Cargo handling system

Abstract

To provide a cargo handling system capable of improving the efficiency of cargo handling by a cargo handling vehicle.SOLUTION: A cargo handling system includes a pallet rack 1 on which a cargo N is placed, a forklift 2 which is a cargo handling vehicle that performs cargo handling, and a database server 3 which communicates with the forklift 2. The forklift 2 includes a vehicle body 2A which travels on a road surface, forks 21R, 21L (transfer device 2B) which delivers the cargo N to and from the rack 1, and a side shift device which can move the forks 21R, 21L in a second horizontal direction perpendicular to the first horizontal direction when the rack 1 and the vehicle body 2A face each other in a first horizontal direction and the vehicle body 2A is stopped traveling. The server 3 stores a database related to the side shift amount (the amount of movement of the forks 21R, 21L by the side shift device).SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a cargo handling system capable of automatically adjusting the position of a transfer device. [Background technology]

[0002] Patent Document 1 describes a forklift (cargo handling vehicle) equipped with a cargo handling device having forks (transfer device) and side shift cylinders (side shift device), and a cargo handling control device that controls cargo handling. The cargo handling control device is equipped with a laser distance sensor that detects the distance to an object (detection target) located in front of the forklift, and controls the side shift cylinder according to the loading start position or cargo placement start position of the forks based on the detection value of the laser distance sensor. In other words, the side shift cylinder moves the forks left and right based on the object detection result by the laser distance sensor.

[0003] However, in Patent Document 1, if the laser distance sensor malfunctions, i.e., if the sensor is in an abnormal state where it cannot detect the detection target, it is not possible to determine the loading start position or the placement start position, and the forks cannot be moved appropriately by the side shift cylinder. This causes a problem in that the loading operation by the forklift is interrupted, and the efficiency of the loading operation progresses. Furthermore, there is a demand for more efficient loading and unloading by loading and unloading vehicles in logistics, not limited to when the sensor malfunctions. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 7156174 Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention has been made in consideration of the above circumstances, and an object of the present invention is to provide a cargo handling system that can improve the efficiency of cargo handling by cargo handling vehicles. [Means for solving the problem]

[0006] In order to solve the above problem, the loading and unloading system of the present invention comprises a rack on which cargo is placed, a loading and unloading vehicle that performs the loading and unloading, and a server that communicates with the loading and unloading vehicle, wherein the loading and unloading vehicle comprises a vehicle body that runs on a road surface, a transfer device that transfers the cargo to and from the rack, and a side shift device that is capable of moving the transfer device in a second horizontal direction perpendicular to the first horizontal direction when the rack and the vehicle body are facing each other in a first horizontal direction and the vehicle body is stopped, and the server is characterized in that it stores a database related to the amount of movement of the transfer device by the side shift device.

[0007] Furthermore, it is preferable that the rack has multiple luggage loading sections in the second horizontal direction, and the loading vehicle is configured so that the transfer device transfers the luggage to any one of the multiple luggage loading sections, and the database is a data group in which data related to the amount of movement of the transfer device by the side shift device is classified by the multiple luggage loading sections.

[0008] Furthermore, it is preferable that the rack has multiple tiers of cargo loading sections in the vertical direction, the loading vehicle is configured so that the transfer device transfers the cargo to any one of the multiple tiers of cargo loading sections, and the database is a data group in which data related to the amount of movement of the transfer device by the side shift device is classified by the multiple tiers of cargo loading sections.

[0009] Furthermore, it is preferable that the loading vehicle is equipped with a sensor that detects a detection object that determines the amount of movement of the transfer device by the side shift device, and that when the sensor is in a normal state where it can detect the detection object, the side shift device is configured to move the transfer device based on the detection result of the detection object, and when the sensor is in an abnormal state where it cannot detect the detection object, the side shift device is configured to move the transfer device based on the database.

