Method and apparatus for automated powered pallet

A trackway-based powered pallet system comprising:

• a) a first trackway;
• b) a second trackway intersecting said first trackway at an angle at an intersection;
• c) at least one powered pallet assembly supported for rolling movement on one of said first trackway and said second trackway, said powered pallet assembly including:
• i) a frame formed for support of a load,
• ii) a plurality of load-supporting first wheels rotatably mounted to said frame for rolling support of said frame on said first trackway;
• iii) a plurality of load-supporting second wheels rotatably mounted to said frame at an angle to said first wheels for rolling support of said frame on said second trackway,
• iv) a power drive assembly carried by said frame and coupled to drive at least one of said first wheels and coupled to drive at least one of said second wheels,
• v) said first wheels being further mounted to said frame in a position causing said first wheels to be disengaged from said second trackway when said pallet assembly is supported for movement on said second trackway by said second wheels, and
• vi) said second wheels being further mounted to said frame in a position causing said second wheels to be disengaged with said first trackway when said pallet assembly is supported for movement on said first trackway by said first wheels.

A method of constructing a powered pallet assembly comprising the steps of:

• a) providing a pallet frame having a load-supporting surface thereon;
• b) rotatably mounting a first set of load-supporting wheels to said frame;
• c) rotatably mounting a second set of load-supporting wheels to said frame;
• d) securing a power drive assembly to said frame and coupling said power drive assembly to drive at least one wheel of said first set of load-supporting wheels and to at least one wheel of said second set of load-supporting wheels;
• and
• e) during said mounting steps, mounting said first set of load-supporting wheels to said frame in a position to be disengaged from a second trackway when said frame is rollingly supported on said second trackway by said second set of load-supporting wheels, and during said mounting steps, mounting said second set of load-supporting wheels to said frame in a position to be disengaged from a first trackway intersecting said second trackway when said frame is rollingly supported on said first trackway by said first set of load-supporting wheels.

A method of controlling the movement of a powered pallet assembly on a trackway, said trackway including at least one intersection of a first trackway and a second trackway and a movable switch assembly at said intersection formed for switching of movement of said pallet assembly between said first trackway and said second trackway, said movable switch assembly being coupled to a controller for control of movement thereof, and said trackway further including at least one movable control member positioned proximate said intersection, said method comprising the steps of:

• controlling operation of a motor carried by said pallet assembly using said movable control member by:
• selectively moving the position of said movable control member from a remote location using a controller coupled to communicate control signals to said movable control member;
• selectively moving said switch assembly using said controller to a desired switch position;
• and
• sensing a position of said movable control member by a sensor carried by said pallet assembly and controlling operation of said motor in response to the position of the control member which is sensed to stop said motor while said pallet assembly is on said first trackway and to start said motor after said step of moving said switch assembly to cause said pallet to move along said second trackway.