Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUS AND METHOD FOR AUTONOMOUS AGRICULTURE INVENTORY
MANAGEMENT
Inventors: Austin Blake Lawrence, Loren Kristofor Russell, Scott Thomas
Landes, James Braxton
Webb and Edward Austin Webb
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a continuation-in-part of US Patent
Application serial number
15/604,343, filed on May 24, 2017 which claims priority to US Provisional
Patent Application serial
number 62/340,952, filed on May 24, 2016, all of which are herein incorporated
by reference in their
entirety.
FIELD OF THE INVENTION
[0002] The present disclosure relates to an apparatus and method for
autonomous Controlled
Environment Agriculture (CEA), including without limitation for the purpose of
cultivation of organic
produce and other organic or natural products and in vertical farming
applications. The disclosed
apparatus and method can also be utilized for more general application in the
fields of agriculture,
material handling, and warehousing, including without limitation, modular
pallet warehousing.
BACKGROUND OF THE INVENTION
[0003] Controlled Environment Agriculture (CEA) is an evolving technique for
the precision
cultivation of organic produce through the artificial control of influential
environmental factors. An
appeal to facilitate the desirable outcomes of growth, this type agriculture
may require the regulation
of parameters pertaining to atmospheric, nutritional, spatial, or
electromagnetic qualities. In doing so,
a precise understanding of an organic system's overall production with respect
to time is much more
attainable. Systems like these can vary in size, ranging from a household
appliance, to a standard
freight shipping container, to a 10,000 square-meter warehouse, to a multi-
hectare greenhouse. CEA
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systems are typically equipped with a general selection of actuators and
sensors to monitor and control
the environment.
[0004] In recent times, the technique has seen market potential in the
cultivation of leafy or
herbal produce, but the method has historically also suited for other organic
applications, such as
production of ornamentals, fungi, simple organisms, and protein sources. CEA
offers the appeal of
being resistant to growth-inhibiting factors, such as droughts, famine,
floods, or winters. Because of
this resiliency, consistent, year-round production is possible for a wide
range of geographic scenarios,
including urban, desert, artic, and deep space regions.
[0005] Typically, CEA systems running at a commercial capacity require a wide
range of
manual tasks to be performed by farmhands on a daily basis. These
responsibilities may include the
harvesting, cleaning, creation, inspection, and moving of product, the
maintenance, sensing, control,
and logistical planning of the environment, and the analysis of any data that
may be subsequently
collected. Despite being computer-controlled and with sensory feedback, CEA
systems have many
logistical points of failure that require technical skills from the farmhands
in order to maintain.
Appropriately so, commercial CEA systems are sometimes referred to as "plant
factories" for their
resemblances to manufacturing environments.
[0006] In industries pertinent to the distribution of inventory, autonomous
warehousing has
grown to prominence with the notion of a distributed robotic network to
satisfy the last-mile issue that
is often faced within large centers. In the 1970's, Autonomous Storage and
Retrieval (ASRS) systems
rose to prominence and were complimented with general conveyance of varying
complexity to create
semi-autonomous zones within the warehouse through the use of a manual crane
operator. Over
decades of innovation, fully autonomous warehousing has seen continued
interest due to improved
accessibility of affordable, functional robotic resources, such as actuators,
sensors, embedded
hardware, and control algorithms. New embodiments and methods include a fleet
of freely-driven
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robots within a warehouse that have created further evolution in automation,
now looking towards
topics of dextrous manipulation, rich image classification, and swarm
optimization.
[0007] Despite the prevalence in autonomous mechanization that has benefitted
warehousing,
few solutions exist that are appropriate for CEA embodiments. Tasks in CEA
systems are largely
manual, requiring redundant work from human laborers. These tasks, often
worsened by day-long
repetition, excessive amounts of walking, and the frequent use of vertical
lifts, all attribute to a
significant portion of operational expenses for a CEA. As reported in Newbean
Capital's 2015 white
paper, "Robotics and Automation in Indoor Agriculture," CEAs in the vegetative
green industry spend
about 26% of their operational expenses on human labor, second to electricity
at 28%. Because a
significant portion of resources are dedicated to accessing manual labor, it
is difficult for CEA
operators to justify committing even more resources to the meticulous capture
and logging of data. A
consequence to this, optimization suffers, and little may be done to reduce
operating expenses in areas
such as electrical, nutritional, and water usages.
