APPLIANCE

Field of the Invention [0001] The present invention relates to the field of material handling and, in particular, to guided material handling devices.

Background

[0002] Advances in autonomous guided vehicle (AGV) technology are driving interest in automation of various tasks in warehousing, manufacturing, and many other fields that require maneuvering around obstacles in an environment from one location to another. In addition, the development of versatile AGV platforms that can accommodate a variety of mounted appliances has created a need for such automated appliances to expand the range of applications for such AGVs. [0003] There has been significant deployment of AGVs in the field of warehousing, where a high level of standardization of shipping containers and shipping pallets facilitates automation by AGVs equipped with suitable warehousing appliances. In other fields where there is less standardization or greater variability in container configurations, the challenges presented by these handling requirements are impeding the adoption of AGV technology. [0004] One such field is material handling, for example, within a manufacturing environment.

In many cases, materials (sheets of paper or fabric, etc.) are stored on rolls in racking at a central storage area within the manufacturing environment. Those rolls of materials must be picked up from the racking, transported through the manufacturing environment from the storage area to a work area, and loaded or installed onto a piece of machinery involved in the manufacturing process. [0005] Accordingly, there is a need for AGV appliances that can perform all of the tasks required to automate material handling tasks within a manufacturing environment.

Summary of the Invention [0006] A material handler, according to the present invention, is mounted on an autonomous guided vehicle. The material handler has: a. A control system; b. A tool positioning system. c. A dynamic ballast having one or more moveable weights configured to move in response to the movement of the tool positioning system; and d. A tool attached to the tool positioning system for transporting, installing, and removing rolls of material.

[0007] In another embodiment, the tool positioning system has three linear tracks configured to provide translational motion of the tool in three dimensions. [0008] In another embodiment, the one or more moveable weights of the dynamic ballast are coupled to one or more timing belts, which are engaged with the tool positioning system.

[0009] In another embodiment, the tool is attached to the tool positioning system by way of a rotating joint and the material handler is configured to operate in left-hand and right-hand modes.

[0010] In another embodiment, the tool has an expandable collet and a gripper. The expandable collet has a proximate end at the distal end of the tool and has a distal end with one or more expandable segments adjacent its distal end.

[0011] In another embodiment, the distal end of the expandable collet is configured to couple with the mandrel to maintain alignment of the expandable collet and mandrel during roll transfer and the expandable collet has a plunging pin and a proximity sensor for docking validation prior to roll transfer.

Brief Description of the Drawings [0012] In order that the invention may be more clearly understood, a preferred embodiment thereof will now be described in detail by way of example, with reference to the accompanying drawings, in which:

[0013] Figure 1 is a perspective view of the material handler, according to the present invention, shown mounted on an autonomous guided vehicle. [0014] Figure 2 is another perspective view of the material handler, shown in Fig. 1.

[0015] Figure 3 is the same perspective view of the material handler, shown in Fig. 1, but with certain covers removed to show details of the tool positioning system.

[0016] Figure 4 is a perspective view of an exemplary autonomous guided vehicle for use with the material handler. [0017] Figure 5 is another perspective view of the exemplary autonomous guided vehicle, shown in Fig. 4.

[0018] Figure 6 is another perspective view of the exemplary autonomous guided vehicle, shown in Fig. 4.

[0019] Figure 7 is a side view of the exemplary autonomous guided vehicle, shown in Fig. 4. [0020] Figure 8 is a perspective view of the end-of-arm tool of the material handler.

[0021] Figure 9 is side view of the end-of-arm tool, shown in Figure 8. [0022] Figure 10 is a side sectional view of the end-of-arm tool, shown in Figure 8.

[0023] Figure 11 is a perspective view of another end-of-arm tool of the material handler.

[0024] Figure 12 is the perspective view of the end-of-arm tool, as shown in Figure 11, with the mandrel removed to show detail of the utility coupler.

Description of the Invention

[0025] The present invention is directed to a material handler, mounted on an autonomous guided vehicle, that is capable of navigating a production facility to load rolls of material onto production equipment, retrieve empty rolls from the production equipment, and dispose of the empty rolls. The autonomous guided vehicle navigates the production facility to move the material handler into position to complete the appropriate loading, retrieving, or disposal operation and thereby automate material handling processes in the production facility.

