Cushioning material holding device, forklift, and cargo handling system

Abstract

To provide such a configuration as to hold a cushioning material at an appropriate height.SOLUTION: A holding mechanism 2 includes a first clamper 41 and a second clamper 42 which are opposite to each other. The holding mechanism 2 includes an actuator 43 for moving the second clamper 42 with respect to the first clamper 41. The holding mechanism 2 includes: an upper end stopper 45 against which the upper end of the cushioning material is pressed when the cushioning material is inserted between the first clamper 41 and the second clamper 42 from below; and a cushioning material sensor 46 which is provided so as to detect that the cushioning material reaches the upper end stopper 45. When the cushioning material sensor 46 has detected that the cushioning material reaches the upper end stopper 45, the actuator 43 moves the second clamper 42, and the cushioning material is sandwiched and held between the first clamper 41 and the second clamper 42.SELECTED DRAWING: Figure 12

Description

[Technical field]

[0001] The present application relates to a cushioning material holding device that releasably holds cushioning material sandwiched between packages. The present application also relates to a forklift including the cushioning material holding device. The present application also relates to a cargo handling system including the forklift. [Background technology]

[0002] As disclosed in Patent Documents 1 and 2, a loading system has been developed for loading cargo onto the bed of a truck. After the cargo is loaded onto the bed, the truck transports the cargo. In order to prevent the cargo from collapsing or being damaged during transportation, plate-shaped cushioning materials (sometimes called separators) are often placed between the cargo.

[0003] In typical loading operations using manned forklifts, a worker (for example, a truck driver working together with the forklift operator) manually places cushioning material against the cargo already loaded on the loading platform. Then, when the operator operates the forklift to load the next cargo, the cushioning material is sandwiched between the previous and next cargo, ensuring that there are no gaps between the cargo. To prevent the cushioning material from falling over in strong winds, the worker may hold onto the cushioning material until just before loading the cargo onto the loading platform, but this can lead to accidents where the cushioning material gets caught in the hand.

[0004] In the system of Patent Document 1, an unmanned forklift loads cargo onto the bed of a truck. In this system, as in the case of a manned forklift, an operator manually places a cushioning material against the cargo already loaded on the bed just before loading.

[0005] This method, whether a manned or unmanned forklift is used, poses a safety risk, as it poses a risk of the worker handling the buffer material getting his or her hand caught in the buffer.

[0006] Patent Document 1 discloses an embodiment in which an unmanned forklift supports one load with the two forks on the left side and another load with the two forks on the right side, transporting two loads at the same time. In this embodiment, when the unmanned forklift stops temporarily, an operator places a buffer material between the loads supported by the forks. Next, the unmanned forklift shifts the forks, so that the buffer material is sandwiched between the two loads and fixed in place. After that, the unmanned forklift loads the loads together with the buffer material onto the loading platform.

[0007] This method assumes that there are four forks and that two loads are loaded onto the platform at the same time. Moreover, the placement of the buffer material between the loads already loaded onto the platform and the loads to be loaded onto the platform ultimately requires the assistance of the worker, as described above.

[0008] In the system of Patent Document 2, a transport vehicle moves along a rail and automatically loads packages onto the platform of a truck parked at a specified location. The transport vehicle loads packages onto the platform one after another so that there is a certain amount of space between the packages. Then, a worker manually inserts cushioning material into the gaps.

[0009] In order to insert the cushioning material after loading the luggage, it is necessary to leave a gap larger than the size of the cushioning material. However, to prevent the luggage from collapsing or being damaged, it is important that the cushioning material is placed between the luggage without any gaps. This is difficult to achieve with the method of Patent Document 2.

[0010] As described above, the arrangement of the cushioning material according to the prior art has several problems. [Prior art documents] [Patent documents]

[0011] [Patent Document 1] Patent Publication No. 2021-195195 [Patent Document 2] JP 2001-301984 A Summary of the Invention [Problem to be solved by the invention]

[0012] The present application provides a structure that holds the cushioning material at the proper height. [Means for solving the problem]

[0013] The present application provides a buffer material holding device for a forklift, The cushioning material holding device is A holding mechanism is provided for releasably holding the plate-shaped cushioning material, The holding mechanism includes: a first clamper and a second clamper facing each other; an actuator for moving the second clamper relative to the first clamper between an open position where a buffer material can be inserted between the second clamper and the first clamper and a clamped position where the buffer material can be sandwiched between the second clamper and the first clamper; an upper end stopper against which an upper end of the buffer material is pressed when the buffer material is inserted between the first clamper and the second clamper from below; a buffer sensor provided to detect when the buffer reaches the upper end stopper; The cushioning material holding device further comprises: The actuator control unit is configured to operate the actuator to move the second clamper from the open position to the clamped position when the cushioning sensor detects that the cushioning has reached the upper end stopper.

[0014] The upper end stopper is provided in a plurality of positions spaced apart from each other in the horizontal direction, The cushioning material sensor is provided for each of the upper end stoppers, The actuator control section may operate the actuator to move the second clamper to the clamp position only when all of the cushioning material sensors detect cushioning materials.

[0015] A plurality of the cushioning material sensors are provided for one of the upper end stoppers, The actuator control section may operate the actuator to move the second clamper to the clamp position only when all of the cushioning material sensors detect cushioning materials.

[0016] The actuator control unit may stop moving the second clamper to the clamp position when at least one of the cushioning material sensors no longer detects cushioning material while moving the second clamper to the clamp position.

[0017] The cushioning material holding device further includes an indicator, The actuator control section may cause an indicator to display information indicating that the cushioning material is being held when the cushioning material sensor detects the cushioning material and the second clamper is in the clamp position.

[0018] The present application also provides a forklift, The forklift in question is: The above-mentioned cushioning material holding device, Forks for supporting the load; a loading device that raises and lowers the fork and the holding mechanism together, The retention mechanism is positioned to retain a shock absorber laterally to the fork.

[0019] The forklift is The forklift further includes an operating device operated by an operator of the forklift. The actuator control section may, in response to receiving a release command from the operation device, operate the actuator to move the second clamper from the clamp position to the release position.

