Patent Publication Number: US-9834228-B2

Title: Apparatus for automated transfer of large-scale missile hardware

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a divisional of U.S. patent application Ser. No. 13/889,161, filed on May 7, 2013 and entitled “APPARATUS FOR AUTOMATED TRANSFER OF LARGE-SCALE MISSILE HARDWARE.” This prior application is hereby incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present disclosure is directed generally to systems that provide automated transfer of hardware. More specifically, this disclosure is directed to systems and methods for automated transfers of large-scale missile hardware from an assembly workstation to an automated guided vehicle or from an automated guided vehicle to an assembly workstation. 
     BACKGROUND OF THE DISCLOSURE 
     In an industrial manufacturing facility, large-scale hardware, such as a missile weighing 8,000 pounds or more and extending approximately 24 feet long or, is assembled on stationary assembly work stations. When appropriate, the large-scale hardware is moved from one assembly location in an industrial facility to another assembly location. For the move, the large-scale hardware may be enclosed in a canister (also referred to as “encanistered”), and then manual labor, involving several people performing a critical lift via hoist, is used to transfer the canister to a wheeled-cart. Other examples of large-scale hardware include the canister, and a missile subassembly. The manual labor of 6-8 people is used to push the carted canister to a different area within a factory. The manual labor of 4 people is used to push a carted subassembly to a different area within the factory. 
     SUMMARY OF THE DISCLOSURE 
     This disclosure provides systems and methods that eliminate critical lifts or manual movement from the process of moving large-scale hardware to various assembly stations within an industrial facility. The present disclosure provides systems and methods for a zero-lift hardware transfer. The zero-lift hardware transfer is an automated transfer of large-scale hardware from an assembly work station onto an automated guided vehicle (AGV), and onto an assembly work station in a different location. 
     According to embodiments of the present disclosure, a cradle drive system includes a cradle drive sled. The sled includes a pin configured to mechanically couple the sled to a cradle. The cradle is configured to hold a hardware load for movement along a factory rail. The cradle drive system also includes a power interface configured to provide torque to move a hardware load. The sled further includes processing circuitry configured to, in response to determining that the sled is mechanically coupled to the cradle and detecting a satisfactory manual cradle brake condition, transfer the cradle and hardware load longitudinally along a common factory rail (CFR). 
     Certain embodiments may provide various technical advantages depending on the implementation. For example, a technical advantage of some embodiments may include transferring large-scale reducing risk of drops or damage to expensive, volatile hardware. A technical advantage of certain embodiments may include significant improvement to factory-workplace ergonomics by eliminating more than a dozen critical lifts and by eliminating manual labor of pushing large heavy carts. A technical advantage of certain embodiments may include the capability of transferring less than a whole assembly, such as subassemblies or components. Certain embodiments may include the capability for providing intelligent transfer between a commercial off the shelf (COTS) factory-wide transportation vehicle (for example, automated guided vehicles) and a stationary assembly work-station. 
     Although specific advantages are described above, various embodiments may include some, none, or all of the enumerated advantages. Additionally, other technical advantages may become readily apparent to one of ordinary skill in the art after review of the following figures and description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the present disclosure and its advantages, reference is now made to the following description taken in conjunction with the accompanying drawings, in which like reference numerals represent like parts: 
         FIG. 1  illustrates an automated transfer and positioning system for large-scale hardware according to embodiments of the present disclosure; 
         FIG. 2  illustrates two automated transfer and positioning systems for large-scale hardware with ends disposed in close proximity to each other according to embodiments of the present disclosure; 
         FIGS. 3A and 3B  illustrates a common factory rail according to embodiments of the present disclosure; 
         FIGS. 4A and 4B  illustrate an end stop pin of the common factory rail of  FIG. 3 ; 
         FIG. 5  illustrates the end stop pin of  FIGS. 4A and 4B  with the housing hidden; 
         FIG. 6  illustrates a front view of the automated transfer and positioning system for large-scale hardware of  FIG. 1 ; 
         FIG. 7  illustrates a gear box of the automated transfer and positioning system for large-scale hardware of  FIG. 1 ; 
         FIG. 8  illustrates a servomotor of the automated transfer and positioning system for large-scale hardware of  FIG. 1 ; 
         FIG. 9  illustrates a cable chain of the automated transfer and positioning system for large-scale hardware of  FIG. 1 ; 
         FIG. 10  illustrates a cradle drive system according to embodiments of the present disclosure; 
         FIG. 11  illustrates a cradle drive sled according to embodiments of the present disclosure; 
         FIG. 12  illustrates a sensor bank assembly of a cradle drive sled according to embodiments of the present disclosure; 
         FIGS. 13A and 13B  illustrate various cradles according to embodiments of the present disclosure; 
         FIG. 14  illustrates a cradle clip engaged with an actuated pin of a cradle drive sled according to embodiments of the present disclosure; 
         FIG. 15  illustrates a zero-lift transfer method incorporating a cradle mapping sequence according to embodiments of the present disclosure; 
         FIG. 16  illustrates an automated guided vehicle common factory rail that includes an automated cradle brake of the automated transfer and positioning system  100  for large-scale hardware of  FIG. 1 ; 
         FIG. 17  illustrates an automated guided vehicle automated transfer and positioning system for large-scale hardware integrated with an automated guided vehicle according to embodiments of the present disclosure; 
         FIG. 18  illustrates an assembly work station automated transfer and positioning system for large-scale hardware according to embodiments of the present disclosure; 
         FIG. 19  illustrates a top view of the stationary assembly work station automated transfer and positioning system of  FIG. 18  in close proximity to an automated transfer and positioning system of the AGV of  FIG. 17 ; and 
         FIG. 20  illustrates a perspective view of the stationary assembly work station automated transfer and positioning system of  FIG. 18  coupled to the automated transfer and positioning system of the AGV of  FIG. 17 . 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1 through 20 , described below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the example implementations, drawings, and techniques described below. Those skilled in the art will understand that the principles of the present disclosure invention may be implemented in any type of suitably arranged device or system. Additionally, the drawings are not necessarily drawn to scale. 