[0008] A growing number of specialized systems have been proposed in the
interest of
improving the operation of CEA systems. For example, Just Greens'
US2014/0137471 embodiment
employs the use of a fabric-like material of particular absorptive and wicking
parameters that may be
mounted onto a variety of tensioning and conveying systems, but is best suited
for aeroponic
environments where suspended roots are given adequate clearance to grow. As
another example,
Living Greens Farm's US9,474,217B2 embodiment contains a mobile track system
for large A-frames
containing plants to transverse along, as well as a mobile irrigation system,
but it does not offer
irrigation methods differentiated from aeroponics.
Lastly, Urban Crop Solutions'
W02017012644(A1) describes an industrial plant growing facility, but limits
scope to the cultivation
only of green produce within flat, off-the-shelf trays. No standardization
exists which offers broad
versatility and inspection in a CEA environment for varying applications.
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[0009] As these mentioned embodiments do bring improvements to CEA in
practice, their
function is often very specific to the type of produce that is being
cultivated and would require
substantial capital investment to convert infrastructure for alternative forms
of agriculture. In addition,
some embodiments make frequent requirement for workers to operate in
precarious situations that may
involve carrying a large, potentially wet, cumbersome pallet of produce on
ladders or scissor lifts.
Lastly, all of these inventions do not facilitate the measurement of produce
quality at a particular site
of production without first requiring substantial manipulation from a human,
or automated mechanism,
to deliver the organic material of interest to a stationary sensory station.
[0010] Embodiments disclosed within contemplate an apparatus and method for
autonomous
inventory management for applications particular to CEA. The system, generally
consisting of a
plurality of tray assemblies (40) configured linearly within a plurality of
track assemblies (18) within
a rack (11) within an environmentally-controlled environment, may receive
autonomous forceful input
from a carriage-mounted manipulator (79) to add, subtract, index, or transfer
tray assemblies (40)
within the growing environment (10).
[0011] The template frame (41), having features for compressive or tensile
input along a serial
chain of the like, orients onto a pair of tracks (19) of at least one track
assembly (18) with low-friction
bearing surfaces that are affixed to the template frame (41). A tag (47),
consisting of an RFID chip or
optical feature, allows for tracking from an inventory management system.
Fasteners (44) on the
template frame (41) accept a frame insert (50) derivation that is pertinent to
the particular CEA
application of interest. An indexing face (49) for the forceful input and
manipulation from a carriage-
mounted manipulator (79) allow the autonomous handling of product.
[0012] The frame insert (50), having mating features for orienting and
affixing to the fasteners
(44) on a template frame (41), may be configured for a variety of scenarios
that are pertinent to the
particular CEA task. For example, one embodiment of a frame insert (50) may
include a rigid frame
(51) along with tensioned fabric (52) principally intended as a growing media
for short, leafy or herbal
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produce. In another embodiment, the frame insert (50) may include an
electronic enclosure (73) to
facilitate tasks such computation, energy generation and storage, wireless
communication, controls,
and sensing. Additional embodiments of the frame insert (50) may be configured
for applications that
are largely pertinent to CEA organic product, such as ornamental crops,
medicinal crops, plants
requiring anchoring at the base, vines, fungi, roots, simple organisms,
carbohydrates, fats, and protein
sources.
[0013] The track (19), having a plurality of flats that are parallel to the
horizon, facilitates
linear motion by providing at least one low-friction bearing (46) on a
template frame (41) to commute.
In an embodiment, two tracks (19) are oriented to be mirrored about a center
plane perpendicular to
the horizon within the rack (11) and do not provide a significant contribution
to the structural integrity
of the structure. In alternative derivations, the track (19) may be configured
with multiple steps for
additional mobile bodies to linearly move independently of one another,
features for the confinement
of mobile bodies, features for electrical or fluidic channels, or features for
mounting hardware, such
as bearings brackets or sensors.
