Docking station monitoring system, docking station and distribution center provided therewith, and method there for.

© Patent holder (s):

Stertil BV in Kootstertille.

© Patent granted:

04.06.2015

5?) I nventor (s):

Jurjen de Jong from Buitenpost.

Jan Berhard Stapensea in St. Annaparochie.

© Patent issued:

10.06.2015 © Authorized representative:

ir. AAG Land et al. in The Hague.

© Docking station monitoring system, docking station and distribution center provided therewith, and method there for.

© The invention relates to a docking station monitoring system for monitoring at least one dock or distribution center, a docking station and distribution system provided therewith, and method there for. The docking station monitoring system according to the invention comprises:

- a dock controller;

- one or more sensors connected to the dock controller and configured for monitoring a state of the dock and / or one or more of the dock components; and

- a dock compliance system configured to receive information from the one or more sensors monitoring the state of the dock and / or one of the dock components, and to provide a compliance signal to the dock controller.

NL C 2011884

This patent has been granted regardless of the attached result of the prior art research and written opinion. The patent corresponds to the documents originally filed.

Docking station monitoring system, docking station and distribution center provided therewith, and method there for

The present invention relates to a docking station monitoring system for monitoring at least one dock of a distribution center. Such distribution centers are in use to receive and send loads including packages, parcels, consumable materials and finished products. Such distribution centers include at least one dock of docking station configured to receive a truck or a trailer for loading and / or unloading. Such dock or docking station includes dock houses, optionally dock levelers and dock shelters and components thereof.

Conventional docks or docking stations are often used intensively and the components exhibit wear due to the use thereof. In addition, control of the dock is often limited.

An object of the invention is to obviate or at least reduce some of the above problems.

This object is achieved with a docking station monitoring system for monitoring of at least one dock of a distribution center according to the invention, the system comprising:

- a dock controller;

- one or more sensors connected to the dock controller and configured for monitoring a state of the dock and / or one or more of the dock components; and

- a dock compliance system configured to receive information from the one or more sensors monitoring the state of the dock and / or one of the dock components, and to provide a compliance signal to the dock controller.

According to the invention a docking station also relates to a dock and dock house. A dock can be provided with a dock shelter and / or dock leveler and optionally a vehicle restraint system.

The dock controller can be used to control one or more docks of a distribution center. The dock controller can be provided centrally for a number of docks, preferably at a central location in the distribution center from where the controller can be operated. This enables the use of a dock controller for a number of docks. Alternatively, or in addition thereto, a dock controller is provided for an individual dock.

The dock controller communicates with relevant dock components, for example a door of the dock, a dock barrier, a vehicle restraint system of locking system, etcetera, using wired or preferably wireless communication, usually one or more transmitters and / or receivers. The dock controller receives information from one or more sensors and is configured for monitoring the state of the dock and / or one or more of the dock components. In a presently preferred embodiment the sensors measure the state of a door of the dock, ie whether the door is closed or open. Also, the state of a vehicle constraint system is monitored. Furthermore, alternatively or in addition thereto, the angular position and load of the dock leveler deck can be measured. This monitoring enables collecting and providing information about the status of the dock at a specific point in time and provides information about activities performed with a specific dock thereby enabling predicting the durability or operational life of the dock and / or its components. In addition, or as an alternative thereto, the information can be used to predict and / or determine maintenance intervals. For example, this prevents ware to the dock or its components that may influence the deployability of a dock.

According to the invention a dock compliance system is configured to monitor the state of the dock and / or one of the dock components as described earlier. The dock compliance system according to the invention is configured to provide a compliance signal to the dock controller and / or relevant dock components thereby enabling the use of the dock.

In a presently preferred embodiment according to the invention this compliance signal acts as a release signal for releasing the dock as soon as its intended use for loading and / or unloading a truck or trailer is authorized by a central controller or authorizing officer.

The compliance signal may also indicate when a dock or dock component needs maintenance or repair. This provides additional safety to the dock and distribution center, and significantly reduces downtime of a dock such that the logistic operations are not hindered. This also enables monitoring and storing incidents and accidents to improve safety of the dock.

In a presently preferred embodiment the docking station monitoring system comprises a network interface unit comprising a network transmitter and / or a network receiver configured for communication with a central controller. This enables wired or wireless communication between the dock controller and a central controller, for example of an external (company) network. Such external network may include one or more of the following: service and maintenance network of the docks, accounting network of the distribution center where the dock is located. The communication may involve one or more of the following: information about the activities to be performed with a truck at the dock, tasks, safety information of the dock, service and maintenance information, software updates, utilization data, authorization and identification data. This data can be shared with relevant parties, provided security precautions have been taken. Such parties may relate to maintenance companies, management, for example. This may also involve remotely reading camera data from the dock or the premises.

