Stacking device

Abstract

To provide a stacking device capable of smoothly and reliably discharging a heavy cart in a discharge direction after stacking.SOLUTION: In a loading area where a luggage 200 is stacked on a cart 100, a stacking device includes: a positioning unit 2 that fixes a position of a cart supplied to the loading area; a stacking unit 3 that stacks the luggage on the cart whose position is fixed by the positioning unit; a discharge control unit 4 that causes a stacked cart after the luggage has been stacked to be removed from the loading area; and a wheel control unit 5 that aligns a direction of wheels of the cart in a discharge direction of the cart. In an empty state before the luggage is stacked on the cart in the loading area, the wheel control unit aligns a direction of the wheels of the cart in the discharge direction, the cart has wheels, and the wheels are capable of rotating freely in the direction.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a stacking device that stacks containers for accommodating cargo on a cart and removes the cart on which the containers are loaded. [Background technology]

[0002] In recent years, e-commerce and internet sales have expanded, and retailers and transport companies are increasing the amount of work they do sorting a wide variety of items and preparing them for delivery.

[0003] For example, a wide variety of goods are stored in a container, which is a storage vessel for delivery. The container with the goods stored in it is then removed. The removed container is then delivered to the delivery destination (which may be the final delivery destination or a relay point). Through this delivery, goods (products) ordered through e-commerce or internet sales are delivered to the customer's hands.

[0004] As mentioned above, e-commerce and internet sales have been growing in recent years compared to retail sales in brick-and-mortar stores. Retail companies (or manufacturing companies) that previously sold products in brick-and-mortar stores are expanding into e-commerce and internet sales. There is also an increasing number of internet sales companies whose main business is e-commerce and internet sales. Furthermore, the volume of goods handled by each of these companies is also growing, and there is an increase in the amount of work involved in sorting a wide variety of products, loading them into containers, and distributing them. This is true all over the world.

[0005] In addition to retail such as e-commerce and internet sales, manufacturers may also store multiple types of goods in containers and other containers, and transport them to the next process or move them to the distribution stage. Alternatively, distributors may sort and store a wide variety of goods in storage containers as part of their business, and have these storage containers delivered. In this case, too, the work of sorting and storing a wide variety of goods in storage containers and transporting them is required.

[0006] In addition to e-commerce and internet sales, traditional retail businesses also sort products for sale into storage containers, transport them out, and move them to the distribution stage.

[0007] In addition, rather than shipping the same product in a cardboard box, for example, a wide variety of items with different sizes, shapes, types, weights, etc. are increasingly being placed in containers or other storage vessels and then shipped. For this reason, it is becoming increasingly necessary to load a wide variety of items into containers of suitable specifications for shipping, and then move multiple containers loaded with these items to the shipping stage.

[0008] At this time, in order to increase the efficiency of delivery, it is necessary to load a plurality of containers containing the goods onto a cart (stacking) and then transport the cart.

[0009] In this situation, techniques relating to stacking devices have been proposed (see, for example, Patent Documents 1, 2, and 3). [Prior art documents] [Patent documents]

[0010] [Patent Document 1] Re-tabled publication No. 2016-051509 [Patent Document 2] JP 2022-149564 A [Patent Document 3] JP 2019-081662 A Summary of the Invention [Problem to be solved by the invention]

[0011] Patent Document 1 discloses a pallet stacking device having a support section that supports one or more stacked pallets, a loading section on which the pallets to be stacked are placed, a lifter that is provided below the support section and stacks the pallets received one by one by placing them on the loading section while lifting the pallet and supporting it on the support section, and a discharge section (45) that discharges the multiple stacked pallets, the pallet stacking device also comprising a cover (31) provided on the frame of the pallet stacking device so as to surround at least a portion of the sides and top of the pallet supported by the support section, and an air blowing means (32) that blows air toward the pallets supported by the support section.

[0012] Patent Document 2 includes a second conveying unit T2 that conveys a full container Cf after some of the articles G have been removed by an retrieval operation from the retrieval operation area Wo to the storage warehouse 1. The second conveying unit T2 also conveys an empty container Ce from which all of the articles G have been removed by an retrieval operation from the retrieval operation area Wo to the storage warehouse 1. The conveying system 100 disclosed herein is further provided with an eighth conveying unit T8 that conveys the empty container Ce stored in the storage warehouse 1 from the storage warehouse 1 to the empty container buffer 3.

[0013] Patent document 3 discloses a stacking device 1 comprising a conveying device 10 that transports a workpiece W to a receiving position R, a pair of support means 20a, 20b that support both sides of the workpiece W transported to the receiving position R so that it can move up and down, and a pair of holding means 30a, 30b that hold the workpiece W raised by the pair of support means 20a, 20b at a predetermined discharge height, the holding means 30a, 30b being arranged to be able to advance and retreat in a direction inclined relative to the vertical direction, and the holding portions 31a, 31b at the tips being configured to abut the underside of the workpiece W when advancing.

[0014] Patent Documents 1 to 3 disclose techniques for stacking workpieces (containers or containers containing articles) to be stacked and moving them to the next process. The containers and articles are transported by a conveyor or the like, and are stacked (stacked) in a stacking device so that multiple containers are stacked on top of each other.

[0015] By stacking in this way, multiple (large numbers) containers can be removed and moved on to the next process, such as delivery.

[0016] However, when multiple containers are stacked, their weight becomes very large. Even if the multiple stacked containers are transported by a conveyor or the like, a dolly or the like must be used to transport them to the next process, such as for delivery. In other words, the multiple stacked containers must be placed on a dolly and transported.

[0017] The containers stacked on the cart contain items, and the weight of the stacked containers can be considerable. For example, it can weigh more than 100 kg. It is very difficult to push a cart with such a weight on it, either manually or automatically. The cart has wheels, but if the direction of the wheels is not aligned with the direction in which the cart is to be carried out, it is difficult to push the cart due to its weight. Or, the cart may snake during the pushing process, making it impossible to carry the containers out via the appropriate route to the next process.

[0018] In addition, the direction of movement of the cart may differ between the process of stacking containers on the cart and the process of removing the cart after stacking. To accommodate such different cases, the direction of the wheels cannot be fixed. The wheels must be able to rotate freely.