     A factory assembly work station is stationary in order to allow for stable assembly of large-scale components and hardware. Examples of large-scale hardware include, but are not limited to, complete Guided Missile Round (GMR) and All-up-Round (AUR). 
     A single factory assembly work station is often used to assemble a whole missile assembly in order to reduce risk of damaging subassemblies associated with lifting or otherwise manually transferring subassemblies from one location to another. The stationary assembly work station may be long (such as 48 feet or longer) in order to allow the complete assembly and the complete encanistering and decanistering of the whole missile assembly (namely, large-scale hardware extending 24 feet and weighing up to 8000 or more pounds). 
     In certain factories, it may be advantageous to assemble subassemblies at a several separate, stationary, smaller assembly work stations throughout the factory, and to combine the subassemblies at one or a few large assembly work stations. For example, a missile factory may include a smaller propulsion subassembly work station, a smaller a separate guidance subassembly work station, and a large work station to combine the two. A wheeled cart provides factory-wide transportation. A commercial off the shelf (COTS) automated guided vehicle (AGV) provides factory-wide transportation according to embodiments of the present disclosure. The AGV is capable of moving a large-scale hardware in various directions and across long distances (e.g., 500 feet). One way of transferring assemblies between stationary assembly work stations is to encanister the assembly for protection against drops or other damage. In some instances, subassemblies or complete assemblies are not encanistered while transferred between stationary assembly work stations. Then, several people (approximately 6-8 people) are required to manually lift (using hoist and push) the assembly or subassembly (using approximately 4-6 people) from the work station onto the cart. After transportation on the cart, several people are again required to manually lift, via hoist and push, the assembly or subassembly from the cart onto the next stationary work station. 
     In certain factories, the risk of damage associated with manual lifting and transferring outweighs the advantages of utilizing several subassembly work stations. Moreover, with increased sizing of parts, movement of such parts becomes untenable. 
     Given the above concerns, certain embodiments of the disclosure provide an automated, modular solution for transferring and positioning large-scale hardware and materials in a factory is needed. 
       FIGS. 1 and 2  illustrate automated transfer and positioning systems  100 ,  200 , and  201  for large-scale hardware according to embodiments of the present disclosure.  FIG. 1  illustrates the automated transfer and positioning system  100  for large-scale hardware according to embodiments of the present disclosure. The automated transfer and positioning systems  100  for large-scale hardware provide an automated, modular solution for transferring and positioning large-scale hardware and materials in a factory. The automated transfer and positioning system  100  eliminates critical lifting and manual movement from the process of moving large-scale hardware to various assembly stations within an industrial facility. The automated transfer and positioning system  100  provides an automated transfer of large-scale hardware from an assembly work station (WS) onto an automated guided vehicle (AGV) and onto an assembly work station in a different location. 
     Although certain details will be provided with reference to the components of the automated transfer and positioning system  100  for large-scale hardware, it should be understood that other embodiments may include more, less, or different components. The automated transfer and positioning system  100  includes a standard factory rail  300  (also referred to as “common factory rail” or “common rail” or “CFR”) and a cradle drive system (“CDS”)  1000 , which includes a cradle drive sled  1100 . The automated transfer and positioning system  100  includes one or more hardware cradles  1300 . Further details about the components  300 ,  1000 ,  1100 , and  1300  of the automated transfer and positioning system  100  are provided with reference to the figures below. 
     Although the present disclosure includes examples of the automated transfer and positioning system  100  being used for missile related functions, the system  100  is not limited missile related functions, and can be used to transfer, translate, or position other large-scale hardware, including: composites, molds, factory dies, fabrication shop jigs and fixtures, aircraft assemblies, spacecraft assemblies, section subassemblies, test equipment, and components of subassemblies. The automated transfer and positioning system  100  can be used for positioning patients in a mechanism, such as a magnetic resonance imaging (MRI) machine or a computed tomography (CT) scanner. 
       FIG. 2  illustrates two automated transfer and positioning systems  200 ,  201  for large-scale hardware with ends disposed in close proximity to each other according to embodiments of the present disclosure. More particularly,  FIG. 2  illustrates a perspective view of a stationary assembly work station automated transfer and positioning system in close proximity to an automated transfer and positioning system of an AGV. Some sheet metal covers are hidden for clarity. A zero-lift hardware transfer method can be implemented at any location where a common rail  300  is installed. In order to implement a zero-lift hardware transfer, the AGV&#39;s automated transfer and positioning systems  201  (also referred to as “AGV system”) docks with the stationary WS automated transfer and positioning system  200  (also referred to as “WS system”). That is, the AGV drives into close proximity to an assembly work station. The deck of the AGV includes hydraulics that, when the AGV reaches a selected distance away from the assembly work station, lowers the AGV&#39;s common rail onto a load-supporting shelf of the stationary assembly work station. The docking assemblies (as shown in  FIGS. 17 and 18 ) cause the common factory rails of the WS system  200  and the AGV system  201  to center with each other. That is, the dual vee rails align with each other. 
