US009701492B2 2, United States Patent (10) Patent No: US 9,701,492 B2 Criswell (45) Date of Patent: Jul. 11,2017 (64) AUTOMATED TRUCK UNLOADER FOR (58) Field of Classification Search UNLOADING/UNPACKING PRODUCT FROM. spc e214 ‘TRAILERS AND CONTAINERS. See application file for complete search history. (71) Applicant: Wynright Corporation, Ek Grove, IL (86) References Cited ws) US. PATENT DOCUMENTS. (72) Anventor: “Tim Criswell, Aringion, TX (US) ere 2386236 A 12967 Shaw et 2197S MeWilliams 1973 Evans tal tore Soh (Continved) (93) Assignees: Wynright Corporation, Fk Grove, IL (US); Daifuku Co., Ltd. (IP) (*) Notice: Suijct to any disclaimer, the term of this patent is extended or adjusted under 38 vere DISC. 154b) by O days, (OTHER PUBLICATIONS International Search Report, PCT (Continved) (21) Appl. No 18/397,484 4.012215, May 14, 2014 (22) Filed: Sam, 3, 2017 Primary Examiner — Kyle Logan 6s) Prior Publication Data (14) Attorney, Agent, ar Firm — Scot. Grigas: Griggs US 200710113885 At Apr. 27,2017 ‘Bergen LLP 7) A Related U.S. Application Data RACT (63) Coatinuation of application No. 15/286,888, ied on Sep. 6 2016, now Prt. No. 9,533,841, which is 3 contination of application No, 14/159,297, filed on, Jan. 20, 2014, now Pat, No. 9,434,558, An automatic tick unloader for unloading/unpocking prod vet, such as boxes or eases, from trailers and containers is disclosed. In one embodiment, a mobile base structure provides a support framework for a drive subassembly. conveyance subassembly, an industrial robot, a distance (60) Provisional aplication No. 61/754,630, filed on Jan. measurement subassembly, and a contol subassembly 20, 2013, ‘Under the operation ofthe conteol subassembly, an industea rmbot having @ suction eup-based gripper arm selectively G1) Inte removes boxes from the trailer and places the boxes on Gosr 700 (2006.01) powered transportation path. The control subassembly coor BOSG 67724 (2006.01) Sinates the selective articulated movemeat of the industrial B6SG 6708 (2006.01) robot and the activation of the drive subassembly based B25) 1506 (2006.01) ‘upon the distance measurement subassembly detecting (2006.01) objects, including boxes, within a detection space, and (2) ‘dimensions ofthe wsiler provided tothe control subassem: B6SG 6724 (201301): B25I 5007 by. (013.01); B2SI 15616 (2013.01); Base ‘67/08 (2013.01) 19 Cai 15 Drawing Sheets x } f EE : ie Ez66) 3931897 abso ses 406629 e019 S257 Sistas Soo 302 Sis7t69 Sias20e S210 264 Sse0at $2595 Ss20218, Sie 588.669 Sissae S08 233 Sosa 1S 128 6.380098 osn2st ssnisi 0719 soll 6.550268, 002931 8.600.007 860.167 References Cited USS. PATENT DOCUMENTS. vise 21976 986 Dios fox 1991 Svs 1D is91 S92 Gi 1095 10.1593 Five Tiv94 G95 rosts9s Hh is97 1099 12000 9000 2002 22003 62003 2003 S2m03 12.2003 2003 "$2004 32008 Bacon et Sweat Richi ta Takahast Chand et Domer etl Angell a Galperin ‘Tate Smith Meclire eta Wott ea. Doster ea Fallse Beckmann Wattsra Bonnst ang ta. acs eal Chrstenson ot al om eal ‘Wierik et Heer Mayr eal Hendrickson eta ‘in ea Hang eal Pfr ea. US 9,701,492 B2 Page 2 6s74615 B242005 6306474 B2—S2008 Sow710 2 $2006 Winker B2 G2011 Crnwell tah BD 102013 Ciewall, ‘92016 Crswall BI 12017 Criswell 20080000854 AL 42004 Good st a Soosoaerses At 32008 2o0s10s%9 AL $2008, annsl3so12 AL 62005, aonsur7siod AL 122005, 30080267756 AL__ 102008 Fehelmeyer etal 00910110822 1 42000. Creme 6566708 ‘14398 2n90R06812 AL* 122009 Cations Bast 3708 700217 20100239408 AL* 972010. Beckor 6547914, “114800 20110139876 81 6/2011 Johanmsen anigotrraer AL 72012 Comgan ea 2O1SO2TDEDE AL 102013 Ante ta (OTHER PUBLICATIONS ‘Wontight, Robotics Solutions Robt Tsk Unload (RTL). Fb, 28,2012 (retovel on Ape. 28, 2014). Retrieved fom the internet * cited by examinerU.S. Patent Sul. 11, 2017 Sheet 1 of 15 US 9,701,492 B2 a Ln 4! YOO Fig.1U.S. Patent Sul. 11, 2017 Sheet 2 of 15 US 9,701,492 B2 ig.2AU.S. Patent Sul. 11, 2017 Sheet 3 of 15 US 9,701,492 B2 u SS) 8 Be i 0d I 6o~fU.S. Patent 36 4152 150 " 136 ai] 140 Jul. 11, 2017 Sheet 4 of 15 US 9,701,492 B2 op 8 | 0) th g ao HT a] LG L 2. & | re a o i Bad fe HL) % fs Le X20) o 4 086 154 142. 138 de | 144 ym BF q ad ay 84.U.S. Patent Sul. 11, 2017 Sheet 5 of 15 US 9,701,492 B2 Rr 1 [ 7~J a |_-70 it Ed 7 UF L *U.S. Patent Sul. 11, 2017 Sheet 6 of 15 US 9,701,492 B2U.S. Patent Jul. 11,2017 Sheet 7 of 15U.S. Patent Sul. 11, 2017 Sheet 8 of 15 US 9,701,492 B2US 9,701,492 B2 Sheet 9 of 15 Sul. 11, 2017 U.S. PatentU.S. Patent Sul. 11, 2017 Sheet 10 of 15 US 9,701,492 B2 Fig.5C 134U.S. Patent Sul. 11, 2017 Sheet 11 of 15 US 9,701,492 B2 [it Hu titi] Hy Fig.6A Fig.6B nu Fig.6C Fig.6DU.S. Patent Sul. 11, 2017 Sheet 12 of 15 US 9,701,492 B2 uo PETTY «J 18 8 20a 206 26 Fig.7D ao. L 36 SoyU.S. Patent Sul. 11, 2017 Sheet 13 of 15 US 9,701,492 B2 56 x e 362 © Gee] foe]! fee Seem SF Fig.8 [recive cer 354 350 Operational Environment Data User Interface 372~| wm yf, 18 Comeye Drive 1 | soy ; suvassempy} | Ev” | | contater | | Robo | Fig.9 * st hs 36 uo 2 A “pS si - 16 re { a 414 Contoter Processor ate 418 Laser | other ah sian Fo Controller Compononts Detector 402 Fig.11 Sai 404~ Laser CircuitUS 9,701,492 B2 Sheet 14 of 15 Sul. 11, 2017 U.S. Patent sowueyoayy }- =| sowvosjoaya J+ Jogoy revisnpuy / sieubig 9s SBIEIS [uonsares Absjens: Ps 0 UaAg 99¢ Jena eoepeU 2esf) OL 440/NO Buwwesbo1g Y ‘wesboid yocoy [ose y 068 eoinieg Bunjesedo yoqoy [28 Beg yuewuos|AUZ, reuogeiedoU.S. Patent Sul. 11, 2017 Sheet 15 of 15 US 9,701,492 B2US 9,701,492 B2 1 AUTOMATED TRUCK UNLOADER FOR UNLOADING/UNPACKING PRODUCT FROM. ‘TRAILERS AND CONTAINERS, PRIORITY STATEMENT & CROSS-REFERENCE. ‘TO RELATED APPLICATIONS ‘This application is a continuation of U.S. patent appli tion Ser. No. 15/2S6488 entitled “Automated Truck Unloader for Unloading’Unpacking Product from Trailers and Containers,” filed on Sop. 6, 2016, in the name of Tim CCriswell, and which issued on Jan. 3, 2017, a8 US, Pat. No, 9,533,841: which sa continuation of US. patent application Ser. No, 14/159,297 entitled “Automated Truck Unloader or Unlooding/Unpacking Product from Trailers and Cone ner." filed on Jan, 20, 2014, in the name of Tim Criswell, and which issued on Sep. 6, 3016, as U.S. Pat. No. 0.434. 558; which claims prioiy from U.S. Patent Application No. 61/754,630, entitled “Automated Truck Unloader for Unloacing/Unpacking Product from Trailers and Contain- ers" filed on Jan. 20,2013, in the name of Tim Criswell all, ‘of whieh are hereby incomporated by reference forall pur- poses, TECHNICAL FIELD OF THE INVENTION This invention relates, in general, to a machine for han dling products and, more paricularly, to a system and method for automated unloading and unpacking. whieh ‘employ an automatic track wnloader designed to unload and unpack product, such as boxes or eases, from tales and BACKGROUND OF THE INVENTION Loading docks and loading bays are commonly found in large commercial and industeial buildings and provide arrival and departure points for large shipments brought .0 fr taken away by trucks and vans. By way of example, a tuck may back into a loading bay sue thatthe bumpers of the loading bay contact the bumpers on the trailer and a gap js created between the loading bay and the truck. A dock levaler or dock plate bridges the gap berwoen the track and ‘2 warehouse 10 provide a fixed and substantially level, surface. Power moving equipment, such at forklifts or ‘conveyor belts is then utilized to transport the eanzo oa the warehouse to the track, Human labor i thea employed to stick the cargo in the track, This is particularly tue ofthe unloading of product, such as boxes or cases, from a truck, ‘or freight container, for example. These systems are ‘designed to maximize the amount the cargo unloaded while minimizing the use of human Tabor to both protect and ‘extend the life of the workforce. Resheing human labor however, has proven dificult as the