Stowage control device

Abstract

To provide a stowage control device that can ensure the accuracy of calculation of stowage positions and shorten the time to complete stowage when multiple pallets are stacked on a cargo bed.SOLUTION: A stowage control device 10 comprises: a stowage planning information acquiring unit 22 that acquires pallet information including the planned number of pallets 5 to be stowed in a specified direction of a cargo bed 4 and the horizontal width dimension; a laser sensor 17 that detects a loading surface 4a of the cargo bed 4 when a forklift 2 is traveling along the specified direction; a cargo bed edge detection unit 25 that detects a side edge 4b of the cargo bed 4 along the specified direction based on detection data of the laser sensor 17; a stowage position calculation unit 26 that calculates stowage positions S corresponding to the planned number of pallets 5 based on the planned number and the horizontal width dimension of the pallets 5 and the side edge 4b of the cargo bed 4; and a stowage control unit 27 that controls the forklift 2 so that the pallets 5 are sequentially stowed at the stowage positions S corresponding to the planned number of pallets.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a stowage control device. [Background technology]

[0002] A known conventional stowage control device, as described in Patent Document 1, for example, is a technology that detects the position of an object using an external sensor such as a laser sensor, extracts points representing a loading platform based on point cloud data, which is a collection of points representing the positions of the objects, and determines the loading position for loading the cargo on the loading platform. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2023-30983 A Summary of the Invention [Problem to be solved by the invention]

[0004] When loading multiple pallets onto the bed of a truck using a forklift, the forklift detects the bed and calculates the loading position while traveling in the front-rear direction of the truck. In this case, it is desirable to quickly complete loading of the pallets onto the bed while accurately calculating the loading position of the pallets.

[0005] An object of the present invention is to provide a stowage control device that can shorten the time required to complete stowage while ensuring the accuracy of calculation of the stowage position when loading a plurality of pallets onto a loading platform. [Means for solving the problem]

[0006] (1) One aspect of the present invention is a loading control device that loads multiple pallets onto a loading platform by a forklift, and includes a pallet information acquisition unit that acquires pallet information including the planned number of pallets to be loaded and width dimensions of the pallets to be loaded in a specified direction on the loading platform, a travel control unit that controls the forklift to travel along the specified direction, a loading platform detection unit that detects the loading surface of the loading platform while the forklift is traveling in the specified direction, a loading platform edge detection unit that detects the edge of the loading platform along the specified direction based on detection data from the loading platform detection unit, a loading position calculation unit that calculates loading positions for the planned number of pallets to be loaded based on the planned number of pallets to be loaded and the width dimensions acquired by the pallet information acquisition unit and the edge of the loading platform detected by the loading platform edge detection unit, and a loading control unit that controls the forklift so that the pallets are sequentially loaded at the loading positions for the planned number of pallets calculated by the loading position calculation unit.

[0007] In such a loading control device, when the forklift is traveling along the specified direction of the platform, the platform detection unit detects the loading surface of the platform. Then, based on the detection data of the platform detection unit, the edge of the platform along the specified direction of the platform is detected. Then, based on the planned number of pallets to be loaded and the width dimension and the edge of the platform that are acquired in advance, the loading positions of the planned number of pallets are calculated. Then, the forklift is controlled so that the pallets are sequentially loaded at the loading positions of the planned number of pallets. Here, the loading positions of the planned number of pallets to be loaded are calculated based on the planned number of pallets to be loaded and the width dimension and the edge of the platform. Therefore, the calculation accuracy of the loading positions of multiple pallets is ensured. Also, in order to detect the loading surface of the platform and detect the edge of the platform, the number of times that the forklift is made to travel along the specified direction of the platform is the minimum necessary. Therefore, the total travel distance of the forklift until the pallets are loaded is shortened, and the time until the pallets are loaded is shortened.

[0008] (2) In the above (1), the loading position calculation unit may collectively calculate the loading positions for the planned number of pallets to be loaded based on the planned number of pallets to be loaded, the width dimension, and the edge of the loading platform.

[0009] In this configuration, the stowage positions for the number of pallets to be stowed are calculated all at once, which simplifies the calculation process overall.

[0010] (3) In (2) above, the stowage position calculation unit may calculate a position offset in a specified direction from the arbitrary stowage position by the width dimension of the pallet or by an amount greater than the width dimension of the pallet by a specified amount as the stowage position adjacent to the arbitrary stowage position in the specified direction.

[0011] With this configuration, the loading positions of the planned number of pallets can be easily calculated all at once.

[0012] (4) In the above (2) or (3), the stowage control device further includes a judgment unit that judges whether or not the use of the loading positions for the planned number of loading positions calculated collectively by the loading position calculation unit has been instructed. When the judgment unit judges that the use of the loading positions for the planned number of loading positions has been instructed, the stowage control unit controls the forklift so that the pallets are sequentially stacked at the loading positions for the planned number of loading positions. When the judgment unit judges that the use of the loading positions for the planned number of loading positions has not been instructed, the stowage control unit may re-execute the processing of the travel control unit, the cargo bed edge detection unit and the loading position calculation unit.

[0013] In this configuration, when it is determined that the use of the stowage positions for the collectively calculated number of pallets is not instructed, the stowage positions for the planned number of pallets are recalculated based on the planned number of pallets, the width dimensions, and the latest edge of the loading platform, thus further improving the calculation accuracy of the stowage positions for the pallets.

[0014] (5) In (1) above, the loading position calculation unit may calculate the loading position of the first pallet to be loaded onto the loading platform based on the edge of the loading platform, and may also calculate the loading position of the current pallet to be loaded onto the loading platform based on the previously calculated loading position, the planned number of pallets to be loaded, the width dimension, and the edge of the loading platform.

[0015] In this configuration, the loading position of the pallet to be loaded currently on the loading platform is calculated using the loading position calculated previously, thereby simplifying the calculation process when calculating the loading position of the first pallet to be loaded.

