CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Application No. 63/333,904, filed April 22, 2022.

TECHNICAL FIELD

[0002] This disclosure relates to automated systems for exchanging goods between delivery vehicles and a warehouse.

BACKGROUND

[0003] At warehouses and distribution centers, large amounts of goods are loaded and unloaded into and from delivery vehicles. The goods are moved throughout a facility to be stored and/or transported to another location. For some warehouses and distribution centers, a loading dock is nearby. The loading dock is where goods are brought into the warehouse or distribution center, and is where goods are distributed from the warehouse or distribution center.

SUMMARY

[0004] This disclosure describes technologies relating to automating delivery vehicle loading and unloading.

[0005] An example implementation of the subject matter described within this disclosure is a loading system with the following features. A pallet is configured to receive and support goods. A shuttle is configured to move the pallet. The pallet is configured to move on a track.

[0006] Aspects of the example loading system, which can be combined with the example loading system alone or in combination with other aspects, include the following. The pallet includes a frame and wheels supporting the frame.

[0007] Aspects of the example loading system, which can be combined with the example loading system alone or in combination with other aspects, include the following. The shuttle includes a frame with an upper surface configured to support and retain the pallet to the shuttle. Wheels support the frame. The shuttle includes a portion of an electric motor.

[0008] Aspects of the example loading system, which can be combined with the example loading system alone or in combination with other aspects, include the following. The track includes a portion of an electric motor.

[0009] Aspects of the example loading system, which can be combined with the example loading system alone or in combination with other aspects, include the following. The motor is a linear motor.

[0010] Aspects of the example loading system, which can be combined with the example loading system alone or in combination with other aspects, include the following. A controller is configured to energize a motor, direct the shuttle along the track by the motor, and load the pallet from the track into a vehicle.

[0011] Aspects of the example loading system, which can be combined with the example loading system alone or in combination with other aspects, include the following. The controller is further configured to remove the pallet from the shuttle prior to loading the pallet into the vehicle.

[0012] Aspects of the example loading system, which can be combined with the example loading system alone or in combination with other aspects, include the following. The controller is further configured to receive a pallet from a vehicle onto the track.

[0013] Aspects of the example loading system, which can be combined with the example loading system alone or in combination with other aspects, include the following. The controller is further configured to receive the pallet by the shuttle and direct the shuttle to a pallet loading location.

[0014] An example implementation of the subject matter within this disclosure is a method with the following features. A motor is energized. A shuttle is directed along a track by the motor. A pallet, carried by the shuttle, is loaded into a vehicle.

[0015] Aspects of the example method, which can be combined with the example 1 method alone or in combination with other aspects, include the following. The pallet is removed from the shuttle prior to loading the pallet into the vehicle. [0016] Aspects of the example method, which can be combined with the example alone or in combination with other aspects, include the following. A pallet is received from a vehicle.

[0017] Aspects of the example method, which can be combined with the example method or in combination with other aspects, include the following. The pallet is received by the shuttle. The shuttle is directed to a pallet loading location.

[0018] An example implementation of the subject matter described within this disclosure is a system with the following features. A matrix has nodes. Each node of the matrix is accessible by a track. A pallet is configured to receive and support a goods. The pallet is supported by the matrix. Linear motors are coupled to the pallet. The linear motors are configured to move the pallet on the track. A controller is configured to regulate the linear motors.

[0019] Aspects of the example system, which can be combined with the example system alone or in combination with other aspects, include the following. The pallet includes a frame and wheels supporting the frame.

[0020] Aspects of the example system, which can be combined with the example system alone or in combination with other aspects, include the following. The pallet further includes a modular package system configured to provide packages to a driver located outside a package retaining portion of the vehicle.

[0021] Aspects of the example system, which can be combined with the example system alone or in combination with other aspects, include the following. A lower conveyor belt is included. An upper carousel includes a closed track. Gondolas are coupled to the track and configured to be moved by the track. The gondolas are configured to support, retain, and move items.

[0022] Aspects of the example system, which can be combined with the example system alone or in combination with other aspects, include the following. A shuttle includes a frame with an upper surface configured to support and retain the pallet to the shuttle. Wheels support the frame. A portion of an electric motor is included on the shuttle.