[0019] The direction of the wheels must be different when the containers are loaded and when the cart is removed. If they are different, the direction of the wheels of the cart carrying the weight of the containers after loading will not be aligned with the direction of removal. As a result, the wheels become a burden during removal, making removal difficult. Or, as mentioned above, the cart will be removed while snaking.

[0020] When the cart zigzags, it is not possible to fix the position of the cart, and the positioning precision when loading the containers must be sacrificed, which can lead to problems during the stacking process or the need for other measures.

[0021] If the position of the cart is fixed when stacked in order to ensure proper positioning accuracy and increase stacking efficiency (or prevent malfunctions), there will be no space for the cart to snake if the direction of the wheels is different from the direction of transport, and transport will not be possible.

[0022] On the other hand, if the supply direction of the empty cart, the stacking direction of the containers on the empty cart, the transport direction of the containers, and the removal direction of the cart after stacking are all aligned (though removal of the cart after stacking is possible),

[0023] In either situation, it is difficult to properly transport the cart carrying the stacked containers, which are quite heavy. In the conventional technology, there was a problem that it was difficult to accurately stack the heavy containers on the cart and to transport the stacked cart as it was.

[0024] In view of the above problems, the present invention aims to provide a stacking device that can efficiently stack containers (luggage) on empty carts in a small space and smoothly and reliably transport heavier carts after stacking in the unloading direction. [Means for solving the problem]

[0025] In view of the above problems, the stacking device of the present invention includes a positioning unit that fixes a position of a cart supplied to a loading area where luggage is stacked on the cart; A stacking unit that stacks luggage on the dolly that is fixed to the positioning unit; a carry-out control unit that carries out the stacked carts after the luggage has been stacked from the loading area; A wheel control unit that aligns the direction of the wheels of the dolly to the direction of discharge of the dolly, The wheel control unit aligns the direction of the wheels of the dolly in the carrying-out direction in an empty state before luggage is stacked on the dolly in the loading area, The cart has wheels, and the wheels are freely rotatable in any direction. Effect of the Invention

[0026] In the stacking device of the present invention, even when the direction in which an empty cart is fed differs from the direction in which packages are stacked on the cart, the wheels of the cart are controlled in the direction in which the cart is carried out. This allows the cart to be carried out smoothly and reliably in the direction in which packages are carried out, even if the package is stacked and heavy.

[0027] In addition, since the direction of the wheels is aligned in the direction of discharge before any cargo is loaded onto the trolley (when there is no weight load), control of the direction of the wheels is easy and can be achieved with high precision.

[0028] Since the direction in which empty trolleys are supplied and the direction in which luggage is transported cross each other, the space required for stacking luggage can be reduced. In addition to reducing the space required, loaded trolleys can be smoothly removed, making it possible to easily stack and remove luggage in a small space.

[0029] In addition, since the position of the dolly can be fixed within a certain range when stacking the luggage and when removing the dolly, the luggage can be stacked in a small space while improving the accuracy of loading the luggage. Also, the burden on the device when loading the luggage can be reduced. [Brief description of the drawings]

[0030] [Figure 1] FIG. [Diagram 2] FIG. 13 is a perspective view showing the relationship between the positional movement of a cart and the direction of wheels when a cart is used in the stacking device. [Diagram 3] FIG. 1 is a perspective view of a stacking device according to a first embodiment of the present invention. [Figure 4] FIG. 2 is a plan view of a portion related to the movement of carriages of the stacking device in the first embodiment of the present invention. [Diagram 5] 13 is a photograph of the cart of the present invention after stacking. [Figure 6] FIG. 2 is a perspective view showing a state before carriages are supplied in the stacking device in the first embodiment of the present invention. [Figure 7]FIG. 2 is a perspective view showing a carriage supply state in the stacking device in the first embodiment of the present invention. [Figure 8] FIG. 2 is a perspective view showing a state in which a cart has been supplied to a loading area in the stacking device in the first embodiment of the present invention. [Figure 9] FIG. 4 is a perspective view showing wheel control in the stacking device in the first embodiment of the present invention. [Figure 10] FIG. 4 is a perspective view showing wheel control in the stacking device in the first embodiment of the present invention. [Figure 11] FIG. 4 is a perspective view showing wheel control in the stacking device in the first embodiment of the present invention. [Figure 12] FIG. 1 is a perspective view showing a stacking state of luggage in a stacking device in accordance with a first embodiment of the present invention. [Figure 13] FIG. 1 is a perspective view showing a stacking state of luggage in a stacking device in accordance with a first embodiment of the present invention. [Figure 14] FIG. 2 is a perspective view showing carriage removal in the stacking device according to the first embodiment of the present invention. [Figure 15] FIG. 2 is a perspective view showing carriage removal in the stacking device according to the first embodiment of the present invention. [Figure 16] FIG. 2 is a perspective view showing carriage removal in the stacking device according to the first embodiment of the present invention. [Figure 17] FIG. 4 is a plan view showing the operation of the stacking device in the first embodiment of the present invention. [Figure 18] FIG. 4 is a plan view illustrating the operation of the stacking device in the first embodiment of the present invention. [Figure 19] FIG. 4 is a plan view illustrating the operation of the stacking device in the first embodiment of the present invention. [Figure 20] FIG. 4 is a plan view illustrating the operation of the stacking device in the first embodiment of the present invention. [Figure 21] FIG. 4 is a plan view illustrating the operation of the stacking device in the first embodiment of the present invention. [Figure 22] FIG. 11 is a perspective view of a stacking device according to a second embodiment of the present invention. [Figure 23]FIG. 11 is a schematic diagram showing a conveying direction and a supply direction in the second embodiment of the invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] The stacking device according to a first aspect of the present invention includes a positioning unit that fixes a position of a cart supplied to a loading area where luggage is stacked on the cart; A stacking unit that stacks luggage on the dolly that is fixed to the positioning unit; a carry-out control unit that carries out the stacked carts after the luggage has been stacked from the loading area; A wheel control unit that aligns the direction of the wheels of the dolly to the direction of discharge of the dolly, The wheel control unit aligns the direction of the wheels of the dolly in the carrying-out direction in an empty state before luggage is stacked on the dolly in the loading area, The cart has wheels, and the wheels are freely rotatable in any direction.

[0032] With this configuration, even if the wheels of the dolly are not facing the direction of removal when it is delivered, the wheels can be aligned in the direction of removal without weight, so that the dolly can be easily removed after loading the goods.