[0016] (6) In (5) above, the stowage position calculation unit may calculate, as the stowage position of the pallet to be loaded this time, a position offset in a specified direction from the previously calculated stowage position by the width dimension of the pallet or by an amount greater than the width dimension of the pallet by a specified amount.

[0017] With this configuration, the loading position of the pallet to be loaded this time can be easily calculated.

[0018] (7) In (5) or (6) above, the stowage control device further includes a judgment unit that judges whether or not the use of the previously calculated stowage position has been instructed. When the stowage position calculation unit judges that the use of the previously calculated stowage position has been instructed, it calculates the stowage position of the pallet to be loaded this time based on the previously calculated stowage position, the number of pallets to be loaded, the width dimension, and the edge of the loading platform. When the judgment unit judges that the use of the previously calculated stowage position has not been instructed, it may execute the processing of the driving control unit, the loading platform edge detection unit and the stowage position calculation unit again.

[0019] In this configuration, when it is determined that the use of the previously calculated stowage position is not instructed, the stowage position of the pallet to be loaded this time is calculated based on the most recent edge of the loading platform, thus further improving the calculation accuracy of the stowage position of the pallet.

[0020] (8) In any of (1) to (7) above, the platform detection unit is a laser sensor that detects the distance to the platform by irradiating a laser toward the platform's loading surface and receiving the reflected laser light to obtain point cloud data, and the platform edge detection unit may detect the edge of the platform by extracting a point cloud representing the edge of the platform along a specified direction based on the point cloud data of the laser sensor.

[0021] In such a configuration, the edge of the loading platform can be detected with high accuracy by extracting a point cloud representing the edge of the loading platform along a specified direction based on the point cloud data of the laser sensor. Effect of the Invention

[0022] According to the present invention, when loading a plurality of pallets onto a loading platform, it is possible to shorten the time required to complete loading while ensuring the accuracy of calculation of the loading position. [Brief description of the drawings]

[0023] [Figure 1] FIG. 1 is a block diagram showing a configuration of a stowage control system including a stowage control device according to a first embodiment of the present invention. [Diagram 2] FIG. 2 is a schematic plan view showing an example of the positional relationship between a forklift, a truck, and a pallet storage area. [Diagram 3] FIG. 2 is a schematic plan view showing a state in which a plurality of pallets are loaded onto the bed of a truck. [Figure 4] 2 is a flowchart showing a procedure of a stowage control process executed by a controller shown in FIG. 1. [Diagram 5] FIG. 2 is a schematic plan view showing a forklift traveling parallel to a truck. [Figure 6] 5 is a flowchart showing details of step S106 shown in FIG. 4. [Figure 7] FIG. 2 is a conceptual diagram showing an example of point cloud data of a laser sensor. [Figure 8] FIG. 2 is a schematic plan view showing the positions of the side edges of a truck bed. [Figure 9] FIG. 2 is a schematic plan view showing a plurality of stowage positions collectively calculated by a stowage position calculation unit shown in FIG. [Figure 10] FIG. 2 is a schematic plan view showing a state in which a pallet is loaded at a loading position by a forklift. [Figure 11] FIG. 2 is a block diagram showing a configuration of a stowage control system including a modified example of the stowage control device according to the first embodiment of the present invention. [Figure 12] 12 is a flowchart showing a procedure of a stowage control process executed by a controller shown in FIG. 11. [Figure 13] FIG. 10 is a schematic plan view showing a modification of the plurality of stowage positions shown in FIG. [Figure 14] FIG. 11 is a block diagram showing a configuration of a stowage control system including a stowage control device according to a second embodiment of the present invention. [Figure 15] 15 is a flowchart showing a procedure of a stowage control process executed by a controller shown in FIG. 14. [Figure 16] 15 is a schematic plan view showing the next stowage position calculated by the stowage position calculation unit shown in FIG. 14 together with pallets already loaded on the loading platform. FIG. [Figure 17] FIG. 11 is a block diagram showing a configuration of a stowage control system including a modified example of the stowage control device according to the second embodiment of the present invention. [Figure 18] 18 is a flowchart showing a modified example of the procedure of the stowage control process executed by the controller shown in FIG. 17. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. In the drawings, the same or equivalent elements are designated by the same reference numerals, and duplicated explanations will be omitted.

[0025] Fig. 1 is a block diagram showing the configuration of a stowage control system equipped with a stowage control device according to a first embodiment of the present invention. As shown in Fig. 2, the stowage control system 1 is a system that automatically stows a plurality of pallets 5 placed in a pallet storage area R located near a truck 3 onto a loading surface 4a of a bed 4 of the truck 3 using a forklift 2. The stowage control system 1 sequentially stows the pallets 5 onto the bed 4 of the truck 3 from the front side to the rear side.

[0026] The forklift 2 has two forks 6 that hold a pallet 5. The pallet 5 is a loading platform on which cargo (not shown) is placed. The pallet 5 is, for example, a flat pallet. The pallet 5 has a rectangular shape in a plan view. The pallet 5 is provided with two fork holes (not shown) into which each fork 6 is inserted. Here, as shown in FIG. 2, the forklift 2 holds the pallet 5 with the forks 6 in the pallet storage area R, then retreats (backs up) once and then moves forward toward the bed 4 of the truck 3 to load the pallet 5.

[0027] In FIG. 1, a stowage control system 1 includes a stowage control device 10 of this embodiment and a host system management device 11.

[0028] The upper system management device 11 includes a controller 12 and a communication device 13. The controller 12 transmits stowage plan information including pallet information to the stowage control device 10 via the communication device 13. The stowage plan information is pre-stored in a memory (not shown) of the controller 12.

[0029] As shown in Fig. 3, the pallet information includes the planned number of pallets 5 to be loaded onto the bed 4 of the truck 3, and the width dimension W of the pallets 5. The planned number of pallets 5 is the planned number of pallets 5 to be loaded in the fore-aft direction (X direction) of the truck 3. The fore-aft direction of the truck 3 corresponds to the specified direction of the bed 4. In Fig. 3, the planned number of pallets 5 to be loaded in the fore-aft direction of the truck 3 is seven only on the left side of the truck 3.

