Storage device and storage system

Abstract

A storage device for storing an open tray containing a plurality of eggs in a transport container is provided with: an egg adsorption unit for adsorbing the plurality of eggs contained in the open tray; a tray holding part for holding the open tray; and a moving mechanism that moves the egg adsorption unit and the tray gripping unit, the moving mechanism being provided with a vertical moving mechanism that moves up and down along a vertical axis, a horizontal moving mechanism that moves horizontally along a horizontal axis, and a rotational moving mechanism that moves the egg adsorption unit and the tray gripping unit. The rotary movement mechanism rotates and moves around an axis in the vertical direction.

Description

TECHNICAL FIELD

[0001] The present application relates to a storage device that stores an open tray containing eggs in a transport container such as a corrugated box, and a storage system. BACKGROUND

[0002] As a container that contains eggs, there is an open tray that does not have a lid and whose upper surface is open. As an example of an open tray, a molded tray, a paper tray, a PET tray, and the like are known. The molded tray, the paper tray are made of, for example, paper, paper pulp, and the PET tray is made of, for example, plastic. These open trays are used for a use of containing many eggs for business or the like.

[0003] In the invention patent document 1, as a storage device that stores an open tray containing eggs in a corrugated box, a mobile device is disclosed that has a head portion having an egg suction device and a tray holding device, and a multi-joint robot that moves the head portion.

[0004] PRIOR ART DOCUMENTS

[0005] PATENT DOCUMENTS

[0006] Patent document of invention SUMMARY

[0007] PROBLEMS TO BE SOLVED BY THE INVENTION

[0008] However, the multi-joint robot has a base portion provided on the floor, and a multi-joint arm portion provided to the base portion, and the storage device of the invention patent document 1 has a tendency to be large-sized.

[0009] Therefore, an object of the present application is to provide a compact storage device and a storage system.

[0010] MEANS FOR SOLVING THE PROBLEMS

[0011] The storage device according to the present application stores an open tray containing a plurality of eggs in a transport container, and has:

[0012] an egg suction portion that suctions the plurality of eggs contained in the open tray;

[0013] a tray holding portion that holds the open tray; and

[0014] a moving mechanism that moves the egg suction portion and the tray holding portion,

[0015] The moving mechanism includes an up-and-down moving mechanism, a horizontal moving mechanism, and a rotational moving mechanism, the up-and-down moving mechanism moves up and down along an up-and-down axis, the horizontal moving mechanism moves horizontally along a horizontal axis, and the rotational moving mechanism moves rotationally around the up-and-down axis.

[0016] According to this structure, since the moving mechanism is composed of the up-and-down moving mechanism, the horizontal moving mechanism, and the rotational moving mechanism, the moving mechanism can be set in a small area, and the storage device can be set compactly.

[0017] Further, in the storage device according to the present application, the rotational moving mechanism can be connected to the egg suction portion and the tray holding portion,

[0018] The up-and-down moving mechanism moves the rotational moving mechanism up and down,

[0019] The horizontal moving mechanism moves the up-and-down moving mechanism horizontally.

[0020] According to this structure, the moving mechanism can be set in a small area efficiently.

[0021] Further, in the storage device according to the present application, the storage device can include:

[0022] a base fixed to the moving mechanism; and

[0023] a box including the egg suction portion and the tray holding portion, and detachable from the base.

[0024] According to this structure, the egg suction portion and the tray holding portion can be detached from the base as a whole, and the egg suction portion and the tray holding portion can be easily changed corresponding to the type of the open tray.

[0025] Further, the storage unit according to the present application includes:

[0026] the above-described storage device;

[0027] a first conveyor that conveys the open tray in which the eggs are housed;

[0028] an inspection portion that is disposed upstream of the first conveyor, and inspects defects of the open tray conveyed to the first conveyor; and

[0029] a second conveyor that moves from a standby position below the first conveyor to a connection position downstream of the first conveyor, and receives the open tray from the first conveyor when it is determined that the open tray has defects.

[0030] According to this structure, it is possible to suppress defective open trays from being stored in the transport container.

[0031] Further, in the storage system according to the present application, it is also possible to configure such that the second conveyer is provided with a conveyer stopper,

[0032] When it is determined that the open tray is not defective, the second conveyer in the standby position causes the conveyer stopper to be positioned at the downstream end of the first conveyer.

[0033] According to this structure, when it is determined that the open tray is not defective, the conveyer stopper is able to stop the open tray conveyed by the first conveyer, and the tray holding portion is able to properly hold the open tray on the first conveyer. BRIEF DESCRIPTION OF DRAWINGS

[0034] Figure 1 is a perspective view showing the overall structure of the storage system according to the first embodiment.

[0035] Figure 2 is a front view showing the overall structure of the storage system according to the first embodiment.

[0036] Figure 3 is a three-view of the open tray.

[0037] Figure 4 is an exploded perspective view of the head.

[0038] Figure 5 is a perspective view of the cassette.

[0039] Figure 6 is a front view of the tray holding portion.

[0040] Figure 7 is a perspective view of the moving device.

[0041] Figure 8 is a perspective view showing a part of the storage system.

[0042] Figure 9 is a side view of the storage system.

[0043] Figure 10 is a perspective view showing a part of the storage system provided with a manual loading section.

[0044] Figure 11 is a perspective view showing a part of the storage system provided with a manual loading section.

[0045] Figure 12 is a perspective view showing the overall structure of the storage system according to the second embodiment.

[0046] Figure 13 is a top view representing a first layout example of an open tray handling line provided with a storage system.

[0047] Figure 14 is a top view representing a second layout example of an open tray handling line provided with a storage system.

[0048] Figure 15A is an example of information printed on the side of a corrugated box regarding the size of the eggs.

[0049] Figure 15B is an example of information printed on the side of a corrugated box regarding the size of the eggs.

[0050] Figure 16 is a top view representing a further layout example of an open tray handling line provided with a storage system.