       FIG. 3  illustrates a common factory rail  300  according to embodiments of the present disclosure. Although certain details will be provided with reference to the components of the common factory rail  300 , it should be understood that other embodiments may include more, less, or different components. 
     The factory rail  300  is a common mechanical interface to cradles, and each cradle includes an interface configured to couple to large-scale hardware, such as a missile or an encanistered missile. That is, each cradle is configured to mechanically couple to the common rail in order to move along the rail. The factory rail  300  supports the weight load of the hardware (not shown) and integrates features that allow the cradles, and therefore the large-scale hardware, to translate longitudinally along the common rail  300 . For example, the hardware cradles  1300  translate longitudinally in the direction of the arrow L. The factory rail  300  also supports the load from canister cradles, parts presentation vehicles (PPVs), and fixture presentation vehicles (FPVs), each of which is configured to mechanically couple to the common rail  300 . 
     In certain factories, the common rail  300  is installed throughout the factory, at every stationary assembly work station, at every encaninsterization-decanisterization station, within test cells, and on every AGV. In certain embodiments, the common rail includes only one track of common rail. In certain embodiments, the common rail  300  includes multiple track sections of various lengths, such as 9 feet, 10 feet, 19 feet, 24 feet, and 48 feet. That is, the common rail  300  can include any number of track sections extending to any length. AGVs of various sizes include tracks of an appropriate length—a length proportional to the surface size of the AGV. 
     The factory rail  300  includes an end stop assembly  310  at each end of each track of the rail. Each end stop assembly includes an end stop pin  316 . The end stop assembly  310  prevents a cradle from sliding off the end of the factory rail  300 . The end stop pin  316  is a safety feature that indicates whether two systems  100  are separated or docked together at the end corresponding to the end stop assembly (namely, the end of the common rail where the end stop pin  316  is disposed). As described in further details below with reference to  FIGS. 4 and 5 , end stop pin  316  retracts when an end stop end  312  is pushed upon. 
     The factory rail  300  includes two or more barcode readers  330 . The barcode reader  330  is configured to read the barcode or quick-response (QR) code of a cradle brake plate that enters onto that specific track of the factory rail  300 . The barcode reader  330  determines the type of cradle, orientation, and serial number of the cradle. 
     A proximity sensor  335  of the factory rail  300 , such as a trigger sensor, is coupled to each end of the factory rail  300 . In certain embodiments, the proximity sensor  335  comprises a Turck proximity sensor that senses a cradle retaining plate on the common rail  300 , and in response, triggers the barcode reader to read a barcode. 
     The ends of the factory rail  300  are configured to dock with an end of another factory rail  300 . For example, the factory rail  300  of a stationary work station (also referred to as “WS rail”) is configured to dock or physically couple with the factory rail  300  of an AGV (also referred to as “AGV rail”). The end of the WS rail  300  includes an adjustable interface  340  configured to actuate an end stop end  312  of the end stop assembly  310  of the AGV rail. Similarly, the end of the AGV rail  300  includes an adjustable interface  341  configured to actuate the end stop end  312  of the WS rail. The actuation of the end stop end  312  causes the end stop pin  316  to lower or recess. The end stop pin  316  is protracted when the end stop end  312  is not actuated. 
     The common factory rail  300  includes several components used while translating cradles longitudinally: a Bishop Wisecarver Dualvee rail along both sides of the common rail  300 ; an aluminum friction surface  345  for manual cradle brake is disposed along both sides of the common rail  300 ; an end plate  350  on each end of the common rail  300 ; SHCS and dowel spacing (eighteen having a size of 5/16 inches), an socket head cap screw (SHCS) interface  355  (for example, a rack or array of small protrusions) along one side of the common rail  300  for a cradle gear; and at least two flanges and web composed from metal, such as steel. In certain embodiments, the SHCS and dowel spacing varies based on a length of the common rail  300 . 
       FIGS. 4A and 4B  illustrate an end stop assembly  310  of the common factory rail of  FIG. 3  within a housing  410 .  FIG. 5  illustrates the end stop assembly  310  of  FIGS. 4A and 4B  without the housing  410 . Referring to  FIGS. 4A, 4B, and 5 , the end stop pin  316  is included within the end stop assembly  310  of the common rail  300 . The end stop assembly  310  is contained within the housing  410  that completely encloses the end stop pin  316  when retracted. The end stop assembly pin  316  prevents a cradle from sliding off the end of the factory rail  300  when protracted. When the AGV rail  300  is docked, the AGV adjustable interface  341  pushes against an end stop end  312  of the WS end stop assembly  310 . At the same time, the WS adjustable interface  340  pushes against an end stop end  312  of the AGV end stop assembly  310 . The force pushing on the end stop ends  312  compresses the end stop pin spring  314  and causes the end stop pin  316  to recess below the top surface of the housing  410 . When the factory rail  300  is not docked, the end stop pin  316  raises and extends above the top surface of the housing  410 , preventing a cradle from passing the end plate  350  and from slipping off the end of the factory rail  300 . 
