PLC controlled robotic carton unloader
A robotic carton unloader is configured for automatic unloading of cartons from a carton pile. In various embodiments, the robotic carton unloader may include a mobile body, a movable robotic arm attached to the mobile body and comprising an end effector, a conveyor system having a front portion, and a lift attached to the mobile body and the front portion of the conveyor system to move the front portion. In some embodiments, the conveyor system may comprise a front-end shelf conveyor configured to be moved (e.g., raised, lowered, laterally moved, tilted, etc.) relative to the body of the unloader. The front-end shelf conveyor may be moved separately for positioning below the robotic arm in order to receive cartons from a small distance. The front-end shelf conveyor may be moved via various mechanisms (e.g., scissor lifts, pedestal lifts, etc.).
1. A robotic carton unloader for unloading cartons in a carton pile, the robotic carton unloader movable across a floor, the robotic carton unloader comprising:
a mobile body;
a movable robotic arm attached to the mobile body and comprising an end effector at an end thereof, the end effector configured to unload cartons from the carton pile;
a conveyor system having a front portion, the conveyor system configured to convey cartons deposited thereon by the moveable robotic arm; and
a lift attached to the mobile body and the front portion of the conveyor system, the lift configured to move the front portion of the conveyor system relative to the floor,
wherein the front portion of the conveyor system is a front-end shelf conveyor having one or more kick rollers operatively attached across a nose of the front-end shelf conveyor for interacting with cartons during the unloading thereof,
wherein a PLC is configured to execute a command to cause the one or more kick rollers to be stationary to stabilize a wall of the carton pile when the one or more kick rollers are determined to be in contact with the wall of the carton pile and the end effector is determined to be unloading cartons from the carton pile.
2. The robotic carton unloader of claim 1 wherein the one or more kick rollers are operably coupled to a motor of the robotic carton unloader to rotate the one or more kick rollers of the front-end shelf conveyor.
3. The robotic carton unloader of claim 2 wherein the one or more kick rollers are operatively coupled to the motor by a chain drive.
4. The robotic carton unloader of claim 3 wherein the one or more kick rollers are operatively coupled to more than one chain drive with each chain drive operably engaged with one or more kick rollers.
5. The robotic carton unloader of claim 3 wherein the motor is an internal motor coupled to a bottom side of the front-end shelf conveyor.
6. The robotic carton unloader of claim 3 wherein the internal motor is configured to drive the rotation of the one or more kick rollers in a backward direction in various speeds to cause cartons within the unloading area to move onto the front-end shelf conveyor.
7. The robotic carton unloader of claim 2 wherein when the one or more kick rollers are rotating and in contact with the carton wall, the one or more rotating kick rollers are configured to kick cartons upwards to loosen a carton wall of the carton pile.
8. The robotic carton unloader of claim 2 wherein the one or more kick rollers comprise protrusions on an exterior of the one or more kick rollers, and when the one or more kick rollers are rotating and the protrusions contact cartons, the protrusions bump the cartons upwards and onto the front-end shelf conveyor.
9. The robotic carton unloader of claim 8 wherein the protrusions form a hex shape having points that form a plurality of lobes.
10. The robotic carton unloader of claim 8 wherein the protrusion is a hard material.
11. The robotic carton unloader of claim 1 further comprising the PLC operatively engaged with a motor and configured to control one or more of an activation, a speed, and a rotation of one or more of the one or more kick rollers.
12. The robotic carton unloader of claim 11 wherein the PLC is configured to execute a command to cause the one or more kick rollers to begin turning causing contacted cartons to be bumped upwards and moved onto a conveying surface of the front-end shelf conveyor.
13. The robotic carton unloader of claim 11 wherein the PLC is configured to execute a command to cause the one or more kick rollers to begin turning when ploughed into contact with cartons on the floor, the rotating one or more kick rollers causing contacted cartons on the floor to be bumped upwards and moved onto a conveying surface of the front-end shelf conveyor.
14. The robotic carton unloader of claim 11 wherein the PLC is configured to selectively activate one or more kick rollers.
15. The robotic carton unloader of claim 14 wherein the PLC is configured to continually activate internal motors engaged with one or more of the kick rollers once the robotic carton unloader has been moved within the unloading area.
16. The robotic carton unloader of claim 1 wherein at least one of the one or more of the rotatable kick rollers are configured to extend from the front-end shelf conveyor to contact cartons.
17. The robotic carton unloader of claim 1 wherein at least one of the one or more of the rotatable kick rollers are configured to retract towards the front-end shelf conveyor to move away from the cartons.
18. The robotic carton unloader of claim 1 wherein the lift is a support configured to place the one or more front kick rollers against cartons of a carton wall of the carton pile.