WO2026038995A1 - Twistlock handling system - Google Patents

Abstract

An actuator assembly of a twistlock handling system, the actuator assembly comprising: a telescopic arm comprising a static part configured to be fixedly attached to a spreader and a moveable end configured to move vertically down and up during extension and retraction respectively of the telescopic arm; a robot arm having six degrees of freedom provided at the moveable end of the telescopic arm; and an end-effector provided at an end of the robot arm and comprising a moveable unlocking interface configured to operate an unlocking mechanism of a twistlock provided at a bottom corner casting of an intermodal freight container when the spreader is coupled to the container.

Description

TWISTLOCK HANDLING SYSTEM

Technical Field

[0001] The present disclosure relates to a twistlock handling system, and in particular to a twistlock handling system for decoupling two intermodal freight containers that are vertically connected by twistlocks.

Background

[0002] To ensure the stability and integrity of intermodal freight containers during turbulent sea voyages when shipping goods by sea, container fittings such as semi-automatic twistlocks are often used to lash containers to each other when the containers are stacked above the hatch covers on a vessel. Semi-automatic twistlocks allow for relatively quick and secure locking because they automatically lock upon placing one container on top of another, and provide a reliable connection that can withstand the significant forces encountered during rough sea conditions.

[0003] However, to decouple two containers which are vertically lashed to each other by twistlocks, the unlocking process of the twistlocks remains largely manual, requiring stevedores to be present on top of the container stacks that are often several tiers high to operate an unlocking mechanism of each twistlock (e.g., by pulling on a flexible handle of a semi-automatic twistlock) which releases the secure connection between the two containers. This exposes the stevedores to a high risk of falls and also to a risk of crush injuries involving the container spreader that is used to move individual containers.

[0004] It is therefore desirable to provide a system for unlocking container twistlocks that can decouple two vertically-connected containers without requiring manual intervention, to improve safety of container handling operations.

Summary

[0005] According to a first aspect, there is provide an actuator assembly of a twistlock handling system, the actuator assembly comprising: a telescopic arm comprising a static part configured to be fixedly attached to a spreader and a moveable end configured to move vertically down and up during extension and retraction respectively of the telescopic arm; a robot arm having six degrees of freedom provided at the moveable end of the telescopic arm; and an end-effector provided at an end of the robot arm and comprising a moveable unlocking interface configured to operate an unlocking mechanism of a twistlock provided at a bottom corner casting of an interm odal freight container when the spreader is coupled to the container.

[0006] The unlocking mechanism of the twistlock may comprise a pullable flexible handle and wherein the unlocking interface comprises a plate having a slot therein for engaging the flexible handle such that movement of the unlocking interface pulls on the flexible handle.

[0007] The end-effector may include a motor-driven ball screw provided to actuate movement of the unlocking interface.

[0008] Extension and retraction of the telescopic sleeve may be actuated by a motor-driven ball screw provided in the telescopic sleeve.

[0009] The actuator assembly may further comprise an integrated camera vision system provided on the robot arm for determining position and orientation of the twistlock relative to the end-effector and for determining a current locking status of the twistlock.

[0010] The robot arm may be configured to autonomously move the end-effector to an initial position based on geometric parameters of the container.

[0011] The initial position of the end-effector may be refined in real-time using feedback from the integrated camera system to identify key features for enabling precise alignment of the end-effector with the twistlock.

[0012] The actuator assembly may further comprise joint encoders provided on the robot arm for providing position feedback of the robot arm to a central control system of the twistlock handling system.

[0013] According to a second aspect, there is provided a twistlock handling system comprising: a plurality of actuator assemblies according to any one of claims 1 to 8 configured to be provided on a spreader; and a central control system provided in electronic communication with each actuator assembly, wherein the central control system is configured to initiate extension of the telescopic arms and the robot arms when the spreader is confirmed to be coupled to an intermodal freight container, and to initiate retraction of the telescopic arms and the robot arms when the end-effectors are confirmed to have unlocked twistlocks provided at bottom corner castings of the container. [0014] The images obtained by the integrated camera vision system may be used to identify and report any faulty twistlocks provided at the bottom corner castings of the container.

[0015] The central control system may be configured to execute synchronized motion planning algorithms in which position feedback from joint encoders provided on each robot arm is monitored to coordinate movement of the robot arms and telescopic arms for avoiding collisions.

