, a remaining upper portion of the stack of items908. When the vacuum head904reaches the bottom of the stack of items908, the conveyor mechanism902advances to a face of the remaining portion of the stack of items908. The vacuum head904is raised to the top, or near the top, of the stack and unloading by the vacuum head904resumes. As the vacuum head904is raised, segments of the segmented take-away conveyor916are returned to a substantially vertical configuration to control a lower portion of the stack of items908, and the upper stack control curtain906is retracted.

FIG. 10depicts a schematic detail view of an automatic unloader system1000according to disclosed embodiments. The base belt1010has been routed over a nose ramp1004, between the nose ramp1004and a nose conveyor1006, and to a spooling roller1008. Note that, in this example, the base belt may be connected to a spooling belt1012by a coupling mechanism1014, or may be directly connected to spooling roller1008. In this example, “base belt1010” is intended to refer to both possibilities, whether the base belt1010is implemented as a single belt connected to spooling roller1008, or implemented as a combination of a base belt coupled to a spooling belt that is then connected to the spooling roller1008.

In this example, spooling roller1008acts as a tensioning mechanism for the base belt1010and also acts as a drive mechanism for automatic unloader system1000. That is, as spooling roller1008winds base belt1010around itself, since base belt1010is removably fastened to the interior of trailer202(or other container), this winding action pulls automatic unloader system1000along base belt1010and into trailer202. The automatic unloader system1000moves itself forward along base belt1010, keeping nose ramp1004under the base belt under the base belt210and loaded items1018by using the spooling roller1008to pull on the base belt1010. As should be clear, spooling roller is physically mounted in a fixed position on the extendible portion1020of automatic unloader system1000, such as proximate to the nose ramp1004or beneath the nose conveyor1006.

In various implementations, when moving forward, the automatic unloader system1000. moves at a speed V1that substantially matches a speed V2of a transport belt of the nose conveyor1006. In this way, the items1018are transferred with substantially no relative motion from the base belt1010to the nose conveyor1006.

Various embodiments can also include a retraction roller system1030, that is mounted in a fixed position relative to the dock or other facility in which the automatic unloader system1000operates. Retraction roller system1030is connected to the extendible portion1020of automatic unloader system1000, for example by a retraction belt, and can be used to retract the automatic unloader system1000from the trailer202(or other container). Retraction roller system1030can also be used to maintain a tension on extendible portion1020for additional control of placement and speed of automatic unloader system1000as it moves along the base belt1310.

Other portions of the automatic unloader system1000can be implemented as described in any of the examples set forth herein.

FIG. 11illustrates additional aspects of some embodiments of an automatic unloader system as disclosed herein. This example shows a top-down view of a portion of an automatic unloader system1100partially deployed into a container1150. The walls of container1150are illustrated by thick lines, including portions around the doorway or other opening, which could include door-roller tracks, hinges, or other hardware. Although the figures are not to scale, those of skill in the art will recognize that the doorway of such a container is typically narrower than the entire width of the container1150.

This example shows base belt1130removably fastened to container1150at interior location1132along the back wall of container1150. Base belt1130passes over nose ramp1104then beneath nose conveyor1106.

This example also shows guide wheels1120, mounted on either side of nose ramp1104. Each guide wheel1120is mounted via one or more controllable actuators1122, which can retract the guide wheels1120partially or fully into (or beneath) nose ramp1104so that they can pass through the doorway of container1150. Moreover, a control system of the automatic unloader system1100can control the actuators1122so as to extend to the walls of container1150to act as a guide for the automatic unloader system1100, so that the relative movement of automatic unloader system1100in container1150can be “steered” using the actuators1122and guide wheels1120. The double-sided arrows on guide wheels1120illustrate that the guide wheels1120can be extended to each side of the nose ramp1104and also retracted, as necessary to guide automatic unloader system1100and to fit into the doorway of container1150.

Similarly, nose ramp1104can be hinged or segmented so that the nose ramp1104can be extended to each side, as indicated by the double-sided arrows, to occupy substantially the entire width of the container1150once the nose ramp has passed the doorway of container1150. This can be implemented, for example, by using overlapping, hinged segments for nose ramp1150that are expanded or contracted using actuators (similar to guide wheels1120).

FIG. 12illustrates additional aspects of some embodiments of an automatic unloader system as disclosed herein. This example shows a top-down view of a portion of an automatic unloader system1200partially deployed into a container1250. The walls of container1250are illustrated by thick lines, including portions around the doorway or other opening, which could include door-roller tracks, hinges, or other hardware. Although the figures are not to scale, those of skill in the art will recognize that the doorway of such a container is typically narrower than the entire width of the container1250.

This example shows a plurality of belts removably fastened to container1250at interior location1232along the back wall of container1250, including base belt1230and side belts1234. In this example, different cross-hatching is used to distinguish between base belt1230and side belts1234, and helps illustrate where base belt1230overlaps side belts1234on each side. Base belt1230is substantially the same width as nose ramp1204, which is narrower than the entire width of the container1250so it can fit through the doorway of container1250. Side belts1234are on each side of base belt1230, extending substantially to the sides of container1250on their outer sides, and are overlapped by base belt1230on their inner sides. Note that each side belt1234has a width transition1236, where the outer edge of each side belt1234moves from substantially along the walls of container1250to a narrower dimension that can pass through the door of container1250.

