U.S. patent application number 14/492383 was filed with the patent office on 2016-03-24 for automated guided vehicle positive stopping system.
This patent application is currently assigned to Toyota Motor Engineering & Manufacturing North America, Inc.. The applicant listed for this patent is Toyota Motor Engineering & Manufacturing North America, Inc.. Invention is credited to John A. Holt, David W. Newberry.
Application Number | 20160083916 14/492383 |
Document ID | / |
Family ID | 55450032 |
Filed Date | 2016-03-24 |
United States Patent
Application |
20160083916 |
Kind Code |
A1 |
Newberry; David W. ; et
al. |
March 24, 2016 |
AUTOMATED GUIDED VEHICLE POSITIVE STOPPING SYSTEM
Abstract
A positive stopping system with an adjustable stopper apparatus
positioned along an automated guided vehicle navigation pathway.
The adjustable stopper apparatus includes a linear actuator
moveable between an extended position and a retracted position. A
stopper end is coupled to the linear actuator. The stopper end is
positioned within the automated guided vehicle navigation pathway
when the linear actuator is in the extended position and removed
from the automated guided vehicle navigation pathway when the
linear actuator is in the retracted position.
Inventors: |
Newberry; David W.;
(Gallipolis, OH) ; Holt; John A.; (Morgantown,
WV) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Toyota Motor Engineering & Manufacturing North America,
Inc. |
Erlanger |
KY |
US |
|
|
Assignee: |
Toyota Motor Engineering &
Manufacturing North America, Inc.
Erlanger
KY
|
Family ID: |
55450032 |
Appl. No.: |
14/492383 |
Filed: |
September 22, 2014 |
Current U.S.
Class: |
404/6 |
Current CPC
Class: |
F16P 7/00 20130101; B60T
7/22 20130101; E01F 13/04 20130101 |
International
Class: |
E01F 13/04 20060101
E01F013/04 |
Claims
1. A positive stopping system comprising: an adjustable stopper
apparatus positioned along an automated guided vehicle navigation
pathway, the adjustable stopper apparatus comprising: a linear
actuator moveable between an extended position and a retracted
position; and a stopper end coupled to the linear actuator, wherein
the stopper end is positioned within the automated guided vehicle
navigation pathway when the linear actuator is in the extended
position and the stopper end is removed from the automated guided
vehicle navigation pathway when the linear actuator is in the
retracted position.
2. The positive stopping system of claim 1, wherein the adjustable
stopper apparatus further comprises a stopper cylinder.
3. The positive stopping system of claim 1, wherein the stopper end
is engageable with a stop block of an automated guided vehicle.
4. The positive stopping system of claim 3, wherein the stopper end
provides resistance to the stop block of the automated guided
vehicle preventing the automated guided vehicle from traveling in a
forward direction of travel.
5. The positive stopping system of claim 1, wherein the stopper end
further comprises a cushioning device coupled to the linear
actuator and configured to provide dampening.
6. The positive stopping system of claim 1, wherein further
comprising a conveyor station having a conveyor frame.
7. The positive stopping system of claim 6, wherein an anti-back
mechanism is coupled to the conveyor station, the anti-back
mechanism comprising an anti-back block that is pivotable when
contacted by an automated guided vehicle in a forward direction of
travel and immobile when contacted by the automated guided vehicle
in a reverse direction of travel.
8. The positive stopping system of claim 6, wherein the conveyor
station further comprises a conveyor station communications device
adapted to transmit control signals to the adjustable stopper
apparatus signaling the adjustable stopper apparatus to move the
linear actuator to the extended position or the retracted
position.
9. The positive stopping system of claim 6, wherein the conveyor
station further comprises an automated guided vehicle presence
sensor configured to detect whether an automated guided vehicle is
located at the conveyor station.
10. The positive stopping system of claim 9, wherein the automated
guided vehicle presence sensor is communicatively coupled to the
adjustable stopper apparatus such that when the automated guided
vehicle presence sensor detects that the automated guided vehicle
is not located at the conveyor station, the linear actuator of the
adjustable stopper apparatus moves into the extended position.
11. An automated guided vehicle system comprising: an automated
guided vehicle comprising a vehicle frame, a drive mechanism, a
sensing head, and a stop block coupled to the vehicle frame; a
conveyor station comprising a conveyor frame; and an adjustable
stopper apparatus mounted on the conveyor station, the adjustable
stopper apparatus comprising: a linear actuator moveable between an
extended position and a retracted position; and a stopper end
coupled to the linear actuator, wherein the stopper end is
positioned within an automated guided vehicle navigation pathway
when the linear actuator is in the extended position and the
stopper end is removed from the automated guided vehicle navigation
pathway when the linear actuator is in the retracted position; and
wherein when the linear actuator is in the extended position, the
stopper end is engageable with the stop block of the automated
guided vehicle and when the linear actuator is in the retracted
position, the automated guided vehicle navigation pathway is
unobstructed.
