Patent Publication Number: US-11021348-B2

Title: Automated cargo transfer system

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application Ser. No. 62/720,994, which was filed on Aug. 22, 2018, the entirety of which is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     This disclosure relates to implementations of an automated cargo transfer system. 
     BACKGROUND 
     Loading and offloading a supply vessel (e.g., an oceangoing ship) using existing equipment is time consuming and extremely hazardous, particular during periods of rough weather. Working on the deck of a supply vessel is one of the most dangerous work environments for crew members. Therefore, there is a need to eliminate crew members, or at least reduce the number of crew member, on deck while a supply vessel is being loaded and/or offloaded. 
     Further, cargo handling technology typically used to load and offload supply vessels relies on multiple workers/crew to individually move each unit of cargo. This is a labor-intensive task that is both time consuming and expensive. Therefore, there is a need to reduce the amount of labor required to load and offload cargo from a supply vessel. 
     Accordingly, it can be seen that needs exist for the automated cargo transfer system disclosed herein. It is to the provision of an automated cargo transfer system configured to address these needs, and others, that the present invention is primarily directed. 
     SUMMARY OF THE INVENTION 
     Implementations of an automated cargo transfer system are provided. The automated cargo transfer system is used, in conjunction with a crane, to load cargo onto, and unload cargo from, the deck of a watercraft. 
     An example automated cargo transfer system comprises: a dynamic positioning system installed on the watercraft, the dynamic positioning system is configured to position and orient the watercraft when actuated; a crane hook system installed on the crane, the crane hook system comprises a hook mechanism configured to interface with cargo; a crane automation system configured to automate the operation of the crane, the crane in conjunction with the crane hook system are used to load cargo onto, and unload cargo from, the deck of the watercraft at the direction of the automated cargo transfer system; and a load plan comprising: data that identifies all cargo being transported by the watercraft, data used by the dynamic positioning system to actively position and orient the watercraft during loading and unloading of the watercraft, and data used by the crane hook system to actively position and orient the hook mechanism during loading and unloading of the watercraft. The automated cargo transfer system is configured to actively track the location of the watercraft, the hook mechanism of the crane hook system, and cargo. The automated cargo transfer system is also configured to actively position and orient the watercraft and the hook mechanism of the crane hook system based on the location and weight of cargo being loaded onto, and unloaded from, the deck of the watercraft. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1-4  illustrate an example automated cargo transfer system according to the principles of the present disclosure. 
         FIG. 5  illustrates an example cargo lifting device of the automated cargo transfer system shown in  FIGS. 1-4 , wherein the cargo lifting device is shown secured to a cargo. 
         FIG. 6  illustrates an exploded view of the cargo lifting device shown in  FIG. 5 . 
         FIGS. 7 and 8  illustrate an example deck section of the automated cargo transfer system shown in  FIGS. 1-4 . 
         FIG. 9  illustrates the automated cargo transfer system as a multi-directional flow chart. 
     
    
    
     Like reference numerals refer to corresponding parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION 
       FIGS. 1-4  illustrate an example implementation of an automated cargo transfer system  100  according to the principles of the present disclosure. The automated cargo transfer system  100  may be used to load cargo onto, and unload cargo from, the deck of a ship  102 . 
     Modern ships  102  frequently use dynamic positioning systems to hold station near an offshore asset (e.g., an oil and/or gas platform). Implementations of the automated cargo transfer system  100  are configured for use with such a vessel  102  and can be used to load cargo onto, and unload cargo from, the deck thereof. In this way, the crew&#39;s exposure to danger while cargo is being unloaded onto the offshore asset, and/or cargo from the offshore asset is being loaded onto the vessel  102 , is minimized. 