[0051] Legend

[0052] 1 storage system, 1a storage system, 1b storage system, 1c storage system, 2 storage device, 3 carrying-in section, 4 storage section, 5 first conveyer, 6 second conveyer, 6a conveyer base, 7 third conveyer, 8 carrying-out section, 9 manual loading section, 21 head section, 22 base section, 23 case, 24 egg suction section, 25 tray gripping section, 26 moving mechanism, 27 rotary moving mechanism, 28 up-and-down moving mechanism, 29 horizontal moving mechanism, 31 case conveying mechanism, 41 first detection sensor, 42 pressing section, 43 stopper plate, 50 belt conveyer, 51 conveyer stopper, 51a tray arrival confirmation sensor, 52 inspection section, 53 second detection sensor, 54 inspection trigger sensor, 55 inspection unit, 56 upstream conveyer, 60 roller conveyer, 60a guide protrusion, 61 inclined guide, 61a guide hole, 70 roller conveyer, 80 roller conveyer, 81 carrying-out detection sensor, 82 carrying-out section free roller, 90 workbench, 91 manual loading section free roller, 221 guide groove, 222 first pipe, 222a connection section, 223 vacuum blower, 224 air cylinder, 225 tool confirmation sensor, 231 guide plate, 232 locking mechanism, 232a case side plate, 241 suction pad, 242 second pipe, 242a connection section, 251 claw member, 251a locking section, 251b pin, 252 claw holder, 253 case cam, 253a cam groove, 253b spring, 254 sliding rod, 255 pressing member, 255a protrusion section, 281 ball screw, 282 vertical screw shaft, 283 nut, 284 workbench, 285 servo motor, 286 guide shaft, 287 ball screw spline, 288 ball screw spline shaft, 289 ball screw nut, 291 feed screw, 292 horizontal screw shaft, 283 nut, 294 top plate, 295 servo motor, 296 linear guide, C corrugated case, T open tray, T1 egg placement section, T11 protrusion section, T2 peripheral section, T3 cutout section. DETAILED DESCRIPTION

[0053] Hereinafter, one embodiment of a storage device and a storage system will be described with reference to the drawings. Note that the dimensional ratios of the drawings are not necessarily the same as actual dimensional ratios, and the dimensional ratios between the drawings are not necessarily the same.

[0054] Hereinafter, description will be made with appropriate reference to an XYZ coordinate system. Also, in the present specification, when a direction is indicated, in the case where a positive or negative orientation is distinguished, the positive or negative sign is noted as "+X direction," "-X direction," and the like. Also, in the case where a direction is indicated without distinguishing a positive or negative orientation, only "X direction" is noted. That is, in the present specification, the case where only "X direction" is noted includes both the "+X direction" and the "-X direction." The same applies to the Y direction and the Z direction. In the present embodiment, a horizontal plane is parallel to the XY plane, and a vertical direction is the -Z direction.

[0055] [Storage system]

[0056] [First embodiment]

[0057] The storage system 1 is provided with a storage device 2, a carrying-in section 3, a storage section 4, a first conveyor 5, a second conveyor 6, a third conveyor 7, and a carrying-out section 8.

[0058] The storage system 1 is controlled by a main control section not shown, which is provided in a management system that comprehensively manages the storage system 1. The storage system 1 can also be controlled by a separate control section provided separately. The main control section and the separate control section can be realized by, for example, a combination structure of hardware, which is a dedicated circuit, firmware, or a processor and a memory and the like, and a program that specifies a control sequence.

[0059] The storage device is provided with a head section 21 and a moving mechanism 26 that moves the head section 21. As shown in Figure 2 The storage device 2 stores an open tray T, which accommodates eggs, carried into the first conveyor 5, in a corrugated box C (an example of a conveyance container) in the storage section 4. The open tray T is a tray that does not have a lid and whose upper surface is open, and is, for example, a molded tray made of pulp, a paper tray made of paper, or a PET tray made of plastic. Also, although the conveyance container is a corrugated box in the present embodiment, it is not limited thereto and can be any container such as a plastic container.

[0060] As shown in Figure 3 The open tray T is provided with an egg placement section T1, a peripheral section T2, and a cutout section T3. The egg placement section T1 is provided with a plurality of recesses, one recess for one egg. The peripheral section T2 is provided in a manner of surrounding the periphery of the egg placement section T1. The cutout section T3 is a recess with respect to the peripheral section T2 toward the center of the open tray T and forms a space into which a person's finger can be inserted. The open tray T can be carried by a person inserting a finger into the cutout section T3. As an example, the open tray T has two cutout sections T3 on one short side and one cutout section T3 on the other short side. Note that, Figure 3The open tray shown is merely an example, and the number of recessed portions in the egg placement portion T1 and the positions and / or number of the cutout portions T3 are not limited thereto.

[0061] like Figure 4 As shown, the head 21 includes a base 22 and a box 23 detachably mounted on the base 22. The base 22 is fixed to a moving mechanism 26 and is moved by the moving mechanism 26. The cross section of the base 22 is substantially U-shaped, and a pair of guide grooves 221, 221 extending in the Y direction are formed on the inner side surface. In addition, the base 22 includes a first pipe 222. The first pipe 222 is connected to a vacuum blower 223 (see FIG. 2 ) via a suction pipe not shown in the figure. Figure 2 ).

[0062] The cassette 23 includes a pair of guide plates 231, 231 extending in the Y direction. The guide plates 231 are guided in the Y direction by guide grooves 221 of the base 22. This allows the cassette 23 to be attached to and detached from the base 22 from the -Y direction. Furthermore, the cassette 23 includes a locking mechanism 232 for securing it to the base 22 and a cassette side plate 232a supporting the locking mechanism 232. The cassette side plate 232a may include an opening for distinguishing the type of cassette 23.

[0063] like Figure 4 as well as Figure 5 As shown, the box 23 includes an egg suction portion 24 and a tray gripping portion 25. Specifically, the egg suction portion 24 and the tray gripping portion 25 are integrally formed as the box 23. Thus, by preparing different boxes 23 in advance to correspond to the open tray T, the egg suction portion 24 and the tray gripping portion 25 can be easily changed to correspond to the type of open tray T.