configuration and size of the boxes inthe trick or freight container cannot be easily predicted in advance. Therefore, a need still exists for Improved truck unloading systems that further reduce the use of human labor when unloading or unpacking product, such as cases and boxes, fom tiles aad containers SUMMARY OF THE INVENTION Trwould be advantageous to achieve a system and method or attomated unloading and unpacking of product, such as ‘eases and boxes, that Would enable a taler or conser to be fully unloaded using minimal or no human labor thereby minimizing the time to unload the tuck and the need for 0 o 2 ‘human capital, I would also be desirable to enable a robotic solution that would address this problem by unloading and Uunstocking trailers and containers with boxes and exses of varying sizes. To better address one or more of these feoncerss, in one embodiment, an automatic truck waloader or unfoading'mpecking product, such as boxes or cases, from tnilers and containers is disclosed, A mobile base structure provides a suppor framework for a drive subas- sembly, conveyance subassembly, an industrial robot, & distance measurement subassembly such as a camera wile- ing an adaptive depth principle, and a control subassembly. Under the operation ofthe control subassembly, an industrial robot having a suetion cup-based ripper arm selectively removes boxes from the taler and places the boxes oa powered transportation path. The contcol subassembly coor inates the selective articulated movement of the industrial robot and the activation of the drive subassembly based ‘upon the distance messurement subassembly. detecting ‘objects, including boxes, within a detection space, and ‘mensions ofthe trailer provided tothe control subassem- bly: These systoms and methodologies utilizing the present aulomiatc truck unloader therefore maximize the amount the product and cargo unloaded while minimizing the use of human labor to both protect and extend the life of the workforce, These and other aspects of the invention will be ‘apparent Urom and elucidated with reference tothe embodi- ‘mens described hereinafter BRIEF DESCRIPTION OF THE DRAWINGS Por a more complete understanding of the features and advantages ofthe present invention, reference is now made to the detailed description ofthe invention along with the accompanying Figures ia which corresponding aumerals the different figures refer to comesponding. parts and in whieh FIG. 1 sa side elevational view with panal eross-section| ‘fone embodiment of an automat tick unloader postion: fing product within a tniler of a truck FIG. 2A stop plan view ofthe automatic ruck unloader ithystrated in FIG. Ts FIG. 2B is a side elevation view of the antomatic truck ‘unloader illustrated in FIG. 1, FIG. 2C isa second side elevation view of the sutomatic snuck unlooder ilustated in FIG. 1 FIG. 2D is rear elevation view of the antomatic truck vunloader illustrated ia FIG. 1 FIG. 2E is front clevation view of the automatic truck vunloader illustrated in FIG. 1; FIG. 2F isa front perspective view ofthe automatic truck ‘unloader illustrated in FIG. 1, FIG. 2G isa rear perspective view of the automatic truck vnloaderilusirated in FIG. 13, FIG. 3A isa perspective view of «portion of the sutomatic truck loader of FIG. 1 and in particular a detailed view of fone embodiment of a mobile base; FIG. 3B is a second perspective view of the mobile base illustrated in FIG. 34; FIG. 4s a front perspective view of one embodiment of anend efector, which fonms a portion ofthe automate tuck ‘unload FIG. 4B is a front elevation view of the end effector in Aside elevation view ofthe end effector in FIG. 4a; IG. 4D is a rear perspective of the end effector in FIG. 4a;US 9,701,492 B2 3 FIG, 4B isa cross-section view of the end effector along, line 4E-4E of FIG, 4C;, TIG, SAisa side elevation view of one embodiment of aa ‘end elector gripping a box in a first gripping positon: IG, SB isa sie elevation view ofthe end elfeetor in FIG. 5A gripping a box in a second gripping postion, FIG, SC isa side elevation view ofthe end elleeor in FIG. 5 gripping a box in third gripping position: FIGS. 6A through 6D are schematic disgrams of one ‘operational embodiment of the automatic track unloader of FIG. 1 unpacking boxes inthe taler of de truck; FIGS. 7 through 7D are op plan views of an opemtional ‘embodiment corresponding to the operation shown in FIGS, 6A through 6D: FIG. 8 isa schematic block diagram of one embodiment of the automatic ease loader, FIG. 9 isa schematic block diagram of one embodiment ‘of the automatic ease loader in additional detail, FIG. 10 isa schematic diagram of one embodiment of a robot contaller which forms portion ofthe automatic case Toader; TG. 11 ie a schematic diagram of one embodiment of 3 sistance measurement subassembly whieh forms & compo- nent of the automatic case loader, and FIG. 12 is a schematic diagram of another embodiment of 2 ‘distance measurement subassembly which forms a com- ponent ofthe automatic tre loader. DETAILED DESCRIPTION OF THE, INVENTION While the making and using of various embodiments of the present invention are discussed in detail below, it shold be appreciated that the present invention provides many applicable inventive concep, which can be embodied in & Wide variety of specific contents, The specific embodiments liscussed herein ate merely ilustative of specific ways to ‘make and use the invention, and do not delimit the scope of the preset invention, Referring initially o FIG, 1, therein is depieted an auto~ matic trick unloader that is schematically illustrated and enerlly designated 10 and may be refered to as the sulomiatic ruck unloader, This automatic truck unlooder 10 js uilized in systems and methods for automated truck unloading and packing of trailers, containers and the ike. A tractor trailer 12 having an aperator cab 14 is towing a teailer 16 having a front wall 18, two side walls 20A, 20B (best seen in FIGS, 6A through 6D, for example), floor 22, 2 ceiling 24, and a rear access opening 26 accessible duc to an ‘open door. A bumper 28 ofthe trailer 16 is hacked up to 3 Joading bay of loading dock 32 such that the bumper 28 touches a bumper 34 of te long bay 30. A dock plate 36 bridges the gap beeen the Noor 22 and a deck 38 of the Joading dock 32, “As will be deseribe in further detail hereinbelow, under the supervision of distance measurement subassembly oF subassemblies that are components of the automatie truck unloder 10, the automatic truck unloader 10 maneuvers and drives automatically into the trailer 16 (© a position as proximate as possible to the front wall 18. It should be appreciated that although an operator is not depicted as ‘operating the automate trick unloader 10, an operator may be at location 40, an operator platform, although unneces- sary. The automatic track unloader 10 operates indepen- ‘dently of an operator and an operator is only necessary for ‘certain types of troubleshooting, maintenance, and the like telescoping conveyor unit 42 is connected to the automatic o 4 truck unloader 10. A stream of product 46, in the for standard cases or boxes 46A-46H, whic may be of any imeusion, is being supplied by the automatic tuck ‘unloader upon removal thereof, as shown by arrow 48. in particular, the automatic tnick unloader 10 has already ‘unloaded boces 46 through 46E, and thers, for example atthe intersection of the product 46 proximate the front Wall 18 and the floor 22. As showa, the automatic ruck wnloader 10 is unloading box 46f, which willbe followed by boxes 446g, 46h and other boxes 46. The automatic truck unloader 10 alternates between unloading the product 46 and driving Torward to create more opportunities to grip the product 46 between the foot wall 18 and the automate truck unloader 10 until he trailer 16 sat least partially unloaded of product 46, PIG. 2A through