     As shown in  FIGS. 1-4 , in some implementations, the automated cargo transfer system  100  may comprise: a deck section  110  that includes an array of sockets  112  therein; at least one cargo lifting device  120  comprised of a base portion  122  and a crane coupling  130 ; a crane hook system  140  configured to interface with the crane coupling  130  and thereby used to reposition a cargo lifting device  120 , and its cargo; and a crane automation system  150  configured to operate a crane  104  equipped with the crane hook system  140  and thereby load cargo onto, or unload cargo from, a deck section  110  of the system  100 ; or a suitable combination thereof. 
     A shown in  FIGS. 3 and 4 , in some implementations, the deck section  110  of an automated cargo transfer system  100  is installed on, or retrofit to, the deck of a ship  102  (e.g., an offshore supply vessel) and configured to removably secure one or more cargo lifting devices  120  thereon. In some implementations, a ship  102  may include more than one deck section  110 . In some implementations, a deck section  110  may be configured to record the relative position and weight of cargo positioned thereon, this data may be used to complete stability calculations for the ship  102 . 
     As shown in  FIGS. 7 and 8 , in some implementations, a deck section  110  comprises an array of sockets  112 , each socket  112  includes a mechanical locking mechanism  114  and is configured to receive a foot  124  of a base portion  122  therein. In some implementations, the sockets  112  of a deck section  110  may be spaced apart from each other in a grid-like array, or matrix. The mechanical locking mechanism  114  of each socket  112  interfaces with a foot  124  of the base portion  122 , thereby securing the cargo lifting device  120  in place. In some implementations, the mechanical locking mechanism  114  may be a sectional lock, or another suitable mechanical locking mechanism known to one of ordinary skill in the art (e.g., pegs). In some implementations, an electromechanical locking mechanism may be used in conjunction with, or in-lieu of, a mechanical locking mechanism  114  to secure the foot  124  of a base portion  122  within a socket  112  of a deck section  110 . One of ordinary skill in the art, having the benefit of the present disclosure, would be able to select an appropriate electrotechnical locking mechanism. 
     In some implementations, one or more sensors configured to record the weight, and relative position, of a cargo lifting device  120  and its cargo may be positioned within each socket  112  of a deck section  110 . In this way, the automated cargo transfer system  100  may record the weight, and track the relative position, of all cargo positioned on a deck section  110  of the ship  102 . This data (i.e., weight and the relative position of cargo) may be used to complete stability calculations for the ship  102 . 
     As shown in  FIG. 8 , in some implementations, a deck section  110  may further comprise one or more electromagnetic locking mechanisms  116  that are positioned amongst, or in-between, the sockets  112 . Each electromagnetic locking mechanism  116  may be positioned and configured to secure a cargo lifting device  120  in position on the deck section  110  by magnetically adhering to the underside of the base portion  122 . In some implementations, one or more electromagnetic locking mechanisms  116  may be used instead of mechanical locking mechanisms  114  to secure one or more cargo lifting devices  120  in position on a deck section  110  of an automated cargo transfer system  100 . 
     Although not shown, in some implementations, a deck section  110  of an automated cargo transfer system  100  may not include any sockets  110  therein. One or more electromagnetic locking mechanisms  116  may be used to secure a cargo lifting device in position on the deck section  110 . 
     As shown in  FIG. 4 , in some implementations, each cargo lifting device  120  may be used to reposition (e.g., lift, lower, and horizontally move) a cargo. In some implementations, the base portion  122  and/or the crane coupling  130  of a cargo lifting device  120  may be retrofitted to a cargo (e.g., an intermodal container, a lifting basket, a tote tank, a pipe rack, or other suitable shipping container). 
     As shown in  FIGS. 5 and 6 , in some implementations, the base portion  122  of a cargo lifting device  120  is configured to support the weight of a cargo placed thereon and to interface with a portion (e.g., one or more sockets  112 ) of the deck section  110 . In this way, the primary and/or secondary locking mechanisms (e.g.,  114 ,  116 ) may be used to secure the cargo lifting device  120  in place on the deck section  110 . 
