Automated package unloading system

Abstract

An apparatus for unloading packages (103) from a container (106), the apparatus comprising: a conveyor system (109); a supporting frame (209) mounted on the conveyor system, the supporting frame being substantially perpendicular to a length of the conveyor system; and an end effector assembly (112) coupled to the supporting frame and being moveable about a horizontal axis relative to the supporting frame, the end effector assembly comprising: a manifold plate (203) extending along a vertical plane that is generally parallel to the supporting frame; a gripping component (115) coupled to and extending outwardly from the manifold plate along the horizontal axis relative to the supporting frame, the gripping component being configured to engage with one or more of the packages stacked in the container; and one or more sensors (303), the one or more sensors being configured to determine a distance between the end effector assembly and the packages.

Therefore, the following is claimed: 
     
         1 . An apparatus for facilitating an unloading of packages ( 103 ) from a container ( 106 ), the apparatus comprising:
 a conveyor system ( 109 );   a supporting frame ( 209 ) mounted on the conveyor system, the supporting frame being substantially perpendicular to a length of the conveyor system; and   an end effector assembly ( 112 ) coupled to the supporting frame and being moveable about a horizontal axis relative to the supporting frame, the end effector assembly comprising:
 a manifold plate ( 203 ) extending along a vertical plane that is generally parallel to the supporting frame; 
 a gripping component ( 115 ) coupled to and extending outwardly from the manifold plate along the horizontal axis relative to the supporting frame, the gripping component being configured to engage with one or more of the packages stacked in the container; and 
 one or more sensors ( 303 ), the one or more sensors being configured to determine a distance between the end effector assembly and the packages. 
   
     
     
         2 . The apparatus of  claim 1 , wherein the gripping component comprises a gripping interface ( 403 ) coupled to a spring-loaded compensator ( 406 ). 
     
     
         3 . The apparatus of  claim 2 , wherein the gripping interface comprises at least one of a vacuum suction cup, a foam member, or an electrostatic plate. 
     
     
         4 . The apparatus of  claims 1  to  3 , further comprising a pair of horizontal members ( 206 ) coupled generally perpendicular to the supporting frame and being laterally offset from one another, wherein the end effector assembly is coupled to the supporting frame via the pair of horizontal members, and wherein each of the pair of horizontal members comprises at least one of a pneumatic actuator, a hydraulic actuator, or an electrical actuator. 
     
     
         5 . The apparatus of  claims 1  to  4 , further comprising a controller ( 121 ) being configured to drive movement of the end effector assembly into and out of the container. 
     
     
         6 . The apparatus of  claims 1  to  5 , further comprising a vacuum source ( 118 ) coupled to the gripping component. 
     
     
         7 . The apparatus of  claims 1  to  6 , wherein the conveyor system is moveable relative to the horizontal axis of the supporting frame, and movement of the end effector assembly is driven by movement of the conveyor system. 
     
     
         8 . The apparatus of  claims 1  to  7 , wherein the conveyor system comprises a conveyor frame ( 609 ), a plurality of rollers ( 606 ) supported on the conveyor frame, and a conveyor belt supported on the rollers for movement relative to a length of the conveyor frame, each of the plurality of rollers being rotatable about a rotational axis that extends in a direction generally transverse to a longitudinal axis relative to the length of the conveyor frame 
     
     
         9 . The apparatus of  claims 1  to  8 , wherein a proximate end of the conveyor system comprises a scoop component ( 603 ). 
     
     
         10 . A method, comprising:
 determining, via one or more controllers ( 121 ), a distance between an automated package unloading system ( 100 ) and one or more packages ( 103 ) packed in a container ( 106 ), the automated package unloading system being coupled to a conveyor system ( 109 );   driving, via the one or more controllers, movement of an end effector ( 112 ) of the automated package unloading system towards the one or more packages into the container according to the distance;   attaching one or more gripping components ( 115 ) of the automated package unloading system to the one or more packages;   pulling the one or more packages by driving, via the one or more controllers, the movement of the end effector out of the container; and   releasing the one or more packages from the one or more gripping components onto the conveyor system for transport to another location.   
     
     
         11 . The method of  claim 10 , wherein the end effector is movable in a reciprocating motion relative to a length of the conveyor system. 
     
     
         12 . The method of  claim 10  or  11 , wherein the one or more gripping components attach to the one or more packages via at least one of a vacuum pressure or an electrostatic force. 
     
     
         13 . The method of  claims 10  to  12 , further comprising driving, via the one or more controllers, the movement of the conveyor system into the container. 
     
     
         14 . The method of  claims 10  to  13 , wherein the one or more packages comprise a plurality of packages stacked on top of one another, and further comprising:
 leaving a bottom layer of packages in the container; and 
 scooping, via the conveyer system, the bottom layer of packages onto the conveyor system. 
 
     
     
         15 . The method of  claims 10  to  14 , further comprising obtaining sensor data from at least one sensor ( 303 ) coupled to the end effector the automated package unloading system, wherein determining the distance is based at least in part on the sensor data.