An automatic carton stacking system

Abstract

The present application relates to an automatic carton stacking system, which includes a carton conveying device, a pallet conveying device, a carton handling device, and a PLC controller. The PLC controller controls the operation of the automatic carton stacking system. The pallet conveying device is located below the carton conveying device. The carton handling device transports the cartons on the carton conveying device to the pallets on the pallet conveying device. The carton conveying device includes a first transportation component and a carton shaping component. The first transportation component conveys the cartons, and the carton shaping component can be used to adjust the positions of the cartons. The pallet conveying device includes a storage rack, a blanking component, and a second transportation component. The storage rack is located above one end of the second transportation component, and the pallets are stored on the storage rack. The blanking component releases the pallets onto the second transportation component, and the second transportation component transports the pallets to the loading position. The carton handling device stacks the cartons after handling. The present application has the advantages of improving the space utilization rate during the carton stacking process and saving production costs.

Description

Technical Field

[0001] This application relates to the technical field of carton stacking, and in particular to an automatic carton stacking system. Background Art

[0002] At present, after the cartons are packaged, in order to reduce the workload of workers and improve work efficiency, an assembly line is often used to stack the packaged cartons on a pallet. After stacking is completed, the pallet is inserted and taken to a designated position by a forklift, such as a factory warehouse or a loading area.

[0003] The carton stacking assembly line includes a carton conveyor for packaging cartons, a carton handling device, and a pallet conveyor. Generally, the carton conveyor and the pallet conveyor are arranged side by side or opposite to each other. After several cartons are aligned at the end of the carton conveyor, multiple cartons are picked up and placed at one time by the carton handling device and placed on one layer of the pallet. After multiple layers of cartons are stacked on the pallet, they are inserted and taken to the designated area by a forklift.

[0004] It can be seen that the carton stacking assembly line occupies a large amount of space in the factory building. Due to the high rent of sites in some cities and the unreasonable use of site space, the production cost is greatly increased. Summary of the Invention

[0005] In order to improve the space utilization rate during carton stacking and save production costs, this application provides an automatic carton stacking system.

[0006] An automatic carton stacking system provided by this application adopts the following technical solutions:

[0007] An automatic carton stacking system includes a carton conveying device, a pallet conveying device, a carton handling device, and a PLC controller. The PLC controller is electrically connected to the carton conveying device, the pallet conveying device, and the carton handling device. The pallet conveying device is located below the carton conveying device. The carton handling device transports the cartons conveyed by the carton conveying device to the pallets conveyed by the pallet conveying device.

[0008] The carton conveying device includes a first transportation component and a carton shaping component. The first transportation component transports cartons, and the carton shaping component can be used to adjust the positions of the cartons to form a group of cartons in a horizontal and vertical structure.

[0009] The pallet conveying device includes a storage rack, a blanking component, and a second transportation component. The storage rack is located above one end of the second transportation component. The storage rack stores pallets carried by a forklift. The blanking component releases pallets one by one onto the second transportation component, and the second transportation component transports the pallets to the loading position.

[0010] The carton handling device includes a three-axis robot and a suction cup. The suction cup is fixed at the end of the three-axis robot. The suction cup picks and places cartons, and the three-axis robot transports and stacks cartons.

[0011] By adopting the above technical solution, in actual work, the storage cavity is pre-filled with pallets. Then, under the combined action of the lifting cylinder and the tray separating cylinder, the pallets are successively placed on the second transportation component and transported to the loading position by the second transportation component. At the same time, during the operation of the cartons on the first transportation component, the positions of the cartons can be adjusted under the action of the carton shaping component, so that the maximum number of cartons can be placed on the pallet. Subsequently, under the action of the three-axis robot and the suction cup, the cartons are transferred to the pallet at the loading position for stacking. Since the pallet conveying device is arranged below the carton conveying device, the space occupied by the carton automatic stacking system is reduced, and the production cost is reduced.

[0012] Preferably, the carton shaping device includes an adjusting member for adjusting the position of the carton, a pushing member for pushing the carton, and a transfer platform for carrying the carton.

[0013] The adjusting member is installed on the first transportation component, and the adjusting member can adjust the angles of multiple cartons by 90° at equal intervals.

[0014] The pushing member and the transfer platform are respectively located on both sides in the width direction of the first transportation component and are installed on the first transportation component. After the pushing member pushes a group of unadjusted / or adjusted cartons, it then pushes another group of adjusted / or unadjusted cartons onto the transfer platform.

[0015] By adopting the above technical solution, in actual use, if the maximum number of cartons placed on each layer of the pallet is an even number, the adjusting member is not started; if the maximum number of cartons placed on each layer of the pallet is an odd number, the adjusting member is operated. The cartons rotate by 90° under the action of the adjusting member and form a row of carton structures at the end of the first transportation component. They are pushed onto the transfer platform by the pushing member. The cartons that have not been affected by the adjusting member also form a row of carton structures at the end of the first transportation component and are then pushed onto the transfer platform by the pushing member. The cartons form a group of cartons with horizontal and vertical distributions on the transfer platform. At the same time, the carton handling device places the cartons horizontally and vertically on the pallet in a staggered manner to improve the stability of the cartons on the pallet.

[0016] Preferably, the adjusting member includes a guiding air cylinder and a first infrared sensor both electrically connected to the PLC controller. The guiding air cylinder and the first infrared sensor are both installed on the first transportation component. The first infrared sensor detects the incoming carton and transmits the data information to the PLC controller. The PLC controller controls the operation of the guiding air cylinder. When the piston rod of the guiding air cylinder extends, it touches a corner of the incoming carton, and the guiding air cylinder cooperates with the first transportation component to cause the carton to rotate by 90° and then separate from the guiding air cylinder.