     As shown in  FIG. 5 , in some implementations, a base portion  122  of a cargo lifting device  120  may include four or more feet  124  on the underside thereof, each foot  124  is configured (e.g., positioned and dimensioned) to be received within a socket  112  of a deck section  110 . In some implementations, there may be less than four feet  124  on the underside of the base portion  122 . In some implementations, the base portion  122  of a cargo lifting device  120  may be configured (e.g., dimensioned) to maximize deck space by not overlapping sockets  112  that it is not intended to interface with. 
     In implementations where the deck section  110  does not include sockets  112  therein, the base portion  122  of the cargo lifting device  120  may not include feet  124  on the underside thereof. 
     As shown in  FIG. 4 , in some implementations, the crane coupling  130 , in conjunction with a crane  104  equipped with the crane hook system  140 , may be used to lift, lower, and horizontally move a cargo lifting device  120 , and its attendant cargo. In some implementations, the crane coupling  130  of a cargo lifting device  120  may be secured, directly or indirectly, to the base portion  122  and thereby used to lift a cargo resting thereon (see, e.g.,  FIG. 5 ). 
     As shown in  FIGS. 5 and 6 , in some implementations, a crane coupling  130  of a cargo lifting device  120  may comprise a self-centering lift cone  132  that is configured to interface with the crane hook system  140 ; and mounting hardware  134  that can be used to secure the crane coupling  130  directly to the base portion  122  or, in some instances, a cargo. 
     As shown in  FIGS. 5 and 6 , in some implementations, the self-centering lift cone  132  of the cargo lifting device  120  may include an annular lip  138  that is larger in diameter than the central body portion  136  of the crane coupling  130 . In this way, a portion of the crane hook system  140  may engage with the underside of the annular lip  138  and thereby lift the cargo lifting device  120  and its attendant cargo. 
     In general, the mounting hardware  134  of a cargo lifting device  120  may be any suitable part, or combination of parts, needed to facilitate attachment of the lift cone  132 , by the central body portion  136  of the crane coupling  130 , to the base portion  122 , or a cargo (see, e.g.,  FIGS. 5 and 6 ). In some implementations, pins  126 , or other suitable mechanical fasteners, may be used to removably secure the mounting hardware  134  to a base portion  122  of a cargo lifting device  120  or, in some instances, a cargo. In some implementations, one or more portions of the mounting hardware  134  may be welded to the base portion  122  of a cargo lifting device  120 , or in some instances, a cargo. 
     In some implementations, a cargo lifting device  120  may also include a sensor that is affixed thereon, or directly to the cargo. This sensor is a unique identifier for the cargo and may be configured to track, for example, movement of the cargo, temperature of the cargo, weight of the cargo, cargo type (e.g., hazardous material(s), etc.), pressure within the cargo vessel, or a combination thereof. 
     As shown in  FIGS. 3 and 4 , in some implementations, the crane hook system  140  of the automated cargo transfer system  100  may comprise a conical hook mechanism  142  that is configured to axially rotate about the crane cable  105  its attached to; and one or more sensor suites  146 ,  148  that collect and provide data to the crane automation system  150 . 
     In some implementations, the conical hook mechanism  142  of the crane hook system  140  is configured to directly interface with the self-centering lift cone  132  of a crane coupling  130 . In this way, the conical hook mechanism  142  may be used to move a cargo lifting device  120 , and its attendant cargo. In some implementations, the conical hook mechanism  142  is a shell that is configured to receive at least a portion of a self-centering lift cone  132  therein; and includes a locking mechanism (e.g., a camming lock mechanism) that is configured to engage with the underside of the annular lip  138  found on the self-centering lift cone  132 . Operation of the locking mechanism may be automated, thereby allowing the crane automation system  150  to connect and/or disconnect the conical hook mechanism  142  to/from the self-centering lift cone  132  of a cargo lifting device  120 . 
     In some implementations, the sensor suite(s)  146 ,  148  of the crane hook system  140  may comprise one or more sensors/input devices (e.g., a camera, lidar, a laser range finder, etc.) that feed data to the crane automation system  150  and/or an operator. 