[0010] Furthermore, it is preferable that the loading vehicle is equipped with a sensor that detects a detection object that determines the amount of movement of the transfer device by the side shift device, and that the side shift device is configured to move the transfer device based on the database while the vehicle body is traveling, or after the vehicle body has stopped traveling and before the sensor detects the detection object. [Effects of the Invention]

[0011] According to the present invention, it is possible to provide a cargo handling system that can improve the efficiency of cargo handling by cargo handling vehicles. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a schematic configuration diagram of a cargo handling system according to an embodiment of the present invention. [Figure 2] FIG. 2A is a perspective view of the rack according to the embodiment, and FIG. 2B is a front view of the rack. [Figure 3] FIG. 2 is a plan view of the rack, illustrating the positional relationship between the luggage placement section of the rack and the stopping position of the cargo handling vehicle. [Figure 4] FIG. 1A is a block diagram showing the general configuration of a cargo handling vehicle according to the embodiment, and FIGS. 1B and 1C are explanatory diagrams illustrating the positional relationship between the sensor provided on the cargo handling vehicle and the object to be detected. [Figure 5] 10 is a table illustrating an example of a database managed by the server according to the embodiment. [Figure 6]10 is a flowchart of a side shift process according to the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0013] An embodiment of the present invention will be described with reference to the drawings. Note that a first horizontal direction X, a second horizontal direction Y, and a vertical direction Z indicated by arrows in Figures 2 and 3 are linear directions that are perpendicular to one another.

[0014] As shown in Fig. 1, the material handling system according to this embodiment is made up of a pallet rack 1 (hereinafter referred to as "rack 1"), a forklift 2, and a database server 3 (hereinafter referred to as "server 3"). This material handling system is established in an unmanned warehouse where work inside the warehouse is unmanned, or an automated warehouse where work inside the warehouse is automated.

[0015] The rack 1 is composed of one or more shelves. The rack 1 stores a pallet P and cargo N. The rack 1 according to this embodiment is composed of three shelves, and cargo N is placed on each shelf via a pallet P.

[0016] The forklift 2 is a cargo handling vehicle made up of a vehicle body 2A and a transfer device 2B. The forklift 2 performs cargo handling operations including picking up cargo N, transporting cargo N, and placing cargo N. The forklift 2 according to this embodiment is a reach-type unmanned forklift that automatically handles cargo.

[0017] The vehicle body 2A is a traveling body that estimates its own position and travels autonomously on a road surface along a predetermined travel route. That is, the vehicle body 2A includes a position estimation device that estimates the vehicle position and a traveling device that travels autonomously.

[0018] The transfer device 2B delivers and receives the cargo N to and from the rack 1. The transfer device 2B is composed of a pair of left and right forks 21R, 21L (see FIGS. 4(B) and (C)) that handle the cargo N. The forks 21R, 21L are claws that are provided so as to be able to be inserted into the pallet P on which the cargo N is placed. The forks 21R, 21L are configured so as to be movable relative to the vehicle body 2A.

[0019] The forklift 2 is configured such that, in a cargo picking operation and a cargo placing operation, the forks 21R, 21L deliver the cargo N to any of a plurality of cargo placing sections described below. That is, the forklift 2 is configured to perform a cargo picking operation by the forks 21R, 21L receiving the cargo N from the cargo placing section, and to perform a cargo placing operation by the forks 21R, 21L delivering the cargo N to the cargo placing section.

[0020] The server 3 is a network device that communicates with the forklift 2. The server 3 receives the side shift amount, which will be described later, from the forklift 2 and stores the side shift amount in a database. In other words, the server 3 stores and manages the database related to the side shift amount. The server 3 also transmits the side shift amount to the forklift 2 as necessary.

[0021] 2(A) and 2(B), the rack 1 includes a support 11, a beam 12, and a sub-beam 13. In this embodiment, two racks 1 are provided side by side in the second horizontal direction Y.

