Patent ID: 12227218

DETAILED DESCRIPTION

As noted above, thousands of items, articles, or products can be stored at materials handling facilities. These items can be stored at many different locations in the materials handling facilities. It is necessary to transport the items from place to place within the materials handling facilities, as items are consolidated for orders to ship and new items are introduced to the facilities for restocking. To that end, many different types of materials handling equipment and systems, including conveyor systems, chutes, carts, robotic systems, and other equipment are often relied upon to facilitate the movement and transport of items within materials handling facilities.

Additionally, more and more items are being shipped to consumers from materials handling facilities. It has become more important to bring efficiency to the distribution chains through which these items are being transported. Additionally, it has become important to carefully track and monitor the schedules by which these items are transported, to ensure compliance with the expectations of and commitments to the consumers. Because a great number of items are processed at and pass through materials handling facilities and sort centers, it would be helpful to further automate the transportation and consolidation of the materials handling processes in these facilities.

A number of different systems have been developed to help automate the transport, organization, and handling of items in a materials handling facility or sort center. Conveyor systems, robotic automation machines, vacuum and gripping systems, and other systems have been designed to provide increased productivity through the automation of materials handling tasks.

In the context outlined above, new types of autonomous mobile robots for transporting carts are described herein. In one example, a robotic cart transport system includes a cart for transport and a robotic transport. The robotic transport includes a transport cab and a load handler. The transport cab includes a drive system and a sensor array positioned over the transport cab. The load handler includes a load base supported by a directable caster wheel, bumper rails that extend along sides of the load base, a lift table positioned over the load base, a lift guide linkage pivotally secured between the load base and the lift table, a lift abutment anchor, and a lift drive. The robotic transport can autonomously position the load handler under a cart, and the lift drive can raise the lift table up and off of the top surface of the load base, to a lifted position seated against the lift abutment anchor. The lift table will contact and lift the cart in this motion, and the cart can be transported and lowered to a new location by the robotic transport.

FIG.1illustrates an example materials handling facility10according to various aspects of the embodiments. Among other materials handling equipment and systems, the materials handling facility10includes carts20,22, and24, and a robotic transport system100(also “robotic transport100”). The robotic transport100is an example of an autonomous mobile robot, and it is capable of lifting and transporting the carts20,22, and24to among various locations in the materials handling facility10.

The materials handling facility10is provided as an example environment or facility in which one or more robotic transports, such as the robotic transport100, can be implemented to automate materials transport and handling tasks. The materials handling facility10can include several other automation tools and systems that are not shown inFIG.1, such as autonomous mobile robots, conveyor systems, chutes, robotic arms and other automation systems, vacuum and gripping systems, and other systems. In practice, the robotic transports and systems described herein can be implemented to assist with a number of different tasks at various locations in materials handling facilities.

The robotic transport100, as shown inFIG.1, is a representative example of an autonomous mobile robot. Among other uses, the robotic transport100can be relied upon to transport carts, such as the carts20,22, and24, among others, to various locations within the materials handling facility10. Like the robotic transport100, the carts20,22, and24are illustrated as representative examples. The robotic transport100is not limited to transporting any particular shape, size, type, or style of cart, carrier, or related transport equipment. The cart lift robotic transport systems described herein can transport, and be extended to transport, various types of carts and carriers for materials transport and handling. The robotic transport100can also be used in other types of materials handling environments and for other purposes as compared to the examples described herein.

The carts20,22, and24can be relied upon to transport items in the materials handling facility10. One example of the carts20,22, and24is described below with reference toFIGS.4A and4B. The carts20,22, and24can secure and carry a number of items, packages, parcels, or other materials, for transport. The carts20,22, and24include wheels to facilitate the transport of items, and the carts20,22, and24can roll within the materials handling facility10. The carts20,22, and24are not motorized or driven, however, and must be moved (e.g., pushed, pulled, etc.) manually by individuals or other robotic systems. In that context, a number of cart lift robotic transport systems are described herein, and the robotic transport100is one example of such a transport system.

InFIG.1, the robotic transport100is positioning itself to lift the cart24, as part of an autonomous process for transporting the cart24to a different location within the materials handling facility10. As described in further detail below, a load handler of the robotic transport100can tunnel (e.g., extend itself in part) under and lift the cart24using a lift table. The lift table includes a number of lifting pins or pillars, which interlock into recesses under the cart24, as the cart24is lifted. Once lifted for transport, the cart24is securely seated over the lift table. The robotic transport100includes a number of sensors positioned at one or more corners, ends, and around the sides and top of the cart24. The robotic transport100can rely upon image, radar, light detection and ranging (LIDAR), and other sensors to safely lift and transport the cart24within the materials handling facility10.

