AUTONOMOUS MOBILE MACHINE WITH LOAD MOVING IMPLEMENT AND LIFT ASSIST ARM
TECHNICAL FIELD
[0001] The presently disclosed subject matter relates generally to autonomously operated mobile machines, and more particularly to a mobile machine having a load moving implement and a lift assist arm.
BACKGROUND
[0002] Mobile machines are generally land vehicles with attached machinery or equipment that are self-propelled or mobile and that, in contrast to automobiles, provide functionality beyond conveying people from one point to another. Mobile machines are known to include, without limitation, forklifts, skid steers, excavators, tractors, earthmovers, farm machinery, dump trucks, garbage trucks, mobile cranes, and other mobile construction equipment. Lift arm mobile machines are generally self-propelled construction vehicles that have one or more lift arms that support and actuate attached work tools or attachments, such as for example skid steer loaders, forklifts, excavators, and tractors. Forklifts, also known as “fork trucks” or “lift trucks,” are vehicles utilized to lift, transport, and place loads. For example, in a construction site, in a warehouse, or in other large commercial areas, supplies or goods are often being transported into, around and out of such sites or areas. In addition, supplies and goods often need to be transported multiple times, for example, between different way points in a site or area. Due to the transient nature of supplies or goods, they are often packaged on pallets for easy transportation and storage.
[0003] The pallets are designed to be moved and lifted easily by the forks of the forklift. Forklifts therefore are often used in commercial setings to lift paletes up and transport the paletes from location to location. Conventional forklifts generally include a manned cabin or cab, where a person operating the forklift manually controls its movements. To control the movements of a conventional forklift, they are generally equipped with a steering mechanism, such as a wheel to control the movements of the vehicle, and with knobs or other controls to manipulate the vertical height of the forks. SUMMARY
[0004] With parenthetical reference to corresponding elements, parts, portions, or surfaces of the disclosed embodiment, merely for the purposes of illustration and not by way of limitation, the present disclosure provides in an exemplary embodiment an autonomous mobile machine (15) comprising: a chassis (16); a controller (70) supported by the chassis and operably configured to receive and transmit signals; a propulsor (20) operably configured to drive the chassis; a load bearing platform (31, 131) supported by the chassis; the load bearing platform operably configured to support a load (90); the load bearing platform operably configured to translate in a first translational axis (z-z) relative to the chassis with at least one degree of freedom; a load bearing lift arm (40) supported by the chassis; the load bearing lift arm operably configured to support the load; the load bearing lift arm operably configured to translate in both the first translational axis (z-z) and in a second translational axis (v-y ) orthogonal to the first translational axis relative to the chassis with at least two degrees of freedom; the controller operably configured to control the propulsor, the load bearing platform, and the load bearing lift arm; whereby the load may be transported on the load bearing platform from a first location to a second location and the load may be conveyed by the lift arm between the load bearing platform and a position peripheral to the load bearing platform.
[0005] The lift arm may comprise a mast (41) and a boom (42) supported by the mast. The lift arm may comprise an end effector (43) supported by the boom and operable to grip the load. The boom may be operably configured to rotate about a first rotational axis (45a) and a second rotational axis (45b) relative to the mast such that the end effector has at least two degrees of freedom. The end effector may be selected from a group consisting of a vacuum suction cup, a hook, and a gripper.
[0006] The load bearing platform may be operably configured to rotate about a second rotational axis (34b) relative to the chassis with a second degree of freedom. The autonomous mobile machine may comprise actuating lift arms (32a, 32b) supported by the chassis and the load bearing platform may be connected to the lift arms. The load bearing platform may comprise multiple forks (31) of a forklift. The load may comprise a pallet. The load bearing platform may comprise a bucket (131).
[0007] The controller may be operably configured to translate the load bearing platform and the translation of the load bearing platform may be automated. The controller may be operably configured to translate the load bearing lift arm and the translation of the load bearing lift arm may be automated. The controller may be operably configured to translate the load bearing platform utilizing signals from a remote control in a remote guidance mode. The controller may be operably configured to translate the load bearing lift arm utilizing signals from a remote control in a remote guidance mode. The remote control may be in wireless communication with the controller. The remote control may comprise a user interface connected to the load bearing lift arm. The controller may be operably configured to control the propulsor utilizing signals from a remote control in a remote guidance mode.