[0022] The support columns 11 are vertical members extending in the vertical direction Z. The beams 12 are horizontal members extending in the second horizontal direction Y, and connect a pair of support columns 11 extending parallel to the vertical direction Z. The sub-beams 13 are horizontal members extending in the first horizontal direction X, and connect a pair of beams 12 extending parallel to the second horizontal direction Y. The beams 12 and sub-beams 13 function as shelves that support luggage N.

[0023] The rack 1 has multiple rows of luggage placement sections in the second horizontal direction Y, and multiple levels of luggage placement sections in the vertical direction Z. Each rack 1 according to this embodiment has two rows of luggage placement sections in the second horizontal direction Y, and three levels of luggage placement sections in the vertical direction Z. In other words, two racks 1 arranged side by side have four rows of luggage placement sections and three levels.

[0024] As shown in Fig. 2(B), the two racks 1 have 12 luggage placement sections 1A to 1L. Luggage placement sections 1A to 1C correspond to the first row, luggage placement sections 1D to 1F correspond to the second row, luggage placement sections 1G to 1I correspond to the third row, and luggage placement sections 1J to 1L correspond to the fourth row. Furthermore, luggage placement sections 1A, 1D, 1G, and 1J correspond to the first lower tier, luggage placement sections 1B, 1E, 1H, and 1K correspond to the second middle tier, and luggage placement sections 1C, 1F, 1I, and 1L correspond to the third upper tier.

[0025] 3, when the forklift 2 performs a load pick-up or load placing operation, the vehicle body 2A is configured to stop at stop positions B1 to B4 corresponding to the row of load placement sections to which the load N is to be delivered. Specifically, when the forks 21R, 21L deliver the load N to the load placement sections 1A to 1C, the vehicle body 2A is configured to stop at stop position B1, when the forks 21R, 21L deliver the load N to the load placement sections 1D to 1F, the vehicle body 2A is configured to stop at stop position B2, when the forks 21R, 21L deliver the load N to the load placement sections 1G to 1I, the vehicle body 2A is configured to stop at stop position B3, and when the forks 21R, 21L deliver the load N to the load placement sections 1J to 1L, the vehicle body 2A is configured to stop at stop position B4.

[0026] As shown in FIG. 4(A), the forklift 2 also includes a side shift device 22, a sensor 23, a notification device 24, a communication device 25, and a control device 26.

[0027] The side shift device 22 is a fork position adjustment device that can move the forks 21R, 21L in the second horizontal direction Y when the rack 1 and the vehicle body 2A are facing each other in the first horizontal direction X and when the vehicle body 2A is stopped. By moving the forks 21R, 21L relative to the stopped vehicle body 2A, the side shift device 22 can adjust the positions of the forks 21R, 21L in the second horizontal direction Y relative to the luggage placement section without causing the vehicle body 2A to move.

[0028] The sensor 23 detects a detection target that determines the amount of movement of the forks 21R, 21L (hereinafter referred to as the "side shift amount") by the side shift device 22. The sensor 23 is configured, for example, by an optical distance measuring sensor, and detects the position of the detection target by projecting laser light into a predetermined detection range C (see FIGS. 4(B) and 4(C)) and receiving the laser light reflected by the detection target present in the detection range C. The sensor 23 according to this embodiment is a sensor with an abnormality detection function, and when the sensor 23 is in an abnormal state where it cannot detect the detection target, it notifies the control device 26 of the abnormal state of the sensor 23.

[0029] When the sensor 23 is in an abnormal state, the alarm device 24 notifies a manager who performs maintenance or inspection of the forklift 2 of the abnormal state of the sensor 23. The alarm device 24 is configured, for example, by an acoustic device that emits sound, a light-emitting device that emits light, or a communication device that transmits an alarm signal to a remote device (not shown) away from the forklift 2.