[0064] The base 22 may also include a tool confirmation sensor 225 for confirming the type of the box 23. As the tool confirmation sensor 225, a photoelectric sensor, a proximity sensor, etc. can be used. Figure 4 As shown, when two tool confirmation sensors 225 are provided, four types of cartridges 23 can be distinguished by the combination of the presence or absence of the opening of the cartridge side plate 232 a facing the tool confirmation sensor 225 .

[0065] The egg suction unit 24 suctions a plurality of eggs stored in the open tray T. The egg suction unit 24 includes a plurality of accordion-shaped suction pads 241 , each suction pad 241 suctioning one egg. The plurality of suction pads 241 are arranged in a row and attached to a suction duct 243 .

[0066] Furthermore, the egg adsorption unit 24 includes a second pipe 242 connected to the plurality of adsorption pipes 243. The second pipe 242 includes a connection portion 222a (see Figure 4 ) of the connection portion 242a (seeFigure 5 ). When the vacuum blower 223 sucks air via the first pipe 222 and the second pipe 242, the egg is adsorbed to the adsorption pad 241, and when the vacuum blower 223 discharges air, the egg is released from the adsorption pad 241.

[0067] The adsorption duct 243 is detachably attached to an adsorption duct base 244 which is integrated with the second pipe 242, and even if the egg liquid intrudes into the inside of the adsorption pad 241 and the adsorption duct 243, the cleaning work is easily performed.

[0068] As shown in Figure 5 , the tray holding section 25 is provided with a pair of claw members 251, 251 which are inserted into the cutout section T3 of the open tray T. The claw member 251 is in the shape of a long strip plate. As shown in Figure 6 , the claw member 251 has a locking section 251a at the front end. The locking section 251a is formed with a plurality of V grooves in parallel. Further, the claw member 251 has a pin 251b at the base end. Further, the claw member 251 is rotatably held to a claw holder 252.

[0069] Further, the tray holding section 25 is provided with a box cam 253. Circular arc-shaped cam grooves 253a are formed in both sides in the X direction of the box cam 253. The pin 251b of the claw member 251 is movable along the cam grooves 253a. Thus, when the box cam 253 moves up and down with respect to the claw holder 252, the pin 251b moves along the cam grooves 253a, and the front ends of the pair of claw members 251, 251 are opened and closed. After the pair of claw members 251, 251 are inserted into the cutout section T3 of the open tray T in the closed state, they are opened by becoming in the open state, and the locking sections 251a are locked to the edge sections of the cutout section T3.

[0070] Further, the tray holding section 25 is provided with a stationary slide rod 254 which guides the box cam 253 in the up and down direction, and a pressing member 255 which is movable up and down with respect to the claw holder 252. The pressing member 255 presses the upper end of the box cam 253 by a protrusion section 255a of the pressing member 255. Further, the pressing member 255 is pressed down by a cylinder 224 (refer to Figure 4 ) which is fixed to the outer side surface of the base 22. By pressing down the pressing member 255 with the cylinder 224, the protrusion section 255a is pressed down together with the box cam 253, and thus the pair of claw members 251, 251 become in the open state from the closed state.

[0071] It should be noted that the box cam 253 is pressed in the upward direction by a spring 253b, and when the pressing down of the cylinder 224 is released, the box cam 253 moves upward, and the claw members 251, 251 are closed.

[0072] As shown in Figure 7As shown, the moving mechanism 26 is provided with a rotational moving mechanism 27 that moves the head 21 about the Z-direction axis, an up-and-down moving mechanism 28 that moves the head 21 up and down along the Z-direction axis, and a horizontal moving mechanism 29 that moves the head 21 horizontally along the X-direction axis.

[0073] The rotational moving mechanism 27 is coupled to the upper surface of the base 22 to move the base 22 about the Z-direction axis. The rotational moving mechanism 27 is, for example, a rotational actuator. The rotational moving mechanism 27 is capable of stopping at three points, a first position (shown) in which the long side direction of the base 22 is parallel to the X-direction, Figure 7 For example, when the base 22 is in the first position, the open tray T is gripped by the tray gripping portion 25, the base 22 is rotated to the second position, the gripped open tray T is stored in the corrugated box C, and then the base 22 is rotated to return to the first position, the next open tray T is gripped by the tray gripping portion 25, the base 22 is rotated to the third position, and the gripped open tray T is stored in the corrugated box C. Thus, a plurality of open trays T can be stacked in the corrugated box C while being alternately inverted.

[0074] The up-and-down moving mechanism 28 is coupled to the rotational moving mechanism 27 to move the rotational moving mechanism 27 up and down. The up-and-down moving mechanism 28 is, for example, a ball screw 281. The ball screw 281 is provided with a vertical screw shaft 282 extending in the Z-direction, and a nut 283 screwed to the vertical screw shaft 282. At the lower end of the vertical screw shaft 282, the rotational moving mechanism 27 is coupled. The nut 283 is rotatably supported on a workbench 284. Further, the nut 283 is rotated by a servo motor 285 fixed to the workbench 284 via a belt. Thus, the vertical screw shaft 282 is moved in the Z-direction with respect to the workbench 284 by rotating the nut 283 by the servo motor 285, and as a result, the rotational moving mechanism 27 is moved in the Z-direction. It should be noted that the up-and-down moving mechanism 28 is provided with a guide shaft 286 extending in the Z-direction so that the vertical screw shaft 282 does not rotate with respect to the workbench 284. The guide shaft 286 and the vertical screw shaft 282 are coupled by a coupling plate 286a. It should be noted that a not-shown suction pipe extending in the Z-direction is disposed between the guide shaft 286 and the vertical screw shaft 282, and moves up and down together with the guide shaft 286 and the vertical screw shaft 282. The suction pipe is fixed to the coupling plate 286a.