[0033] In the stacking device according to the second aspect of the present invention, in addition to the features of the first aspect, when the dolly is supplied to the loading area, the orientation of the wheels of the dolly is not aligned with the unloading direction.

[0034] With this configuration, the dollies can be easily moved out by aligning them in the direction of removal from an unaligned state.

[0035] In the stacking device of the third invention of the present invention, in addition to the first invention, the wheel control unit aligns the direction of the wheels with the unloading direction by pushing the end face of the cart in the loading area opposite the unloading direction in the unloading direction.

[0036] With this configuration, the free rotation of the wheels caused by pushing the dolly while it is light in weight can be utilized to align the wheels in the direction of removal.

[0037] In a stacking device according to a fourth aspect of the present invention, in addition to the third aspect, the wheel control section pushes out one corner of the end face.

[0038] This configuration allows the wheels to be pushed diagonally forward along the path they travel when facing the unloading direction while rotating. By pushing the wheels diagonally forward, the wheels rotate within a short travel distance and face the unloading direction.

[0039] In a stacking device according to a fifth aspect of the present invention, in addition to the third aspect, the wheel control section pushes out a distance equal to or greater than a rotation radius of the wheel.

[0040] This configuration ensures that the wheels are aligned in the unloading direction.

[0041] The stacking device according to a sixth aspect of the present invention, in addition to the features of the first aspect, further comprises an empty cart supply unit that supplies the cart in an empty state to the loading area.

[0042] With this configuration, empty carts are supplied to the loading area 50 one after another, and the stacking and removal of luggage is carried out efficiently.

[0043] A seventh aspect of the present invention provides a stacking device according to the sixth aspect of the present invention, further comprising a transport section that transports luggage to the stacking section, The stacking unit stacks the luggage transported by the transport unit on the cart along a transport direction of the transport unit, The conveying direction and the direction in which the empty cart supply unit supplies the carts intersect with each other.

[0044] With this configuration, even in such a case, the wheels are aligned in the direction of unloading, so unloading can be performed smoothly.

[0045] In the stacking device according to the eighth aspect of the present invention, in addition to the seventh aspect, the wheel control unit controls the stacking device as follows: The orientation of the wheels of the cart when it is supplied to the loading area by the empty cart supply unit is changed from the supply direction to the unloading direction.

[0046] This configuration allows the wheels to be aligned before loading the cargo, and also makes it easier to unload the cargo after it has been loaded.

[0047] In a ninth aspect of the present invention, in addition to the sixth aspect, the stacking device further comprises a guide member extending along a side surface of the carriage, The side position of the cart is kept within a certain range from the stage where it is supplied by the empty cart supply unit to the stage where it is unloaded by the unloading control unit.

[0048] This configuration allows luggage to be stacked accurately on the cart.

[0049] In a stacking device according to a tenth aspect of the present invention, in addition to the features of the first aspect, the stacking section has a gripping mechanism which grips the luggage and stacks it on the cart.

[0050] This configuration allows luggage to be stacked reliably on the cart.

[0051] In the stacking device according to an eleventh aspect of the present invention, in addition to the first aspect, the cargo includes a container containing an article.

[0052] This configuration efficiently handles the stacking required for the delivery of a wide variety of goods, such as e-commerce.

[0053] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0054] (Embodiment 1)

[0055] (Inventor's Analysis) A dolly is used in the stacking device. Fig. 1 is a perspective view of the dolly. The dolly 100 has a frame 101 and wheels 102. Baggage is loaded (stacked) on the frame 101. When the dolly 100 is pushed, the wheels 102 rotate, allowing the dolly 100 to move.

[0056] Here, the wheels 102 can rotate freely in their direction. In other words, they are free wheels. By rotating freely, the direction of movement can be freely changed. When the cart 100 is pushed manually or automatically, the wheels 102 move in the same direction as the cart 100 is pushed.

[0057] Therefore, when the cart 100 is pushed out, the direction of the wheels 102 becomes the pushing direction. As the cart 100 moves due to the pushing, the direction of the wheels 102 becomes aligned with the pushing direction, and the cart moves along the pushing direction.

[0058] That is, the direction of the wheels 102 of the cart 100 that are freely rotating can be changed by pushing the wheels 102 in the direction of movement. This change allows the cart 100 to move in various directions. Conversely, if the direction of the wheels 102 is fixed (if they do not rotate freely), the cart 100 can only move in a set direction.

[0059] Fig. 2 is a perspective view showing the relationship between the position movement of a dolly and the direction of the wheels when a dolly is used in a stacking device. Fig. 2 shows the vicinity of the dolly of the stacking device. Fig. 2 shows an example of the stacking device.

[0060] In the stacking device, the cart 100 is supplied to a loading area where stacking is performed. Baggage is stacked on the cart 100 supplied to the loading area. The cart 100 loaded with the stacked baggage is then carried out.

[0061] Here, as an example of a stacking device, a trolley 100 is supplied from position A to position B (loading area) along the X direction. Meanwhile, luggage is stacked on the trolley 100 along the Y direction. After stacking, the trolley 100 is carried out along the Y direction. As shown in FIG. 2, the X direction and the Y direction are not parallel but intersect. That is, the supply direction (X direction) of the trolley 100 and the carry-out direction (Y direction) of the trolley 100 after stacking are not parallel but intersect.

[0062] This is because, when adopting a mechanism in which the dollies 100 are supplied one after another while the cargo is supplied one after another by a conveyor or the like and stacked, it is difficult to align the supply direction and the carry-out direction of the dollies. To align the supply direction and the carry-out direction when the dollies are supplied, it is necessary to supply the dollies from underground in the loading area (position B) to the floor surface, or to supply the dollies from below the conveyor that supplies the cargo in accordance with the movement direction of the conveyor. These configurations lead to problems such as complicating the stacking device and its peripheral devices, and complicating operations. There is also the problem that the entire device becomes large in size.

[0063] To address such problems, a suitable configuration would be to supply empty trolleys 100 in the X direction, move the conveyor in the Y direction to stack cargo, and then transport the stacked trolleys 100 in the same Y direction, as shown in FIG. 2 (as an example).

[0064] 2, an empty dolly 100A is placed at position A. The dolly 100A moves from position A to position B, which is a loading area. At this time, the dolly 100A moves in the X direction, so the wheels 102A of the dolly 100A face in the X direction.