12. The automated guided vehicle system of claim 11 further
comprising an anti-back mechanism is coupled to the conveyor
station, the anti-back mechanism comprising an anti-back block that
is pivotable when contacted by the automated guided vehicle in a
forward direction of travel and immobile when contacted by the
automated guided vehicle in a reverse direction of travel.
13. The automated guided vehicle system of claim 11, wherein the
automated guided vehicle further comprises an automated guided
vehicle communications device and the conveyor station further
comprises a conveyor station communications device.
14. The automated guided vehicle system of claim 13, wherein the
automated guided vehicle communications device and the conveyor
station communications device are commutatively coupled when the
automated guided vehicle is stopped at a conveyor station stopping
location.
15. The automated guided vehicle system of claim 13, wherein the
conveyor station communications device is adapted to transmit
control signals to the adjustable stopper apparatus signaling the
adjustable stopper apparatus to move the linear actuator to the
extended position or the retracted position.
16. The automated guided vehicle system of claim 11, wherein the
automated guided vehicle navigation pathway further comprises a
slow tape detectable with the sensing head of the automated guided
vehicle to signal the automated guided vehicle to reduce speed.
17. The automated guided vehicle system of claim 11, wherein the
automated guided vehicle navigation pathway further comprises a
stop tape detectable with the sensing head of the automated guided
vehicle adapted to provide a stop signal to the automated guided
vehicle.
18. A method of navigation assistance, the method comprising:
extending a linear actuator of an adjustable stopper apparatus into
an automated guided vehicle navigation pathway wherein the
adjustable stopper apparatus is coupled to a conveyor station;
approaching the conveyor station with an automated guided vehicle
following the automated guided vehicle navigation pathway, wherein
the automated guided vehicle comprises a vehicle frame, a drive
mechanism, and a stop block coupled to the vehicle frame; engaging
the stop block of the automated guided vehicle with the linear
actuator of the adjustable stopper apparatus; stopping the
automated guided vehicle; and retracting the linear actuator of the
adjustable stopper apparatus from the automated guided vehicle
navigation pathway.
19. The method of navigation assistance of claim 18, the method
further comprising: detecting, with an automated guided vehicle
presence sensor, whether the automated guided vehicle is located at
the conveyor station; and extending the linear actuator of the
adjustable stopper apparatus into an extended position if the
automated guided vehicle is not located at the conveyor
station.
20. The method of navigation assistance of claim 18, wherein the
conveyor station further comprises an anti-back mechanism, the
anti-back mechanism comprising an anti-back block that is pivotable
when contacted by the automated guided vehicle in a forward
direction of travel and immobile when contacted by the automated
guided vehicle in a reverse direction of travel.
Description
TECHNICAL FIELD
[0001] The present disclosure is generally directed positive
stopping systems for automated guided vehicles.
BACKGROUND
[0002] Automated guided vehicles (AGVs) are used in factory
environments to assist with inventory management by transporting
parts from one area of the factory to another. For example, parts
may be loaded on an AGV in a staging area. Once the parts are
loaded, the AGV may drive to an assembly area where the parts are
unloaded and used in assembly processes. The AGV may travel from
the staging area to the assembly area based on a control system and
without intervention from users.
[0003] In some environments, robots may be used to load and/or
unload parts from the AGVs. To facilitate reliable unloading of the
parts from the AGVs, the position of the AGVs relative to the
robots should be accurate and repeatable. Previously, AGVs would
drive to stations affixed to the floor of the factory and
automatically stop at a predetermined stopping location.
[0004] However, the automatic stop may be unreliable, causing the
AGVs to overrun the conveyor station. This unreliability may harm
the efficiency of the AGVs. Further, failure to stop at the
predetermined location may initiate a fault that forces the AGVs to
become inoperable. Accordingly, positive stopping systems for AGVs
may be desired.
SUMMARY
[0005] In one embodiment, positive stopping system includes an
adjustable stopper apparatus positioned along an automated guided
vehicle navigation pathway. The adjustable stopper apparatus
includes a linear actuator moveable between an extended position
and a retracted position. A stopper end is coupled to the linear
actuator. The stopper end is positioned within the automated guided
vehicle navigation pathway when the linear actuator is in the
extended position and removed from the automated guided vehicle
navigation pathway when the linear actuator is in the retracted
position.