FIG. 2G and FIG. 3A through FIG. 3B. pict the automatic truck unloader 10 in further detail. A mobile base $0 supports a drive subassembly 82, a convey- ance subassembly $4, an industrial robot 86, a positioning subassembly §8, a safety subsystem 60, and a control stibassembly 62, which inferomnects the drive subassembly 52, conveyance subassembly $4, industrial robot $6, posi- tioning subassembly S8, and safety sbsystem 60, The ole base 0 inclides frontend 64 and a rer od well as sides 68, 70, a surface 72, and an undercarriage 74 The drive subassembly 82 is coupled to the undercarriage 74 of the mobile hase 0 t0 provide mobility. As will be iscussed in further detail hereinbelow, drive wheel assem- bles 78, 80, are disposed on the undercarriage 74 proximate {o the sides 70,68 respectively, A universal whee! assembly 2isdisposedon the undercarriage 74 more proximate to the rear end 66 and centered hesween the sides 68, 70, respec- tively. In combination, wheel assemblies 78, 80, 82 provide Torward and reverse drive and steering, Retractable stabil zation assemblies 84, 86 are also dispoved on the wdercar- rique 7 proximate othe intersection of the end 64 and side 68, the intersection of end 66 and the side 7, respectively. As alluded to, in a forward or reverse drive and steoring ‘operation, such as moving ino or out of the tile 16, drive ‘whoo! assemblies 78, 80 and the universal whee! assembly ‘8Zare actuated and in contact with the deck 38 of the loading dock 32 while the retractable stabilization sssemblies 84, are ‘withdraw fre contact with the deck 38 in a position close {o the underarriqge 74, On the other band, when the ‘aulomiatic ruck unloader 10 conducting product loading for unloading operation, such as during. the use of the industrial robot 86, the retractable stabilization assemblies 84, 86 are positioned in contact with the deck 38 t0 anchor the automatic trick unloader 19. It should be appreciated that althoogh the automatic truck unloader 10" is being described relative to unloading and unpacking. the auto- ‘matic truck unloader 10 may also be used to load and pack product, including boxes and cases ito a trier "The conveyance subassembly 84 is disposed on the sar: ‘ace 72 of the mobile base $0 to provide a powered trans- portation path 88 operable for messuring, separating, car ying, and stacking, as required by the application and job assignment of the automatic truck unloader 10, boxes fom the ear end 66 the front end 64 proximate tthe industrial robot 56, As shown, the powered transportation path $8 includes @ posvered roller conveyor 90 having roller ele- ‘ments 92 which deliver the boxes 46 t0 a landing platform 94 where manipulation by the industrial robot $6 is initiate. It should be appreciated that although only a single powered roller conveyor 90 is display, the powered transportation path 88 may include any combination and type of conveyors, elevators, stackers, and bypasses and the particular combi-US 9,701,492 B2 5 nation of components selected for the powered trnsports- tion path 84 will depend upon the particular Boxes or other produet and application of the automatic tek unloader 10. “The eonveyance subassembly 84 as well asthe telescop- ing conveyor unit 42 may also each be equipped with 2 series of end stop photo eyes to adjust the rate of automatic flow of product through the telescoping conveyor unit 42 and the conveyance subassembly 84. Such an implements tion provides a steady and continuous flow of product, maintains proper box or product separation, and prevents unnecessary gaps between the product and product backups ‘and jams. ‘A telescoping conveyor interfice 104 couples the roller conveyor 90 of the conveyance subassembly 4° the telescoping conveyor unit 42 and the rest of a pick belt system Which may be atthe warehouse associated with the Joading dock 32. Auto-follow eieuity associated with the telescoping interface 104 of the telescoping conveyor unit and the conveyance subassembly 54 may utilize fiber optic sensors atthe last boom of the telescoping coaveyor unit 42 dotct reflective tape at the edge of the conveyance subas- sembly to cause the telescoping conveyor unit 42 to extend ‘nd retract to maintain the proper position with respect to the ‘automatic trick unloader 10. In another embodiment, the telescoping conveyor unit 42 may be passive and the auto- matic uck unloader 10 may provide the force to extend or retract the telescoping conveyor unit 42 “The industrial robot 56 is disposed atthe frontend 64 and adapted to provide selective aieulated movement ofan end ‘effecior 130 between the landing platform 94 of the powered transportation path 88 and a reachable space 132 such that the industrial robot 56 is operable to place the product 46 in the reachable space 132. The end effector 190 includes ripper arm 134 adapted for manipulating. product with ‘cooperating and complementary grapplers 136A, 136B. It should be appreciated that any type of end effector 130 may be employed the industrial robot and the choice of end ‘effecior 130 will depend upon the product 46 and specific futomatic trick unlooder 10 application. By way of ‘example, the gripper arm 134 with grapplers 136A, 1388 is preferred for unloading and unpacking boxes 464-46. I ‘should be understood, however, thatthe product 46 may be ny type of good such as other cased or non-cased objects resuiring loading. ‘In one implementation, the industrial rbot $6 includes seven segments 130, 138, 140, 142, 144, 146, 148 joined hy six joints 150, 152, 154, 186, 158, 160 to furnish selective articulates! movement having six degrees of freedom. More particularly. the referenced reachable space 132, as best see In FIGS. 2F and 2G, is defined by the movement of the industrial robot 56 which provides rotation about six sxex including rotary movement of the ene industrial robot 56 ‘about a primary vertical axis rotary movement of segment 146 having a tower strctore about horizontal exist provide ‘extension and retraction ofthe sepment 144 having a boom, fm rotary movement of the boom arm abou the horizontal ais 1 provide euising and lowering of the boom arm; and selective rotary movement about three wrist axes. The positioning subassembly $8 is dispersed throughout the mobile base 50. distance measurement subassembly 179 disposed at the front end 64 of the mobile base 50 measures distance and determines the presence of objects ‘within a detection space 172 whichis located infront ofthe font end 64, In one embodiment, the detetion space 172 ‘and the reachable space 132 at leat partially overip. The distance measurement subassembly 170 assists the auto- matic tuck unloader 10 with forward and reverse movement 0 o 6 and the repositioning of the automatic ease loader 10 10 ‘reste additional empty reachable space 132 forthe place- ‘meat of the produet 46. Further, the distance measurement stibassembly 170 assists withthe coordination and operation fof the industrial robot §6, Distance and measurement infor ‘mation gathered by the distance measurement subassembly 170 is provided 10 the coateol subassembly 62. ‘As will be discussed in further detail hereinbelow, the distance measurement subassembly 170 may be a laser rrnge finding apparatus operating on a time-oF-fight mea sureient basis or priniple or a camera system operating on ‘an adaptive depth principle, It should be appreciated, how- ever, that other types of distance measurements are within the teachings of the present invention, By Way of example, and not by way of limitation, the distance measurement subassembly may’ include a laser range finding apparatuses, cameras, ultrasonic measurement apparatuses, inclinom- ler, and combinations thereot. Similar to distance mea surement subassembly’ 170, distance measurement subas- semblies 174, 176 are respectively disposed at the sides 68. 