[0065] Next, cargo is loaded onto the dolly 100A, resulting in the loaded dolly 100B. This is the state at position B, which is the loading area. At this time, the wheels 102B are still facing in the X direction. This is because this is the state after the dolly 102B has moved from position A to position B. The stacked dolly 102B needs to be carried out in the Y direction, which is the carrying-out direction.

[0066] However, at this time, the wheels 102B are still facing in the X direction. In this state, it is not easy to push the cart 100B in the Y direction, which is the carrying-out direction. As explained in the prior art, the stacked luggage weighs 100 kg or so, and the wheels 102B are not facing in the Y direction, so the cart 100B cannot move in the Y direction.

[0067] In this state, if one were to forcefully push the cart 100B out in the Y direction, a considerable force would be required, placing a large burden on the stacking device. Also, in order for the wheels 100B to switch from the X direction to the Y direction, the cart 100B needs a range in which it can move vertically and horizontally, so it is necessary to provide a wide loading area. In this case, the loading area at position B becomes wide, making it difficult to fix the position of the cart 100B and to load luggage.

[0068] In this way, it is important to properly align the directions of the wheels 102 of the cart 100 in the supply direction and the discharge direction in a stacking device that uses the cart 100. The inventors performed the analysis in this manner.

[0069] (Overview)

[0070] An overall overview of the stacking device will be described. Fig. 3 is a perspective view of the stacking device in the first embodiment of the present invention. Fig. 3 shows the stacking device 1 including elements that are peripheral functions. For convenience of illustration, only the control unit 10 is shown as a block diagram. Furthermore, for components that are difficult to see only in a perspective view such as Fig. 3, they can be understood from other perspective views or plan views.

[0071] 4 is a plan view of a portion related to the movement of the carriages of the stacking device in the first embodiment of the present invention, showing a state seen from above with a focus on the vicinity of the floor surface on which the carriages 100 of the stacking device 1 in FIG.

[0072] The stacking device 1 stacks luggage on the supplied empty trolleys 100 in the loading area 50. After stacking, the trolleys 100 loaded with luggage are transported in the unloading direction. After unloading, the trolleys 100 are handed over to the next process, such as delivery. At this time, as shown in Figs. 3 and 4, the X direction is the trolley supply direction in which the trolleys 100 are supplied to the stacking area 50. The Y direction is the unloading direction in which the trolleys 100 that have finished stacking luggage 200 are transported to the next process. The X direction and the Y direction intersect, for example, are approximately perpendicular to each other.

[0073] 3 and 4, the conveying direction of the cargo 200 by the conveyor 210 is substantially parallel to the Y direction, which is the carry-out direction. That is, the cargo 200 is conveyed in the Y direction, stacked, and then carried out in the Y direction. Meanwhile, the carts 100 carrying the cargo 200 are supplied in the X direction, which intersects with the Y direction (or is substantially perpendicular in some cases). In this way, the carry-out direction and the cart supply direction intersect.

[0074] The stacking device 1 includes a positioning unit 2, a stacking unit 3, a carry-out control unit 4, and a wheel control unit 5. As described with reference to FIG. 1, the cart 100 has wheels 102, which can rotate freely. The cart also includes a control unit 10. The control unit 10 stores a program for controlling stacking and carry-out, and outputs instructions based on the program to each element such as the stacking unit 3. The control unit 10 can also input necessary instructions by an operator, and can accept manual operations by the operator.

[0075] The positioning unit 2 fixes the position of the trolley 100 supplied to the loading area 50 where luggage is stacked. An empty trolley 100 is supplied from position A to position B. Position B is the loading area 50. When luggage is loaded, the positioning unit 2 fixes the trolley 100 so that the trolley 100 falls within a certain range. Using a guide member 21 along the width direction of the trolley 100 in FIG. 4, the positioning unit 2 positions the position of the trolley 100 so that the position falls within a certain range.

[0076] In addition, when the dolly 100 is supplied to the stacking area 50, a stopper 22 is provided which protrudes toward the dolly 100 and reliably fixes its position range. After the dolly 100 is supplied, the stopper 22 stops the dolly 100 which has reached the stacking area 50 so as not to protrude too far in the conveying direction when the wheel control unit 5 pushes the dolly 100 in the conveying direction.

[0077] Since the stopper 22 can prevent the dolly 100 from going too far in the conveying direction, the dolly 100 is reliably positioned at the stacking position of the baggage 200 by the stacking section 3.

[0078] In this way, the positioning unit 2 (including the guide member 21) determines the position of the cart 100 in the width direction (direction parallel to the cart supply direction), and the stopper 22 determines the position of the cart 100 in the unloading direction.

[0079] In this manner, the positioning unit 2 may include the guide member 21 and the stopper 22 to position the dolly 100 within a certain range. This allows the cargo 200 to be stacked reliably.

[0080] At the stage when the cart 100 is supplied from position A to position B, the cart 100 is in an empty state (empty cart).

[0081] The luggage is transported by a conveyor 210 or the like, and a stacking unit 3 equipped with a robot arm or the like stacks the luggage on the cart 100. For this reason, it is preferable that the position of the cart 100 is fixed within a certain range. Since the cart 100 is supplied from outside the loading area 50, such as position A, it is preferable that the position is fixed each time.

[0082] The stacking unit 3 stacks luggage transported by the conveyor 210 or the like on the cart 100. The stacking unit 3 is also preferably provided with a gripping mechanism for gripping luggage, and is provided with a robot arm or the like for moving the gripping mechanism and the gripped luggage to a predetermined position on the cart 100.

[0083] The stacking section 3 stacks luggage on the cart 100 in accordance with the specifications of the stacking device 1. In the first stage, luggage is loaded onto an empty cart. After that, the next luggage is loaded beside or on top of the luggage, and finally, luggage is stacked on the cart 100 until it reaches the state shown in FIG. 5. FIG. 5 is a photograph of the cart after stacking according to the present invention. For ease of viewing, the luggage 200 is a container that is empty. In reality, the luggage 200 may be a container containing articles or a cardboard box. For this reason, the weight of the cart 100 after stacking becomes considerable. In some cases, it may be more than 100 kg.

[0084] The carry-out control unit 4 carries out the stacked cart 100 from the loading area 50 after stacking is completed as shown in Fig. 5. At this time, since the Y direction is the carry-out direction as shown in Fig. 4, the cart is carried out along the Y direction.