[0030] The stowage control device 10 is mounted on the forklift 2. The stowage control device 10 includes a communication device 14, a laser sensor 15, a map storage unit 16, a laser sensor 17, a traveling drive unit 18, a loading and unloading drive unit 19, and a controller 20. The communication device 14 wirelessly communicates with the communication device 13 of the higher-level system management device 11.

[0031] The laser sensor 15 is a laser sensor for self-position estimation. The laser sensor 15 is disposed, for example, on the upper part of the forklift 2. The laser sensor 15 irradiates a laser toward the periphery of the forklift 2 and receives the reflected light of the laser to detect the distance to an object present around the forklift 2 and acquire point cloud data. The point cloud is a collection of laser reflection points. For example, a 3D LIDAR or the like is used as the laser sensor 15.

[0032] The map storage unit 16 stores map data of the area in which the forklift 2 travels. The map data includes buildings, pillars, shelves, walls, etc. The map data is created in advance using the laser sensor 15.

[0033] The laser sensor 17 is a detection laser sensor. The laser sensor 17 is disposed, for example, on both sides of the forklift 2. The laser sensor 17 irradiates a laser toward the side of the forklift 2 and receives the reflected laser light to detect the distance to an object present on the side of the forklift 2 and acquire point cloud data. As the laser sensor 17, for example, a 3D LIDAR or the like is used, similar to the laser sensor 15.

[0034] The traveling drive unit 18 is a drive unit that drives the forklift 2. The traveling drive unit 18 has, for example, a traveling motor that rotates the drive wheels of the forklift 2 and a steering motor that steers the steering wheels of the forklift 2, although not shown in the figure.

[0035] The cargo handling drive unit 19 is a drive unit that operates the forks 6 of the forklift 2. The cargo handling drive unit 19 extends and retracts hydraulic cylinders such as lift cylinders that raise and lower the forks 6.

[0036] The controller 20 is composed of a CPU, RAM, ROM, an input / output interface, etc. The controller 20 has a self-position estimation unit 21, a stowage plan information acquisition unit 22, a cargo handling control unit 23, a travel control unit 24, a bed edge detection unit 25, a stowage position calculation unit 26, and a stowage control unit 27.

[0037] The self-position estimation unit 21 estimates the self-position of the forklift 2 based on the point cloud data of the laser sensor 15 and the map data stored in the map storage unit 16. Specifically, the self-position estimation unit 21 estimates the self-position of the forklift 2 by matching the point cloud data of the laser sensor 15 with map data, for example, using a SLAM (simultaneous localization and mapping) method. SLAM is a self-position estimation technology that estimates the self-position using sensor data and map data.

[0038] The stowage plan information acquiring unit 22 acquires stowage plan information including pallet information from the controller 12 of the higher-level system management device 11 via the communicators 13 and 14. The stowage plan information acquiring unit 22 constitutes a pallet information acquiring unit that acquires pallet information including the planned number of pallets 5 to be loaded in a specified direction on the loading platform 4 and the width dimension W of the pallets 5.

[0039] The load-receiving control unit 23 controls the traveling drive unit 18 and the load-handling drive unit 19 based on the self-position of the forklift 2 estimated by the self-position estimation unit 21 and the point cloud data of the laser sensor 17 so as to retrieve the pallet 5 placed in the pallet storage area R. As a result, the forklift 2 is brought into a state in which the forks 6 hold the pallet 5, as shown in FIG.

[0040] The travel control unit 24 controls the travel drive unit 18 so that the forklift 2 holding the pallet 5 travels along the front-rear direction (X direction) of the truck 3 (see FIG. 5). At this time, the travel control unit 24 controls the travel drive unit 18 so that the forklift 2 travels parallel to the truck 3 on one side of the truck 3.

[0041] When the forklift 2 is traveling along the longitudinal direction of the truck 3, the laser sensor 17 irradiates a laser toward the loading surface 4a of the loading platform 4 of the truck 3, thereby detecting the distance to the loading surface 4a of the loading platform 4. Therefore, the laser sensor 17 constitutes a loading platform detection unit that detects the loading surface 4a of the loading platform 4 when the forklift 2 is traveling along the specified direction (X direction).

[0042] The bed edge detection unit 25 detects the side edge 4b ​​of the bed 4 of the truck 3 based on the point cloud data (detection data) of the laser sensor 17 acquired while the forklift 2 is traveling along the front-rear direction of the truck 3. The side edge 4b ​​of the bed 4 is the edge in the width direction of the bed 4. At this time, the bed edge detection unit 25 detects the side edge 4b ​​of the bed 4 on the loading side (the forklift 2 side). The processing of the bed edge detection unit 25 will be described in detail later.

[0043] The stowage position calculation unit 26 calculates the stowage positions S (see FIG. 9) of the planned number of pallets 5 to be stacked, based on the planned number of pallets 5 to be stacked and the width dimension W acquired by the stowage plan information acquisition unit 22 and the side edge 4b ​​of the bed 4 detected by the bed edge detection unit 25. At this time, the stowage position calculation unit 26 calculates the stowage positions S of the planned number of pallets 5 to be stacked all at once.

[0044] In addition, the stowage position calculation unit 26 calculates a position offset from the arbitrary stowage position Sa in the fore-and-aft direction (X direction) of the truck 3 by an amount slightly larger than a specified amount than the width dimension W of the pallet 5, as the stowage position Sb adjacent to the arbitrary stowage position Sa in the fore-and-aft direction of the truck 3.

[0045] The stowage control unit 27 controls the traveling drive unit 18 and the loading drive unit 19 so that the pallets 5 are sequentially stacked at the stacking positions S corresponding to the planned number of pallets to be stacked calculated by the stacking position calculation unit 26 .

[0046] 4 is a flowchart showing the procedure of the stowage control process executed by the controller 20. This process is executed when an instruction to start stowage of the pallet 5 is given. After the forklift 2 starts, the process of the self-position estimation unit 21 is omitted because the process of the self-position estimation unit 21 is always performed. Also, the number of stowage times (described later) is set to 0.