[0006] In another embodiment, an automated guided vehicle system
includes an automated guided vehicle having a vehicle frame, a
drive mechanism, a sensing head, and a stop block coupled to the
vehicle frame. The automated guided vehicle system further includes
a conveyor station having a conveyor frame and an adjustable
stopper apparatus mounted on the conveyor station. The adjustable
stopper apparatus includes a linear actuator moveable between an
extended position and a retracted position. A stopper end is
coupled to the linear actuator. The stopper end is positioned
within the automated guided vehicle navigation pathway when the
linear actuator is in the extended position and removed from the
automated guided vehicle navigation pathway when the linear
actuator is in the retracted position. When the linear actuator is
in the extended position, the stopper end is engageable with the
stop block of the automated guided vehicle. Further, when the
linear actuator is in the retracted position, the automated guided
vehicle navigation pathway is clear and the automated guided
vehicle can travel in a forward direction without obstruction.
[0007] In yet another embodiment, a method of navigation assistance
includes extending an adjustable stopper apparatus linear actuator
into an automated guided vehicle navigation pathway where the
adjustable stopper apparatus is coupled to a conveyor station and
approaching the conveyor station with an automated guided vehicle
following the automated guided vehicle navigation pathway. The
automated guided vehicle includes a vehicle frame, a drive
mechanism, a sensing head, and a stop block coupled to the vehicle
frame. The method of navigation assistance also includes engaging
the stop block of the automated guided vehicle with the linear
actuator of the adjustable stopper apparatus, stopping the
automated guided vehicle, and retracting the linear actuator of the
adjustable stopper apparatus from the automated guided vehicle
navigation pathway.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The embodiments set forth in the drawings are illustrative
and exemplary in nature and not intended to limit the subject
matter defined by the claims. The following detailed description of
the illustrative embodiments can be understood when read in
conjunction with the following drawings, where like structure is
indicated with like reference numerals and in which:
[0009] FIG. 1 depicts a perspective view of an AGV system including
an AGV, a conveyor station, and an adjustable stopper apparatus in
an extended position according to one or more embodiments described
herein;
[0010] FIG. 2 depicts a perspective view of an AGV system including
an AGV, a conveyor station, and an adjustable stopper apparatus in
a retracted position according to one or more embodiments described
herein;
[0011] FIG. 3 depicts a schematic top view of an AGV according to
one or more embodiments described herein;
[0012] FIG. 4 depicts a perspective view of an AGV navigation
pathway positioned along a conveyor station according to one or
more embodiments described herein;
[0013] FIG. 5 depicts a partial view of an AGV on a navigation
pathway according to one or more embodiments described herein;
[0014] FIG. 6A depicts a top perspective view of an adjustable
stopper apparatus in an extended position according to one or more
embodiments described herein;
[0015] FIG. 6B depicts a top perspective view of an adjustable
stopper apparatus in a retracted position according to one or more
embodiments described herein;
[0016] FIG. 7A. depicts a top view of an anti-back mechanism
according to one or more embodiments described herein;
[0017] FIG. 7B. depicts another top view of an anti-back mechanism
according to one or more embodiments described herein;
[0018] FIG. 8 depicts a standalone adjustable stopper apparatus
according to one or more embodiments described herein; and
[0019] FIG. 9 depicts a perspective view of a standalone adjustable
stopper apparatus and an AGV according to one or more embodiments
described herein.
DETAILED DESCRIPTION
[0020] Embodiments of the present disclosure are directed to
adjustable stopper apparatuses positioned near conveyor stations
and navigation pathways. The adjustable stopper apparatuses are
moveable between an extended position to provide a positive stop
for an AGV following along an AGV navigation pathway and a
retracted position to remove obstruction from the AGV navigation
pathway, allowing the AGV to exit the conveyor station without
changing direction. When an AGV drives into an adjustable stopper
apparatus positioned in the extended position, a stop block mounted
on an AGV frame comes into contact with portions of the adjustable
stopper apparatus. This contact stops the AGV and accurately and
repeatably locates the AGV for a part loading and unloading
process. When the AGV is prepared to leave the conveyor station,
the adjustable stopper apparatus is repositioned into a retracted
position. The retracted position of the adjustable stopper
apparatus provides clearance to allow the AGV to continue to follow
a pre-determined path along a forward direction of travel. Allowing
the AGV to continue along the forward direction of travel, and
therefore not requiring the AGV to sequentially reverse or alter
the direction of travel, increases the predictability of behavior
of movement of the AGV.
[0021] Referring now to FIGS. 1-2, an AGV system 100 is depicted.
The AGV system 100 includes an AGV 110, a conveyor station 150, an
adjustable stopper apparatus 170, and an anti-back mechanism 190.