[0026] As shown in Figures 1-3, a material handler 1 is mounted on an autonomous guided vehicle (AGV) 2. The AGV 2 may be any type of industrial self-driving vehicle, suitable for mounting and transporting an electromechanical device, known as an "appliance", such as a robotic arm with an end-of-arm tool. Preferably, the AGV 2 contains the motion control and sensor systems that permit the AGV 2 to detect and maneuver around obstacles and to its destination in a working environment, such as a production facility. The material handler 1 includes an end-of-arm tool 11 and a tool positioning system 12 for moving the end-of-arm tool 11 into position after the AGV 2 has maneuvered the material handler 1 to the destination.

[0027] As shown in Figures 4-7, the AGV 2 is preferably a mobile platform with a generally flat top surface 3, configured for mounting the material handler 1 thereon, an opposing bottom surface 4, a front 5, and a rear 6. The AGV 2 has drive wheels 7 and optional stabilizers 8 on its bottom surface 4. Preferably, the AGV 2 has two drive wheels 7 positioned approximately midway between the front 5 and rear 6 and four stabilizers 8 positioned about the periphery of the bottom surface 4, such as at the comers of the bottom surface 4 where the bottom surface 4 is generally rectangular. Preferably, the stabilizers 8 are caster wheels. Alternatively, the AGV 2 may have treads or other suitable means for maneuvering the AGV 2, depending on the conditions of the intended working environment.

[0028] The AGV 2 has a sensor system, which may include one or more types of sensor systems that work cooperatively, to detect the environment around the AGV 2. Examples of suitable sensor systems include: LIDAR scanners, cameras, following systems, such as magnetic tape following systems or line following systems, and encoder based absolute positioning systems. Preferably, the AGV 2 uses a LIDAR sensor system. The sensor system provides information about the surrounding area of the AGV 2 to a motion control system on the AGV 2, which controls the drive supplied from a motor to the drive wheels 7 in order to maneuver the AGV 2 about its working environment. The motion control system is preferably an onboard computer or programmable logic controller (PLC), which controls an onboard motor to drive the drive wheels 7. The AGV 2 is preferably powered by an onboard battery, but may be connected to an external power source or have another form of onboard power source, such as an internal combustion engine.

[0029] As shown in Figure 1, the material handler 1 has an end-of-arm tool 11 and a tool positioning system 12. Preferably, the tool positioning system 12 has three linear tracks 13, 14, and 15, slidably engaged with one another and configured to provide translational motion of the end-of-arm tool 11 in three dimensions. Alternatively, other types of tool positioning systems may be used, such as a robotic arm. The first linear track 13 acts as a base for the material handler 1 and is mounted on the top surface 3 of the AGV 2. The second linear track 14 is mounted on the first linear track 13 and the third linear track 15 is, in turn, mounted on the second linear track

14 [0030] As shown in Figure 3, the first linear track 13 permits a shuttle 13a to move in one axis along a rail 13b. The shuttle 13a provides a platform for mounting the second linear track 14, which moves, with the shuttle 13a, along the rail 13b. Preferably, the rail 13b extends substantially the length of the AGV 2 between the front 5 and rear 6 of the AGV 2. The second linear track 14 similarly has a shuttle 14a and a rail 14b, which is arranged perpendicular to the rail 13b and, preferably, parallel to the top surface 3 of the AGV 2. The third linear track 15 also has a shuttle 15a and a rail 15b, which is arranged perpendicular to the rail 14b and, preferably, perpendicular to the top surface 3 of the AGV 2.

[0031] In order to permit the material handler 1 to manipulate a roll of material and reposition it over the AGV 2 in the course of operation, the AGV 2 has a dynamic ballast that permits the AGV 2 to maintain a safe center of gravity during operation. The AGV 2 may also have a static ballast, in addition to, or in place of the dynamic ballast, depending on the requirements of the particular application. The dynamic ballast has one or more moveable weights 9, which may be positioned inside the AGV 2, outside the AGV 2 or partially inside and outside the AGV 2. Alternatively, the dynamic ballast may be a part of the material handler 1, rather than the AGV 2. The static ballast has one or more fixed weights 9a, which are positioned about the AGV 2, depending on the anticipated position of the load that will be manipulated by the material handler 1. Preferably, as shown in Figures 6 and 7, the fixed weights 9a are attached at the rear 6 of the AGV 2.