[0047] 4, the controller 20 first acquires stowage plan information including pallet information via the communication device 14 (step S101). The pallet information includes the number of pallets 5 to be loaded and the width dimension W of the pallets 5.

[0048] Next, the controller 20 controls the traveling drive unit 18 and the loading drive unit 19 based on the self-position of the forklift 2 and the point cloud data of the laser sensor 17 so as to load the pallet 5 (step S102).

[0049] Specifically, based on the self-position of the forklift 2, the controller 20 controls the traveling drive unit 18 so that the forklift 2 travels to the pallet storage area R, and then, based on the self-position of the forklift 2 and the point cloud data of the laser sensor 17, controls the traveling drive unit 18 and the loading drive unit 19 so that the forks 6 hold the pallet 5.

[0050] Next, the controller 20 judges whether the data of the loading position S is stored in the internal memory (not shown) (step S103). When the controller 20 judges that the data of the loading position S is not stored in the internal memory, the controller 20 generates a parallel running path for the forklift 2 to run parallel to the truck 3 (step S104). The parallel running path is a path that extends in the front-rear direction of the truck 3. The parallel running path is a path that is parallel to the side edge 4b ​​of the bed 4 of the truck 3. Then, the controller 20 controls the traveling drive unit 18 so that the forklift 2 runs from the rear side to the front side of the truck 3 along the parallel running path, as shown in FIG. 5 (step S105).

[0051] Next, the controller 20 detects the position of the side edge 4b ​​of the bed 4 of the truck 3 based on the point cloud data of the laser sensor 17 (step S106).

[0052] Fig. 6 is a flowchart showing details of step S106. In Fig. 6, the controller 20 first acquires point cloud data Dp of the laser sensor 17 (step S201) as shown in Fig. 7. The point cloud data Dp includes a plurality of points P.

[0053] Next, the controller 20 extracts a point cloud representing a horizontal plane from the point cloud data Dp of the laser sensor 17 (step S202). Then, the controller 20 calculates a plane equation of the point cloud representing the horizontal plane using a robust estimation method such as RANSAC or a least squares method, and extracts a point cloud representing the loading surface 4a of the bed 4 of the truck 3 (step S203).

[0054] 7 is a point P obtained when the laser emitted from the laser sensor 17 hits the mounting surface 4a of the loading platform 4. Point P2 shown by a white circle in Fig. 7 is a point P obtained when the laser emitted from the laser sensor 17 hits a surface other than the mounting surface 4a. Therefore, in this procedure, a point cloud consisting of multiple points P1 is extracted as a point cloud representing the mounting surface 4a of the loading platform 4.

[0055] Next, the controller 20 extracts a point cloud representing the side edge 4b ​​of the loading platform 4 from the point cloud representing the loading surface 4a of the loading platform 4 (step S204). A point cloud consisting of a plurality of points P11 present at the end on the laser sensor 17 side among the plurality of points P1 indicated by black circles in FIG. 7 is extracted as the point cloud representing the side edge 4b ​​of the loading platform 4.

[0056] Next, the controller 20 calculates a straight line L (see FIG. 7) representing the side edge 4b ​​of the loading platform 4 from a point group consisting of a plurality of points P11 using a robust estimation method such as RANSAC or a least squares method (step S205). As a result, the position Q of the side edge 4b ​​of the loading platform 4 is obtained as shown in FIG.

[0057] Returning to Fig. 4, after executing step S106, the controller 20 collectively calculates the loading positions S of the planned number of pallets 5 to be loaded based on the position of the side edge 4b ​​of the loading platform 4 and the width dimension W of the pallets 5 as shown in Fig. 9 (step S107). The planned number of pallets 5 to be loaded and the width dimension W were acquired in the above step S101.

[0058] The loading position S1 of the first (first) pallet 5 to be loaded onto the loading platform 4 is offset from the front end of the loading platform 4 toward the rear of the truck 3 by a distance r0 that is slightly greater than half the width W of the pallet 5. The loading position S2 of the second pallet 5 to be loaded onto the loading platform 4 is offset from the center of the loading position S1 of the first pallet 5 toward the rear of the truck 3 by a distance r that is slightly greater than the width W of the pallet 5. Similarly, the loading positions S3 to S7 of the third and subsequent pallets 5 to be loaded onto the loading platform 4 are offset from the center of the loading positions S2 to S6 of the pallet 5 loaded immediately before toward the rear of the truck 3 by a distance r that is slightly greater than the width W of the pallet 5.

[0059] Furthermore, the loading positions S1 to S7 of each pallet 5 are positions where the front surface 5a of the pallet 5 is a predetermined distance away from the side edge 4b ​​of the loading platform 4 toward the rear side of the loading platform 4. The rear side of the loading platform 4 is on the inside in the width direction (Y direction) of the loading platform 4. Note that the loading positions S1 to S7 of each pallet 5 may be positions where the front surface 5a of the pallet 5 coincides with the side edge 4b ​​of the loading platform 4.

[0060] Next, the controller 20 stores data of the stacking positions S for the planned number of pallets 5 to be stacked in the internal memory (step S108). After executing step S108, or when it is determined in step S103 that the data of the stacking positions S has been stored in the internal memory, the controller 20 increments (adds 1) the current stacking count (step S109).

[0061] Next, the controller 20 generates a travel route for the stacking position S of the pallet 5 corresponding to the current stacking number (step S110). When the current stacking number is 1, a travel route for the stacking position S1 of the first (first) pallet 5 is generated. When the current stacking number is 2, a travel route for the stacking position S2 of the second pallet 5 is generated.

[0062] Next, the controller 20 controls the traveling drive unit 18 and the loading drive unit 19 so that the forklift 2 travels along the travel path and the pallet 5 is loaded at the loading position S (step S111).

[0063] Specifically, the controller 20 controls the traveling drive unit 18 so that the forklift 2 travels to a target position corresponding to the stowage position S based on the current position of the forklift 2, and then controls the loading drive unit 19 so that the forks 6 are lowered. The target position is a position where the pallet 5 held by the forks 6 reaches directly above the stowage position S.

