Automatic case loader and method for use of same

[0001] This application claims priority from co-pending U.S. Patent Application No. 60/939,689, entitled “System and Method for Automated Truck Loading” and filed on May 23, 2007, in the name of Tim Criswell; which is hereby incorporated by reference for all purposes.

[0002] This invention relates, in general, to a machine for handling products and, more particularly, to an automatic case loader designed to stack product, such as standard cardboard cases of various heights, within a trailer and a method for use of the same.

[0003] Loading docks and loading bays are commonly found in large commercial and industrial buildings and provide arrival and departure points for large shipments brought to or taken away by trucks and vans. By way of example, a truck may back into a loading bay such that the bumpers of the loading bay contact the bumpers on the trailer and a gap is created between the loading bay and the truck. A dock leveler or dock plate bridges the gap between the truck and a warehouse to provide a fixed and substantially level surface. Power moving equipment, such as forklifts or conveyor belts, is then utilized to transport the cargo from the warehouse to the truck. Human labor is then employed to stack the cargo in the truck. These systems are designed to maximize the amount the cargo loaded while minimizing the use of human labor to both protect and extend the life of the workforce. A need still exists, however, for improved truck loading systems that further reduce the use of human labor.

[0004] An automatic case loader for loading product in a trailer is disclosed. A mobile base structure provides a support framework for a drive subassembly, conveyance subassembly, an industrial robot, a distance measurement sensor, and a control subassembly. Under the operation of the control subassembly, product advances through a powered transportation path and is stacked as product columns which are presented to an industrial robot which places the product columns within the trailer. The control subassembly coordinates the selective articulated movement of the industrial robot and the activation of the drive subassembly based upon the distance measurement sensor detecting objects within a detection space, dimensions of the trailer provided to the control subassembly, and dimensions of the product provided to the control subassembly. The drive assembly provides for forward and reverse movement as well as traverse movement between so that product may be loaded within multiple trailers without interruption. These systems and methodologies utilizing the present automatic case loader therefore maximize the amount the product and cargo loaded while minimizing the use of human labor to both protect and extend the life of the workforce.

[0025] While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the present invention.

[0026] Referring initially to FIG. 1, therein is depicted an automatic case loader that is schematically illustrated and generally designated 10. A tractor trailer 12 having an operator cab 14 is towing a trailer 16 having a front wall 18, two side walls 20A, 20B (best seen in FIGS. 9A through 9D), a floor 22, a ceiling 24, and a rear access opening 26 accessible due to an open door. A bumper 28 of the trailer 16 is backed up to a loading bay 30 of loading dock 32 such that the bumper 28 touches a bumper 34 of the loading bay 30. A dock plate 36 bridges the gap between the floor 22 and a deck 38 of the loading dock 32.

[0027] As will be discussed in detail hereinbelow, under the supervision of distance measurement sensors, the automatic case loader 10 maneuvers and drives automatically into the trailer 16 to a position proximate to the front wall 18. It should be understood that although an operator 40 is depicted as operating the automatic case loader 10, an operator is unnecessary. The automatic case loader 10 operates independently of the operator 40 and the operator 40 is only necessary for certain types of troubleshooting, maintenance, and the like. A telescoping conveyor unit 42 having a skate wheel 44 for position compliance is connected to the automatic case loader 10. A stream of product 46, in the form standard cardboard cases 46A-46H of various heights (and, as shown, fixed widths), is being supplied by the telescoping conveyor unit 42 to the automatic case loader 10 which, in turn, stacks the product 46 in vertical columns and loads the product 46 into the trailer 16 as a product column 48. In particular, the automatic case loader 10 has already stacked cases 46F, 46G, 46H as a product column 48 at the intersection of the front wall 18 and the floor 22. The automatic case loader 10 alternates between loading the product columns 48 and reversing to create more space for the product 46 between the front wall 18 and the automatic case loader 10 until the trailer 16 is at least partially loaded of product 46.

[0028] FIGS. 2A through 2C depict the automatic case loader 10 in further detail. A mobile base 50 supports a drive subassembly 52, a conveyance subassembly 54, an industrial robot 56, a positioning subassembly 58, a safety subsystem 60, and a control subassembly 62, which interconnects the drive subassembly 52, conveyance subassembly 54, industrial robot 56, positioning subassembly 58, and safety subsystem 60. The mobile base 50 includes a front end 64 and a rear end 66 as well as sides 68, 70, a surface 72, and an undercarriage 74. An operator platform 76 is positioned proximate to the rear end 66 and the side 68 to be adapted to safely accommodate the operator 40.