[0008] The load bearing lift arm may comprise a counter-balance mass operably configured to offset a moment of the load. The autonomous mobile machine may comprise an electric power source (70) supported by the chassis and operatively configured to power the propulsor, the load bearing platform and the load bearing lift arm. The chassis may be free of an operator cabin.
[0009] The controller may comprise a transceiver. The autonomous mobile machine may comprise a plurality of perception sensors (50) supported by the chassis and operably configured to transmit a signal to the controller and the plurality of perception sensors may be operably configured to detect environmental features. The autonomous mobile machine may comprise a global positioning satellite receiver electrically connected with the controller and the controller may be operably configured to navigate an environment utilizing signals from the global positioning satellite receiver in an automated guidance mode. The controller may be operable to navigate an environment utilizing one or more pre-planned routes in an automated guidance mode as a function of guidance from a global controller; the controller may be operable to navigate the environment in a localized remote guidance mode as a function of signals from a remote control; and the controller may be operable to change between the automated guidance mode and the localized remote guidance mode.
[0010] The autonomous mobile machine may comprise a leveling assembly (80) between the chassis and the load bearing lift arm and the leveling assembly may be operably configured to rotate about both a first leveling axis (84a) and a second leveling axis (84b) orthogonal to the first leveling axis relative to the chassis with at least two degrees of freedom. The leveling assembly may comprise a leveling platform (83) supporting the load bearing lift arm and a plurality of actuators (82a, 82b, 82c, 82d) disposed between the chassis and the load bearing lift arm and operably configured to rotate the leveling platform about the first leveling axis and the second leveling axis relative to the chassis with the at least two degrees of freedom. BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings are incorporated herein as part of the specification. The drawings described herein illustrate embodiments of the presently disclosed subj ect matter and are illustrative of selected principles and teachings of the present disclosure. How ever, the drawings do not illustrate all possible implementations of the presently disclosed subject matter and are not intended to limit the scope of the present disclosure in any way.
[0012] FIG. 1 is a right perspective view of an embodiment of an improved autonomous mobile machine.
[0013] FIG. 2 is a left perspective view of the mobile machine shown in FIG. 1.
[0014] FIG. 3 is a perspective view of the lift assist arm shown in FIG. 1.
[0015] FIG. 4 is a perspective view of the lift assist leveling platform shown in FIG. 3.
[0016] FIG. 5 is a right perspective view' of an alternative embodiment of the mobile machine shown in FIG. 1.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0017] It is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific assemblies and systems illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the inventive concepts defined herein. Hence, specific dimensions, directions, or other physical characteristics relating to the embodiments disclosed are not to be considered as limiting, unless expressly stated otherwise. Also, although they may not be, like elements in various embodiments described herein may be commonly referred to with like reference numerals within this section of the application.
[0018] It is to be appreciated that the present teaching is by w ay of example only, not by limitation. The concepts herein are not limited to use or application with a specific system or method. Thus, although the instrumentalities described herein are for the convenience of explanation, shown and described with respect to exemplary embodiments, it will be appreciated that the principles herein may be applied equally in other types of systems and methods involving autonomous mobile machines.
[0019] Where used herein, the terms “first'’, “second”, and so on, do not necessarily denote any ordinal, sequential, or priority relation, but are simply used to more clearly distinguish one element or set of elements from another, unless specified otherwise. [0020] Where used herein, the term “about’' when applied to a value is intended to mean within the tolerance range of the equipment used to produce the value, or, in some examples, is intended to mean plus or minus 10%, or plus or minus 5%, or plus or minus 1%, unless otherwise expressly specified.
[0021] Where used herein, the term “substantially'’ is intended to mean within the tolerance range of the equipment used to produce the value, or, in some examples, is intended to mean plus or minus 10%, or plus or minus 5%, or plus or minus 1%, unless otherwise expressly specified.
[0022] Referring to the draw ings, an improved autonomous mobile machine is provided, of which a compact loader embodiment is generally indicated at 15. As shown, autonomous loader 15 generally comprises self-propelled vehicle frame or chassis 16, having propulsion system 20 that engages the ground to move chassis 16 along the ground, and load moving platform 30, load bearing lift arm 40, autonomous sensor array 50, and electronics enclosure 70 all supported by chassis 16.
