Drone forklift

A UAV includes a fork lift system and a length component. The forklift system includes one or more elongated members extending at least partially in a horizontal direction. The forklift system also includes an extension mechanism configured to selectively retract and extend the one or more elongated members relative to an opposing surface. For example, the elongated members may include the tines of the fork or supporting member of the forklift system. The length component is configured to control the extension mechanism to adjust a distance between the opposing surface and the one or more elongated members to accommodate a payload.

TECHNICAL FIELD

The disclosure relates generally to unmanned aerial vehicles (UAVs) or drones and more particularly relates to systems, methods, and devices for loading and releasing a payload of a drone.

BACKGROUND

Very large numbers of packages are delivered to business, residential, and other locations on a daily basis. Package delivery of small quantities of items is often completed using a delivery truck, van, or other vehicle that is driven by a human driver. The human may drive the vehicle between delivery locations and walk with a package up to or into a building, mailbox, or other location in order to deliver the package. Recently, discussion of delivery using aerial vehicles or drones has been discussed. For example, systems such as Amazon Prime Air® propose the use of a drone to deliver a single package from a warehouse to a destination.

DETAILED DESCRIPTION

Applicants have recognized the need for and developed significant improvements to systems, methods, and devices for package delivery. For example, drone delivery often requires that a human attaches and/or detaches a payload to the drone. Requiring human involvement reduces efficiency and slows the processes. In some cases, drones that can use a hook or mechanical arm may take the human out of the loop, but can only load payloads that are spaced properly for the hook or arms to secure the payload. This is a problem because it does not allow for stacking many packages in a tight space.

In light of the foregoing, applicants have developed a drone forklift and mini crate system used for drone package delivery. In one embodiment, a UAV includes a fork lift system and a length component. The forklift system includes one or more elongated members extending at least partially in a horizontal direction. The forklift system also includes an extension mechanism configured to selectively retract and extend the one or more elongated members relative to an opposing surface. For example, the elongated members may include the tines of the fork or supporting member of the forklift system. The length component is configured to control the extension mechanism to adjust a distance between the opposing surface and the one or more elongated members to accommodate a payload.

In one embodiment, the forklift system allows a drone to pick up packages that are stacked vertically and horizontally in a tight space such as a delivery truck, or from a tightly packed cluster of packages in a warehouse or other location. In one embodiment, the packages, or other payload, may be stacked using cardboard, plastic, or other miniature or size appropriate crates. The cardboard crates may be similar to wooden crates used by traditional heavy forklifts, except they are lighter and may be used with smaller boxes or packages. In one embodiment, a cardboard crate is placed under every package when stacking the boxes.

In order to perform a delivery, a drone or UAV may move or fly to a location of stacked boxes or packages and identify a box to load and/or deliver. In one embodiment, the UAV may scan one or more packages using a sensor that can read a quick response (QR) code, bar code, text, or the like to identify a package. For example, the UAV may include a camera or other optical sensor. In one embodiment, the UAV may scan the one or more packages using another type of reader such as a radio-frequency identification (RFID) tag reader to read RFID tags.

Based on the identity of the package, box, or payload, the UAV may determine metadata about the package. For example, the information read from the tag or code may include the metadata or may include a key to look up the metadata in a database or table. The metadata for the package, box, or payload may include a height of the package, a delivery destination (e.g., GPS or address information), or the like. The height may be relevant so that the UAV can actuate a forklift to create enough space between a forklift and an opposing surface to accommodate the payload so the UAV can pick it up. The UAV may include a forklift mechanism that is actuated using one or more electronically powered telescoping masts. For example, a telescoping mast may actuate a prong or tine of a fork. In one embodiment, multiple prongs or tines may be actuated by a single mast if the mast is rigid and/or powerful enough. An example of a powerful electrically powered telescoping mast may include telescopic cylinders which are actuated with a hydraulic or pneumatic pump.

In one embodiment, in response to determining the height of a package, payload, or box, the UAV may adjust a mast or other extension mechanism to match or exceed the height. When the mast is of sufficient length, the drone may fly or otherwise maneuver to slide the prongs or tines of the fork into a cardboard create underneath the targeted package. A fuselage may be located over the package and may form an opposing surface above the tines or prongs. Once the forks are positioned below the package and the fuselage, or other opposing surface, is positioned above the package, the UAV may telescope or actuate the mast up slightly to create a snug grip on the package. The UAV may then lift off to fly the package to its destination.