     In certain embodiments, the end stop assembly  310  includes a sensor  420  that detects whether the end stop pin  316  is recessed. As shown in  FIG. 4B , when the end stop pin  316  is raised, a lever  422  of the end stop pin  316  is in a high position and engages with an upper portion of the sensor  420 . In response to the engagement of the lever  422  and the upper portion of the sensor  420 , the sensor  420  sends a protracted-end-stop-pin indication to a controller within the AGV system  100 . As shown in  FIG. 4A , when the end stop pin  316  is retracted, the lever  422  of the end stop pin  316  is in a low position and engages with a lower portion of the sensor  420 . In response to the engagement of the lever  422  and the lower portion of the sensor  420 , the sensor  420  sends a recessed-end-stop-pin indication to a controller within the AGV system  100 . The controller within the AGV and WS system  100  uses the recessed-end-stop-pin sensor indication to trigger a fault condition that stops the AGV from driving and stops CDS sled  1100  movement when the AGV is undocked and the end stop pin is recessed. The fault condition prevents a cradle from slipping off the AGV factory rail. 
       FIG. 6  illustrates a front view of the automated transfer and positioning system  100  for large-scale hardware of  FIG. 1 . The sheet metal that covers the internal components of the automated transfer and positioning system  100  is hidden for clarity. The automated transfer and positioning system  100  includes the common rail system  300 , the cradle drive system  1000  that includes a CDS sled  1100 . The hardware cradle  1300  is partially shown—a top portion of the cradle is not shown in  FIG. 6 . 
     When the AGV includes the automated transfer and positioning system  100 , the cradle drive system includes an automated AGV cradle brake  610 . The automated AGV cradle brake  610  is not shown in  FIG. 6 , but the location of the brake  610  on each side of the common rail  300  is shown. The automated AGV cradle brake  610  stops the cradle from moving, especially while the AGV is in motion or detached from an assembly work station. 
       FIGS. 6 and 10  refer to the cradle drive system  1000 .  FIG. 10  illustrates a cradle drive system  1000  according to embodiments of the present disclosure. The CDS  1000  is integrated within the common rail  300  and provides the torque and power to move the hardware. For example, a CDS  1000  is integrated within every common rail  300  of a factory, including on WSs and AGVs. The CDS  1000  pushes or pulls hardware cradles, canister cradles, PPVs, FPVs along the common rail  300 . Although certain details will be provided with reference to the components of the CDS  1000 , it should be understood that other embodiments may include more, less, or different components. The CDS  1000  includes a drive assembly, a belt drive system, a slip coupling, and the CDS sled  1100 . The CDS  1000  is primarily disposed within the confines of the common rail system  300 , and certain components are disposed beneath the common rail  300 . 
     The CDS belt drive system includes a belt drive linear actuator  1010 , such as a Tolomatic belt drive linear actuator. The CDS belt drive system includes a gearbox  615 , disposed below the common rail  300 . More particularly,  FIG. 7  illustrates a gear box  615  of the automated transfer and positioning system  100  for large-scale hardware of  FIG. 1 . For example, the gearbox  615  can include a CGI 28:1 right angle gearbox. The gearbox  615  is coupled, such as by attachment, to a belt drive-to-gearbox adapter. 
     The slip coupling is disposed between the belt drive and the gearbox  615 . In certain embodiments, the slip coupling comprises an integral slip clutch that, in an overload condition, prevents damage to the belt drive system and hardware loaded onto the cradle. In certain embodiments, the slip coupling includes a slip coupling proximity sensor and an adjustable bracket. In the event that the CDS sled  1100  causes hardware to collide by translating a first loaded cradle too close to second loaded cradle, the slip clutch triggers the CDS sled  1100  to stop translating the first loaded cradle. The cradle drive system includes error proofing sensors to prevent collisions. 
     The CDS drive assembly includes a servomotor  620 . More particularly,  FIG. 8  illustrates a servomotor  620  of the automated transfer and positioning system  100  for large-scale hardware of  FIG. 1 . 
     The CDS  1000  includes a cable chain  630  and a cable chain guide  635  that guides the cable chain  630 . In certain embodiments, the cable chain guide  635  is composed from sheet metal.  FIG. 9  illustrates a cable chain  630  of the automated transfer and positioning system  100  for large-scale hardware of  FIG. 1 . In certain embodiments, the cable chain includes an electrostatic discharge (ESD) cable chain, such as an ESD Igus E-chain for routing high flex power or signals through cables and pneumatic lines. 
       FIG. 11  illustrates a cradle drive system sled  1100  according to embodiments of the present disclosure. The CDS sled  1100  is a component of the cradle drive system  1000 . The CDS sled is an intelligent modular device that transfers power and torque from the cradle drive system  1000  to the cradles coupled to the common rail system  300 . That is, the CDS sled  1100  provides the torque and power to move the hardware by pulling or pushing hardware cradles  1300 . More particularly, the CDS sled  1100  applies the torque and power required for translation and transfer of the hardware along the common rail  300 . For example, the CDS sled  1100  incorporates a sensor bank assembly  1110  that includes an interface  1115  configured to couple to the hardware cradle  1300  in order to transfer the torque. The CDS sled  1100  is capable of translating the full distance of the length of the common rail  300 . More particularly, when coupled to a loaded hardware cradle  1300  (hardware load not shown), the CDS sled  1100  is capable of supplying the energy required to cause a hardware cradle  1300  (including the hardware loaded thereunto) to translate the full distance of the length of the common rail  300 . Although certain details will be provided with reference to the components of the CDS sled  1100 , it should be understood that other embodiments may include more, less, or different components. 