[0017] By adopting the above technical solution, in actual use, the first infrared sensor detects the cartons transported on the first transportation component. If the maximum number of cartons placed on each layer of the pallet is odd, the PLC controller can control the guiding air cylinder to perform a 90° position adjustment on multiple equally spaced cartons. After the guiding air cylinder contacts a corner of the carton, since the first transportation component drives the carton to continue running, the carton rotates by 90° along the contact point with the guiding air cylinder, and finally, the maximum number of cartons placed on the pallet is completed.

[0018] Preferably, the second transportation component includes a first chassis, a first gear set, a first conveying chain, a first motor, and a first guide rail; the first chassis is installed on the ground, the first gear set can be set in multiple groups, the first gear set is rotatably installed at both ends of the first chassis, and each group of the first gear sets is wound with a first conveying chain. The first guide rail is installed on the first chassis and is used to support the first conveying chain. The first motor is installed on the first chassis and drives the rotation of the first gear set.

[0019] By adopting the above technical solution, in actual use, the first motor drives the first gear set to rotate, driving the first chain on the first gear set to run. Due to the friction between the first chain and the pallet, the pallet is driven to the loading position, completing the conveying operation of the pallet.

[0020] Preferably, the unloading component includes a lifting air cylinder and a tray separating air cylinder; the lifting air cylinder is installed on the first chassis and is located below the storage rack, the tray separating air cylinder is installed outside the storage rack, and the piston rod of the tray separating air cylinder can extend into the interior of the storage rack. The lifting air cylinder pushes the pallet upward, the piston rod of the tray separating air cylinder is inserted between the two lowermost pallets, the tray separating air cylinder supports the pallet above the piston rod of the tray separating air cylinder, the lifting air cylinder retracts, and the pallet on the lifting air cylinder falls onto the first conveying chain.

[0021] By adopting the above technical solution, in actual use, through the cooperative operation of the lifting cylinder and the dividing cylinder, the pallets in the storage rack are placed on the first conveying chain one by one, ensuring that the pallets are normally transported to the loading position of the second transportation component and ensuring the stable progress of the carton stacking operation.

[0022] Preferably, the pallet conveying device further includes a third transportation component arranged side by side with the second transportation component on the ground for transporting pallets, a pallet transfer device is arranged between the third transportation component and the second transportation component, the pallet transfer device is electrically connected to the PLC controller, the pallet transfer device moves the pallets on the second transportation component to the third transportation component, and a blocking component for limiting is arranged at the ends of the second transportation component and the third transportation component, and the blocking component is used for limiting the pallets at the loading position.

[0023] By adopting the above technical solution, in actual use, the PLC controller controls the pallet transfer device to transfer the pallets on the second transportation device to the third transportation component, completing the loading work of the pallets on the third transportation component; the setting of the double loading positions can seamlessly connect the material taking work after the carton stacking is completed. Whether the cartons at the loading position are taken and placed in time or not after the carton stacking is completed, the work will not be interrupted, ensuring the normal progress of the work.

[0024] Preferably, the pallet transfer device includes a transfer rack, a transfer gear set, a transfer chain, a moving plate, a transfer motor and a transfer slide rail; both ends of the transfer rack are respectively installed above the second transportation component and the third transportation component, the transfer gear sets are respectively installed at both ends of the transfer rack, the transfer chain is wound around the transfer gear sets, the moving plate is fixed on the transfer chain, the transfer motor is fixed on the transfer rack and drives the transfer gear sets to rotate, and the transfer slide rail is installed between the second transportation component and the third transportation component and is used for the moving plate to drive the pallets on the second transportation component to enter the third transportation component along the transfer slide rail.

[0025] By adopting the above technical solution, in actual use, the transfer motor drives the transfer gear sets to rotate, drives the transfer chain to run, makes the moving plate move along the length direction of the transfer rack, drives the pallets on the second transportation component to enter the third transportation component along the transfer track, and ensures the transfer of the pallets to the third transportation component through the pallet transfer device, completing the loading of the pallets on the third transportation component.

[0026] Preferably, the blocking component includes a linkage rod, a blocking rod and a driving member, the blocking rod is fixed on the linkage rod, the driving member is electrically connected to the PLC controller, and the driving member drives the linkage rod to rotate on the second transportation component or the third transportation component to release the cartons stacked on the pallets.

[0027] By adopting the above technical solution, in actual use, after the shift lever contacts the tray, during the operation of the first shipping chain, the position of the tray does not change, which is convenient for stacking cartons on the tray stably; after the cartons on the tray are stacked, the PLC controller controls the driving member to drive the linkage rod to rotate. After the shift lever is separated from the tray, the tray is released, which is convenient for taking and placing the tray at the designated position.

[0028] Preferably, the tray conveying device further includes two fourth transportation components, which are respectively arranged along the direction of transporting the tray by the second transportation component and the third transportation component. The fourth transportation component transports the cartons stacked on the tray released by the second transportation component and the third transportation component. An induction device for detecting the tray is arranged at the end of the fourth transportation component. The induction device is electrically connected to the PLC controller. When the induction device senses the tray, it sends a signal to the PLC controller, and the PLC controller issues an instruction to stop the operation to the fourth transportation component, and the fourth transportation component stops operating.

[0029] By adopting the above technical solution, in actual use, if it is too late to take and place the cartons stacked on the tray, it will affect the production efficiency. The setting of the fourth transportation component can store the trays with two stacks of cartons, ensuring the stable progress of normal work and the production efficiency; through the induction device, it can be determined whether the tray on the fourth transportation component has been taken away, and the PLC controller can issue an instruction to carry the tray on the corresponding fourth transportation component.

[0030] Preferably, the carton handling device further includes a pressure sensor arranged on the suction cup. The pressure sensor is electrically connected to the PLC controller. When the three-axis robot handles the stacked cartons, when the value of the pressure sensor changes, it transmits a signal to the PLC controller, and the PLC controller controls the suction cup to release the carton.