70. The distance measurement subassemblies 174, 176 each ‘may include in one embodiment, detection spaces. (not illustated) to provide measurement and distance informa- ‘ion to the control subassembly 62 during traverse move- ‘meat operations of the automatic track unloader 10 The safety subsystem 60 is distributed and mounted tothe mobi base 0. The safety subsystem 60 may include light ‘ower whieh provides a quick indiation of the current status fof the automatic truck unfoader 10 to an operator and a ‘wireless operator alert system 182 which contacts pagers oF cellular devices of individuals through a wireless network. Also a cage and railing may be included around the operator atform 40 to provide additional safety to the operator. mengency buttons may be located throoghout the automat truck unloader 10 to provide for instant and immediate power down. Front safety seanners 188 and rear safety Scanners 190 may be positioned at the frontend 64 andl the war end 64 to protect the automatic truck unloader 10, people, and product during « collision with an obstacle Additionally, the front safety bumpers 188 and the rear safety bumpers 190 may include detectors that detect the presence of an object al cause an automatic power down during a collision, Side safety scanners, although not ills- twated, may also be utilized, Tt should be appreciated that other safety features, such as safety bumpers, may be integrated into the automatic truck unloader 10, ‘The control subassembly 62, which i also distributed and ‘mounted to the mobile base $0, may include contro station having a user interface disposed at the side 70 near the ‘operator platform 76. As discussed, the drive subassembly 2, the conveyance subassembly 84, the industrial rbot 86. the positioning subassembly $8, and the safety subassembly 60 ar interconnected und in communication with te contol subassembly 62 via a network of concealed and sheathed cables and wires. With this arrangement, the contol subas- sembly 62 may coordinate the manta and automatic opert- tion of the automatic truck unloader 10. Further, a visual detection subsystem 162 is associated with the end effector seh thatthe visual detection subsystem 162 captures aa image of a produet space for processing by the contol subassembly, as will be discussed further hereinbelow. ‘A main frame 200 is constrcted of welded stel tubing ‘includes tubular sections 202, 204, 206, and 208 which provide # rectangular framework. The tubular sections 202- 208 are supported by tubular sections 208, 210, 214, 216 218, and 220, which sugment and further support the rectangle framework, All mounting plates, seh as mountUS 9,701,492 B2 7 ing plates 222, 224 and bolt oles necessary to bold the ‘various components attached tothe mobile base are included ‘nthe main frame 200. The lage plates 222, 224 hold, for ‘example, the control station and the user interface in postion ‘while providing counter weight for the automatic truck tnloader 10 as well a balance with respect tothe industrial robot 56 disposed proximate to the mounting plates 222, 224. Additional covnter weight may be supplied by trictor ‘weights mounted proximate to the rear end 66, which also serve to add additional support and integrity to the mia Fame 200, Drive wheel assemblies 78, 80 include pair of font drive wheels 252, 250 disposed proximate tothe front end 64 and, more particularly, proximate the intersection of tubular sections 208, 214 and tubular sections 204, 214, respectively. Respective AC motors 254, 256 with double reduction gearboxes 258, 260 supply power thereto. The AC ‘motor 284 with double reduction gearbox 258 is disposed adjacent to the tubular section 214 and the front drive whoo) 280, Similarly, the AC motor 256 with double reduction _genrbox 260 is disposed adjacent tothe tubular setion 214 ‘andthe front drive wheel 282, The universal wheel assembly 182 includes a rear secting wheel 284 mounted to a frame 286 disposed proximate to the ear end 66. ‘With reference tothe operation of the drive subassembly 52 in conjunction with the mobile base 50, the deve wheel assemblies 78,80 and universal whee! assembly 82 provide mobility long the length ofthe automatie truck unloader 10. ‘The AC motors 284, 256 with the respostive double reduc- tion gearboxes 258, 260 drive the front drive wheols 250, 282. In particular. each font drive whecl 280, 282 is independently driven to provide the ability to turn and t0 provide a pivoting drive mode. The universal wheel assem- bly 82 provides a rear steering wheel 284 to provide ‘enhanced steering capability Jor the automatic truck Uunloader 10, In addition t providing forward and reverse ‘capability, the one embodiment, the drive subassembly 82, may fumish a averse drive system providing the capability to move the entire automatic track wnloader 10 perpendicn- Jar to a trailer or fixed abjeet atthe loading dock 32 ‘Referring now to FIGS, 4 through 4F, wherein a gripper am 134 ofthe end effector 130 having grippers 136, 13613 Js depicted, More particularly the gripper arn 134 includes ‘a main frame 280 having suppor frame 281 for attachment to the indusiial ruhot $6, A moving frame ball 282 is selectively pivotally coupled to the main frame 280 by Joint 284 1 provide a range of motion between approxi- mately a parallel presentation between the main frame 280 ‘and the moving frame 282 and approximately an orhogonal presentation between the main frame 280 and the moving frame 282, The joint 284 comprises hinge pairs 286, 288 secured by hinge pins 290, 292. Self aligning ball bearings 294, 296 are respectively located at cach of the hinge pairs 286, 288 to provide for improved engagement berween the ‘main frame 280, moving frame half 282 and the surface of product, such asa case or box. A shoulder fastener 298 and bull joint end rod 300, whieh also couple the mainframe 280 1p the moving frame half 282, actuate the selective pivotal movement of the moving frame half 282 relative to the fame 280, ‘Moltiple suetion cups 302 are associated with a fice 303 ‘of the main frame 280 and, similarly, multiple suction cups 304 aro associated witha face 30 of the moving fame half 282, Bulk head fitings 306 secure the multiple suction eups 304 10 the moving frame half 282. Within the main frame 280, a paddle cylinder 308, straight fiting 310, and an elbow ‘iting 312 secure vacuum manifolds 314, 316 within the 0 o 8 ‘main frame 280 in pneumatic communication with the suction cups. 302, 30M. Vacuum sensors 318, 320 are ‘mounted in the main frame 280 proximate to the suction ‘cups 302, A visual detection subsystem 162 is housed in the ‘main frame and inclndes a camera assembly 322, lighting assembly 324, and a camera mount 326, Referring now to FIGS. 4 through SC, in an unloading ‘opemtion, the vacuum sensors 318, 320 senses for the presence ofa box 46. In response to detecting an object, such fsa box 46 having a top T, the vacuum sensors 318, 320 fcuate the vacwm manifolds 314, 316 0 generate a vacuum force to grip the object via the suction cups 302, 304, As shown in FIGS. SA through SC, the industrial robot ‘36 and gripper arm 134 may grip a box 46 in any one of three positions depending on the demands of the unloading oF Unpacking operation. A hottomsfront grip (FIG. SA), a ‘op-font grip (FIG. SB) ora top grip (FIG. 8C) may be use. TFIGS, 6A through 6D depict one opertional embodiment of the automatic truck unloader 10 unloading or unpacking boxes 46A-468 in the tuiler of the tuck, Referring now to FIG. 6A, boxes 464-46G are positioned in an empty trailer of the trick to be unloaded by the automatic tack unloader 10, More specifically, the distance measurement subassem- bly 170 continuously determines the position of the auto- ‘atic truck unloader 10 within the taller and the presence ‘of objects, inclading boxes 46, is known, When beginning @ removal operation, the automatic truck unloader 10 identi