[0029] The drive subassembly 52 is coupled to the undercarriage 74 of the mobile base 50 to provide mobility. As will be discussed in further detail hereinbelow, drive wheel assemblies 78, 80, are disposed on the undercarriage 74 proximate to the sides 70, 68 respectively. A universal wheel assembly 82 is disposed on the undercarriage 74 more proximate to the rear end 66 and centered between the sides 68, 70, respectively. In combination, wheel assemblies 78, 80, 82 provide forward and reverse drive and steering. Retractable wheel assemblies 84, 86 are also disposed on the undercarriage 74 proximate to the sides 70, 68, respectively. The retractable wheel assemblies 84, 86 have an orientation which is orthogonal to the retractable wheel assemblies 78, 80 to, in conjunction with the universal wheel assembly 82, provide transverse drive and steering. As alluded to, in a forward or reverse drive and steering operation, such as moving into or out of the trailer 16, drive wheel assemblies 78, 80 and the universal wheel assembly 82 are actuated and in contact with the deck 38 of the loading dock 32 while the retractable wheel assemblies 84, 86 are withdrawn from contact with the deck 38 in a position close to the undercarriage 74. On the other hand, in a transverse drive and steering operation, such as a repositioning between loading bays at the loading dock 32, the retractable wheel assemblies 84, 86 and the universal wheel assembly 82 are actuated and in contact with the deck 38 while the retractable wheel assemblies 78, 80 are off the deck 38. In particular, during traverse movement operations, the retractable wheel assemblies 78, 80 hydraulically extend and lift the drive wheel assemblies 78, 80 off of the deck 38.

[0030] The conveyance subassembly 54 is disposed on the surface 72 of the mobile base 50 to provide a powered transportation path 88 operable for measuring, separating, carrying, and stacking, as required by the application and job assignment of the automatic case loader 10, product from the rear end 66 to the front end 64 proximate to the industrial robot 56. As shown, the powered transportation path 88 includes a powered belt conveyor 90 disposed in conveying communication with a stacking elevator 92 to deliver the product 46 thereto. Thereafter, the product 46 is stacked as product columns 48 in a receiving tubular 94 where manipulation by the industrial robot 56 is initiated. It should be appreciated that although a powered belt conveyor 90 and stacking elevator 92 arrangement is display, the powered transportation path 88 may include any combination and type of conveyors, elevators, stackers, and bypasses and the particular combination of components selected for the powered transportation path 84 will depend upon the particular product 46 and application of the automatic case loader 10.

[0031] With respect to measuring the product 46, a curtain 96 may form a portion of the conveyance subassembly 54 and be disposed thereon to measure with light the dimensions of the product 46 and forward the measured dimensions to the control subassembly 62 as will be discussed in more detail hereinbelow. It should be appreciated that the automatic case loader 10 may be equipped with further product size detection equipment in addition to the measuring light curtain 96. By way of example, spaced photo-eyes 98 disposed along the conveyance subassembly 54 may measure the product length and determine if any product has non-standard or unacceptable length. As with the dimension data gathered by the curtain 96, the product length data captured by the spaced photo-eyes 98 is supplied to the control subassembly 62.

[0032] The conveyance subassembly 54 as well as the telescoping conveyor unit 42 may also each be equipped with a series of end stop photo eyes, such as end stop photo eyes 100, 102, to adjust the rate of automatic flow of product through the telescoping conveyor unit 42 and the conveyance subassembly 54. Such an implementation provides a steady and continuous flow of product, maintains proper product separation, and prevents unnecessary gaps between the product and product backups and jams.

[0033] A telescoping conveyor interface 104 couples the roller conveyor 90 of the conveyance subassembly 54 to the telescoping conveyor unit 42 and the rest of a pick belt system which may be at the warehouse associated with the loading dock 32. Auto-follow circuitry associated with the telescoping interface 104 of the telescoping conveyor unit 42 and the conveyance subassembly 54 may utilize fiber optic sensors at the last boom of the telescoping conveyor unit detect reflective tape at the edge of the conveyance subassembly to cause the telescoping conveyor unit 42 to extend and retract to maintain the proper position with respect to the automatic case loader 10.

[0034] The industrial robot 56 is disposed at the front end 64 and adapted to provide selective articulated movement of an end effector 130 between the receiving tubular 94 of the powered transportation path 88 and a reachable space 132 such that the industrial robot 56 is operable to place the product columns 48 in the reachable space 132. The end effector 130 includes a gripper 134 adapted for manipulating product by way of cooperating opposing paddle assemblies 136A, 136B. For purposes of illustration and explanation, the end effector 130 and the gripper 134 is only shown in FIG. 2C. It should be appreciated that any type of end effector 130 may be employed the industrial robot and the choice of end effector 130 will depend upon the product 46 and specific automatic case loader 10 application. By way of example, the gripper 134 with opposing paddle assemblies 136A, 136B is preferred for loading rectangular cases 46A-46H, such as cardboard box cases of goods, as a product column 48.

[0035] In one implementation, the industrial robot 56 includes seven segments 130, 138, 140, 142, 144, 146, 148 joined by six joints 150, 152, 154, 156, 158, 160 to furnish selective articulated movement having six degrees of freedom. More particularly, the referenced reachable space 132, as best seen in FIG. 2A, is defined by the movement of the industrial robot 56 which provides rotation about six axes including rotary movement of the entire industrial robot 56 about a primary vertical axis; rotary movement of segment 146 having a tower structure about horizontal axis to provide extension and retraction of the segment 144 having a boom arm; rotary movement of the boom arm about the horizontal axis to provide raising and lowering of the boom arm; and selective rotary movement about three wrist axes.