[0031] By adopting the above technical solution, in actual use, when the value of the pressure sensor changes, the carton handled by the three-axis robot has been placed on the tray for stacking. After the suction cup releases the carton, the three-axis robot performs the next round of carton taking and placing operations, effectively avoiding the problem of carton damage caused during the process of taking and placing cartons.

[0032] In summary, the present application includes at least one of the following beneficial technical effects:

[0033] Pre-fill the storage cavity with pallets. Under the action of the blanking component, the pallets are successively placed on the second transportation component and conveyed to the loading position; meanwhile, the cartons are transported on the first transportation component and can reach the maximum placement quantity on the pallets under the action of the carton shaping component; subsequently, under the action of the carton handling device, stacking operations are performed on the pallets; by setting the pallet conveying device below the carton conveying device, the space occupied by the carton automatic stacking system is reduced, and the production cost is decreased;

[0034] If the placement quantity of each layer of cartons on the pallet is odd, the adjustment part does not operate; on the contrary, the cartons can rotate 90° under the action of the adjustment part to achieve the setting of arranging a row horizontally and a row vertically on the transfer platform, so as to achieve the maximum placement quantity of cartons on the pallet;

[0035] The pallet transfer device completes the conveyance of the pallets from the second transportation component to the third transportation component. After the pallets are transported on the third transportation component, a second carton stacking station is formed to ensure the continuous progress of the carton stacking operation and improve production efficiency; the setting of the fourth transportation component can store the pallets for two stacked cartons, further ensuring the stable progress of the stacking work and ensuring production efficiency. Brief Description of the Drawings

[0036] Figure 1 is the overall structural schematic diagram of the embodiment of the present application;

[0037] Figure 2 is the structural schematic diagram of the carton conveying device in the embodiment of the present application;

[0038] Figure 3 is Figure 2 the enlarged schematic diagram of part A in

[0039] Figure 4 is the structural schematic diagram of the pallet conveying device in the embodiment of the present application;

[0040] Figure 5 is the structural schematic diagram of the third transportation component in the embodiment of the present application;

[0041] Figure 6 is Figure 4 the enlarged schematic diagram of part B in

[0042] Figure 7 is the structural schematic diagram of the fourth transportation component, the induction device and the anti-collision frame in the embodiment of the present application;

[0043] Figure 8 is the structural schematic diagram of the pallet transfer device in the embodiment of the present application;

[0044] Figure 9 is the structural schematic diagram of the second limit component in the embodiment of the present application;

[0045] Figure 10 It is a schematic structural diagram of the carton handling device in the embodiment of the present application;

[0046] Figure 11 It is a schematic overall structural diagram with a protection structure in the embodiment of the present application.

[0047] Explanation of reference numerals: 1. Carton conveying device;

[0048] 11. First transportation component; 111. Conveyor roller; 112. Support frame; 113. Driving motor;

[0049] 12. First limiting component; 121. First limiting plate; 1211. Chute; 122. First guide rod; 1221. Sliding plate; 123. Column; 1231. Sliding hole; 124. Handle bolt;

[0050] 13. Carton shaping component; 131. Adjusting part; 1311. Guiding cylinder; 1312. First infrared sensor; 132. Pushing part; 1321. Pushing cylinder; 1322. Pushing plate; 1323. Reinforcing frame; 1324. Tripod; 1325. Guide rod; 133. Transfer platform; 1331. Transfer frame; 1332. Baffle;

[0051] 2. Pallet conveying device;

[0052] 21. Storage rack; 211. Vertical plate; 212. Storage cavity;

[0053] 22. Unloading component; 221. Lifting cylinder; 222. Tray separating cylinder; 223. Mounting plate; 224. Lifting frame; 225. Telescopic rod; 226. Support;

[0054] 23. Second transportation component; 231. First chassis; 232. First gear set; 233. First towing chain; 234. First motor; 235. First guide rail; 236. Guide plate; 237. Guide frame; 2371. Guide rail plate; 2372. Pressing plate; 238. Second guide rod;

[0055] 24. Third transportation component; 241. Second chassis; 242. Second gear set; 243. Second towing chain; 244. Second motor; 245. Second guide rail;

[0056] 25. Gear position component; 251. Linking rod; 252. Gear lever; 253. Driving part;

[0057] 26. Fourth transportation component; 261. Third chassis; 262. Third gear set; 263. Third towing chain; 264. Third motor; 265. Third guide rail; 266. Orientation plate;

[0058] 27. Second limit component; 271. Limit bracket; 272. Limit cylinder; 273. Second limit plate; 274. Guide rod;

[0059] 3. Carton handling device;

[0060] 31. Three-axis robot; 32. Suction cup; 33. Pressure sensor;

[0061] 34. Clamping component; 341. Fixed plate; 342. Movable plate;

[0062] 4. Pallet transfer device; 41. Transfer rack; 42. Transfer gear set; 43. Transfer chain; 44. Moving plate; 45. Transfer motor; 46. Transfer slide rail;

[0063] 5. Induction device; 51. Second infrared sensor; 52. Induction rack;

[0064] 6. Anti-collision rack; 7. Protection rack; 8. Protection net; 9. Warning light. Detailed implementation manners

[0065] The following further elaborates on this application in conjunction with the attached Figures 1-11 drawings.

[0066] The embodiment of this application discloses an automatic carton stacking system.

[0067] As Figure 1 shown, the automatic carton stacking system includes a carton conveying device 1, a pallet conveying device 2, a carton handling device 3 and a PLC controller. The PLC controller is electrically connected to the carton conveying device 1, the pallet conveying device 2 and the carton handling device 3. The pallet conveying device 2 is located below the carton conveying device 1. The cartons after packaging are conveyed from one end of the carton conveying device 1 to the other end of the carton conveying device 1, and the empty pallets are conveyed from one end of the pallet conveying device 2 to the other end of the pallet conveying device 2. The carton handling device 3 conveys the conveyed cartons onto the conveyed pallets for neat stacking, completing the automatic stacking of the cartons and improving work efficiency.