Information about the loading and / or unloading activities scheduled for a specific dock can be useful for an operator and / or truck driver.

Tasks may relate to information of the scheduling work or job orders, detailed order information, time budget and / or recording hours of labor associated with a dock. This information may be provided by a server with a storage facility capable of storing relevant information and / or may be provided to such server by the dock controller.

Safety information relates to providing information on safety measures such as a barrier of the dock and the position of a door of a dock. Additionally or alternatively, this information may relate to sending warning signals and / or warning recordings to a server with a storage facility capable of storing relevant information.

Service, repair and maintenance indication relates to keeping records of the utilization data of the dock and providing the operator and / or maintenance people with a service indication after reaching a number of dock operations and / or after a specific time interval. In a presently preferred embodiment the dock controller provides a service message by the network interface unit to the maintenance people. The maintenance people may involve a maintenance company and / or a manufacturer of the docking systems according to the invention.

Software updates are enabled through the network interface unit by externally providing update information from a server to the dock controller. The dock controller receives the update to improve the operation of the docking system thereby enabling a remote software update.

Utilization data relates to the data representing the use of the dock, such as a number of trucks and trailers using the dock, specific loads and / or the lengths of time intervals wherein the dock is in use. The utilization is provided to a server by a network interface unit. This enables utilization of a pay-per-dock system wherein the user of the dock pays for the dock depending on the use thereof.

Authorization and identification data relates to data enabling a specific user to start using the dock. For example, a user identifies himself at one of the docks through an interface unit. In a preferred embodiment this identification data is communicated via the dock controller and a network interface unit to an external network. In case the user is not authorized to use the dock the operation of the dock can be blocked by sending a corresponding command to the dock controller. In case the user is authorized to use the dock a compliance signal indicating a release or clearance command is communicated to the dock controller and the user may start to operate the dock.

User wireless communication means enables optimal utilization of the flexibility of the dock (s). Per se known wireless communication means are usually based on the use of electromagnetic radiation, such as Bluetooth and Wi-Fi. Also, the system can make use of transmission in a ultra wide band (UWB).

The presently preferred embodiment of the docking station monitoring system further comprises a user interface unit comprising a transmitter and / or receiver configured for communication with the dock controller, a processor, a display device, and input means and configuring the user interface to receive user input , wherein the user interface unit being adapted to communicate command signals to the dock controller on the basis of the user input and adapted to receive display information obtained from the dock controller.

The user interface enables the user to provide information, such as operating instructions and / or identification data, to the dock controller and / or external network. In fact, the user interface is adapted to communicate command signals to the dock controller on basis of user input. The user may provide such user input through user buttons, keyboard and / or preferably at a touch screen. Optionally, the display can also be used as a warning signal by providing red, yellow and green lights to a fork lift truck driver without requiring an additional traffic light.

In a presently preferred embodiment according to the present invention the docking station monitoring system further comprises a release system configured for receiving a compliance signal of the compliance system to release the dock and / or truck.

By providing a release system the dock and / or truck can be released. For example, the door of a dock can be released for opening to enable docking of a truck or trailer. It is noted that for the purpose of this description referral to truck also includes a trailer. Also, the release system may release the dock leveler for positioning relative to the truck thereby enabling loading and / or unloading thereof.

In a presently preferred embodiment the release system comprises a vehicle restraint system or locking system capable of blocking a truck. Such locking system is described in EP 2 371 745 and comprises a guide track, a carriage guided by the guide track provided with locking means for blocking a wheel of a vehicle, a locking member provided on the carriage for releasably locking the carriage relative to the guide track, and displacing means for displacing the carriage. Such locking system can block the truck and the truck is not authorized to leave the dock.

In an advantageous preferred embodiment according to the present invention the one or more sensors comprise a load sensor.

Providing a load sensor enables collecting information about the use of the dock. In addition thereto, information can be collected about the weight of the load that is loaded into the truck and / or unloaded from the truck. This data can be provided to a controller that compares this data with the logistic data available to this system. When a mismatch is detected a warning signal can be sent to a user and / or other system. For example, when such warning signal is created this can be used to prevent sending a release signal to the locking system that is described earlier. In a presently preferred embodiment the load sensor is positioned in a dock leveler.