[0075] The horizontal moving mechanism 29 is connected to the vertical moving mechanism 28 to move the vertical moving mechanism 28 horizontally. The horizontal moving mechanism 29 is, for example, a feed screw 291. The feed screw 291 includes a horizontal screw shaft 292 extending in the X direction and a nut 293 screwed to the horizontal screw shaft 292. The horizontal screw shaft 292 is fixed to a top plate 294 (see Figure 1 ) is rotated by the servo motor 295. The nut 293 is fixed to the upper surface of the workbench 284. In addition, the workbench 284 is connected to the workbench 284 via a linear guide 296 (see Figure 1 ) is placed on the top plate 294 and is slidable in the X direction relative to the top plate 294. As a result, the horizontal screw shaft 292 is rotated by the servo motor 295, so that the nut 293 moves in the X direction relative to the top plate 294, and as a result, the worktable 284 (vertical moving mechanism 28) can be moved in the X direction.

[0076] like Figure 8 As shown, the loading section 3 is provided with a roller conveyor capable of transporting in the +Y direction, and loads the empty corrugated cardboard box C into the storage device 2. A box making machine (not shown) is arranged upstream of the loading section 3, and the loading section 3 is connected to the box making machine. The loading section 3 transports the empty corrugated cardboard box C assembled by the box making machine to a standby position below the storage device 2. The loading section 3 may also be provided with a box conveying mechanism 31 for transporting the empty corrugated cardboard box C in the +X direction. After transporting the corrugated cardboard box C to the standby position, the corrugated cardboard box C is transported to the storage section 4 by the box conveying mechanism 31. The box conveying mechanism 31 may be driven by a narrow conveyor that can be raised and lowered and is arranged in the gap between the rollers of the roller conveyor, or by an air cylinder that is arranged in a position that does not interfere with the corrugated cardboard box C.

[0077] It should be noted that the storage system 1 becomes Figure 13 In the case of the layout shown (described later), since the loading unit 3, storage unit 4, and unloading unit 8 are arranged in a straight line in the +Y direction, the box conveying mechanism 31 for conveying the corrugated cardboard box C in the +X direction may not be provided.

[0078] The storage unit 4 is equipped with a roller conveyor capable of conveying in the +X direction, and conveys the corrugated cardboard boxes C received from the loading unit 3. The storage unit 4 is equipped with a first detection sensor 41. The first detection sensor 41 detects whether the corrugated cardboard box C has arrived on the storage unit 4. As an example, the first detection sensor 41 may be a load sensor or an optical sensor, but is not limited thereto.

[0079] The storage unit 4 includes a pressing unit 42. The pressing unit 42 contacts the swing flap of the cardboard box C to suppress the movement of the cardboard box C.

[0080] The storage unit 4 includes a stopper plate 43. The stopper plate 43 is moved up and down in the Z direction between adjacent rollers to allow or prohibit the conveyance of the corrugated cardboard box C.

[0081] The first conveyor 5 includes a belt conveyor 50 capable of conveying in the +X direction and is connected to, for example, an egg-filling device (not shown) disposed upstream. The first conveyor 5 receives an open tray T filled with eggs from the egg-filling device.

[0082] The first conveyor 5 includes a conveyor stopper 51. The conveyor stopper 51 stops the open pallet T being conveyed by the belt conveyor 50. The first conveyor 5 may also include a pallet arrival confirmation sensor 51a that confirms that the open pallet T has reached a position in contact with the conveyor stopper 51. The pallet arrival confirmation sensor 51a is fixed to the inner side surface of the inclined guide 61 described later.

[0083] The storage system 1 further includes an inspection unit 52 disposed upstream of the first conveyor 5. The inspection unit 52 includes a second detection sensor 53, an inspection trigger sensor 54, and an inspection unit 55. The inspection unit 52 may also include an upstream conveyor 56 disposed upstream of the belt conveyor 50.

[0084] The second detection sensor 53 detects the open pallet T carried into the belt conveyor 50. As an example, the second detection sensor 53 may be a load sensor, a light sensor, an ultrasonic sensor, or an electrostatic capacitance sensor, but is not limited thereto. When a light sensor is used as the second detection sensor 53, the light sensor is arranged on the side of the upstream conveyor 56 and irradiates light in the Y direction (see FIG. Figure 9 ).

[0085] The inspection trigger sensor 54 detects the convex portion T11 when the egg loading portion T1 of the open tray T loaded onto the belt conveyor 50 is viewed from the side (see FIG. Figure 3 As an example, the inspection trigger sensor 54 may be a light sensor, an ultrasonic sensor, or an electrostatic capacitance sensor, but is not limited thereto. When a light sensor is used as the inspection trigger sensor 54, the light sensor is arranged on the side of the upstream conveyor 56, arranged below the second detection sensor 53, and irradiates light in the Y direction (see Figure 9 ).

[0086] The inspection unit 55 is disposed above the second detection sensor 53. When the open tray T is detected by the second detection sensor 53 and the convex portion T11 is detected by the inspection trigger sensor 54, the inspection unit 55 inspects whether the open tray T has a defect. The inspection unit 55 is, for example, an image sensor that takes an image of each column of the open tray T. The main control unit determines whether the eggs in the open tray T are unbroken and whether the eggs are contained in the Y-direction column of the open tray T (or whether the eggs are not contained in the open tray T) based on the image taken by the inspection unit 55. Note that the inspection unit 55 is not limited to an image sensor. As the inspection unit 55, a load sensor, a light sensor, an ultrasonic sensor, an electrostatic capacitance sensor, a millimeter wave radar sensor, or the like can be used. In the case where a light sensor is used as the inspection unit 55, the light sensor is disposed above the upstream conveyor 56 and is disposed in the same number as the number of columns of the open tray T (the number of egg holders in the Y direction), and irradiates light in the Z direction. The light is irradiated on the upper portion of the eggs contained in the open tray T. Thus, it is checked whether all of the column has eggs or does not have eggs.

[0087] When the second detection sensor 53 is ON and the inspection NG signal from the inspection unit 55 is ON, the main control unit determines that the tray is defective and stores the tray as a defective tray. The determination can be made with an offset of the difference (delay amount) in the response speed of the inspection unit 55.