Upon arrival at or near a destination, the UAV flies until it is positioned above a receiving container or landing pad. While approximately above the receiving container or landing pad, the drone may rotate or tilt a few degrees from horizontal to allow gravity to pull the package off of the fork prongs or tines. The UAV may also actuate the masts or extension mechanism to increase a distance between the fork and opposing surface to release a grip on the package. While tilting, the UAV may also slowly fly laterally in an opposite direction of the tilting to allow the package to down into a receiving container or onto the landing pad. Once the package is delivered, the UAV may retract the mast and fly away.

Embodiments disclosed herein may allow for reducing the amount of human involvement in drone deliveries. For example, embodiments disclosed herein may allow for a drone to load and unload a package without human involvement. In some embodiments, drones may be able to access the packages even if they are stacked or located in small or tight spaces. For example, a UAV may be able to load a package located within a delivery truck, stacked within a warehouse, or other location. Thus, embodiments disclosed herein may lead to more efficient delivery from a truck or vehicle, not just a warehouse. Furthermore, forklift mechanisms presented herein may allow for secure holding of a package or payload relative to the UAV such that there is no swinging of the payload. Absence of a swinging payload, which may occur with hooks and cables, may make it more difficult and/or dangerous for the UAV to fly or maneuver with the payload.

As used herein the terms “drone” or “unmanned aerial vehicles (UAV)” are given to mean vehicles that are capable of flight and/or navigation with little or no real-time human input. For example, embodiments of drones or aerial vehicles disclosed herein may deliver packages from a ground vehicle to a delivery location with no input from a local or remote human operator. However, it will be appreciated that embodiments of drones or aerial vehicles disclosed herein may also deliver packages from a ground vehicle to a delivery location with some input from a local or remote human operator.

Further embodiments and examples will be discussed in relation to the figures below.

FIG. 1illustrates a perspective view of a UAV100with a fork lift system102. The UAV100includes a plurality of rotors104for moving or flying the UAV100. Motors for the rotors104and/or a control system may be located within a fuselage106. The forklift system102extends below the fuselage106and includes one or more prongs108. The prongs are secured relative to the fuselage106with one or more masts110. In the present embodiment, the masts110include telescopic cylinders that can be selectively extended or retracted. For example, a pneumatic pump may be used to extend the prongs108away from the fuselage106and/or retracted the prongs108toward the fuselage106. InFIG. 1, the forklift system102is shown in an extended state. A bottom side of the fuselage106may provide an opposing surface112for the prongs108. For example, a package or other payload may be pressed or gripped firmly between the prongs and the opposing surface112to limit or prevent movement of the payload during flight.

FIG. 2illustrates a rear view of the UAV100andFIG. 3illustrates a side view of the UAV100.FIG. 4illustrates a side view of the UAV100with the forklift system102in a collapsed state. Specifically, a mast110is shown collapsed within the fuselage106and the prongs108are shown up close to the bottom side of the fuselage106(i.e., the opposing surface112). In one embodiment, the forklift system102may be placed in a collapsed state when no payload is being carried by the UAV100to increase safety and/or reduce drag.

FIG. 5is a schematic block diagram illustrating example components of a UAV100, according to one implementation. In the depicted embodiment, the UAV100includes a flight system502, a radio504, a forklift system506, sensors508, an identification component510, a size component512, a length component514, a load component516, and an unload component518. The components502-518are given by way of illustration only and may not all be included in all embodiments. In fact, some embodiments may include only one or any combination of two or more of the components502-518. Some of the components502-518may be located within a control system within a body or fuselage106of a UAV100.

The flight system502is configured to fly the UAV100. The flight system502may include one or more motors, propellers, engines, wings, or the like. For example, the flight system502may include one or more motors per rotor. The UAV100may include a single or multi rotor air vehicle capable of hovering and vertical take-off and landing. For example, the flight system502may include one, two, three, four, five, six, or any other number of rotors. The UAV100illustrated inFIG. 1is an example of a quad-rotor. The flight system502may allow the UAV100to autonomously fly the UAV100between locations, avoid object, or perform other autonomous flight control maneuvers.

The radio504may include a radio for communication of instructions and/or for tracking of the UAV100. The radio504may be configured to provide communication between the UAV100and a server, monitoring system, or control system. For example, the radio504may receive instructions about what package or payload to deliver, a delivery location, information about a size, weight, or other aspect of a payload.