The robotic transport100offers several advantages. The robotic transport100is particularly designed to transport carts, carriers, or related equipment safely and reliably. The robotic transport100is capable of lifting the cart24securely, without (or nearly without) tilting, shaking, or disturbing the cart24or the contents within the cart24. The sensors of the robotic transport100are also placed at positions to monitor all sides around the robotic transport100for obstacle avoidance. These and other features of the robotic transport100are described below.

FIG.2illustrates the robotic transport100according to various aspects of the embodiments of the present disclosure. The robotic transport100is provided as a representative example inFIG.2, to convey the concepts of cart lift robotic transports for moving and repositioning carts and other materials handling equipment. The robotic transport100is not drawn to any particular scale, and the robotic transport100can range in size and dimensions, as needed for the implementation. Overall, the structural components of the robotic transport100can be embodied using a range of suitable materials, including a combination of metal, plastic, composite, or other bar, tube, rail, and sheet stock, rubber, wood, combinations thereof, and other materials, without limitation to any particular materials. The robotic transport100can be assembled together with a range of suitable mechanical fasteners, including screws, bolts and nuts, welds, rivets, adhesives, pins and interlocks, mechanical interferences, and other suitable fastening means, without limitation to any particular fastening solutions.

As shown, the robotic transport100includes a transport cab200, a load handler300, an upper sensor array400, a handler sensor array450, and a control environment500, among other components. However, the concepts described herein do not require all of the components shown inFIG.2in all cases. For example, one or more components of the transport cab200, the load handler300, the upper sensor array400, or other components can be replaced, repositioned, or omitted as compared to that shown in the illustrations.

The transport cab200can be embodied as a housing and support structure for the control environment500, the main drive system of the robotic transport100, the upper sensor array400, one or more batteries of the robotic transport100, and other systems of the robotic transport100. The drive system and other components of the transport cab200are described in greater detail below with reference toFIG.3G.

Among other components, the load handler300includes a load base310, bumper rails312that extend along top corners or edges of the load base310, and a lift table320. The lift table320is designed to lift a cart, so that the cart can be transported by the robotic transport100to another location. The lift table320is illustrated in a raised position inFIG.2, but the lift table320can also rest upon the top of the load base310as described below.

With the lift table320resting on the load base310, the robotic transport100can maneuver the load handler300underneath a cart for transport, such as under one of the carts20,22, or24shown inFIG.1. The load handler300is designed to have dimensions small enough to permit a mechanical clearance between the load handler300and an open channel between wheels of the cart for this purpose. The cart can also be designed for this clearance. Thus, the control environment500can direct the main drive system of the robotic transport100to slide or tunnel the load handler300underneath the cart, such as between wheels of the cart, using operational feedback data from the upper sensor array400, the handler sensor array450, and possibly other sensors and other operational data. The bumper rails312can facilitate this sliding or tunneling, by providing surfaces for incidental contact with structural features under the cart, as the load handler300is extended and tunnels under the cart.

With the load handler300positioned under the cart, the robotic transport100can actuate a lift drive, as described below with reference toFIGS.3E and3F. The lift drive is capable of raising the lift table320up and off of the top of the load handler300, in the direction “A” shown inFIG.2. As it is raised, the lift table320will contact the underside of the cart, and the cart will be lifted, with the cart resting upon the lift table320. The wheels of the cart will also be lifted off the ground as part of this lifting motion, so that no parts of the cart are contacting the ground. Mechanical interferences or interlocks between features of the lift table320and the underside of the cart can help to maintain the cart in a secure position over the robotic transport100. These features are described below with reference toFIG.4B.

Once a cart is lifted, the robotic transport100can autonomously navigate to a new location, repositioning the cart with it. Once the cart has been transported to the new location, the lift drive can lower the lift table320. The lift table320will then lower back down to a position resting upon the top of the load handler300. The wheels of the cart will contact the ground again as part of this lowering motion. The mechanical interferences or interlocks between the lift table320and the underside of the cart will also be released as part of this lowering motion, and a clearance will again exist between the cart and the robotic transport100. The robotic transport100can then autonomously navigate itself, to pull the load handler300out from underneath the cart, leaving the cart at the new location.

The upper sensor array400includes a support frame402, with a number of sensors mounted and positioned on the support frame402. The support frame402can be formed from any suitable materials, such as metal or plastic tubing or rods, among other structural supports. A number of different sensors of the sensor array400are secured at various locations about the support frame402, among other locations on, in, and around the robotic transport100. Example locations are shown inFIG.2, although any suitable positions can be used. The support frame402allows the individual sensors of the sensor array400to be positioned at many different locations and orientations, so that the front, back, and sides of the robotic transport100can be evaluated using the sensor array400.