[0036] The positioning subassembly 58 is dispersed throughout the mobile base 50. A distance measurement sensor 170 disposed at the front end 64 of the mobile base 50 measures distance and determines the presence of objects within a detection space 172 which is located in front of the front end 64. In one embodiment, the detection space 172 and the reachable space 132 at least partially overlap. The distance measurement sensor 170 assists the automatic case loader 10 with forward and reverse movement and the repositioning of the automatic case loader 10 to create additional empty reachable space 132 for the placement of the product 46. Further, the distance measurement sensor 170 assists with the coordination and operation of the industrial robot 56. Distance and measurement information gathered by the distance measurement sensor 170 is provided to the control subassembly 62.

[0037] As will be discussed in further detail hereinbelow, the distance measurement sensor 170 may be a laser range finding apparatus operating on a time-of-flight measurement basis or principle. It should be appreciated, however, that other types of distance measurements are within the teachings of the present invention. By way of example, and not by way of limitation, the distance measurement sensor may include a laser range finding apparatuses, ultrasonic measurement apparatuses, inclinometers, and combinations thereof. Similar to distance measurement sensor 170, distance measurement sensors 174, 176 are respectively disposed at the sides 68, 70. The distance measurement sensors 174, 176 each include detection spaces (not illustrated) to provide measurement and distance information to the control subassembly 62 during traverse movement operations of the automatic case loader 10.

[0038] The safety subsystem 60 is distributed and mounted to the mobile base 50. The safety subsystem 60 may include a light tower 180 which provides a quick indication of the current status of the automatic case loader 10 to an operator 40 and a wireless operator alert system 182 which contacts pagers or cellular devices of individuals through a wireless network. Also a cage and railing 184 may be included around the operator platform 76 to provide additional safety to the operator 40. Emergency buttons, such as emergency button 186, may be located throughout the automatic case loader 10 to provide for instant and immediate power down. Front safety bumpers 188 and rear safety bumpers 190 may be positioned at the front end 64 and the rear end 64 to protect the automatic case loader 10, people, and product during a collision with an obstacle. Additionally, the front safety bumpers 188 and the rear safety bumpers 190 may include detectors that detect the presence of an object and cause an automatic power down during a collision. Side safety bumpers, although not illustrated, may also be utilized. It should be appreciated that other safety features may be integrated into the automatic case loader 10.

[0039] The control subassembly 62, which is also distributed and mounted to the mobile base 50, includes control station 192 having a user interface 194 disposed at the side 70 near the operator platform 76. As discussed, the drive subassembly 52, the conveyance subassembly 54, the industrial robot 56, the positioning subassembly 58, and the safety subassembly 60 are interconnected and in communication with the control subassembly 62 via a network of concealed and sheathed cables and wires. With this arrangement, the control subassembly 62 may coordinate the manual and automatic operation of the automatic case loader 10.

[0040] FIGS. 3A through 3C depict the mobile base 50 in further detail. A main frame 200 is constructed of welded steel tubing includes tubular sections 202, 204, 206, and 208 which provide a rectangular framework. The tubular sections 202-208 are supported by tubular sections 208, 210, 214, 216, 218, and 220, which augment and further support the rectangular framework. All mounting plates, such as mounting plates 222, 224, 226, 228, 230, 232, 234, and bolt holes necessary to hold the various components attached to the mobile base 50 are included in the main frame 200. The large plates 228, 230, 232, 234 disposed toward the rear end 66 of the mobile base 50 hold the control station 192 and the user interface 194 in position while providing counter weight for the automatic case loader 10 as well as balance with respect to the industrial robot 56 disposed proximate to the mounting plates 222, 224. Additional counter weight is supplied by tractor weights 236, 238 mounted proximate to the rear end 66, which also serve to add additional support and integrity to the main frame 200. A tray 240 securely coupled to the main frame 200 by mounting brackets 242, 244 at the rear end 66 provides support to the rear safety bumpers 190.

[0041] Drive wheel assemblies 78, 80 include a pair of front drive wheels 252, 250 disposed proximate to the front end 64 and, more particularly, proximate the intersection of tubular sections 208, 214 and tubular sections 204, 214, respectively. Respective AC motors 254, 256 with double reduction gearboxes 258, 260 supply power thereto. The AC motor 254 with double reduction gearbox 258 is disposed adjacent to the tubular section 214 and the front drive wheel 250. Similarly, the AC motor 256 with double reduction gearbox 260 is disposed adjacent to the tubular section 214 and the front drive wheel 252.

[0042] Referring now to FIGS. 3A through 3C and FIGS. 4A through 4B, the retractable wheel assembly 84 includes a side lift wheel 262 with a drive motor 264 coupled thereto and providing rotational torque through a pulley 266. The side lift wheel 262 and the drive motor 264 are secured to a frame 268 which, in turn, is coupled to the tubular section 208. A hydraulic cylinder 270, under the power of a hydraulic power cylinder 272, is coupled to a crossbar mount 274 disposed on the frame 268. The hydraulic power cylinder 272 is mounted via mounting bracket 276 to the tubular section 216. Referring now to FIGS. 3A through 3C and FIG. 5, the retractable wheel assembly 86 includes a side lift wheel 278 secured via a frame 280 to the tubular section 204. A crossbar mount 282 secures the hydraulic cylinder 270 thereto such that the hydraulic cylinder 270 spans the space between the retractable wheel assemblies 84, 86.