     A controller provides intelligence to the CDS sled  1100 . In certain embodiments, the controller is included within the system  100 , such as the WS system  200 . In other embodiments, the controller is integrated into the automated transfer and positioning system  100  coupled to the CDS sled  1100 . The controller performs certain functions of the CDS sled  1100 . In certain embodiments, the controller includes executable instructions stored in a machine-usable, computer-usable, or computer-readable medium in any of a variety of forms, wherein the instructions cause the processing circuitry to perform a mapping sequence method or a zero-lift hardware transfer method. In certain embodiments, the controller includes a memory. The memory may include any suitable volatile or non-volatile storage and retrieval device(s). For example, the memory can include any electronic, magnetic, electromagnetic, optical, electro-optical, electro-mechanical, or other physical device that can contain, store, communicate, propagate, or transmit information. The memory can store data and instructions for use by the controller cause processing circuitry to execute the instructions. 
     The CDS sled  1100  includes a sensor bank assembly  1110  on each end of the sled.  FIG. 12  illustrates a sensor bank assembly  1110  of a cradle drive sled  1100  according to embodiments of the present disclosure. Although certain details will be provided with reference to the components of the sensor bank assembly  1110 , it should be understood that other embodiments may include more, less, or different components. The sensor bank assembly  1110  also includes pneumatic pins  1115  configured to be captured within a spring loaded capture clip  1310  of the hardware cradle  1300 . In certain embodiments, the pin  1115  includes a pneumatic cylinder that, when extended, raises up above the top surface of the CDS sled&#39;s  1100  sheet metal housing. The pin  1115  is capable of lowering to recess below the top surface of the CDS sled. 
     The sensor bank assembly  1110  includes two or more proximity sensors  1120  that sense in a vertically upward direction (namely, in the direction of the arrow VU). A first proximity sensor  1120  detects the presence of a cradle coupled to the common rail  300 . 
     A second proximity sensor  1120  determines engagement of the pin  1115  into a cradle&#39;s capture clip  1310 . Another sensor within the pin  1115  pneumatic cylinder indicates whether the pin  115  is extended or recessed. When the pin  1115  is extended, the second proximity sensor  1120  detects alignment of the pin  1115  with the capture clip  1310  to determine whether the CDS sled  1100  is in the correct position for moving the cradle associated with the capture clip  1310 . Based on the extended-pin signal and the alignment of the CDS sled  1100  with the cradle into the correct position, and the second proximity sensor  1120  signal that indicates the CDS sled  1100  is mechanically coupled to the cradle, and the retro-reflective sensor  1125  indicating satisfactory manual cradle brake and ring roll brake conditions, the cradle drive system deduces that the CDS sled  1100  is ready to begin moving the cradle. 
     The sensor bank assembly  1110  includes a polarized retro-reflective sensor  1125  that detects the engagement status of the manual cradle brake. When the sensor  1125  detects that the manual cradle brake or ring roll brake is engaged, the CDS sled  1100  sends a signal to a controller to alarm a user that the detected cradle should not be moved while the manual cradle brake is in an engaged status. The alarm associated with the engaged manual cradle brake prompts the user to disengage the manual cradle brake before attempting to move the cradle. The retro-reflective sensor  1125  also detects engagement of the ring roll brake of the hardware cradle  1300 . The ring roll brake of the hardware cradle is described below in reference to  FIG. 13A . 
     Other components of the CDS sled  1100  include: a cable chain bracket coupled to the cable chain  630 ; a pneumatic supply connection; a power and signal connection configured to receive electricity and signals to provide intelligence (for example, an instruction or a command) to move hardware loads; a via (also referred to as “access for removal”) configured for to receive an object to remove the CDS sled  1100  from the common rail  300 ; a pneumatic stopper cylinder; solenoid valves; supply tubing; a sled frame providing structural stability for the components of the CDS sled; and sheet metal covers. Movement of the CDS sled  1100  causes the cable chain  630  to move. Movement of the CDS sled  1100  causes the cable chain  630  to move. 
     As a specific non-limiting example, a user selects a hardware item to be moved from a WS rail to a test cell located 500 feet away through a corridor. The user selection may include a type of hardware component, assembly, or subassembly (namely, a group of identifiers corresponding to the type of hardware selected). The user selection may include a specific identifier (e.g., barcode or QR code) corresponding to a specific hardware component, assembly, or subassembly. In response to receiving the user selection, the WS CDS sled  1100 , moves to a first end of the WS rail  300 . While the CDS sled  1100  translates an entire length of the factory rail, the CDS sled  1100  reads the identifiers of each cradle coupled to the common rails  300 , looking for an identifier that matches the user selection. Upon determining that a the equipment of a cradle on the factory rail  300  matches the user selection, the CDS sled  1100  sends a signal to a user computer indicating that the selected equipment is located on the factory rail. Upon determining that none of the equipment of the cradle on the factory rail matches the user selection, the CDS sled  1100  sends a signal to a user computer indicating that the selected equipment is not located on the factory rail. 