The sensor array400can include one or more cameras, radar systems, LIDAR systems, optical sensors, and other sensors and systems that provide the data needed for computer-based image and vision processing. Other sensors of the robotic transport100can include pressure, contact, optical, or vision-based sensors, to detect a number of different operating parameters of the robotic transport100. In other examples, the sensors can be embodied as position encoders that provide absolute or relative position information related to drive motors. The cameras can include one or more charge-coupled device (CCD) image sensors, active-pixel complimentary metal-oxide semiconductor (CMOS) image sensors, or other image sensor arrays capable of capturing images and distinguishing depth. In one example, the cameras can include Intel® RealSense™ cameras, capable of depth tracking data collection. The data captured by the sensor array400and other sensors can be stored and processed by the control environment500, as described below. The control environment500can use the data, in part, to direct the operations of the robotic transport100.

In the example illustrated, the sensor array400includes image sensors421-423and LIDAR sensors410and411, among other sensors secured on the support frame402. The sensor array400is provided as a representative example inFIG.2, and other arrangements of sensors can be relied upon. The relatively high positions of the sensors in the sensor array400provide a good vantage point for object avoidance and route planning over relatively large distances. The robotic transport100also includes a LIDAR sensor431positioned at the front, bottom corner of the transport cab200in the example shown, and a similar radar sensor can be positioned at the other front corner of the transport cab200. It should be noted that although sensors410,411, and431are represented as LIDAR sensors, in some embodiments, one or more of sensors410,411, and431can comprise radar sensors.

The handler sensor array450includes an image sensor424, an image sensor425, a LIDAR sensor430, and possibly other sensors. The relatively low positions of the sensors in the handler sensor array450provide a good vantage point for capturing image data for tunneling under carts, as the image sensor424, the image sensor425, and the LIDAR sensor430can evaluate the structural features, fiducials, and other features under carts, to direct tunneling motion. The image, radar, and other operational feedback data gathered by the sensors of the sensor array400, the handler sensor array450, and other sensors of the robotic transport100can be relied upon for computer-based image, vision, and point cloud processing, for cart alignment and onboarding, for example. For example, the data gathered by the image sensor424can be used for optical detection while the data gathered by the sensor425can be used for localization. The robotic transport100can also include a number of human-machine interface buttons, such as panic or stop buttons, resume buttons, and other human-machine interface buttons.

The robotic transport100can also incorporate other sensors, such as weight sensors, position sensors, position encoders, interlock sensors, and other sensors within the drive systems, latching and catching assemblies, and other components. The operational feedback data from all the sensors in the robotic transport100can be stored and processed by the control environment500.

The control environment500can be embodied as a control system for the robotic transport100, including one or more processors, processing devices, circuits, and memory devices. The control environment500can be implemented using a combination of hardware and software, for example, as described in further detail below with reference toFIG.7. The control environment500can be implemented as an embedded control system of the robotic transport100itself (e.g., a programmable logic controller (PLC) of the robotic transport100), implemented separate from the robotic transport100, or be embodied as a hybrid of local and remote processing systems. The control environment500can interface with the electromechanical and sensor systems of the robotic transport100in any suitable way, such as through one or more local interfaces, wired or wireless network interfaces, or other suitable interfaces. Additionally, the control environment500can include one or more network interfaces for data communications, including wireless network interfaces for data and control communications with other computing environments and systems within the materials handling facility10, for example.

The control environment500is configured to direct the overall operation of the robotic transport100in the automated transport of carts within the materials handing facility10. In that sense, the control environment500is configured to direct the drive, wheel, and lift systems of the robotic transport100, among other electromechanical systems. The control environment500is also configured to direct the operation of the sensors of the robotic transport100, gather operational feedback data from the sensors, process the data, and direct the drive systems of the robotic transport100based on the data.

The control environment500includes a data store510and a robotic automation engine520. The data store510can store operational data for the robotic transport100. For example, the data store510can store route data, cart data, sensor data, operational status data, and other system operation and telematics data, among other types of data. The data store510can also store operational feedback data generated by the sensor array400, the handler sensor array450, and other sensors of the robotic transport100. The data in the data store510can be processed by the robotic automation engine520, as part of one or more command and control algorithms for the operation of the robotic transport100. Example control operations of the robotic automation engine520are described in further detail below.

Turning to other aspects,FIG.3Aillustrates the load handler300of the robotic transport100shown inFIG.2.FIG.3Billustrates a closer view of one end of the load handler300.FIG.3Cillustrates the same end of the load handler300as that shown inFIG.3B, with certain components omitted from view.FIG.3Dillustrates an underside view of the same end of the load handler300as that shown inFIG.3B, also with certain components omitted from view. Reference is made amongFIGS.3A-3D, below, which each provides a different view of the load handler300.

Referring first toFIG.3A, the lift table320includes longitudinal rails321and322and cross rails323and324. The longitudinal rails321and322and cross rails323and324are secured together, at their ends, in an open frame arrangement as illustrated inFIG.3A. The rails321-324can be secured together in any suitable way for sufficient structural integrity, such as using screws, bolts and nuts, clips, brackets, welds, rivets, adhesives, pins and interlocks, mechanical interferences, and other suitable fastening means. The lift pins331-334extend up from corners of the lift table320, and the lift pins331-334can be secured at the top surface of the rails321-324at the corners using threaded screws or other fastening means. The lift pins331-334are designed for a mechanical interface with mating or corresponding features on the underside of a cart, as described below.