[0014] The track (19) may be configured as a track assembly (18) to achieve
various functions
pertinent to a specialized CEA system. For example, an embodiment illustrated
herein contemplates
an aeroponic configuration in which a flexible sheet (20) is formed and
affixed to fit between a hat
(16) and track (19). Supporting hardware, such as aeroponic modules (29), a
fluidic drain (27), a
fluidic inlet (28), and at least two bulkheads (22) and stiffeners (23) are
incorporated into said track
assembly (18) embodiment. In another embodiment, a low pressure fluidic system
(37) may be derived
consisting of a flexible sheet (20) to function as a channel for waste fluids,
a fluidic drain (27) and
inlet (28), and fluidic emitters (36) to deliver a chemical solution to tray
assemblies (40). In exemplary
embodiments, a track assembly (18) may be configured for applications relevant
to the production of
ornamentals crops, medicinal crops, plants requiring anchoring at the base,
vines, fungi, roots, simple
organisms, carbohydrates, fats, and protein sources.
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[0015] In accordance with CEA system design, the apparatus may include
peripherals to assist
in regulating environmental parameters. A fertigation system may use a
combination of pumps,
solenoids, filters, chemical reservoirs, and sensors to regulate and
distribute a fluid of nutritional
significance throughout the growing environment (10) and more directly to tray
assemblies (40). A
light (33) can be used to provide supplemental light to living organisms,
preferably through color and
intensity-specified LED modules, and facilitate desirable growth on each tray
assembly (40). Fans
(30) may be included to ensure proper mixing of gasses, to improve thermal
distribution, and to redirect
undesired moisture away from plant canopies. In continuation of said
embodiment and common
knowledge, the apparatus is confined within an environmentally-controlled
enclosure and is equipped
with an air quality unit for the monitoring and regulation of atmospheric
parameters within the grow
environment (10). These parameters may include the active control of relative
humidity, temperature,
particulate frequency and size through mechanical filtration, pathogen through
UV treatment, and
carbon dioxide supplementation. Contents within the enclosure are physically
isolated from an outside
environment and undergo a minimal number of air exchanges, thus satisfying the
function as a CEA
system. Enclosure embodiments may fit the form factor found in industrial
warehousing, shipping
containers, and greenhouses while still benefitting from the embodiment of
this invention.
[0016] Exemplary embodiments are generally pertinent to the apparatus and
method of
autonomous inventory management in CEA systems through the active input of one
or more carriage-
mounted manipulators (79). In one embodiment, which is described in this
document with the intent
for illustration, an automated inventory management system is described for
environments relevant to
the cultivation of leafy or herbal produce inside facilities that are
configured over multiple layers of
plants grown within tray assemblies (40). In function, the manipulator (82)
may navigate to a first
location of interest, extend its linear extensor (87) and perform a grasping
maneuverer by closing its
clamps (86), forcibly push tray assemblies (40) configured within a track
assembly (18), and insert
said tray assembly (40) into a new respective location within a track assembly
(18) within a rack (11),
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or processing line. In the embodiment, the manipulator (82) may perform
retrieval, indexing, and
insertion functions to tray assemblies (40) within the growing environment
(10), and may optionally
operate tray assemblies (40) to or from a processing line.
[0017] Additional embodiments contemplate a system providing last-in-first-
out (LIFO) inventory
management.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Figure 1 shows an overall apparatus of autonomous controlled
environment agriculture
according to the embodiment of the invention as a grow environment.
[0019] Figure 2 shows an embodiment of the template frame.
[0020] Figure 3 shows one embodiment of a tray assembly having a fabric frame
insert.
[0021] Figure 4 shows one embodiment of a tray assembly having a deep bin
frame insert.
[0022] Figure 5 shows one embodiment of a tray assembly having a shallow bin
frame insert.
[0023] Figure 6 shows one embodiment of a tray assembly having a net pot frame
insert.
[0024] Figure 7 shows one embodiment of a tray assembly having a sensory and
actuated frame
insert.
[0025] Figure 8 shows one embodiment of a track assembly configured for high-
pressure
irrigation.
[0026] Figure 9 shows one embodiment of a track assembly configured for low-
pressure
irrigation.