[0064] Next, the controller 20 determines whether or not the planned number of pallets 5 has been loaded based on the current loading count (step S112). If the controller 20 determines that the planned number of pallets 5 has not been loaded, it executes the above step S101 again. If the controller 20 determines that the planned number of pallets 5 has been loaded, it ends this process.

[0065] Here, the stowage plan information acquisition unit 22 executes step S101. The cargo removal control unit 23 executes step S102. The travel control unit 24 executes steps S103 to S105. The cargo bed edge detection unit 25 executes step S106. The stowage position calculation unit 26 executes steps S107 and S108. The stowage control unit 27 executes steps S109 to S112.

[0066] In the stowage control system 1 equipped with the stowage control device 10 as described above, when stowage of pallets 5 is performed, stowage plan information including pallet information is transmitted from the host system management device 11 to the stowage control device 10 of the forklift 2. The pallet information includes the planned number of pallets 5 to be loaded onto the bed 4 of the truck 3 and the width dimension W.

[0067] The forklift 2 first holds the pallet 5 with the forks 6 in the pallet storage area R, then backs up once to one of the left and right sides (here, the left side) of the truck 3, and then travels forward to the rear of the truck 3. Then, as shown in Fig. 5, the forklift 2 backs up parallel to the truck 3 from the rear to the front of the truck 3. At this time, a laser is irradiated from the laser sensor 17 toward the bed 4 of the truck 3, and point cloud data Dp of the laser sensor 17 is acquired, as shown in Fig. 7.

[0068] Then, as shown in Fig. 8, the side edge 4b ​​of the bed 4 of the truck 3 is detected based on the point cloud data Dp of the laser sensor 17. Then, as shown in Fig. 9, the loading positions S1 to S7 of the planned number of pallets 5 to be loaded are calculated collectively based on the position of the side edge 4b ​​of the bed 4 and the width dimension W of the pallets 5.

[0069] 10, the forklift 2 travels forward to a target position corresponding to the loading position S1 of the first pallet 5 and lowers the forks 6. As a result, the first pallet 5 is placed on the platform 4 at the loading position S1.

[0070] Next, the forklift 2 holds the second pallet 5 with the forks 6 in the pallet storage area R, then backs up once and travels forward to the target position corresponding to the loading position S2 of the second pallet 5, and lowers the forks 6. As a result, the second pallet 5 is placed on the loading position S2 on the platform 4.

[0071] Similarly, the third and subsequent pallets 5 are placed in order at loading positions S3 to S7 on the bed 4. This completes the loading of the planned number of pallets 5 onto the bed 4 of the truck 3, as shown in FIG.

[0072] However, if the forklift 2 travels parallel to the truck 3 and irradiates a laser from the laser sensor 17 toward the bed 4 of the truck 3 each time a pallet 5 is loaded, the travel distance of the forklift 2 required to acquire detection information becomes long. This results in a long time being required to complete loading of all the pallets 5 onto the bed 4.

[0073] In response to such a problem, in this embodiment, when the forklift 2 travels along the front-rear direction (prescribed direction) of the platform 4 of the truck 3, the laser sensor 17 detects the placement surface 4a of the platform 4. Then, based on the point cloud data (detection data) of the laser sensor 17, the side edge 4b ​​of the platform 4 along the front-rear direction of the platform 4 is detected. Then, based on the planned number of pallets 5 to be loaded and the width dimension W and the side edge 4b ​​of the platform 4 that are acquired in advance, the loading positions S of the planned number of pallets 5 to be loaded are calculated. Then, the forklift 2 is controlled so that the pallets 5 are sequentially loaded at the loading positions S of the planned number of pallets 5 to be loaded. Here, the loading positions S of the planned number of pallets 5 to be loaded are calculated based on the planned number of pallets 5 to be loaded and the width dimension W and the side edge 4b ​​of the platform 4. Therefore, the calculation accuracy of the loading positions S of the multiple pallets 5 is ensured. Also, in order to detect the placement surface 4a of the loading platform 4 and sense the side edge 4b ​​of the loading platform 4, the number of times the forklift 2 travels along the front-rear direction of the loading platform 4 is kept to a minimum. Therefore, the total travel distance of the forklift 2 until the loading of the pallets 5 is completed is shortened, and the time until the loading of the pallets 5 is completed is shortened.

[0074] Furthermore, in this embodiment, the stacking positions S of the planned number of pallets 5 are calculated collectively based on the planned number of pallets 5 to be stacked, the width dimension W, and the side edge 4b ​​of the cargo platform 4. By calculating the stacking positions S of the planned number of pallets 5 to be stacked collectively in this manner, the calculation process is generally simplified.

[0075] In this embodiment, a position offset from the arbitrary stowage position Sa by a specified amount larger than the width dimension W of the pallet 5 in the front-rear direction of the loading platform 4 is calculated as the stowage position Sb adjacent to the arbitrary stowage position Sa in the front-rear direction of the loading platform 4. Therefore, the stowage positions S for the planned number of pallets 5 to be stowed can be easily calculated all at once.

[0076] In addition, in this embodiment, the side edge 4b ​​of the loading platform 4 can be detected with high accuracy by extracting a point cloud representing the side edge 4b ​​of the loading platform 4 along the fore-and-aft direction of the loading platform 4 based on the point cloud data of the laser sensor 17.

[0077] Furthermore, in this embodiment, even if the stowage work of pallets 5 is interrupted due to an operational problem, for example, if the current stowage count data is retained, the number of pallets 5 that have been stowed so far can be determined, and the stowage work of pallets 5 can be resumed.

[0078] Fig. 11 is a block diagram showing the configuration of a stowage control system including a modified example of the stowage control device according to the first embodiment of the present invention. In Fig. 11, the controller 20 of the stowage control device 10 of this modified example further includes a determination unit 28 in addition to the self-position estimation unit 21, stowage plan information acquisition unit 22, cargo handling control unit 23, travel control unit 24, bed edge detection unit 25, stowage position calculation unit 26, and stowage control unit 27 described above.