The load handler300also includes a lift guide linkage that is pivotally secured between the load base310and the lift table320. The lift guide linkage helps to maintain a range of motion for the lift table320, as it is moves in the direction “A”. Particularly, the lift guide linkage maintains or defines the range of motion of the lift table320to within a single degree of freedom, so that it extends in a curved motion from a lower or seated position on the top surface of the load base310to the lifted or elevated position over the top surface of the load base310, as illustrated inFIG.3A. The lift guide linkage also supports the weight of the lift table320and any cart resting on the lift table320, at least in part.

The lift guide linkage includes two pivotable swing guides in the lift table320and two complimentary pivotable swing guides in the load base310. The cross rail323of the lift table320is omitted from view inFIG.3C, so that a pivotable swing guide in the lift table320is shown. The pivotable swing guide includes a pivoting bar360, a first radial bearing mount361, and a second radial bearing mount362. The pivoting bar360extends between the mounts361and362. The mounts361and362include internal, radial roller bearings, and the pivoting bar360is secured and extends between the roller bearings. Thus, the pivoting bar360can freely rotate along its longitudinal axis. The lift table320includes a similar arrangement of another pivoting bar and radial bearing mounts under the lift pins333and334(seeFIG.3A).

FIG.3Dillustrates a pivotable swing guide that is positioned within the load base310. The side panels of the load base310are omitted from view inFIG.3D, so that internal components of the load base310are visible. The load base310includes an internal frame390, as shown. The frame390of the load base310can be formed from any materials of suitable strength, weight, and other characteristics, such as aluminum, steel or other metals, plastic composites, combinations thereof, or other materials.

The pivotable swing guide includes the pivoting bar367, a first radial bearing mount368, and a second radial bearing mount (hidden, not shown). The pivoting bar367extends between the mount368and a mount at the opposite end of the pivoting bar367. The mount368includes an internal, radial roller bearing, and the pivoting bar367is secured and extends between roller bearings at both ends. Thus, the pivoting bar367can freely rotate along its longitudinal axis. The load base310includes a similar arrangement of another pivoting bar and radial bearing mounts toward the transport cab200(seeFIG.3AandFIG.3F).

The pivotable swing guides in the load handler300also include a number of swing guide armatures. As shown inFIG.3A, the load handler300includes the swing guide armatures341-344. The swing guide armatures341-344extend between and mechanically couple the load base310with the lift table320, in an arrangement that permits the degree of freedom discussed above. Referring betweenFIGS.3C and3D, the swing guide armature342, as one example, extends between one end of the pivoting bar360, next to the radial bearing mount362, to one end of the pivoting bar367, at the radial bearing mount368. The swing guide armature342is secured to both the pivoting bar360and the pivoting bar367, respectively, at ends of the swing guide armature342. The swing guide armatures341,343, and344are also similarly secured between the pivoting bars in the robotic transport100. Because the bars360and367rotate, the lift table320can move in a single degree of freedom, in a curved motion from a seated position on the top surface of the load base310to the elevated position over the top surface of the load base310. The motion of the lift table320is separately controlled by a lift drive.

FIG.3Eillustrates part of a lift drive395extending through an opening in a top of the load handler300, andFIG.3Fillustrates a side view of the lift drive395. The side panels of the load handler300are omitted from view inFIG.3F, so that the position and mechanical arrangement of the lift drive395is visible within the load handler300. The lift drive395is positioned and secured between the frame mount391within the load handler300, at one end, and the lift drive mount328on the lift table320, at another end, as shown inFIG.3F. The cable raceway397also extends between the load handler300and the lift table320, for routing wires and other control interfaces.

The lift drive395is capable of pushing up and lifting the lift table320, as well as releasing and lowering the lift table320. As the drive shaft396of the lift drive395is extended, it pushes the lift drive mount328and the lift table320up. The pushing forces provided by the lift drive395are sufficient to lift both the lift table320and any cart that may be positioned above the lift table320. The control environment500can direct the extension and retraction of the lift drive395, to raise and lift carts, as described herein. The lift drive395can provide feedback signals to the control environment500during extension. The feedback signals can provide position information, power draw or sink information, and other operational data. The feedback signals can be relied upon, in one example, to calculate the weight of a cart being lifted for transport.