[0027] Figure 10 shows a profile view of one embodiment of a track assembly
configured for
high-pressure irrigation.
[0028] Figure 11 shows one embodiment of a rack.
[0029] Figure 12 shows one embodiment of a rack.
[0030] Figure 13 shows one embodiment of a rack with walkways.
[0031] Figure 14 shows an embodiment of a carriage-mounted manipulator.
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[0032] Figure 15 shows an interaction of a carriage-mounted manipulator and a
tray assembly.
[0033] Figure 16 shows a perspective view of interlocked tray assemblies
within track
assemblies of a rack according to another embodiment.
[0034] Figure 17 shows a perspective view of a frame assembly according to the
embodiment
of Figure 16.
[0035] Figure 18 shows a perspective view of a tray assembly according to the
embodiment of
Figure 16.
[0036] Figure 19 is a detailed view of a frame assembly positioned on a
friction surface.
[0037] Figure 20 is a perspective view of two frame assemblies coupled
together.
[0038] Figure 21 is a detailed view of frame assemblies on a rack.
[0039] Figure 22 is a detailed view of two frame assemblies coupled together.
[0040] Figure 23 is a perspective view of a single carriage-mounted
manipulator LIFO system
operating system.
[0041] Figure 24 is a perspective view of a single carriage-mounted
manipulator LIFO system
operating system having racks on both sides of the manipulator.
[0042] Figure 25 is a detailed view of a frame assembly secured by a
manipulator.
[0043] Figure 26 is a detailed view of an engagement thumb of a manipulator
connected to a
frame assembly coupler.
DETAILED DESCRIPTION
[0044] It is to be understood that at least some of the figures and
descriptions of the invention
have been simplified to illustrate elements that are relevant for a clear
understanding of the invention,
while eliminating, for purposes of clarity, other elements that those of
ordinary skill in the art will
appreciate may also comprise a portion of the invention. However, because such
elements are well
known in the art, and because they do not facilitate a better understanding of
the invention, a
description of such elements is not provided herein.
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[0045] One embodiment of the present invention, as depicted in Figure 1,
comprises a carriage-
mounted manipulator (79), consisting of a carriage (80) which is further shown
in an embodiment in
Figure 14 and 15, and a manipulator (82) which is further shown in preferred
embodiments in Figure.
1, 14, and 15 as being affixed to said carriage (80) through fastening to a
mounting bracket (81).
Further detail of the embodiment consists of a rack (11) which is further
shown in an embodiment in
Figures 1, 11, 12, and 13, a track assembly (18) which are further shown in an
embodiments in Figures
1, 8, 9 and 10, and tray assembly (40) comprising of a template frame (41) and
frame insert (50),
assuming a variety of utilities and embodiments demonstrated in Figures 3, 4,
5, 6, and 7, such as
housing plant grow media for the cultivation of produce, a bin for retaining
organic material, or a
wireless sensory and actuation hub. The manipulator (82) may push or pull a
tray assembly (40)
through the forceful contact, or alternatively retrieve said tray assembly
(40) through a multitude of
grasping techniques, such as through the use of a clamp (86) directly to at
least two wheels (46)
mounted to the template frame (41). Tags (47) on a rack (11) and the tray
assembly (40) may assist the
manipulator (82) and carriage (80) in localization and may also serve the
function of tracking. As one
manipulator (82) indexes a tray assembly (40), an antagonistic manipulator
(82) may retrieve a tray
assembly (40) to provide linear clearance along the track assembly (18). A
multitude of tray assembly
(40) and track assembly (18) derivations may be incorporated into a rack (11),
offering sensory,
sterilization, and actuation resources in addition to methods and apparatuses
for the cultivation of
produce.
[0046] As alluded to in the background section, vertical farms are burdened
with human
labored tasks. In incorporating a manipulator (82) with the wide range of
functions possible by the
template frame (41), laborious tasks, such as handling tray assemblies (40),
sterilization, sensing, and
data logging may be completely automated by machines along a processing line.
Doing so reduces the
need for human intervention in the growing environment (10), thus advancing
towards autonomous
controlled environment agriculture.