[0088] When the open tray T that is determined to have no defect in the inspection reaches the detection position of the tray arrival confirmation sensor 51a, the main control unit controls the storage device 2 to lift the open tray T on the belt conveyor 50 and store the open tray T in the corrugated box C on the storage portion 4.

[0089] On the other hand, when the open tray T that is determined to have a defect in the inspection reaches the detection position of the tray arrival confirmation sensor 51a, the main control unit moves the second conveyor 6 in the X direction from the lower side of the first conveyor 5. More specifically, the main control unit moves the second conveyor 6 so as to be continuous with the first conveyor 5. At this time, the belt conveyor 50 is temporarily stopped until the first conveyor 5 is continuous with the second conveyor 6. By the temporary stop, the open tray T is prevented from falling.

[0090] The second conveyor 6 has a conveyor base 6a that is movable in the X direction. The conveyor base 6a is moved by a cylinder or the like not shown. The second conveyor 6 moves between a standby position (position shown in the drawing) below the first conveyor 5 and a connection position downstream of the first conveyor 5. Figure 8

[0091] ​A conveyor stopper 51 is provided at the downstream end (+X direction end) of the conveyor base 6a. Thus, when the second conveyor 6 is in the standby position, the conveyor stopper 51 is located at the downstream end of the belt conveyor 50, stopping the open pallet T being conveyed by the belt conveyor 50. On the other hand, when the second conveyor 6 moves to the connected position, the conveyor stopper 51 moves together with the conveyor base 6a, away from the downstream end of the belt conveyor 50.

[0092] The second conveyor 6 also includes a roller conveyor 60 capable of conveying in the +X direction. The downstream end (+X direction end) of the roller conveyor 60 is supported by the conveyor base 6a so as to be rotatable up and down. The upstream end (-X direction end) of the roller conveyor 60 includes a guide protrusion 60a that protrudes laterally.

[0093] An inclined guide 61 is provided on both sides of the second conveyor 6 in the Y direction. The inclined guide 61 is a stationary plate and is formed with a guide hole 61a. The guide hole 61a guides the guide protrusion 60a of the roller conveyor 60. The front end (+X direction end) of the guide hole 61a is higher than the other parts. Therefore, the roller conveyor 60 becomes horizontal in the standby position, and on the other hand, the front is lower than the back when the guide protrusion 60a is raised in the connection position (refer to Figure 9 ).

[0094] The third conveyor 7 includes a roller conveyor 70 capable of conveying in the X direction. Figure 9 As shown, when the second conveyor 6 is in the connected position, the roller conveyor 70 is connected to the roller conveyor 60. Specifically, when an open pallet T is determined to be defective, the second conveyor 6 moves to the connected position, and the roller conveyor 60 is connected to the belt conveyor 50 and the roller conveyor 70. Thus, the open pallet T determined to be defective is conveyed from the belt conveyor 50 to the roller conveyor 60, and then from the roller conveyor 60 to the roller conveyor 70. Furthermore, by connecting the conveyors in the event of a system failure, conventional manual loading operations can be performed. It should be noted that a conveyor (not shown) may be disposed downstream of the roller conveyor 70 to convey open pallets T determined to be defective.

[0095] The main control section detects whether or not the corrugated box C has stored a prescribed number of open trays T (i.e., whether or not the corrugated box C is full). As an example, the main control section counts the number of times of stacking based on the storage device 2, and in the case where the count reaches a prescribed number decided in advance, determines that the corrugated box C is full, whereas in the case where the count does not reach the prescribed number, determines that the corrugated box C is not full. The storage device 2 stores the open trays T in the corrugated box C until the main control section detects that the corrugated box C is full. When the main control section detects that the corrugated box C is full, the storage section 4 conveys the corrugated box C to the convey-out section 8. Further, in the case where the open tray T determined to be defective by the inspection of the inspection unit 55 is discharged, the discharged open tray T is also counted to a prescribed number, and the corrugated box C is conveyed to the convey-out section 8 in a state of lacking the number of discharges.

[0096] It should be noted that the storage device 2 can place an empty open tray T not containing eggs on the uppermost egg-containing open tray T in the corrugated box C. The empty open tray T functions as a lid of the uppermost egg-containing open tray T, and suppresses damage to the eggs.

[0097] The convey-out section 8 is adjacent to the storage section 4, and is provided with a convey-out free roller 82 that receives the corrugated box C conveyed from the storage section 4 in the X direction, a roller conveyor 80 that conveys the corrugated box C in the Y direction, and a convey-out detection sensor 81 that detects the corrugated box C conveyed out from the storage section 4 or a corrugated box C packed by another device or a person. When the corrugated box C is detected by the convey-out detection sensor 81 to be conveyed out from the storage section 4, the convey-out free roller 82 is lowered to a lower position than the roller conveyor 80, the corrugated box C is loaded onto the roller conveyor 80, and is conveyed in the Y direction. Further, in the case where a corrugated box C packed by another device or a person is detected, the convey-out is temporarily stopped, and when the passage is confirmed, the convey-out is performed. Although not illustrated, in the present embodiment, a weight checker is provided downstream of the convey-out section 8, the weight of the corrugated box C storing the open trays T is measured, and the weight is adjusted as necessary. The corrugated box C not filled with a prescribed number of open trays T can also be detected by the weight checker. A carton sealer is provided downstream of the weight checker, and a palletizer is provided downstream of the carton sealer. The convey-out section 8 is continuous to the weight checker, and conveys the corrugated box C storing the open trays T to the weight checker.

[0098] As Figure 10 and Figure 11As shown, the storage system 1 may also include a manual loading section 9 adjacent to the unloading section 8. The manual loading section 9 includes a liftable work table 90 on which corrugated cardboard boxes C can be placed during manual loading, and manual loading section free rollers 91 for receiving the corrugated cardboard boxes C unloaded from the unloading section 8. In the event of a system failure, the roller conveyor 60 and roller conveyor 70 that transport the open pallet T are connected, allowing the open pallet T to be transported to the roller conveyor 70, and conventional manual loading operations to be performed in the manual loading section 9.