[0043] Referring now to FIGS. 3A through 3C and FIG. 6, the universal wheel assembly 82 includes a rear steering wheel 284 mounted to a frame 286 disposed proximate to the rear end 66. An AC motor 288 with a reduction gearbox 290 provides power and is also coupled to the frame 286. Also coupled to the frame 286, a rotational mounting 292 is cooperating with a vertical axis 294 to furnish steering capability. A servomotor 296 attached to a planetary gearbox 298 provides the steering motion.

[0044] Returning to FIGS. 3A through 6 to describe the operation of the drive subassembly 52 in conjunction with the mobile base 50, the drive wheel assemblies 78, 80 and universal wheel assembly 82 provide mobility along the length of the automatic case loader 10. The AC motors 254, 256 with the respective double reduction gearboxes 258, 260 drive the front drive wheels 250, 252. In particular, each front drive wheel 250, 252 is independently driven to provide the ability to turn and to provide a pivoting drive mode. The universal wheel assembly 82 provides a rear combination steering and drive wheel 284 that is driven by the AC motor 288 and the gearbox 290. The rear steering wheel 284 spins on the vertical axis 294 to provide enhanced steering capability for the automatic case loader 10.

[0045] In addition to providing forward and reverse capability, the drive subassembly 52 furnishes a traverse drive system providing the capability to move the entire automatic case loader 10 perpendicular to a trailer or fixed object at the loading dock 32. During normal operation, the retractable wheel assemblies 84, 86 and particularly the side lift wheels 262, 270 are tucked up under the main frame 200. When traverse mode is activated, the hydraulic cylinder 270 forces the side lift wheels 262, 270 down, lifting the front drive wheels 250, 252 off of the ground. The drive motor 264 provides rotational torque to the side lift wheel 262 while the side lift wheel 278 is passive and follows the side lift wheel 262. In this embodiment, the steering and drive wheel 284 of the universal wheel assembly 82 rotates and provides steering.

[0046] FIG. 7A and FIG. 7B illustrate one embodiment of the stacking elevator 92. A tubular frame 300, which includes a support frame 302 that is raised, is coupled to the mobile base 50. An elevator conveyor 304, which is depicted as a belt conveyor, is secured to the support frame 302 to furnish powered transportation of the product 46. The elevator conveyor 304 is disposed in conveying communication with the conveyor 90 such that product may seamlessly advance from the conveyor 90 to the elevator conveyor 304. Horizontal guide rails 306 are coupled to the sides of the elevator conveyor 304 to guide the product 46 as the product 46 passively traverses the elevator conveyor 304 from the end near the conveyor 90 to the opposite end where a launch point 308 is located at a raised point distal to the mobile base 50. A floor 310, which extends from the tubular frame 300, is positionable between a location near the launch point and a location proximate to the mobile base 50. The floor 310 is adapted for receiving product 46 and moves from a location near the launch point to a location more proximate to the mobile base 50 as product 46 is received and product column 48 formed. An actuator 320 mounted to the tubular frame 300 controls the vertical positioning of the floor 310 in response to the placement of product 46 and the formation of the product column 48. Generally speaking, the launch point 308 and the floor 310 have a spaced horizontal alignment such that the floor 310 is positioned in a coplanar relationship with the launch point 308 or slightly below and parallel to the launch point 308 to utilize gravity during the positioning of the product 46 into the receiving tubular 94.

[0047] Accordingly, the receiving tubular 94 intersects the launch point 308 and the floor 310, which forms the lower boundary of the receiving tubular 94 and moves the appropriate distance downward as product 46 is received. Vertical guide rails 312, including vertical guide rails 312A, 312B, 312C, extend from the tubular frame 300 and define three sides to guide the product from the launch point 308 to a resting place or location more proximate to the floor 310. In one implementation, one or more of the vertical guide rails 312 may be biased toward the center of the receiving tubular 94 to provide resistance and create friction during a controlled decent of the product 46, under the power of gravity, from the launch point 308 to the aforementioned resting location, which will be the floor 310 for the first product in the receiving tubular and the top surface of a product for subsequent products. Further, any bias of the vertical guide rails 312 may assist in maintaining the position of the product column 48 within the receiving tubular 94. In one embodiment, a sensor subassembly 314 including transmitters and receivers is mounted to the tubular frame 300 and disposed in communication with the control subassembly 62. The sensor subassembly 314 monitors the height of the product column 48 so that the speed and spacing of the product 46 on the telescoping conveyor unit 42 and the conveyance subassembly 54 may be controlled. Further, the sensor subassembly 314 may provide information to the actuator 320 to maintain the appropriate height of the floor 310.