[0079] The determination unit 28 determines whether or not an instruction has been issued to use the stowage positions S corresponding to the planned number of pallets 5 collectively calculated by the stowage position calculation unit 26 .

[0080] When the loading control unit 27 determines that the judgment unit 28 has instructed the use of loading positions S for the planned number of loading, it controls the traveling drive unit 18 and the loading drive unit 19 so that the pallets 5 are loaded sequentially at the loading positions S for the planned number of loading calculated collectively.

[0081] When the determination unit 28 determines that the use of the stacking positions S for the planned number of pallets 5 to be stacked has not been instructed, the travel control unit 24, the bed edge detection unit 25 and the stacking position calculation unit 26 each execute the above-mentioned processes again. Therefore, the stacking position calculation unit 26 recalculates the stacking positions S for the planned number of pallets 5 to be stacked based on the point cloud data of the laser sensor 17.

[0082] FIG. 12 is a flowchart showing a modified example of the procedure of the stowage control process executed by the controller 20, and corresponds to FIG.

[0083] 12, the controller 20 executes steps S101 to S103, and when it is determined in step S103 that the data of the stowage position S is stored in the internal memory, it determines whether or not an instruction to use the data of the stowage position S stored in the internal memory has been issued based on an instruction signal transmitted from the upper system management device 11 (step S120). The instruction signal is a signal that the upper system management device 11 uses to issue an instruction to the stowage control device 10 of the forklift 2. Step S120 is executed by the determination unit 28.

[0084] When the controller 20 determines that the use of the stowage position S data stored in the internal memory has not been instructed, it executes steps S104 and after, whereby the stowage positions S for the planned number of pallets 5 to be stowed are recalculated based on the point cloud data of the laser sensor 17, and the pallets 5 are stowed at the stowage positions S.

[0085] When the controller 20 determines that the use of the stowage position S data stored in the internal memory is instructed, it executes steps S109 and after, whereby the pallets 5 are stowed at the stowage positions S corresponding to the planned number of stowage stored in the internal memory.

[0086] In this modified example, when it is determined that the use of the stacking positions S for the planned number of pallets 5 calculated collectively has not been instructed, the stacking positions S for the planned number of pallets 5 are recalculated based on the planned number of pallets 5 to be stacked, the width dimension W, and the latest side edge 4b ​​of the cargo platform 4. Therefore, the calculation accuracy of the stacking positions S for the pallets 5 is further improved.

[0087] In the above first embodiment and modified example, the stowage position calculation unit 26 calculates a position offset from the arbitrary stowage position Sa in the fore-and-aft direction of the truck 3 by a specified amount greater than the width dimension W of the pallet 5, as the stowage position Sb adjacent to the arbitrary stowage position Sa in the fore-and-aft direction of the truck 3, but is not limited to such a form.

[0088] 13, the stacking position calculation unit 26 may calculate a position offset by the width dimension W of the pallet 5 in the front-rear direction of the truck 3 from any stacking position Sa as a stacking position Sb adjacent to the any stacking position Sa in the front-rear direction of the truck 3. In other words, the distance r corresponding to the offset amount is equal to the width dimension W of the pallet 5. In this case, in addition to being able to easily calculate the stacking positions S for the planned number of pallets 5 to be stacked all at once, there is no gap between adjacent pallets 5 in the front-rear direction of the truck 3.

[0089] Fig. 14 is a block diagram showing the configuration of a stowage control system including a stowage control device according to a second embodiment of the present invention. In Fig. 14, a stowage control device 10A of this embodiment includes a controller 20A instead of the controller 20 in the first embodiment.

[0090] The controller 20A has a self-position estimation unit 21, a stowage plan information acquisition unit 22, a cargo handling control unit 23, a driving control unit 24, a cargo bed edge detection unit 25, a stowage position calculation unit 26A, and a stowage control unit 27A.

[0091] The loading position calculation unit 26A calculates the loading positions S (see Figure 9) for the planned number of pallets 5 to be loaded based on the planned number of pallets 5 to be loaded and the width dimension W acquired by the loading plan information acquisition unit 22 and the side edge 4b ​​of the loading platform 4 detected by the loading platform edge detection unit 25.

[0092] At this time, the loading position calculation unit 26A calculates the loading position S of the pallet 5 to be first loaded onto the loading platform 4 based on the side edge 4b ​​of the loading platform 4, and also calculates the loading position S of the pallet 5 to be currently loaded onto the loading platform 4 based on the previously calculated loading position S, the planned number of pallets 5 to be loaded, the width dimension W, and the side edge 4b ​​of the loading platform 4.

[0093] In addition, the loading position calculation unit 26A calculates the loading position S of the pallet 5 to be loaded this time as a position offset from the previously calculated loading position S in the fore-and-aft direction (X direction) of the truck 3 by an amount slightly larger than a specified amount than the width dimension W of the pallet 5.

[0094] The stowage control unit 27A controls the traveling drive unit 18 and the loading and unloading drive unit 19 so that the pallets 5 are successively stacked at the stacking positions S corresponding to the planned number of pallets to be stacked calculated by the stacking position calculation unit 26A.

[0095] FIG. 15 is a flowchart showing the procedure of the stowage control process executed by the controller 20A, and corresponds to FIG.

[0096] 15, the controller 20A executes the above steps S101 to S106. After executing step S106, the controller 20A calculates the loading position S (loading position S1) of the first pallet 5 to be loaded first onto the bed 4 of the truck 3 (step S121).

[0097] When the controller 20A determines in step S103 that data on the loading position S is stored in the internal memory, it calculates the loading position S of the next pallet 5 to be loaded this time onto the bed 4 of the truck 3 based on the previous loading position S stored in the internal memory (step S122). The loading position S of the next pallet 5 is offset from the previous loading position S to the rear of the truck 3 by an amount slightly larger than the width dimension W of the pallet 5 by a specified amount, as shown in Figure 16.