Base belt1230passes over nose ramp1204then beneath nose conveyor1206. Side belts1234can also pass over nose ramp1204then beneath nose conveyor1206, and can be collected or spooled, for example beneath nose conveyor1206. Because side belts1234are not integral with base belt1230, they can be drawn inward to the narrower dimensions of the nose ramp1204, beneath the base belt1230, while base belt1230remains spanning substantially the entire width of nose ramp1204.

In this way, side belts1234can ensure that all of the loaded items in container1250are properly unloaded by automatic unloader system1200, and none are missed because they fell off of the sides of base belt1230.

This example shows a case where nose ramp1204includes side panels1260so that the nose ramp1204to be extended to each side. Once inside the doorway of container1250, the side panels1260extend outwards to that the width of nose ramp1204(including side panels1260) is expanded to match, at its end, the combined width of the base belt1230and side belts1234.

In this example, each of the side panels1260has a side belt slot1262through which the respective side belts1234pass. When the side panels1260are fully outwardly extended, they substantially reach the walls of container1250, and the side belt slots1262are placed to accept the full, wide width of the side belts1234. When the side panels1260are fully inwardly located, can pass through the doorway of container1250, and the side belt slots1262are placed to except the narrower width of the side belts1234(on the narrower side of width transition1236).

As the unloader system1200moves into the container1250, the side belts1234pass through the side belt slots1262of the side panels126and beneath unloader system1200. Items located in the container1250on the side belts1234are gathered onto nose conveyor1206and processed with the items on base belt1230.

FIG. 13depicts a schematic detail view of an automatic unloader system1300according to disclosed embodiments that uses side belts1340. In this side view, only the “near-side” side belt1340is shown, but those of skill in the art will recognize that there is a similar side belt on the other side of automatic unloader system1300. The base belt1310has been routed over a nose ramp1304, between the nose ramp1304and a nose conveyor1306, and to a spooling roller1308. Note that, in this example, the base belt may be connected to a spooling belt1312by a coupling mechanism1314, or may be directly connected to spooling roller1308. In this example, “base belt1310” is intended to refer to both possibilities, whether the base belt1310is implemented as a single belt connected to spooling roller1308, or implemented as a combination of a base belt coupled to a spooling belt that is then connected to the spooling roller1308.

In this example, spooling roller1308acts as a tensioning mechanism for the base belt1310and also acts as a drive mechanism for automatic unloader system1300. That is, as spooling roller1308winds base belt1310around itself, since base belt1310is removably fastened to the interior of trailer202(or other container), this winding action pulls automatic unloader system1000along base belt1310and into trailer202. The automatic unloader system1300moves itself forward along base belt1310, keeping nose ramp1304under the base belt under the base belt1310and loaded items1318by using the spooling roller1308to pull on the base belt1310. As should be clear, spooling roller is physically mounted in a fixed position on the extendible portion1320of automatic unloader system1300, such as proximate to the nose ramp1304or beneath the nose conveyor1306.

In various implementations, when moving forward, the automatic unloader system1300. moves at a speed V1that substantially matches a speed V2of a transport belt of the nose conveyor1306. In this way, the items1318are transferred with substantially no relative motion from the base belt1310to the nose conveyor1306.

Various embodiments can also include a retraction roller system1310, that is mounted in a fixed position relative to the dock or other facility in which the automatic unloader system1300operates. Retraction roller system1330is connected to the extendible portion1320of automatic unloader system1300, for example by a retraction belt, and can be used to retract the automatic unloader system1300from the trailer202(or other container). Retraction roller system1330can also be used to maintain a tension on extendible portion1320for additional control of placement and speed of automatic unloader system1300as it moves along the base belt1310.

In this example, side belts1340are connected to the inside of the trailer202(or other container) and are overlapped by base belt1310. The side belts1340pass over the end of nose ramp1304and pass through slots in nose ramp1304(such as through side belt slots in side panels as described above). After passing through the nose ramp1304, the side belts1340, in this example, pass under the frame of automatic unloader system1300to tensioners1342that maintain tension on the side belts1340. In this example, “side belts1340” is intended to refer to side belts running from the container to the tensioner, whether the side belts1330are each implemented as a single belt between the container and tensioner or implemented as a combination of belt portions connected between the container and the tensioner.

Other portions of the automatic unloader system1300can be implemented as described in any of the examples set forth herein.

Those skilled in the art will recognize that, for simplicity and clarity, the full structure and operation of all systems suitable for use with the present disclosure is not being depicted or described herein. Instead, only so much of the physical systems as is unique to the present disclosure or necessary for an understanding of the present disclosure is depicted and described. The remainder of the construction and operation of the systems disclosed herein may conform to any of the various current implementations and practices known in the art.

Although an exemplary embodiment of the present disclosure has been described in detail, those skilled in the art will understand that various changes, substitutions, variations, and improvements disclosed herein may be made without departing from the spirit and scope of the disclosure in its broadest form. In particular, the features and operations of various examples described herein and in the incorporated applications can be combined in any number of implementations.