Perception-based robotic manipulation system and method for robotic truck unloader that unloads/unpacks product from trailers and containers

A robotic truck unloader for unloading/unpacking a plurality of product, the robotic truck unloader comprising:

• a mobile base structure having first and second ends;
• a drive subassembly coupled to the mobile base, the drive subassembly including a plurality of wheels for steering and driving the mobile base;
• a conveyance subassembly disposed on the mobile base, the conveyance subassembly including a powered transportation path configured for transporting the plurality of product between the first end and the second end;
• a pivoting front conveyor disposed at the second end of the mobile base, the pivoting front conveyor having a deck conveyor unit integrated therewith, the deck conveyor unit configured for transporting the plurality of product to the conveyance subassembly, the pivoting front conveyor configured to handle the plurality of product;
• the pivoting front conveyor being fixedly secured to the robotic truck unloader for each of pivoting, extension, and retraction relative to the robotic truck unloader;
• the deck conveyor unit including a plurality of conveyor subassemblies;
• a plurality of sensors positioned to monitor the pivoting front conveyor;
• a control subassembly located in communication with the pivoting front conveyor, the deck conveyor unit, and the plurality of sensors, the control subassembly coordinating selective articulated movement of the pivoting front conveyor, the control subassembly coordinating selective actuation of each of the plurality of conveyor subassemblies of the deck conveyor unit;
• and
• the control subassembly including a memory accessible to a processor, the memory including processor-executable instructions that, when executed cause the processor to:
• specify a search operation within the pivoting front conveyor via the plurality of sensors to identify a product in-handling located on the pivoting front conveyor, and
• specify, in response to the product in-handling located on the pivoting front conveyor, an automatic error handling operation, the automatic error handling operation including the selective actuation of each of the plurality of conveyor subassemblies of the deck conveyor unit.

A robotic truck unloader for unloading/unpacking a plurality of product, the robotic truck unloader comprising:

• a mobile base structure having first and second ends;
• a drive subassembly coupled to the mobile base, the drive subassembly including a plurality of wheels for steering and driving the mobile base;
• a conveyance subassembly disposed on the mobile base, the conveyance subassembly including a powered transportation path configured for transporting the plurality of product between the first end and the second end;
• a pivoting front conveyor disposed at the second end of the mobile base, the pivoting front conveyor having a deck conveyor unit integrated therewith, the deck conveyor unit configured for transporting the plurality of product to the conveyance subassembly, the pivoting front conveyor configured to handle the plurality of product;
• the pivoting front conveyor being fixedly secured to the robotic truck unloader for each of pivoting, extension, and retraction relative to the robotic truck unloader;
• the deck conveyor unit including a plurality of conveyor subassemblies;
• a control subassembly located in communication with the pivoting front conveyor, the deck conveyor unit, and the plurality of sensors, the control subassembly coordinating selective articulated movement of the pivoting front conveyor, the control subassembly coordinating selective actuation of each of the plurality of conveyor subassemblies of the deck conveyor unit;
• and
• the control subassembly including a memory accessible to a processor, the memory including processor-executable instructions that, when executed cause the processor to:
• specify a search operation within the pivoting front conveyor via the plurality of sensors to identify a product in-handling located on the pivoting front conveyor, and
• specify, in response to the product in-handling located on the pivoting front conveyor, an automatic error handling operation, the automatic error handling operation including the selective actuation of each of the plurality of conveyor subassemblies of the deck conveyor unit.