[0016] The twistlock handling system may further comprise a user interface provided in electronic communication with the central control system for an operator to initiate an unlocking sequence that activates the central control system to initiate the extension of the telescopic arms and the robot arms.

[0017] The user interface may be configured to allow the user to receive feedback from the twistlock handling system on task completion and system faults.

[0018] The user interface may be further configured to allow the user to override the system and to halt all operations.

[0019] The twistlock handling system may be configured to be retrofitted onto the spreader.

Brief Description of the Drawings

[0020] In order that the invention may be fully understood and readily put into practical effect there shall now be described by way of non-limitative example only exemplary embodiments of the present invention, the description being with reference to the accompanying illustrative drawings.

Fig. 1 is a schematic illustration of a perspective view of an exemplary twistlock handling system.

Fig. 2 is a photograph of the twistlock handling system in use.

Fig. 3 is an exemplary block diagram of the twistlock handling system of FIG. 1.

Fig. 4 is a perspective view of an exemplary telescopic arm with and without a motor housing.

Fig. 5 is cross-sectional perspective and front views of the telescopic arm of Fig. 4 showing a ball screw and linear guide system. Fig. 6 is a block diagram of integrated camera vision systems of the twistlock handling system in electronic communication with a first computer provided on the spreader.

Fig. 7 is a block diagram of a second computer provided in an operator area in electronic communication with the first computer.

Fig. 8 is a front view of an exemplary user interface of the twistlock handling system.

Fig. 9 is a perspective view of an exemplary end-effector of the twistlock handling system.

Fig. 10 is a perspective view of an exemplary semi-automatic twistlock.

Fig. 11 is a perspective view of a moveable unlocking interface of the end-effector of Fig. 9. Fig. 12 is a front view of the unlocking interface of Fig. 11.

Fig. 13 is a flow chart of an exemplary instance of use of the twistlock handling system.

Detailed Description

[0021] Exemplary embodiments of a twistlock handling system 1000 will be described with reference to Figs 1 to 13 in which the same reference numerals refer to the same or similar parts.

[0022] The twistlock handling system 1000 comprises a plurality of actuator assemblies 100 and a central control system 40 provided in electronic communication with the actuator assembly 100. Each actuator assembly 100 comprises a telescopic arm 10, a robot arm 20 attached to the telescopic arm 10, and an end-effector 30 attached to the robot arm 20 for unlocking a twistlock 400 (see Fig. 10) that lashes a first container 301 to a second container 302 (the second container 302 being located under the first container 301). Each actuator assembly 100 is configured to be mounted onto a spreader 200 that is configured to hoist, move, and lower containers, as can be seen in Figs 1 and 2. Appreciably, one spreader 200 may be provided with up to four units of the actuator assembly 100 each at or adjacent one of four corners of the spreader 200, as shown in the exemplary embodiments in Figs 1-3. In other embodiments (not shown), two units of the actuator assembly 100 may be provided on one spreader 200, each actuator assembly 100 preferably being centrally provided at each of the two short sides of the spreader 200 and configured to unlock twistlocks provided at two bottom corner castings 310B of the first container 301 .

[0023] As shown in Figs 4 and 5, the telescopic arm 10 of each actuator assembly 100 is configured to be vertically extendable and retractable. A static part 19 of the telescopic arm 10 is configured to be fixedly attached to the spreader 200. A moveable end 11 of the telescopic arm 10 is configured to move vertically down and up during extension and retraction respectively of the telescopic arm 10. The telescopic arm 10 is multi-segmented and is preferably driven by a high-performance synchronized linear electric servo motor 12 coupled with a precision planetary gearbox and integrated with absolute encoder feedback. Preferably, the motor 12 and gearbox are protected within a motor housing 13 provided on the telescopic arm 10. In a preferred embodiment, the telescopic arm 10 uses a high-precision ball screw mechanism 15 directly driven by the motor 12 and coupled with a precision linear guide shaft 16 system employing low-friction linear bearings to achieve precise and repeatable vertical extension and retraction of the telescopic arm 10. This direct drive eliminates backlash and provides exceptional positional accuracy and repeatability. The servo motor's high dynamic response enables rapid acceleration and deceleration, contributing to the system's high operational speed. The integration of the absolute encoder ensures that precise position control is maintained even after power interruption, enhancing system reliability and simplifying initialization. The linear guide shaft 16 effectively constrains vertical movement of the telescopic arm 10, preventing rotational or lateral deviations to ensure smooth and stable motion throughout its entire stroke. Optimized spacing and mounting of the linear bearings minimize bending moments and contribute to the overall rigidity of the telescopic arm 10.