[0068] As Figure 2 shown, the carton conveying device 1 includes a first conveying component 11 for transporting cartons. The first conveying component 11 includes conveying rollers 111, a support frame 112 for installing the conveying rollers 111 and a driving motor 113 for driving the conveying rollers 111 to rotate. The conveying rollers 111 are rotatably installed on the support frame 112 at equal intervals. The conveying rollers 111 are driven by a chain, and the driving motor 113 is fixedly installed at the starting end of the conveying of the support frame 112 by bolts. The driving motor 113 is connected to one of the conveying rollers 111 by a chain.

[0069] AsFigure 2 As shown in the figure, the carton conveying device 1 further includes a first limiting component 12 for limiting the cartons. The first limiting component 12 includes a first limiting plate 121 for limiting the cartons, a first guide rod 122 connecting the first limiting plate 121, and a column 123 adjustably arranged with the first guide rod 122. The column 123 is fixed to the top of the support frame 112 by bolts.

[0070] As Figure 3 shown, specifically, the column 123 is provided with a sliding hole 1231 along the width direction of the support frame 112 and slidably matched with the first guide rod 122. A handle bolt 124 is threadedly engaged with the top of the column 123. The end of the handle screw rod penetrates into the sliding hole 1231 to press the first guide rod 122 against the inside of the sliding hole 1231, thereby realizing the adjustable setting of the first guide rod 122 and the column 123.

[0071] At the same time, in order to facilitate the installation of the first limiting component 12, a chute 1211 extending along the length direction of the first limiting plate 121 and in a T shape is provided on one side of the first limiting plate 121. One end of the first guide rod 122 is formed with a sliding plate 1221 slidably matched with the chute 1211, reducing the installation difficulty of the first limiting component 12.

[0072] As Figure 2 shown, in order to improve the handling efficiency of the cartons and maximize the placement quantity of the cartons on the pallet, the carton conveying device 1 further includes a carton shaping component 13 for adjusting the orientation of the cartons. Specifically, the carton shaping component 13 includes an adjusting member 131 for adjusting the direction of the cartons, a pushing member 132 for pushing the cartons, and a transfer platform 133 for carrying the cartons. The adjusting member 131 is installed on one side in the width direction of the top of the support frame 112, and the transfer platform 133 and the pushing member 132 are located on opposite sides of the top of the conveying end of the support frame 112.

[0073] During use, when the maximum placement quantity of each layer of cartons on the pallet is an even number, the adjusting member 131 does not work, and the pushing member 132 pushes the grouped cartons onto the transfer platform. When the maximum placement quantity of each layer of cartons on the pallet is an odd number, the adjusting member 131 can adjust the angles of multiple cartons at equal intervals by 90°. After the pushing member 132 pushes a group of unadjusted / or adjusted cartons onto the transfer platform 133, it then pushes multiple adjusted / or unadjusted cartons onto the transfer platform 133 to form a group of cartons in a horizontal and vertical arrangement. With such a setting, the maximum placement quantity of the cartons on the pallet is achieved.

[0074] In the actual stacking operation of cartons, the distribution of cartons on the pallet is determined by the size of the cartons, that is, the distribution of cartons on the transfer platform 133. In this embodiment, if the maximum number of cartons placed on each layer of the pallet is five. Then the cartons need to form two cartons arranged horizontally and three cartons arranged vertically on the transfer platform 133. If the length direction of the cartons is along the conveying direction of the first transport component 11, two cartons directly pass through the first transport component 11 and are directly pushed to the transfer platform 133 by the push member 132, and then the push member 132 returns to the initial state. The other three cartons are rotated 90° by the adjustment member 131 and are directly pushed to the transfer platform by the push member 132. The cartons form a whole layer structure on the transfer platform 133 that can be stacked on the pallet, so that the cartons can be placed in maximum quantity on the pallet, thereby improving the efficiency of transporting cartons.

[0075] Correspondingly, if the width direction of the cartons is along the conveying direction of the first transport component 11, the adjustment member 131 adjusts the directions of two cartons every three cartons, thereby completing the arrangement of the cartons on the transfer platform and achieving the maximum placement amount on the pallet.

[0076] Continue as Figure 2 As shown, in this embodiment, the adjustment member 131 includes a guide cylinder 1311 and a first infrared sensor 1312. The first infrared sensor 1312 and the guide cylinder 1311 are both mounted on the support frame 112, and the guide cylinder 1311 is arranged near the conveying tail of the support frame 112. The guide cylinder 1311 and the first infrared sensor 1312 are both electrically connected to the PLC controller. The first infrared sensor 1312 detects the conveyed cartons and transmits data to the PLC controller. The PLC controller issues instructions for the operation and reset of the guide cylinder 1311 according to the number of cartons detected, and controls the operation of the guide cylinder 1311. After the guide cylinder 1311 is extended, a corner of the carton in transportation collides with the piston rod of the guide cylinder 1311, and the carton is driven by the conveying roller 111 and rotates along the end of the piston rod of the guide cylinder 1311 until the carton rotates 90° and disengages from the piston rod of the guide cylinder 1311, and the carton continues to be transported with the conveying roller 111.

[0077] Specifically, the pushing member 132 includes a pushing cylinder 1321 and a pushing plate 1322. The pushing cylinder 1321 is fixed at the conveying tail of the support frame 112. The pushing cylinder 1321 is arranged along the width direction of the support frame 112. The pushing plate 1322 is fixed on the piston rod of the pushing cylinder 1321. The pushing member 132 further includes a reinforcing frame 1323. The reinforcing frame 1323 is fixed on the support frame 112. The pushing cylinder 1321 is fixed on the reinforcing frame 1323. And a tripod 1324 arranged along the length direction of the pushing cylinder 1321 is fixed on the reinforcing frame 1323. The setting of the tripod 1324 improves the stability of the pushing cylinder 1321. Guide rods 1325 arranged along the length direction of the pushing cylinder 1321 are slidably fitted at both ends of the reinforcing frame 1323 respectively. The ends of the guide rods 1325 are fixed to the pushing plate 1322, improving the stability of the operation of the pushing plate 1322.