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[0047] In another embodiment, as shown in Figure 1, the rack (11) is
configured to provide
attachment sites to the track assembly (18), linear guides (83 and 84) for the
carriage (80), and
horticultural lights (33). The track assembly (18) bears directly onto the
rack runner (12), where load
may be transmitted through the rack verticals (13), distributed through the
foot pads (14) and onto a
sturdy floor. Though the rack (11) in Figures 1, 11-13 describe track
assemblies (18) at six levels high,
the rack (11) may conceivably be any number of track assemblies (18) wide, at
any length, at any
number of layers high. Should hallways (17) for human access be required, the
linear guides (83 and
84) may be extended across at heights that are unobtrusive for a human to
navigate around. Brackets
(15) are used to provide stiffness to the rack (11) shown in FIG. 1, 11-13.
Plumbing for drains (27)
and pressurized lines may be routed within the proximity of the rack verticals
(13).
[0048] As the linear guides (83 and 84) are located at opposite ends of the
rack (11) shown in
Figure 1, the carriage-manipulator (79) shown in Figure 1, 14, and 15 may
freely navigate along the
width of the rack (11) while still having access to the tray assemblies (40)
derived in Figures 2-7. The
carriage (80), shown in Figures 1, 14, and 15, provides vertical linear motion
via its linear guides (98)
and drive motor (91). Other forms of linear actuation, such as friction
roller, lead screw, scissor
mechanism, or fluidic actuator may also be suitable. The carriage vertical
(97) provides structure to
the overall integrity of the carriage (80) shown in Figure 1, 14, and 15.
Bearings may be tensioned to
fit securely onto the linear guides (98). The carriage (80) may store
electronics, hyperspectral cameras,
or sensors for querying the tray assembly (40). In alternative derivations,
the motor (90) controlling
motion along the linear guides (83 and 84) may be housed remote of the
carriage (80) in Figures 1, 14,
and 15.
[0049] In another embodiment, the manipulator (82), shown in Figures 1, 14,
and 15, is
intended to manipulate the tray assembly (40), shown in Figures 3-7, through a
mode of actuation. The
stiffeners (42 and 43) are bonded together with brackets (48). Bearings
provide controlled linear
motion about the linear extensor (87). A motor (92) provides power to the
linear extensor (87). In
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alternative derivations, the linear extension function could be accomplished
through fluidic actuation,
a lead screw, linkage, or magnetic suspension.
[0050] As shown Figure 15, to acquire a template frame (41) in one embodiment,
the linear
extensor (87) is oriented directly over the top surface of the template frame.
To place a template frame
(41) back into the rack (11), the manipulator (82) shown in Figures 15 is
oriented in front of a cutout
feature of the track assembly (18), and extended through the actuation input
of the motor (92). The
indexing face (49) comes into contact with the indexing face (49) of another
template frame (41), and
continues to exert force until the template frames (41) within the track
assembly (18) have indexed
one full template frame (41) width.
[0051] In one embodiment, as shown in Figures 5, 8, and 9, the track assembly
(18) resides
within the rack (11) expressed in Figures 11-13, and houses template frames
(41) and plumbing. The
track (19) bears features for securing template frames (41) and mitigating
risk for buckling. In Figure
10, the track (19) has a two-sided feature to allow for the manipulator (82),
in Figures 1, 14, and 15,
to access the template frames (41). The track assembly (18) bears a flange
feature for bearing onto
rack runner (12), and a small pitch to motivate water drainage towards its
center. An overflow drain
(56) assures no risk for water to flood the track assembly (18) in Figure 9,
whereas a drain (57) provides
a smaller orifice for water to fully evacuate the tray assembly (40). The
bulkhead (22) retains water,
and bears a cutout feature for the manipulator (82) to engage the template
frame (41).
[0052] As depicted in Figures 3-7, the template frame (41) in one embodiment
is compatible
with features demonstrated on the manipulator (82) in Figures 14 and 15, and
also the track assembly
(18) of Figures 8-10. The template frame (41) comprises a tag (47), which may
be but is not limited to
RFID, or a binary matrix. Grasping features, such as a flange for a forklift
approach, features for
vacuum holding, latches, or keys may also be considered. Low-friction bearings
(46) nest within the
track (19), permitting motion along its length. A template frame (41) serves
as a surface for mounting
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farm peripherals, such materials for cultivating product (Figures 3-6),
materials for sensing the
environment, or materials for actuation (Figure 7).
