Abstract: A data analytics system has been developed for conveyor systems that helps to monitor items along conveyors as well as assist in monitoring the status or health of equipment of the conveyor. Tracking items in conveying systems within a facility can be difficult. Conveyed items can become jammed, lost, or even fall off the conveyor. Based on input from motors and sensors along the conveyor, the data analytics system is able to detect lost or jammed items. With input from the sensors, the data analytics system is also configured to detect equipment wear and damage. The data analytic system further aggregates data from the various conveyor systems to generate statistics as well as other information that can be used for modeling and simulating the conveyor system. The aggregate data can be used to generate measures such as travel efficiency analytics for reporting purposes.

Abstract: A system includes a camera, a robot, and a management system. The camera is configured to capture one or more images of a material handling environment. The material handling environment normally includes one or more items. The robot is at least in part configured to move along a travel path relative to the items, and the robot is configured to pick the items. The management system is configured to monitor the material handling environment through the images from the camera. The management system is configured to determine dynamically multiple picking solutions for the items in real-time while the robot moves along the travel path.

Abstract: A system includes a camera system configured to capture images of items in a tote. The camera system is configured to interface with an artificial intelligence (AI) system to process images in a variety of ways to support picking and/or placing operations by a robot. Such processing includes planning pick points for items, applying a filter to an image, and planning movement of a robot to perform a picking operation. The camera system further includes an augmented reality tag (ARTag) that is used to calibrate cameras and other devices. The system is configured to train the AI system based on images collected by the camera system wherein the camera system randomly varies the camera settings for each image.

Abstract: An automated material handling system includes a robot configured to handle one or more items and an operator device. The robot is configured to send an alert to the operator device in response to a fault by the robot in handling at least one of the items. The robot is configured to receive instructions from the operator device. The robot is configured to remedy the fault based on the instructions. A camera configured to capture an image of the fault in handling the items by the robot, and the robot is configured to send the image of the fault to the operator device with the alert.

Abstract: An AMU system includes an Autonomous Mobile Unit (“AMU”), base station, lanyard, and Warehouse Management System (“WMS”) configured to communicate with one another over a network. The AMU includes a microphone configured to receive verbal commands from an individual. The individual can further provide verbal commands through the base station and the lanyard when worn by the individual. The lanyard can also provide a geo-fence around the individual where the AMU slows down to enhance safety.

Abstract: A palletizing system includes one or more palletizers. A database is configured to maintain a stacking pattern library containing multiple stacking patterns for the palletizers. A computer is operatively connected to the database. The computer is configured to automatically select a stacking pattern for a selected one of the palletizers. In other words, the computer is configured to change the stacking pattern of one of the palletizers without changing the other palletizers. The database is configured to maintain unique palletizer identifiers used for identifying individual palletizers to promote expandability.

Abstract: A system includes one or more robot arms configured to pick and/or place items into totes. The system is designed to reduce overall downtime. In the system, if the robot arm is unable to pick and/or place items into the tote, the system routes the tote to a human operator who rearranges the items in the tote in such a way that the robot arm is more likely to be able to pick the items from the tote. The system further includes an artificial intelligence (AI) system that determines whether totes are able to be picked by the robot arm. The AI system further monitors the operation of the robot arms and human operators for training purposes. The data from picking and rearranging operations are used to train the AI system.

Abstract: A forklift includes a carriage that has one or more forks. A drop camera assembly is coupled to the forklift. The drop camera assembly includes a drop camera. The drop camera is configured to move from a retracted position to an extended position. The drop camera is located proximal to the forks when in the retracted position. The drop camera is positioned away from the carriage when in the extended position so as to image one or more obstacles under the forks of the carriage. The drop camera assembly further includes a carriage camera that is secured to the carriage. The carriage camera is configured to show alignment of the forks relative to a pallet or other object to be handled by the forklift.

Abstract: A forklift system includes a steering system. The steering system includes a steer arm. A controller is operatively coupled to the steering system, and a homing system is configured to determine a home position of the steering system. The homing system is configured to determine the home position by rotating the steer arm in a single direction, such as in a clockwise or counterclockwise direction. In one variation, the homing system includes at least two sensors and at least two encoders. The sensors are configured to detect a target coupled to the steering system, and the encoders are configured to measure the angular rotation of the steering system.

Abstract: An AMU system includes an Autonomous Mobile Unit (“AMU”), base station, lanyard, and Warehouse Management System (“WMS”) configured to communicate with one another over a network. The AMU includes a microphone configured to receive verbal commands from an individual. The individual can further provide verbal commands through the base station and the lanyard when worn by the individual. The lanyard can also provide a geo-fence around the individual where the AMU slows down to enhance safety.

Abstract: A system has been developed to facilitate hands-free autonomous control of material handling equipment or vehicles, such as forklifts and pallet trucks. The system has been designed to facilitate visual tracking by the automated vehicle and further facilitates voice commands. In some use cases, visual tracking is only used, and in other cases only voice commands are used. In other cases, both visual tracking and voice commands are used to control the material handling vehicle. For visual tracking, one or more cameras are configured to capture one or more images of a fiducial. In one case, the vehicle moves, turns, and/or stops based on the movement of the fiducial. For voice control, the operator provides voice commands via a voice controller. The voice controller converts the voice commands to vehicle control commands that are sent to a remote receiver unit (RRU) in the vehicle.