The lift drive395can be embodied as a linear actuator in one example, such as a hydraulic, pneumatic, electro-mechanical, or other type of linear actuator. In one example, the lift drive395is capable of moving or displacing the drive shaft396in the linear direction “C,” as shown inFIG.3F, by pneumatic control. Pneumatic, hydraulic, or other supporting systems for the lift drive395can be maintained within the transport cab200, for example, among other locations. In other examples, the lift drive395is capable of converting rotary motion into linear motion in the linear direction “C,” using one or more motors, gearboxes, and a leadscrew, ball screw, roller screw, cam, or other mechanical motion translation mechanism.

Referring back toFIG.3A, the robotic transport100also includes a number of bumpers, such as the bumpers351and352, which are positioned at the back side or surface of the transport cab200. The bumpers351and352can be embodied as relatively soft rubber, plastic, or other suitable materials. When a cart is lifted by the lift table320, one or more rails or features of the cart can come into contact with the bumpers351and352, which provide dampening. The bumpers351and352are illustrated as examples inFIG.3A. In other cases, the bumpers351and352can be positioned at other locations, and more bumpers can be relied upon in addition to those shown.

Referring toFIGS.3B and3E, the lift table320includes a contact sensor326positioned at a relative center of the cross rail323(FIG.3B) and a contact sensor327positioned at a relative center of the cross rail324(FIG.3E). The contact sensors326and327can be embodied as contact switches, for example, or other sensors capable of identifying when the lift table320is proximate to or makes contact with the underside of a cart. Thus, in addition to the use of the other sensors described herein, the control environment500can rely upon feedback signals from the contact sensors326and327to determine when a cart is present on the lift table320.

Referring toFIG.3C, the lift table320includes support bridges363and364, and the load base310includes support pads365and366. The support bridges363and364can be formed from metal, plastic, or other materials, and the pivoting bar360extends through an aperture or opening in the support bridges363and364. The support pads365and366can be formed from metal, plastic, or other materials and provide a contact surface for the support bridges363and364. When the lift table320is lowered and resting upon the load base310, the support bridges363and364rest upon the support pads366and365, respectively.

Additionally, the load base310includes a lift abutment anchor370secured at or on a top surface of the load base310. The lift abutment anchor370helps to align and seat the lift table320, particularly when it is raised to the lifted position. For that purpose, the lift table320also includes a centering abutment guide371, which is secured at a relative center of the cross rail323(seeFIG.3B). The centering abutment guide371seats into a bumper372of the lift abutment anchor370when the lift table320is raised to the lifted position. The load base310includes a similar lift abutment anchor at the other end of the lift table320.

To direct the movement of the robotic transport100, the load base310includes a directable caster wheel381, as shown inFIG.3D. The directable caster wheel381can be secured to the frame390of the load base310, along with other components of the load base310. The directable caster wheel381includes one or more motors, gears, and couplings that facilitate the ability to control the angular orientation or direction of the wheel381. The control environment500can direct the rotary position or orientation of the directable caster wheel381, for example, to enable particular and directed movements of the robotic transport100in connection with the main drive system of the robotic transport100.

The main drive system of the robotic transport100is shown inFIG.3G. In the example shown, the main drive system includes the drive wheel210and the drive wheel211, which are both secured to a frame220of the transport cab200. The drive wheels210and211are coupled with drive motors capable of driving rotation of the drive wheels210and211. The drive motors can rotate the drive wheels210and211, respectively and independently. The control environment500can direct the operation of the drive motors for the drive wheels210and211. The drive wheels210and211can provide a type of differential drive system for the robotic transport100, based on control signals provided from the control environment500. The control signals can maneuver the robotic transport100, based on control algorithms executed by the robotic automation engine520.

In some cases, the drive wheels210and211can be embodied as a holonomic drive system, in which the drive wheels210and211are capable of rotating to change orientation, before spinning to reposition the robotic transport100. In that case, the holonomic drive system of the robotic transport100can facilitate the immediate movement of the robotic transport100in any direction, without the robotic transport100itself spinning or turning about an axis formed between differential drive wheels. Thus, the drive system illustrated inFIG.3Gis provided as an example, and other types of drive systems can be relied upon.

In addition to the active drive system, the robotic transport100includes tow or passive drive wheels. For example, as shown inFIG.3G, the passive drive wheels230and231are typically maintained in a retracted or elevated position, without making ground contact. However, the passive drive wheels230and231can be extended and lowered down, using a bolt or other extension means, lifting the drive wheels210and211of the transport cab200off of the ground. Additionally, as shown inFIG.3B, the robotic transport100can include a passive drive wheel380on one side of the handler sensor array450. The robotic transport100can also include another passive drive wheel on another side of the handler sensor array450, although it is not visible inFIG.3B. The passive drive wheel380can also be maintained in a retracted or elevated position, without making ground contact. However, the passive drive wheel380can be extended and lowered down, using a bolt or other extension means, lifting the load base310off of the ground. The passive or tow wheels of the robotic transport100can be relied upon to reposition the robotic transport100in the event of mechanical or system failure, depleted battery, or other condition.

