Dock door automation system and method

Patent metadata

Field	Value
Publication number	US-10106342-B2
Application number	US-201514855175-A
Country	US
Kind code	B2
Filing date	Sep 15, 2015
Priority date	Sep 17, 2014
Publication date	Oct 23, 2018
Grant date	Oct 23, 2018

Abstract

A system and method are provided for automated engaging of a truck trailer at a loading dock. Sensors measure a distance and an angle of alignment between the incoming trailer and a wall of the loading dock. An outside lighting system guides a truck driver backing the trailer toward the dock door. A vehicle restraint system fixates the trailer within the loading dock in response to signals from the sensors. An overhead dock door opens once the trailer is successfully fixated by the vehicle restraint system. A dock leveler deploys after the overhead dock door opens. An inside dock light indicates to dock personnel that the trailer is ready to be serviced. Once servicing of the trailer is finished, an automated release of the trailer from the loading dock may be initiated by PLC communication.

First claim

What is claimed is:

1. A system for servicing a truck trailer at a docking bay, comprising:
a programmable logic controller (PLC) system configured to operate the docking bay to accept, secure, and release the truck trailer;
at least a first sensor and a second sensor to detect an angle between a centerline of the docking bay and the truck trailer during backing into the docking bay;
at least a third and fourth sensors to detect a distance between a wall of the docking bay and a rearmost portion of the truck trailer;
an outside lighting system in communication with the PLC system and configured to provide feedback to a truck driver during backing the truck trailer into the docking bay, the lighting system configured to operate in response to signals from the first, second, third, and fourth sensors;
a vehicle restraint system in communication with the PLC system and configured to fixate the truck trailer within the docking bay;
an overhead door in communication with the PLC system and configured to open once the trailer is fixated by the vehicle restraint system;
a dock leveler in communication with the PLC system and configured to deploy after the overhead door opens; and
an inside dock light in communication with the PLC system and configured to indicate a status of the truck trailer to dock personnel.

2. The system of claim 1 , wherein the first sensor and the second sensor are positioned with a substantially equivalent distance from a dock centerline and a substantially equal height above the top of a dock shelter.

3. The system of claim 2 , wherein each of the first sensor and the second sensor comprises two sensors positioned adjacent to one another, such that the sensors have a substantially equal height above the top of the shelter, the two sensors being oriented vertically so as to detect the presence of a top of the truck trailer.

4. The system of claim 3 , wherein the two sensors are laser guided vehicle (LGV) sensors.

5. The system of claim 1 , wherein the third and fourth sensors further comprise a first sensor and a second sensor located below the floor of the docking bay.

6. The system of claim 5 , wherein the first and second sensors are LGV sensors.

7. The system of claim 5 , wherein the vehicle restraint system engages the truck trailer following a time delay after the truck trailer is sufficiently positioned within the docking bay.

8. The system of claim 7 , wherein once the vehicle restraint system engages the truck trailer, the overhead door is opened and the dock leveler is deployed.

9. The system of claim 7 , wherein the PLC system is configured to switch to an Alarm Mode and flash the outside signal lights and the inside dock light red and green simultaneously to indicate a fault when the vehicle restraint system fails to properly engage the truck trailer.

10. The system of claim 1 , wherein the outside lighting system comprises outside signal lights configured to indicate to the driver when to move the truck trailer during backing into and exiting the docking bay.

11. The system of claim 10 , wherein the outside signal lights flash green to indicate to the truck driver that the docking bay is ready to receive the truck trailer, and wherein the inside dock light flashes red to indicate to dock personnel that the trailer is not yet ready for servicing.

12. The system of claim 11 , wherein the outside signal lights switch from greed to red to indicate to the truck driver to stop backing the trailer into the docking bay once the truck trailer is sufficiently aligned and centered within the docking bay.

13. The system of claim 1 , wherein the outside lighting system comprises directional arrow lights configured to help the driver to properly orient the truck trailer with respect to the centerline of the docking bay, and wherein a passenger side and a driver side of the directional arrow lights communicate to the driver directions to steer the trailer.

14. The system of claim 13 , wherein the directional arrow lights remain off while the truck trailer is properly aligned with the centerline.

15. The system of claim 14 , wherein either the passenger side or the driver side of the directional arrow lights illuminate with a steady yellow color when the trailer is not properly aligned with the centerline.

16. The system of claim 14 , wherein either the passenger side or driver side of the directional arrow lights flash yellow when the trailer has an improper offset angle relative to the centerline of the docking bay.

17. A method for providing an automated docking bay, comprising:
positioning one or more sensors to detect an orientation of a truck trailer and the docking bay;
deploying at least a first sensor and a second sensor so as to detect at least one angle of an alignment of the truck trailer relative to a centerline of the docking bay; deploying at least one sensor to detect a distance between a wall of the docking bay and a rearmost portion of the truck trailer;
coupling a programmable logic controller (PLC) system with the one or more sensors;
configuring the PLC system to signal a truck driver in response to orientation data received from the one or more sensors;
placing the PLC system in communication with a vehicle restraint system, such that the PLC system causes the vehicle restraint system to engage and fixate the truck trailer in response to the orientation data;
configuring the PLC system to raise an overhead door and deploy a dock leveler once the vehicle restraint system fixates the truck trailer; and
configuring the PLC system to indicate a status of the truck trailer to dock personnel.

18. The method of claim 17 , wherein configuring the PLC system to signal the truck driver comprises implementing outside signal lights whereby the PLC system may direct the driver during backing into and exiting the docking bay.

19. The method of claim 17 , wherein configuring the PLC system to deploy the dock leveler comprises receiving signals from at least one of the one or more sensors so as to determine that the dock leveler is clear of obstruction before deployment thereof.

Assignees

• Niagara Bottling Llc

Inventors

• Avalos Robert Paul

Classifications

• B60P1/00

  Vehicles predominantly for transporting loads and modified to facilitate loading, consolidating the load, or unloading (vehicles for carrying harvested crops with means for self-loading or self-unloading A01D90/00; peculiar to refuse collecting-vehicles B65F; loading or unloading vehicles by means not incorporated therein B65G) · CPC title

• E06B3/44

  Vertically-sliding wings · CPC title

• G05B2219/10

  Plc systems · CPC title

• B60Q9/00

  Arrangement or adaptation of signal devices not provided for in one of main groups B60Q1/00 - B60Q7/00 {, e.g. haptic signalling} · CPC title

• B65G2207/40

  Safety features of loads, equipment or persons · CPC title