The AGV 110 is configured to travel along a factory floor 104 and
follow an AGV navigation pathway 140. In FIGS. 1-2, the AGV 110 is
positioned alongside the conveyor station 150. The adjustable
stopper apparatus 170 is mounted on the conveyor station 150 and is
positioned such that the adjustable stopper apparatus 170 can be
moved between an extended position 106, positioned within an AGV
navigation pathway 140 as depicted in FIG. 1, and a retracted
position 108, removed from the AGV navigation pathway 140 as
depicted in FIG. 2. The various components of the AGV system 100
are described in detail below.
[0022] Referring now to FIG. 3, the AGV 110 is schematically
depicted in more detail. The AGV 110 includes a vehicle frame 112
and a plurality of wheels or casters 114 that are coupled to the
underside of the vehicle frame 112 and support the AGV 110 as it
moves about the factory floor 104 (FIG. 1). The AGV 110 also
includes at least one drive mechanism 116 and at least one sensing
head 122. In the embodiment depicted in FIG. 3, the drive mechanism
116 is controlled by a drive unit 120 and is configured to rotate
and provide a directional drive force to the AGV 110 to translate
the AGV 110 along the AGV navigation pathway 140. The sensing head
122 may be coupled to the AVG 110 and used to detect and follow the
AGV navigation pathway 140 (FIG. 1). The casters 114 are free to
rotate, but rotation of the casters 114 may or may not be
controllable. Thus, direction of movement of the AGV 110 may be
determined based on the direction of drive force applied by the
drive mechanism 116.
[0023] The AGV 110 may include a programmable logic controller 126
(PLC) that contains communication and sensor controls. The PLC 126
may control or provide a start/stop switch, lane and status lights,
route selector switches, a serial switch, an RF modem, an RFID
reader and an IR I/O transmitter. Both the drive unit 120 and the
PLC 126 may control or receive information from the sensing head
122. In some embodiments, the AGV 110 may further include a power
switch, a bumper safety switch, an emergency stop switch, a chime
box, a status light, and a speed controller. In some embodiments,
the drive unit 120 and the PLC 126 are communicatively coupled. For
example, the drive unit 120 may provide driving information (e.g.,
driving/not driving) and route detecting information (e.g.,
slow/stop tape detected) to the PLC 126, and the PLC 126 may
provide turn information (e.g. right turn/no right turn) and speed
setting information to the drive unit 120 to control the speed and
direction of the drive mechanism 116. In some embodiments, the AGV
110 includes infrared and/or ultrasonic sensors to provide the AGV
110 with collision avoidance assistance.
[0024] Referring still to FIG. 3, the AGV 110 may further include
an AGV communication device 124 that can communicate with the PLC
126. The AGV communication device 124 may be wireless and
communicatively coupled to a wireless communications network, or
other wireless sources, for example, a wireless network that
conforms to an FL-net standard, or the like. In operation, the AGV
communication device 124 may receive wireless signals from a
plurality of location beacons (e.g., RFID tags) that provide the
AGV communication device 124 with information regarding the
location of the AGV 110 along the AGV navigation pathway 140 within
a factory environment, a location of one or more conveyor stations
150 (FIG. 1), and a location of one or more obstacles. The speed
and direction of the AGV 110 may be set based on the wireless
signals that are received by the AGV communication device 124 from
the location beacons and/or the PLC 126. As described in greater
detail below, the AGV communication device 124 can also communicate
with a conveyor station communications device 160 (FIG. 6A) when
the AGV 110 is located at or near a conveyor station 150.
[0025] Referring now to FIGS. 1-3, the AGV 110 may further include
one or more stop blocks 118 coupled to the vehicle frame 112 and
extending from the side of the vehicle frame 112. The stop blocks
118 include an engagement surface 119 extending laterally from the
vehicle frame 112. The engagement surface 119 is engageable with a
stopper end 176 of the adjustable stopper apparatus 170 to stop the
AGV 110, as described in more detail below. In some embodiments,
the engagement surface 119 of the stop block 118 may extend between
30 mm and 50 mm from the side of the vehicle frame 112 such as, for
example, 40 mm. The stop blocks 118 further include a rear surface
117 extending laterally from the vehicle frame 112 and providing a
surface engageable with an anti-back mechanism 190, as described in
greater detail below. In some embodiments, rear surface 117 of the
stop block 118 may extend between 20 mm and 40 mm from the side of
the vehicle frame 112, for example, 25 mm. The stop block 118 may
comprise steel, however, any exemplary material is contemplated,
for example, other metal alloys and plastics.