[0020] The upper end stopper includes a receiving portion that receives an upper end of the cushioning material; The cushioning sensor may be arranged to detect when an upper end of the cushioning enters the receiving portion.

[0021] The upper end stopper further includes a guide portion extending in the up-down direction, The receiving portion is provided on an upper portion of the guide portion, The guide portion may be located inside the forklift with respect to a gap between the first clamper and the second clamper.

[0022] The present application also provides an automatically operable forklift, The forklift in question is: The above-mentioned cushioning material holding device, Forks for supporting the load; A loading device that raises and lowers the forks and the holding mechanism together and shifts them in a lateral direction perpendicular to the horizontal protruding direction of the forks; A control unit that controls the operation of the forklift according to a work instruction related to loading and unloading, The retention mechanism is positioned to retain a shock absorber laterally to the fork.

[0023] The present application also provides a loading / unloading system that includes the above-mentioned automatically operable forklift, and automatically operates the forklift to load cargo onto a loading platform of a transport vehicle parked in a predetermined parking area in accordance with a work instruction related to loading / unloading, comprising: The control unit of the forklift After loading the cargo onto the forks, the forklift is temporarily stopped at a predetermined stop position laterally spaced from the rear of the loading platform of the transport vehicle stopped in the stopping area; In response to receiving an instruction to resume operation, the forklift truck, with the buffer material held by the holding mechanism, is caused to travel from the temporary stop position to the loading platform of the transport vehicle; The baggage is loaded onto the loading platform next to the baggage already loaded onto the loading platform, and When the luggage is loaded onto the loading platform, the second clamper is moved to the open position to release the buffer material and sandwich the buffer material between the luggage and the previously placed luggage. The operation of the forklift is controlled. [Brief description of the drawings]

[0024] [Figure 1] FIG. 1 illustrates a schematic of an exemplary cushioning retention device. [Diagram 2] FIG. 2 shows an enlarged view of the cushioning material holding device of FIG. [Diagram 3] FIG. 3 is a view of the cushioning material holding device of FIG. 1 as seen from obliquely below. [Figure 4] FIG. 4 is a diagram for explaining the operation of the cushioning material holding device of FIG. [Diagram 5] FIG. 5 is a diagram for explaining the operation of the cushioning material holding device of FIG. [Figure 6] FIG. 6 is a diagram for explaining a preferred arrangement of the holding mechanism. [Figure 7] FIG. 7 illustrates a schematic of an exemplary non-actuator based retention mechanism. [Figure 8] FIG. 8 shows how the cushioning material is inserted into the holding mechanism of FIG. [Figure 9] FIG. 9 is a diagram for explaining the holding of the cushioning material by the holding mechanism of FIG. [Figure 10] FIG. 10 is a diagram for explaining the holding of the cushioning material by the holding mechanism of FIG. [Figure 11] FIG. 11 is a diagram for explaining a loading / unloading operation of a forklift using the holding mechanism of FIG. [Figure 12] FIG. 12 illustrates a schematic diagram of an exemplary actuator-based retention mechanism. [Figure 13] 13A is a plan view of the holding mechanism in FIG. 12 with the second clamper (movable clamper) in the open position, and FIG. 13B is a plan view of the holding mechanism in FIG. 12 with the second clamper in the clamped position. [Figure 14] 14A is a front view of FIG. 13A, and FIG. 14B is a front view of FIG. 13B. [Figure 15] 15A and 15B each illustrate an upper end stopper. [Figure 16]16A and 16B each illustrate a cushioning sensor. [Figure 17] FIG. 17 is a block diagram showing a configuration related to the actuator control section. [Figure 18] FIG. 18 is a diagram for explaining a loading / unloading operation of a forklift using the holding mechanism of FIG. [Figure 19] FIG. 19 partially illustrates the work area of ​​an exemplary material handling system. [Figure 20] FIG. 20 is a schematic block diagram of an exemplary autonomous forklift. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] Hereinafter, exemplary embodiments of the present application will be described with reference to the accompanying drawings. Note that the components shown in the drawings are not necessarily to scale or proportion, but are merely representative of their functions or operations.

[0026] FIG. 1 shows a schematic diagram of a cushioning material holding device 1 according to an example. The cushioning material holding device 1 is attached to a forklift 7 (FIG. 19) as an attachment, and releasably holds a plate-shaped cushioning material S. The forklift 7 may be a manned forklift or an unmanned forklift. The forklift 7 includes forks 70 for supporting a load W. Here, the load W refers to a pallet P and all of the objects placed thereon. The forklift 7 supports the load W by inserting the forks 70 into the pallet P and scooping it up. Although four forks 70 are shown in FIG. 1, the number is not limited, of course.

[0027] 1, the horizontal protruding direction of the fork 70 is designated as X1, and the lateral direction perpendicular to the horizontal protruding direction X1 is designated as Y (Y1, Y2). Note that the horizontal protruding direction X1 may be referred to as the front of the forklift 7, and the lateral direction Y may be referred to as the left-right direction of the forklift 7.

[0028] The cushioning material holding device 1 comprises a slide guide 10, a slider 11 provided on the slide guide 10 so as to be movable in the lateral direction Y, a rotating shaft 12 attached to the slider 11 and extending from the slider 11 in a horizontal protruding direction X1, and a holding mechanism 2 connected to the slider 11 via the rotating shaft 12 so as to be freely rotatable around the rotating shaft 12.

[0029] The slide guide 10 is attached to the backrest 71. Therefore, the holding mechanism 2 and the fork 70 are raised and lowered together by the lifting operation of the forklift 7, and are shifted together in the lateral direction Y by the side-shifting operation. In order to move the holding mechanism 2 and the fork 70 together, the slide guide 10 may be attached to other members, such as a finger bar or a lift bracket, instead of the backrest 71.

[0030] 2, the slide guide 10 includes, for example, two side frames 100 spaced apart in the horizontal direction Y, and two upper and lower guide bars 101 that are hung across the side frames 100 and extend in the horizontal direction Y. The slider 11 is slidably attached to the guide bars 101. This allows the slider 11 to move in the horizontal direction Y between the side frames 100.