[0023] In an embodiment, propulsion system 20 of loader 15 includes two electric gear motors
21a and 22b and two continuous tracks 22a and 22b. Right gear motor 21b controls movement of right track 22b and left gear motor 21a controls movement of left track 22a. In another embodiment, wheels can be used in place of tracks 22a and 22b. Thus, chassis 16 may be propelled by two or more tracks, two or more wheels, or a combination of tracks and wheels. Motors 21a and 22b are pow ered by and in electric communication with the battery and controller of electronic enclosure 70.
[0024] As shown in FIGS. 1 and 2, load moving platform 30 generally includes left and right side lift arms 32a and 32b rotationally coupled to frame 16 of loader 15 and front forks 31 coupled to the front ends of the two lift arms 32a and 32b. A platform actuation system having a plurality of electric powered actuators mounted between frame 16 and lift arms 32a and 32b and between lift arms 32a and 32b and forks 31 actuate lift arms 32a and 32b and forks 31 relative to frame 16 of loader 15 within a range of motion. In this embodiment the platform actuator system includes parallel lift actuators 33a and 33b and parallel tilt actuators 33c and 33d. Lift arms 32a and 32b pivot about axis of rotation 34a in a first degree of freedom at their base to lift forks in vertical axis z relative to frame 16 using the pair of actuators 33a and 33b on the left and right sides of loader 15. Forks 31 may likewise be rotated about axis 34b in a second degree of freedom at the end of lift arms 32a and 32b with actuators 33c and 33d. Forks 31 are generally operable to acquire and deposit a payload, such as without limitation a pallet of solar panels for example. Forks 31 are translatable in vertical axis z relative to chassis 16. In an embodiment, forks 31 may also be configured to translate in horizontal fore-and-aft axis x relative to chassis 16. In an embodiment, forks 31 include two forks, each describing a generally ”L" shaped load bearing member having a first leg orientated generally parallel to the ground or terrain surface and operable to support at least a portion of a load acquired by loader 15 and a second leg oriented generally orthogonal to the first leg and pivotally connected to lift arms 32a and 32b. Actuators 33a, 33b, 33c and 33d are powered by and in electric communication with the battery and controller of electronic enclosure 70.
[0025] While in this embodiment loader 15 is shown actuating forks 31 , other load bearing attachments may be driven by the load bearing platform actuation system, including without limitation bucket 131 shown in FIG. 5. Thus, forks 31 or bucket 131 can be replaced with a variety of other load bearing tools or attachments that may be powered by the actuation system of loader 15. While in this embodiment the lift arm mobile machine comprises loader 15, other lift arm mobile machines that are generally self-propelled construction vehicles that have one or more lift arms that support and actuate attached load bearing platforms or attachments may be used, such as for example and without limitation skid steer loaders, forklifts, excavators, bulldozers, backhoes, and tractors.
[0026] As shown in FIGS. 1-3, lift assist arm 40 generally comprises mast 41 supported on chassis 16 by self-leveling assembly 80, articulating boom 42 extending from the distal end of mast 41 and rotationally supported by mast 41, and load bearing suction grip 43 extending from the distal end of boom 42 and supported by boom 42. A lift arm actuation system having a plurality of electric powered actuators mounted between mast 41 and boom 42 actuate boom 42 and grip 43 relative to mast 41 and chassis 16 within a range of motion.
[0027] In this embodiment the lift arm actuation system includes boom rotation actuator 46a and boom extension actuator 46b supported on boom base 45 at the top end of mast 41. Boom base 45 with boom 42 pivots about axis of rotation 45a in a first degree of freedom at the top of mast 41 to rotate grip end effector 43 in horizontal axes x and y relative to frame 16 using actuator 46a on boom base 45. Actuator 46a is powered by and in electric communication with the battery and controller of electronic enclosure 70.
[0028] In this embodiment, boom 42 comprises a four bar linkage mechanism comprising crank link 42a pivotally coupled to boom base 45 at a first end and configured to actuate about axis 45b using actuator 46b, coupler link 42c pivotally coupled at a first end to the other end of link 42a and having extension portion 42d, rocker link 42b pivotally coupled at a first end to link 42c at the start of extension portion 42d, and ground link 42e pivotally coupled at a first end to the other end of linkage 42b and to boom base 45 and pivotally coupled at the second end to the first end of linkage 42a. The distal end of linkage extension 42d is coupled to load grip 43. Link 42a does not translate and only rotates about axis of rotation 45b relative to frame 16 in a first degree of freedom using actuator 46b on boom base 45. Link 42b does not translate and only rotates relative to base 45 and link 42e is fixed at both ends to base 45 and does not move relative to base 45. Both ends of link 42c are able to translate so portion 42d of link 42c provides both translational and rotary movement of load grip 43. Actuators 46b is powered by and in electric communication with the battery' and controller of electronic enclosure 70.