[0048] A gate 316 having doors 316A, 316B, which are coupled to the tubular frame 300, forms a fourth side of the receiving tubular 94. The gate 316 may be actuated, under the power of actuators 318A, 318B coupled to the tubular frame 300 and doors 316A, 316B respectively, between a closed position for receiving product 46 within the receiving tubular 94 and an open position for receiving the gripper 134 of the end effector 130 so that the formed product column 48 may be repositioned by the industrial robot 56. It should be understood that although the receiving tubular 94 is described as having four sides, it may include any number of sides and the receiving tubular 94 may have any shape and include openings or perforations between the components defining the sides.

[0049] During operation, a stream of spaced product 46 travels from the telescoping conveyor unit 42 to the conveyor 90 to the elevator conveyor 304 where at the launch point 308, under the power of gravity and/or the elevator conveyor 304, and any resistance furnished by the vertical guide rails 312, the product 46 is received by the receiving tubular 94 and guided by the vertical guide rails 312 and closed gate 316 to a resting place at the floor 310. As discussed, initially the floor 310 may be approximately coplanar with the launch point 308. Thereafter, the top of the most recent product 46 is approximately coplanar with the launch point 308. Then, sequentially, additional product 46 is then stacked on the product resting on the floor 310 in the same manner until the product column 48 is formed.

[0050] FIG. 8A and FIG. 8B depict one embodiment of the gripper 134 having a frame 324 that is securable to the industrial robot 56. A pusher weldment 326 is attached to the frame 324. A column shelf 328 is located at a base of the frame 324 while lateral opposing paddle assemblies 330 which include opposing paddles 330A, 330B are respectively linked by links 332A, 332B to sides of the frame. A pneumatic subassembly 334 secured to the frame 324 includes supports the column shelf 328. Pairs of upper actuators 336A, 336B and lower actuators 338A, 338B, which are also coupled to the frame 324 actuate the opposing paddles 330A, 330B.

[0051] The form factor of the gripper 134 and the receiving tubular 94 of the stacking elevator 92 are complimentary so that the gripper 134 may releasably engage the receiving tubular 94 and releasably grip and manipulate the product column 48. In operation, when the gate 316 of the stacking elevator 92 is open, the column shelf 328 and pusher weldment 326 form a pocket 340 for engaging the product column 48. The column shelf 328, due to its shape, may be wedged between the product column 48 and the floor 310 of the stacking elevator 92 to support and handle the product column 48 from beneath. In one embodiment, the column shelf 328 has a wedged fork design that permits interlacing with the floor 310 of the stacking elevator 92. The pusher weldment 326 is pressed against a face of the product column 48. The lateral opposing paddles 330A, 330B fit between the product column 48 and the respective vertical guide rails 312 of the stacking elevator 92. The lateral opposing paddles 330A, 330B are adapted to, in cooperation with the column shelf 328 and pusher weldment 326, releasably grip the product column 48 so that the product column 48 may be removed from the stacking elevator 92 and manipulated by the industrial robot 56. In one embodiment, the paddles 330A, 330B cover the two-thirds and one-third of the product 46 in the product column 48. The product column 48 may be maneuvered through the reachable space 132 of the industrial robot 56 and positioned at a location in the trailer 16, for example.

[0052] Referring now to FIGS. 9A through 9D, wherein one embodiment of an automated loading system and methodology are illustrated for the automatic case loader 10 of the present invention. Initially, as shown in FIG. 9A, the trailer 16 is positioned under the power of the tractor trailer 12 at the loading bay 30 of the loading dock 32 approximate to the deck 38 where the automatic case loader 10 is working. Additionally, a trailer 344 is also positioned at adjacent loading bay 346 of the loading dock. The trailers 16, 344 are set-up, cleaned, and activated in a usual manner. Dock plates 36, 348 are respectively deployed from the loading bays 30, 346 into the trailers 16, 344. Thereafter, the trailers 16, 344 are inspected for significant damage that may interfere with the automated loading operations of the automatic case loader 10. Additional inspection may include ensuring the trailers 16, 344 are reasonably centered within the respective loading bays 30, and ensuring the deck 38 is clear of any obstructions. At this time, by way of further safety measures, kingpin lockouts may be installed to prevent a driver from accidentally pulling out either of the trailers 16 from the loading dock 32 when the automatic case loader 10 is operating therein. The kingpin lockouts or similar safety precautions protect both the operator 40 and the equipment and ensures that the wheels of the appropriate trailer are chocked and will not roll during the use of the automatic case loader 10.

[0053] Continuing to refer to FIG. 9A, once the trailer 16 is positioned in the loading bay 30, the automatic case loader 10 is moved in front of the rear access opening 26 of the trailer 16. The automatic case loader 10 utilizes either a manual or automatic reverse mode to assist the operator 40 in backing the automatic case loader 10 up to the telescoping conveyer unit 42 in a position that is square thereto. The conveyance subassembly 54 of the automatic case loader 10 is then coupled to the telescoping conveyor unit 42. At this time, as the dock plate 36 has been positioned from the deck 38 to the trailer 16, the automatic case loader 10 may be advanced into the interior of the trailer 16.