[0023] Aspects of the example system, which can be combined with the example system alone or in combination with other aspects, include the following. A lift is configured to separate the pallet and the shuttle. [0024] Aspects of the example system, which can be combined with the example system alone or in combination with other aspects, include the following. A loading area includes a loading dock configured to receive a delivery vehicle to be loaded.

[0025] Aspects of the example system, which can be combined with the example system alone or in combination with other aspects, include the following. The loading area further includes a cantilevered extendable rail configured to align with the delivery vehicle to be loaded.

[0026] Particular implementations of the subject matter described in this disclosure can be implemented so as to realize one or more of the following advantages. The concepts described within this disclosure can be used to make warehouses and distribution systems improve throughput at loading docks. The concepts described throughout this disclosure allow for flexible layouts and allow for higher density throughput when compared with standard mechanical warehouses and/or loading systems. The subject matter within this disclosure describes systems capable of offering rapid retrieval by simultaneous movement of multiple products. In this context, a single pallet is capable of moving a weight equivalent of a several tons. Precise acceleration and velocity profdes and accurate position information allow for faster movement within the system and the recovery of energy through regenerative braking.

[0027] The details of one or more implementations of the subject matter described in this disclosure are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] FIG. 1A is a perspective view of an example tracked matrix system that can be used with aspects of this disclosure.

[0029] FIGS. IB and 1C are perspective views of an example pallet.

[0030] FIGS. 2A and 2B are perspective views of an example shuttle.

[0031] FIG. 2C is a perspective view of an example shuttle supporting the example pallet.

[0032] FIGS. 3 A and 3B are perspective views of example loading areas. [0033] FIG. 3C is a close-up view of an example loading mechanism.

[0034] FIG. 3D is a front view of an example loading mechanism in the retracted position.

[0035] FIG. 3E is a top-down view of the example loading mechanism in the extended position.

[0036] FIGS. 4A-4C are perspective views of modular package systems to be loaded into delivery vehicles.

[0037] FIG. 5 is a block diagram of an example controller that can be used with aspects of this disclosure.

DETAILED DESCRIPTION

[0038] Goods from warehouses and distribution centers are often loaded into delivery vehicles for distribution manually with human workers. This disclosure describes providing automated systems to augment or replace such loading arrangements. The subject matter described herein is capable of integrating with existing warehouse or distribution center infrastructure, but can also be used as a stand-alone system. In some implementations, the system includes various warehouse elements such as inventory systems, scanning systems, security systems, steel support grids, and moving pallets. In some implementations, goods are moved on pallets that are propelled by linear synchronous motors (LSMs). Other motor technologies can be used without departing from this disclosure, for example, induction rotary motors, synchronous rotary motors, or linear induction motors. Turntables can be employed to move the pallets to the correct orientation for loading and unloading into and from delivery vehicles. In some implementations, the only other moving parts are wheels and some lifting and safety interlocking devices in two of the design options.

[0039] In some implementations, the loading dock itself includes a steel lattice or matrix with one or more levels. The steel lattice defines multiple rows of staging areas, for example, on either side of one or more shuttle aisles. Multiple-level loading docks, in some implementations, include multiple elevators.

[0040] FIG. 1A is a perspective view of an example tracked matrix system 100 that can be used with aspects of this disclosure. The system includes a steel matrix and/or track 102. Each node of the matrix is accessible by the track. The tracked matrix system 100 includes one or more shuttles 104 that are configured to move around the steel matrix and/or track 102. In some implementations, the steel matrix and/or track 102 is a portion of an electric motor, for example, a stator of an LSM. In such implementations, the shuttles 104 include a second portion of the electric motor, for example, a row of magnets acting as a moving portion of the LSM. The LSM is controlled by a controller 106. Details on the controller 106 are described later within this disclosure. The shuttle 104 itself is configured to move a pallet (FIGS. IB andlC). The pallet receives and supports goods, and the shuttle 104 moves the pallets. In some implementations, the pallet is supported by the steel matrix and/or track 102.