[0029] In an alternative embodiment, an electric motor on mast head 45 may power a pneumatic cylinder that provides a counterbalance load to make load 90 at end effector 43 effectively weightless for easy movement by an operator. Various other alternative embodiments of a lift assist arm and end effector may be used as alternatives to convey a load with the lift arm between the load bearing platform and a position peripheral to the load bearing platform and vice versa. Such alternatives may have more degrees of freedom and may have different kinematics. The end effector may be a vacuum suction cup, a hook, a gripper or any other lifting or attachment implement for a load.
[0030] As shown in FIG. 4, in this embodiment leveling actuation system 40 comprises four electric powered hydraulic linear actuators 82a. 82b, 82c and 82d mounted between base 81 and leveling platform 83 that actuate leveling platform 83 relative to base 81 within a range of motion. With actuators 82a, 82b, 82c and 82d, the pitch and roll of leveling platform 83 may be controlled relative to base 81, with actuators 82b and 82d providing control of the roll of platform 83 about axis 84a and sharing the loads of the axis and actuators 82a and 82c providing control of the pitch of platform 83 about axis 84b and sharing the loads of the axis. Controller 70 receives sensor input from one or more accelerometer and/or gyroscope sensors that measure the platform tilt and roll relative to a reference plane, such as a horizontal plane relative to the earth’s surface, and controller 70 sends signals to actuators 82a, 82b, 82c and 82d so that they extend or retract such that platform 83 stays level despite movement of frame 16 to which base 81 is attached. Actuators 82a, 82b, 82c and 82d are powered by and in electric communication with the battery7 and controller of electronic enclosure 70.
[0031] As shown in FIGS. 1 and 2, loader frame 16 includes sensor array 50 supported on rear scaffold 51. Scaffold 51 is generally a support structure affixed to frame 16 that provides support for lights, cameras, sensors and other equipment for autonomous and/or remote navigation and control. Thus, autonomous loader 15 includes sensor system 50 operable to provide data to an autonomous navigation controller. Scaffold 51 enables one or more optical sensors to be located at elevation to, inter alia, minimize the effects of dust contamination and increase field of view (FOV). In an exemplary' embodiment, one or more sensors of the sensor system are arranged at elevation about the perimeter of loader 15. For example, one or more of the sensors arranged about the perimeter of loader 15 may be opto-electronic devices comprising a transmitter and receiver configured to produce a safety curtain (e g., light curtain, virtual barrier, etc.). In another example, one or more of the sensors arranged about the perimeter of loader 15 may be cameras (e.g., charge-coupled device sensors (CCD), complementary metal-oxi de-semiconductor sensors (CMOS)) configured to produce a safety curtain (e.g., virtual barrier).
[0032] In an embodiment, sensor system 50 includes two depth sensing cameras 56, each having a right imager and a left imager in order to build a composite image that can be used to calculate distance. Depth camera 56 also has, in an embodiment, an infrared projector to give infrared (IR) illumination of the surroundings to ensure accuracy and image detection in low light or no light situations. In an exemplary embodiment, depth sensing cameras 56 may be mounted on a separate camera pole facing outw ards towards the front of loader 15. Depth sensing cameras 56 are in electronic communication with the navigation controller in electronic enclosure 70.
[0033] In an embodiment, sensor system 50 includes LED Lidar sensor 59. Lidar sensors emit a light (e.g. a laser or an LED) and measure the time for the reflected light to return to the sensor. This time measurement is converted to a distance measurement corresponding to the distance of the object or obstacle that reflected the light. LED Lidar sensor 59 is mounted to the top of scaffold 51 to provide a useful “bird's eye’' view of surrounding obstacles. Each separate LED beam of light is a separate data point, measured by reflection return time. This results in a data point “cloud” that generally paints a general picture of obstacles in the surroundings. This data is sent to the navigation controller. LED Lidar sensor 59 is in electric connection with the battery' and in electronic communication with the navigation controller in electronic enclosure 70. [0034] In an embodiment, sensor system 50 includes radio frequency (RF) beacon 60 for emitting radio signals that help with locating and identifying loader 15. RF beacon 60 is mounted on scaffold 51 and is in electric connection with the battery and in electronic communication with the navigation controller in electronic enclosure 70. [0035] In an embodiment, hom 52 is mounted on scaffold 51 for auditory' warning noises in certain trigger situations. Hom 52 is in electric connection with the battery’ and in electronic communication with the navigation controller in electronic enclosure 70.
