Robotic Design for the Supply Chain

Fast Loading & Unloading from Containers by RAH

This is a concept design we called RAH (Robotic Auto Handler) that could be the basis for fast loading and unloading from containers that are transported by either semi-truck trailer combinations, locomotive railway systems or ship based containers that are removed from the ship to the dock. RAH is designed to be an all weather operational machine working indoors or outdoors, recharging the battery system from the available sunlight and or when indoors recharging from a dedicated wall socket or charging from the on board motor and power supply. The RAH design is not a replacement for the forklift and never will be, as the forklift is just too versatile from an operational perspective.

We see the RAH design being operated in an (semi) autonomous role where the design uses both 3D visual information for object detection and robot path planning for accurate positioning in relation to moving objects (transport delivery medium), further that the RAH design could be simplified to work in a dedicated area by using navigation by using curb detection (bounded by concrete curbs or painted lines like a shopping centre car park). The purpose of this design is to improve the efficiency, reduce costs and increase productivity in the supply chain.

Loading and unloading from 20 foot or 40 foot containers that have at a minimum of one long side open for the RAH design to work irrespective of whether the container has structural vertical bars or not. These transport goods can be any configuration that resides on a pallet or where the goods are carton based and not stacked on a pallet.

This RAH design can also be used to work with newer containers that now feature multi door openings on the long side, but it is not designed to work from the containers rear doors.

The RAH carton clamp is designed to facilitate loading and unloading of carton based goods (like a 2 door refrigerator) from within the container, whereas the RAH tines design is for working directly with palletised based loads. New designs have been completed for specialised attachments for the handling of petro-chemical based goods.

Sensors located on all sides and each corner coupled with video based object recognition assist with accurate alignment for loading and unloading of either type of container based goods.

Together with offsite monitoring and or remote control for goods that may have shifted in transit, the video based monitoring has a 360 degree view around the horizontal axis and approximate 60 degree view around a vertical axis. Thereby giving RAH the ability to recognise different categories of goods based loads and remember those configurations for later use.

Smart pallet technology could be deployed that use optical sensors and laser guidance that permit accurate alignment with RAH alignment sensors. Reading barcodes from smart pallets and or containers would enable RAH to recognise loads characteristics for any transport medium, store and retrieve that data for fast operation and the required destination for either a loading or loading scenario.

RAH was designed to work in and around conveyor systems in a warehouse and or distribution centre, loading or unloading directly from the transport medium.

Reproduced for clarity to the reader

Technical Design - Hydraulics

Hydraulic all-wheel drive in both directions, turning in a 90 degree arc. Using two stage hydraulic rams to lower and raise the robot from ground level (for loading/unloading pallets) to a maximum height of 5 feet 8 inches ( 1.7 Mt) approx. Designing a turret that rotates 360 degrees and fitted with either a set of tines ( forklift like) or a carton clamp for handling oversize cartons. Attached are the counterweight to offset the opposing load designed with an extendable two stage boom for a maximum reach of 6 foot 6 inches (2 Mt) approximately , thereby allowing the robot to reach over other obstacles (like conveyors) to gain access to the container (transport medium) to the opposite side. Designed with a rotating knuckle to allow tilting the attached device (tines or carton clamp) to gain access to a pallet that may have shifted in transit, fitted with a rotary head to allow the attached device (tines or carton clamp) to rotate in a 25 degrees arc to gain access to a pallet that may have shifted in transit.

Electrical & Electronics

Solar panels fitted to the upper most part of the turret to maintain and charge the lithium ion batteries (fitted below) while in use. Using an array of 12 motion and proximity detection sensors around the robots base to monitor movement by other machines (trucks etc). Two proximity detection sensors are designed and attached to any device to facilitate the positioning and placement of the attachment for loading and unloading of the respective transport medium. Surveillance camera mounted just above the solar panels for use by the remote operator as a live video feed while the robot is in operation.

Robotic Pallet Handling for the Supply Chain

Innovative robotic machine design can improve the supply chain productivity for pallet handling from side loaded containers that arrive by either semi-truck (lorry, tractor) trailer or railway wagon transport systems. The graphic representation in this article serves to show what may be possible in the near future for side loading/unloading containers on road or railway transport systems. Automation of the pallet handling process coupled together with smart pallets may well reduce the time and costs for side unloading or loading, together with an integrated and automated warehouse conveyor systems. Warehousing and or manufacturers need fast methods to move palletised loads and new methods for material handling equipment are evolving at a fast pace. New designs are required by warehousing or manufacturing plant for quick movement of goods and localizing pallet loads for distribution. Flexibility in warehouse/manufacturing operations, are vital for vision guided robotics, where they help to reduce the downtime and improve productivity in the movement of palletised loads.

Basic Principles of Operation

The auto handler is a combination of mechanical, hydraulic, electronic sensors and camera detection systems, that when integrated together would operate on an autonomous basis from human interaction (for the most part) by the way of dedicated lanes within a defined area. Operating within an environment and ultimately controlled by a human operator monitoring the functionality of the machine at a remote location. Loading from warehouse conveyor systems to transport and alternately unloading from transport to conveyors systems, employing diesel engine power (or high capacity battery power) to move the auto handler. Hydraulic pumping force for steering and directional movement of the wheels, raise and lower the auto handler by the hydraulic legs to the height of the transport mediums loaded pallets, hydraulic rotation for the turntable ( counterweight, booms and tines) of 360 degrees. Utilizing an extendable/retractable 2 stage boom connected to the knuckle and tines to support a loaded pallet, also using an extendable/retractable counterweight on the opposing side of the load to maintain the auto handler’s stability in operation. Using cameras to detect the accurate engagement height and alignment of the loaded pallet, sensors used to detect proximity with other machinery or humans and motion sensors to detect movement.

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