The forklift system506allows the UAV100to support or hold a package or other payload. In one embodiment, the forklift system506includes prongs or tines, which may be placed under package or payload to hold it. For example, the prongs or tines may include elongated members extending at least partially in a horizontal direction (e.g., seeFIG. 1). For example, the prongs or tines may extend in a direction in relation to the UAV100that is generally horizontal during flight. For example, a UAV100may tilt and turn during flight, but may generally have a default horizontal position, such as the position of the UAV100when it lands on the ground or when the UAV100hovers. The tines or prongs may be substantially horizontal in that they are substantially or approximately parallel to a fuselage106or frame of the UAV100when the UAV100is in a hovering or resting position.

The forklift system506also includes an extension mechanism configured to selectively retract and extend the one or more elongated members (e.g., tines or prongs). The extension mechanism may include a mast, rod, telescopic cylinders and/or any length-adjustable mechanism for adjusting a distance of the elongated members (or fork) from a body of the UAV100. For example, the extension mechanism may extend below the UAV100and support the elongated members at some distance from an underside of a fuselage106of the UAV100, or any other opposing surface. The distance between the elongated members and the opposing surface may determine what height of package or payload can be held by the forklift system506and/or the UAV100.

The sensors508may include sensors for sensing or identifying objects or surfaces in an environment near the UAV100. In one embodiment, the sensors508may be used to obtain or detect identifying information on a package or payload. For example, the sensors508may include an optical sensor or tag reader configured to read identifying information from the tag or barcode. Example sensors508may include a camera, RFID tag reader, laser barcode scanner, or the like.

The identification component510is configured to identify one or more potential payloads. For example, the sensors508may scan/image each package or payload they encounter and the identification component510may identify each scanned/imaged package or payload based on the sensor data. In one embodiment, the identification component510may identify a package or payload by determining a serial number or other identifier corresponding to the package or payload. For example, a tag or barcode may be read to determine the identity of a payload. In one embodiment, the UAV100may receive instruction to deliver a specific package and the identification component510may identify packages until a match for the specific package is found.

Based on the identity, or identifying information, the identification component510may determine one or more characteristics for the package or payload. In one embodiment, the identification component510may determine a serial number or unique identifier for a package and then query, via the radio504, a database for characteristics or requirements for the package. The identification component510may determine one or more dimensions of a package. The dimensions may be needed to allow the forklift system506to accommodate and/or hold the package. The identification component510may identify a delivery location based on an identity of the payload. The delivery location may include an address, GPS location, or the like. The delivery location may include enough information to allow the UAV100to fly to and deliver the package.

The size component512is configured to determine a dimension of the payload. For example, the size component512may determine a vertical height, horizontal height, or depth of the package. The size component512may determine the dimension based on data gathered by the identification component510or may determine the size based on a camera image or other data. The size component512may also determine a weight or other information about the package relative to delivery.

The length component514is configured to control an extension mechanism of the forklift system506to adjust a distance between the opposing surface and the one or more elongated members. For example, the length component514may actuate a mast of the forklift system506so that there is sufficient vertical height between the forks (elongated members) and an underside of a fuselage to accommodate the payload. As another example, the length component514may retract the mast completely when there is no payload (e.g., upon unloading a payload and returning to a warehouse, vehicle, or package location). The length component514may also actuate the mast to maintain a gripping force on a payload, when applicable. In one embodiment, the length component514may adjust the height during flight or may land to perform height adjustments for the forklift system506.

The load component516is configured to control the UAV100to load a payload. In one embodiment, the load component516causes the UAV100to fly or move the UAV100to position the payload between the one or more elongated mechanisms and the opposing surface. For example, the load component516may cause the flight system502to fly the UAV100to position the forks or elongated members of the forklift system506underneath a target package and an opposing surface (such as an underside of a fuselage) above the target package. For example, the elongated members may be positioned under or in a cardboard crate underneath the package or payload. Once the UAV100is positioned, the length component514may retract the mast of the forklift system506to secure and/or grip the payload between the one or more elongated mechanisms and an opposing surface. When the payload is secured, the UAV100may lift off for payload delivery.