[0031] The slide guide 10 is provided on the upper surface of the backrest 71 at the end in the lateral direction Y (the end on the Y1 side in the example), and the holding mechanism 2 is provided at the tip of the rotating shaft 12 extending forward X1 from the slider 11. As a result, the holding mechanism 2 is located forward in X1 from the backrest 71 and outboard (on the Y1 side) from the outermost fork 70, as shown in FIG. 1. Therefore, when the holding mechanism 2 holds the cushioning material S, the cushioning material S is located beside the fork 70. When a package W is supported by the fork 70, the held cushioning material S faces the side of the package W.

[0032] The holding mechanism 2 is connected to the slider 11 via the rotating shaft 12, and is therefore movable together with the slider 11 in the lateral direction Y. The specific configuration of the holding mechanism 2 will be described later.

[0033] As shown in FIG. 2, the cushioning material holding device 1 further includes a first biasing member 13 and a second biasing member 14.

[0034] The first biasing member 13 biases the slider 11 and the holding mechanism 2 in a direction (direction Y2 in the example) in the lateral direction Y (Y1, Y2) in which the cushioning material S held by the holding mechanism 2 approaches the fork 70, and positions the slider 11 and the holding mechanism 2 in the lateral direction Y when the holding mechanism 2 is not holding the cushioning material S.

[0035] In this example, the first biasing member 13 is a spring, more specifically a tension spring, which is connected to the slider 11 and the slide guide 10 (the side frame 100 on the Y2 side thereof) and biases the slider 11 by pulling it in the direction Y2. As a result, when the cushioning material S is not held, the slider 11 and the holding mechanism 2 are positioned closer to the direction Y2 within their movable range in the lateral direction Y.

[0036] The second biasing member 14 biases the cushioning material S held by the holding mechanism 2 in a direction (direction R1 in this example) away from the fork 70 in the rotational direction R (R1, R2) around the rotating shaft 12. As a result, the second biasing member 14 positions the holding mechanism 2 with respect to the rotational direction R when the holding mechanism 2 is not holding the cushioning material S.

[0037] In this example, the second biasing member 14 is a spring, more specifically a tension spring, which is connected to the slider 11 (its mounting part 110) and the holding mechanism 2 (its mounting part 21) and pulls the holding mechanism 2 in the direction R1 against its own weight to position it. If the second biasing member 14 were not present, the holding mechanism 2 would hang down vertically from the rotating shaft 12 due to its own weight.

[0038] As shown in Fig. 3, the holding mechanism 2 has a downward receiving port 20 into which the cushioning material S is inserted. As described below, an operator C (Fig. 19) stands next to the forklift 7 and inserts the cushioning material S from below into the receiving port 20 to be held by the holding mechanism 2. Since the second biasing member 14 positions the holding mechanism 2 with respect to the rotational direction R, when the cushioning material S is not being held, the receiving port 20 faces downward and outward (Y1 in this example) from the forklift 7, in a diagonally downward direction d (Fig. 2).

[0039] As shown in Fig. 4, the worker C inserts the cushioning material S from below into the receiving port 20, holds it in the holding mechanism 2, and releases the cushioning material S. As shown in Figs. 4 and 5, due to the weight of the cushioning material S, the holding mechanism 2 and the held cushioning material S rotate vertically downward around the rotation axis 12, i.e., in the direction R2, against the biasing force of the second biasing member 14. At this time, in conjunction with the rotational movement, the slider 11 and the holding mechanism 2 are pulled and moved in the direction Y1 against the biasing force of the first biasing member 13, and the cushioning material S becomes stable in a state of contact with the side surface of the baggage W, as shown in Fig. 5.

[0040] 5, the cushioning material S is biased in the direction Y2 by the first biasing member 13, so that the cushioning material S is pressed against the luggage W and adheres closely to the side of the luggage W. In order to realize such an operation, the biasing forces of the first and second biasing members 13 and 14 (i.e., the spring constants of both springs in the example) are appropriately set in consideration of the weight of the cushioning material S, etc.

[0041] For example, the position of the side of the luggage W on the forks 70 may differ each time due to differences in the width of the luggage W, differences in the insertion position of the forks 70 into the pallet P, etc. According to the above configuration, even if the position of the side of the luggage W on the forks 70 differs, the deviation in the left-right direction Y can be absorbed and the cushioning material S can be brought into close contact with the side of the luggage W.

[0042] The forklift 7 can carry the luggage W to the loading platform 80 (Fig. 19) of the transport vehicle 8 with the cushioning material S tightly attached to the luggage W. This eliminates the need for the worker C to lean the cushioning material S against the luggage W' (Fig. 6) already placed on the loading platform 80, thereby eliminating the risk of fingers getting pinched. In addition, the tight attachment reduces the risk of the cushioning material S interfering with the luggage W' next to it during loading, and the risk of the cushioning material S flapping about in strong winds.

[0043] As described below, the forklift 7 places the cargo W on the loading platform 80 so that the buffer material S is sandwiched between the cargo W. Normally, the front row of the loading platform 80 does not sandwich the buffer material S. As shown in Fig. 6, in the non-holding state, it is preferable to position the holding mechanism 2 by the first biasing member 13 so that the holding mechanism 2 does not protrude beyond the side surface of the cargo W supported by the forks 70, taking into consideration the size of the cargo W. This makes it possible to avoid interference between the front wall 800 of the loading platform 80 and the holding mechanism 2.

[0044] The mounting height of the holding mechanism 2 is determined taking into consideration the height of the cargo W transported by the forklift 7. The holding mechanism 2 is located higher than the upper surface of the cargo W on the forks 70, and interference with the cargo W is avoided. Therefore, the holding mechanism 2 is located higher than "the height of the forks 70 + the height of the cargo W", and depending on the size of the cargo W, it may be as tall as the height of the worker C or higher.

[0045] As shown in Fig. 6, when the holding mechanism 2 is retracted inward from the side of the baggage W, it is considered that it becomes difficult for the worker C to insert the cushioning material S into the receiving opening 20 (Fig. 3). However, as described above, when the holding mechanism 2 is not holding the cushioning material S, the holding mechanism 2 is tilted outward by the second biasing member 14, and the receiving opening 20 faces in the diagonally downward direction d. This makes it easier for the worker C to insert the cushioning material S.