       FIGS. 13A and 13B  illustrate various cradles according to embodiments of the present disclosure.  FIG. 13A  illustrates a hardware cradle  1300  coupled to a hardware ring  1320 . The hardware ring  1320  includes an interface  1325  configured to couple to a large-scale hardware cylinder (not shown), such as a missile. The hardware cradle  1300  includes a ring roll brake, such as a friction brake. The ring roll brake stops the hardware ring from rotating or rolling in the hardware cradle  1300 .  FIG. 13B  illustrates a hardware cradle  1301  configured to couple to a rectangular canister. The hardware cradle  1301  includes a rectangular interface  1330  configured to couple to a rectangular canister, such as an encanistered missile. 
     Although certain details will be provided with reference to the components of the cradles  1300  and  1301 , it should be understood that other embodiments may include more, less, or different components. Also, it should be understood that other embodiments may include different shapes, configured to couple to various shaped hardware rings  1320 , canisters, or other large-scale hardware. For example, a PPV is a cradle that holds various piece parts, fasteners, or other types of hardware. Each cradle  1300 - 1301  includes a manual cradle brake  1340 , such as a friction brake. To engage or disengage the manual cradle brake  1340 , a user manually turns a cradle brake handle that causes the manual cradle brake  1340  to engage with the aluminum friction surface  345  of the common rail  300 . The cradle brake prevents the cradle  1300 - 1301  from moving. 
     Using user-input data and information from the barcode reader  330  indicating the type of cradle and orientation, the controller can determine the type, size, or shape of the hardware load and prevent the CDS sled  1100  from moving a second loaded cradle too close to a first loaded cradle, thereby preventing a collision of protruding equipment. 
     Each cradle  1300 - 1301  includes a cradle capture clip  1310 .  FIG. 14  illustrates a cradle capture clip  1310  engaged with an actuated pneumatic pin  1115  of a cradle drive sled  1100  according to embodiments of the present disclosure. In certain embodiments, the capture clip  1310  includes a sensor that indicates whether the capture clip  1310  has completed engagement or capture of the CDS sled pin  1115  into the clips  1310 . 
       FIG. 15  illustrates a zero-lift transfer method  1500  according to embodiments of the present disclosure. The zero-lift transfer method  1500  incorporates a mapping sequence method according to embodiments of the present disclosure. The embodiment of the zero-lift transfer method  1500  shown in  FIG. 15  is for illustration only. Other embodiments could be used without departing from the scope of this disclosure. 
     As a specific and non-limiting example, an implementation of the zero-lift transfer method  1500  begins with an empty AGV rail  300  and a single-loaded WS rail. The AGV is described as empty because no cradles  1300 - 1301  are coupled to the AGV rail  300 . The WS rail is described as single loaded because only one large-scale hardware load is loaded onto the WS rail. The hardware load is coupled to two hardware cradles  1301 . A front portion of the hardware load is coupled to a first hardware cradle mechanically coupled to the WS rail. A rear portion of the hardware load is coupled to a second hardware cradle  1301  mechanically coupled to the WS rail. A controller of the AGV and WS automated transfer and positioning systems  201  and  200  respectively receives user selection. The user selection instructs the AGV to dock to the empty AGV rail to the single-loaded WS rail, to transfer the single hardware load onto the AGV rail, and to drive the single-loaded AGV rail a location that is non-collinear with the WS rail. 
     In block  1510 , the AGV drives into alignment with the work station. More particularly, the AGV drives into close proximity with the work station and substantially aligns AGV rail to the WS rail in a parallel manner. Processing circuitry within a controller of AGV and WS automated transfer and positioning systems  201  and  200  causes the AGV to position the AGV rail such that when the hydraulic system of the AGV lowers the AGV rail to be coplanar with the WS rail, the AGV rail is collinear with the WS rail. 
     In block  1520 , when the dual vee rails of the AGV and work station are aligned, and when the common rail  300  of the AGV system  201  is docked to the common rails of the work station system  200 , the CDS sled  1100  of the WS system  200  initializes a mapping sequence method. In certain embodiments, the AGV system  201  initializes a mapping sequence method. As described below, during the mapping sequence process, the system  100  determines the location, type, identifiers, and cradle brake status of each cradle coupled to the factory rail  300 . In certain embodiments, after the docking mechanically couples the AGV system  201  to the WS system  200 , the WS system  200  causes the utility connector to extend and couple to a utility terminal of the AGV system  201 . 
     In a mapping sequence process, the CDS sled  1100  travels the end of the common rail, and then translates the entire length of the rail and work station rail, using the proximity sensors  1120  to look for or detect each cradle coupled to the factory rail  300 , and detect their associated manual brake/ring-roll brake status. More particularly, the AGV system  201  implements a mapping sequence process using the AGV CDS sled  1100  and the AGV rail, but not the WS rail. The WS system  200  implements a mapping sequence process using the WS CDS sled  1100  and WS rail  300 , but not the AGV rail. When the CDS sled  1100  moves under a cradle, such as a hardware cradle  1300 , the proximity sensors  1120  identify or detect that the cradle  1300  is coupled to the common rail  300  and detect the associated manual brake and ring roll brake status of the cradle. The cradle drive system  1000  identifies the type of the detected cradle based on a code (e.g., barcode or QR code) on the servomotor  620 . The reading of the servomotor&#39;s  620  code is sent to a controller of the system  100 , which uses the code to determine information about the cradle  1300 , such as a location of the cradle along the length of the rail. For example, the CDS  1000  identifies whether the detected cradle is a hardware cradle  1300  or a canister type cradle. The controller of the system  100  uses signals from the CDS sled  1100  to determine the location of the detected cradle, including whether the cradle is disposed on the station&#39;s factory rail  300  or the AGV&#39;s factory rail  300 . 