[0098] After executing step S121 or step S122, the controller 20A stores the data of the stacking position S of the pallet 5 calculated in step S121 or step S122 in the internal memory (step S123).

[0099] Next, the controller 20A generates a travel route for the latest stowage position S stored in the internal memory (step S124). Next, the controller 20A controls the travel drive unit 18 and the loading drive unit 19 so that the forklift 2 travels along the travel route and the pallet 5 is loaded at the stowage position S (step S125).

[0100] Next, the controller 20A increments the current number of loading times (step S126). Then, the controller 20A executes the above step S112.

[0101] Here, the stowage position calculation unit 26A executes steps S121 to S123. The stowage control unit 27A executes steps S124 to S126, and S112.

[0102] In the stowage control system 1 equipped with the above-described stowage control device 10A, when stowage of a pallet 5 is performed, first, the forklift 2 holding the pallet 5 travels parallel to the truck 3 to acquire point cloud data of the laser sensor 17. Then, based on the point cloud data of the laser sensor 17, the side edge 4b ​​of the bed 4 of the truck 3 is detected. Then, as shown in FIG. 16, the loading position S1 of the pallet 5 to be first loaded onto the bed 4 is calculated based on the side edge 4b ​​of the bed 4. Then, the forklift 2 travels to a target position corresponding to the loading position S1, and places the first pallet 5 at the loading position S1.

[0103] Next, the loading position S2 of the next pallet 5 to be loaded onto the loading platform 4 is calculated based on the side edge 4b ​​of the loading platform 4, the loading position S1 of the pallet 5, and the width dimension W of the pallet 5. Then, the forklift 2 travels to a target position corresponding to the loading position S2, and places the second pallet 5 at the loading position S2.

[0104] Next, the loading position S3 of the next pallet 5 to be loaded onto the loading platform 4 is calculated based on the side edge 4b ​​of the loading platform 4, the loading position S2 of the pallet 5, and the width dimension W of the pallet 5. The forklift 2 then travels to the target position corresponding to the loading position S3, and places the third pallet 5 at the loading position S3. Thereafter, loading positions S4 to S7 are calculated in a similar manner, and the fourth to seventh pallets 5 are successively placed at the loading positions S4 to S7.

[0105] In the present embodiment as described above, when a plurality of pallets 5 are loaded onto the bed 4 of the truck 3, the calculation accuracy of the loading position S can be ensured and the time required to complete loading can be shortened.

[0106] Furthermore, in this embodiment, the stacking position S of the pallet 5 to be first loaded onto the loading platform 4 is calculated based on the side edge 4b ​​of the loading platform 4, and the stacking position S of the pallet 5 to be currently loaded onto the loading platform 4 is calculated based on the previously calculated stacking position S, the planned number of pallets 5 to be loaded, the width dimension W, and the side edge 4b ​​of the loading platform 4. In this way, the stacking position S of the pallet 5 to be currently loaded onto the loading platform 4 is calculated using the previously calculated stacking position S, which simplifies the calculation process for calculating the stacking position S of the pallet 5 to be first loaded.

[0107] Furthermore, in this embodiment, a position offset from the previously calculated stowage position S by a specified amount greater than the width dimension W of the pallet 5 in the front-to-rear direction (specified direction) of the bed 4 of the truck 3 is calculated as the stowage position S of the pallet 5 to be loaded this time. Therefore, the stowage position S of the pallet 5 to be loaded this time can be easily calculated.

[0108] Fig. 17 is a block diagram showing the configuration of a stowage control system including a modified example of the stowage control device according to the second embodiment of the present invention. In Fig. 17, the controller 20A of the stowage control device 10A of this modified example further includes a determination unit 28A in addition to the self-position estimation unit 21, stowage plan information acquisition unit 22, cargo handling control unit 23, travel control unit 24, bed edge detection unit 25, stowage position calculation unit 26A and stowage control unit 27A.

[0109] The judgment unit 28A judges whether or not an instruction has been given to use the stowage position S previously calculated by the stowage position calculation unit 26A.

[0110] When the loading position calculation unit 26A determines that the judgment unit 28A has instructed to use the loading position S calculated previously, it calculates the loading position S of the pallet 5 to be loaded this time based on the loading position S calculated previously, the planned number of pallets 5 to be loaded, the width dimension W, and the side edge 4b ​​of the cargo bed 4.

[0111] When the travel control unit 24, the bed edge detection unit 25 and the stowage position calculation unit 26A determine that the use of the previously calculated stowage position S has not been instructed by the judgment unit 28A, they each execute the above-mentioned processes again. Therefore, the stowage position calculation unit 26 calculates the stowage position S of the pallet 5 to be stowed this time based on the point cloud data of the laser sensor 17.

[0112] FIG. 18 is a flowchart showing a modified example of the procedure of the stowage control process executed by the controller 20A, and corresponds to FIG.

[0113] 18, the controller 20A executes steps S101 to S103, and when it is determined in step S103 that the data of the stowage position S is stored in the internal memory, it determines whether or not an instruction to use the data of the stowage position S stored in the internal memory has been issued based on an instruction signal transmitted from the upper system management device 11 (step S130). Step S130 is executed by the determination unit 28A.

[0114] When the controller 20A determines that the use of the stowage position S data stored in the internal memory has not been instructed, it executes steps S104 and after. As a result, the stowage position S of the next pallet 5 is calculated based on the point cloud data of the laser sensor 17, and the pallet 5 is stowed at that stowage position S.

[0115] When the controller 20A determines that the use of the stowage position S data stored in the internal memory has been instructed, it executes steps S122 and after. As a result, the stowage position S of the next pallet 5 is calculated based on the stowage position S stored in the internal memory, and the pallet 5 is stowed at that stowage position S.

[0116] In this modified example, when it is determined that the use of the previously calculated stowage position S is not instructed, the stowage position S of the pallet 5 to be loaded this time is calculated based on the latest side edge 4b ​​of the loading platform 4. This further improves the calculation accuracy of the stowage position S of the pallet 5.