[0099] like Figure 10 As shown, in normal use, the work table 90 is raised and the corrugated cardboard box C is unloaded from the unloading section 8 to a subsequent process.

[0100] When a corrugated cardboard box C that is not full and is judged to be defective by the inspection of the inspection unit 55 is carried out, Figure 11 As shown, by lowering the workbench 90 and protruding the manual loading section free roller 91, the corrugated cardboard box C is conveyed to the workbench 90. When the conveyance is confirmed by the conveyance detection sensor 81, as shown in FIG. Figure 10 As shown, by raising the work table 90, the corrugated cardboard boxes C can be placed on the work table 90. Subsequently, the open tray T that has been determined to be defective and transported to the roller conveyor 70 is corrected and loaded onto the corrugated cardboard boxes C waiting on the work table 90. It is then manually pushed into the unloading section 8 and unloaded to the subsequent process. Although not shown, a robot or the like can also be used to correct defects discovered by the inspection unit 55, such as excess or deficiency, or replace defective eggs, and then automatically unload them to the unloading section 8.

[0101] <Second embodiment>

[0102] Since the second embodiment has the same structure as the first embodiment except for the structure described below, the common points are omitted and the description is mainly focused on the differences. It should be noted that in the second embodiment, the structure or elements having substantially the same functions (actions) as those described in the first embodiment are shown, and their descriptions are not repeated.

[0103] The moving mechanism 26 includes a rotational movement mechanism 27 that rotates the head 21 about the Z axis, a vertical movement mechanism 28 that moves the head 21 vertically along the Z axis, and a horizontal movement mechanism 29 that moves the head 21 horizontally along the X axis.

[0104] The up-and-down moving mechanism 28 is a ball screw spline 287. The ball screw spline 287 has a ball screw spline shaft 288 extending in the Z direction, and a ball screw nut 289 screwed to the ball screw spline shaft 288. At the lower end of the ball screw spline shaft 288, the head 21 is fixed. The ball screw nut 289 is rotated by a servo motor 285 via a belt. Thus, the head 21 is moved in the Z direction by rotating the ball screw nut 289 by the servo motor 285, as a result of which the ball screw spline shaft 288 is moved in the Z direction.

[0105] The rotation moving mechanism 27 rotates the ball screw spline shaft 288. The rotation moving mechanism 27 is, for example, a rotary actuator. The rotation moving mechanism 27 rotates the ball screw spline shaft 288 via a belt, for example.

[0106] According to the second embodiment, the guide shaft 286 as in the first embodiment is not needed. Further, since the suction pipe can be formed in the ball screw spline shaft 288, the suction pipe can be simplified.

[0107] [Open tray processing line]

[0108] [First layout example]

[0109] Figure 13 is a plan view showing a first layout example of an open tray processing line in which the storage system 1 is installed.

[0110] The open tray processing line 100a has a repackaging device 101, a case maker 102, a weight checker 103, an automatic lid placer 104, a case sealer 105, a 90° rotation conveyor 106, a lettering machine 107, and a small-scale palletizer 108. Further, the open tray processing line 100a is controlled by a main control section not shown, which is installed in a management system that comprehensively manages the open tray processing line 100a.

[0111] Eggs produced from a henhouse are moved to a temporary container after being washed and dried, and are stored. The repackaging device 101 has a tray supply section 101a that supplies the stacked empty open trays one by one. The repackaging device 101 transfers the eggs from the temporary container to the empty open trays. The open trays T containing a plurality of eggs are carried to the storage system 1.

[0112] The case maker 102 assembles corrugated paper into a box shape, and joins the lower surface by a tape, heat fusion, stapling, or the like. The corrugated paper case C is carried to the carrying-in section 3 of the storage system 1 by a case receiving conveyor 102a. Note that, in this example, the carrying-in section 3, the storage section 4, and the carrying-out section 8 of the storage system 1 are arranged in a line.

[0113] The weight checker 103 measures the weight of the corrugated case C in which the open tray T is stored. In a case where the weight of the corrugated case C in which the open tray T is stored does not reach a prescribed weight (for example, 10 kg), the corrugated case C is distributed to the NG conveyor 103b by the NG distribution conveyor 103a.

[0114] The automatic lid placer 104 places an empty open tray T in which no egg is accommodated on the open tray T that is the uppermost layer in the corrugated case C. The automatic lid placer 104 is provided with a tray supply section 104a that supplies the stacked empty open trays T one by one. The empty open tray T functions as a lid for the open tray T that is the uppermost layer.

[0115] The automatic lid placer 104 can also be provided with a plurality of tray supply sections 104a. If a tray supply section 104a that is used in cooperation with the open tray T being processed is selected, it is possible to shorten the step change time.

[0116] The case sealer 105 seals the top surface of the conveyed corrugated case C by joining with a tape, heat fusion, stapling, or the like.

[0117] The 90° rotation conveyor 106 rotates the corrugated case C by 90° in the horizontal plane.

[0118] The lettering machine 107 prints information related to the egg on the side surface of the corrugated case C.

[0119] The small-scale stacker 108 stacks the corrugated case C on a pallet or a flatbed truck.

[0120] <Second Layout Example>

[0121] Figure 14 is a plan view that shows a second layout example of an open tray processing line in which the storage system 1 is provided.

[0122] The open tray processing line 100b is provided with the sorting device 109, the case maker 102, the weight checker 103, the automatic lid placer 104, the case sealer 105, the 90° rotation conveyor 106, the lettering machine 107, and the stacker 110. Furthermore, the open tray processing line 100b is controlled by a main control section (not shown) that is provided in a management system that comprehensively manages the open tray processing line 100b. Note that the open tray processing line 100b is provided with a plurality of storage systems 1a, 1b, and 1c.