[0046] Instead of the above example in which the holding mechanism 2 (receiving port 20) is tilted by applying tension with a second biasing member 14 (spring, etc.), for example, the center of gravity position of the holding mechanism 2 may be adjusted, and in some cases a weight may be added, so that the receiving port 20 is tilted due to its own weight.

[0047] Next, an example of the holding mechanism 2 will be described. Fig. 7 is a diagram of the non-actuator type holding mechanism 2 as viewed from a direction X2 opposite to the horizontal protruding direction X1, and Fig. 8 is a perspective view showing the whole. Note that some components of the cushioning material holding device 1 (e.g., biasing members 13, 14) may be omitted from the illustration (hereinafter the same).

[0048] The holding mechanism 2 includes a holder 30. In this example, the holder 30 is configured to be substantially U-shaped, and is open on the side in the horizontal protruding direction X1. The holder 30 may be configured of one member, or may be configured of a combination of multiple members. The holder 30 is connected to the rotating shaft 12, so that the holding mechanism 2 can rotate around the rotating shaft 12. Although not shown in the figure, a second biasing member 14 is connected to the mounting portion 21.

[0049] As shown in Fig. 7, the holder 30 has a first plane 301 and a second plane 302 that face each other with a gap between them. A socket 20 for inserting the cushioning material S between the first plane 301 and the second plane 302 from below is defined by the lower end of the first plane 301 and the lower end of the second plane 302. In Fig. 7, a portion 303 that defines the first plane 301 and a portion 304 that defines the second plane 302 are hatched. These portions 303 and 304 are portions that extend in the horizontal protruding direction X1 from a base end portion 300 connected to the rotating shaft 12 as shown in Fig. 8.

[0050] 7, the first plane 301 and the second plane 302 face each other in a wedge shape. That is, the first plane 301 and the second plane 302 form a wedge shape that narrows toward the socket 20, and the distance between them gradually narrows toward the socket 20.

[0051] Furthermore, the holding mechanism 2 includes a rolling member 31 supported by the holder 30 so as to be rollable on the second plane 302 in a direction approaching and receding from the socket 20. In this example, the rolling member 31 is a roller. For example, a shaft of the roller extending in the horizontal direction X (FIG. 8) is guided along the second plane 302 by a guide body (not shown) provided on the holder 30 (for example, its base end portion 300), so that the roller can roll on the second plane 302. The movable range is indicated by an arrow e. The rolling member 31 is not limited to a roller, as long as it has a circumferential side surface that allows it to roll on the second plane 302. Two or more rolling members may be arranged coaxially.

[0052] When the cushioning material S is not being held, the rolling member 31, due to its own weight, is at the lowest end of its movable range, i.e., at the position closest to the receiving port 20. The rolling member 31 is positioned so that the upper end of the cushioning material S abuts against the rolling member 31 when the cushioning material S is inserted from below through the receiving port 20.

[0053] As shown in Fig. 8, worker C holds the cushioning material S and inserts it from below between the first plane 301 (part 303) and the second plane 302 (part 304) through the receiving port 20 (see arrow f). At this time, the rolling member 31 is pushed up by the cushioning material S and rolled upward along the second plane 302, and as shown in Fig. 9, the cushioning material S is positioned between the rolling member 31 and the first plane 301.

[0054] From there, when worker C presses cushioning material S against the rolling member 31 and pulls it downward (see arrow g in Figure 9), the rolling member 31 rolls downward on the second plane 302, but due to the wedge shape of both planes 301, 302, when it is pulled down to a certain extent, as shown in Figure 10, the rolling member 31 and cushioning material S are in close contact with each other and are sandwiched between the first plane 301 and the second plane 302.

[0055] 10, there is no gap for the rolling member 31 to roll further toward the receiving port 20. Therefore, even if the worker C tries to pull the cushioning material S further down, the rolling member 31, which is in close contact with the cushioning material S, rotates in the direction h and tries to move down (but does not actually move down), so that the cushioning material S is pressed further against the first plane 301, and as a result, the cushioning material S cannot be pulled down any further. In this way, the cushioning material S is restricted from slipping out of the receiving port 20 and is held in place.

[0056] When the worker C releases his / her hand in this state, the state shown in Fig. 11 is reached. Although the weight of the cushioning material S acts in a direction in which the cushioning material S slips out of the receiving port 20, the cushioning material S is sandwiched between the rolling member 31 and the first plane 301 for the same reason as described above, and does not slip out, so the held state is maintained.

[0057] Naturally, to prevent the cushioning material S from slipping through, the friction coefficient of the surface of the rolling member 31 (roller) and the wedge angle of both flat surfaces 301, 302 are appropriately set in advance taking into consideration the characteristics of the material, weight, etc. of the cushioning material S.

[0058] The release of the cushioning material S will be described. As shown in Fig. 11, the worker C holds the cushioning material S in the holding mechanism 2 so that it protrudes below the pallet P. The forklift 7 travels to the front of the loading platform 80 and positions the cargo W on the forks 70 at a position where there is a certain amount of space between the cargo W' (hereinafter referred to as the already-placed cargo) already loaded on the loading platform 80, and positions the cushioning material S against the side of the already-placed cargo W'. At this time, the height of the bottom end of the pallet P on the forks 70 is lower than the height of the top end of the pallet P of the already-placed cargo W, and the bottom end of the cushioning material S is not in contact with the loading platform 80.

[0059] Next, the forklift 7 side-shifts the forks 70 and the holding mechanism 2 in the direction Y1 toward the placed baggage W' by the loading device 74 (FIG. 19). As a result, the buffer material S comes into contact with the side surface of the placed baggage W' and is interposed between the bags W and W'.

[0060] Next, the forklift 7 lifts down the forks 70 and the holding mechanism 2 by the cargo handling device 74, and places the cargo W on the loading platform 80. At this time, the lower end of the buffer material S comes into contact with the loading platform 80, so that the buffer material S receives an upward force and is displaced upward relative to the holding mechanism 2, whereby the fixing of the rolling member 31 is released. Therefore, the holding of the buffer material S is released.