In an advantageous preferred embodiment according to the present invention the one or more sensors comprise a position switch, including an angle position switch, for a dock leveler and / or a door of the dock.

By providing a position switch the change of position of the dock leveler and / or a door of the dock can be detected indicating a change in the stage of the dock. This provides user information that can be used in a manner as described earlier.

In an advantageous preferred embodiment according to the present invention one or more sensors comprise a camera.

A camera can be used to detect a truck at a dock thereby providing information about the status of the dock.

The camera can also detect the truck leaving the dock. In addition, the camera can be used to provide security and observation means to improve the overall security of the distribution center. Also, the camera can be used to observe and monitor the locking system described earlier.

In a further advantageous preferred embodiment according to the present invention the system further comprises an identification system configured for identifying the fork lift truck, pallet truck and / or user.

Providing an identification system or device enables the user of the dock to identify himself to the dock control and enable access to the dock to enable operation of the dock and / or maintenance and repair. This also applies to the fork lift truck or pallet truck. The identification system in a presently preferred embodiment is provided with an IDreader configured to operate with an ID-key, ID-card, PINcode, digital signature, fingerprint or other biometrical means, voice activation, password etcetera.

Preferably, the identification data is provided to the user interface as described earlier. In a possible embodiment according to the invention authorization of the user and preferably also release or clearance of the dock is requested from an external / central controller or dock controller.

In a further advantageous preferred embodiment according to the present invention the system further comprises an identification system configured for identifying the truck and / or truck driver.

The identification system or device may comprise similar components as for identifying the fork lift truck, pallet truck and / or user. The identification system can be used to identify the fork lift truck, pallet truck and / or user, as well as the truck and / or truck driver.

Identification of the truck can be performed with a camera involving a vision system, for example. This identification preferably detects the type of vehicle. Identification means can use a camera and / or RFID system with a reader for reading a RFID tag provided in a vehicle.

The identification information can be used by the dock controller to adjust the settings of the dock. In addition or as an alternative thereto, this information can be used by the system to provide additional information and improve the operation of the entire dock. This may involve use of this information for sending payment instructions. Optionally, the identification device is used for vehicle recognition such that the operation costs for the docking operation can be linked to a specific vehicle. For example, this recognition for a specific vehicle can be performed to the license plate number that can be recognized by the camera. For example, the compliance system generates a compliance signal involving a release signal after receiving a payment for performing the required docking operation.

This payment can be received through a pre-paid card that is offered to the dock directly at the dock and / or at the compliance system. Alternatively, or in addition thereto, the compliance system comprises an authorization to perform the docking operation, optionally in a specific time period. Furthermore, the compliance system may send a signal and collect a data such that debit information can be provided to the accountant / billing department and / or debit client directly. This enables a direct coupling of the docking operation to (end) -user. This renders the use of the dock according to the present invention cost controlled, thereby further preventing a desired and / or needed docking operation. Furthermore, this provides the opportunity and possibility for operational leasing or renting the dock according to the present invention and paying for a specific dock operation as an alternative to or in addition to payment for the payment of the dock as such.

In a further advantageous preferred embodiment according to the present invention the system further comprises a breath analyzer.

Providing a breath analyzer enables a check on the capabilities of the user of the dock to operate the docking system. For example, when starting the docking operation or continuing such operation after a break, the user has to utilize the breath analyzer. After checking, the dock is released by a compliance signal and the user may start operating the dock. This provides additional safety when using the dock according to the invention.

In a further advantageous embodiment according to the present invention the system further comprises a docking assistance system configured for assisting docking of a truck to the dock.

The assistant system provides assistance to the truck and / or truck driver when docking to the dock and / or when leaving the dock. Such docking assistance system preferably comprises a camera for determining the position of the truck relative to the dock. Optionally, the camera data is recorded to determine cause of damage to the truck and / or dock. In addition, the docking assistance system may monitor the position of the truck relative to a locking system that is described earlier. Guidance information and / or instructions for the truck and for the truck driver can be provided by sound and / or signals such as signaling lights, for example involving LEDs that are located at or close to the dock or locking system. Alternatively, or in addition thereto, the dock can be provided with a projector to project signs on the ground surface as indication for the truck driver, for example green arrows signaling ok to dock in this direction and red stop signal to stop the docking process. This may improve the safety of the docking operation and reduce the risk of damaging the dock, docking system and other components of the distribution center or truck.