[0024] An extension sequence of the telescopic arm 10 may be governed by predefined motion profiles and/or dynamically adjusted based on real-time container height data acquired using an integrated laser distance scanning system (not shown) that is provided on the spreader 200. Where multiple units of the actuator assembly 100 are provided on a single spreader 200, synchronization of the multiple telescopic arms 10 is configured to be managed by the central control system 40 to avoid uneven loading and for uniform deployment and controlled access for the robot arms 20. The extended position of each telescopic arm 10 may be maintained through closed-loop servo control, to compensate for any external disturbances.

[0025] In use, when the spreader 200 has been coupled to the first container 301, each telescopic arm 10 is configured to extend to a designated vertical position to provide optimal spatial positioning in order for the end-effector 30 that is provided at an end 21 of each robot arm 20 to access a twistlock located at a bottom corner casting 301 B of the first container 301 . The extended position of the telescopic arm 10 may be precisely maintained through a closed- loop servo control in order to compensate for any external disturbances.

[0026] In an exemplary embodiment, the telescopic arm 10 is preferably configured to have high-speed capability, achieving linear velocities up to 300 millimetres per second. This rapid actuation significantly reduces the cycle time for deploying and retracting the robot arm 20, directly contributing to increased operational efficiency of the actuator assembly 100. Furthermore, the inherent mechanical precision of the ball screw 15 and linear guide 16 system, combined with the sophisticated control algorithms of the servo drive 12, results in minimal vibration and shaking during movement, crucial for maintaining the stability and accuracy of the robotic manipulation tasks performed by the end-effector 30 at the end of the telescopic arm 10.

[0027] The telescopic arm 10 is preferably optimized for a load capacity of up to 500 kilograms, which has been determined to be suitably robust for the anticipated weight of the robot arm 20, the end-effector, 30 and any handled components within current system specifications. Materials selected for the ball screw 15, linear guide shaft 16, and supporting structure are preferably high-strength alloys chosen for their durability and resistance to wear, ensuring a long operational lifespan and minimal maintenance requirements.

[0028] In each actuator assembly 100, the robot arm 20 is attached to the moveable end 11 of the telescopic arm 10 and has six degrees of freedom (6-DOF). The robot arm 20 is preferably driven by high-performance servo motors with integrated torque sensors, enabling precise and agile movement of the robot arm 20. The robot arm 20 may comprise a commercially available 6-DOF robot arm, for example.

[0029] Provided at the distal end of the robot arm 20 is an integrated camera vision system (not shown) that preferably comprises high-frame-rate cameras to capture detailed images of the bottom corner castings 301 B of the first container 301. For example, each camera may comprise an analogue camera with a standard frame that may be varied according to the broadcast standard used, i.e., 25 frames per second (fps) for PAL (Phase Alternating Line) and 30 fps for NTSC (National Television System Committee). Analog cameras offer several advantages, these being primarily lower cost, simpler installation, broad compatibility with existing systems, and robustness for use in harsh weather conditions. Preferably, two cameras are provided per robot arm 20, see Fig. 6, each having a different lens angle so that one camera can obtain a broad overview while the other camera can obtain a detailed field of view. The images are preferably captured under optimized lighting conditions that may be provided by integrated light-emitting diode (LED) modules having controlled intensity and illumination angles that may be provided with the integrated camera vision system.

[0030] The robot arm 20 is configured to be able to autonomously move the end-effector 30 provided at the end 21 of the robot arm 20 to an initial position based on geometric parameters of the first container 301. This initial position is preferably refined in real-time using feedback from the integrated camera vision system described above, preferably using advanced image processing algorithms to identify key features for enabling precise alignment of the end-effector 30 with the target twistlock area 301 B. Further preferably, image processing is executed on an embedded graphical processing unit (GPU). Obstacle avoidance algorithms are preferably incorporated into the motion planning of the robot arm 20 to prevent collisions with the first container 301, the spreader 200, or another robot arm 20.