The robotic transport100can also include a battery bank, a wireless charging module, power converters, and other components of a power system. The battery bank can be embodied as any suitable battery bank, including one or more sealed lead acid, lithium ion, nickel metal hydride, or other battery technologies, along with a power converter to charge and discharge the battery bank. The battery bank can be distributed among the transport cab200and the load handler300in some cases or located only in one of the transport cab200or the load handler300. The battery bank can supply power to the drive wheels210and211, the control environment500, sensors, and other components of the robotic transport100. The wireless charging module can be embodied as a wireless inductive charger for charging the battery bank. Thus, the robotic transport100can be easily recharged without the need for a direct bare-conductor connection to a power source.

FIG.4Aillustrates a perspective view of an example cart900, andFIG.4Billustrates a bottom view of the cart900according to various aspects of the embodiments of the present disclosure. The cart900can be autonomously transported by the robotic transport100, but the cart900can also be transported by other autonomous robotic systems and individuals when necessary. The cart900is provided as a representative example inFIGS.4A and4B. The cart900is not drawn to any particular scale, and the cart900can range in size and dimensions, as needed for the implementation. Additionally, one or more of the components of the cart900, as illustrated and described herein, can be omitted, and the cart900can also include other components not shown in some cases.

Among other components, the cart900includes a cart platform910, a cart cage920mounted around the cart platform910, and a roller pedestal930that supports the cart platform910. The cart900can be formed from a range of suitable materials, including a combination of metal, plastic, composite, or other bar, tube, rail, and sheet stock, rubber, wood, combinations thereof, and other materials, without limitation to any particular materials. The cart900can be assembled together with a range of suitable mechanical fasteners, including screws, bolts and nuts, welds, rivets, adhesives, pins and interlocks, mechanical interferences, and other suitable fastening means, without limitation to any particular fastening solutions.

A number of items, packages, parcels, and other materials can be placed, stored, and secured within the cart cage920, for transport. Items can be placed into the cart900through the relatively large openings in the top of the cart cage920, through the door921of the cart cage920, or in other ways. Among other components, the cart cage920includes the door921and a door latch922. The cart cage920can include similar door and latch features on the other side of the cart cage920.

The roller pedestal930includes a number of wheels931-936, among others, as shown inFIG.4A. The wheels931-936can be embodied as casters in one example. In some cases, one or more of the wheels931-936can include brake mechanisms. The brake mechanisms can prevent the wheels931-936from rotating in certain operating configurations. The cart900also includes brake or lift arms951and952, which can also be relied upon to brake the cart900. In one example, the brake or lift arms951and952can be actuated and released with downward pressure provided on individual levers by the foot of an individual.

InFIG.4B, a number of recesses960-963are shown in the bottom of the cart900. The recesses960-963can be embodied as recessed areas (e.g., of between about ¼ to 2 inches deep) under the cart900. Each of the recesses960-963can be between about 1 to 5 inches in length and between about 1 to 5 inches in width, as one example, although the recesses960-963can be other sizes. The recesses960-963can be located at other positions under the cart900, asFIG.4Bis provided as a representative example.

Overall, the positions of the recesses960-963coincide or correspond to the positions of the lift pins331-334of the lift table320(seeFIG.3A). An example outline970is also shown inFIG.4B. The outline970is representative of the peripheral size of the lift table320of the robotic transport100. When the load handler300of the robotic transport100is positioned under the cart900, the lift pins331-334of the lift table320can be positioned within the peripheral boundaries of the recesses960-963, or close to that shown inFIG.4B. From this position, the lift table320can be lifted, and the lift pins331-334can seat securely into the recesses960-963. Thus, the recesses960-963help to securely maintain the lift pins331-334in place, based on a mechanical interference, when the cart900is lifted by the robotic transport100.

FIG.5Aillustrates an example alignment of the robotic transport100shown inFIG.2and the cart900shown inFIG.4A. The robotic automation engine520of the robotic transport100can direct the drive system of the robotic transport100into the alignment shown inFIG.5A, based on feedback obtained from the sensor array400, the handler sensor array450, and other data. Particularly, the robotic automation engine520can tunnel the load handler300under the cart900. InFIG.5A, the cart900is still resting on the ground, with the load handler300positioned under the cart900, and the lift table320in the lowered position. In some cases, the cart900can include one or more fiducials printed or otherwise positioned on the underside of the cart900, to assist the robotic automation engine520with accuracy in positioning.

The load handler300is designed to have dimensions small enough to permit a mechanical clearance between the load handler300and an open channel between the wheels of the cart900. The cart900can also be designed for this clearance. Thus, the control environment500can direct the main drive system of the robotic transport100to slide or tunnel the load handler300underneath the cart900, such as between wheels of the cart, using operational feedback data from the upper sensor array400, the handler sensor array450, and possibly other sensors and other operational data. The bumper rails312can facilitate this sliding or tunneling, by providing surfaces for incidental contact with structural features under the cart, as the load handler300is extended and tunnels under the cart.