[0078] Continuing as Figure 2 shown, in this embodiment, the transfer platform 133 includes a transfer frame 1331. The transfer frame 1331 is welded to the conveying tail of the support frame 112. And the conveyor roller 111 at the conveying tail of the support frame 112 passes through the support frame 112 and is rotatably fitted with the transfer frame 1331. A baffle 1332 for blocking the carton is fixedly installed on the transfer frame 1331.

[0079] As Figure 4 shown, in this embodiment, the pallet conveying device 2 includes a storage rack 21 for storing pallets, a blanking assembly 22 for releasing pallets, and a second conveying assembly 23 for transporting pallets. Among them, the storage rack 21 is located directly below the conveying tail end of the support frame 112. The storage rack 21 includes two L-shaped vertical plates 211, forming a storage cavity 212 for storing pallets. And the ends of the two vertical plates 211 are bent away from each other, so as to facilitate the forklift to place the pallet into the storage cavity 212.

[0080] Continuing as Figure 4 shown, specifically, the second conveying assembly 23 includes a first chassis 231 located below the vertical plate 211, a first gear set 232 rotatably arranged on the first chassis 231, a first towing chain 233 sleeved on the first gear set 232, and a first motor 234 for driving the first gear set 232 to rotate. Among them, the first motor 234 is fixed on the first chassis 231. The first gear set 232 is divided into three groups, which are respectively arranged at both ends of the first chassis 231. A first towing chain 233 is wound around each group of the first gear set 232. A first guide rail 235 for carrying the first towing chain 233 is installed on the first chassis 231. The pallet is placed on the first towing chain 233. Starting the first motor 234 will drive the pallet on the first towing chain 233 to move to the place where the carton is supported (the feeding place) and stop, that is, the other end of the first chassis 231.

[0081] In this embodiment, each set of the first gear sets 232 includes a driving gear and a driven gear, and the driving gear and the driven gear are respectively rotatably mounted at both ends of the first chassis 231. The three driving gears are of the same size and are coaxially fixed by a rotating shaft. At the same time, the three driving gears are equidistantly distributed in the width direction of the first chassis 231, and the first motor 234 drives the rotating shaft on the driving gear to rotate through a transmission chain.

[0082] Continuing as Figure 4 shown, specifically, the blanking assembly 22 includes a lifting cylinder 221 for lifting the tray and a tray separating cylinder 222 for separating the trays. Among them, the lifting cylinder 221 is located directly below the storage cavity 212, and a mounting plate 223 is welded to the bottom of the first chassis 231, and the lifting cylinder 221 is fixed on the mounting plate 223. In order to facilitate the stability of lifting the tray, a lifting frame 224 is fixed on the piston rod of the lifting cylinder 221. The lifting frame 224 can pass through the first chassis 231. Telescopic rods 225 are respectively arranged at the four corners of the lifting frame 224, and both ends of the telescopic rods 225 are fixed to the lifting frame 224 and the mounting plate 223 respectively. The tray separating cylinder 222 is fixed on the outside of the vertical plate 211. A support 226 is fixed on the vertical plate 211, and the tray separating cylinder 222 is fixed on the support 226, and one end of the piston rod of the tray separating cylinder 222 can extend into the storage cavity 212.

[0083] When the tray is blanked, the lifting cylinder 221 first lifts the tray to a specific position (that is, the two bottom trays are located on both sides of the tray separating cylinder 222). The piston rod of the tray separating cylinder 222 extends into the storage cavity 212 and is located between the two bottom trays, playing a role in supporting the tray above the piston rod. Then, after the piston rod of the lifting cylinder 221 contracts, the separated tray falls onto the first conveying chain 233 and runs to the feeding place along with the first conveying chain 233. When the next tray needs to be separated, the piston rod of the lifting cylinder 221 extends until it lifts the tray, the piston rod of the tray separating cylinder 222 contracts, and then the lifting cylinder 221 lowers by the height of one tray. The piston rod of the tray separating cylinder 222 extends between the trays again, and the lifting cylinder 221 moves downward until the trays are successively lowered onto the first conveying chain 233.

[0084] Continuing as Figure 4 shown, in this embodiment, in order to ensure the stable transportation of the tray, a guide plate 236 for guiding the tray is fixed on the top of the first chassis 231, and the ends of the guide plate 236 are chamfered. The guide plate 236 is adjustably arranged on the first chassis 231. Among them, a guide frame 237 is fixedly installed on the first chassis 231 by bolts, a second guide rod 238 is welded on the guide plate 236, and the second guide rod 238 is locked on the guide frame 237.

[0085] Specifically, the guide frame 237 includes a guide rail plate 2371 and a channel-shaped pressing plate 2372 covering the guide rail plate 2371. The pressing plate 2372 is adapted to the second guide rod 238. The guide rail plate 2371 is fixed on the first chassis 231, and the pressing plate 2372 is fixed on the guide rail plate 2371 by bolts. A rubber pad is provided between the pressing plate 2372 and the second guide rod 238 to ensure the stability of the fixation of the second guide rod 238.

[0086] As Figure 1 shown, after the cartons are stacked on the tray at the loading position, the tray needs to be removed in time by a forklift, and the cartons are transported to the warehouse. In this process, it takes a certain amount of time for the forklift to pick up and place the cartons, reducing the work efficiency. To ensure the work efficiency, in this embodiment, two loading positions are arranged side by side. A tray transfer device 4 is connected to the middle of the first chassis 231, and the other end of the tray transfer device 4 is connected to a third transportation component 24. The tray transfer device 4 moves the tray on the first transportation component 11 to the third transportation component 24, and the third transportation component 24 transports the tray to another loading position.