[0041] FIGS. IB andlC are perspective views of an example pallet 108. The pallet 108 includes a steel frame 110 supported by wheels 112. The pallet 108 includes an upper surface 114 configured to support goods, for example, a delivery module (described later), a vehicle, or a stack of goods. In some implementations, the pallet 108 is configured to support several tons, for example, twenty eight tons. The pallets can be sized and scaled for the desired application. A “pallet”, within the context of this disclosure, can be any cargo carrying substrate, including but not limited to totes, standard cargo pallets, or individual packages.

[0042] FIGS. 2A-2B is a perspective view of an example shuttle 104. The shuttle 104 includes a steel frame 202 with an upper surface 204 configured to support and retain the pallet 108 to the shuttle 104. In some implementations, the shuttle 104 includes wheels 206 supporting the steel frame 202. In some implementations, the shuttle 104 includes a portion of an electric motor, for example, permanent magnets 208 acting as a moving component of an LSM. In some implementations, the shuttle 104 and the pallet 108 are integrated into a single, unitary unit.

[0043] FIG. 2C is a perspective view of an example shuttle 104 supporting the example pallet 108. In some implementations, other items can be supported by the shuttle 104 and pallet 108 (e.g., packaged goods). In some implementations, the shuttle 104 or pallet 108 includes a lift mechanism to couple or decouple the shuttle 104 and pallet 108. In some implementations, an external lift mechanism is used. While primarily described and illustrated as being configured to interface with pallets, other devices and/or components can interface with the shuttle 104 without departing from this disclosure. For example, the shuttle 104 can interface with a cargo container or a package distribution module.

[0044] FIG. 3 A is a perspective view of an example loading area 300. The loading area 300 includes various loading dock elements, such as a steel grid for support, and moving pallets. In some implementations, mechanical turntables may be employed to orient the system, particularly to move the containerized retrieval system to the correct orientation for insertion into a delivery vehicle 302. In some implementations, the containerized retrieval system is propelled by LSMs. In some instances, the trucks include rails, or tracks 102, similar to the storage facility such that pallets can be exchanged between the truck and the storage facility. In the illustrated implementation, pallets are on either side of a main aisle. A bed of the delivery vehicle 302 and the main aisle are at a same elevation with one another. As such, the delivery vehicle 302 needs be substantially aligned (angle, offset, and gap tolerances vary depending on the implementation), and a palette is loaded or unloaded by the systems described within this disclosure. In some implementations, a lift system is included in the docking area. In some implementations, the lift system is capable of changing a vertical distance between the pallet and the shuttle. In some implementations, the lift system is capable of changing a horizontal distance between the shuttle and the pallet. Alternatively or in addition, as shown in FIG. 3B, the pallet 108 is delivered directly to the delivery vehicle 302 without the use of an aisle or staging areas adjacent to the delivery vehicle 302.

[0045] In one implementation, a sequence using the system shown in FIG. 3 A includes: Step A: Robot A brings Pallet 1 into position, places Pallet 1 on jacks. Step B: LSM tugs take Pallet 1 and move it to the right. Step C: Robot A leaves and Robot B brings Pallet 2 to dock jacks. Step D: Arm comes out of van and takes Pallet 2. In some implementations, the van is adjusted left to right (for example, during Step C). In certain implementations, an LSM extends to place a pallet on rollers.

[0046] FIG. 3C is a close-up view of an example loading mechanism. In some implementations, the loading mechanism includes a cantilevered extendable rail 304 configured to align with the delivery vehicle 302 to be loaded. FIG. 3D is a front view of an example cantilevered arm 306, in a retracted state, that can be used with aspects of this disclosure. The arm 306 includes multiple stacked stages 308 that are nested within one another. In some implementations, each stage includes an LSM 310 to extend or retract each stage 308. Other motor configurations can be used without departing from this disclosure, for example, rotary motors couple to a high friction track interface or a rack-and-pinion interface can be used without departing from this disclosure. FIG 3E is a top-down view of the example cantilevered arm 306 in an extended position.