[0031] Images captured by the integrated camera vision system are preferably transmitted to a central processing unit of a first computer (Computer 1 in Fig. 6) or a distributed processing architecture for parallel analysis, preferably via high-speed, shielded cables. The first computer is preferably provided on the spreader 200 and is in electronic communication with the central control system 40. A sophisticated, pre-trained deep learning-based Al module is preferably provided to perform real-time analysis of the acquired images in order to:

• detect and localize individual twistlocks under varying lighting and environmental conditions,

• identify the specific type of twistlock present (e.g., manual, semi-automatic, fully automatic, dovetail),

• determine the current locking status of the twistlock (e g. locked, unlocked, potentially damaged), and

• accurately estimate the precise 3D pose (position and orientation) of the twistlock relative to the end-effector 30 at the end of the robot arm 20.

[0032] The obtained images may also be used to identify and report on faulty twistlocks, such as jammed twistlocks or twistlocks with missing unlocking mechanisms such as missing knobs or operating rods. Preferably, the Al module is further configured to generate a comprehensive report of the identified twistlock location, type, and status, which is then communicated to the central control system 40. The central control system 40 is configured to generate precise motion commands for the robot arm 20 based on the output of the Al module such that the end-effector 30 is able to autonomously unlock the twistlock. These commands take into consideration the identified twistlock type and its 3D pose.

[0033] The first computer (Computer 1) provided on the spreader is preferably also in electronic communication with a second computer (Computer 2 in Fig. 7) that is provided in an operator area such as a crane cabin. A user interface 80 as shown in Fig. 8 is preferably integrated with the second computer to allow a human operator to initiate an unlocking sequence using the twistlock handling system 1000 by activating the central control system 40 to initiate extension of the telescopic arms and the robot arms 20 when the spreader 200 is confirmed to be coupled to the container 301. For example, the user interface 80 may include a ‘Start’ button 82 that the operator may depress to initiate the unlocking sequence when a ‘Ready’ LED light 81 of the user interface 80 is turned on, indicating that the system 1000 is ready for use.

[0034] As shown in Fig. 9, the end-effector 30 attached to the end 21 of the robot arm 20 comprises a moveable unlocking interface 38 that is configured to operate an unlocking mechanism 401 of a twistlock 400 as shown in Fig. 10. The unlocking interface 38 may be configured to be interchangeable in order to be form-fitting for engaging with the specific geometry of a specific type of twistlock. To move the unlocking interface 38, a high-precision actuation mechanism (e.g., rotary servo motor, linear solenoid) is preferably provided. Force sensors may be integrated within the end-effector 30 to provide real-time feedback on the unlocking force applied, ensuring controlled and damage-free operation. In an exemplary embodiment, the actuation mechanism may comprise a compact, high-performance brushless servo motor 32 with integrated encoder feedback directly driving a miniature, high-lead precision ball screw 35 to which the moveable unlocking interface 38 is attached and supported by a linear guide shaft 36 assembly. Use of a ball screw 35 in the end-effector 30 enables rapid linear motion of the unlocking interface 38, achieving operational speeds of up to 300 millimetres per second. The direct drive configuration of the end-effector 30 minimizes backlash and provides precise control over the linear displacement of the unlocking interface 38 required to engage and disengage the unlocking mechanism 401 of the twistlock 400. The integrated encoder of the motor 32 provides high-resolution positional feedback for executing complex unlocking sequences and for verifying the final unlocked state. The linear guide shaft 16, paired with low-friction linear bearings, provides rigid and stable support for the moving components 15, 38 of the end-effector 30. This ensures that the unlocking force is applied linearly and without unwanted lateral movement or rotation, which could potentially damage the twistlock mechanism or reduce reliability of the unlocking operation. Robust construction of the guide shaft 16 and bearings of the end-effector 30 contributes to the overall durability and longevity of the end-effector 30, even after many operational cycles.

[0035] The end-effector 30 is preferably configured to withstand a load capacity of up to 30 kilograms, which is deemed suitable for interacting with standard container twistlocks and overcoming any frictional forces or minor obstructions that may be present. The end-effector 30 is preferably also configured to be lightweight in order to minimize overall inertia of the robot arm 20, allowing for faster and more agile movements.