[0053] Other contemplated embodiments, as shown in Figures 3-6, of the frame
insert (50)
comprise of features such as a deep bin (54) or shallow bin (55) to retain
organic matter. A lid (53)
may be included to regulate environment within the deep bin (54). Fasteners
(44) hold the template
frame (41) to the frame insert (50).
[0054] Other contemplated embodiments of the template frame (41) comprise
features such as
solar panels (72) that may provide power to be stored in a battery. In one
embodiment depicted in
Figure 7, an electronics enclosure (73) may store power generated from a solar
panel (72) and perform
sensory and control tasks through the locomotion along a track assembly (18).
Wheels (60) may be
deployed through active actuation from the assistance of motors (67). A
linkage (61) system allows
for the height of the template frame (41) to be adjusted. An antenna (74)
facilitates wireless
communication to a central hub. A camera (71) provides data in the visible,
infrared, or ultraviolet
spectra.
[0055] If not otherwise stated herein, it may be assumed that all components
and/or processes
described heretofore may, if appropriate, be considered to be useable with or
interchangeable with
similar components and/or processes disclosed in the following embodiments,
unless an express
indication is made to the contrary. Similar are corresponding features are
identified with references
numbers increased by one hundred.
[0056] While the embodiments shown in Figures 1-15 allow for first-in-first-
out (FIFO)
inventory management, other embodiments, shown in Figures 16-26, allow for
last-in-first-out (LIFO)
inventory management of tray assemblies 140 each having a frame assembly 141.
In the embodiments
shown in Figures 1-15, the inventory management is FIFO because the system
includes a pair of
coordinated carriage mounted manipulators 82 wherein the first manipulator 82
manipulator which
can then unload a the tray assembly 40 from the lane that had been in the lane
the longest. The
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embodiments of Figures 16-26 are capable of LIFO without the use of a gravity
conveyor because a
single manipulator 182 is capable of pulling the last loaded tray assembly 140
off of a lane 200, and
in doing so indexes each tray assembly 140 one step rearwards towards the
manipulator 182. Referring
to Figure 23, a single manipulator 182 mounted on a carriage 180 is used which
provides the same
amount of productivity as the above-described embodiments utilizing two
manipulators 82 while
removing the need to coordinate movements of two manipulators 82. This allows
for more consistent
grasps by the manipulator 182 and requires fewer movements to access a frame
assembly 141. A
friction based staging area may also be provided.
[0057] Referring to Figures 16-26, frame assemblies 141 are slidable forwardly
and rearwardly
in long track assemblies 118 along a forward and rearward direction of travel
within a plurality of
horizontal lanes 200 arranged in a plurality of vertical columns 202 in rack
111. Like in the above-
described embodiments, each frame assembly 141 includes stiffeners 142 and low-
friction bearings
146 rollable on tracks 119 of a track assembly 118 to move the frame assembly
141 in the forward and
rearward direction of travel X. As shown in Figure 19, frame assembly 141 is
configured to move on
a track assembly 118 that is secured to rack 111. Frame assembly 141 bears
directly onto a friction
surface 220 incorporated into the track assembly 118. The friction surface 220
exerts countering forces
overcome linear motion that is normally facilitated by the low-friction
bearing 146 on the track 119.
The static forces produced by the friction surface facilitate the precise
positioning of the frame
assembly 141 when being placed and retrieved by a carriage-mounted manipulator
182. A guard 222
prevent linear displacement of the frame assemblies 141. Alternatively, tracks
119 may include wheels
204 on which the frame assemblies 141 slide upon.