[0036] In an embodiment, a plurality of ultrasonic radar sensors may also be provided. These sensors use sonic waves and sensors to detect close range obstacles. The ultrasonic sensors are mounted without any blockage from any components of loader 15 or its structure. Each ultrasonic sensor has a programmable range, and the optimal range will vary based on the speed of operation of loader 15. The ultrasonic sensors are in electric connection with the battery and in electronic communication with the navigation controller in electronic enclosure 70.
[0037] In an embodiment, scaffold 51 may also support curtain lights, where the light projection from the curtain lights provides a visual indication of a safety exclusion zone to warn personnel who might come in contact with loader 15. The curtain lights can be arranged in various orientations on scaffold 51. In an embodiment, the curtain lights are in electric communication with the battery. In an embodiment, the curtain lights emit light outside the visible spectrum and do not emit light within the visible spectrum. In an embodiment, one or more signal lights that provide additional visual warnings to people in the surrounding environment under certain trigger situations may be provided. Such trigger situations and following signal modes can include the travel, translation, lift or other movement of loader 15, forks 31 and/or end effector 43, a fault, an E-stop, parking brake engaged, close range obstacle detected, far range obstacle detected, automated route active, automated route inactive/paused and remote guidance mode enabled. In an exemplary embodiment, the signal light may include signal modes such as a steady red light, a blinking red light, a steady yellow' light, a blinking green light, a steady green light, a blinking blue light, and a steady blue light. In an embodiment, the signal lights are in electric connection with the battery and in electronic communication with the controller in electronic enclosure 70.
[0038] An embodiment may also include one or more mechanical emergency stops on loader 15. The emergency stop may be a mechanical switch or mushroom button. When engaged, the emergency stop will break the electric communication powering the right and left propulsion motors 21b and 21a, the platform actuators 33a, 33b, 33c and 33d, and/or the lift arm actuators 46a and 46b. It should be understood that there can be provided several individual emergency stops, and that any one emergency stop can break the electric connection between the battery' and all the motors and actuators. This emergency stop may provide personnel an immediate override in case of urgent need to stop loader 15 or its movements. [0039] In an embodiment, electronic enclosure 70 is positioned in place of an operator cab and includes one or more drive controllers, navigation controllers, mobile machine electronics and a main battery pack. The battery provides power to all the electronic components that are contained in loader 15. In an alternative embodiment, the battery powers some of the components, while others are supplied power by a component's own internal battery'. In yet another embodiment, there are two or more batteries provided. The battery may comprise a battery pack. The battery or batteries are in electric communication with the powered components, so as to provide power to them.
[0040] In an embodiment, the mass of the electronic enclosure 70 contributes to a counterbalance of a load carried by forks 31 and end effector 43. The counterbalance effect of electronic enclosure 70. including the battery, helps ensure that loader 15 does not tip over when a payload 90 is carried by forks 31 or end effector 43.
[0041] The electronics of enclosure 70 includes an electric drive controller in electronic communication with the actuators of loader 15, including actuators 21a, 21b, 33a, 33b, 33c, 33d, 46a, 46b. 82a, 82b, 82c and 82d. The controller includes a processor/processing unit and a memory. The controller provides automated control and operation of actuators 21a, 21b, 33a. 33b, 33c, 33d, 46a, 46b, 82a, 82b, 82c and 82d. The autonomous loader 15 includes an on-board autonomous operating system (“AOS’’) having sensor array 50. As the AOS enters an operating environment, the on-board sensor suite provides localization and situational awareness data to the processing unit. The controller handles high-level decision making for loader 15, including handling guidance mode selections, transitions, and faults. Thus, the loader controller provides automated control and operation of loader 15 and sensor system 50 is operable to provide data to the controller.