[0036] In an exemplary embodiment, as can be seen in Figs 9, 11 and 12, the unlocking interface 38 may comprise a plate 34 having a centrally provided slot 37 therein through which an unlocking mechanism such as an operating rod or flexible handle 401 of the twistlock 400 may pass. In an exemplary embodiment where the twistlock 400 is a semi-automatic twistlock, the twistlock 400 is unlocked by pulling on the flexible handle 401 having an enlarged knob 402 at its end. This may be achieved by first fitting the slot 37 of the unlocking interface 38 over the flexible handle 401 such that the knob 402 is located between the unlocking interface 38 and the motor 32, and then moving the unlocking interface 38 towards the motor 32 (in the direction indicated by the white arrow in Fig. 9) so that the unlocking interface 38 pulls against the knob 402 and thereby pulls on the flexible handle 401 . Appreciably, the slot 37 should have a width smaller than the diameter of the knob 402 to ensure a precise fit and sufficient contact area with the knob 402 in order to effectively grasp and manipulate the flexible handle 401 with minimal slippage or deformation. This is critical for efficient and safe operation of the twistlock handling system 1000, even when the twistlock unlocking mechanism 401 is subject to significant loads or adverse environmental factors such as corrosion or debris accumulation.

[0037] The unlocking interface 38 of the end-effector 30 is preferably modular or interchangeable to engage with the operating mechanisms of different types of twistlocks (e.g., manual, semi-automatic). This can be achieved by providing unlocking interfaces 38 having different gripping jaws or specialized adapters that can be readily changed based on the identified twistlock type. The end-effector 30 preferably comprises integrated quick-release mechanisms to facilitate such changes of the unlocking interface 38, thereby enhancing the versatility of the twistlock handling system 1000.

[0038] Further preferably, the end-effector 30 incorporates integrated sensors to enhance the reliability and safety of the unlocking process. Miniature force sensors may be strategically positioned within the gripping mechanism to provide real-time feedback on the applied force, preventing over-actuation or damage to the twistlock. Proximity sensors or micro-switches may also be integrated to provide direct physical confirmation of the unlocked state of the twistlock. Such multi-sensor feedback is crucial for closed-loop control of the unlocking process and for reliable verification of successful operation. [0039] Following the unlocking command of the central control system 40, the integrated camera vision system on the robot arm 20 is preferably configured to perform a secondary verification step, capturing new images of the twistlock area 301 B for the Al module to analyse these images and confirm the successful unlocking of the twistlock. Integrated proximity sensors or micro-switches may also be provided within the unlocking jig in order to provide direct physical confirmation of the unlocked state. Confirmation that unlocking of the twistlock is completed along with verification data from all the above-described sensors is preferably transmitted to the central control system 40.

[0040] Upon receiving confirmation that twistlock unlocking by the end-effector 30 is complete, the central control system 40 is configured to initiate a retraction sequence of the actuator assembly 100 that follows a pre-defined, collision-free trajectory back to its designated home position on the spreader 200. An example of an actuator assembly 102 being in its home position on the spreader 200 is shown in Fig. 2. On a single spreader 200, retraction movements of the multiple robot arms 20 and telescopic arms 10 are coordinated to ensure that no interference or collisions occur. This coordination is achieved through the use of synchronized motion planning algorithms executed by the central control system 40, in which position feedback from joint encoders provided on each robot arm 20 is continuously monitored to ensure accurate and safe retraction of the telescopic arms 10 and return of the robot arms 20 to their home positions. Once all the robot arms 20 are in their home positions and the telescopic arms 10 are fully retracted, the system 100 signals its readiness for another container handling cycle.

[0041] In an exemplary embodiment of use to remove a first container 301 that is lashed to a second container 302 on which the first container 301 rests, twistlocks that secure bottom corner castings 301 B of the first container 301 to corresponding top corner castings 302T of the second container 302 must first be unlocked. The unlocking will take place when the spreader 200 engages the first container 301 in preparation for lifting the first container 301 .