[0058] Each frame assembly 141 in each horizontal lane 200 is configured to
couple to an adjacent
frame assembly 141. Each frame assembly 141 has at least one coupler 206, 208
on the forward and
rearward ends 210, 212 of the tray assembly. In the embodiment shown in
Figures 16-24, the at least
one coupler 206 on the forward end 210 are first and second forward couplers
206, and the at least one
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coupler 208 on the rearward end 112 are first and second rearward couplers
208. In this embodiment,
the first and second forward couplers 206 and the first and second rearward
couplers 208 are a pair of
spaced hook shaped components 214 each having a first proximal portion 216
substantially
perpendicular to the respective end 210, 212 of the frame assembly 141 and
substantially parallel to
the direction of travel X, and a distal portion 218 substantially
perpendicular to the forward and
rearward direction of travel X and parallel to the corresponding end 212, 214
of the frame assembly
141. Each pair of the first and second forward couplers 206 on a frame
assembly 141 is configured to
couple with the first and second rearward couplers 208 of an adjacent frame
assembly 141 in the
forward direction of travel. In order to couple with adjacent frame assemblies
141, the second distal
portion 218 of each first and second forward couplers 206 extends in the
opposite direction to the
second distal portions 218 of the first and second rearward couplers 208 of an
adjacent tray assembly
such that each frame assembly 141 is rotationally symmetrical about an axis
normal to the width and
length frame assembly plane. This rotational symmetry allows for bidirectional
operation of the
manipulator 182 and allows for frame assemblies 141 to be placed anywhere
without the need to rotate
the frame assembly 141. Other forms of couplers and arrangements are
acceptable. For example,
having multiple coupling features; having a positive engagement latch or drop
pin, as commonly found
in gates and train cars; dropping a tray assembly onto a hitch; powerful
magnets; engagement of a cam
or key feature; fastening and unfastening with screws; no coupler, instead a
gravity flow rack and a
sufficiently powerful manipulator to overcome increased indexing loads. The
manipulator would then
be configured to correspond to the coupler to allow for coupling and
decoupling.
[0059] The couplers 206, 208 may be integral with the frame assembly 141 of
each tray
assembly 140 material and be made from a corrosion-resistant cast low carbon
steel, aluminum, or
stainless steel. They may also be made from aluminum extrusions, formed heavy
gauge steel,
aluminum, or stainless sheets, formed stainless wire, or subtractively or
additively manufactured metal.
The couplers 206, 208 may also be attached to stiffeners 142 of the frame
assembly 141.
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[0060] The forward and rearward couplers 206, 208 are the features that the
manipulator 182
uses to couple, push, and pull the frame assemblies 141. Because the carriage-
mounted manipulator
182 positions itself spatially to a plus or minus tolerance from nominal, it
is best for the first and second
forward and rearward couplers 206, 208 to be oversized in accordance with
tolerances expected from
the carriage-mounted manipulator 182. This ensures that a manipulator 182
positioned "slightly off'
can still couple to a coupler 206, 208 without the need for sophisticated
actuation or sensing. Because
the coupler 206, 208 is oversized in this way, there exists a small (about
0.25") amount of linear play
from one coupler 206, 208 engaged to another.
[0061] According to an embodiment, a first frame assembly 141a being added to
a lane 200 is
coupled to second frame assembly 141b on the lane 200 as follows:
[0062] 1. The carriage-mounted manipulator 182 engages to the first frame
assembly
141a and positions the first and second forward couplers 206 on the first
frame assembly 141a
above the first and second rearward couplers 208 of the second frame assembly
141b.
[0063] 2. Manipulator 182 lowers the first frame assembly 141a (for example, a
few
inches) such that the first and second forward couplers 206 on the first frame
assembly 141a
slide into the first and second rearward couplers 208 of the second frame
assembly 141b.
[0064] 3. The first frame assembly 141a is now coupled to the second frame
assembly
141b in the direction of travel X of the lane 200 with the couplers 206 and
208 being coplananr
a configured to transmit force in the direction of travel X.
[0065] 4. The manipulator 182 may push the first frame assembly 141a towards
the
second frame assembly 141b and index the series of interconnected frame
assemblies 141a,
141b one index.
[0066] 5. Manipulator 182 disengages from the first frame assembly 141a.
[0067] According to an embodiment, a first frame assembly 141a is decoupled
from a second
frame assembly 141b on the lane as follows:
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[0068] 1. Manipulator 182 engages to the first frame assembly 141a.