[0061] Next, the forklift 7 moves backward (in the X2 direction), causing the forks 70 to slip out of the holes in the pallet P. Since the tip side of the holder 30 in the X1 direction is open, the cushioning material S can be left between the packages W, W' at this time. As a result, the cushioning material S is sandwiched and positioned between the packages W, W' with no gaps.

[0062] In addition, in the case of a manned forklift, the loading operation of the cargo W is performed by the operator operating the forklift 7, and in the case of an unmanned forklift, the control unit 75 (Figure 20) that controls the automatic operation of the forklift controls the travel of the forklift 7 and the operation of the forks 70.

[0063] The illustrated holding mechanism 2 can hold the cushioning material S without using a dedicated actuator for holding the cushioning material S. Moreover, it has the advantage that the holding of the cushioning material S can be released naturally as the loading operation is performed, and the cushioning material S can be placed between the luggage W, W' without any gaps.

[0064] In this example, it is necessary to hold the cushioning material S with an appropriate amount of overhang from the bottom end of the pallet P. To facilitate this, as shown only in Fig. 10, the holding mechanism 2 preferably includes an over-insertion prevention stopper 32 against which the upper end of the cushioning material S abuts when the cushioning material S is inserted from below through the receiving port 20. The over-insertion prevention stopper 32 is attached to the holder 30. The worker C inserts the cushioning material S until it hits the over-insertion prevention stopper 32 and then pulls it down to hold the cushioning material S in the holding mechanism 2. This ensures that the amount of cushioning material S inserted by the worker C is always constant, making it possible to stably create the state of Fig. 11.

[0065] Next, another exemplary holding mechanism 2 will be described. Figures 12 to 14 show an actuator-type holding mechanism 2. In Figure 13, the cushioning material S is hatched for distinction.

[0066] The holding mechanism 2 includes a base 40. As shown in Fig. 12, the base 40 is generally U-shaped in this example, and is open on the side in the horizontal protruding direction X1. Although not shown, the base 40 is connected to the slider 11 via the rotating shaft 12, similar to the holder 30 in the previous example, and is biased by the second biasing member 14.

[0067] Furthermore, the holding mechanism 2 includes a pair of a first clamper 41 and a second clamper 42 facing each other, and an actuator 43 for moving the second clamper 42 relative to the first clamper 41.

[0068] The clampers 41 and 42 are used to sandwich the cushioning material S. These clampers 41 and 42 define a socket 20 (FIG. 14A) into which the cushioning material S is inserted. The first clamper 41 is attached and fixed to the inside of a substantially U-shaped base 40. The first clamper 41 may be a separate body from the base 40 or may be formed integrally with the base 40.

[0069] The second clamper 42 is located inside the substantially U-shaped base 40 and faces the first clamper 41. The second clamper 42 is attached to the base 40 via a link 44, which allows the second clamper 42 to move toward and away from the first clamper 41.

[0070] In this example, the actuator 43 is a linear actuator, more specifically a cylinder, and moves a rod that is a movable part thereof to move the second clamper 42. The actuator 43 is supported by the base 40 so as to be operable on the base 40. The second clamper 42 is connected to the movable part (rod) of the actuator 43 via a link 44.

[0071] When the actuator 43 moves the second clamper 42 to the farthest position from the first clamper 41, the distance between these clampers 41, 42 is greater than the width of the cushioning material S, so that the cushioning material S can be inserted between the clampers 41, 42 from below through the socket 20 (FIGS. 13A and 14A). This position of the second clamper 42 is the open position.

[0072] On the other hand, when the actuator 43 is actuated to move the second clamper 42 from the open position toward the first clamper 41, the inserted cushioning material S can be sandwiched between the first clamper 41 and the second clamper 42 (FIGS. 13B and 14B). Hereinafter, this position of the second clamper 42 is referred to as the clamped position.

[0073] The actuator 43 is not limited to a linear actuator such as a cylinder, and other actuators, for example, a motor, may be used. In addition, the connection between the actuator 43 and the second clamper 42 is not limited to the link 44, and any configuration may be adopted depending on the type of actuator and the overall configuration of the holding mechanism 2.

[0074] Furthermore, the holding mechanism 2 includes one or more upper end stoppers 45 against which the upper end of the cushioning material S abuts when the cushioning material S is inserted between the first clamper 41 and the second clamper 42 from below through the receiving port 20.

[0075] In this example, two upper end stoppers 45 are provided, spaced apart along the horizontal direction X. The upper end stopper 45 is made up of a guide portion 450 extending in the vertical direction and a hook-shaped receiving portion 451 that is provided continuously with the upper portion of the guide portion 450 and receives the upper end of the cushioning material S. The upper end stopper 45 is attached to the second clamper 42, and the guide portion 450 extends upward from the second clamper 42. The upper end stopper 45 may be attached to the first clamper 41 or the base 40.

[0076] As shown in this example, the guide portion 450 is preferably located on the inside of the forklift 7 (hence on the Y2 side) of the gap between the clampers 41, 42 into which the cushioning material S is inserted. As described above, the worker C stands beside the forklift 7 and inserts the cushioning material S into the holding mechanism 2 (receiving port 20) that is inclined diagonally outward. If the guide portion 450 is located on the inside, as shown in FIG. 15A, the cushioning material S hits the guide portion 450 and is reliably guided into the receiving portion 451 (see arrow i) when inserted. If the guide portion 450 is on the opposite side, there is a possibility that the cushioning material S will not enter the receiving portion 451 as shown in FIG. 15B.

[0077] The holding mechanism 2 includes a cushioning material sensor 46 for detecting that the upper end of the cushioning material S has reached the upper end stopper 45. In this example, the cushioning material sensor 46 turns ON when it detects that the upper end of the cushioning material S has reached and entered the receiving portion 451. A plurality of cushioning material sensors 46 are provided, one for each upper end stopper 45 (FIG. 12).