     As shown in  FIG. 4 , in some implementations, a sensor suite  146  of the system  100  may be positioned on the crane cable  105 , a fixed distance above the conical hook mechanism  142 . In this way, data collected by one or more sensors of the sensor suite  146  can be related to the actual position of the conical hook mechanism  142 . In some implementation, the one or more sensors/input devices of the cable sensor suite  146  may be configured to, for example, detect vessel movement, locate and identify cargo, communicate with the computer system of the crane  104 , or a combination thereof. 
     As shown in  FIG. 3 , in some implementations, another sensor suite  148  of the system  100  may be positioned at, or near, the end of a crane&#39;s  104  boom  106 . In some implementations, the one or more sensors/input devices of the boom&#39;s  106  sensor suite  148  may be configured to, for example, detect vessel location, detect the location of the hook mechanism  142 , detect the identity of cargo, or a combination thereof. 
     In some implementations, the computer system of the crane  104  may be configured to control all aspects of its operation. In some implementations, the computer system of the crane  104  may be configured to move and/or rotate the conical hook mechanism  142  in order to: compensate for overswing, heave, and/or vessel movement, and to position a cargo loading device  120  so that it is properly oriented to interface with a deck section  110  of the system  100 . Further, the computer system of the crane  104  may be configured to interface with other portions of the automated cargo transfer system  100  (e.g., the crane automation system  150 , the computer system of the vessel  102 , etc.). 
     In some implementations, the crane automation system  150  of the automated cargo transfer system  100  may be configured to perform the following task: 
     The crane automation system  150  may be configured to automate the operation of a crane  104  equipped with the crane hook system  140 . In this way, without the assistance of the crew, cargo loading devices  120  and attendant cargo may be loaded onto, or unloaded from, a deck section  110  of a supply vessel  102  equipped with the system  100 . 
     Further, the crane automation system  150 , using the sensor suite(s)  146 ,  148 , may be configured to locate cargo positioned on a deck section  110  of the system  100 , secure the conical hook mechanism  142  to the crane coupling  130  of a cargo lifting device  120 , and reposition the cargo lifting device  120 , and its attendant cargo, on the deck section  110  of a vessel  102  and/or unload it from the supply vessel  102 . 
     Further still, the crane automation system  150 , using the sensor suite(s)  146 ,  148 , may be configured to load cargo onto a deck section  110  of the system  110  by using the conical hook mechanism  142  to lift a cargo lifting device  120 , its attendant cargo, and position it on a portion of the deck section  110  of the system  110 . 
     In some implementations, the crane automation system  150  uses the sensor suite(s)  146 ,  148  to, for example, detect/track vessel  102  movement, locate specific cargo loading devices  120 , orient (or register) the conical hook mechanism  142  so that it is positioned to interface with the crane coupling  130  of a cargo lifting device  120 , position a cargo lifting device  120  being carried by the crane  104  so that the feet  124  located on the base portion  122  thereof are received by the appropriate sockets  112  in the deck section  110 , or a suitable combination thereof. 
     In some implementations, the computer system of a vessel  102  equipped with an automated cargo transfer system  100  may be used to interface the components of the system  100  (e.g., any locking mechanism(s)  114 ,  116 , a crane  104  equipped with a crane hook system  140 , the crane automation system  150 , location beacons  160 , etc.) with the dynamic positioning system of the vessel  102 , one or more systems of an offshore asset, one or more systems of an onshore loading facility, or a suitable combination thereof. 
     The following is an example scenario in which an automated cargo transfer system  100  may be used. The following scenario is an example only and is not meant to limit the scope of the automated cargo transfer system  100  invention. 
     Initially, the loadout requested by an offshore asset (e.g., an oil rig) is planned. The loadout may comprise a variety of cargo that is to be transported to the offshore asset by a supply vessel  102 . 