[0054] With reference to FIG. 9B, the automatic case loader 10 has advanced forward into the trailer 16 and, in one embodiment, the positioning subassembly 58 and, in particular, the distance measurement sensor 170 continuously determines the position of the automatic case loader 10 within the trailer 16. More specifically, several measurements are made. The position and angle of the automatic case loader 10 are measured with respect to the sidewalls 20A, 20B and an interior width defined thereby. Also, measurements are made with respect to a near wall within the trailer 16 and the floor 22. The near wall being the closer of the front wall 18 of the trailer or the edge formed by product 46, e.g. cases, positioned within the trailer 16. The angle relative to the floor 22 proximate to the automatic case loader 10 is measured as the automatic case loader traverses the dock plate 36 and moves into the trailer 16. In one embodiment, following successful traversal, the angle relative to the floor 22 may be assumed to be constant.

[0055] In this way, as the automatic case loader 10 moves, the position of the automatic case loader 10 relative to objects in its environment is known and the automatic case loader 10 may adjust operation appropriately. Adjustments in operation may include, but are not limited to, the operation of the industrial robot 56, the operation of the conveyance subassembly 54, and the actuation of the drive subassembly 52. The position of the sidewalls 20A, 20B and the near wall is utilized to determine the position of the automatic case loader 10 along the length of the trailer 16, the position across the width of the trailer 16, and the automatic case loader's angle relative to the sidewalls 20A, 20B or yaw. The measurements also determine the position of the automatic case loader 10 relative to the floor 22 of the trailer 16. To assist the automatic case loader 10 in determining position within the trailer 16, in one implementation, the automatic case loader 10 is programmed with the dimensions of the trailer 16.

[0056] Additionally, in one embodiment, the automatic case loader 10 is programmed with the reachable space 132 of the industrial robot 56. As illustrated, once the automatic case loader is positioned proximate to the front wall 18 of the trailer 16 such that the placement of product 46 against the front wall 18 of the trailer 16 is within the reachable space 132 of the industrial robot 56, the automatic case loader 10 stops advancing. Product 46 is then conveyed from the telescoping conveyor unit 42 to the conveyance subassembly 54 and this stream of product 46 is presented to the industrial robot 56 as product columns 48. With selective articulated movement through the reachable space 132, the industrial robot 56 places the product columns 48 within the trailer and sequentially loads the product columns 48 according to a stacking routine designed to optimize the use of available space within the trailer 16.

[0057] In one embodiment, this stacking routine places product columns in sequentially vertically stacked horizontal rows. This stacking routine or other alternative stacking routine may be optimized for the size of the end effector 130 of the industrial robot 56, the dimensions of the trailer 16, and the dimensions of the product 46.

[0058] As depicted in FIG. 9B, the automatic case loader 10 has completed stacking a second horizontal row of product columns 48 on top of the first horizontal row of product columns 48. The loading of the product 46 by the industrial robot 56 is temporarily interrupted in response to the distance measurement sensor 170 detecting the presence of the product 46 within the reachable space 132. Further, with this information being available to the control subassembly 62, a signal may be sent to the conveyance subassembly 54 to slow down or temporarily halt the powered transport of the product 46.

[0059] The automatic case loader 10 then reverses and is repositioned to refresh the reachable space 132 such that the automatic case loader 10 is positioned proximate to the wall of placed product 46 in order that the placement of additional product columns 48 against the wall of placed product columns 48 is within the reachable space 132 of the industrial robot 56. During the repositioning of the automatic case loader 10, the telescoping conveyor unit 42 appropriately retracts, while maintaining contact with the conveyance subassembly 54, to accommodate the new position of the automatic case loader 10.

[0060] Referring to FIG. 9C, the iterative stacking operations and repositioning of the automatic case loader 10 described in FIGS. 9A and 9B continues and the trailer 16 is filled. The trailer 16 is completely filled with product 46 and the automatic case loader 10 is reversed to a position entirely on the deck 38. Thereafter, as shown in FIG. 9C, the trailer 16 filled with product 46 is able to leave the loading dock 32. Utilizing transverse drive capabilities of the automatic case loader 10, with respect to FIG. 9D, the automatic case loader moves perpendicular to the trailers to arrive at the trailer. This fresh empty trailer may then be loaded in the manner described herein. In this manner, the automatic case loader may services multiple trailers and lose a minimum amount of time between filling operations.

[0061] FIG. 10A and FIG. 10B show one operational embodiment of the automatic case loader 10 implementing a stacking methodology for product 46 represented as product columns 48, wherein the numbers 1-12 denote product columns 48 and representations of the order in which the product columns are placed within the trailer which is defined by width (W), height (H), and length (L). The “A” and “B” indications denote the row. In particular, the “A” row is placed within the trailer before the B row. Accordingly, the order of placement of the product columns 48 is 1A, 2A, 3A, 4A, 5A, 6A, 7A, 8A, 9A, 10A, 11A, 12A, 1B, 2B, 3B. The ghosted line represents an outline of the reachable space 132 of the industrial robot 56 which must maneuver to avoid contact with any of the interior surfaces, e.g., front wall 18, floor 22, ceiling 24, of the trailer 16.