[0078] The cushioning material sensor 46 may be of either a non-contact type or a contact type. As an example, the cushioning material sensor 46 in Fig. 16A is a photoelectric switch that projects light 460 from the outside of the receiving portion 451 through a hole to the inside thereof and turns ON when the cushioning material S enters the receiving portion 451 and blocks the light 460. As another example, the cushioning material sensor 46 in Fig. 16B may be a contact type switch provided so that a contact 461 is positioned on the inner top surface of the receiving portion 451, and turns ON when the cushioning material S enters the receiving portion 451 and presses the contact 461.

[0079] 17, the cushioning material holding device 1 includes an actuator control unit 50 (comprised of, for example, a control circuit) for controlling the actuator 43. The actuator control unit 50 is electrically connected to a cushioning material sensor 46 provided for each upper end stopper 45. The actuator control unit 50 is also electrically connected to the actuator 43, and can determine the position of the second clamper 42 based on a signal from the actuator 43.

[0080] The actuator control unit 50 operates the actuator 43 to move the second clamper 42 from the open position to the clamped position only when all of the cushioning material sensors 46 detect the cushioning material S (only when all of the cushioning material sensors 46 are ON).

[0081] In other words, when at least one of the cushioning material sensors 46 does not detect the cushioning material S, the actuator control unit 50 does not operate the actuator 43 to move the second clamper 42 to the clamp position. In the example of Fig. 12, even if one of the cushioning material sensors 46 is ON, if the other cushioning material sensor 46 is OFF, the actuator control unit 50 keeps the second clamper 42 in the open position.

[0082] According to this configuration, when the worker C inserts the cushioning material S between the clampers 41, 42 from below and presses it against the upper end stopper 45 (receiving portion 451), the actuator 43 is activated and the inserted cushioning material S is sandwiched and held by the clampers 41, 42. As a result, even if the worker C releases his / her hand from the cushioning material S, the cushioning material S is held by the holding mechanism 2 and comes into close contact with the side of the baggage W (FIG. 18).

[0083] Thanks to the upper end stopper 45 and the cushioning material sensor 46, it is possible to prevent the worker C from over-inserting the cushioning material S, and to keep it at an appropriate height.

[0084] If the worker C inserts the cushioning material S in a bad posture (orientation), at least one of the cushioning material sensors 46 remains OFF. On the other hand, if the worker C inserts the cushioning material S in a correct posture, all of the cushioning material sensors 46 turn ON and the cushioning material S is held. Therefore, the cushioning material S can be held in the holding mechanism 2 at an appropriate height and in an appropriate posture.

[0085] In this regard, unlike the example, three or more upper end stoppers 45 and cushioning material sensors 46 may be provided. Alternatively, one upper end stopper 45 having a large width in the horizontal direction X may be provided, and multiple cushioning material sensors 46 may be provided at intervals in the horizontal direction X for this one upper end stopper 45.

[0086] If any of the cushioning material sensors 46 turn OFF while the second clamper 42 is being moved from the open position to the clamped position, the actuator control unit 50 determines that the posture of the cushioning material S has been disturbed, and stops the movement to the clamped position. For example, in this case, the actuator control unit 50 returns the second clamper 42 to the open position. This allows the worker C to redo the insertion of the cushioning material S.

[0087] 17, the cushioning material holding device 1 may include an indicator 51. When all the sensors are ON and a signal indicating that the second clamper 42 is in the clamped position is received from the actuator 43, the actuator control unit 50 determines that the cushioning material S is being held, and causes the indicator 51 to display information indicating this. For example, the indicator may be an LED that lights up green when the cushioning material S is being held. This allows the worker C to easily understand that the cushioning material S is being properly held by the holding mechanism 2, and he or she can release the cushioning material S with confidence.

[0088] In the case of a manned forklift: while the cushioning material S is being held, the actuator control unit 50, in response to receiving a release command from the controller 72 as a result of the operator operating the controller 72 (FIG. 17), operates the actuator 43 to move the second clamper 42 to the open position and release the hold on the cushioning material S. The controller 72 may be, for example, a button, a lever, or the like, provided in the driver's seat of the forklift 7.

[0089] In the case of an unmanned forklift: When the forklift 7 loads the cargo W on the forks 70 onto the loading platform 80, the actuator control unit 50 activates the actuator 43 at a predetermined timing to move the second clamper 42 to the open position and release the retention of the cushioning material S.

[0090] As an example, as shown in FIG. 18, when the forklift 7 loads the baggage W on the platform 80 next to the already placed baggage W', a gap of about 50 to 60 mm is provided between the held buffer material S and the already placed baggage W. This gap can be detected by a sensor such as an environmental sensor 76 (FIG. 20) such as a LiDAR of the unmanned forklift. Next, the forklift 7 releases the buffer material S and drops it onto the platform 80 between the baggage W and the already placed baggage W' to separate it from the holding mechanism 2. Next, the forklift 7 side-shifts the fork 70 toward the already placed baggage W by the loading device 74, thereby sandwiching the buffer material S between the baggage W and W'. Next, the forklift 7 lifts down the fork 70 by the loading device 74 to place the baggage W on the platform 80. Next, the forklift 7 moves backward to remove the fork 70 from the pallet P.

[0091] This allows the cushioning material S to be placed without any gaps between the packages W, W' when the packages W are loaded onto the loading platform 80. This operation of the forklift 7 is performed by a control unit 75 including an actuator control unit 50. In the case of a manned forklift, an operator operates the forklift 7 to perform the above operation.

[0092] The above-mentioned exemplary cushioning material holding device 1 (holding mechanism 2) is provided on the left side (Y1 side) of the forklift 7, but it may be provided on the right side (Y2 side) of the forklift 7. When provided on the Y2 side, it may be configured symmetrically to the above-mentioned exemplary examples. Also, the holding mechanism 2 may be provided on both sides. This depends on the design of the loading and unloading system.

[0093] Next, a loading and unloading system for loading cargo W onto a loading platform 80 of a transport vehicle 8 using an automatically operable forklift 7 (unmanned forklift) equipped with a buffer material holding device 1 will be described. Note that in the following, explanations of configurations similar to those of the loading and unloading system of Patent Document 1 will be omitted.