lies product space, eg., space of boxes 464 through 465, ‘including a product skyline 330. and chooses an active quadrant 332 t0 hogin unstacking operations. The active (quadrant 432 is a subspace ofthe product space. Addition- ally, using the visual detection subsystem 162, a protruding object is identified and removed. In FIG. 6, the removal is initiated by removing box 468, With reference to FIG. 6B, the unloading and unpacking continves in the active quadrant 332 at newly defined skyline 332 with the removal of box 464, then 46C. As the raduct space diminishes, the active quadrant i readjusted fnd within each new skyline, the boxes are removed based ‘on protrusion, which in one embodiment may be height. With reference to FIG. 6C. this methodology continues with the skyline 330 and activity in quadrant 332. In this active quazunt 332, box 46), dhen 46K. then 461 are removed. The ‘Sequential removal of boxes continues until the tale of the truck is almost empiy as shown in FIG. 6D, with boxes 46D through 468 remaining to be removed. FIGS. 7A through 7D, wherein one embodiment of an automated truck unloading system and methodology are ‘llystated for the automat tick unloader 10 ofthe present invention. Initially, as shown in FIG. TA, the tale 16 is positioned under the power ofthe trctor trailer 12 at the loading bay 30 of the loading dock 32 approximate to the deck 38 where the automatic truck ualoader 10 is working. ‘The trailer 16 is reversed, set-up, and activated in a usual ‘manner. The dock plate 36 is deployed from the loading bay 30 into the trailer 16 to provide a bridge. Thereafter, the twiler 16 is inspected for significant damage that may interfere with the automated losing operations of the auto- ‘matic ruck ualoader 10, Additional inspection may include ensuring the railris reasonably centered within the loading bay 30 and ensuring the deck 38 is clear oF any obstructions. At this time, by way of further safety measures, © kingpin Tockout may be installed to prevent a driver from acciden- tally pulling out the trailer 16 fom the loading bay 30 when the atomatic teuck unloader 10 is operating within the trailer 16, The kingpin lockout or similar safety proeautions protect both the operator andthe equipment and ensures thatUS 9,701,492 B2 9 the wheels of the trailer 16 are chocked and will not roll during the use of the automatic trick unloader 10 Continuing 0 refer © FIG. 7A, once the trailer 16 is positioned in the loading bay 30, the automatic truck Unloader 10 is moved in front ofthe rear access opening 26 fof the tmiler 16. The automatic track unloader 10 utilizes ‘either a manual or automatic reverse mode to assist the ‘operator (whether on the automatic trick unloader 10 or at a remote location) in backing the automatic truck unloader 10 upto the telescoping conveyer unit 42 in a postion that js square thereto. The conveyance subassembly $4 of the ‘automate truck unloader 10 is then coupled tothe elescop- Jing conveyor unit 42, AV tis time, asthe dock plate 36 has been positioned from the deck 38 to the trailer 16, the automatic truck unloader may’ be advanced into the interior Of the taller 16 proximate the row of boxes 344), whic forms one ofthe rows of boxes 444e through 344) with 34a being proximate to the font ofthe truiler 16 and 344) at dae ‘With reference to FIG. 7B, the automatic tick unloader 10 has advanced forward into the trailer 16 and, in one ‘embodiment, the positioning subassembly $8 and, in par- ticular, the distance measurement subassembly 170 contins- ‘ously “determines the position of the automatic truck unloader 10 within the wailer 16. More specifically, several measurements are made. The position and angle of the suiomatie truck unloader 10 are measured with respect the Sdewalls 204, 208 and an iateroe with defined thereby. Also, measurements are made with respect to @ near wall, ‘within the trailer 16 and the floor 22. The near wal being the closce of th front wall 18 ofthe tile or the edge formed by product 46, eg. cases, positioned within the trailer 16 “The angle relative tothe Noor 22 proximate to the automatic teuck unloader 10 is measured as the automatic ruck unloader traverses the dock plate 36 and moves into the trailer 16, Tn one embodiment, following suecesstul te vers, the angle relative tothe Roor 22 may be assumed t0 be constant. Inthis way. as the automatic track unloader 10 moves, the position af the automatic truck unloader 10 relative ‘objects in its environment, including boxes, is known and, the automatic track unloader 10 may adjust operation appro- Prately. Adjustments in operation may include, but are not Timited to, the operation of the industrial robot $6, the ‘operation ofthe conveyance subassembly $4, andthe actus tion of the drive subassembly $2. The position of the sidewalls 204, 208 and the near walls utilized to determine the position of the automatic track unloader 10 along the length of the trailer 16. the position across the width of the teailer 16, and the automatic ease loaders angle relative to the sidewalls 204, 208 or yaw. The measurements also ‘determine the positon of the automatic trck unloader 10, relative to the Noor 22 of the trailer 16. To assist the fulomatie truck unload 10 in determining position within the tnler 16, in one implementation, the automatic truck tunloader 10 is programmed with the dimensions of the tesiler 16, ‘Additionally in one embodiment, the automatic truck unloader 10 is programmes withthe reachable space 132 of the industrial robot $6. As illustrated, once the automatic ttuck unloader is positioned proximate (othe row of boxes $344) such that the removal of boxes 46 within the trailer 16 ‘may bogin and the boxes 46 aro within the reachable space 132 ofthe industrial robot §6, the automatic track tnloader 10 tops advancing. Continuing to refer to FIG. 7B, boxes 46 are conveyed to the telescoping conveyor wit 42 form the ‘conveyance subassembly $4 und this stream of boxes 46 is, 0 o 10 presented by the industrial obot $6 during the unloading! ‘unpacking operation. With selective articulated movement through the reaehuble space 132, the industrial robot 56 removes the boxes 46 from the trailer and sequentially solets the box to be removed hased on how far particular boxes in an active quidmnt protrude. ‘As depicted in FIG. 7C, the automatic track unloader 10 thas completed unloading multiple horizontal rows M4B- 4 ot ces Abn aan ulead [omental ‘unloading of the boxes 46 by the industrial robot 56 is ‘temporarily interrupred in response fo the distance measure- meat subassembly 170 detecting the absence ofthe boxes 46 ‘within the reachable space 132. Further, with this informa tion being available wo the contol subassembly 62 0 signal ‘may be sent othe conveyance subessemibly 54 to slow down fr temporarily alt the powered transport of the product 46. As a result ofthe completion of the removal of boxes in ‘arow, such as roves M4B-344), the automatic truck ualoader 10 porioically drives forward and repositions to refresh the reachable space 132 suc that the automatic trick unloader 10 is positioned proximate to the wall of placed boxes 46, leg, the product space, in order that the removal of addi tional boxes 46 against the wall of placed boxes 46 i within the reachable space 132 of the industrial robot $6. During the repositioning of the automatic truck unloader 10, the Telescoping conveyor unit appropriately advances, while ‘maintaining contact with the conveyance subassembly 54, t0 aecommodate the ne position ofthe automatic caseload ‘unloader 1, Referring to FIG. 7D, the iterative unstacking operations ‘and repositioning of the automatic tmick unloader 10 eseribed in FIGS. 7A through 7C continues and the taler 16 is empty. With respect to FIG. &D, the tesiler 16 is completely empty with boxes 46, including rows MA-344) being removed, and the attomatic