[0026] Referring now to FIGS. 4-5, the AGV 110 may operate by
following an AGV navigation pathway 140 that defines a
pre-determined path of travel along the factory floor 104. The AGV
navigation pathway 140 may include magnetic tape 142 or other
detectable path components placed on the factory floor 104. The AGV
navigation pathway 140 may also include one or more pieces of slow
tape 144 and one or more pieces of stop tape 146. When the AGV 110
detects the slow tape 144, for example, with the sensing head 122,
the AGV 110 reduces speed. When the AGV 110 detects the stop tape
146, for example, with the sensing head 122, the AGV 110 stops. The
slow tape 144 may be positioned near the stop tape 146 such that
the AGV 110 reduces speed as it approaches the stop tape 146. In
alternative embodiments, the AGV navigation pathway 140 may include
a wire that carries a radio frequency signal or a guide tape of a
particular color. The AGV navigation pathway 140 may further
include location beacons (e.g., RFID tags) that carry directional
information that is receivable by the AGV 110.
[0027] The sensing head 122 of the AGV 110 may be used to detect
the presence of the magnetic tape 142 and provide this information
to the drive unit 120 or directly to the drive mechanism 116,
allowing the drive unit 120 to guide the AGV 110 along the magnetic
tape 142 using the drive mechanism 116. When the sensing head 122
reaches the slow tape 144, the sensing head 122 signals the drive
unit 120 to reduce the speed of the AGV 110. When the sensing head
122 reaches the stop tape 146, the sensing head signals the drive
unit 120 to stop the AGV 110. Any turns along the AGV navigation
pathway 140 may be identified by the sensing head 122, which
instructs the drive mechanism 116 to rotate to apply a force that
tends to turn the AGV 110 to follow the AGV navigation pathway 140.
It should be understood that one or more pieces of slow tape 144
and stop tape 146 can be located along the AGV navigation pathway
140, for example, at one or more conveyor stations 150 positioned
along the AGV navigation pathway 140. Further, it should be
understood that slow tape 144 and stop tape 146 can be positioned
along the AGV navigation pathway 140 at locations that are not
associated with the one or more conveyor stations 150. For example,
slow tape 144 may be positioned at a location preceding a turn such
that the AGV 110 can perform the turn without becoming misaligned
from the AGV navigation pathway 140.
[0028] In some embodiments, the AGV navigation pathway 140 may be a
loop pathway, such that the AGV 110 starts at a starting location,
travels to one or more conveyor stations 150 and returns to the
starting location while traveling in a forward direction of travel
102 along the AGV navigation pathway 140 such that a complete trip
covers the length of the AGV navigation pathway 140 once. In other
embodiments, the AGV navigation pathway 140 may be a bidirectional
pathway, such that the AGV 110 travels from the starting location
to a conveyor station 150 in a forward direction of travel 102
along the AGV navigation pathway 140 and returns from the conveyor
station 150 to the starting location in a reverse direction of
travel 103 along the AGV navigation pathway 140 such that a
complete trip covers the length of the AGV navigation pathway 140
twice.
[0029] Referring now to FIGS. 6A-6B, the adjustable stopper
apparatus 170 is depicted. The adjustable stopper apparatus 170 may
be coupled to the conveyor station 150 or positioned near the
conveyor station 150, for example, mounted on a standalone floor
mount 180 (FIGS. 8-9). In some embodiments, the adjustable stopper
apparatus 170 comprises a stopper cylinder 174 partially or wholly
disposed within a stopper base 172 and coupled to a stopper end
176. The stopper cylinder 174 may be movable within the stopper
base 172 such that the stopper cylinder 174 can extend and retract
between the extended position 106 and the retracted position 108.
The adjustable stopper apparatus 170 further includes an actuator
171 mechanically coupled to the stopper base 172, the stopper
cylinder 174, and the stopper end 176. The actuator 171 may be any
of a variety of linear actuators to facilitate linear motion of the
stopper cylinder 174 and/or the stopper end 176, including a
servo-mechanical actuator, an air pressure actuator, a hydraulic
actuator, and/or the like. In some embodiments, the adjustable
stopper apparatus 170 is an RSH Series or RSQ Series Stopper
Cylinder by SMC Corporation.TM.. In some embodiments, the actuator
171 is directly coupled to the stopper end 176. For example, the
actuator 171 can extend and retract the stopper end 176 between the
extended position 106 and the retracted position 108. In other
embodiments, the actuator 171 itself can extend and retract between
the extended position 106 and the retracted position 108.