[0069] 2. Manipulator 182 pulls the first frame assembly 141a, subsequent
frame
assemblies 141 are pulled towards the manipulator 182 one index. The first
frame assembly
141a is now secured by the manipulator 182.
[0070] 3. Manipulator 182 raises the first frame assembly 141a (for example, a
few
inches) such that the first and second forward couplers 206 of the first frame
assembly 141a
slide from the first and second rearward couplers 208 of the second frame
assembly 14 lb.
[0071] 4. The first frame assembly 141a is now decoupled from the second
frame
assembly 141b in the direction of travel.
[0072] Referring to Figures 25 and 26, an engagement thumb 224 having
projections 230 for
connecting to a coupler 208 on a frame assembly 141 fixedly connects to a
parallel-driven belts 226.
Pulleys 228 driven clockwise or anticlockwise, are used to provide
transmission to the belts 226, which
power and guide linear motion of the engagement thumb 224 in the direction of
travel X as dictated
by the track assembly 118. Bi-directional motion of the engagement thumb 224
is possible, allowing
for manipulation paradigms to both available sides of the manipulator 182.
[0073] As illustrated in Fig. 26, to grasp a frame assembly 141b positioned
first-out of the track
assembly 118, the carriage-mounted manipulator 182 is fixed near the frame
assembly 141 with the
engagement thumb 224 positioned below the coupler 208 to be manipulated. The
pulleys 228 provide
power to the belts 226, which motions vertical movement of the engagement
thumb 224 to slide into
the coupler 206 and engage. The pulleys 228 continue to drive as the motion of
the engagement thumb
224 transitions from vertical movement to horizontal, pulling the first-out
frame assembly 141b and
all subsequently coupled frame assemblies 141 along the same track assembly
118 a distance of one
index. With the frame assembly 141b secured aboard the manipulator 182, the
manipulator 182 moves
vertically to disengage the coupler 208 of the secured frame assembly 141 from
the newly positioned
first-out frame assembly 141a, if present.
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[0074] To place a frame assembly 141, the carriage-mounted manipulator 182 is
positioned
near the track assembly 118 of interest. As is shown in Figure 25, the
manipulator 182 is oriented
vertically to engage the coupler 208 of the secured frame assembly 141a to the
coupler 206 of the first-
in frame assembly 141b within a track assembly 118. The engagement thumb 224,
in contact to the
coupler 208 of the secured frame assembly 141a in the direction of the first-
in frame assembly 141b,
is powered through the input of the pulley 228 and belt 226 drive system.
Compressive force is exerted
from the engagement thumb 224 and through the secured frame assembly 141a,
causing motion of the
secured frame assembly towards the rack 111.
[0075] A guide 232 is used to center the frame assembly 141b during ingress,
and guards 222
are used to center the frame assembly 141b along the length of the track
assembly 118. Subsequent
frame assemblies 141 within the track assembly 118, if present, move one full
index. The manipulator
182 disengages its engagement thumb 224 from the newly-positioned first-out
frame assembly 141,
and the motion is complete.
[0076] Like in the above-described embodiments, the embodiment of Figures 16-
24, may also
use identifying tags 147 such as an RFID chip or optical feature allowing for
tracking from an
inventory management system
[0077] According to the embodiment of Figures 16-24, a lane 200 containing
frame assemblies
141 may be completely emptied by a single manipulator 182, easing manual
functions around cleaning
and inspecting farm equipment. It is to be understood that the disclosed
embodiments are not limited
to the farming industry but may be utilized in other autonomous material
handling industries such as
food and fulfillment operations.
[0078] The above description of the disclosed embodiments is provided to
enable any person
skilled in the art to make or use the invention. Various modifications to
these embodiments will be
readily apparent to those skilled in the art, and the generic principles
described herein can be applied
to other embodiments without departing from the spirit or scope of the
invention. Thus, it is to be
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understood that the description and drawings presented herein represent a
presently preferred
embodiment of the invention and are therefore representative of the subject
matter which is broadly
contemplated by the present invention. It is further understood that the scope
of the present invention
fully encompasses other embodiments that may become obvious to those skilled
in the art and that the
scope of the present invention is accordingly limited by nothing other than
the appended claims.
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