[0062] In this manner, the illustrated stacking routine places the product columns 48 in sequentially vertically stacked horizontal rows. This stacking routine optimizes for size of the gripper of the industrial robot, dimensions of the trailer, and dimensions of the product, the amount of product 46 already placed as well as the amount of product 46 remaining. As previously alluded to, the dimensions of the gripper are known as are the industrial robot. These dimensions are preferably preprogrammed into the automatic case loader 10. The dimensions of the product may be obtained from one or more sources. In particular, the dimensions may be preprogrammed or measured by one or more components of the automatic case loader 10 including the curtain 96, spaced photo-eyes 98, and sensor subassembly 314. The automatic case loader 10, with the use of these same components, may determine the amount of product 46 already placed within the trailer 16. The amount of product 46 remaining may be determined by the automatic case loader 10 from the difference of the amount of product 46 initially provided, a quantity preprogrammed, and the amount of product 46 already stacked.

[0063] In a fixed width application, which is common with product 46 that includes cardboard cases, the automatic case loader 10 may be optimized to place two product columns 48 in each stack. For example, the automatic case loader 10 optimizes for the placement of a first product column 48, column 1A, and then optimizes for the placement of a second product column 48, column 2A, on top of the first product column 48. This optimization involves determining the space remaining after the first product placement. This remaining space is optimized for a product column that will best fill the space after considering the difference between the trailer height and gripper height, for example.

[0064] It should be understood that the stacking routine selected will depend on the application and is not limited to the fixed-width application presented hereinabove. By way of example, FIG. 11 depicts another operational embodiment of the automatic case loader implementing a stacking methodology. In this application, palates of product are optimally arranged in the trailer 16.

[0065] FIG. 12 depicts one embodiment of the automatic case loader 10 and the control signals associated therewith. The illustrated components coordinate the various functions and operations of the automatic case loader 10. The user interface 194, operational environment database 350, programmable logic controller 352, robot controller 354, and distance measurement sensors 170, 174, 176 are interconnected. The drive subassembly 52, conveyance subassembly 54, as represented by control 356 for conveyors/elevators, and safety controller 358 are connected to the programmable logic controller 352. Finally, the industrial robot 56 is connected to the robot controller 354. In one implementation, the user interface 194, operational environment database 350, and programmable logic controller 352 are part of the control subassembly 62 and the robot controller 354 forms a portion of the industrial robot 56. The safety controller 358 is included in the safety subsystem 60 and provides operation to the aforementioned components of this subsystem.

[0066] The user interface 194 provides user control and interaction with the automatic case loader 10. The user interface 194 may utilize icons in conjunction with labels and/or text to provide navigation and a full representation of the information and actions available to the operator. In addition to loading operations, user interactions may be related to maintenance, repair and other routine actions which keep the automatic case loader 10 in working order or prevent trouble from arising.

[0067] The operational data environment database 350 includes data about the reachable space 132 of the industrial robot 56, stacking methodology data, product information as well as information about the standard sizes of trailers. The product information may be stored in the operational data environment database 350, gathered by the conveyance subassembly 54 as previously discussed, or gained by a combination thereof. By having the standard sizes of trailers pre-loaded, operator time is saved from having to enter this data and performance of the automatic case loader 10 is improved with this additional information. By way of example, Tables I & II present exemplary examples of type of trailer data that the automatic case loader 10 may utilize in determining position and product placement.

[0068]

TABLE I
TRAILER DIMENSIONS
			Inside	Inside	Door
Trailer		Inside	Height	Height	Opening
Type	Length	Width	Center	Front	Width
28′	27′3″	100″	109″	107″	93″
(8.5 m)	(8.3 m)	(2.5 m)	(2.8 m)	(2.7 m)	(2.4 m)
High Cube
45′	44′1½″	93″	109″	106″	87″
(13.7 m)	(13.4 m)	(2.4 m)	(2.8 m)	(2.7 m)	(2 m)
Wedge
48′	47′3″	99″	110½″	108½″	93″
(14.6 m)	(14.4 m)	(2.5 m)	(2.8 m)	(2.8 m)	(2.4 m)
Wedge

[0069]

TABLE II
TRAILER DIMENSIONS CONTINUED
	Door	Rear
Trailer	Opening	Floor	Cubic	Overall	Overall
Type	Height	Height	Capacity	Width	Height
28′	104″	47½″	2029 cft	102″	13′6″
(8.5 m)	(2.6 m)	(1.2 m)	(57.5 cm)	(2.6 m)	(4.1 m)
High Cube
45′	105½″	50″	3083 cft	96″	13′6″
(13.7 m)	(2.7 m)	(1.3 m)	(7.3 cm)	(2.4 m)	(4.1 m)
Wedge
48′	105″	48½″	3566 cft	102″	13′6″
(14.6 m)	(2.7 m)	(1.2 m)	(101 cm)	(2.6 m)	(4.1 m)
Wedge

[0070] The programmable logic controller 352 coordinates overall operation and switches between various modes of operation including manual and automatic. The programmable logic controller 352 also provides for the high-level calculation and coordination required during automatic operation for items such as the stack height during loading and steering angle calculations during automatic navigation.

[0071] The robot controller 354 controls the motions of the industrial robot 56 through built in inputs and outputs wired through the industrial robot 56 and the end effector 130. It should be appreciated that although a particular architecture is presented for the control of the automatic case loader, other architectures are within the teachings of the present invention. By way of example, any combination of hardware, software, and firmware may be employed. By way of further example, the distribution of control may differ from that presented herein.