[0030] The communication device 25 is configured with a wireless communication device that communicates with the server 3. The communication device 25 relays communication between the server 3 and the control device 26 by transmitting and receiving data related to the amount of side shift. When a detection target is detected by the sensor 23, the communication device 25 transmits data related to the amount of side shift based on the detection result of the detection target to the server 3. Furthermore, when the control device 26 refers to a database stored in the server 3, the communication device 25 receives data related to the amount of side shift contained in the database from the server 3.

[0031] The control device 26 performs a side shifting process, which will be described later. In the side shifting process, when the sensor 23 is in a normal state where it can detect the detection target, the control device 26 controls the side shifting device 22 based on the detection result of the detection target by the sensor 23, and when the sensor 23 is in an abnormal state where it cannot detect the detection target, the control device 26 controls the side shifting device 22 based on a database stored in the server 3.

[0032] 4(B) and 4(C), the detection of the detection target by the sensor 23 will be described. Note that in FIGS. 4(B) and 4(C), the illustration of the cargo N placed on the pallet P is omitted.

[0033] 4(B), during loading work by the forklift 2, the sensor 23 sets the periphery of the load placement section where the forks 21R, 21L hand over the load N as a detection range C, and detects an object present in this detection range C as a detection target that determines the amount of side shift. Specifically, the sensor 23 detects the support 11 as a detection target, and further, if a load N has already been placed around the load placement section, it detects the pallet P on which the load N is placed as a detection target.

[0034] 4(C), during cargo pick-up operation by the forklift 2, the sensor 23 sets the center of the cargo placement section where the forks 21R, 21L receive the cargo N as the detection range C, and detects an object present in this detection range C as the detection target that determines the amount of side shift. Specifically, the sensor 23 detects the girder Pa of the pallet P as the detection target. The girder Pa is a part of the pallet P that separates the fork insertion openings (two openings into which the forks 21R, 21L are inserted) that the pallet P has.

[0035] The database stored and managed by the server 3 will be described with reference to Fig. 5. Fig. 5 shows an example of the database. The side shift amount in Fig. 5 is a positive value indicating the amount of movement of the forks 21R, 21L in one direction in the second horizontal direction Y, and a negative value indicating the amount of movement of the forks 21R, 21L in the other direction in the second horizontal direction Y. Also, "0 mm" indicates that no side shift was performed.

[0036] As shown in Fig. 5, the database is a data group in which data relating to the amount of side shift is classified for each of the plurality of luggage placement sections 1A to 1J. In the database shown in Fig. 5, the amount of side shift during luggage placement and the amount of side shift during luggage removal are managed separately for each of the plurality of luggage placement sections 1A to 1J. Furthermore, the database shown in Fig. 5 manages the amount of side shift for the past several times of luggage placement and the amount of side shift for the past several times of luggage removal in association with the date and time when the side shift process was performed.

[0037] Therefore, the amount of side shift during the most recent loading or unloading operation or the average amount of side shift during the past several loading or unloading operations can be known from the database shown in Fig. 5, and the amount of side shift for the next time can be estimated. Therefore, it is possible to determine the amount of side shift by referring to the database without using the sensor 23.

[0038] 5 also shows that the amount of side shift for the luggage placement sections 1A to 1C was "0 mm" before 10:49 on 6 / 6 / 2023, but was "-10 mm" after 11:01 on 6 / 6 / 2023. Therefore, it can be assumed that the rack 1 having the luggage placement sections 1A to 1C has moved in the second horizontal direction Y for some reason, and by improving the position of the rack 1, it is possible to make the amount of side shift for the luggage placement sections 1A to 1C 0 mm.

[0039] 5, it can be seen that the side shift amount for the luggage placement sections 1J to 1L changes in increments of a predetermined amount. Therefore, it can be estimated that the rack 1 having the luggage placement sections 1J to 1L is tilted, and by correcting the tilt of the rack 1, the side shift amount for the luggage placement sections 1J to 1L can be made 0 mm.