[0030] Referring still to FIGS. 6A-6B, the stopper cylinder 174 may
have a diameter of between about 45 mm and about 90 mm, such as,
for example, 50 mm, 63 mm, or 80 mm. In operation, a larger stopper
cylinder 174 may be able to withstand a large impact force, for
example, impact from a large AGV 110. A smaller stopper cylinder
174 may be able to provide more sensitive dampening, which may
reduce bounce back when an AGV 110 contacts the stopper end 176
coupled to the stopper cylinder 174. In some embodiments, the
stopper cylinder 174 may comprise carbon steel, however, it should
be understood that any exemplary material capable of providing a
positive stop is contemplated, for example, other metal alloys and
plastics. The stopper cylinder 174 may be a single-acting cylinder,
a double-acting cylinder, or the like.
[0031] Referring still to FIGS. 6A-6B, the stopper end 176 is
mounted on the end of the stopper cylinder 174. In some
embodiments, the stopper end 176 may be pivotably coupled to a
stopper end coupling device 175 positioned between the stopper end
176 and the stopper cylinder 174. The stopper end 176 may include a
pivoting end 177 pivotably coupled to the stopper end coupling
device 175 and a swinging end 179 coupled to a cushioning device
178. The cushioning device 178 may extend between the swinging end
179 and the stopper cylinder 174 or between the swinging end 179
and the stopper end coupling device 175. The cushioning device 178
may be configured to damper impact received by the stopper end 176.
In operation, when impact is received by the stopper end 176, the
stopper end 176 may pivot, pressing into the cushioning device 178
such that the cushioning device compresses the stopper cylinder
174. This compression dampens the impact received by the stopper
end 176. In alternative embodiments, the stopper end 176 is
directly coupled to the stopper cylinder 174.
[0032] The stopper cylinder 174 is depicted in the extended
position 106 in FIG. 6A and depicted in retracted position 108 in
FIG. 6B. When the stopper cylinder 174 is in the extended position
106, the stopper end 176 is positioned within the AGV navigation
pathway 140 such that, for example, the stop block 118 of an AGV
110 (FIG. 1) following the AGV navigation pathway 140 can contact
the stopper end 176, stopping the AGV 110. When the stopper
cylinder 174 is in the retracted position 108, the stopper end 176
is removed from the AGV navigation pathway 140, such that an AGV
110 (FIG. 2) following the AGV navigation pathway 140 is
unobstructed by the stopper end 176. The difference between the
length of the stopper cylinder 174 that is removed from the stopper
base 172 when in the extended position 106 and the length of the
stopper cylinder 174 that is removed from the stopper base 172 when
in the retracted position 108 defines a stroke distance of the
adjustable stopper apparatus 170. The stroke distance should be
large enough to extend the stopper end 176 into the AGV navigation
pathway 140 and retract the stopper end 176 from the AGV navigation
pathway 140. In some embodiments, the stroke is between 20 mm and
50 mm, for example, a 30 mm stroke or a 40 mm stroke.
[0033] Referring again to FIGS. 1-2 and 6A-6B, the adjustable
stopper apparatus 170 may be coupled to the conveyor station 150.
The conveyor station 150 includes a conveyor base plate 154 coupled
to a conveyor frame 152 using two conveyor mounts 156 although any
number of conveyor mounts 156 can be used. Further, the conveyor
base plate 154 can be mounted to the conveyor frame 152 without the
use of conveyor mounts 156. In some embodiments, the adjustable
stopper apparatus 170 is mounted on the conveyor base plate 154. In
some embodiments, the adjustable stopper apparatus 170 may be
mounted directly to the conveyor frame 152.
[0034] The conveyor station 150 may further include a loading and
unloading system configured to transfer goods between the conveyor
station 150 and the AGV 110. The loading and unloading system of
the conveyor station 150 may be manually operated or may include
automated equipment, such as robots, or the like. It should be
understood that the conveyor station 150 is configured to
repeatably receive one or more AGVs 110 each traveling along the
AGV navigation pathway 140. As an example and not a limitation, the
conveyor station 150 may be located at an assembly station where
the conveyor station 150 receives parts for assembly from each AGV
110 and transfers the parts to the assembly station where the parts
are assembled.
[0035] The conveyor station 150 may include the conveyor station
communications device 160 communicatively coupled to the AGV
communications device 124 using a wireless connection. When the AGV
110 reaches a stopping location, (i.e. the location of the stop
tape 146 and/or the location of the adjustable stopper apparatus
170) the conveyor station communications device 160 and the AGV
communication device 124 transfer communications stating that the
AGV 110 is aligned and ready for the loading and unloading process.
Once the loading and unloading process is complete, the conveyor
station communications device 160 sends a START signal to the AGV
communication device 124 and the adjustable stopper apparatus 170.
The START signal signals the adjustable stopper apparatus 170 to
move into the retracted position 108 and signals the AGV 110 to
move in the forward direction of travel 102 along the AGV
navigation pathway 140.