The unload component518is configured to control the UAV100to release or unload a payload. For example, after flying to a delivery destination the unload component518may cause the UAV100to perform an unload procedure. In one embodiment, the unload component518may cause the forklift system506to increase a distance between the at least one elongated member and the opposing surface to release the payload. In one embodiment, the unload component518may additionally cause the UAV100to tilt the UAV100in a first direction and fly or move the UAV100in a second direction substantially opposite the first direction to cause the payload to slide off of the at least one elongated member. Often, vertical take-off UAVs100with rotors tend to move in a direction of tilt rather than in a direction opposite tilt. However, when unloading there are often different forces involved than in generalized flying situations. For example, the movement of the package due to release of the forklift mechanism, contact of the package with the ground, delivery box, or the like may produce forces that allow the UAV100to tilt in one direction and fly in the opposite direction. In one embodiment, the unload component518may set the package and/or a cardboard crate on the ground or other surface for delivery and then fly sideways to unload the payload.

Turning toFIGS. 6A-6E, a method for loading a package is illustrated. Specifically,FIGS. 6A-6Eillustrate a side view of a UAV100and a package602during loading.FIG. 6Ashows a UAV100hovering near a package602that is stacked on a crate604on top of a plurality of other packages. The prongs108are positioned at a distance from the fuselage106to accommodate a height of the package602.FIG. 6Bshows the UAV100moving laterally to insert the prongs108under the package602into a space between packages created by a crate604.FIG. 6Cshows UAV100positioned such that the prongs108are below the package602and the fuselage106is above the package.FIG. 6Dshows the UAV100with the mast110retracted enough to apply pressure to the package600between the prongs108and the fuselage106.FIG. 6Eshows the UAV100lifting off with the package602and crate604secured.

Turning toFIGS. 7A-7D, a method for unloading a package is illustrated. Specifically,FIGS. 7A-7Dillustrate a side view of a UAV100and a package602during unloading.FIG. 7Ashows the UAV100arriving at a destination and positioned above a delivery box702.FIG. 7Bshows the UAV100positioned low above the delivery box702and tilting to the left.FIG. 7Cshows the UAV100releasing the package602with an increased distance between the prongs108and the fuselage106while moving to the right. The package602and crate604may slide off the prongs and into the delivery box702. A flap704may act as a trap door to allow the package602to drop into the box.FIG. 7Dshows the package602within the delivery box702. The UAV100is free to retract the prongs108and return to a package source location.

FIG. 8is a schematic diagram illustrating delivery of package from a vehicle800using a UAV100. The vehicle800may include a delivery vehicle for driving a delivery route. The vehicle800includes a cargo area802. The cargo area802may receive and/or store a plurality of packages804containing items to be delivered. The cargo area802may include one or more docking locations806for one or more UAVs100to land and ride with the automated vehicle800. For example, the docking locations806may include a mat and/or a connector for the UAVs100to anchor, power down, and/or recharge. The docking locations806may include wired charging connectors or wireless charging coils to charge the UAVs100.

The vehicle800also includes doors810, which may be opened for loading/or unloading the packages804. In one embodiment, the doors810may be opened to allow a human, robot, or other entity to enter or exit the cargo area802. The vehicle800also includes one or more windows812. The windows812may be sized to allow the UAVs100, with or without a package, to fly through. For example, one or more windows812(such as a window on each door that can be opened to form a single opening) may be opened to allow UAV100to exit or enter the cargo area802. When it is time to deliver a package, UAV100may power on, begin flight and retrieve/load one of the packages804, for example, in a manner discussed herein. The UAV100may then fly out the windows812with the package and then proceed to a delivery location for placement/delivery of the package. After the package is delivered, the UAV100may return to the vehicle800, fly through the windows812and either land on a docking location806or retrieve yet another package for delivery. In one embodiment, a UAV100with a forklift mechanism may be used to quickly, efficiently, and/or autonomously load packages within the tight confines of the vehicle800and deliver the packages.

Referring now toFIG. 9, a schematic flow chart diagram of a method900for package delivery is illustrated. The method900may be performed by a UAV, such as the UAV100ofFIG. 1 or 5.

The method900begins and an identification component510identifies at902a payload based on a tag or barcode. A size component512determines at904a dimension of the payload. A length component514adjusts at906a distance between at least one elongated member of a fork lift system and an opposing surface to accommodate the dimension. A load component516flies at908the UAV to position the payload between the at least one elongated member and the opposing surface.

EXAMPLES

The following examples pertain to further embodiments.

Example 1 is a UAV that includes a forklift system and a length component. The forklift system includes one or more elongated members extending at least partially in a horizontal direction. The forklift system also includes an extension mechanism configured to selectively retract and extend the one or more elongated members relative to an opposing surface. The component is configured to control the extension mechanism to adjust a distance between the opposing surface and the one or more elongated members to accommodate a payload.