[0032] Preferably, as shown in Figure 3, the dynamic ballast has left and right side moveable weights 9, which are coupled to timing belts 10. The timing belts 10 are coupled to the tool positioning system 12, such that the moveable weights 9 move in response to the movement of the tool positioning system. In particular, the timing belts 10 are coupled to the first linear track 13, such that the moveable weights 9 move opposite to the shuttle 13a. As a result, as the mass of the tool positioning system 12, the end-of-arm tool 11, and any roll of material carried on the end-of-arm tool 11 moves from the rear 6 of the AGV 2 towards the front 5, the mass of the moveable weights 9 moves in the opposite direction, from the front 5 of the AGV 2 towards the rear 6. Preferably, the moveable weights 9 and the fixed weights 9a are made up of a plurality of stacked metal plates, which may be easily adjusted to provide the desired mass. [0033] As shown in Figure 3, the end-of-arm tool 11 is mounted on the shuttle 15a of the third linear track 15. The end-of-arm tool 11 is configured to perform four main functions: (i) receiving rolls of material, (ii) loading the rolls onto equipment (i.e. a mandrel), (iii) retrieving empty rolls from the equipment, and (iv) dispensing empty rolls into a designated waste area. In order to perform these functions, the end-of-arm tool 11 preferably has an expandable collet 16 and a gripper 17 attached at its distal end. The expandable collet 16 is sized to fit inside the roll of material it is intended to handle and expands to press against the inside of the roll to secure it in place during transport.

[0034] Preferably, as shown in Figures 8-10, the expandable collet 16 is a servo-driven four segment collet with an outer diameter approximately the same size as the mandrel with which it is intended to operate. The four expanding segments 18 of the collet are operated by a servo motor and driven outwardly to engage and press against the inside of the roll of material. The expanding segments 18 are preferably located at a distal end 16a of the expandable collet 16 and may also have gripping elements, such as teeth, grooves, pins, or other similar gripping elements thereon. [0035] The gripper 17 has opposing clamp arms 19, or jaws, which are separated by a distance larger than the outer diameter of the empty rolls. Preferably, the gripper 17 operate like a vice, with clamp arms 19 that move towards one another to clamp the empty rolls. Alternatively, the gripper 17 may operate like a scissor clamp, with clamp arms 19 that pivot towards one another to clamp the empty rolls. The gripper 17 is configured to move along the length of the expandable collet 16 and beyond the distal end 16a of the expandable collet 16. This permits the gripper 17 to reach the empty roll on the mandrel, grip it, and pull it onto the expandable collet 16. It also permits the gripper 17 to be used to push rolls of material off of the expandable collet 16, such as when loading rolls onto the mandrel or dispensing empty rolls into a designated waste area in the working environment.

[0036] As shown in Figure 8, the gripper 17 is attached to the end-of-arm tool 11 by way of an articulating arm 20. The articulating arm 20 has two arm segments 21 and 22, which are joined together at a rotating arm joint 23. The free end of the first arm segment 21 is rotatably attached to the end-of-arm tool 11. The free end of the second arm segment 22 is rotatably attached to the gripper 17. Articulation of the arm, preferably by a servo-motor in the end-of-arm tool 11 causes the arm segments 21 and 22 to pivot at the arm joint 23 and move the gripper 17 along the length of the expandable collet 16, towards and past its distal end 16a.

[0037] Optionally, the end-of-arm tool 11 is mounted to the shuttle 15a of the third linear track 15 by way of a rotating joint 24 at its proximate end, which permits the material handler 1 to operate in a left or right-handed mode. The material handler 1 is shown in Figures 1-3 in a left- handed mode, with the end-of-arm tool 11 facing to the right of the AGV 2. To switch to a right- handed mode, the end-of-arm tool 11 is rotated about the rotating joint 24 through 180°, such that the end-of-arm tool 11 faces to the left of the AGV 2. The rotating joint 24 may also be configured to rotate through angles less or greater than 180°, if a different orientation of the end-of-arm tool 11 is desired. For example, an empty roll may be deposited into a bin by positioning the end-of- arm tool 11 over the bin and rotating the rotating joint 24 through 90°, such that the distal end 16a of the expandable collet 16 is pointed downwards, permitting the empty roll to drop off the expandable collet 16 and into the bin. [0038] Preferably, the distal end 16a of the expandable collet 16 is configured to couple with the end of the mandrel to maintain alignment between the expandable collet 16 and the mandrel during operation. As shown in Figure 8, the distal end 16a of the expandable collet 16 has a slot 25 for receiving a complimentary shaped button on the end of the mandrel. Both the slot 25 and the button have a T-shaped cross section, so as to limit unwanted relative motion between the expandable collet 16 and the mandrel during operation.