[0094] FIG. 19 partially shows the working area 9 of the forklift 7. The working area 9 is provided with a parking area 90 for a manned transport vehicle 8 to stop. The transport vehicle 8 is, for example, a truck, and includes a loading platform 80 and a driver's seat 81. The loading platform 80 is provided behind the driver's seat 81. The loading platform 80 is, for example, of a wing type, and is opened on both sides by rotating and opening wings (not shown) on both sides. This allows the forklift 7 to load luggage W onto the loading platform 80 from both the left and right sides of the transport vehicle 8.

[0095] The forklift 7 loads the cargo W onto the loading platform 80 starting from the front. When loading the cargo W onto the loading platform 80, the forklift 7 places a buffer material S between the cargo W and an already placed cargo W' (FIGS. 11 and 18). To achieve this, the position of the buffer material holding device 1 relative to the forklift 7 is taken into consideration. For example, in FIG. 19, the mounting positions of the buffer material holding devices 1 are reversed between the forklift 7 (upper side of the figure) handling the right side of the loading platform 80 and the forklift 7 (lower side of the figure) handling the left side of the loading platform 80. The buffer material holding devices 1 may be provided on both sides of the forklift 7 so that the forklift 7 can handle loading work from both sides of the loading platform 80.

[0096] 20, the forklift 7 includes a traveling device 73 and a loading device 74. The traveling device 73 is composed of a traveling motor, drive wheels, etc., and drives the forklift 7. The loading device 74 includes a lift mechanism, a shift mechanism, etc., and can raise and lower the fork 70 and the holding mechanism 2 as a unit, and can also side-shift (i.e., move in the lateral direction Y).

[0097] The forklift 7 includes a control unit 75 and an environmental sensor 76. The control unit 75 is a calculation device and includes a calculation circuit such as a CPU (Central Processing Unit). The control unit 75 controls the operation of the forklift 7 by executing a program stored in a storage medium.

[0098] The environmental sensor 76 is used for automatic operation of the forklift 7. The control unit 75 estimates its own position in the work area 9 based on the detection of the environmental sensor 76, controls the traveling device 73 and the loading / unloading device 74 based on its own position, and drives the forklift 7 and operates the forks 70 according to work instructions related to loading and unloading (received from the server of the loading and unloading system).

[0099] For example, a laser guidance method may be adopted in which the vehicle's own position is estimated using a laser scanner (e.g., 2D-LiDAR (Light Detection And Ranging)) as the environmental sensor 76 that projects laser light into the surroundings and a plurality of reflectors arranged in the work area 9 to perform automatic driving. Alternatively, a SLAM (Simultaneous Localization and Mapping) guidance method may be adopted in which the vehicle's own position is estimated using SLAM technology using a distance measuring sensor (e.g., a laser range finder, a stereo camera, a depth camera, or a 3D-LiDAR) as the environmental sensor 76 that measures the distance to surrounding objects to perform automatic driving. These technologies are well known, so their description will be omitted.

[0100] 20, the configuration shown by the dashed dotted line is a configuration in which the above-mentioned actuator type holding mechanism 2 is adopted. Here, the actuator control section 50 can be regarded as a part of the control section 75.

[0101] An example of the operation of the cargo handling system will now be described.

[0102] Before the loading operation, a driver drives the transport vehicle 8 with a large number of cushioning materials S loaded on the loading platform 80, and stops the vehicle in the parking area 90. Then, a worker C (e.g., the driver of the transport vehicle 8) moves all of the cushioning materials S to the rear of the loading platform 80 as shown in FIG.

[0103] Then, the forklift 7 starts loading the cargo W onto the loading platform 80 of the transport vehicle 8. The following operation of the forklift 7 is executed by the control unit 75. First, the forklift 7 travels to a cargo storage area (not shown) and places the cargo W on the forks 70, as in Patent Document 1.

[0104] Next, the forklift 7 travels to a predetermined temporary stop position 91 and stops there. This temporary stop position 91 is a position away from the side of the rear of the loading platform 80 of the transport vehicle 8 stopped in the stopping area 90. In this example, the temporary stop positions 91 are provided on both the left and right sides of the loading platform 80. The forklift 7 stops temporarily so that the buffer holding device 1 faces the loading platform 80. The distance from the loading platform 80 to the temporary stop position 91 may be such that a worker C can work therewith, and may be, for example, 2 to 3 m.

[0105] Next, the worker C picks up one of the cushioning materials S that has been moved to the rear of the loading platform 80 and has it held by the cushioning material holding device 1 (holding mechanism 2) of the temporarily stopped forklift 7 as described above. The cushioning material S comes into close contact with the side of the luggage W. As described above, when loading the luggage W at the front of the loading platform 80, the cushioning material S does not need to be held.

[0106] Next, the worker C operates the work indicator 92 in Fig. 20 to send an operation restart instruction to the control unit 75 of the forklift 7. The work indicator 92 is, for example, a terminal carried by the worker C or a button installed on a wall 93 of the work area 9, and is configured to wirelessly transmit an operation restart instruction to the control unit 75 when operated by the worker. Alternatively, the work indicator 92 may be provided at a predetermined location on the forklift 7 that is easy for the worker C to operate.

[0107] In response to receiving the operation restart instruction, the control unit 75 restarts the automatic operation of the forklift 7. The forklift 7 travels from the temporary stop position 91 to the loading platform 80 along the route indicated by the arrow j in Fig. 19 and stops there.

[0108] Next, the forklift 7 loads the luggage W onto the loading platform 80. When the forklift 7 loads the luggage W onto the loading platform 80, the specific operation of sandwiching the cushioning material S between the luggage W and the previously placed luggage W' while releasing the hold of the cushioning material S is as described above regarding the non-actuator type and actuator-direction holding mechanism 2.

[0109] The cargo handling system repeats the above-mentioned operation of the forklift 7 until a predetermined number of cargo W is loaded. In this example, loading onto the left side and the right side of the cargo platform 80 is performed simultaneously in parallel, and a worker C moves around the rear of the cargo platform 80 to install the cushioning material S. The movement line of the worker is indicated by an arrow k.