In Example 2, the extension mechanism as in Example 1 includes one or more telescopic cylinders.

In Example 3, the UAV as in any of Examples 1-2 further includes an identification component configured to identify a payload based on one or more of a tag or barcode on the payload.

In Example 4, the UAV as in any of Examples 1-3 further includes an optical sensor or tag reader configured to read identifying information from the tag or barcode.

In Example 5, the UAV as in any of Examples 1-4 further includes a size component configured to determine a dimension of the payload, wherein the length component is configured to adjust the distance to accommodate the dimension of the payload.

In Example 6, the UAV as in any of Examples 1-5 further includes a load component configured to fly or move the UAV to position the payload between the one or more elongated mechanisms and the opposing surface. The length component is further configured to adjust the distance to grip the payload using the one or more elongated mechanisms and the opposing surface.

In Example 7, the UAV as in any of Examples 1-6 further includes an unload component configured to fly or move the UAV to release the payload.

Example 8 is a method for delivering a payload using an UAV. The method includes identifying a payload based on a tag or barcode and determining a dimension of the payload. The method includes adjusting a distance between at least one elongated member of a fork lift system and an opposing surface to accommodate the dimension. The method includes flying the UAV to position the payload between the at least one elongated member and the opposing surface.

In Example 9, the method of Example 8 further includes, in response to flying the UAV to position the payload between the at least one elongated member and the opposing surface, adjusting the distance between the at least one elongated member and the opposing surface to grip the payload between the at least one elongated member and the opposing surface.

In Example 10, the method as in any of Examples 8-9 further includes flying the UAV to a delivery location. The method further includes increasing the distance between the at least one elongated member and the opposing surface to release the payload.

In Example 11, the method as in any of Examples 8-10 further includes tilting the UAV in a first direction. The method further includes flying the UAV in a second direction substantially opposite the first direction whereby the payload slides off of the at least one elongated member.

In Example 12, the opposing surface as in any of Examples 8-11 includes an underside of the UAV, wherein the at least one elongated member extends in a substantially horizontal direction. Adjusting the distance includes actuating an extension mechanism configured to selectively retract and extend the at least one elongated member below the opposing surface.

In Example 13, determining a dimension of the payload as in any of Examples 8-12 includes determining the payload based on an identity of the payload.

In Example 14, the method as in any of Examples 8-13 further includes identifying a delivery location based on an identity of the payload.

Example 15 is a computer readable storage media storing instructions that, when executed by one or more processors, cause the processors to identify a payload based on a tag or barcode based on sensor data of an UAV. The instructions cause the processors to determine a dimension of the payload. The instructions cause the processors to adjust a distance between at least one elongated member of a fork lift system and an opposing surface to accommodate the dimension. The instructions cause the processors to fly the UAV to position the payload between the at least one elongated member and the opposing surface.

In Example 16, the instructions as in Example 15 further cause the processors to, in response to flying the UAV to position the payload between the at least one elongated member and the opposing surface, adjust the distance between the at least one elongated member and the opposing surface to grip the payload between the at least one elongated member and the opposing surface.

In Example 17, the instructions as in any of Examples 15-16 further cause the processors to fly the UAV to a delivery location and increase the distance between the at least one elongated member and the opposing surface to release the payload.

In Example 18, the instructions as in any of Examples 15-17 further cause the processors to tilt the UAV in a first direction and fly the UAV in a second direction substantially opposite the first direction, whereby the payload slides off of the at least one elongated member.

In Example 19, the opposing surface as in any of Examples 15-18 includes an underside of the UAV, wherein the at least one elongated member extends in a substantially horizontal direction. The instructions cause the processors to adjust the distance by actuating an extension mechanism configured to selectively retract and extend the at least one elongated member below the opposing surface.

In Example 20, the instructions as in any of Examples 15-19 further cause the processors to determine a delivery location based on an identity of the payload.

Example 21 is a system or device that includes means for implementing a method, system, or device as in any of Examples 1-20.

As used herein, “autonomous vehicle” may be a vehicle that acts or operates completely independent of a human driver; or may be a vehicle that acts or operates independent of a human driver in some instances while in other instances a human driver may be able to operate the vehicle; or may be a vehicle that is predominantly operated by a human driver, but with the assistance of an automated driving/assistance system.