[0123] The sorting device 109 is provided with a plurality of stations 109a, 109b, 109c, for example, the open tray T containing the S size eggs is allocated to the station 109a, the open tray T containing the M size eggs is allocated to the station 109b, and the open tray T containing the L size eggs is allocated to the station 109c. The open trays T of the stations 109a, 109b, 109c are respectively carried to the first conveyors 5 of the storage systems la, lb, lc.

[0124] Between the stations 109a, 109b, 109c and the first conveyors 5, conveyors corresponding to the respective upstream conveyors 56 can be arranged, and the stations 109a, 109b, 109c can also be provided with the functions of the upstream conveyors 56.

[0125] The box making machine 102 assembles the corrugated paper into a box shape, and joins the lower surface by means of tape, hot melt, stapling, etc. The corrugated paper box C is carried to the storage system 1 by the box receiving conveyor 102a.

[0126] Note that in this example, the in-feed portions 3 of the storage systems la, lb, lc are formed by a continuous one conveyor. Also, the out-feed portions 8 of the storage systems la, lb, lc are formed by a continuous one conveyor. Therefore, the in-feed portions 3 can be provided with stop plates 3a, 3b, 3c, and the out-feed portions 8 can be provided with stop plates 8a, 8b, 8c.

[0127] The main control portion controls the carrying of the empty corrugated paper box C and the carrying of the full corrugated paper box C by lowering and raising the stop plates 3a, 3b, 3c and the stop plates 8a, 8b, 8c.

[0128] For example, in the storage system lb, when the boxing of the corrugated paper box C of the open tray T containing the M size eggs is completed, the corrugated paper box C is carried from the storage portion 4 to the out-feed portion 8. Next, in the storage system lb, the empty corrugated paper box C is carried from the in-feed portion 3 to the storage portion 4. Next, by lowering the stop plate 3a, the empty corrugated paper box C is carried from the in-feed portion 3 of the storage system la to the in-feed portion 3 of the storage system lb. Next, by raising the stop plate 3a, the empty corrugated paper box C is carried to the in-feed portion 3 of the storage system la. Similarly, in the storage system lc, when the empty corrugated paper box C is carried from the in-feed portion 3 to the storage portion 4, by lowering the stop plate 3b, the empty corrugated paper box C is carried from the in-feed portion 3 of the storage system lb to the in-feed portion 3 of the storage system lc. Thus, the empty corrugated paper box C is appropriately supplied to the in-feed portion 3 of each of the storage systems la, lb, lc.

[0129] Further, in a case where, for example, the cartoning of the corrugated boxes C into the storage system la and the cartoning of the corrugated boxes C into the storage system lb are completed almost simultaneously, the upward stopper 8a is raised, whereby the removal of the corrugated boxes C from the storage system la can be temporarily stopped. Thus, the corrugated boxes C removed from the storage system la can be prevented from contacting the corrugated boxes C removed from the storage system lb.

[0130] The weight checker 103 measures the weight of the corrugated box C in which the open tray T is stored. In a case where the weight of the corrugated box C in which the open tray T is stored does not reach a prescribed weight (for example, 10 kg), the corrugated box C is distributed to the NG conveyor 103b by the NG distribution conveyor 103a.

[0131] The automatic lid placer 104 places an empty open tray T in which no eggs are accommodated on the open tray T that is the uppermost layer in the corrugated box C. The automatic lid placer 104 is provided with a tray feeder 104a that feeds the stacked empty open trays T one by one. The empty open tray T functions as a lid for the uppermost open tray T. Note that, in this example, since different open trays T are fed according to each size of the eggs, a plurality of tray feeders 104a are provided. The automatic lid placer 104 can also be provided with a box imaging section 104b. With the box imaging section 104b, the recognition of the contents is performed based on the shape of the open tray T, the recognition color, the egg placement portion Tl, the number of the eggs, and the like, and the corresponding open tray T is fed from the tray feeder 104a selected based on the recognition result.

[0132] The box sealer 105 seals the top surface of the conveyed corrugated box C by taping, heat sealing, stapling, or the like.

[0133] The 90° rotation conveyor 106 rotates the corrugated box C by 90° in the horizontal plane.

[0134] The lettering machine 107 prints information related to the eggs on the side surface of the corrugated box C.

[0135] The palletizer 110 stacks the corrugated boxes C on a plurality of pallets or flat cars. The palletizer 110 is provided with, for example, a multi-joint robot.

[0136] The palletizer 110 can also be provided with a box recognition section 110a that reads the information printed on the corrugated box C by the lettering machine 107. The box recognition section 110a imparts information of a transfer destination based on the read information. At this time, in a case where there is no transfer destination or the printed information cannot be read, the corrugated box C is made to retreat. The palletizer 110 stacks the corrugated boxes C on the corresponding pallet or flat car selected from the plurality of pallets or flat cars according to the transfer destination information imparted by the box recognition section 110a.

[0137] Note that the storage device and the storage system are not limited to the structures of the above-described embodiments, and are also not limited to the above-described effects. Furthermore, needless to say, the storage device and the storage system can be added with various changes within a range not departing from the gist of the present application. For example, each structure, each method, and the like of the above-described multiple embodiments can be arbitrarily adopted and combined.

[0138] (1) In the storage system 1 related to the above-described embodiments, the main control section is configured to judge whether or not the eggs in the open tray T are unbroken and whether or not the eggs are housed on the Y-directional alignment of the open tray T (or whether or not the eggs are not housed in the open tray T) based on the photographing by the inspection unit 55. However, the storage system 1 is not limited to this structure. The main control section can also be configured to judge the orientation of the open tray T based on the photographing by the inspection unit 55. In a case where the orientation of the open tray T is opposite to the desired orientation, the open tray T cannot be properly stacked in the corrugated box C. The orientation of the open tray T is judged, for example, by the position and / or the number of the cutout portions T3.

[0139] In a case where the orientation of the open tray T is opposite to the desired orientation, the open tray T can be conveyed from the belt conveyor 50 to the roller conveyor 60, and then from the roller conveyor 60 to the roller conveyor 70. The open tray T conveyed to the roller conveyor 70 can be manually loaded after reversing the orientation.