[0085] The wheel control unit 5 controls the orientation of the wheels 102 of the cart 100. Specifically, the wheels 102 are aligned in the direction in which the cart 100 is carried out (the Y direction in FIG. 4).

[0086] As explained in the inventor's analysis, the dolly 100 is supplied to the loading area 50 along the X direction. In this state after supply, the wheels 102 are aligned along the X direction. On the other hand, when unloading, the wheels 102 need to face the Y direction. However, after heavy luggage 200 is stacked as shown in FIG. 5, it is difficult to push the dolly 100 and change the direction of the wheels 102 because the weight is too large.

[0087] For this reason, the wheel control unit 5 aligns the wheels 102 in the carry-out direction when the dolly 100 in the loading area 50 is in an empty state (empty dolly) before the luggage 200 is stacked. In the empty state, the weight of the dolly 100 is small, and if a pushing pressure in the carry-out direction is applied from the rear of the dolly 100, the wheels 102 rotate and the wheels 102 are aligned in the carry-out direction. In Fig. 4, the wheels 102 switch from the X direction to the Y direction.

[0088] The wheel control unit 5 switches the direction of the wheels 102 of the cart 100 to align with the carry-out direction when the cart 100 is empty before any baggage 200 is placed on it. Therefore, since the weight is small, when the wheel control unit 5 pushes the cart 100 in the conveyance direction, the wheels 102 rotate to align with the carry-out direction.

[0089] At this time, the wheels 102 rotate freely with a slight push and movement distance, and face the direction of carry-out. Therefore, the positioning unit 2 can maintain the position of the dolly 100 within a predetermined range, so there is no effect on the stacking of the luggage 200.

[0090] The wheels 102 of the dolly 100 when supplied to the loading area 50 face the X direction (the supply direction of the dolly 100). That is, when supplied to the loading area 50, the orientation of the wheels 102 of the dolly 100 is not aligned with the carry-out direction. In contrast, under the control of the wheel control unit 5, the wheels 102 face the carry-out direction (Y direction) before the baggage 200 is stacked on the dolly 100.

[0091] After the wheels 102 are aligned in the carry-out direction, the stacking unit 3 stacks the luggage 200 on the cart 100. Even if the result of stacking is the state shown in FIG. 5 (even if the weight becomes heavy), the wheels 102 are still facing the carry-out direction. After this, the carry-out control unit 4 pushes the cart 100 in the carry-out direction. As a result, the cart 100 loaded with the luggage 200 is smoothly carried out in the carry-out direction.

[0092] In this way, even if the supply direction of the cart 100 and the unloading direction of the cart intersect, the cart 100 with the cargo stacked thereon is smoothly unloaded. After unloading, the cargo 200 is handed over to the next process. Once handed over, the cargo can proceed to the next process, such as delivery.

[0093] The baggage 200 includes various objects such as a container (for example) that contains an item, or a cardboard box that contains an item.

[0094] (Operation description) Next, the operation of the stacking device 1 will be described with reference to the drawings. The drawings here show only elements necessary for the explanation of the operation, for ease of understanding. Figures 6 to 16 are in the order of the operation procedure.

[0095] (Before trolley supply) Fig. 6 is a perspective view showing a state before a carriage is supplied in the stacking device in the first embodiment of the present invention. Fig. 7 is a perspective view showing a carriage supply state in the stacking device in the first embodiment of the present invention.

[0096] As shown in Fig. 6, there are shown the positioning unit 2, stacking unit 3, carry-out control unit 4, wheel control unit 5, and conveyor 210 for transporting luggage 200 of the stacking device 1. In Fig. 7 and subsequent figures, the reference numerals in the figures are omitted for elements that overlap with Fig. 6.

[0097] Initially, the cart 100 is empty and has not been supplied to the loading area 50. From this state, the cart 100 is moved toward the loading area 50. It moves in the X direction described in Fig. 4. Fig. 7 shows the state of the cart 100 in the middle of being supplied.

[0098] At this time, for example, a cart supply device may be provided that stores a large number of carts 100 and supplies the carts 100 one by one to the loading area 50. In this way, the carts 100 may be moved to the loading area 50 automatically. Alternatively, the carts 100 may be moved manually.

[0099] (Provision of trolleys) FIG. 8 is a perspective view showing a state in which a cart has been supplied to a loading area in the stacking device in the first embodiment of the present invention.

[0100] Proceeding from the state in Fig. 7, the dolly 100 reaches the loading area 50. The dolly 100 is pushed in the X direction and reaches the loading area 50. In the loading area 50, the position of the dolly 100 is fixed by the positioning unit 2 that keeps the position of the dolly 100 within a certain range. As described above, the positioning unit 2 includes a guide member to keep the width direction of the dolly 100 within a certain range.

[0101] Furthermore, the stopper 22 allows for more reliable positioning in the width direction.

[0102] Furthermore, in this state, the wheels 102 of the cart 100 are facing in the X direction because the cart 100 has been moved in the X direction. That is, the wheels 102 are aligned in the supply direction of the cart.

[0103] (Wheel directional control) When the cart 100 reaches the loading area 50 as shown in Fig. 8, the wheel control unit 5 then controls the direction of the wheels 102 to be aligned in the Y direction (discharge direction). Fig. 9 to Fig. 11 explain this wheel control. Fig. 9 to Fig. 11 are perspective views showing wheel control in the stacking device in the first embodiment of the present invention.

[0104] When the cart 100 reaches the loading area 50, the wheel control unit 5 pushes the end face of the cart 100 on the side opposite to the direction of discharge in the direction of discharge. Figures 9 and 10 show this pushing state. The wheel control unit 5 is provided with a protruding pushing member, so that it can push out the end face of the cart 100.

[0105] In this pushed-out state, the dolly 100 is not carrying any luggage 200. Therefore, the dolly 100 is light, and by pushing in the unloading direction, the wheels 102 rotate freely while the dolly 100 moves in the unloading direction. During the free rotation, the wheels 102 turn toward the unloading direction because they are aligned with the movement vector. In other words, the dolly 100 aligns the wheels 102 with the unloading direction while moving in the unloading direction.