[0042] Thus, in an embodiment, sensor system 50 includes at least one depth camera, a global positioning system (“GPS”) receiver, an inertial measurement unit (“IMU”), a light detection and ranging unit (“LIDAR”), radar, an ultrasonic unit, and/or an odometry unit. The controller is operable to receive command signals from the processing unit and control the steering, throttle, and brakes of the autonomous loader utilizing the sensor data In an embodiment, the controller is also operable to receive signals from the sensor array and the sensor system may include two depth sensing cameras in order to build a composite image that can be used to calculate distance. The sensor system may include a plurality of ultrasonic radar sensors that use sonic waves to detect close range obstacles and a LIDAR sensor that emits a light (e.g., a laser or an LED) and measures the time for the reflected light to return to the sensor that is converted to a distance measurement corresponding to the distance of the object or obstacle that reflected the light. The sensor system may also include a radio frequency (RF) beacon for emitting radio signals that help with locating and identifying load bearing platform 30 and a payload and for delivering the payload to a location and installation platform via lift assist arm 40. Autonomous loader 15 thereby utilizes the sensor data to automatically navigate, steer, propel, and/or stop and to engage apayload. Loader 15 may utilize the AOS to complete a task without on-board human operators. In an embodiment, the AOS determines an optimal path through construction site or other operating environment and navigates through the environment along programmed path with user input only to deal with unexpected events on an as-needed basis. Thus, the AOS enables one or more autonomous loaders to traverse a work site according to a pre-planned route/path. The AOS may include a safety system that includes monitoring for obstacles, stopping the autonomous loader when obstacles are detected, and keeping the autonomous loader within the programmed path and allowed boundaries during operation thereof. Any adjustments to the autonomous loader made during operation thereof may also be automated. The adjustments may include, for example, speed and location of fork 31 and gripper 43 height and rotational settings.
[0043] In operation, when loader 15 enters a worksite or other operating environment, the on-board sensors provide localization and situational awareness data to the loader controller. The sensor data and status information enable the controller to determine the optimal guidance mode and locates loader 15 with respect to any detected feature and/or GPS waypoints in the vicinity. The localization process performed utilizing the controller creates heading and path planning commands utilized by the controller for steering, throttling, and braking loader 15 to move unimpeded in its environment while simultaneously mapping its surroundings.
[0044] In an embodiment, the controller is operable in at least four guidance modes: (i) automated guidance, (ii) localization guidance and (iii) localized remote guidance. Automated guidance mode enables loader 15 to navigate in work site via a planned or pre-planned route or path. For example, in the automated guidance mode the controller may navigate the loader 15 via specified GPS w aypoints. Localization guidance mode enables loader 15 to navigate based on detectable objects or features, identified via the perception sensors. These features may be determined via the on-board, non-GPS based sensors such as the LIDAR, RADAR, depth camera, and/or ultrasonic sensors. Upon identifying the local features, the localization guidance mode generates a heading command to safely navigate around or between objects. Localized remote guidance mode enables loader 15 to follow a planned or pre-planned path route or path, such as described with regard to the automated guidance mode, and cooperatively provide at least limited control of loader 15 to an operator positioned generally local loader 15. In an exemplary embodiment, such limited controls include start, stop, engage payload, lift payload, transfer payload, lower payload, disengage payload, and similar commands and functionality. The memory unit of the controller is able to save position and location information of detected environmental features and provide a map of the environment surrounding loader 15 during operation. Coordinates and position information of environmental features relative to the location of the loader AOS are saved in the memory unit and are updated as loader 15 moves about the work site. The on-board vision system and depth camera may be used to enhance the environment mapping through object detection and classification. Further, with available GPS data, the position of each local feature may be determined. In an embodiment, the automated guidance mode for loader 15 is developed using model-based design. This model-based design allows the pre-planned route to be rapidly modified and updated in a simulation environment before being autocoded directly to the on-board loader AOS. In the automated guidance and localization guidance modes, the AOS is operable to navigate throughout an environment via sensor fusion techniques that enhance situational awareness using a combination of sensors. The AOS may be outfitted with a tactical-grade IMU and a single GPS antenna to allow for a GPS/1NS (inertial navigation system) solution. In addition, the AOS is operable to receive signals from laser, vision, and sound-based localization sensors (e.g., LIDAR, RADAR, ultrasonic, and depth cameras) to allow for obstacle detection and continued operation in a GPS-denied environment.
