DESC:FORM 2
The Patent Act 1970
(39 of 1970)
&
The Patent Rules, 2005

COMPLETE SPECIFICATION
(SEE SECTION 10 AND RULE 13)

TITLE OF THE INVENTION

AN AUTOMATED INTELLIGENT RAIL GUIDED VEHICLE (i-RGV) FOR FREE ROLLER CONVEYORS

Toyota Kirloskar Auto Parts Pvt Ltd
Plot No # 21, Bidadi Industrial Area,
Bidadi, Ramanagara District,
Karnataka 562109, India
An Indian Company

The following specification particularly describes and ascertains the nature of this invention and the manner in which it is to be performed:

TECHNICAL FIELD
[001] The present invention relates to a Rail guided vehicle for transferring goods from one location to another, more particularly an intelligent automated rail guided vehicle (i-RGV) for free roller conveyors to transfer goods from one location to another.
BACKGROUND
[002] Currently manufacturing industries continuously facing the challenge of cost reduction through various productivity improvement activities. Looking at the uncertain volumes, increase in labor cost, fluctuating demands, changes in customer needs etc., it’s a challenge for the manufacturing industries to not only to level up but also to sustain the current condition at industrial shop floor. Further. increase in manpower cost year on year plays a significant role in increase in product cost. Therefore, manpower must be efficiently used for better productivity. Further, the manufacturing industries faces a major lose in man hour. The man hours mainly include conveyance or transfer of goods from one location to another location. Therefore, to overcome the man hour loses spent in part conveyance or transfer from one area to another area. The manufacturing industries uses several equipment’s such as tow motors, automatic guided vehicles (AGV) and conveyor systems.
[003] Further, some of the manufacturing industries uses power conveyors to transfer the heavy pallets, which requires very high investments and high running cost. These power conveyors are not only cost consuming solution, but also involves a difficult process of maintenance and they are less flexible for change over (layout, process, parts etc.). Further, most of the conventional conveyors require multiple motors throughout the conveyor’s length, thereby makes the power conveyor a costly affair. Further, the conventional powered conveyors use multiple sensors which are placed throughout the conveyors to detect the parts or pallets. These sensors communicate with each other through wired communication, which is complex and expensive and results in poor flexibility. Therefore, there is a need for low cost and eco-friendly power conveyors to transfer heavy pallets.

OBJECTS
[004] The principal object of the embodiments herein is to disclose [001] an intelligent automated rail guided vehicle (i-RGV) for free roller conveyors to transfer goods from one location to another.