Turning toFIG.5B, with the load handler300positioned under the cart900, the robotic transport100can actuate the lift drive395, as described above with reference toFIGS.3E and3F. The lift drive395is capable of raising the lift table320, and the lift table320will contact the underside of the cart900. In turn, the cart900will be lifted, with the cart resting upon the lift table320. The wheels of the cart900will also be lifted off the ground as part of this lifting motion, so that no parts of the cart900are contacting the ground. Mechanical interferences or interlocks between the lift pins331-334of the lift table320and the recesses960-963under the cart900can help to maintain the cart900in a secure position over the robotic transport100. The cart900can also be lowered back down and off of the load handler300in a similar way, by reversing the operation of the lift drive395.

FIG.6illustrates an example method of cart transport using the robotic transport100shown inFIG.2. The process shown inFIG.6is described in connection with the robotic transport100, although related or similar robotic transports can perform the process. Although the process diagram shows an order of operation, the order can differ from that which is shown. For example, the order of two or more steps can be switched relative to the order shown or as described below. Also, two or more steps shown in succession can be executed concurrently or with partial concurrence. Further, in some examples, one or more of the steps can be skipped or omitted, and the process can continue on with additional steps for any period of time.

At step600, the process includes the robotic automation engine520directing the drive system of the robotic transport100to drive into alignment with a cart, such as the cart900shown inFIG.4A. Here, the robotic automation engine520can use image, radar, LIDAR, and other feedback data from the sensor array400, a handler sensor array450, and other sensors of the robotic transport100as input for computer-vision algorithms suitable for directing the robotic transport100. In some cases, one or more fiducials or other markers can be placed at suitable locations on or under the cart900, for example, to help in steering control. As part of this alignment process, the control environment500can direct the main drive system of the robotic transport100to slide or tunnel the load handler300underneath the cart900, such as between wheels of the cart, as shown inFIG.5A.

At step602, the process includes the robotic automation engine520identifying alignment of the robotic transport100with the cart900. The robotic automation engine520can identify when the lift pins331-334of the lift table320are aligned sufficiently with the recesses960-963under the cart900, using computer-vision algorithms or other suitable techniques. In some cases, the cart900can include one or more fiducials printed or otherwise positioned on the underside of the cart900, to assist the robotic automation engine520with accuracy in positioning.

At step604, the process includes the robotic transport100lifting the cart900. For example, the robotic automation engine520can direct the lift drive395to lift or raise the lift table320based on extension of the drive shaft396of the lift drive395, as also described above with reference toFIGS.3E and3F. The lift table320will contact the underside of the cart900as part of this lifting motion. In turn, the cart900will be lifted, with the cart resting upon the lift table320. The wheels of the cart900will also be lifted off the ground as part of this lifting motion, so that no parts of the cart900are contacting the ground. Mechanical interferences or interlocks between the lift pins331-334of the lift table320and the recesses960-963under the cart900can help to maintain the cart900in a secure position over the robotic transport100.

At step606, the process includes transporting the cart900using the robotic transport100. For example, the robotic automation engine520can direct the drive system of the robotic transport100to relocate the cart900to any suitable location. At step608, the process includes the robotic transport100lowering the cart900. Here, the robotic automation engine520can direct the lift drive395to lower the cart900, by reversing the extension of the lift drive395, as also described above with reference toFIGS.3E and3F.

At step610, the process includes the robotic automation engine520identifying that the cart900has been lowered down onto the ground and guiding the robotic transport100away from the cart900. For example, the robotic automation engine520can cause the robotic transport100to travel in a reverse direction away from the cart900until the robotic transport100is outside the proximity of the cart900to allow the robotic transport100to move to another location without interference of the cart900. Once the robotic transport100has moved away from the cart900, the robotic automation engine520can direct the robotic transport100to drive to another location.

FIG.7illustrates an example computing device1000for the robotic transport100according to various aspects of the embodiments of the present disclosure. The control environment500, as shown inFIG.2, can be implemented in the computing device1000, using hardware, software, or a combination of hardware and software. As shown inFIG.7, the computing device1000includes at least one processing system, for example, having a processor1002and a memory1004, both of which are electrically and communicatively coupled to a local interface1006. The local interface1006can be embodied as a data bus with an accompanying address/control bus or other addressing, control, and/or command lines, for data communications and addressing between the processor1002, the memory1004, network interfaces, the sensors described herein, and other peripherals and systems.

In various embodiments, the memory1004stores the data in the data store510, automation data, and other software or executable-code components executable by the processor1002. The memory1004can store data related to the operation of the robotic transport100, the sensors described herein, and other data in the data store510. Among others, the executable-code components can include components associated with the robotic automation engine820and an operating system for execution by the processor1002. Where any component discussed herein is implemented in the form of software, any one of a number of programming languages can be employed such as, for example, C, C++, C#, Objective C, JAVA® JAVASCRIPT®, Perl, PHP, VISUAL BASIC®, PYTHON®, RUBY, FLASH®, or other programming languages.