[0045] In this embodiment, autonomous loader 15 includes a wireless connection such that it may communicate with a centralized controller via wireless technologies such as, without limitation, Wi-Fi, Bluetooth, a 3G, 4G or 5G network, infrared communications, near field communications, ultraband communications, satellite communications, proprietary license band radios, and the like. In an embodiment, the wireless connection is a radio frequency (RF) connection such as, but not limited to, a Wi-Fi connection. However, other modes of wireless communication may be employed. The wireless connection enables a user or centralized controller to monitor loader sensor data and provider operating commands in real-time. Thus, in this embodiment, the controller electronics of loader 15 comprises a transceiver arranged to transmit data related to loader 15 wirelessly and to receive wireless operating instructions from the centralized controller.
[0046] In an embodiment, loader 15 includes a wireless remote control unit. In an embodiment, the remote control unit includes a user hand station operable to receive and transmit user inputs via a transceiver, and a user interface operable to display sensor and/or status information from loader 15 and if desired the payload. The remote control is operable to communicate with loader 15 through a wireless connection w ith the transceiver of loader 15. The remote control may be, but is not limited to, a tablet and/or laptop. The remote control may communicate with the loader on-board electronics 70 such as the controller and transceiver via wireless technologies such as, without limitation, Wi-Fi, Bluetooth, a 3G, 4G or 5G network, infrared communications, near field communications, ultraband communications, satellite communications, proprietary license band radios, and the like. In an embodiment, the wireless connection is a radio frequency (RF) connection such as, but not limited to, a Wi-Fi connection. For example, the controller of loader 15 and the remote control may each include an RF module or transceiver. However, other modes of wireless communication may be employed. The AOS is operable to receive remote signals from the remote control unit via wireless communication. In an embodiment, the wireless connection between the remote control and the AOS enables the user to change guidance modes and monitor telemetry and sensor data in real-time. In an exemplary embodiment, the on-board vision system and depth cameras 56 provide the user with visual feedback of the current environment and operating conditions of loader 15. In an exemplary embodiment, real-time status information about the AOS, loader 15 and the controller is provided to the remote control unit via the wireless connection.
[0047] In an embodiment, the remote control includes controls such as, without limitation, “start,” “stop,” “follow,” “drive,” “turn,” “lift platform,” “lower platform,” “tilt platform,” “lift arm,” “low er arm,” “extend arm,” “retract arm,” “rotate arm,” “engage load,” and “disengage load.” In an embodiment, the automated guidance, localization guidance, and localized remote guidance modes include preprogrammed acceleration and/or deceleration limits. In an exemplary’ embodiment, the acceleration and/or deceleration limits may be a function of environmental and/orterrain conditions. Acceleration and deceleration may also be afunction of the load sensed mass. In an exemplary embodiment, the automated guidance, localization guidance, and localized remote guidance modes include preprogrammed vehicle speed limits. These limits may be the same in each guidance mode. Other operating limits of loader 15 may be programmed for each of the automated guidance, localization guidance, and localized remote guidance modes. [0048] While the AOS provides fully autonomous navigation and control of loader 15 in the automated guidance mode, in an embodiment, the remote control has the ability to override the processing unit guidance modes and take control of the AOS. Steering, throttling, and braking commands to the controller, along with guidance mode selections, may be input directly from the remote control, allowing the user to teleoperate loader 15. In an embodiment, the AOS provides a hybrid automated guidance mode and localized remote control mode. For example, loader 15 is operable in the fully autonomous navigation and control automated guidance mode to traverse an environment to a work crew, where the remote control may be utilized to control movement of loader 15 and its independent load bearing systems 30 and 40 in the localized remote control guidance mode.