[0087] As Figure 5 shown, specifically, the third transportation component 24 includes a second chassis 241, a second gear set 242 rotatably arranged on the second chassis 241, a second towing chain 243 sleeved on the second gear set 242, and a second motor 244 driving the second gear set 242 to rotate. In this embodiment, the structure of the third transportation component 24 is the same as that of the second transportation component 23, and will not be elaborated here. Correspondingly, a guide plate 236 for guiding the tray is also installed on the second chassis 241 to facilitate the stable operation of the tray on the third transportation component 24.

[0088] As Figure 4 and Figure 6 shown, since the second transportation component 23 and the third transportation component 24 are both operating during the process of transferring the tray, in order to prevent the tray at the loading position from running, a blocking component 25 for limiting the tray is provided at the ends of the second transportation component 23 and the third transportation component 24. The structures and functions of the two blocking components 25 are the same. Now, taking the blocking component 25 on the second transportation component 23 as an example, the blocking component 25 includes a linkage rod 251 rotatably arranged on the first chassis 231, a blocking rod 252 fixed on the linkage rod 251, and a driving member 253 driving the linkage rod 251 to rotate. In this embodiment, the driving member 253 can be set as a cylinder, and the two ends of the cylinder are respectively hinged to the linkage rod 251 and the first chassis 231. In the initial state, the blocking rod 252 is in a vertical state to limit the tray.

[0089] Correspondingly, a gear component 25 is provided on the third transportation component 24. A linkage rod 251 on the gear component 25 is rotatably arranged on the second chassis 241, and the driving member 253 is hinged to the linkage rod 251 and the second chassis 241.

[0090] As Figure 7 shown, in this embodiment, fourth transportation components 26 are provided at the ends of the second transportation component 23 and the third transportation component 24. The fourth transportation components 26 are respectively arranged along the directions in which the second transportation component 23 and the third transportation component 24 transport pallets. The fourth transportation components 26 transport pallets filled with cartons. Specifically, the fourth transportation component 26 includes a third chassis 261, a third gear set 262 rotatably arranged on the third chassis 261, a third shipping chain 263 sleeved on the third gear set 262, and a third motor 264 for driving the third gear set 262 to rotate.

[0091] The structure of the fourth transportation component 26 is the same as that of the second transportation component 23, and will not be elaborated here too much. The second transportation component 23 and the third transportation component 24 release the pallets with stacked intact cartons onto the fourth transportation component 26, and under the action of the third shipping chain 263, transport the pallets to the unloading position (i.e., the end of the fourth transportation component 26). An induction device 5 electrically connected to the PLC controller is provided at the unloading position. When the induction device 5 detects the pallet, it sends a signal to the PLC controller, and the PLC controller controls the third motor 264 to stop operating.

[0092] Continuing as Figure 7 shown, specifically, the induction device 5 includes a second infrared sensor 51 electrically connected to the PLC controller and an induction frame 52 for installing the second infrared sensor 51. The induction frame 52 is installed on the ground. When the second infrared sensor 51 detects the pallet, it sends the information to the PLC controller. The PLC controller issues an instruction to stop the fourth motor, causing the fourth motor to stop running, and issues an instruction to unload the pallet. The staff starts the forklift to unload the pallet.

[0093] Continuing as Figure 7 shown, in this embodiment, to ensure the stable operation of the pallet on the fourth transportation component 26, a guiding plate 266 for guiding the pallet is installed on the third chassis 261. The structure of the guiding plate 266 is the same as that of the aforementioned guiding plate 236, and will not be elaborated here too much.

[0094] Continuing as Figure 7 shown, during the process of the forklift unloading the pallet, it is easy to occur that the forklift touches the fourth transportation component 26. To avoid this situation, the fourth transportation component 26 is protected. A collision prevention frame 6 is fixed on the ground, and the forklift forks can be placed on the collision prevention frame 6 to insert and take the pallet.

[0095] As Figure 8 shown, in this embodiment, the tray transfer device 4 includes a transfer frame 41, a transfer gear set 42, a transfer chain 43, a moving plate 44, a transfer motor 45, and a transfer slide rail 46. Specifically, both ends of the transfer frame 41 are respectively installed on the first bottom frame 231 and the second bottom frame 241 by bolts. The transfer gear set 42 can be set to two groups, which are respectively coaxially rotatably arranged at both ends of the transfer frame 41. A transfer chain 43 is wound around each transfer gear set 42. The moving plate 44 is fixedly installed on the transfer chain 43, and the moving plate 44 is slidably matched with the transfer frame 41. The transfer motor 45 is fixedly installed on the top of the transfer frame 41 and drives the transfer gear set 42 to rotate. The transfer slide rail 46 is installed between the first bottom frame 231 and the second bottom frame 241. The transfer motor 45 drives the transfer gear set 42 to rotate, driving the moving plate 44 on the transfer chain 43 to move along the length direction of the transfer chain 43, driving the tray onto the transfer slide rail 46, and transporting the tray to the second consignment chain 243.

[0096] In this embodiment, each group of transfer gear sets 42 includes a driving gear and a driven gear, and the driving gear and the driven gear are respectively rotatably installed at both ends of the transfer frame 41. The two driving gears are coaxially fixed by a rotating shaft and are equidistantly distributed in the width direction of the transfer frame 41. The two driven gears are coaxially fixed by a rotating shaft, and the transfer motor 45 drives the rotating shaft on the driving gear through a transmission chain.