In a further advantageous preferred embodiment according to the present invention the docking station monitoring system further comprises a load control system configured for monitoring the loading and / or the unloading of a truck.

By providing a load control system the loading and / or unloading can be monitored. Such load control system may involve a load sensor as described earlier thereby enabling a check of the dock operation relative to the data present in the logistic center of the distribution center. This prevents unloading of unauthorized loads and / or loading of such loads in a truck by comparing the load handled with the scheduled load for the specific batch to that is scheduled to be handled at that time at that dock. In addition, a speed sensor may be provided and coupled to the dock controller to increase dock safety. So would it be possible to apply the speed sensor in combination with the load sensor and / or angle sensor of the leveler to predict or estimate the impact forces on the leveler. This enables the system according to the invention to provide an indication of the estimated operating life of dock components and / or to determine required maintenance intervals.

The invention further relates to a signaling system for a docking station, for example as part of a docking assistance system, the signaling system configured for providing a truck driver with guidelines on the docking operation of the truck. This docking operation may relate to moving the truck backwards towards the dock and / or leaving the dock in a forward direction of the truck. The signaling system may involve LEDs that are arranged on or close to the locking system and / or a projector for projecting signs on the ground surface, for example, and / or communication means configured for providing the truck driver with driving / docking instructions on his mobile or navigation system of the truck, and / or traffic lights arranged in the neighborhood of the docking station.

The invention further also relates to a locking system as mentioned at other places of this description with the locking system comprising docking assistance means. These assistance means may comprise LEDs indicating the direction of suggested movement to a truck driver when docking a truck and / or indicating a warning signal to prevent a collision, for example.

The invention also relates to a docking station and / or distribution center comprising a docking station monitoring system as described earlier.

The same effects and advantages apply for the docking station and / or the distribution center as described for the docking station monitoring system.

The invention further also relates to the method for monitoring a docking station, comprising the steps of:

- providing a docking station monitoring system as described earlier;

- determining the state of the dock and / or one or more of the dock components; and

- providing a compliance signal by the dock compliance system to the dock controller.

The same effects and advantages apply for the method as described for the docking station monitoring system and / or distribution center and docking station. This method provides additional safety to the docking station and optimizes maintenance and repair.

In a presently preferred embodiment the compliance signal is provided in response to receiving and / or generating payment instructions. This enables a pay-perdock system for using the dock.

Further advantages, features and details of the invention are elucidated on the basis of preferred embodiments thereof, wherein reference is made to the accompanying drawings, in which:

Fig. 1 illustrates a docking station according to the invention;

Fig. 2 illustrates a preferred embodiment of the docking station monitoring system according to the invention; and

Fig. 3 illustrates the operation of the dock with the docking station monitoring system according to the invention.

Distribution center 2 (Figure 1) comprises a number of docks or docking stations 4 that in the illustrated embodiment are provided with shelter 6, door 8, seals 10, barrier 12 and bumper 14. In the illustrated embodiment dock 4 further comprises dock leveler 16 Dock leveler 16 is provided with load cell 18 for measuring the loads that are loaded and / or unloaded, and position sensor 20 to measure the (angular) position of leveler 16. Door 8 is provided with one or more door position sensors 22 to detect the position of door 8. Barrier 12 is provided with status sensor 24.

In the illustrated embodiment dock 4 is provided with locking system 26 comprises guide track 28, carriage 30 guided by guide track 28 provided with locking means 32 for blocking wheel 34 of truck 36, locking member 38 provided on carriage 30 for releasably locking carriage 30 relative to guide track 28, displacing means 40 for displacing carriage

30, and locking system status sensor 41. LED lights 42 of truck docking assistance system 44 assist a driver of truck 36 when docking truck 36. In the illustrated embodiment assistance system 44 further comprises camera 46 for detecting truck positions, signaling light 48 for further assisting the driver of truck 36, and projector 47 for projecting signals, such as arrows 49, on the ground surface assisting the truck driver. Camera 51 is preferably remotely controlled and used for identification / recognition of truck 36 when entering the premises of distribution center 2. After identifying truck 36 the driver is provided with a message or signals to direct truck 36 to the assigned dock 4. This significantly improves the docking process.

In addition to its preferred use in assistance system camera 46 monitors part of the surroundings of dock 4 and / or monitors the inside dock area. Furthermore, camera 46 can be used to identify truck 36, in a presently preferred embodiment through number plate recognition. Alternatively, a separate camera system is provided for identification purposes.