     Then, the loadout request is transmitted to the onshore loading facility which may use a legacy crane, or a crane  104  equipped with the crane hook system  140  that is operated by the crane automation system  150 , to load cargo onto a supply vessel  102  equipped with at least one deck section  110  of the system  100  (see, e.g.,  FIGS. 2 and 3 ). If a legacy crane is used to load cargo onto the deck section(s)  110  of the supply vessel  102 , shoreside personal could be used to assist with positioning cargo loading devices  120  so that the feet  124  thereof interface with the sockets  112  of a deck section  110 . In some implementations, as the crane  104  lifts a cargo lifting device  120  and its attendant cargo, a weight detecting sensor of the cable sensor suite  146  may be used to detect the weight of the cargo as it is loaded onto the supply vessel  102 . The recorded weight of the cargo may be associated with the sensor affixed to the cargo loading device  120 , or directly to the cargo, that serves as its unique identifier. 
     Next, at the direction of the offshore asset, the requested cargo is loaded onto the supply vessel  102  using the automated cargo transfer system  100 . To initiate the requested cargo being loaded onto the supply vessel  102 , the offshore asset would communicate with the computer system of the supply vessel  102  and thereby activate the supply vessel&#39;s  102  dynamic positioning system and verify that the requested cargo will not create an unsafe stability issue for the supply vessel  102  (see, e.g.,  FIG. 9 ). 
     Then, the supply vessel  102  travels to the offshore asset and establishes itself in a proper location, suitable for unloading cargo, near the offshore asset. 
     Next, the offshore asset will initiate a discharge plan in which a crane  104  equipped with a crane hook system  140  will be used to unload cargo from the deck section(s)  110  of the supply vessel  102  onto a desired location of the offshore asset. Each cargo loading device  120 , and its attendant cargo, will be unloaded in a specified order that will be completed based on vessel stability, crane  104  load limitations, and any required cargo unloading sequence that was included as part of the discharge plan. 
     Then, using the sensor suite(s)  146 ,  148  of the system  100  to scan the deck section(s)  110  and identify cargo that is part of the loadout request, the crane  104  at the direction of the crane automation system  150  will begin to unload identified cargo from the supply vessel  102 . The crane  104 , in conjunction with the crane automation system  150 , is configured to compensate for the unintended movement of the supply vessel  102  and thereby adjust the movements of the conical hook mechanism  142  so that it can interface with the self-centering lift cone  132  of the desired cargo lifting device  120 . Further, in some implementations, the supply vessel  102  may also include one or more location beacons  160  thereon that are configured to precisely track the movement of the supply vessel  102  and communicate that data to the crane automation system  150  (see, e.g.,  FIGS. 1 and 9 ). 
     Once the conical hook mechanism  142  of the crane hook system  140  is secured to the crane coupling  130  of a cargo lifting device  120 , the locking mechanism(s)  114 ,  116  securing the feet  124  of the base portion  122  within the sockets  112  of the deck section  110  will be released. In this way, the crane  104  is able to lift the cargo loading device  120 , and its attendant cargo, off the deck section  110  of the supply vessel  102  and transfer it to the offshore asset. 
     This process continues until all cargo lifting devices  120 , and attendant cargo, identified as part of the requested loadout are unloaded from the supply vessel  102 . 
     While the above operations are described in a particular order, this should not be understood as requiring that such operations be performed in that particular order, or that all operations be performed, to achieve desirable results. 
     In some implementations, the release of any locking mechanism(s) (e.g.,  114 ,  116 ) holding a particular cargo lifting device  120  in position on the supply vessel  102  may be simultaneous, or follow a staged process. As an example, a staged process may comprise the mechanical locking mechanism(s)  114  being released from engagement with a cargo lifting device  120  prior to any electromagnetic locking mechanism(s)  116 . In some implementations, when cargo is being transported between the onshore loading facility and the offshore asset, any mechanical locking mechanism(s)  114  of a system  100  may be used to secure one or more cargo lifting devices  120  in position on the deck section(s)  110  of the supply vessel  102 . In general, it is envisioned that any electromagnetic locking mechanism(s)  116  of a system  100  will primarily be used when cargo is initially loaded onto, or just prior to cargo being unloaded from, the deck section(s)  110  of the vessel  102 , while the mechanical locking mechanism(s) are not being used (i.e., disengaged from the cargo loading device(s)  120 ). 