[0039] The end-of-arm tool 11 may also have a laser distance sensor for locating the mandrel centerline prior to docking the distal end 16a of the expandable collet 16 with the mandrel. The laser distance sensor and the tool positioning system 12 are used to execute a laser search routine, as described herein. Preferably, the laser distance sensor is positioned within the slot 25 on the distal end 16a of the expandable collet 16.

[0040] A plunging pin and a sensor may be provided on the distal end 16a of the expandable collet 16 inside the slot 25 to assist in docking validation with the mandrel. As the distal end 16a of the expandable collet 16 is coupled with the end of the mandrel, the button moves into the slot 25 and depresses the plunging pin. Preferably, the other end of the plunging pin acts as a flag for the sensor, which is located some distance from the distal end 16a of the expandable collet 16, in order to conserve space within the distal end 16a. This triggers a docking validation signal, which indicates that the distal end 16a of the expandable collet 16 is correctly coupled with the end of the mandrel for transfer of a roll of material. Although a mechanical coupling between the expandable collet 16 and the mandrel, such as by way of the button and slot 25, is preferred for safety reasons, this arrangement or any type of mechanical coupling is optional.

[0041] Other types of end-of-arm tool 11 may be substituted for the expandable collet 16 and gripper 17 tool, as shown in Figures 1-3 and 8-10. In another embodiment, an end-of-arm tool 29 may be provided, as shown in Figures 11 and 12, which uses a master coupler 30 to engage with and hold a utility coupler 31 on one end of a specially configured mandrel 28 for transport, installation, and removal from equipment. The specially configured mandrels 28 are manipulated by the end-of-arm tool 29 with pre-mounted rolls of material already positioned on the mandrels 28. This end-of-arm tool 29 is able to accommodate rolls of material having different interior diameters, since the master coupler 30 may be configured to engage with and hold the utility coupler 31 on various sizes of mandrel 28. The master coupler 30 has one or more male pins 32, which are sized and positioned to fit within one or more female pins 33 in the utility coupler 31 on the ends of the specially configured mandrels 28. Preferably, the master coupler 30 also functions as a utility coupler, which may engage with the utility coupler 31 on the end of the specially configured mandrels 28 to connect the electronic, hydraulic, or pneumatic systems of the material handler 1 with the specially configured mandrel 28. The utility connections may be made through the male pins 32 on the master coupler 30 and the female pins 33 on the utility coupler 31.

[0042] Optionally, auxiliary safety scanners 27 may be provided on the AGV 2 or the material handler 1. The auxiliary safety scanners 27 are safety-rated area laser scanners, which scan the vicinity of the AGV 2 for workers and obstacles, to improve the safety of human workers in the working environment.

[0043] Preferably, the material handler 1 and AGV 2 safety circuits are connected, such that triggering an emergency stop in either safety circuit disables all motion in both the material handler 1 and the AGV 2.

[0044] An uninterruptable power supply (UPS) may be provided on either the material handler 1 or the AGV 2 to enable the control system to maintain low voltage power in order to promote a rapid recovery from an e-stop condition. Where the power source is an external power source, the UPS may be an onboard batery. Where the power source is an onboard batery, the UPS may be a second onboard batery.

[0045] In a typical loading operation, the process has two phases: a rough positioning of the AGV 2, followed by a precision docking of the material handler 1. In the first phase, the AGV 2 will maneuver a roll of material, which is secured on the expandable collet 16 of the material handler 1 in a travel position for safety during transport, to the intended destination in the working environment. The travel position will vary depending on the size and weight of the roll of material, but is intended to maintain a low, stable center of gravity for safety during travel. The control system of the AGV 2 uses information from the LIDAR scanners of the sensor system to detect obstacles and control the movement of the AGV 2 to avoid the obstacles and maneuver to a rough position at the intended destination. Once the AGV 2 is in position at the intended destination, such as next to a mandrel on a piece of production equipment, the rough positioning phase ends and the precision docking phase begins. Preferably, for safety reasons, the tool positioning system 12 remains static (i.e. locked in the travel position) while the AGV 2 is in motion. Once the AGV 2 is in position, a safety circuit is made to permit the tool positioning system 12 to begin the second phase of the loading operation. Preferably, this is achieved using dual-channel, category three safety devices.