[0106] At this time, it is also preferable that the wheel control unit 5 pushes out one corner of the end face. Figures 9 and 10 show the state in which this corner is pushed out. By pushing out one corner, the cart 100 moves slightly diagonally toward the unloading direction. The wheels 102 rotate while moving in an arc from the X direction to the Y direction. As a result of this rotation, the direction of the wheels 102 becomes oriented in the unloading direction.

[0107] In order to rotate the wheels 102 while moving in such an arc, it is effective to push out one of the corners. Therefore, by pushing out one of the corners, the wheels 102 can be aligned in the unloading direction with a small amount of movement.

[0108] By pushing out the wheel control unit 5 in this way, the wheels 102 are aligned in the carry-out direction. Fig. 11 shows the state in which the wheels 102 are aligned in the carry-out direction. The wheels 102 are aligned in the carry-out direction by the operation of the wheel control unit 5. As described above, the wheels are easily aligned because the luggage 200 has not yet been loaded.

[0109] It is also preferable that the wheel control unit 5 pushes out a distance equal to or greater than the rotation radius of the wheels 102. By pushing out this distance, the freely rotatable wheels 102 rotate and are reliably aligned in the unloading direction. For example, even if the supply direction (X direction) and the unloading direction (Y direction) are approximately perpendicular, pushing out the rotation radius allows the wheels 102 to rotate by 90 degrees or more, and the direction of the wheels 102 is reliably changed from the supply direction to the unloading direction.

[0110] Furthermore, because of the positioning unit 2, even if the cart 100 is pushed out by the wheel control unit 5, it only moves within the range contained by the positioning unit 2. The absence of the luggage 200 and its light weight, combined with the range fixed by the positioning unit 2, allows the wheels 102 of the cart 100 to be aligned without significantly changing its position. In this state, the luggage 200 can be stacked while knowing the position of the cart 100.

[0111] (Stacking luggage) Next, stacking of the luggage 200 on the dolly 100 will be described with reference to Fig. 12 and Fig. 13. Fig. 12 and Fig. 13 are perspective views showing a stacked state of luggage in the stacking device in the first embodiment of the present invention. As described up to Fig. 11, before stacking the luggage 200, the wheels 102 are aligned (facing) in the carry-out direction.

[0112] As shown in FIG. 12, the luggage 200 is transported by a conveyor 210. The transported luggage 200 reaches the tip of the conveyor 210 (the cart 100 side). The stacking unit 3 has a gripping mechanism 31 that grips the luggage 200 and moves it to the cart 100. The gripping mechanism 31 pinches both sides of the luggage and grips it. Although not shown in FIG. 12, there is also an arm that lifts and moves it in a gripped state. With this structure, the luggage 200 is gripped by the conveyor 210 and placed on the cart 100.

[0113] 12 shows a state in which the luggage 200 is grasped and lifted from the conveyor 210 and moved. The stacking unit 3 proceeds further and places the luggage 200 on the cart 100 as shown in FIG. 13. The luggage 200 is now placed on the cart 100.

[0114] The stacking unit 3 stacks the luggage 200 by grasping the luggage 200 and loading it onto the cart 100. Stacking can be achieved by stacking the luggage 200 in several layers. Eventually, the luggage 200 is stacked as shown in Fig. 5. In the stacked state, the cart 100 loaded with the luggage 200 is in a carry-out state.

[0115] Here, the conveyor 210 is an example of a transport section that transports the luggage 200 to the stacking section 3. Other than the conveyor 210, various patterns such as a roller mechanism that transports the luggage 200 may be used. The stacking section 3 stacks the luggage 200 transported by the transport section on the cart 100 along the transport direction of the transport section.

[0116] Moreover, the stacking device 1 is provided with a positioning unit 2 in the loading area 50. The positioning unit 2 keeps the dolly 100 within a certain range. This allows the stacking unit 3 to accurately load the baggage 200 onto the dolly 100. This is because the positions of the dolly 100 are not all over the place. Also, the dolly 100 does not move significantly and change position when loading.

[0117] At this time, the carriage supply direction of the carriage 100 may cross the conveyance direction as shown in Figures 12 and 13. For this reason, it is preferable that the wheels 102 of the carriage 100 are moved so as to be aligned in the carry-out direction as shown in Figure 11 before the cargo 200 is stacked by the stacking unit 3.

[0118] Through control by the wheel control unit 5, the orientation of the wheels 102 of the dolly 100 supplied to the loading area 50 is changed from the supply direction to the unloading direction. Here, the dolly 100 is supplied from the X direction (supply direction) of the loading area, and the luggage 200 is supplied from the Y direction (unloading direction), but they may be supplied at an angle other than these. Even in this case, the orientation of the wheels 102 at the stage when supplied to the loading area 50 is different from the unloading direction. Even in such a case, the wheel control unit 5 aligns the orientation of the wheels 102 to the unloading direction before loading the luggage 200. As a result, unloading of the dolly, which will be described later, becomes easy and reliable.

[0119] 13, in a state where the baggage 200 is stacked on the dolly 100, the wheels 102 are already aligned in the direction of carrying out the baggage. In this manner, at the stage where the baggage 200 is stacked, the dolly 100 is ready for carrying out the baggage.

[0120] (Carrying out the trolley) After the baggage 200 is loaded onto the dolly 100, the dolly 100 is carried out in the carrying-out direction by the carry-out control unit 4. The carrying-out of the dolly 100 will be described with reference to Fig. 14 to Fig. 16. Fig. 14 to Fig. 16 are perspective views showing the carrying-out of the dolly in the stacking device in the first embodiment of the present invention.

[0121] As shown in Fig. 13, stacking of the luggage 200 on the dolly 100 is completed. At this time, the wheels 102 are aligned in the carry-out direction at the previous stage. In this state, the carry-out control unit 4 pushes the dolly 100 from the rear side (the side opposite to the carry-out direction). The carry-out control unit 4 is provided with a mechanism for pushing the dolly 100 in the carry-out direction as shown in Figs. 14 to 16.

[0122] First, as shown in Fig. 14, the carry-out control unit 4 starts to push out the rear of the cart 100. As the pushing progresses further, the cart 100 starts to move in the carry-out direction (is carried out) as shown in Fig. 15. At this time, since the wheels 102 are aligned in the carry-out direction, the cart 100 can move in the carry-out direction even if the cart 100 is loaded with a large amount of baggage 200.