[0047] FIGS. 4A-4C are perspective views of modular package systems 400 to be loaded into delivery vehicles 302. In some implementations, the modular package system 400 is mounted to the pallet 108 and is loaded onto the delivery vehicle 302 with the pallet 108. The modular package system 400 itself is configured to provide packages to a driver (not shown) located outside a package retaining portion of the vehicle. In the illustrated implementation, the modular package system 400 includes a lower conveyor belt 402. The lower conveyor belt 402 is arranged to provide heavier and bulkier packages to the delivery driver in an ergonomic fashion. For example, in some implementations, the conveyor belt 402 is near waist level. Above the conveyor belt 402 is a carousel 404. The carousel 404 includes a closed track. Several gondolas 406 are coupled to the track and are configured to be moved by the track. Each gondola 406 is configured to hold packages. The carousel 404 is configured to deliver a desired package to the delivery driver in an ergonomic fashion. For example, in some implementations, the carousel is configured to provide a package near chest level. In general, the carousel and gondolas are configured to hold smaller, lighter packages.

[0048] In some implementations, the modular package system 400 is preloaded and preprogrammed prior to being loaded on the delivery vehicle 302. In such implementations, the delivery vehicle 302 is pulled up to the loading area 300, the modular package system 400 is loaded, and the delivery vehicle 302 goes on its delivery route. During the delivery route, the modular package system 400 is used to ergonomically provide packages to the driver for completing delivery.

[0049] FIG. 5 is a block diagram of an example controller 106 that can be used with aspects of this disclosure. The controller 106 can, among other things, monitor parameters of the system and send signals to actuate and/or adjust various operating parameters of the system. As shown in FIG. 5, the controller 106, in certain instances, includes a processor 550 (e.g., implemented as one processor or multiple processors) and a memory 552 (e.g., implemented as one memory or multiple memories) containing instructions that cause the processors 550 to perform operations described herein. The processors 550 are coupled to an input/output (I/O) interface 554 for sending and receiving communications with components in the system, including, for example, the electric motors, such as LSMs. In certain instances, the controller 106 can additionally communicate status with and send actuation and/or control signals to one or more of the various system components (including an actuable system, such as the steel matrix and/or tracks 102) of the tracked matrix system 100, as well as other sensors (e.g., the position sensor, current sensors, and other types of sensors) provided with the system. In certain instances, the controller 106 can communicate status and send actuation and control signals to one or more of the components within the tracked matrix system 100, such as a graphical user interface. The communications can be hardwired, pneumatic, hydraulic, wireless, or a combination. In some implementations, the controller 106 can be a distributed controller with different portions located throughout the tracked matrix system 100. For example, in certain instances, the controller 106 can be a motor control unit, or it can be a separate controller apart from the motor control unit. Additional controllers can be used throughout the tracked matrix system 100 as stand-alone controllers or networked controllers without departing from this disclosure.

[0050] The controller 106 can have varying levels of autonomy for controlling the tracked matrix system 100. For example, the controller 106 can begin sensing a parameter, such as a delivery vehicle pulling into the loading dock area, and an operator sends a signal to load a pallet, by the controller 106, in response. Alternatively, the controller 106 can begin sensing a parameter and send a pallet to the delivery vehicle with no input from an operator.

[0051] The following operations, in some implementations and/or instances, can be executed in full or in part by the controller 106. In operation, the motor or motors are energized. A shuttle is directed to a location along the track. The shuttle is moved by the energized motor. A pallet is directed to a delivery vehicle by the shuttle. The pallet is loaded into the delivery vehicle from the track. In some implementations, the pallet is removed from the shuttle prior to being loaded in the truck. In some implementations, the shuttle is loaded onto the delivery vehicle with the pallet.

[0052] Once the delivery vehicle returns to the loading dock, in some implementations, the pallet is received from the delivery vehicle. In some implementations, the pallet is received by the shuttle, and the shuttle is directed to a pallet loading location to be re-loaded and/or serviced.

[0053] While this disclosure contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features specific to particular implementations. Certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

[0054] Similarly, 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. Moreover, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products.

[0055] Thus, particular implementations of the subject matter have been described. Other implementations are within the scope of the following claims. In some cases, the actions recited in the claims can be performed in a different order and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results.