[0140] Furthermore, in a case where the orientation of the open tray T is opposite to the desired orientation, the open tray T can also be stored in the corrugated box C by being gripped by the tray gripping section 25. At this time, the rotary moving mechanism 27 is configured to be able to stop at a fourth position rotated by 180° from the first position in addition to the three points of the first position in which the base 22 is parallel to the X direction in the long side direction of the base 22, the second position rotated by 90° to the right from the first position, and the third position rotated by 90° to the left from the first position. When it is judged that the orientation of the open tray T is opposite to the desired orientation, the base 22 is first rotated to the fourth position, the open tray T is gripped by the tray gripping section 25, and then the base 22 is rotated to the second position or the third position, and the gripped open tray T is stored in the corrugated box C.

[0141] (2) Regarding the open tray T, although an open tray T having a substantially rectangular shape is illustrated, it is not limited thereto, and an open tray having a substantially square shape may also be used. As square open trays, there are known open trays having egg holders (recesses for placing eggs) with five rows and six columns and capable of accommodating thirty eggs, and open trays having egg holders with six rows and six columns and capable of accommodating thirty-six eggs. When stacking eggs in a square open tray, the orientation is usually changed by 90° each time, unlike a rectangular open tray. In the storage system 1, when such a square open tray is packed in a corrugated cardboard box C, the rotating and moving mechanism 27 can position the base 22 at two points: a first position where the front and rear tray gripping portions 25 are located in the forward direction of the open tray, and a second position rotated 90° to the right or left from the first position. Specifically, for example, the pallet gripping unit 25 may repeat the following operations: gripping the open pallet at the first position and packing it into the corrugated cardboard box C while maintaining its orientation; and gripping the open pallet at the first position, lifting it, changing its orientation to the second position, and then packing it into the corrugated cardboard box C. Of course, depending on the open pallet being handled, the pallet gripping unit 25 may also repeat the following operations: gripping the open pallet at the second position and packing it into the corrugated cardboard box C while maintaining its orientation; and gripping the open pallet at the second position and changing its orientation to the first position, and then packing it into the corrugated cardboard box C.

[0142] (3) In the storage system 1 according to the above embodiment, the main control unit is configured so that, when an open pallet T determined to be defective reaches the detection position of the pallet arrival confirmation sensor 51a, the main control unit moves the second conveyor 6 from the standby position below the first conveyor 5 to the connection position downstream of the first conveyor 5 (moving the second conveyor 6 so as to be continuous with the first conveyor 5). However, the storage system 1 is not limited to this configuration. For example, the main control unit may be configured so that, when an open pallet T determined to be defective reaches the detection position of the pallet arrival confirmation sensor 51a, the main control unit controls the storage device 2 to lift the open pallet T on the belt conveyor 50 and transfer it to the roller conveyor 70.

[0143] (4) In the open tray processing line according to the above embodiment, the printer 107 prints information related to the egg on the side of the corrugated cardboard box C. Here, the information related to the egg refers to the size of the egg, etc. For example, the size of the egg is printed in Figure 15A as well as Figure 15B Such a form is printed on the side of the corrugated box C. Figure 15A In the example, the letter M is printed, and in Figure 15B In the example, there is a mark printed under the letter M, which means that M-sized eggs are stored in corrugated box C.

[0144] The box recognition unit 110a reads the information printed on the corrugated cardboard box C by the printer 107, and provides the transfer destination information based on the read information. The box recognition unit 110a is, for example, an image sensor, which obtains an image and reads the information printed on the corrugated cardboard box C from the obtained image. Figure 15A In the example shown, the box recognition unit 110a sets an inspection range for each cell of the table and determines the size based on the cells with stamps. Figure 15B In the example shown, the box recognition unit 110a searches for letters of the object size (LL, L, M, S, etc.) and determines whether there is a mark underneath.

[0145] Furthermore, the box recognition unit 110a can be configured to read information printed on the corrugated cardboard box C by the printer 107, as well as information printed or affixed to the corrugated cardboard box C in advance. The information printed or affixed to the corrugated cardboard box C is, for example, the brand name of eggs. The box recognition unit 110a reads the brand name from the acquired image and assigns transfer destination information based on the read brand name.

[0146] Should be explained, such as Figure 16 As shown, the box recognition unit 110a can also read information (including printed or pasted information) printed on the corrugated cardboard box C fed from the conveyor 111. The corrugated cardboard box C is carried into the conveyor 111 by manual labor, for example.

Claims

1. A storage device that stores an open tray containing a plurality of eggs in a transport container, and is provided with: an egg suction portion that suctions a plurality of eggs contained in the open tray; a tray holding portion that holds the open tray; and a moving mechanism that moves the egg suction portion and the tray holding portion, the moving mechanism being provided with an up-and-down moving mechanism that moves up and down along an axis in the up-and-down direction, a horizontal moving mechanism that moves horizontally along an axis in the horizontal direction, and a rotational moving mechanism that moves rotationally about an axis in the up-and-down direction.

2. The storage device according to claim 1, wherein the rotational moving mechanism is connected to the egg suction portion and the tray holding portion, the up-and-down moving mechanism moves the rotational moving mechanism up and down, and the horizontal moving mechanism moves the up-and-down moving mechanism horizontally.

3. The storage device according to claim 1, provided with: a base that is fixed to the moving mechanism; and a box that includes the egg suction portion and the tray holding portion and is detachable on the base.

4. A storage system provided with: the storage device according to claim 1; a first conveyor that conveys the open tray containing eggs; an inspection portion that is arranged upstream of the first conveyor and inspects defects of the open tray conveyed to the first conveyor; and a second conveyor that moves from a standby position below the first conveyor to a connection position downstream of the first conveyor to receive the open tray from the first conveyor when the open tray is judged to have defects.

5. The storage system according to claim 4, wherein a conveyor stopper is provided on the second conveyor, and the second conveyor in the standby position has the conveyor stopper positioned at a downstream end of the first conveyor when the open tray is judged to have no defects. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​

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