truck unloader 10 is reversed toa postion entirely on the deck 38, Therealler, the trailer 16 emptied of boxes may leave the loading dock 32 and fresh full ailer may then be positioned atthe loading bay 30 and unloaded inthe manner described herein, FIG, 8 depicts one embodiment of the automatic truck vnloader 10 in which the automatic trick unloader 10 is schematically depicted to include 2 computer-based archi- fecture including a processor 380 coupled to a bus 382 having _tansmiterreceiver circuityy 354, outputs 386, inputs 388, memory 360, and storage 362 interconnected therewith, in one embodiment, the control assembly 192 includes the memory 360, which is accessible 10 the pro- cessor 360, The memory 360 inchudes processor-executable ‘nstactions tht, when executed cause the processor 380 10 ‘execute instructions for unpacking or unloading boxes 46 or cher objects, By way of example and not by way of Jimitation, the instructions may be directed specifying. « search operation lo identity a product skyline within a product space. Then, search operation may be specified t0 ‘dentify an active quadront within the produet space and a search operation may be specified to klentify « protrading product within the active quadrant atthe product skyline ‘Upon the identification ofthe protruding prot, a removal ‘operation may be specified to unload the product eome- sponding 10 the protruding product and instructions ealew- Jated for removing the product corresponding to the pro- trading product, These instructions may’ iteratively continue FIG. 9 depicts one embodiment of the automatic teuck unloader 10 and the control signals associated therewith, Which may be deployed across the computer architectare shown in FIG. 9, for example, The ilstratd components coordinate the various functions and operations of the auto-US 9,701,492 B2 un matic truck unlosder 10, The user interface 194, operational ‘environment database 370, programmable logic controller 372, obot controller 374, and distance measurement sub- assemblies 170, 174, 176 are interconnected. The dive subassembly $2, conveyance subassembly $4, as repre- sented by contol 376 for conveyors/levators, and saety controller 378 are connected to the programmable logic ‘controller 372, Finally, the industrial robot 6 is connected to the robot controller 374, In one implementation, the user Jmerface 194, operational environment database 370, and progrimmable logie controller 372 are part of the control Subassembly 62 and the robot contolee 374 forms 8 portion ‘of the industrial robot 86, The safely controller 388 is Included inthe safety subsystem 60 and provides operation to the aforementioned components of this subsystem. The user interface 194 provides user control and interae> tion With the tomatic truck unloader 1. The wser interface 194 may utilize icons in conjunetion wth labels anor text to provide navigation and a full representation of the infor mation and actions available to the operator. In addition 19 Toading opentions, user interactions may be related ‘maintenance, repairand other routine actions which keep the ‘automatic trick unloader 10 in Working order or prevent trouble from arising. ‘The operational data environment database 370 includes ‘data abot the reachable space 132 ofthe industrial robot 56, stacking methodology data, product information as well as information abou the standard sizes of trailer. The product information may be stored in the operational data environ- ment database 380, gathered by the conveyance subassem- bly 84 as previonsly diseussed, or gained By a combination thereof. By having the standard sizes of trailers pre-oaded, ‘operator time is saved from having 10 enter this data and Performance ofthe automatic tack unloader 10 is improved with this additonal information. By way of example, Tables 1 Il present exemplary examples of type of trailer data that the automatic trek unoader 10 may utilize in detemnining position and product placement TABLE L Insite tide Door Tate lade eae tah Ope Gsm) 3m 25m 28m) eam ca a rT a er (sem (stm G3m 8m) Gham) atm ‘wolee TABLE I aren ems comme Door Rew Tail oping Foor Cate Onl ovel pees Hee Copcty “Wem Ne Sm) 26m) 2m) rsa) ebm IR BES ose sot noe (37m) 7m) G3m) 3am) Cam) Tm 0 o 12 ‘TABLE I-continued Tralee Opening Fase Cubic Oremll_ Oven “ype ke Hg Capacey_— Wis) ig Weige er ee ee ee (asm 27m G2m) elem Gem) tm Wales The programmable logic controller 372 coordinates over- all operation and switches between various modes of oper ‘ion including. manual and automatic. The programmable logic controller 972 also provides forthe high-level ealew- Jation and coordination required during automatic operation Tor items such as the curent unload quadraat unloading and steering angel calculations during automatic navigation, The robot controller 374 controls the motions of the industrial robot $6 through built in inputs and outpats wire ‘through the industrial robot 56 and the end effector 130. It should be appreciated that although a particular architecture is presented for the control of the automatic ease loader, other architectures are within the teachings of the present invention. By way of example, any combination of hard ‘ware, software, and finmware may be employed. By way of further example, the distribution of contol may differ Irom that presente! herein, ‘Tn.ono operation embodiment, the programmable logic controller 372 accesses the dimensions of the teil fom the ‘operational envinyament database 372. The operator 40 has Jndicated through the user interface 194 which typeof trailer thas arrived atthe docking bay 30. Alternatively, the distance ‘measurement subassembly 170 is operable to detect this information, The distance measurement subassemblies 170, 174, 176 relay distance and positon data to the program able logic contoller 952 which uses this information t0 send control signals to the robot controller 374, the drive ‘Subassembly 52, the controle 372, andthe safety controller 378. Additionally, the programmable logic controller 372 receives contol signals, which are inputs into the behavior process, from each ofthese components. Constant updates ‘nd status information are provided to the operator by the programmable logie controller 382 through the user inter Tice 194, FIG. 10 depicts one embodiment of the robot controller 372 which forms a portion ofthe automatic truck unloader 10, The essence of the robot control 372 isa roo system or control program 380, which conteos te industrial robo 56. Te coutrol program 380 ean he operated by the operator 40 by means of an operating service 362 in communication with the user interface 194 and reveives input data (as well fas provide instrctions as appropriat) from the operational environmental database 370, programmable logie controller 372, and distance measurement subassembly 170 by means ff a driver 384. It should be appreciated, thatthe indepen- sence of the rbot controller ¥24 may vary. In one iniple- ‘mentation, the robot controller 374 may’ be under the contol ofthe programmable logie controller 374. In another imple- ‘mentation, as illustrated, the robot controller 374 is more fonomows and may inchide features such as direct con- feetion tthe user interface 194, "According to one embodiment, between the driver 384 ‘and the control program 380 is provided an independent data processing lay in the form ofa frame program 386, which ‘contol the robot movements, snd unit 388 for automatedUS 9,701,492 B2 13 ‘or eventcontrolled strateuy or behavioral selection on the basis ofthe stetes and signals which occur. User application programs, event-coatrlled strategy selections and sensor programs in the frame program 386 ean be programmed by the operator 40 and directed by a robot program 399, which ‘monitors the balance and implementation of mantial and automatic control ofthe industial robot 56 IG. 