[0123] The carriage 100 moves further in the unloading direction due to the inertia of the carriage 100 that has started to move and the pushing by the unloading control unit 4. In this way, the carriage 100 is completely unloaded as shown in Fig. 16. The carriage 100 is unloaded from the working area (operating area) of the stacking device 1.

[0124] Here, the stacking device 1 includes a positioning unit 2. The positioning unit 2 includes, as an example, a guide member 21 that is aligned along the side direction of the cart 100. The guide member 21 keeps the side position of the cart 100 within a certain range from the stage at which the cart 100 is supplied to the loading area 50 to the stage at which the cart 100 is carried out by the carry-out control unit 4.

[0125] 14 to 16, the side position of the cart 100 remains within a certain range. This reduces the deviation in the direction of movement of the cart 100 in the lateral direction when it is carried out. It also reduces wobbling to the left and right with respect to the carrying-out direction (left and right of the carrying-out direction). Since the wheels 102 face the carrying-out direction, less wobbling to the left and right means that the wheels 102 can easily rotate (move) while maintaining the carrying-out direction.

[0126] Therefore, the guide member 21 of the positioning unit 2 allows the load 200 to be carried out more smoothly. The load 200 is carried out smoothly and reaches the state shown in FIG. 16. When the load 200 reaches the state shown in FIG. 16, the cart 100 carrying the load 200 is handed over to the next process. The carry-out control unit 4 is also returned to the front again.

[0127] This has the advantage of reducing the load on the discharge control unit 4. As a result, the stacking device 1 can be prevented from becoming complicated.

[0128] When this series of operations is completed, the carry-out control unit 4 and the wheel control unit 5 are returned to their initial positions. These operate according to a processing procedure determined by the control unit 10. Alternatively, they operate according to instructions input by the operator.

[0129] When the necessary elements return to their initial positions, the next empty cart 100 is supplied to the loading area. That is, the operation from Fig. 6 is performed. By repeating such operations, the baggage 200 is stacked on the carts 100 one after another and carried out.

[0130] As described above, the stacking device 1 in the first embodiment can control the direction of the wheels 102 to the unloading direction even when the direction of the wheels 102 at the stage when the dolly 100 is supplied differs from the unloading direction. As a result, the dolly 100 can be smoothly unloaded even after the baggage 200 is loaded.

[0131] The entire operation has been explained in sequence above using perspective views including the movement of the luggage 200 in Fig. 6 to Fig. 16. This operation will be explained in a more understandable manner using plan views from Fig. 17 onwards, showing the components of the stacking device 1 in an easily understandable manner, while also explaining wheel control. Fig. 17 to Fig. 21 show the supply of carts, the control of the wheels, and the removal of the carts, as viewed from above the stacking device 1.

[0132] (Before trolley supply) Fig. 17 is a plan view showing the operation of the stacking device in the first embodiment of the present invention. Fig. 17 shows a state before the carriage 100 is supplied. The positioning unit 2, the carry-out control unit 4, the wheel control unit 5, the guide member 21, the stopper 22, and the conveyor 210 are shown.

[0133] The carriage 100 is in a state before supply. The carriage 100 is moved in the X direction, and is moved to the stacking area 50.

[0134] (Cart supply) Fig. 18 is a plan view illustrating the operation of the stacking device in the first embodiment of the present invention. Fig. 18 shows a state in which the cart 100 has been supplied to the stacking area 50. When the cart 100 reaches the stacking area 50, the guide members 21 keep the cart 100 within a certain range in its width direction.

[0135] At this point in time, the wheel control unit 5 and the stopping tool 22 have not yet started to operate, and stacking of the luggage 200 has not yet started. At this time, the wheels 102 are facing in the X direction (cart supply direction).

[0136] (Wheel Control) Fig. 19 is a plan view illustrating the operation of the stacking device in the first embodiment of the present invention. This shows the stage where wheel control of the cart 100 supplied to the stacking area 50 is performed. The wheel control unit 5 protrudes a member in the conveying direction, and pushes out the rear end (rear end face) of the cart 100. In particular, as shown in Fig. 19, one side of the rear end of the cart 100 is pushed out. This causes the cart 100 to move in the conveying direction. When one side is pushed, the wheels 102 are more likely to rotate, and the orientation of the wheels 102 becomes aligned with the unloading direction.

[0137] During the movement caused by this pushing pressure, the wheels 102, which were facing in the X direction, start to face in the Y direction. As this progresses, the wheels 102 are aligned in the Y direction, that is, the carry-out direction.

[0138] Furthermore, the dolly 100 pushed out in the unloading direction is stopped by the stopper 22. That is, even when the wheel control unit 5 pushes out the dolly 100 to align the orientation of the wheels 102 in the unloading direction, the dolly 100 can be prevented from being pushed out too far. In combination with the guide member 21, the dolly 100 can align the wheels 102 in the unloading direction while remaining within a predetermined range in the X and Y directions.

[0139] After this state is reached, the stacking unit 3 stacks the luggage 200 on the cart 100. When the luggage 200 is stacked, the wheels 102 are aligned in the direction of discharge, and the position fixing unit 2 (including the guide member 21) and the stopper 22 keep the cart 100 within a certain range, so that the luggage 200 can be stacked accurately.

[0140] (Carts begin to be removed) 20 is a plan view for explaining the operation of the stacking device in the first embodiment of the present invention. It shows the start of removal of the dolly after stacking. The dolly 100 is stacked, and the baggage 200 is stacked on it. At this time, it has a considerable weight of, for example, 100 kg, compared to an empty dolly.

[0141] The carry-out control unit 4 pushes out the dolly 100 to carry it out, but before or at the same time as the carry-out control unit 4 pushes out the dolly 100, the stopper 22 moves to open the carry-out space in the carry-out direction. The state transitions from stopped to released. In the carry-out direction, the stopper 22 is no longer in front of the dolly 100.

[0142] The carry-out control unit 4 protrudes a member in the carry-out direction to push out the rear end of the cart 100. By pushing out the rear end of the cart 100, the cart 100 receives a moving pressure in the carry-out direction. Due to this moving pressure, the cart 100 starts moving in the carry-out direction. As described above, since the stopper 22 is no longer stopping, there is no obstruction and the cart 100 can move in the carry-out direction.

[0143] (Export) 21 is a plan view illustrating the operation of the stacking device in the first embodiment of the present invention, showing a state in which the cart 100 has been carried out.