Optionally, camera 46 provides information about the type of vehicle, such as truck 36, to controller 50 enabling controller 50 to adjust the settings of dock components, such as leveler 16 and / or use vehicle specific information for debiting the user of dock 4 for the docking operation that is performed. Optionally, camera 46 detects the vehicle registration, for example by the license plates, optionally providing the relevant information to the accounting department such that the vehicle owner can be debited for the actual docking operation (s).

Furthermore, by monitoring the use of dock components, such as the leveler, the system is capable of providing information about how often and under what conditions the dock components are used. The user, for example the vehicle owner, can be debited on the actual use. Such option could be of interest also when dock equipment is rented / leased. In such case the system may communicate with an external network / system to enable monitoring and / or debiting the user or other party based on actual use by the equipment owner, for example.

Docking station monitoring system 50 (Figure 2) comprises dock controller 52 with transmitter / receiver 54, and compliance system 56. Dock controller 52 receives information from a number of sensor, including one or more of load sensor 18, position sensor 20 of leveler 16 , door position sensor (s) 22, barrier position sensor 24, camera 46, locking system status sensor 41, and other sensors. Dock controller 52 provides information to display 58 that in the preferred embodiment includes input means comprising buttons, switches and the like to enable receiving user input.

Docking system 50 is optionally connected to a number of sub-systems. Optionally, breath analyzer 60 is coupled to dock controller 52. In the illustrated embodiment ID-means 62 are coupled to dock controller 52 to enable identification of a user / operator, fork lift truck or other device being used to load / unload goods, truck 36, and / or the driver of truck

36. This may involve the use of a card, fingerprint, PIN code, number plate recognition etc.

Compliance system 56 directly or indirectly receives information from sensors and / or sub-systems. In the presently preferred embodiment dock 4 can only be used after compliance system 56 generated a release signal for dock system 50. In addition, in the illustrated embodiment compliance system 56 generates a compliance signal that can be used to control one or more sub-systems , including the sub-systems that are described earlier. In addition, in the illustrated embodiment the sub-systems further include assistance system 44 for assisting docking of truck 36, one or more release systems 64 for release of one or more of dock components such as leveler 16, barrier 12, door 8, locking system 26, and adjustment systems 66 such as position control of leveler 16 depending on vehicle type, and optionally for releasing controller 52 enabling control of dock 4. The compliance signal resulting in a release signal may release a software lock preventing a motor and / or pump to operate. Alternatively or in addition thereto this signal may release a hardware lock such as a clamp lock for a device of dock 4.

Furthermore, compliance system 56 may communicate with one or more external networks 68 that may involve logistics / scheduling system 70, accounting system 72 for enabling a pay-per-dock application, maintenance and / or repair system 74 including software updating possibilities, safety system 76 to perform safety checks, and / or monitoring system 78 for performing monitoring and control tasks optionally including measuring and comparing weight data of the goods loaded and / or unloaded to / from truck 36 at dock 4. In a pay-per-dock application payments may be received via a payment card, or through generation of payment instructions to the accounting department of the user enabling the use of dock 4 for a number of times, optionally linked to a specific truck 36. Alternatively, compliance system 56 involves sending a request for authorization to use dock 4 and / or a reply relating to the authorization or denial to use dock 4. In order to send any authorization and / or clearance / release signals compliance system 56 receives payments, for example with a pre-paid lift card, or payment confirmations, for example via an automatic debit order, and / or sends payment instructions.

It will be understood that several alternative configurations for system 50 can be provided by a skilled person. For example, in stead of compliance system 56 indirectly communicating via dock controller 52 with other systems and / or networks, compliance system 56 may communicate directly with one or more of these sub-systems and / or networks 68.

Docking operation 80 (Figure 3) starts with arrival 82 of truck 36. In identification step 84 truck 36 is identified by dock system 50. After generation of a compliance signal, for example after authorizing truck 36 or receipt of a payment in a pay- per-dock system, that may be in the form of a release signal for door 8, dock 4 is ready to be used. In activation step 86 dock 4 is made ready for use involving opening door 8, docking truck 36 using assistance system 44, blocking wheel 34 of truck 36 with locking system 26, and positioning leveler 16. Thereafter, loading / unloading 88 of truck 36 can be performed. Optionally, in monitoring and control step 90 a determination step is performed whether truck 36 can be released. This may involve a check on the weight of the loads that were handled, receipt of payments, ID-authorization, approval of breath analysis.

The present invention is by no means limited to the above described preferred embodiments thereof. The rights sought are defined by the following claims within the scope of which many modifications can be envisaged.