Abstract: A sideband communication system has been developed for a conveyor system. A controller card controls the operation of a conveyor zone and communicates information about each conveyor in the conveyor zone. The controller card is assigned to control and monitor the operation of one or more of these zones of conveyors. The cards of adjacent zones are daisy-chained together to facilitate communication with one another and with other systems like a programmable logic controller (PLC). In addition to the standard controller area network (CAN) communication protocol, the controller cards further communicate amongst themselves using a sideband communication protocol that is outside the realm of the standard CAN communication protocol. The sideband communication protocol allows the cards to communicate with each other without interfering with normal network communications which provides additional capabilities such as automatic card self-identification.

Abstract: A roller detection system has been developed in which a controller card is configured to automatically detect the type of motorized drive roller being used in the conveyor system. With this automatic detection capability, the controller card is able to automatically control the motorized drive roller without the need for manual reprogramming or reconfiguration. For instance, the controller card can detect whether the motorized drive roller is controlled through an analog or digital signal as well as the voltage required to control or power the motorized drive roller, and based on this roller type detection, the controller card is automatically configured to control the motorized drive roller. The system is further adapted to facilitate a sensor-less or photoeye-less zero pressure (ZP) conveyor system. The controller card is configured to support a secondary power source that allows the motorized drive roller settings during e-stop and other power loss conditions.

Abstract: A data analytics system has been developed for conveyor systems that helps to monitor items along conveyors as well as assist in monitoring the status or health of equipment of the conveyor. Tracking items in conveying systems within a facility can be difficult. Conveyed items can become jammed, lost, or even fall off the conveyor. Based on input from motors and sensors along the conveyor, the data analytics system is able to detect lost or jammed items. With input from the sensors, the data analytics system is also configured to detect equipment wear and damage. The data analytic system further aggregates data from the various conveyor systems to generate statistics as well as other information that can be used for modeling and simulating the conveyor system. The aggregate data can be used to generate measures such as travel efficiency analytics for reporting purposes.

Abstract: An AMU system includes an Autonomous Mobile Unit (“AMU”), base station, lanyard, and Warehouse Management System (“WMS”) configured to communicate with one another over a network. The AMU includes a microphone configured to receive verbal commands from an individual. The individual can further provide verbal commands through the base station and the lanyard when worn by the individual. The lanyard can also provide a geo-fence around the individual where the AMU slows down to enhance safety.

Abstract: An AMU system includes an Autonomous Mobile Unit (“AMU”), base station, lanyard, and Warehouse Management System (“WMS”) configured to communicate with one another over a network. The AMU includes a microphone configured to receive verbal commands from an individual. The individual can further provide verbal commands through the base station and the lanyard when worn by the individual. The lanyard can also provide a geo-fence around the individual where the AMU slows down to enhance safety.

Abstract: A system includes a robot configured to load and/or unload from a location, such as a cargo carrier or building. The robot includes a base unit that has a transport system to move the base unit. A mast extends from the base unit, and the mast has a mast conveyor. The mast is configured to extend and retract. An End of Arm Tool (EoAT) is coupled to the mast in a rotatable manner. The EoAT includes an EoAT conveyor configured to move a cargo item to and from the mast conveyor. A gripper mechanism is configured to move between a retracted position where the gripper mechanism is clear of the cargo item on the EoAT conveyor and an extended position where the gripper mechanism is able to grip the cargo item.

Abstract: A robotic shuttle system includes a rack system and one or more shuttles. The rack system includes a rack and a shuttle frame. The rack has storage locations for containers containing items. The shuttle frame has rails disposed along the rack. The shuttle includes a powertrain, container transfer mechanism, and a robot arm. The power train is configured to move the shuttle along the rails of the rack and on a surface outside of the rack system. The container transfer mechanism is configured to transfer the containers between the rack and the shuttle. The robot arm extends from the shuttle to transfer the items between one of the containers on the shuttle and a container in a container holder of the shuttle.

Abstract: A robotic shuttle system includes a rack system and one or more shuttles. The rack system includes a rack and a shuttle frame. The rack has storage locations for containers containing items. The shuttle frame has rails disposed along the rack. The shuttle includes a powertrain, container transfer mechanism, and a robot arm. The power train is configured to move the shuttle along the rails of the rack and on a surface outside of the rack system. The container transfer mechanism is configured to transfer the containers between the rack and the shuttle. The robot arm extends from the shuttle to transfer the items between one of the containers on the shuttle and a container in a container holder of the shuttle.

Abstract: A drive system for a high torque mechanical load includes a power supply, a controller, and a high torque electric motor. The electric motor includes a rotor that is oriented eccentrically relative to a stator. In one form, the electric motor has a crankshaft that transmit the torque to the mechanical load. In other variations, the electric motor includes at least two electric motor lobes with opposite stroke positions to provide a smoother output at higher speeds. During operation, the rotor is magnetically attracted to the energized electromagnet. With the rotor attracted to the electromagnet in the stator, the rotor contacts or comes in close proximity to the stator at a contact area. The close proximity between the rotor and stator at the contact area allows very large magnetic forces to be utilized to produce torque without increasing the size or weight of the electric motor.