[0097] As Figure 8 and Figure 9 shown, wherein, to ensure that the tray smoothly enters the transfer slide rail 46, the end of the transfer slide rail 46 is turned outwards. And a second limiting component 27 for limiting the tray is installed on the second bottom frame 241. The second limiting component 27 includes a limiting bracket 271, a limiting cylinder 272, and a second limiting plate 273. Specifically, the limiting bracket 271 is fixed on the first bottom frame 231 by bolts, the limiting cylinder 272 is fixed on the limiting bracket 271 by bolts, and the second limiting plate 273 is fixed on the piston rod of the limiting cylinder 272. The limiting cylinder 272 drives the second limiting plate 273 to block the tray to prevent the tray from running with the first consignment chain.

[0098] To ensure the stability of the second limiting plate 273 during operation, a guiding rod 274 that is slidably matched with the limiting bracket 271 is fixed on the second limiting plate 273 by bolts.

[0099] As Figure 10As shown in the figure, in this embodiment, the carton handling device 3 includes a three-axis robot 31 and a suction cup 32 located at the end of the three-axis robot 31. Both the three-axis robot 31 and the suction cup 32 are electrically connected to the PLC controller. Among them, both the three-axis robot 31 and the suction cup 32 are existing technologies and will not be elaborated here. The three-axis robot 31 drives the suction cup 32 to pick up a group of cartons on the transfer platform 133, and the three-axis robot 31 drives the cartons to move directly above the tray at the loading position and drives the cartons to move directly downward until the cartons touch the foreign object, and then the suction cup 32 releases the cartons. The three-axis robot 31 drives the suction cup 32 to perform the picking and releasing operations of the next group of cartons until the tray is stacked full of cartons, and then performs the stacking operation of the cartons on the tray at the next loading position.

[0100] Continue as Figure 10 As shown in the figure, in order to facilitate the suction cup 32 to release the cartons, a pressure sensor 33 is installed at the bottom of the suction cup 32, and the pressure sensor 33 is electrically connected to the PLC controller. When the cartons on the suction cup 32 are placed on the tray, the pressure value measured by the pressure sensor 33 changes. The pressure sensor 33 transmits the information to the PLC controller, and the PLC controller controls the suction cup 32 to release the cartons and controls the three-axis robot 31 to move to perform the picking operation on the next group of cartons.

[0101] Continue as Figure 10 As shown in the figure, in this embodiment, in order to prevent the operation of the three-axis robot 31 from affecting the pipelines on the suction cup 32, a clamping component 34 for clamping the pipelines is fixed on the robotic arm of the three-axis robot 31. Specifically, the clamping component 34 includes a fixed plate 341 and a movable plate 342 arranged in an arc shape. The fixed plate 341 is fixed on the robotic arm through a connecting rod, and the pipeline is clamped in the cylindrical cavity formed by the fixed plate 341 and the movable plate 342. Both ends of the fixed plate 341 and the movable plate 342 are fixed by bolts. Similarly, one end of the fixed plate 341 and the movable plate 342 can be rotatably connected, and the other end can be fixed by bolts.

[0102] As Figure 11 As shown in the figure, in this embodiment, a protective frame 7 is fixed on the periphery of the carton automatic stacking system, and a protective net 8 is installed on the protective frame 7 through bolts. The protective net 8 and the protective frame 7 serve the purpose of safety protection.

[0103] A warning light 9 is installed on the protective frame 7, and the warning light 9 is electrically connected to the PLC controller. When the carton automatic stacking system is working normally, the warning light 9 emits green light. If the carton automatic stacking system malfunctions, the warning light 9 emits red light and makes an alarm sound.

[0104] The implementation principle of a carton automatic stacking system according to an embodiment of the present application is as follows:

[0105] When the carton automatic stacking system is running, the storage cavity 212 is pre-filled with pallets. Then, under the combined action of the lifting cylinder 221 and the pallet separating cylinder 222, the pallets are successively placed on the second transportation component 23. The pallets can be directly transported to the first loading position while running on the second transportation component 23. The pallets can also be transported to the third transportation component 24 under the action of the pallet transfer device 4 until they are transported to the second loading position.

[0106] Meanwhile, during the running process of the cartons on the first transportation component 11, the cartons are adjusted in position under the action of the carton shaping component 13 and are grouped and placed on the transfer platform 133. Subsequently, under the action of the three-axis robot 31 and the suction cup 32, the cartons are transferred to the pallets at the loading position for stacking. After the stacking operation is completed, the pallets at the corresponding loading positions are released onto the corresponding fourth transportation component 26 and are transported to the unloading location, where the pallets are picked up and placed in the designated area by a forklift.

[0107] This application reasonably designs the carton automatic stacking system, reduces the space occupied by the carton automatic stacking system, improves the degree of automation, completes the neat stacking operation of the cartons on the pallets, and improves the work efficiency.

[0108] The above are all the preferred embodiments of this application. It does not limit the protection scope of this application accordingly. Therefore, all equivalent changes made according to the structure, shape, and principle of this application should be covered within the protection scope of this application.