     In some implementations, the method or methods described above in connection with the automated cargo transfer system  100 , the crane automation system  150  in particular, may be executed or carried out by a computing system including a tangible computer-readable storage medium, also described herein as a storage machine, that holds machine-readable instructions executable by a logic machine (i.e. a processor or programmable control device) to provide, implement, perform, and/or enact the above described methods, processes and/or tasks. When such methods and processes are implemented, the state of the storage machine may be changed to hold different data. For example, the storage machine may include memory devices such as various hard disk drives, CD, or DVD devices. The logic machine may execute machine-readable instructions via one or more physical information and/or logic processing devices. For example, the logic machine may be configured to execute instructions to perform tasks for a computer program. The logic machine may include one or more processors to execute the machine-readable instructions. The computing system may include a display subsystem to display a graphical user interface (GUI) or any visual element of the methods or processes described above. For example, the display subsystem, storage machine, and logic machine may be integrated such that the above method may be executed while visual elements of the disclosed system and/or method are displayed on a display screen for user consumption. The computing system may include an input subsystem that receives user input. The input subsystem may be configured to connect to and receive input from devices such as a mouse, keyboard, or gaming controller. For example, a user input may indicate a request that a certain task is to be executed by the computing system, such as requesting the computing system to display any of the above described information, or requesting that the user input updates or modifies existing stored information for processing. A communication subsystem may allow the methods described above to be executed or provided over a computer network. For example, the communication subsystem may be configured to enable the computing system to communicate with a plurality of personal computing devices. The communication subsystem may include wired and/or wireless communication devices to facilitate networked communication. The described methods or processes may be executed, provided, or implemented for a user or one or more computing devices via a computer-program product such as an application programming interface (API). 
     In another example implementation of the automated cargo transfer system, the crane hook system may be configured to facilitate the transfer of fluid cargo (e.g., liquids, gases, and/or solids). In some implementations, a crane hook system configured to facilitate the transfer of fluid cargo may be similar to the crane hook system  140  discussed above but includes a hose and a hose connector junction configured to interface with the discharge manifold found on a fluid containing cargo, instead of a conical hook mechanism  142 . In some implementations, such a crane hook system may include one or more sensors that are configured to detect the location of a discharge manifold on a cargo, detect if the hose connector junction is locked to the discharge manifold, and/or detect the movement of fluids. In some implementations, the crane automation system  150  may be configured to automate the positioning and engagement of the hose connector junction with the discharge manifold of a cargo. 
     Implementations of the crane hook system that are configured to facilitate the transfer of fluid cargo may also include a pumping mechanism configured to facilitate the movement of a fluid through the hose and/or an automated shutdown mechanism that activates if a fluid leak is detected. 
     In some implementations, the automated cargo transfer system  100  may further comprise an onboard crane that is secured to the supply vessel  102  (not shown). The onboard crane may be equipped with a crane hook system  140 . The onboard crane can be used when the primary crane  104  is unable to effectively reach all portions of the deck section  110  and/or to further consolidate one or more cargo lifting devices  120 , and their attendant cargo, on the deck section  110  of the supply vessel  102 . In some implementations, the onboard crane includes a crane automation system configured to operate the onboard crane. The crane automation system of the onboard crane may be the same as, or similar to, the crane automation system  150  described above. 
     Reference throughout this specification to “an embodiment” or “implementation” or words of similar import means that a particular described feature, structure, or characteristic is included in at least one embodiment of the present invention. Thus, the phrase “in some implementations” or a phrase of similar import in various places throughout this specification does not necessarily refer to the same embodiment. 
     Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. 
     The described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the above description, numerous specific details are provided for a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that embodiments of the invention can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations may not be shown or described in detail. 
     While operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results.