Autonomous tiered laundry folding devices, systems, and methods of use

Abstract

Devices, systems, and methods for autonomously shuffling a plurality of platters through a plurality of tiered folding bays are described. Each of the platters includes a platter coupling, and the plurality of tiered folding bays each include a bidirectionally driven receiving coupling, at least one of a sliding folding rod and blade, and a lifting mechanism configured to separate the platter coupling from the receiving coupling. The system includes a loading elevator for loading a platter and unfolded laundry article disposed thereon into a bay, and an unloading elevator for lowering a platter and a folded laundry article thereon to an unloading station for handing off to packing. A return conveyor returns each emptied platter to a repositioning station for receiving another spread laundry article for folding. The loading elevator, unloading elevator and each of the plurality of folding bays includes a pair of driven conveyors for transferring platters.

What is claimed is: 
     
         1 . A method of determining a presence of unacceptable folding conditions in a folded laundry article, following the use of an autonomous folding device to fold said laundry article,
 wherein one or more sensors are provided which are configured to output a signal indicative of a folding state of the laundry article,   and wherein the method comprises: determining, based on at least one of the one or more sensor signals and a user input, whether a folded laundry article comprises one or more unacceptable folding conditions.   
     
     
         2 . The method of  claim 1 , wherein the one or more unacceptable folding conditions comprise an appearance unacceptable for customer satisfaction as indicated by a user input in response to a real-time image delivery or based on a stored image flagged asynchronously via a customer portal by a household customer after receiving the returned, folded article. 
     
     
         3 . The method of  claim 1 , wherein the user input comprises at least one of a screen button tap or toggle button selection on a user interface screen of an application running on a remote device. 
     
     
         4 . The method of  claim 3 , wherein the remote device comprises at least one of a tablet, smartphone, smart watch, and a remote computing device. 
     
     
         5 . The method of  claim 1 , wherein a controller is provided that utilizes a neural network to determine whether the laundry article is acceptably folded or comprises one or more unacceptable folding conditions. 
     
     
         6 . The method of  claim 5 , wherein the controller learns over time to autonomously detect an unacceptable fold and an acceptable fold of various types of laundry articles based on inputs comprising at least one of: detecting a fold that unfolds itself, detecting one or more dimensions of the folded laundry article exceeding a standardized threshold size compatible with packing in a container of known dimensions, and receiving a remote user input indicative of an unacceptable fold based on visual appearance. 
     
     
         7 . The method of  claim 6 , wherein a database is provided in communication with the controller and stores article type, size, and quantity data, along with acceptable fold images for each repeat remote user, so that preferences can be personalized and optimized per remote user. 
     
     
         8 . The method of  claim 5 , wherein the controller, upon determining one or more unacceptable folding conditions, returns the laundry article to a repositioning station preceding the autonomous folding device. 
     
     
         9 . The method of  claim 1 , wherein the laundry article is spread apart and/or partially folded by an autonomous spreading station adjacent the autonomous folding device. 
     
     
         10 . The method of  claim 1 , wherein the one or more sensors comprise at least one of a 3-D camera, an IR sensor, a 2-D camera, LIDAR, LADAR, a sonar proximity sensor, an ultrasonic ranging sensor, a radar sensor, and a pair of stereo depth cameras. 
     
     
         11 . An autonomous folding device comprising:
 a rotatable coupling configured to receive a rotatable platter in reversible engagement, the rotatable coupling being in operative engagement with a drive motor;   an extendable and retractable support configured to transit the rotatable platter into and out of the folding bay in a level orientation and align a protrusion extending from an underside surface of the rotatable platter with the rotatable coupling;   at least one of a folding blade and folding rod configured to fold a laundry article disposed on a top surface of the rotatable platter engaged with the rotatable coupling;   one or more sensors configured to output a signal indicative of a folding state of the laundry article; and   a controller in operative communication with the one or more sensors and a remote user device, the controller being configured to determine, based on at least one of the one or more output sensor signals and a user input transmitted from the remote user device, whether a folded laundry article disposed on the rotatable platter comprises one or more unacceptable folding conditions.   
     
     
         12 . The device of  claim 11 , wherein the controller is in operable communication with the drive motor of the rotatable coupling, the drive motor being configured to bi-directionally rotate the rotatable platter about a spin axis vertically aligned through a center of the rotatable platter. 
     
     
         13 . The device of  claim 11 , wherein the remote user input comprises at least one of a screen button tap or toggle button selection on a user interface screen of an application running on the remote device. 
     
     
         14 . The device of  claim 13 , wherein the remote device comprises at least one of a tablet, smartphone, smart watch, and a remote computing device. 
     
     
         15 . The device of  claim 11 , wherein the autonomous folding device includes:
 a plurality of tiered folding bays configured to independently and simultaneously fold a plurality of household laundry articles, wherein each of the plurality of folding bays includes one of said rotatable couplings; and   at least one elevator configured to raise and lower the rotatable platter into and out of one of the plurality of folding bays,   wherein the rotatable platter is one of a plurality of rotatable platters and two or more rotatable platters of the plurality of rotatable platters are configured to occupy simultaneously two or more of the plurality of tiered folding bays.   
     
     
         16 . The device of  claim 15 , wherein the extendable and retractable support further comprises a pair of spaced apart transfer conveyers configured to support in an extending state the rotatable platter thereon with the platter therebetween. 
     
     
         17 . The device of  claim 16 , wherein the pair of spaced apart transfer conveyers comprise centering pins configured to abut one or more edge locations of the platter and center the platter, and the platter protrusion extending therefrom, above the receiving coupling for mating alignment. 
     
     
         18 . The device of  claim 17 , wherein the platter protrusion comprises a conically shaped receiving bore. 
     
     
         19 . The device of  claim 15 , wherein each folding bay of the plurality of tiered folding bays comprises a first open end opposite a second open end, the open ends disposed adjacent the ends of a pair of spaced apart transfer conveyers. 
     
     
         20 . The device of  claim 15 , wherein the controller is further configured to determine the one or more acceptable folding conditions based on a database in communication with the controller, wherein the database comprises acceptable fold images.