[0040] The flow of the side shift process performed by the control device 26 will be described with reference to Fig. 6. The side shift process is performed when a detection target that determines the amount of side shift is located within the detection range C of the sensor 23.

[0041] First, the control device 26 determines, based on the result of communication with the sensor 23, whether or not the sensor 23 is in an abnormal state where it cannot detect the detection target, that is, whether or not the sensor 23 is in an abnormal state (step S1).

[0042] If the control device 26 determines that the sensor 23 is not in an abnormal state (step S1: NO), it controls the sensor 23 to detect a detection object that determines the amount of side shift (step S2), and determines the amount of side shift of the forks 21R, 21L based on the detection result of the detection object (step S3).

[0043] On the other hand, when the control device 26 determines that the sensor 23 is in an abnormal state (step S1: YES), it controls the notification device 24 to notify the abnormal state of the sensor 23 (step S4). Next, the control device 26 communicates with the server 3 via the communication device 25 to receive data related to the amount of side shift from the server (step S5). That is, in step S5, the control device 26 receives data related to the baggage placement section where the baggage N is to be transferred, that is, data related to the amount of side shift in the past.

[0044] After determining the side shift amount in step S3 or after receiving the data related to the side shift amount in step S5, the control device 26 determines whether or not to perform a side shift by the side shift device 22 based on the side shift amount (step S6). Specifically, if the side shift amount is "0 mm" or a value close to "0 mm" and less than a predetermined value, the control device 26 determines not to perform a side shift, and otherwise determines to perform a side shift.

[0045] If the control device 26 determines that a side shift should be performed (step S6: YES), it controls the side shift device 22 to move the forks 21R, 21L in the second horizontal direction Y relative to the vehicle body 2A that is stopped by the side shift amount determined in step S3 or the side shift amount included in the data received in step S5 (step S7).

[0046] In this embodiment, the following effects are obtained. (1) The efficiency of cargo handling by the forklift 2 (cargo handling vehicle) can be improved based on the database stored in the server 3. Specifically, for example, if the sensor 23 fails, the position of the forks 21R, 21L (transfer device) in the second horizontal direction Y can be adjusted by determining the side shift amount (the amount of movement of the forks 21R, 21L) based on the database, thereby preventing an interruption of cargo handling. Furthermore, because the side shift amount can be determined based on the database, the position of the forks 21R, 21L in the second horizontal direction Y can be adjusted in advance, for example, before the sensor 23 detects a detection target, thereby reducing the time required for cargo handling. Furthermore, for example, by predictively diagnosing changes over time in the environment in which the rack 1 is installed or the operating status of the forklift 2 based on the database, the layout of the rack 1 or the operation of the forklift 2 can be improved, preventing a deterioration in cargo handling efficiency.

[0047] (2) The database stored in the server 3 is a group of data in which the side shift amount is classified for each of multiple consecutive luggage loading sections, so that the side shift amount can be managed according to the position of the luggage loading section in the second horizontal direction Y.

[0048] (3) The database stored in the server 3 is a group of data in which the side shift amount is classified for each of the multiple luggage storage sections, so that the side shift amount can be managed according to the position of the luggage storage section in the vertical direction Z.

[0049] (4) The forklift 2 is configured such that, when the sensor 23 is in a normal state where it can detect the detection target, the side shift device 22 moves the forks 21R, 21L based on the detection result of the detection target, and, when the sensor 23 is in an abnormal state where it cannot detect the detection target, the side shift device 22 moves the forks 21R, 21L based on the database stored in the server 3. With this configuration, even if the sensor 23 breaks down or the signal line connecting the sensor 23 and the control device 26 is disconnected, the positions of the forks 21R, 21L in the second horizontal direction Y are adjusted based on the database, thereby preventing interruption of cargo handling due to the abnormal state of the sensor 23.

[0050] The present invention is not limited to the above-described embodiment, and the above configurations can be modified. For example, the following modifications can be made, or the following modifications can be combined to make the present invention.