[0046] In the second phase, the material handler 1 will move the roll of material from the travel position to an approximate alignment with the mandrel. The material handler 1 then performs a laser search routine using the laser distance sensor on the end-of-arm tool 11 to locate the precise center of the end of the mandrel and determine the precise distance between the distal end 16a of the expandable collet 16 and the end of the mandrel. To execute the laser search routine, the control system first directs the laser distance sensor at the end of the mandrel. Next, the control system directs the tool positioning system of material handler 1 to move the end-of- arm tool 11 in a plane parallel to the end of the mandrel along a first axis, until the laser distance sensor detects the laser has moved off the end of the mandrel. The control system then moves the end of arm tool in the opposite direction, until the laser distance sensor detects the laser has moved off the end of the mandrel in the opposite direction. This provides the control system with the center point of the end of the mandrel in the first axis. This operation is then repeated along a second axis in the same plane, perpendicular to the first axis, to provide the control system with the center point of the end of the mandrel in second axis. At the same time, the laser distance sensor measures the distance between the end of the mandrel and the distal end 16a of the expandable collet 16. The control system then calculates the precise center point of the end of the mandrel.

[0047] The next step of the second phase is to mechanically couple the button on the end of the mandrel with the slot 25 on the distal end 16a of the expandable collet 16. Based on the location of the center point and distance to the end of the mandrel, the control system then directs the movement of the end-of-arm tool 11, such that the distal end 16a of the expandable collet 16 moves to one side of the mandrel and toward the end of the mandrel. In this position, the distal end 16a of the expandable collet 16 is aligned just in front of and beside the end of the mandrel with the open side of the slot 25 facing the mandrel. From this position, the control system moves the expandable collet 16 into axial alignment with the mandrel and, in the process, slides the button on the end of the mandrel into the slot 25, thereby mechanically coupling the mandrel and the expandable collet 16.

[0048] The control system then retracts the expanding segments 18 and extends the articulating arm 20, thereby moving the gripper 17 along the length of the expandable collet 16 towards the distal end 16a. As it travels along the expandable collet 16, the gripper 17 contacts of the roll of material. The gripper 17 then pushes the roll of material off the distal end 16a of the expandable collet 16 and onto the mandrel. The articulating arm 20 then retracts the gripper 17 and the control system moves the expandable collet 16 to the side to undock from the end of the mandrel before moving the end-of-arm tool 11 back to a travel position. The AGV 2 then maneuvers to the next destination.

[0049] In a typical empty roll retrieval and disposal operation, the same two phase process is followed, whereby the AGV 2 maneuvers into position next to a mandrel, as described above, except with an empty expandable collet 16. The material handler 1 then completes the same precision docking of the distal end 16a of the expandable collet 16 with the end of the mandrel. The articulating arm 20 extends the gripper 17 along the expandable collet 16 and along the mandrel until it is positioned with the clamp arms 19 about the empty roll on the mandrel. The control system then closes the clamp arms 19 onto the outside diameter of the roll to grip the empty roll. The articulating arm 20 then retracts the gripper 17 onto the expandable collet 16, bringing the empty roll into position over the expanding segments 18. The clamp arms 19 open to release the roll from the gripper 17 and the expanding segments 18 expand to grip the inside of the roll to secure it in place on the expandable collet 16. The same undocking process is then followed before the end-of-arm tool 11 moves to a travel position for transporting the empty roll. [0050] The AGV 2 then maneuvers to a designated disposal area and the material handler 1 moves the end-of-arm tool 11 into position over a bin or other disposal container for empty rolls. The expanding segments 18 retract to release the empty roll and the articulating arm 20 extends the gripper 17 along the expandable collet 16 with the clamp arms 19 in position to contact the end of the empty roll. The gripper 17 continues along the expandable collet 16 until the empty roll has been pushed off the distal end 16a of the expandable collet 16 and into the bin. The end- of-arm tool 11 then moves back to a travel position and the AGV 2 maneuvers to the next destination.

[0051] The present invention has been described and illustrated with reference to an exemplary embodiment, however, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention as set out in the following claims. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed herein.