[0042] Fig. 13 shows a flow of an unlocking sequence using the twistlock handling system 1000 described above. At the start of the sequence, when the system 1000 is ready (1301), the 'Ready’ LED light 81 of the user interface 80 is turned on (1302). The spreader 200 is then moved to land on the first container 301 (1303). Preferably, the spreader 200 is equipped with an array of high-precision proximity and position sensors (e.g., LIDAR, ultrasonic, inductive sensors, not shown), and is configured to autonomously approach the first container 301. Positional data is preferably continuously fed to the central control system 40 to ensure sub- mm accuracy in horizontal and vertical alignment of the spreader 200 with the first container 301. A high-performance descending mechanism, employing either a closed-loop hydraulic servo system or a multi-stage electromechanical linear actuator with integrated force feedback, is preferably also provided, to precisely lower the spreader 200 onto the first container 301. Controlled descent of the spreader 200 minimizes impact forces and ensures optimal alignment for twistlock engagement between the spreader 200 and the first container 301. When the spreader 200 has been lowered onto the first container 301, integrated self-aligning twistlocks provided on the spreader 200 actively engage the top corner castings 301T of the first container 301. This engagement may be facilitated by a cam-driven or solenoid-actuated mechanism within the spreader twistlock assembly, ensuring a positive and secure connection between the spreader 200 and the first container 301 .

[0043] Upon successful mechanical interlocking of the spreader 200 with the first container 301 , a dedicated sensor array (e g., inductive proximity switches, optical sensors) that is integrated within each twistlock of the spreader 200 confirms secure engagement of the spreader 200 with the first container 301, upon which a robust confirmation signal, incorporating a unique identifier for each engaged twistlock, is transmitted to the central control system 40, preferably via a high-bandwidth communication protocol (e g., EtherCAT, PROFINET).

[0044] Upon receipt of the signal by the central control system 40 confirming that the spreader 200 is engaged with the first container 301 , the operator can depress the ‘Start’ button 82 (1304) to activate the central control system 40 to extend the telescopic arms 10 (1306) to lower the moveable ends 11 of the telescopic arms 10 to a position where, upon extension of the robot arms 20 (1307), the end-effectors 30 at the ends 21 of the robot arms 20 can reach the twistlocks at the bottom corner castings 301 B of the first container 301. After extension of the telescopic arms 10, the robot arms subsequently extended (1307), and in the extended positions, presence and precise location of each twistlock is detected (1308) by the integrated camera vision system. If no twistlock is detected at one or more of the bottom corner castings 301 B of the first container 301 , a signal can be sent to turn on a ‘Faulty’ LED light 81 (1314) provided on the user interface 80 to alert the operator. If twistlocks are detected, the endeffectors 30 unlock the twistlocks (1309).

[0045] Upon receiving confirmation that the twistlocks have been successfully unlocked (1310), the central control system 40 initiates the retraction sequence of the actuator assemblies 100 so that the robot arms 20 and telescopic arms 10 retract fully to their home positions (1311) on the spreader 200. If unlocking of one or more of the twistlocks proves unsuccessful, the ‘Faulty’ LED light 81 can also be turned on (1313) to alert the operator. Upon full retraction of the actuator assemblies 100, a ‘Completed’ LED light 84 provided on the user interface 80 may be turned on (1312) to alert the operator that the unlocking sequence is completed. This serves as an indication that the operator is now cleared to hoist the first container 301 as it is no longer lashed to the second container 302. The user interface 80 thus allows the operator to initiate the unlocking sequence and also to receive feedback from the system 1000 on task completion and system faults. Preferably, the user interface 80 is also provided with a ‘Reset’ button 85 that allows the operator to activate an override if the system 1000 pauses, or to reset the system 1000 if at the start of the unlocking sequence it is detected that the system 1000 is not ready for whatever reason. An emergency ‘E-stop’ button may also be provided on the user interface 80 for the operator to halt all operations if necessary.