11 depicts one embodiment of a distance measure= rent subassembly, ie. laser measurement sensor 400. A staging circuit 402 causes pulsed laser 404 to transit ight pulses while causing the rotation of a ight deflecting device 406 via controller 408 which muy be equipped with a rotational means and a motor. The angular position of the Tight deflecting device 406 is continuously communicated t0 the staging circuit 402 bythe conteoller 408. Light pulses are transmitted into the detection space 172 via the transmiter Jens and the mirtors associated with the light deflection device 406. More particulary, when the rotary mieror ofthe light defletion device 46 is driven by the controller 408 10 ‘execute a continuous rotry movement, the staging circuit 4402 causes the pulsed laser 404 to transmit ight pulse. The Fight pulse is transmitted into the detection space 172 and is reflected from an object, s0 that finely a received pulse enters into a photo receiving arrangement 410. In this manner the fight reaches the photo receiver arrangement 410 ‘after a ight transit time tof 2d, where dis the space inthe ‘object from the apparatus and e isthe spoed of light. “The time « bewween the ransnission snd reception af the fight pulse is measured with the aid of a comparator 412 having time interval computer funetionality. On transmitting the light pulse, counter fnetion within the comparator 412 is triggered and is stopped again by the photo receiver arrangement 410 via the comparator 412 on receiving the Tight pulse from the detection space 172 ‘A comesponding electrical signal is formed and applied via comparator 412 fo a ser scanner contolle 414, signal to noise processor 416 and a detector 418, which analyzes the signal for objects and inthe instant example determines that an object is present. The task of the signal 9 noise processor 416 isto contol the detection threshold indepen- dence on the received noise level. This control ensures 3 ‘constant fale alarm rate with varying illumination situations land object reflection factors. The signal to noise processor 416 makes available this information to the laser seannee ‘controller 414, The laser scanner controller 414 performs peak value calculations based on the data from the eom- parator 412, the signal to noise procestor 416, and the dector 418, ‘As the laser scanner controller 414 knows the instant nous angular position of the Hight pulses by way of com ‘munication with the staging cicuit 402, the laser scanner ‘contoller 414 determines the location of the object and ‘her navigational properties. The laser seanner controller 4414 is adapted to forward this information to other eompo- TIG. [2isaschemati diagram ofa distance measurement subassembly 170, which is depicted asa three dimensional G-D) measurement system 450, which ineludes an iami- nation assembly 482 and an image capture subassembly 454 that together utilize a laser andlor infrared-based camera ‘application employing an adaptive depth principle. The ‘tkimination assembly 482 includes a light source 486 and @ transparency 458, which may include a postive image on 2 transparent suppor with a various sors of fixed, uncorre- Tated pattems of spots, for example. “The light source 456 transilliminates transparency 458 with optical radiation so as t project an image of the spot 0 o 14 pattem that is contained by the transparency onto object 6A, which is depicted as a product, but may also include various envizonmental information about the storage con. tainer. The imoge capture assembly 484 eaptures an imageot the pattem that is projected by illumination assembly 452 ‘onto the prodict 464. The image capture assembly 454 may include objective optics 464, which focus the image onto an image sensor 460, Typically. the image sensor 460 inclides areeilinear aay of detector elements 462, soch as 8 CCD for CMOS-based image sensor aay As should be appreciated, although the illumination assembly and image capture assembly are shown as hed in ‘fixed spatial relation, various other positioning techniques ‘may be employed to ereate a dynamic relationship therebe- tween. Moreover, the threedimensional x,y, 7 axis may be employed inthis regard. To generate a 3D map of object or product 46A, including the environment, a processor, Which ‘may incorporated inlo processor 350 or associated there- with, compares the group of spots in each ares of the captured image t the reference image in order to find the ‘most closely-matching group of spots in the reference ‘mage. The relative shift between the matching groups of spots in the image gives the appropriate x,y ar Z-dtection shift of the area of the captured image relative to the reference image. The shift in the spot pattem may be measured using imag correlation or other image matching computation methods that are known in the art. By way of ‘example, the operation prineiple may include an intrared ‘adaptive depth principle utilizing laser or infared cameras ‘While this invention has been described with reference 10 illustative embodiments, this description i not intended to be construed ina limiting sense. Various mociicaions and combinations persons skilled in the art upon reference to the deseription 1s therefore, intended hate appended claims encompass ‘any such modifications or embodiments ‘What is claimed is 1. An automatic truck unloader for unlooding/unpacking product from a tile, the automatic truck unloader com- prising ‘a base structure having frst and second ends ‘an industrial robot disposed atthe second end ofthe base f distance measurement subassembly disposed at the second end, the distance measurement subassembly configured to determine presence of objects within detection space: «4 contro subassembly mounted fo the base structure, the ‘control subassembly being in communication with the industrial robot, and the distance measurement subas- sembly. the control subassembly coordinating the selective articulated movement ofthe industrial robot ‘and the aetivation ofthe drive subassembly based upon the distance measurement subassembly detecting ‘objects within the detection space; and the contro assembly including a memory accessible 1 3 processor, the memory ineluding processon-exccutable instructions that, when executed cause the processor specify a searel operation to ently a product skyline ‘within a product space, specify a search operation to ident ‘within the product space, specify 9 search operation 10 identify a protruding Product within the active quadrant at the product skyline, and amaetive quadrantUS 9,701,492 B2 15 specify a removal operstion (0 unload the product corresponding to the protruding product. 2, The antomatic tick unloader a recited in claim 1 wherein the industrial robot further comprises selective ‘articulated movement of an end ellector between the pow ‘ered transportation path and a reachable space such thatthe industrial robot is operable to handle the product in the reachable space, the end effector further including a suction ‘eup-based gripper arm. 3. The automatic tick unloader as recited in claim 2, wherein the end effector further comprises a suction cup” based gripper arm adapted for manipulating a box with ‘cooperating rappers that rip the box in gripping position flected from the group consisting of parallel to the box and perpendicular tothe box. 4. The automatic tuck unloader as rected in claim 2, ‘herein the end elfector further comprises: ‘main frame having a support frame for ataehment to the industrial robot: ‘a moving Irame half seletively pivotally coupled 10 the ‘main frame by a joint to provide a range of motion hhetween approximately a parallel presentation between the main frame and the moving frame and approx ‘mately an orthogonal presentation between the main fame and the moving frame; «first plurality of suction cups associated with «fice of the main frame: 1 second plurality of suction cups associated with a face ‘of the main frame; ‘vacuum manifold housed within the main frame in ‘pneumatic communication with the fist and second pluralities of suetion cups; Vacuum sensor mounted inthe main frame proximate t0 the frst plurality of suction cups the vacttm sensor, response 10 deieeting an object, being configured to fctiate the vacitim manifold and generate a vacuum force to grip the object; and 1 visual detotion subsystem housed in the main frame, the visual detection subsystem being configured to capture an image ofthe proc space for processing by the control subassembly 5, The automatic rick unloader a recited in claim 1 Jurter comprising a visual detection subsystem associated With the end effector, the Visual detection subsystem being ‘configured fo capture an image of the product space for processing by the contol subassembly. 