[0072] In one operation embodiment, the programmable logic controller 352 accesses the dimensions of the trailer 16 from the operational environment database 352. The operator 40 has indicated through the user interface 194 which type of trailer has arrived at the docking bay 30. Alternatively, the distance measurement sensor 170 is operable to detect this information. The distance measurement sensors 170, 174, 176 relay distance and position data to the programmable logic controller 352 which uses this information to send control signals to the robot controller 354, the drive subassembly 52, the controller 352, and the safety controller 358. Additionally, the programmable logic controller 352 receives control signals, which are inputs into the behavior process, from each of these components. Constant updates and status information are provided to the operator 40 by the programmable logic controller 352 through the user interface 194.

[0073] FIG. 13 depicts one embodiment of the robot controller 354 which forms a portion of the automatic case loader 10. The essence of the robot control 352 is a robot system or control program 360, which controls the industrial robot 56. The control program 360 can be operated by the operator 40 by means of an operating service 362 in communication with the user interface 194 and receives input data (as well as provide instructions, as appropriate) from the operational environmental database 350, programmable logic controller 352, and distance measurement sensor 170 by means of a driver 364. It should be appreciated, that the independence of the robot controller 354 may vary. In one implementation, the robot controller 354 may be under the control of the programmable logic controller 352. In another implementation, as illustrated, the robot controller 354 is more autonomous and may include features such as direct connection to the user interface 194.

[0074] According to one embodiment, between the driver 364 and the control program 360 is provided an independent data processing layer in the form of a frame program 366, which controls the robot movements, and a unit 368 for automated or event-controlled strategy or behavioral selection on the basis of the states and signals which occur. User application programs, event-controlled strategy selections and sensor programs in the frame program 366 can be programmed by the operator 40 and directed by a robot program 370, which monitors the balance and implementation of manual and automatic control of the industrial robot 56.

[0075] FIG. 14 depicts one embodiment of a distance measurement sensor, i.e., a laser measurement sensor 380. A staging circuit 382 causes a pulsed laser 384 to transmit light pulses while causing the rotation of a light deflecting device 386 via controller 388 which may be equipped with a rotational means and a motor. The angular position of the light deflecting device 386 is continuously communicated to the staging circuit 382 by the controller 388. Light pulses are transmitted into the detection space 172 via the transmitter lense and the mirrors associated with the light deflection device 386. More particularly, when the rotary mirror of the light deflection device 386 is driven by the controller 388 to execute a continuous rotary movement, the staging circuit 382 causes the pulsed laser 384 to transmit a light pulse. The light pulse is transmitted into the detection space 172 and is reflected from an object, so that finely a received pulse enters into a photo receiving arrangement 390. In this manner the light reaches the photo receiver arrangement 390 after a light transit time t of 2d/c, where d is the space in the object from the apparatus and c is the speed of light.

[0076] The time t between the transmission and reception of the light pulse is measured with the aid of a comparator 392 having time interval computer functionality. On transmitting the light pulse, a counter function within the comparator 392 is triggered and is stopped again by the photo receiver arrangement 390 via the comparator 392 on receiving the light pulse from the detection space 172.

[0077] A corresponding electrical signal is formed and applied via comparator 392 to a laser scanner controller 394, signal to noise processor 396 and a detector 398, which analyzes the signal for objects and in the instant example determines that an object is present. The task of the signal to noise processor 396 is to control the detection threshold independence on the received noise level. This control ensures a constant false alarm rate with varying illumination situations and object reflection factors. The signal to noise processor 396 makes available this information to the laser scanner controller 394. The laser scanner controller 394 performs peak value calculations based on the data from the comparator 392, the signal to noise processor 396, and the detector 398.

[0078] As the laser scanner controller 394 knows the instantaneous angular position of the light pulses by way of communication with the staging circuit 382, the laser scanner controller 394 determines the location of the object and other navigational properties. The laser scanner controller 394 is adapted to forward this information to other components.

[0079] FIG. 15 depicts another embodiment of an automatic case loader which is schematically illustrated and designated 400. Similar to the automatic case loader 10, the automatic case loader 400 includes a mobile base 402 having a drive subassembly 404 providing forward/reverse as well as traverse movement capability. A conveyance subassembly 406, an industrial robot 408, positioning subassembly 410, a safety subsystem 412, and a control subassembly 414 are also included and provide functionality similar to the respective component counterparts discussed with respect to the automatic case loader 10. In this implementation the conveyance subassembly 406 includes parallel roller conveyors 416, 418 that define a powered transportation path 420 and a powered return path 422. Entire pallets are received by the parallel roller conveyors 416, 418 and presented to the industrial robot 408 having a pallet handling end effector 424 for handling the palleted product stacked on the pallet. After the industrial robot 408 removes the pallet product from the launch platform 426, an actuator assembly 428 associated with the launch platform 426 causes the empty pallet to be returned along the powered return path 422 via return conveyor. Accordingly, the automatic case loaders 10, 400 presented herein may handle varied product.

[0080] While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.