Claims

1. An automatic carton stacking system, characterized in that: it includes a carton conveying device (1), a pallet conveying device (2), a carton handling device (3) and a PLC controller. The PLC controller is electrically connected to the carton conveying device (1), the pallet conveying device (2) and the carton handling device (3). The pallet conveying device (2) is located below the carton conveying device (1). The carton handling device (3) transports the cartons conveyed by the carton conveying device (1) to the pallets conveyed by the pallet conveying device (2); the carton conveying device (1) includes a first transportation component (11) and a carton shaping component (13). The first transportation component (11) conveys cartons, and the carton shaping component (13) can be used to adjust the positions of the cartons to form a group of cartons in a horizontal and vertical structure; the pallet conveying device (2) includes a storage rack (21), a blanking component (22) and a second transportation component (23). The storage rack (21) is located above one end of the second transportation component (23). The storage rack (21) stores pallets carried by a forklift. The blanking component (22) releases pallets one by one onto the second transportation component (23), and the second transportation component (23) transports the pallets to the loading position; the carton handling device (3) includes a three-axis robot (31) and a suction cup (32). The suction cup (32) is fixed at the end of the three-axis robot (31). The suction cup (32) picks up and places cartons, and the three-axis robot (31) transports and stacks cartons; the pallet conveying device (2) further includes a third transportation component (24) arranged side by side with the second transportation component (23) on the ground to transport pallets. A pallet transfer device (4) is arranged between the third transportation component (24) and the second transportation component (23). The pallet transfer device (4) moves the pallets on the second transportation component (23) to the third transportation component (24). Positioning components (25) for limiting are arranged at the ends of the second transportation component (23) and the third transportation component (24). The positioning components (25) are used to limit the pallets at the loading position; the pallet conveying device (2) further includes two fourth transportation components (26). The two fourth transportation components (26) are respectively arranged along the directions of transporting pallets by the second transportation component (23) and the third transportation component (24). The fourth transportation components (26) transport the cartons stacked on the pallets released by the second transportation component (23) and the third transportation component (24); The carton shaping assembly (13) includes an adjusting member (131) for adjusting the position of the carton, a pushing member (132) for pushing the carton, and a transfer platform (133) for carrying the carton; the adjusting member (131) is installed on the first transportation assembly (11), and the adjusting member (131) can adjust the angles of multiple cartons by 90° at equal intervals; the pushing member (132) and the transfer platform (133) are respectively located on both sides of the first transportation assembly (11) in the width direction and are installed on the first transportation assembly (11). After the pushing member (132) pushes a group of unadjusted / or adjusted cartons, it then pushes a group of adjusted / or unadjusted cartons onto the transfer platform (133).

2. An automatic carton stacking system according to claim 1, wherein: The adjusting member (131) includes a guiding air cylinder (1311) and a first infrared sensor (1312) both electrically connected to the PLC controller. The guiding air cylinder (1311) and the first infrared sensor (1312) are both installed on the first transportation assembly (11). The first infrared sensor (1312) detects the carton conveyed and transmits the data information to the PLC controller. The PLC controller controls the operation of the guiding air cylinder (1311). When the piston rod of the guiding air cylinder (1311) extends, it touches a corner of the conveyed carton, and the guiding air cylinder (1311) cooperates with the first transportation assembly (11) to cause the carton to rotate by 90° and then separate from the guiding air cylinder (1311).

3. An automatic carton stacking system according to claim 1, wherein: The second transportation assembly (23) includes a first chassis (231), a first gear set (232), a first conveying chain (233), a first motor (234), and a first guide rail (235); the first chassis (231) is installed on the ground, the first gear set (232) can be provided in multiple groups, the first gear set (232) is rotatably installed at both ends of the first chassis (231), and a first conveying chain (233) is wound around each first gear set (232). The first guide rail (235) is installed on the first chassis (231), and the first guide rail (235) is used to support the first conveying chain (233). The first motor (234) is installed on the first chassis (231) and drives the rotation of the first gear set (232).

4. An automatic carton stacking system according to claim 3, wherein: The blanking component (22) includes a lifting cylinder (221) and a tray separating cylinder (222); the lifting cylinder (221) is installed on the first chassis (231) and is located below the storage rack (21), the tray separating cylinder (222) is installed outside the storage rack (21), the piston rod of the tray separating cylinder (222) can extend into the interior of the storage rack (21), the lifting cylinder (221) pushes the tray upward, the piston rod of the tray separating cylinder (222) is inserted between the two lowermost trays, the tray separating cylinder (222) lifts the tray above the piston rod of the tray separating cylinder (222), the lifting cylinder (221) retracts, and the tray on the lifting cylinder (221) falls onto the first conveying chain (233).

5. A carton automatic stacking system according to claim 4, characterized in that: The tray transfer device (4) is electrically connected to the PLC controller.

6. A carton automatic stacking system according to claim 5, characterized in that: The tray transfer device (4) includes a transfer frame (41), a transfer gear set (42), a transfer chain (43), a moving plate (44), a transfer motor (45) and a transfer slide rail (46); both ends of the transfer frame (41) are installed above the second transportation component (23) and the third transportation component (24) respectively, the transfer gear set (42) is installed at both ends of the transfer frame (41) respectively, the transfer chain (43) is wound around the transfer gear set (42), the moving plate (44) is fixed on the transfer chain (43), the transfer motor (45) is fixed on the transfer frame (41) and drives the transfer gear set (42) to rotate, the transfer slide rail (46) is installed between the second transportation component (23) and the third transportation component (24), and is used for the moving plate (44) to drive the tray on the second transportation component (23) to enter the third transportation component (24) along the transfer slide rail (46).

7. A carton automatic stacking system according to claim 5, characterized in that: The blocking component (25) includes a linkage rod (251), a blocking rod (252) and a driving member (253), the blocking rod (252) is fixed on the linkage rod (251), the driving member (253) is electrically connected to the PLC controller, and the driving member (253) drives the linkage rod (251) to rotate on the second transportation component (23) or the third transportation component (24) to release the stacked cartons on the tray.

8. A carton automatic stacking system according to claim 7, characterized in that: An induction device (5) for detecting the tray is provided at the end of the fourth transportation component (26). The induction device (5) is electrically connected to the PLC controller. When the induction device (5) senses the tray, it sends a signal to the PLC controller, and the PLC controller issues an instruction to stop operation to the fourth transportation component (26), and the fourth transportation component (26) stops operating.

9. An automatic carton stacking system according to claim 1, characterized in that: The carton handling device (3) further includes a pressure sensor (33) provided on the suction cup (32). The pressure sensor (33) is electrically connected to the PLC controller. When the three-axis robot (31) handles the carton stack, when the value of the pressure sensor (33) changes, a signal is transmitted to the PLC controller, and the PLC controller controls the suction cup (32) to release the carton.

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