[0036] Referring again to FIGS. 6A-6B, the conveyor station 150
further comprises an AGV presence sensor 162 mounted to the
conveyor station 150. The AGV presence sensor 162 can be
communicatively coupled to the adjustable stopper apparatus 170
either directly or through the conveyor station communications
device 160. The AGV presence sensor 162 measures whether the AGV
110 is present at the conveyor station 150. If the AGV 110 is not
present at the conveyor station 150, a signal is sent to the
adjustable stopper apparatus 170 to move the stopper cylinder 174
into the extended position 106. In operation, when the AGV 110
arrives at the stopping location of the conveyor station 150, for
example, when the stop block 118 of the AGV 110 contacts the
stopper end 176 of the adjustable stopper apparatus 170, and the
AGV 110 and conveyor station 150 complete the loading and unloading
process, the stopper cylinder 174 retracts from the AGV navigation
pathway 140, allowing the AGV 110 to travel forward without
obstruction. The AGV presence sensor 162 measures whether the AGV
110 remains near the conveyor station 150 and once the AGV 110
clears the conveyor station 150, for example, once the AGV 110 is
outside the detection range of the AGV presence sensor 162, the AGV
presence sensor 162 signals the adjustable stopper apparatus 170 to
extend the stopper cylinder 174 into the extended position 106.
[0037] Referring now to FIGS. 7A-7B, an anti-back mechanism 190 is
depicted. The anti-back mechanism 190 may comprise an anti-back
block 192 pivotably mounted on an anti-back mounting surface 191 or
pivotably mounted directly to the conveyor station 150, for
example, the conveyor frame 152. The anti-back block 192 may
comprise a first end 193, extending into the AGV navigation pathway
140, and a second end 195 which may be coupled to an extension
spring 194, or other biasing device, which biases the first end 193
of the anti-back block 192 into the AGV navigation pathway 140. The
extension spring 194 can be coupled to a spring block return 196 to
provide the extension spring 194 with a rigid mounting location.
The anti-back mechanism 190 further includes a hard-stop device 198
engageable with the second end 195 of the anti-back block 192 to
prevent the anti-back block 192 from pivoting beyond the hard-stop
device 198.
[0038] In operation, when a stop block 118 of the AGV 110, moving
in the forward direction of travel 102, contacts the first end 193
of the anti-back block 192, the anti-back block 192 pivots to allow
the AGV 110 to travel past the anti-back block 192, extending the
extension spring 194. Once the stop block 118 passes the anti-back
block 192, the extension spring 194 retracts and the first end 193
of the anti-back block 192 re-extends into the AGV navigation
pathway 140. If the AGV 110 moves in a reverse direction of travel
103, for example, if the AGV 110 reverses from contact with the
stopper end 176 (FIG. 1), the rear surface 117 of the stop block
118 contacts the first end 193 of the anti-back block 192 pivoting
the second end 195 of the anti-back block 192 into contact with the
hard-stop device 198. The hard-stop device 198 prevents motion of
the anti-back block 192, providing the AGV 110 a positive stopping
device in the reverse direction of travel 103.
[0039] Referring now to FIGS. 8 and 9, the adjustable stopper
apparatus 170 is mounted on a standalone floor mount 180,
positioned on the factory floor 104 along the AGV navigation
pathway 140. The standalone floor mount 180 may comprise a
standalone base plate 182 mounted on one or more standalone base
plate legs 184. The standalone base plate 182 can provide a
mounting location for the adjustable stopper apparatus 170. The
standalone floor mount 180 may also provide a mounting location for
a sensor mount 164. The sensor mount 164 provides a mounting
location for one or more sensors, for example, an AGV presence
sensor 162. The standalone floor mount 180 may also include a
standalone floor mount communications device communicatively
coupled to the adjustable stopper apparatus 170 and the AGV
communication device 124 (FIG. 3). In some embodiments, the
standalone floor mount communications device may signal the
adjustable stopper apparatus 170 to move between the extended
position 106 and the retracted position 108 and signal the AGV 110
to move in the forward direction of travel 102. In some
embodiments, the standalone floor mount 180 is positioned adjacent
the conveyor station 150. In other embodiments, the standalone
floor mount 180 may be positioned at other locations along the AGV
navigation pathway 140.
[0040] Operation of the AGV system 100 will now be discussed in
reference to FIGS. 1 and 2. As discussed previously, the adjustable
stopper apparatus 170 may be positioned relative to the conveyor
station 150 and is moveable between an extended position 106 and a
retracted position 108. The adjustable stopper apparatus 170 is
depicted in FIG. 1 in an extended position 106 and depicted in FIG.