6, Tho aniomatic nick unloader as rected in elaim 5, wherein the visual detection subsystem fhther comprises 3 ‘camera and Tighting assembly for digitally imaging. the product space 7. The automatic truck unloader as recited in claim 1, wherein dhe product space is @ subspace of the detection space '8, The automatic tek unloader as recited ia claim 1 ‘wherein the active quadrant is @ subspace of the product space 9, The automatic tick unloader as rected in claim 1, Jarther comprising a drive subassembly coupled to the base structure, the drive subassembly including a plurality of ‘wheels having @ pair of front drive wheels disposed prox ate to the second end, the pair of front drive wheels being powered by respective AC motors with double reduction _Benrboxes, 10, The automatic trck unloader as reited in claim 1 ‘wherein the base stricture further comprises a mobile base structure 0 o 16 11, The automatic tick unload 2s recited in ela 1, a conveyance subassembly disposed on the mobile base strtc- ture, the conveyance subassembly including 2 powered transportation path operable for transporting product between the first end and the second end, 12, The automatic track unloader 98 recited in claim 1 ‘wherein the conveyance subassembly further comprises @ ‘conveyor having a telescoping conveyor interface for ou pling the automatic case Ioader to a telescoping conveyor 13, The automatic tuck unloader as reited in elim 1, wherein the distance measurement subassembly comprises & threesdimensional measurement system operating on an adaptive depth measurement principle. 14, The automatic tuck unloader as recited in claim 1, wherein the distance measurement subassembly comprises a device selected ftom the group consisting of laser range finding apparatuses, cameras, ultrasonic measurement sppa- ratuses,inclinometers, and combinations thereat 15, The aulomatie tuck unloader as recited in claim 1 ‘wherein the dimensions of the trailer are programmed into ‘the control subassembly 16, An automatic truck unloader for unloading/anpacking product from a trailer, the automatic truck unloader com- prising a base structure having fist and second ends; ‘an industrial robot disposed atthe second end ofthe base structure, the industrial robot providing selective niculated movement of an end effector between the powered transportation path and a reachable space sch that the industrial robot is operable to handle the product in the reachable space: the end effector including a tion cup-based gripper arm ‘adapted for manipulating a box with cooperating arap- plers that grip the box in gripping postion selected from the group consisting of parallel to the box and perpendicular to the box: -means for determining presence of objects within a dete tion space, wherein the detection space andthe reach able space atleast panially overlap: 1 control subassembly mounted tothe base stricture, the ‘control subassembly being in communication with the industrial robot, and the distance measurement subas- sembly, the control subassembly coordinating the selective articulated movement of the industrial robot ‘and the setivation ofthe deve subassembly based upon the distance measurement subassembly detecting ‘objects within the detection space, and dimensions of the trailer provided to the control subassembly’: and the contro assembly including a memory accessible 10 3 processor, the memory including processor-exccutable Instructions that, when executed cause the processor speci a search operation to deat a praduct skyline ‘within a product space, specify a search operation to identify an active quadrant ‘within the product space, and specify 0 search operation 10 identify a protruding product within the active quadrant at the product skyline 17. The automatic truck unloader as rected in claim 16, further comprising a visual detection subsystem assoviated with the end effector, the visual detection subsystem being configured to capture an image of the product space for processing by the contol subassembly. 18, An aulomatie truck unlonder for unlooding/anpacking product fom a trailer, the automatic truck unloader com riUS 9,701,492 B2 17 a base structure having first and second ends: ‘an industrial robot disposed at the second end ofthe base ‘zeture, the indistrial robot providing. selective Ariculated movement of an end effector between the ‘powered transportation path anda reachable space such {hat the industrial robot is operable to handle the product in the reachable space; the ead effector including a main frame having a support ime for attachment fo the industrial robot ‘a moving frame half seletively pivotally coupled to the ‘main frame by a joint to provide a range of motion between approximately parallel presentation between the main frame and the moving frame and approxi- imately an orthogonal presentation between the main ame and the moving frame: a first plurality of suetion cups associated with a fave of the main frame: a second plurality of suetion cups associated witha face fof the mainframe: 4 vacuum manifold housed within the main frame ‘pacummatic communication with the first and second plurals of suetion eups ‘Vacuum sensor mounted in the main frame proximate to the first plurality of suction cups, the vaeuum sensor, in response to detecting an objec, being configured to fetate the vacuum manifold and generate a vacuum force to grip the object: 4 visual detection subsystem housed in the main frame, the visual detection subsystem being configured to capture an image ofthe product space for processing by ‘control subassembly 18 distance measurement subassembly disposed at the second end, the distance measurement subassembly configured to determine presence of objects within a detection space, wherein the detection space and the reachable space at least partially overlap the control subassembly mounted to the hase stucture, the contol subassembly being in communication with the industrial robot, and the distance measurement sulbassombly, the conto subassembly coordinating the selective articulated movement of the industrial robot ‘and the etivation ofthe drive subassembly based upon the distance measurement subassembly detcting ‘objects within the detection space, and dimensions of the trailer provided to the control subassembly: and the control assembly including a memory accessible 1 a procestor, the memory incliding processor-excettable instnictions that, when executed eause the procestoe specify a search operation to identify product skyline within a product space, specify a search operation to identi ‘within the produet space, and specify search opemtion to identify a protruding product within the active quadrant atthe product slline 19. The automatic trick unloader 3s recited in claim 18, further comprising & visual detection subsystem associated with the end effector, the visual detection subsystem being configured to capture an image of the product space for processing by the contol subassembly. inactive quadrant