     In block  1530 , the AGV system  201  implements a docking process and docks to the WS system  200 . More particularly, the AGV rail docks with the WS rail. That is, the AGV rail has been lowered to become coplanar, collinear, and mechanically coupled to the WS rail. Upon mechanical coupling, such as, when the AGV and WS end stop pins  310  recess, the WS utility connectors extend toward the AGV to electrically and pneumatically couple to the AGV system  201  to the electrical and pneumatic source of the WS system  200 . While the AGV and WS are electrically coupled, the WS system  200  controls the AGV CDS through the utility connection. 
     In block  1540 , the AGV system  201  initializes a mapping sequence. In certain embodiments, the WS system  200  initializes a mapping sequence method. As described above, during the mapping sequence process, the system  100  determines the location, type, and identifiers of each load and cradle coupled to the factory rail  300 . 
     Also in block  1540 , the WS CDS sled  1100  latches to the second hardware cradle  1300  coupled to the rear portion of the hardware load. That is, the capture clip  1310  of the second cradle  1300  captures the pin  1115  of the WS CDS sled. A CDS sled  1100  is not required to latch to the second cradle, and is capable of latching to any cradle  1300 . In certain embodiments, the CDS  1000  instructs the WS CDS sled  1100  to couple to the loaded cradle furthest away from the AGV CDS sled  1100 , enabling the WS CDS sled  1100  to translate the attached cradle  1300  the longest distance prior to transferring control over movement of the hardware load to the AGV CDS  1000  (namely, moved by the AGV CDS sled  1100 ). 
     In block  1550 , in response to the latching in block  1540 , the front portion of the single hardware load is transferred from the WS rail  300  to the AGV rail. The rear portion of the single hardware load, is coupled to a second cradle, which is disposed a further distance way from the front end of the WS rail (namely, further away from the AGV rail) than the first cradle coupled to the front portion of the single hardware load. To move the first cradle  1300 , which is coupled to the front portion of the single hardware load, to the AGV rail, the WS system moves the rear portion of the single hardware load to the front end of the WS rail. To locate the second cradle coupled to the rear position of the single hardware load, the WS system  200  performs a partial mapping sequence, such as a cradle locating sequence, using the WS CDS sled  1100 . The WS CDS sled  1100  translates the WS rail  300  sensing for the second cradle  1300  coupled to the rear portion of the hardware load. In certain embodiments, a controller of the WS system  200  sends command signals to the WS CDS sled  1100  to locate and latch to a specified cradle, such as the second cradle  1300 . In certain embodiments, the command signal includes identifying information that identifies the specified cradle to be located and latched. For example, the identifying information can include the barcode or QR code of the specified cradle. In certain embodiments, while the WS CDS sled  1100  is currently coupled to the first cradle, the command signal instructs the WS CDS sled  1100  to locate a next cradle disposed closest to the first cradle, such as the second cradle  1300 . In a cradle locating sequence, the CDS sled  1100  translates only the portion of the rail  300  necessary to locate and latch to the specified cradle, namely, the second cradle  1300 . In response to locating the specified cradle (i.e., the second cradle  1300 ), the WS CDS sled  1100  latches to the second cradle  1300  coupled to the rear portion of the hardware load. Then, the WS CDS sled pushes the second cradle  1300  as close as possible to the front end of the WS rail  300 , and accordingly, the rear portion of the single hardware load is pushed to the forward-most position on the WS rail. As a result, the first cradle coupled to the front portion of the hardware load longitudinally translates onto the AGV rail, and the front portion of the hardware load is disposed above the AGV rail. 
     The WS system  200  sends control or data signals to the AGV system  201  during the transfer of a cradle between the AGV rail and WS rail. A large-scale hardware load can be coupled to any number of cradles, such as 2, 4, or 6 cradles. In this particular embodiment, only a CDS sled  1100  of one rail can move the large-scale hardware load. That is, when the WS system  200  enables the WS CDS sled  1100  to move the cradles coupled to the hardware load, the WS system  200  sends a control signal to the AGV system  201  disabling the AGV CDS sled  1100  from moving any of the cradles coupled to the hardware load. Similarly, when the WS system  200  disables the WS CDS sled  1100  from moving the cradles coupled to the hardware load, the WS system  200  sends a control signal to the AGV system  201  enabling the AGV CDS sled  1100  to move any of the cradles coupled to both the hardware load. In certain embodiments, the AGV system  201  is configured to send enable-disable control signals to the CDS sled  1100  of the WS system  200 . That is, once the AGV CDS sled  1100  engages or couples to the cradle  1300 , the WS CDS sled  1100  disengages. 
     Although only one CDS sled  1100  is shown in this embodiment for moving large-scale hardware, more than one can be used in other embodiments. For example, in certain embodiments, one may push while the other pulls. 