[0110] In this cargo handling system, thanks to the cushioning material holding device 1, the task of sandwiching the cushioning material S between the packages W, W' when loading onto the loading platform 80 can be automated. There is no need for the worker C to be in the vicinity when loading with the forklift 7, so there is no risk of the worker C's hand being caught or coming into contact with the package. The worker C can remain within the roughly U-shaped area 94 around the rear of the loading platform 80, and can work safely and efficiently without intersecting with the flow path of the forklift 7.

[0111] Since the process of attaching the cushioning material S is carried out next to the transport vehicle 8, there is no need to temporarily transfer the cushioning material S from the loading platform 80 to another location.

[0112] In the case of the actuator-type holding mechanism 2, if at least one of the cushioning material sensors 46 turns OFF when traveling from the temporary stop position 91 to the loading platform 80, there is a high possibility that the cushioning material S may be in an inappropriate position due to slipping off, or may have completely come out of the holding mechanism 2. In this case, the control unit 75 may stop the automatic operation of the forklift 7, and may notify the operator C of this by using a sound (warning sound) from an alarm device (not shown) and / or a display (such as lighting up a color indicating a warning).

[0113] When loading is performed using a manned forklift, the operator operates the forklift 7 in the same manner as in the automatic driving operation described above. After the worker C attaches the buffer material S, he or she sends a signal to the operator, who then resumes driving the forklift 7 upon receiving the signal. Since the area 94 is small, the risk of a contact accident between the worker C and the manned forklift can also be reduced.

[0114] Although the preferred embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments. [Explanation of symbols]

[0115] 1 Cushioning material holding device 2 Retention mechanism 20 socket 41 First clamper 42 Second Clamper 43 Actuator 45 Upper end stopper 450 Guide part 451 Receptor 46 Cushioning material sensor 50 Actuator control section 51 Indicator 7. Forklift 70 Fork 75 Control Unit 8 Transport Vehicles 80 Cargo Bed 9. Work Area 90 Parking area for transport vehicles 91 Stop position for forklifts C. Worker S Cushioning material W Luggage W' Already placed luggage X1 Horizontal protrusion direction of fork Y Horizontal

Claims

1. A cushioning material holding device provided on a forklift, A holding mechanism is provided for releasably holding the plate-shaped cushioning material, The holding mechanism includes: a first clamper and a second clamper facing each other; an actuator for moving the second clamper relative to the first clamper between an open position where a buffer material can be inserted between the second clamper and the first clamper and a clamped position where the buffer material can be sandwiched between the second clamper and the first clamper; an upper end stopper against which an upper end of the buffer material is pressed when the buffer material is inserted between the first clamper and the second clamper from below; a buffer sensor provided to detect when the buffer reaches the upper end stopper; The cushioning material holding device further comprises: an actuator control unit that operates the actuator to move the second clamper from the open position to the clamp position when the buffer sensor detects that the buffer has reached the upper end stopper, Cushioning material holding device.

2. The upper end stopper is provided in a plurality of positions spaced apart from each other in the horizontal direction, The cushioning material sensor is provided for each of the upper end stoppers, the actuator control section activates the actuator to move the second clamper to the clamp position only when all of the cushioning material sensors detect a cushioning material.

2. The cushioning material holding device according to claim 1.

3. A plurality of the cushioning material sensors are provided for one of the upper end stoppers, the actuator control section activates the actuator to move the second clamper to the clamp position only when all of the cushioning material sensors detect a cushioning material.

2. The cushioning material holding device according to claim 1.

4. the actuator control section stops moving the second clamper to the clamp position when at least one of the buffer material sensors no longer detects a buffer material while the second clamper is being moved to the clamp position. The cushioning material holding device according to claim 2 or 3.

5. Further comprising an indicator, the actuator control unit causes an indicator to display information indicating that the cushioning material is being held when the cushioning material sensor detects the cushioning material and the second clamper is at the clamp position.

2. The cushioning material holding device according to claim 1.

6. A forklift, The cushioning material holding device according to claim 1 ; Forks for supporting the load; a loading device that raises and lowers the fork and the holding mechanism together, The retention mechanism is arranged to retain the cushioning material next to the fork. forklift.

7. The forklift further includes an operating device operated by an operator of the forklift. the actuator control unit, in response to receiving a release command from the operation device, operates the actuator to move the second clamper from the clamp position to the release position.

7. The forklift according to claim 6.

8. The upper end stopper includes a receiving portion that receives an upper end of the cushioning material; The cushioning material sensor is provided to detect when an upper end of the cushioning material enters the receiving portion.

7. The forklift according to claim 6.

9. The upper end stopper further includes a guide portion extending in the up-down direction, The receiving portion is provided on an upper portion of the guide portion, The guide portion is located on the inner side of the forklift with respect to a gap between the first clamper and the second clamper.

9. The forklift according to claim 8.

10. An automatically operable forklift, The cushioning material holding device according to claim 1 ; Forks for supporting the load; A loading device that raises and lowers the forks and the holding mechanism together and shifts them in a lateral direction perpendicular to the horizontal protruding direction of the forks; A control unit that controls the operation of the forklift according to a work instruction related to loading and unloading, The retention mechanism is arranged to retain the cushioning material next to the fork. forklift.

11. A loading / unloading system comprising the forklift according to claim 10, the forklift being automatically operated to load cargo onto a loading platform of a transport vehicle parked in a predetermined parking area in accordance with a work instruction relating to loading / unloading, The control unit of the forklift After loading the cargo onto the forks, the forklift is temporarily stopped at a predetermined stop position laterally spaced from the rear of the loading platform of the transport vehicle stopped in the stopping area; In response to receiving an instruction to resume operation, the forklift truck, with the buffer material held by the holding mechanism, is caused to travel from the temporary stop position to the loading platform of the transport vehicle; The baggage is loaded onto the loading platform next to the baggage already loaded onto the loading platform, and When the luggage is loaded onto the loading platform, the second clamper is moved to the open position to release the buffer material and sandwich the buffer material between the luggage and the previously placed luggage. Controlling the operation of the forklift. Cargo handling system.

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