2 in a retracted position 108. The adjustable stopper apparatus 170
may provide a positive stopping location to provide additional
accuracy and repeatability of locating the AGV 110 along the
factory floor 104 when the AGV 110 is stopped at the conveyor
station 150.
[0041] In operation, the adjustable stopper apparatus 170 is
positioned in the extended position 106 as the AGV 110 approaches
the adjustable stopper apparatus 170. If the AGV 110 has not
stopped when it reaches the adjustable stopper apparatus 170, the
engagement surface 119 of the stop block 118 engages with the
stopper end 176 of the adjustable stopper apparatus 170, stopping
the AGV 110. It should be understood that the adjustable stopper
apparatus 170 may be used together with the slow tape 144 and the
stop tape 146 (FIGS. 4-5), for example, as a back-up device when
the AGV 110 does not respond to the stop tape 146. Once the AGV 110
is stopped, the AGV communications device 124 signals the conveyor
station communications device 160 that the AGV 110 is ready for the
loading and unloading process. Once the loading and unloading
process is complete, the conveyor station communications device 160
signals the adjustable stopper apparatus 170 to retract from the
AGV navigation pathway 140. When the stopper cylinder 174 is in the
retracted position 108, the conveyor station communications device
160 sends the AGV communications device 124 a signal to move in the
forward direction of travel 102. With the stopper cylinder 174
retracted, the AGV 110 has clearance to drive forward along the AGV
navigation pathway 140 without obstruction. Once the AGV 110 leaves
the conveyor station 150, for example, when the AGV presence sensor
162 is unable to detect the AGV 110 or detects that the AGV 110 has
progressed beyond the adjustable stopper apparatus 170, the stopper
cylinder 174 re-extends into the AGV navigation pathway 140. It
should be understood that this operation is repeatable for multiple
AGVs 110 and can be performed at multiple conveyor stations
150.
[0042] In some embodiments, the adjustable stopper apparatus 170 is
positioned alongside an AGV navigation pathway 140, for example a
loop running automated guided vehicle navigation pathway. In these
embodiments, the adjustable stopper apparatus 170 can translate
laterally relative to the loop running automated guided vehicle
navigation pathway to provide a positive stopping location for an
AGV 110. In alternative embodiments, the adjustable stopper
apparatus 170 is positioned within an AGV navigation pathway 140,
for example a bidirectional automated vehicle navigation pathway.
In these embodiments, the adjustable stopper apparatus 170 can be
mounted on or positioned within the factory floor 104 such that an
AGV 110 can travel above the adjustable stopper apparatus 170 when
the stopper end is in the retracted position 108. In this
embodiment, the adjustable stopper apparatus 170 can translate
vertically within the AGV navigation pathway 140 such that it can
engage with a stop block 118 and provide a positive stopping
location for an AGV 110.
[0043] It should now be understood that AGV systems incorporating
adjustable stopper apparatuses can be positioned along an AGV
navigation pathway to provide a positive stopping system for one or
more AGVs. The adjustable stopper apparatuses can be mounted on
conveyor stations or positioned near conveyor stations to
positively stop AGVs at the conveyor stations. The adjustable
stopping apparatuses include a stopper cylinder moveable within a
stopper base and coupled to a stopper end. The stopper cylinder can
be moved between an extended position, such that the stopper end is
positioned within the AGV navigation pathway, and a retracted
position, such that the stopper end is removed from the AGV
navigation pathway. When the stopper cylinder is in the extended
position, a stop block of the AGV moving in a forward direction of
travel can contact the stopper end stopping the AGV. When the
stopper cylinder is in the retracted position, the AGV can continue
moving in the forward direction of travel unobstructed.
[0044] Having described the disclosure in detail and by reference
to specific embodiments thereof, it will be apparent that
modifications and variations are possible without departing from
the scope of the disclosure defined in the appended claims. More
specifically, although some aspects of the present disclosure are
identified herein as preferred or particularly advantageous, it is
contemplated that the present disclosure is not necessarily limited
to these preferred aspects of the disclosure.
[0045] Directional terms used herein--for example widthwise,
lengthwise, vertical, up, down, right, left, front, back, top,
bottom, upper, lower--are made only to supply directional context.
For example, the terms "extending vertically" or "extending
generally vertically" are not meant to exclude a vertically and
horizontally extending component.
[0046] While particular embodiments have been illustrated and
described herein, it should be understood that various other
changes and modifications may be made without departing from the
spirit and scope of the claimed subject matter. Moreover, although
various aspects of the claimed subject matter have been described
herein, such aspects need not be utilized in combination. It is
therefore intended that the appended claims cover all such changes
and modifications that are within the scope of the claimed subject
matter.
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