SUMMARY
[005] Accordingly, the embodiments herein provide an automated Intelligent Rail Guided Vehicle (i-RGV) for free roller conveyors to transfer goods from one location to another. The i-RGV includes a chassis, wherein the chassis equipped with 4-wheels for self-balancing the i-RGV on rails, wherein the rails are mounted below a free roller conveyor. Further, the i-RGV includes a drive control unit, wherein the drive control unit includes a drive motor with a rack and pinion gear to enable a liner motion of the i-RGV to move forward and reverse on the rails. Further, the i-RGV includes a guide unit, wherein the guide unit includes a set of cam follower bearings for Y axis control and a set of cam follower bearings for Z axis control to ensure the liner motion of the i-RGV. Further, the i-RGV includes a front sensor unit, wherein the front sensor unit indicates a source position at which the i-RGV initiates its liner motion. Further, the i-RGV includes a rear sensor unit, wherein the rear sensor unit indicates the destination position at which the i-RGV stops its liner motion. Further, the i-RGV includes a towing pin unit, wherein the towing pin unit connected with a towing motor which enables the towing pin unit to lock and unlock a jig automatically, whenever the i-RGV senses pallets or heavy parts. Further, the i-RGV includes a communication unit, wherein the communication unit configured to establish a wireless communication with a control panel to remotely monitor and control the drive control unit. Further, the i-RGV includes a battery unit, wherein the battery unit supplies the power to the drive control unit to enable the i-RGV to move on the rails forward and reverse.
[006] In an embodiment, the i-RGV is mounted on the rails below the free roller conveyor to enable the liner motion of the i-RGV to move the free roller conveyor to transfer the goods from one location to another.
[007] In an embodiment, the rails are designed with Z axis flexibility to adopt and adjust movement height of the rails depending on floor undulations or conveyor height fluctuations.
[008] In an embodiment, the Z axis adjustment enhances ease of joining rails, when one intended to extend the i-RGV movement by increasing number of free rollers conveyers.
[009] In an embodiment, teeth of the pinion gear in mesh with the teeth of the rack to enable the liner motion of the i-RGV to move forward and reverse.
[0010] In an embodiment, the front sensor unit and the back-sensor unit includes a mechanical combination of a wedge and an electric switch to automatically detect the source position and the destination position.
[0011] In an embodiment, the towing pin unit includes a towing motor attached to which helps the towing pin unit move up and down to lock and unlock the jig automatically.
[0012] In an embodiment, the rails include a set of mild steel tubes on which the 4-wheels of the i-RGV rests.
[0013] In an embodiment, the battery unit enabled with an intelligent auto charging unit which enables 24-hour operation by allowing the battery unit to charge when the i-RGV is in idle condition.
[0014] These and other aspects of the example embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating example embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the example embodiments herein without departing from the spirit thereof, and the example embodiments herein include all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Embodiments herein are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0016] FIG. 1 is a schematic diagram illustrating a chassis of an intelligent rail guided vehicle (i-RGV) for free roller conveyor to transfer goods from one location to another, according to an embodiment as disclosed herein;
[0017] FIG. 2a and 2b are schematic diagrams illustrating rails for the i-RGV to enable liner motion to move the free roller conveyor to transfer goods from one location to another, according to an embodiment as disclosed herein;
[0018] FIG. 3 is a schematic diagram illustrating a drive control unit of an intelligent rail guided vehicle (i-RGV), according to an embodiment as disclosed herein;
[0019] FIG. 4 is a schematic diagram illustrating a guide unit of the i- RGV, according to an embodiment as disclosed herein;
[0020] FIG. 5 is a schematic diagram illustrating an auto-stoppage with pulse mechanism for the i- RGV to detect source and destination, according to an embodiment as disclosed herein;
[0021] FIG. 6a and 6b are schematic diagrams illustrating a towing pin unit of the i- RGV to lock and unlock the jig, according to an embodiment as disclosed herein; and
[0022] FIG. 7 is a schematic diagram illustrating a communication unit for the i-RGV to communicate with a control panel, according to an embodiment as disclosed herein.