[0144] The carry-out control unit 4 further pushes out the rear end of the dolly 100. This pushing causes the dolly 100 to move further. Since the wheels 102 are already aligned in the carry-out direction as described above, the dolly 100 can move without any problems even if a heavy baggage 200 is loaded on it.

[0145] As a result, the cart 100 is carried out and handed over to the next process. After the carrying out is completed, each element returns to its original state, and the operation of supplying the cart 100 from the outside to the stacking area 50 starts again. These operations are repeated.

[0146] (Embodiment 2)

[0147] FIG. 22 is a perspective view of a stacking device according to the second embodiment of the present invention.

[0148] 22 further includes an empty cart supply unit 11 that continuously supplies empty carts 100 to the loading area 50. The empty cart supply unit 11 stores a plurality of carts 100 (which are empty). For example, the plurality of carts 100 are stacked in the height direction.

[0149] The empty cart supply unit 11 supplies the multiple carts 100 one by one to the loading area 50. The supply is performed in accordance with the operation procedures described in Figs. 6 to 21. When multiple carts 100 are stacked in the height direction, the empty carts 100 may be supplied from the lowest cart 100. This is because the carts 100 can be supplied efficiently in this way.

[0150] By efficiently and continuously supplying the carts 100, the cargo 200 can be efficiently stacked on and removed from the carts 100. Since a large amount of cargo 200 can be removed in a short period of time, the delivery preparation capacity of the stacking device 1 is improved.

[0151] Also, a transport section such as a conveyor 210 for transporting the baggage 200 is provided. The transport direction intersects with the supply direction of the carts 100 by the empty cart supply section 11. This is how it is shown in FIG.

[0152] Due to the intersection, the orientation of the wheels 102 of the dolly 100 at the stage when it is supplied to the loading area 50 is different from the unloading direction. This state is also handled by the control of the wheel control unit 5. That is, the orientation of the wheels 102 of the dolly 100 at the stage when it is supplied to the loading area 50 by the empty dolly supply unit 11 or the like is changed from the supply direction to the unloading direction.

[0153] Also, there may be cases where the supply direction of the cart 100 and the transport direction of the luggage 200 do not intersect as in Fig. 23. Fig. 23 is a schematic diagram showing the transport direction and supply direction in the second embodiment of the present invention.

[0154] There are also cases where the conveying direction of the cargo 200 conveying unit such as the conveyor 210 and the supply direction of the cart 100 do not intersect. In this case, they are parallel.

[0155] However, even in this case, the baggage 200 is stacked on the cart 100 in a direction intersecting with the conveyance direction. If the direction of delivery of the cart 100 is as shown in Fig. 18, it is still necessary to control the direction of the wheels 102 to change to the delivery direction.

[0156] Whether it is the stacking device 1 described in the first embodiment or the stacking device 1 in Fig. 23, the stacking device 1 has various mechanisms and elements around the loading area 50 as shown in Fig. 22. It is also necessary to consider the combination with the next process after unloading. When considering the overall miniaturization and work flow lines, it is often necessary to make the supply direction of the cart 100 different from the unloading direction of the cart 100. The same is true for Fig. 6 and Fig. 22.

[0157] In this way, in order to reduce size and streamline traffic flow, it is inevitable that the supply direction and the unloading direction of the cart 100 will differ (the direction of the wheels 102 will differ). There are cases in which the orientation of the wheels 102 is not aligned with the unloading direction when the cart is supplied. Even in such cases, as described in the first and second embodiments, the wheels 102 are aligned with the unloading direction by the wheel control unit 5, so that no problems occur during unloading.

[0158] In other words, luggage can be stacked and carried out in a small space.

[0159] The stacking device described in the first and second embodiments is merely an example for explaining the gist of the present invention, and includes modifications and alterations that do not depart from the gist of the present invention. [Explanation of symbols]

[0160] 1-tier stacking device 2 Positioning part 3-tiered section 4. Delivery control section 5 Wheel control unit 10 Control section 11 Empty truck supply department 100 Carts 102 wheels 200 Baggage 210 Conveyor

Claims

1. a positioning unit that fixes a position of a carriage provided in a loading area where luggage is loaded onto the carriage; A stacking unit that stacks luggage on the dolly that is fixed to the positioning unit; a carry-out control unit that carries out the stacked carts after the luggage has been stacked from the loading area; A wheel control unit that aligns the direction of the wheels of the dolly to the direction of discharge of the dolly, The wheel control unit aligns the direction of the wheels of the dolly in the carrying-out direction in an empty state before luggage is stacked on the dolly in the loading area, A stacking device, wherein the cart has wheels, and the wheels are freely rotatable in their directions.

2. 2. The stacking device according to claim 1, wherein the wheels of the carriage are not aligned in the unloading direction when the carriage is supplied to the loading area.

3. The stacking device according to claim 1 , wherein the wheel control unit aligns the orientation of the wheels in the unloading direction by pushing an end face of the cart in the loading area that is opposite to the unloading direction in the unloading direction.

4. The stacking device according to claim 3 , wherein the wheel control section pushes out one corner of the end surface.

5. The stacking device of claim 3 , wherein the wheel control unit pushes a distance equal to or greater than a rolling radius of the wheel.

6. The stacking device according to claim 1 , further comprising an empty cart supply section that supplies the cart in an empty state to the loading area.

7. Further comprising a conveying section for conveying luggage to the stacking section, The stacking unit stacks the luggage transported by the transport unit on the cart along a transport direction of the transport unit, 7. The stacking device according to claim 6, wherein the conveying direction intersects with a direction in which the empty cart supply unit supplies the carts.

8. By the control of the wheel control unit, 8. The stacking device according to claim 7, wherein a direction of the wheels of the cart when the cart is supplied to the loading area by the empty cart supply unit is changed from the supply direction to the unloading direction.

9. The positioning unit has a guide member aligned along a side surface of the carriage, 7. The stacking device according to claim 6, wherein a side position of the cart is kept within a certain range from the stage where the cart is supplied by the empty cart supply unit to the stage where the cart is unloaded by the unloading control unit.

10. The stacking device according to claim 1 , wherein the stacking section has a gripping mechanism that grips the luggage and stacks it on the cart.

11. The stacking apparatus of claim 1 , wherein the load comprises a container containing an item.

Images