     In block  1560 , the AGV system  201  performs a cradle locating sequence, by using the AGV CDS sled  1100  to translate the AGV rail  300  sensing for the first cradle  1300  coupled to the front portion of the hardware load. In response to locating the first cradle  1300 , the AGV CDS sled  1100  latches to the second cradle  1300  coupled to the front portion of the hardware load. 
     In block  1570 , the AGV CDS sled  1100  completes the transfer of the remaining portion of the hardware from the WS rail to the AGV rail. That is, the AGV CDS sled  1100  pulls the first cradle  1300  in a direction away from the WS rail and far enough for the second cradle to couple to the AGV rail. As a result, the second cradle coupled to the rear portion of the hardware load longitudinally translates onto the AGV rail, and the rear portion of the hardware load is disposed above the AGV rail. 
     In block  1580 , the AGV rail is single loaded, and the WS rail is empty. The WS system  200  electrically and pneumatically decouples by disengaging the WS utility connectors from the AGV power source. The AGV system  201  causes the AGV rail  300  to undock from the WS rail, including using the hydraulic system to raises the AGV rail. As a result of the undocking, the assembly stop pins  310  of the AGV rail and WS rail extend. 
       FIG. 16  illustrates an automated cradle brake  610  of an automated transfer and positioning system for large-scale hardware of  FIG. 1 . Although certain details will be provided with reference to the components of the cradle brake  610  for large-scale hardware, it should be understood that other embodiments may include more, less, or different components. The cradle brake  1600  includes one or more brake pads  1610 , and a brake actuator cylinder  1620  that senses which the cradle brake pads  1610  are engaged. In certain embodiments, the brake plates  1610  include an array of friction brake pads arranged in a line along the length of the CFR  300 . 
       FIG. 17  illustrates an AGV system  1701  integrated on an AGV  1710  according to embodiments of the present disclosure. Although certain details will be provided with reference to the components of the AGV system  1701  for large-scale hardware, it should be understood that other embodiments may include more, less, or different components. The AGV system  1701  includes the components and functions of the AGV system  201 . The AGV system  1701  includes a utility connection terminal  1730  for receiving electrical energy from an external source, such as from a work station utility connector. The AGV system also includes a docking assembly  1720  configured to mechanically couple to a WS system  200 , such as via a WS system docking assembly. The AGV docking assembly  1720  includes sensors that detect the position of the AGV common rail  300  relative to the position of the WS common rail  300 , and causes the AGV common rail to mechanically align centered with the WS common rail using the hydraulic system of the AGV. 
       FIG. 18  illustrates a WS system  1800  according to embodiments of the present disclosure. Although certain details will be provided with reference to the components of the WS system  1800  for large-scale hardware, it should be understood that other embodiments may include more, less, or different components. The WS system  1800  includes the components and functions of the WS system  200 . The WS system  1800  includes a utility connection terminal or port  1820  for transmitting electrical energy to an external source, such as to the AGV system  201 ,  1701  via the utility connection terminal  1730 . In certain embodiments, the WS system utility connection port  1830  and the AGV system utility connection terminal  1730  are configured to couple with each other. The WS system  1800  includes a docking assembly  1830  configured to mechanically couple to the AGV system docking assembly  1720 . The WS docking assembly  1820  detects the position of the AGV common rail  300  relative to the position of the WS common rail  300 , and causes the AGV common rail to align centered with the WS common rail. For example, the docking assemblies  1720  and  1820  indicate to the AGV  1710  to move the AGV common rail  300  come into center alignment with the WS common rail. 
       FIG. 19  illustrates a top view of the stationary assembly work station automated transfer and positioning system  1800  in close proximity to an automated transfer and positioning system  1701  of an AGV  1710 . 
       FIG. 20  illustrates a perspective view of the stationary assembly work station automated transfer and positioning system  1800  coupled to the automated transfer and positioning system  1701  of the AGV  1710 . 
     It is important to note that while the present disclosure includes a description in the context of a fully functional system, those skilled in the art will appreciate that at least portions of the mechanism of the present disclosure are capable of being distributed in the form of instructions contained within a machine-usable, computer-usable, or computer-readable medium in any of a variety of forms, and that the present disclosure applies equally regardless of the particular type of instruction or signal bearing medium or storage medium utilized to actually carry out the process  1500 . Examples of machine usable, machine readable or computer usable, computer readable mediums include: nonvolatile, hard-coded type mediums such as read only memories (ROMs) or erasable, electrically programmable read only memories (EEPROMs), 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). 
     Although various features have been shown in the figures and described above, various changes may be made to the figures. For example, the size, shape, arrangement, and layout of components shown in  FIGS. 1 and 14 and 16-20  are for illustration only. Each component could have any suitable size, shape, and dimensions, and multiple components could have any suitable arrangement and layout. Also, various components in  FIGS. 1 through 14 and 16-18  could be combined, further subdivided, or omitted and additional components could be added according to particular needs. Further, each component in a device or system could be implemented using any suitable structure(s) for performing the described function(s). In addition, while  FIG. 15  illustrates various series of steps, various steps in  FIG. 15  could overlap, occur in parallel, occur multiple times, or occur in a different order. 
     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. 
     None of the description in the present application should be read as implying that any particular element, step, or function is an essential element which must be included in the claim scope: the scope of patented subject matter is defined only by the allowed claims. Moreover, none of these claims are intended to invoke paragraph six of 35 USC §112 unless the exact words “means for” are followed by a participle.