DETAILED DESCRIPTION OF THE DRAWINGS
[0023] The example embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted to not unnecessarily obscure the embodiments herein. The description herein is intended merely to facilitate an understanding of ways in which the example embodiments herein can be practiced and to further enable those of skill in the art to practice the example embodiments herein. Accordingly, this disclosure should not be construed as limiting the scope of the example embodiments herein.
[0024] The embodiments herein provide an automated Intelligent Rail Guided Vehicle (i-RGV) for free roller conveyors to transfer goods from one location to another. The i-RGV includes a chassis, wherein the chassis equipped with 4-wheels for self-balancing the i-RGV on rails, wherein the rails are mounted below a free roller conveyor. Further, the i-RGV includes a drive control unit, wherein the drive control unit includes a drive motor with a rack and pinion gear to enable a liner motion of the i-RGV to move forward and reverse on the rails. Further, the i-RGV includes a guide unit, wherein the guide unit includes a set of cam follower bearings for Y axis control and a set of cam follower bearings for Z axis control to ensure the liner motion of the i-RGV. Further, the i-RGV includes a front sensor unit, wherein the front sensor unit indicates a source position at which the i-RGV initiates its liner motion. Further, the i-RGV includes a rear sensor unit, wherein the rear sensor unit indicates the destination position at which the i-RGV stops its liner motion. Further, the i-RGV includes a towing pin unit, wherein the towing pin unit connected with a towing motor which enables the towing pin unit to lock and unlock a jig automatically, whenever the i-RGV senses pallets or heavy parts. Further, the i-RGV includes a communication unit, wherein the communication unit configured to establish a wireless communication with a control panel to remotely monitor and control the drive control unit. Further, the i-RGV includes a battery unit, wherein the battery unit supplies the power to the drive control unit to enable the i-RGV to move on the rails forward and reverse. In an embodiment, the i-RGV is mounted on the rails below the free roller conveyor enables the liner motion of the i-RGV to move the free roller conveyor to transfer the goods from one location to another. In an embodiment, the rails are designed with Z axis flexibility to adopt and adjust movement height of the rails depending on floor undulations or conveyor height fluctuations. In an embodiment, the Z axis adjustment enhances ease of joining rails, when one intended to extend the i-RGV movement by increasing number of free rollers conveyers. In an embodiment, teeth of the pinion gear in mesh with the teeth of the rack to enable the liner motion of the i-RGV to move forward and reverse. In an embodiment, the front sensor unit and the back-sensor unit includes a mechanical combination of a wedge and an electric switch to automatically detect the source position and the destination position. In an embodiment, the towing pin unit includes a towing motor attached to which helps the towing pin unit move up and down to lock and unlock the jig automatically. In an embodiment, the rails include a set of mild steel tubes on which the 4-wheels of the i-RGV rests. In an embodiment, the battery unit enabled with an intelligent auto charging unit which enables 24-hour operation by allowing the battery unit to charge when the i-RGV is in idle condition.
[0025] Referring now to the drawings, and more particularly to FIGS. 1 through 7, where similar reference characters denote corresponding features consistently throughout the figures, there are shown example embodiments.
[0026] FIG. 1 is a schematic diagram illustrating a chassis of an intelligent rail guided vehicle (i-RGV) 100 for free roller conveyor to transfer goods from one location to another, according to an embodiment as disclosed herein.
[0027] The i-RGV 100 includes a monocoque chassis 102, where a drive control unit (i.e. drive motor 106), towing pin unit 114, towing motor 108, a front sensor unit 110, a rear sensor unit 112, and a control panel (not shown) along with a battery for the power supply are mounted on a single frame. The compact and unique design of chassis 102 makes it highly modular and flexible in nature. The i-RGV 100 can be mounted below a free roller conveyor and can pass through any number of conveyors. The i-RGV chassis 102 can be supported by 4 wheels (104) for self-balancing on rails and has a drive motor for both forward and reverse movement of the i-RGV. The i-RGV comprise an intelligent auto charging unit which enables the battery to perform 24-hour operation by letting the i-RGV 100 charged whenever there is idle operation.
[0028] The embodiments herein provide the automated i-RGV 100 for free roller conveyors to transfer goods from one location to another. The i-RGV 100 includes the chassis 102, wherein the chassis equipped with 4-wheels 104 for self-balancing the i-RGV on rails, wherein the rails are mounted below a free roller conveyor. Further, the i-RGV includes the drive control unit, wherein the drive control unit includes the drive motor 106 with a rack and pinion gear to enable a liner motion of the i-RGV 100 to move forward and reverse on the rails. Further, the i-RGV 100 includes a guide unit, wherein the guide unit includes a set of cam follower bearings for Y axis control and a set of cam follower bearings for Z axis control to ensure the liner motion of the i-RGV 100. Further, the i-RGV 100 includes a front sensor unit 110, wherein the front sensor unit 110 indicates a source position at which the i-RGV 100 initiates its liner motion. Further, the i-RGV 100 includes a rear sensor unit 112, wherein the rear sensor unit 112 indicates the destination position at which the i-RGV 100 stops its liner motion. Further, the i-RGV 100 includes the towing pin unit 114, wherein the towing pin unit 114 connected with a towing motor 108 which enables the towing pin unit 114 to lock and unlock a jig automatically, whenever the i-RGV 100 senses pallets or heavy parts. Further, the i-RGV 100 includes a communication unit (not shown), wherein the communication unit configured to establish a wireless communication with a control panel to remotely monitor and control the drive control unit. Further, the i-RGV includes a battery unit (not shown), wherein the battery unit supplies the power to the drive control unit to enable the i-RGV 100 to move on the rails forward and reverse. In an embodiment, the i-RGV 100 mounted on the rails below the free roller conveyor to enable the liner motion of the i-RGV 100 to move the free roller conveyor to transfer the goods from one location to another.
[0029] FIG. 2a and 2b are schematic diagrams illustrating rails 202 for the i-RGV 100 to enable liner motion to move the free roller conveyor 204 to transfer goods from one location to another, according to an embodiment as disclosed herein.
[0030] The embodiments herein show the rails 202 on which i-RGV 100 is placed. The i-RGV 100 mounted on the rails 202 below the free roller conveyor 204 to enable the liner motion of the i-RGV 100 to move the free roller conveyor 204 to transfer the goods from one location to another. The rails 202 are provided for the movement of the i-RGV 100 from one end to another end. The rails 202 are made up of mild steel tubes on which the wheels 104 of i-RGV rest.
[0031] Further, FIG. 2b depicts the top view of rails 202 for the i-RGV 100. The rails 202 are designed with Z axis flexibility to adopt and adjust the movement height depending on floor undulations or conveyor height fluctuations. The Z axis adjustments also enhances the ease of rails 202 joining when one intends to extend the i-RGV 100 movement by increasing the number of free roller conveyors. The i-RGV 100 is mounted below the free roller conveyor 204 thereby controlling the movement of conveyor without the need of multiple motors.
[0032] FIG. 3 is a schematic diagram illustrating the drive control unit of the i-RGV 100, according to an embodiment as disclosed herein. The i-RGV 100 features a single electric drive motor 104 with rack and pinion gear. The drive motor 104 is coupled to the pinion gear. The drive motor 104 can be adapted to drive the pinion gear, wherein teeth of the pinion gear is in mesh with teeth of the rack which is mounted on a center rail. Further, the rack converts the pinion’s rotatory motion into a linear motion. The drive motor 104 can be used to drive the i-RGV 100 in both the direction (forward & reverse) without additional actuator for reverse direction motion. The Rack and pinion arrangements in the drive motor 104 helps in controlled positive braking in case of an emergency. This positive and direct drive mechanism helps i-RGV 100 to move even in slippery oil surface making its operation more.
[0033] FIG. 4 is a schematic diagram illustrating a guide unit of the i- RGV, according to an embodiment as disclosed herein.
[0034] The i-RGV consistently moves in the linear motion on the rails 202. The guide unit ensure the linear motion of the i-RGV 100. The guide unit includes a set of cam follower bearing (frictionless) 402,404 are placed on the i-RGV 100 which allows the i-RGV to move in the linear motion. The cam follower bearing 402,404 reduces the sliding friction and wear of a guiding surface. The Cam followers 402,404 also help to maintain precise motion of the i-RGV 100. Each of these guide unit includes 2 axis control cam and followers for both Y axis (deflection control) and Z axis (up and down control) as shown in FIG. 4.
[0035] FIG. 5 is a schematic diagram illustrating an auto-stoppage with a pulse mechanism for the i-RGV 100 to detect source and destination, according to an embodiment as disclosed herein.
[0036] The auto stoppage feature in the i-RGV 100 can be built with a mechanical wedge and an electric switch combination. This combination is used to automatically detect source and destination of i-RGV 100. Each of the i-RGV 100 includes a set of such features which are mounted at each end. The forward set (front sensor unit 110) confirms part presence (source) and a rear set (rear sensor 112) confirms the stoppage position (destination). The i-RGV 100 also features a pulse mechanism to control the stoppage position accuracy. Here, a drive plate is divided in to “N” number of segments which is continuously monitored by a rear sensor 112 which is present at rear end of the i-RGV 100. Each segment is in turn linked to the i-RGV 100 movement distance. The combination of auto stoppage with pulse mechanism helps the i-RGV 100 to stop at set distance before the part or pallet which is being conveyed hit to each other. Thus, enhancing the Safety features of overall operation by eliminating crush or pinch hazard.
[0037] FIG. 6a and 6b are schematic diagrams illustrating a towing pin unit 114 of the i- RGV 100 to lock and unlock the jig, according to an embodiment as disclosed herein.
[0038] The i-RGV 100 is developed with the towing pin which is capable of moving up and down as shown in FIG. 6a and 6b. The towing pin automatically locks the jig, whenever i-RGV 100 senses the pallets or heavy parts on it. The towing pin unit 114 is build using a scotch-yoke mechanism (i.e., rotation motion to linear motion) and by using single motor (i.e., towing motor 108). The pin goes up and down for locking jig and has excellent repeatability in pallet or part handling. The Scotch yoke is a reciprocating motion mechanism, that coverts the linear motion of a slider into rotational motion, or vice versa.
[0039] FIG. 7 is a schematic diagram illustrating a communication unit for the i-RGV to communicate with a control panel, according to an embodiment of the present invention. The control panel is used to wirelessly control the i-RGV 100 using a Wi-Fi communication. The communication unit is designed with a user-friendly interface which eliminates cables that runs throughout the conveyors and also eliminates the maintenance of the cables. The communication unit continuously controls and monitors the actuators in an efficient manner.
[0040] All equivalent relationships to those illustrated in the drawings and described in the application are intended to be encompassed by the present invention. The examples used to illustrate the embodiments of the present invention, in no way limit the applicability of the present invention to them. It is to be noted that those with ordinary skill in the art will appreciate that various modifications and alternatives to the details could be developed in the light of the overall teachings of the disclosure, without departing from the scope of the invention.
[0041] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein. ,CLAIMS:We claim
1. An automated Intelligent Rail Guided Vehicle (i-RGV) for free roller conveyors to transfer goods from one location to another, the i-RGV comprising:
a chassis, wherein the chassis equipped with 4-wheels for self-balancing the i-RGV on rails, wherein the rails are mounted below a free roller conveyor;
a drive control unit, wherein the drive control unit includes a drive motor with a rack and pinion gear to enable a liner motion of the i-RGV to move forward and reverse on the rails;
a guide unit, wherein the guide unit includes a set of cam follower bearings for Y axis control and a set of cam follower bearings for Z axis control to ensure the liner motion of the i-RGV;
a front sensor unit, wherein the front sensor unit indicates a source position at which the i-RGV initiates its liner motion;
a rear sensor unit, wherein the rear sensor unit indicates the destination position at which the i-RGV stops its liner motion;
a towing pin unit, wherein the towing pin unit connected with a towing motor which enables the towing pin unit to lock and unlock a jig automatically, whenever the i-RGV senses pallets or heavy parts;
a communication unit, wherein the communication unit configured to establish a wireless communication with a control panel to remotely monitor and control the drive control unit; and
a battery unit, wherein the battery unit supplies the power to the drive control unit to enable the i-RGV to move on the rails forward and reverse.

2. The i-RGV as claimed in claim 1, wherein the i-RGV is mounted on the rails below the free roller conveyor to enable the liner motion of the i-RGV to move the free roller conveyor to transfer the goods from one location to another.
3. The i-RGV as claimed in claim 1, wherein the rails are designed with Z axis flexibility to adopt and adjust movement height of the rails depending on floor undulations or conveyor height fluctuations.
4. The i-RGV as claimed in claim 3, wherein the Z axis adjustment enhances ease of joining rails, when one intended to extend the i-RGV movement by increasing number of free rollers conveyers.
5. The i-RGV as claimed in claim 1, wherein teeth of the pinion gear in mesh with the teeth of the rack to enable the liner motion of the i-RGV to move forward and reverse.
6. The i-RGV as claimed in claim 1, wherein the front sensor unit and the back-sensor unit includes a mechanical a combination of a wedge and an electric switch to automatically detect the source position and the destination position.
7. The i-RGV as claimed in claim 1, wherein the towing pin unit includes a motor attached to which helps the towing pin unit move up and down to lock and unlock the jig automatically.
8. The i-RGV as claimed in claim 1, wherein the rails include a set of mild steel tubes on which the 4-wheels of the i-RGV rests.
9. The i-RGV as claimed in claim 1, wherein the battery unit enabled with an intelligent auto charging unit which enables 24-hour operation by allowing the battery unit to charge when the i-RGV is in idle condition.