The memory1004stores software for execution by the processor1002. In this respect, the terms “executable” or “for execution” refer to software forms that can ultimately be run or executed by the processor1002, whether in source, object, machine, or other form. Examples of executable programs include, for example, a compiled program that can be translated into a machine code format and loaded into a random access portion of the memory1004and executed by the processor1002, source code that can be expressed in an object code format and loaded into a random access portion of the memory1004and executed by the processor1002, or source code that can be interpreted by another executable program to generate instructions in a random access portion of the memory1004and executed by the processor1002.

In various embodiments, the memory1004can include both volatile and nonvolatile memory and data storage components. Volatile components are those that do not retain data values upon loss of power. Nonvolatile components are those that retain data upon a loss of power. Thus, the memory1004can include, a random access memory (RAM), read-only memory (ROM), magnetic or other hard disk drive, solid-state or semiconductor memory, a universal serial bus (USB) flash drive, memory card, optical disc (e.g., compact disc (CD) or digital versatile disc (DVD)), floppy disk, magnetic tape, or any combination thereof. In addition, the RAM can include, for example, a static random access memory (SRAM), dynamic random access memory (DRAM), or magnetic random access memory (MRAM), and/or other similar memory device. The ROM can include, for example, a programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), or other similar memory device. An executable program can be stored in any portion or component of the memory1004.

The processor1002can be embodied as one or more microprocessors, one or more discrete logic circuits having logic gates for implementing various logic functions, application specific integrated circuits (ASICs) having appropriate logic gates, and/or programmable logic devices (e.g., field-programmable gate array (FPGAs), and complex programmable logic devices (CPLDs)).

If embodied in software, the robotic automation engine820can represent a module or group of code that includes program instructions to implement the specified logical function(s). The program instructions can be embodied in the form of source code that includes human-readable statements written in a programming language or machine code that includes machine instructions recognizable by a suitable execution system, such as a processor in a computer system or other system. Thus, the processor1002can be directed by execution of the program instructions to perform certain processes, such as those illustrated inFIG.6. In the context of the present disclosure, a non-transitory computer-readable medium can be any tangible medium that can contain, store, or maintain any logic, application, software, or executable-code component described herein for use by or in connection with an instruction execution system.

Also, one or more of the components described herein that include software or program instructions can be embodied in a non-transitory computer-readable medium for use by or in connection with an instruction execution system, such as the processor1002. The computer-readable medium can contain, store, and/or maintain the software or program instructions for execution by or in connection with the instruction execution system. The computer-readable medium can include a physical media, such as, magnetic, optical, semiconductor, and/or other suitable media or drives. Further, any logic or component described herein can be implemented and structured in a variety of ways. For example, one or more components described can be implemented as modules or components of a single application. Further, one or more components described herein can be executed in one computing device or by using multiple computing devices.

The flowchart or process diagram inFIG.6is representative of certain processes, functionality, and operations of the embodiments discussed herein. Each block can represent one or a combination of steps or executions in a process. Alternatively, or additionally, each block can represent a module, segment, or portion of code that includes program instructions to implement the specified logical function(s). The program instructions can be embodied in the form of source code that includes human-readable statements written in a programming language or machine code that includes numerical instructions recognizable by a suitable execution system such as the processor1002. The machine code can be converted from the source code, etc. Further, each block can represent, or be connected with, a circuit or a number of interconnected circuits to implement a certain logical function or process step.

Although the flowchart or process diagram inFIG.6illustrates a specific order, it is understood that the order can differ from that which is depicted. For example, an order of execution of two or more blocks can be scrambled relative to the order shown. Also, two or more blocks shown in succession can be executed concurrently or with partial concurrence. Further, in some embodiments, one or more of the blocks can be skipped or omitted. In addition, any number of counters, state variables, warning semaphores, or messages might be added to the logical flow described herein, for purposes of enhanced utility, accounting, performance measurement, or providing troubleshooting aids, etc. Such variations, as understood for implementing the process consistent with the concepts described herein, are within the scope of the embodiments.

Although embodiments have been described herein in detail, the descriptions are by way of example. In other words, the embodiments of the frame described herein are not limited to frame structures for aircraft, however, and may be relied upon as frame structures for both airborne and ground-based crafts, vehicles, etc. The features of the embodiments described herein are representative and, in alternative embodiments, certain features and elements may be added or omitted. Additionally, modifications to aspects of the embodiments described herein may be made by those skilled in the art without departing from the spirit and scope of the present invention defined in the following claims, the scope of which are to be accorded the broadest interpretation so as to encompass modifications and equivalent structures.