[0049] In a construction site or other operating environment, such as a solar farm installation site, multiple loaders 15 with payloads may navigate the site at the same time or in series. A centralized controller includes a transceiver in communication with the transceiver of the loader controller of each loader 15 and the centralized controller is operable to generate each loader route for operating loader 15 in the automated guidance mode. For example, the centralized controller generates the loader routes utilizing a site map, operational boundaries, hazard zones, and the real-time obstacle data generated by the sensor systems on each loader 15. The data acquired/transmitted by the sensor systems may be utilized to modify the loader routes as well as operate loader 15 in a localized guidance mode or obstacle avoidance mode. In an embodiment, the centralized controller is operable to source satellite imagery utilized to determine reference points and operational boundaries. For example, the centralized controller may source satellite imagery' from a cloud sendee. In an exemplary embodiment, the centralized controller generates routes in the automated guidance mode as a function of, or on the basis of, a field operator (e.g., a human operator or a crew) location. For example, the field operator may utilize the remote control to indicate to the centralized controller that a payload is required at their location (e.g., via GPS data or latitude and longitude coordinates). In another example, the field operator may utilize a handheld transceiver to communicate to a staging area operator that a payload is required at their location (e.g., GPS data or latitude and longitude coordinates), and the staging area operator may provide this information to the centralized controller (e.g., enter the field operator location into route planning/generating software of the centralized controller). The centralized controller may store planned route data in the cloud, where each loader 15 is operable to access navigation instructions. A peer-to-peer architecture may also be utilized to communicate data from payloads or acquired by the sensors systems between loader 15. The peer-to-peer architecture may be utilized by loader 15 to ensure a standardized obstacle avoidance response on planned routes. [0050] In an exemplary embodiment, the centralized controller communicates with a material handler (e.g., an automated handler or human operator) in a material staging area a designated payload to be loaded onto loader 15. For example, the controller may send a signal to the material handler to load a loader 15 with a designated pallet, and the material handler will direct loader 15 to the staging area exit (e.g., via a remote control). In an exemplary embodiment, the material handler is a human operator with a remote machine controller in wireless or wired connection with loader 15. For example, the machine controller may include one or more joysticks and user inputs operable to drive and control the position of platform 30 and translation of arm 40 of loader 15. The centralized controller then communicates a signal to loader 15 to traverse a planned route to and through an installation area. When loader 15 is autonomously traversing a planned route and reaches a waypoint designated in the planned route, loader 15 pauses its traverse to enable a work crew to unload, via arm 40, and in some situations install, the pay load 90. Receiving a signal from one of the on-board sensors or a member of the work crew that indicates the payload is unloaded, and in some situations installed, loader 15 continues to traverse the planned route through the installation area and eventually back to the material staging area.
[0051] In an embodiment, the loader controller is operable to provide load management. For example, leveling platform 83 may be tilted or raised by one or more of actuators 82a, 82b, 82c and 82d to balance the payload carried by assist arm 40. Forks 31 may also be tilt, raised or lowered based on the orientation in which loader 15 is driving (e.g., backwards/forwards) or the terrain over which loader 15 is navigating.
[0052] Thus, as an example only and without limitation, loader 15 may be used to install solar panels in a solar farm employing the following operation. 1) The operator remotes loader 15 to a supply location. 2) The operator remote pickups a pallet with forklift 30. 3) The operator remotes loader 15 to an install location. 4) The operator swings arm 40 to fork lift 30 of loader 15 and releases gripper 43 for usage. 5) The operator remotes loader 15 in position in a row a desired distance from a torque tube. 6) The operator picks a panel from forks 31 with gripper 43, lifts the panel and moves it to an install location. 7) The crew7 snaps in the panel. 8) The operator releases gripper 43 and moves gripper 43 back to forks 31 of loader 15. 9) Repeat steps 5-7 until loader 15 must be moved. 10) The operator moves gripper 43 back to forks 31 of loader 15. 11) The operator presses remote control button on gripper 43 to advance loader 15 forw ard. 12) Loader 15 moves forward pre-programmed distance, following torque tube line (semi-automate). 13) Repeat steps 6-12 until pallet on forks 31 is empty. 14) The operator remotes loader 15 to supply location. 14) Repeat from 2 until work complete. 15) The operator swings arm 40 to rear of loader 15 and secures loader 15 for transport. 16) The operator remotes loader 15 to mobile machine storage location.
[0053] Loader 15 provides a number of advantages. For example, the field of construction often requires material to be delivered and handled prior to installation, in particular during solar fields construction solar panels need to be installed into racks. The solar panels are large, bulky, and heavy. Two operators are required to lift each solar panels from a pallet and place it into the racks. Loader 15 allows a single operator to install panels without the need of a second operator and with much less fatigue than when lifting the solar panels manually with another operator, as loader 15 has remote control or semi-autonomous capabilities, and an operator cab is no longer needed for mobile machine control.
[0054] It should be appreciated that certain features of the system, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination. While various embodiments have been described in detail above, it should be understood that they have been presented by w ay of example, and not limitation. It will be apparent to persons skilled in the relevant arts that the disclosed subject matter may be embodied in other specific forms, variations, and modifications without departing from the scope, spirit, or essential characteristics thereof. The embodiments described above are therefore to be considered in all respects as illustrative, and not restrictive. The scope of the invention is indicated by the appended claims, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein.