Robotic gantry with end effector for product lifting

Abstract

A robotic gantry system, end-effector for a robotic gantry system and method of transporting products using a robotic gantry system is provided. The end-effector includes a movable floor that can be positioned below picked products to prevent products from being dropped during transport. The movable floor also permits selecting individual rows of products from a given layer of products of a product stack. The end-effector may include a vacuum assembly for vacuum adhering to the products. The method permits selection of varying portions of a stack of products with the end-effector and protecting the selected portions of products using the movable floor.

What is claimed is: 
     
         1 . An end-effector for a robotic system comprising:
 a) a frame structure;   b) a first product engagement structure mounted to and movable relative to the frame structure;   c) a second product engagement structure movable toward and away from the first product engagement structure along a first axis; and   d) a floor moveable relative to the frame structure and the first and second product engagement structures between a closed position in which the floor covers at least a portion of a product opening formed between the first and second product engagement structures and an open position in which the floor exposes the covered portion of the product opening, wherein the floor is configured to travel along a path between the open position and the closed position, wherein all portions of the floor travel in a same direction along the path when transitioning from the open position to the closed position, wherein the end-effector is coupled to a gantry system movable in three-dimensions in support of operation of the end-effector.   
     
     
         2 . The end-effector of  claim 1 , wherein the second product engagement structure is mounted to and movable relative to the frame structure. 
     
     
         3 . The end-effector of  claim 2 , further comprising third and fourth product engagement structures mounted to and movable relative to the frame structure, the third and fourth product engagement structures movable toward and away from one another along a second axis being generally orthogonal to the first axis. 
     
     
         4 . The end-effector of  claim 3 , wherein the first, second, third and fourth product engagement structures are movable between a released position and a clamped position, in the clamped position the first, second, third and fourth product engagement structures defining the product opening. 
     
     
         5 . The end-effector of  claim 1 , further including a vacuum pad mechanism defining a vacuum surface facing the floor when the floor is in the closed position. 
     
     
         6 . A robotic system comprising:
 an end-effector including:
 a) a frame structure; 
 b) a first clamping mechanism having a first product engagement structure, the first clamping mechanism mounted to and movable relative to the frame structure; 
 c) a second product engagement structure movable toward and away from the first product engagement structure along a first axis; and 
 d) a floor moveable relative to the frame structure and the first and second product engagement structures such that the floor selectively closes a vertical opening defined between the first and second product engagement structures; and 
 e) a gantry system coupled to the end-effector and configured to move and support the end-effector in three dimensions. 
   
     
     
         7 . The robotic system of  claim 6 , including a controller configured to move the end-effector along a first axis while maintaining a position of a leading edge of the floor along the first axis. 
     
     
         8 . A method of transporting at least one product of a stack of products with a robotic system configured with an end-effector coupled to a gantry, the end-effector having a movable floor, the method comprising the steps of:
 a) removing at least one first product with the end-effector from the stack of products;   b) transitioning the movable floor under the at least one first product;   c) grasping the at least one first product with at least one clamping mechanism of the end-effector; and,   d) transitioning the movable floor out from underneath the at least one product prior to releasing the at least one product from the at least one clamping mechanism.   
     
     
         9 . The method of  claim 8 , wherein the step of removing at least one first product from the stack of products includes laterally translating an entire layer of products of the stack such that at least one product of the layer of products, including the at least one first product, is no longer vertically supported by the stack of products. 
     
     
         10 . The method of  claim 10 , further comprising vertically aligning a top surface of the movable floor with a top of the products supporting the layer of products being laterally translated by the end-effector and removed from the stack of products. 
     
     
         11 . The method of  claim 11 , further comprising laterally positioning a leading edge of the movable floor proximate a side of the stack of products over which the at least one product will be removed, prior to removing at least one product from the stack of products. 
     
     
         12 . The method of  claim 10 , wherein laterally translating an entire layer of products includes supporting at least one of the products of the translated layer with the movable floor when it is translated off of the stack of products. 
     
     
         13 . The method of  claim 10 , wherein the at least one first product that is no longer vertically supported by the pallet or the stack of products is initially entirely vertically supported by the movable floor. 
     
     
         14 . The method of  claim 9 , wherein the step of grasping occurs before the step of removing, and the step of removing is performed by vertically lifting the at least one first product from the stack of products and the step of transitioning occurs after the step of lifting. 
     
     
         15 . The method of  claim 10 , further comprising a step of grasping the at least one first product, the grasping of the at least one first product providing sufficient friction to provide vertical support of the at least one first product. 
     
     
         16 . The method of  claim 9 , wherein the step of grasping further includes grasping at least one second product that will ultimately remain on the stack after the step of removing is complete, and the step of transitioning excludes transitioning the movable floor under the at least one second product. 
     
     
         17 . The method of  claim 17 , further comprising re-stacking the at least one second product including setting the at least one second product back onto the stack of products and ungrasping the at least one second product. 
     
     
         18 . The method of  claim 18 , further comprising a step of re-grasping the at least one first product which excludes grasping the at least one second product. 
     
     
         19 . A method of transporting at least one product of a stack of products having at least a first layer of products and a second layer of products positioned on top of the first layer with a system including an end-effector having a movable floor comprising the steps of: removing at least one first product of the second layer of products off of the first layer of products with the end-effector from the stack of products; and transitioning the movable floor under the at least one first product wherein the step of grasping further includes grasping at least one second product that will ultimately remain on the stack after the step of removing is complete, and the step of transitioning excludes transitioning the movable floor under the at least one second product further comprising re-stacking the at least one second product including setting the at least one second product back onto the first layer of products and ungrasping the at least one second product; further comprising a step of re-grasping the at least one first product which excludes grasping the at least one second product. 
     
     
         20 . The method of transporting at least one product of a stack of products having at least a first layer of products and a second layer of products positioned on top of the first layer with a system including an end-effector having a movable floor according to  claim 19  wherein the end-effector is configured as a vacuum pad mechanism defining a vacuum surface.