[0117] In the above second embodiment and modified example, the stowage position calculation unit 26A calculates the stowage position S of the pallet 5 to be loaded this time as a position offset in the fore-and-aft direction of the truck 3 by an amount greater than a specified amount than the width dimension W of the pallet 5 from the previously calculated stowage position S, but this is not limited to this form.

[0118] Although not shown, the stowage position calculation unit 26A may calculate, as the stowage position S of the pallet 5 to be loaded this time, a position offset by the width dimension W of the pallet 5 in the front-rear direction of the truck 3 from the previously calculated stowage position S. In this case, in addition to being able to easily calculate the stowage position S of the pallet 5 to be loaded this time, there is no gap between adjacent pallets 5 in the front-rear direction of the truck 3.

[0119] Although several embodiments of the present invention have been described above, the present invention is not limited to the above-mentioned embodiments. For example, in the above-mentioned embodiments, the pallets 5 are stacked on the bed 4 of the truck 3 in order from the front side to the rear side of the truck 3, but the present invention is not particularly limited to such a form. The pallets 5 may be stacked on the bed 4 of the truck 3 in order from the rear side to the front side of the truck 3. In this case, the first pallet 5 is stacked at the rear end of the bed 4. The stacking direction of the pallets 5 may be instructed by the upper system management device 11.

[0120] In the above embodiment, the stowage control device 10, 10A includes the controller 20, 20A, but the number of controllers is not limited to 1. For example, a self-position estimation controller having a self-position estimation unit 21 may be provided separately from the controller 20, 20A, which is the main controller.

[0121] In the above embodiment, the pallet information including the planned number of pallets 5 to be loaded and the width dimension W is acquired by being transmitted from the higher-level system management device 11, but the present invention is not limited to such a form. For example, the pallet information may be acquired by inputting it using an input device such as a touch panel.

[0122] In the above embodiment, the pallets 5 are loaded onto the bed 4 of the truck 3. However, the bed on which the pallets 5 are loaded is not limited to the truck 3, and may be, for example, a truck berth. [Explanation of symbols]

[0123] 2...forklift, 4...platform, 4a...loading surface, 4b...side edge (edge), 5...pallet, 10, 10A...loading control device, 17...laser sensor (platform detection unit), 22...loading plan information acquisition unit (pallet information acquisition unit), 24...travel control unit, 25...platform edge detection unit, 26, 26A...loading position calculation unit, 27, 27A...loading control unit, 28, 28A...judgment unit, Dp...point cloud data (detection data), S...loading position, W...width dimension.

Claims

1. A loading control device for loading a plurality of pallets onto a loading platform by a forklift, A pallet information acquisition unit that acquires pallet information including a planned number of pallets to be loaded and a width dimension of the pallets to be loaded in a specified direction of the loading platform; A travel control unit that controls the forklift to travel along the specified direction; a loading platform detection unit that detects a loading surface of the loading platform when the forklift is traveling along the specified direction; a bed edge detection unit that detects an edge of the bed along the specified direction based on detection data from the bed detection unit; a loading position calculation unit that calculates loading positions of the planned number of pallets to be loaded based on the planned number of pallets to be loaded and the width dimension of the pallets acquired by the pallet information acquisition unit and the edge of the loading platform detected by the loading platform edge detection unit; a stowage control unit that controls the forklift so that the pallets are sequentially stowed at the stowage positions corresponding to the planned number of stowage calculated by the stowage position calculation unit.

2. 2. The stowage control device according to claim 1, wherein the stowage position calculation unit collectively calculates the stowage positions of the planned number of pallets based on the planned number of pallets and a width dimension of the pallet and an edge of the loading platform.

3. 3. The stowage control device according to claim 2, wherein the stowage position calculation unit calculates a position offset in the specified direction from an arbitrary stowage position by the width dimension of the pallet or by an amount greater than the width dimension of the pallet by a specified amount as the stowage position adjacent to the arbitrary stowage position in the specified direction.

4. a determination unit for determining whether or not use of the stowage positions corresponding to the planned number of stowage positions collectively calculated by the stowage position calculation unit is instructed, when the stowage control unit determines that the determination unit has instructed the use of the stowage positions for the planned number of stowage, the stowage control unit controls the forklift so that the pallets are sequentially stowed at the stowage positions for the planned number of stowage, 3. A stowage control device as described in claim 2, wherein when the judgment unit judges that the use of the stowage positions for the planned number of stowage has not been instructed, the travel control unit, the bed edge detection unit and the stowage position calculation unit are executed again.

5. 2. The stowage control device according to claim 1, wherein the stowage position calculation unit calculates the stowage position of the pallet to be first loaded onto the loading platform based on the edge of the loading platform, and calculates the stowage position of the pallet to be currently loaded onto the loading platform based on the previously calculated stowage position, the planned number of pallets to be loaded, the width dimension, and the edge of the loading platform.

6. 6. The stowage control device according to claim 5, wherein the stowage position calculation unit calculates a position offset in the specified direction from the previously calculated stowage position by the width dimension of the pallet or by an amount greater than the width dimension of the pallet by a specified amount as the stowage position of the pallet to be stowed this time.

7. a determination unit for determining whether or not use of the previously calculated stowage position is instructed, When the loading position calculation unit determines that the use of the previously calculated loading position is instructed, the loading position calculation unit calculates a loading position of the pallet to be loaded this time based on the previously calculated loading position, the planned number of pallets to be loaded, the width dimension, and the edge of the loading platform, 6. A stowage control device as described in claim 5, wherein when the judgment unit judges that the use of the previously calculated stowage position has not been instructed, the processing of the travel control unit, the bed edge detection unit and the stowage position calculation unit is executed again.

8. the loading platform detection unit is a laser sensor that irradiates a laser toward a loading surface of the loading platform and receives reflected light of the laser to detect a distance to the loading surface and acquire point cloud data; 2. The stowage control device according to claim 1, wherein the platform edge detection unit detects the platform edge by extracting a point cloud representing the platform edge along the specified direction based on the point cloud data of the laser sensor.

Images