[0046] Notably, the twistlock handling system 1000 is designed to be retrofitted to the spreader 200 of an existing crane system, leveraging existing infrastructure to eliminate the need for costly modifications to cranes, promoting wider adoption and faster implementation of the system 1000. The twistlock handling system 1000 is preferably also configured to be detachable from the spreader 200 after it has been retrofitted on, allowing for ready removal and replacement where necessary. In other embodiments, the twistlock handling system 1000 can be integrally provided with the spreader if desired. The telescopic arms 10 advantageously optimize space utilization while maintaining a robust load capacity for handling heavy containers. This allows for operation in diverse environments with space constraints, ensuring functionality without compromising container handling capabilities. The disclosed end-effectors 30 optimize grasping and manipulation of twistlocks for effective operation to achieve secure and efficient handling of containers, thereby minimizing the risks of accidents and equipment damage. Incorporating Al technology with the integrated camera vision system enhances unlocking accuracy and automates decision-making to increase reliability and reduce the potential for errors during container handling, leading to safer operations.

[0001] While there has been described in the foregoing description exemplary embodiments of the present invention, it will be understood by those skilled in the technology concerned that many variations in details of design, construction and/or operation may be made without departing from the present invention. Many further alterations, modifications and permutations of various aspects of the described embodiments are possible that fall within the spirit and scope of the appended claims.

Claims

Claims

1 . An actuator assembly of a twistlock handling system, the actuator assembly comprising: a telescopic arm comprising a static part configured to be fixedly attached to a spreader and a moveable end configured to move vertically down and up during extension and retraction respectively of the telescopic arm; a robot arm having six degrees of freedom provided at the moveable end of the telescopic arm; and an end-effector provided at an end of the robot arm and comprising a moveable unlocking interface configured to operate an unlocking mechanism of a twistlock provided at a bottom corner casting of an intermodal freight container when the spreader is coupled to the container.

2. The actuator assembly of claim 1, wherein the unlocking mechanism of the twistlock comprises a pullable flexible handle and wherein the unlocking interface comprises a plate having a slot therein for engaging the flexible handle such that movement of the unlocking interface pulls on the flexible handle.

3. The actuator assembly of claim 1 or claim 2, wherein the end-effector includes a motor-driven ball screw provided to actuate movement of the unlocking interface.

4. The actuator assembly of any one of the preceding claims, wherein extension and retraction of the telescopic sleeve is actuated by a motor-driven ball screw provided in the telescopic sleeve.

5. The actuator assembly of any one of the preceding claims, further comprising an integrated camera vision system provided on the robot arm for determining position and orientation of the twistlock relative to the end-effector and for determining a current locking status of the twistlock.

6. The actuator assembly of any one of the preceding claims, wherein the robot arm is configured to autonomously move the end-effector to an initial position based on geometric parameters of the container.

7. The actuator assembly of claim 6 when dependent on claim 5, wherein the initial position of the end-effector is refined in real-time using feedback from the integrated camera system to identify key features for enabling precise alignment of the end-effector with the twistlock.

8. The actuator assembly of any one of the preceding claims, further comprising joint encoders provided on the robot arm for providing position feedback of the robot arm to a central control system of the twistlock handling system.

9. A twistlock handling system comprising: a plurality of actuator assemblies according to any one of claims 1 to 8 configured to be provided on a spreader; and a central control system provided in electronic communication with each actuator assembly, wherein the central control system is configured to initiate extension of the telescopic arms and the robot arms when the spreader is confirmed to be coupled to an intermodal freight container, and to initiate retraction of the telescopic arms and the robot arms when the end-effectors are confirmed to have unlocked twistlocks provided at bottom corner castings of the container.

10. The twistlock handling system of claim 9 when dependent on claim 5 or claim 7, wherein images obtained by the integrated camera vision system are used to identify and report any faulty twistlocks provided at the bottom corner castings of the container.

11 . The twistlock handling system of claim 9 or 10, wherein the central control system is configured to execute synchronized motion planning algorithms in which position feedback from joint encoders provided on each robot arm is monitored to coordinate movement of the robot arms and telescopic arms for avoiding collisions.

12. The twistlock handling system of any one of claims 9 to 11 , further comprising a user interface provided in electronic communication with the central control system for an operator to initiate an unlocking sequence that activates the central control system to initiate the extension of the telescopic arms and the robot arms.

13. The twistlock handling system of claim 12, wherein the user interface is configured to allow the user to receive feedback from the twistlock handling system on task completion and system faults.

14. The twistlock handling system of claim 12, wherein the user interface is further configured to allow the user to override the system and to halt all operations.

15. The twistlock handling system of any one of claims 9 to 14, wherein the twistlock handling system is configured to be retrofitted onto the spreader.