[0051] The data relating to the side shift amount contained in the database may be changed as appropriate. For example, the data relating to the side shift amount contained in the database may not be classified by the number of luggage storage sections, but may be classified by the number of rows of luggage storage sections. Furthermore, the data relating to the side shift amount contained in the database may not be classified by the number of rows of luggage storage sections, but may be classified by the number of rows of luggage storage sections. Furthermore, the data relating to the side shift amount may be stored in a database of average values ​​of the side shift amounts over the past several times.

[0052] The operation of the forklift 2 may be changed based on the database. Specifically, as will be described in Modification 1 below, the forklift 2 may operate based on the database regardless of whether the sensor 23 is in an abnormal state.

[0053] (Variation 1) The forklift 2 may be configured such that the side shift device 22 moves the forks 21R, 21L based on a database stored in the server 3 while the vehicle body 2A is traveling or after the vehicle body 2A has stopped traveling and before the sensor 23 detects the detection target. With this configuration, the positions of the forks 21R, 21L in the second horizontal direction Y can be adjusted in advance based on the database before the sensor 23 detects the detection target. Therefore, the time required to move the forks 21R, 21L in the second horizontal direction Y after the vehicle body 2A has stopped traveling or the time required for the sensor 23 to detect the detection target after the vehicle body 2A has stopped traveling can be shortened or eliminated.

[0054] The number of racks 1 and forklifts 2 may be changed as appropriate. When the cargo handling system includes a plurality of forklifts 2, it is preferable that one server 3 communicates with the plurality of forklifts 2 to store and manage a database relating to the side shift amounts of the plurality of forklifts 2.

[0055] The cargo handling vehicle may be equipped with a transfer device other than the forks 21R, 21L (for example, a clamp, a crane, or a ram). That is, the cargo handling system may be configured with cargo handling vehicles other than the forklift 2. [Explanation of symbols]

[0056] 1 Pallet rack (rack) 1A~1L Luggage storage area 2. Forklift (cargo handling vehicle) 2A Vehicle body 2B Transfer equipment 3 Database Server (Server) 21R, 21L fork 22 Side shift device 23 Sensors N Luggage P Palette X 1st horizontal direction Y 2nd horizontal direction Z vertical direction

Claims

1. a rack on which luggage is placed; A cargo handling vehicle that handles cargo; a server that communicates with the cargo handling vehicle; The loading vehicle is a vehicle body running on a road surface; a transfer device that transfers the load to and from the rack; a side shift device that is capable of moving the transfer device in a second horizontal direction perpendicular to the first horizontal direction when the rack and the vehicle body are facing each other in a first horizontal direction and the vehicle body is stopped from traveling, The server stores a database relating to the amount of movement of the transfer device by the side shift device. A cargo handling system characterized by:

2. The rack has a plurality of consecutive luggage placement sections in the second horizontal direction, The cargo handling vehicle is configured so that the transfer device transfers the cargo to any one of the multiple cargo placement sections, The database is a data group in which data relating to the amount of movement of the transfer device by the side shift device is classified for each of the plurality of luggage placement sections.

2. The cargo handling system according to claim 1.

3. The rack has a plurality of luggage placement sections in a vertical direction, The cargo handling vehicle is configured so that the transfer device transfers the cargo to any one of the multiple cargo loading sections, The database is a data group in which data relating to the amount of movement of the transfer device by the side shift device is classified for each of the multiple levels of the luggage loading sections.

3. A cargo handling system according to claim 1 or 2.

4. The loading vehicle is a sensor for detecting a detection object that determines the amount of movement of the transfer device by the side shift device; When the sensor is in a normal state in which it can detect the detection object, the side shift device moves the transfer device based on the detection result of the detection object, When the sensor is in an abnormal state where it cannot detect the detection target, the side shift device moves the transfer device based on the database.

2. The cargo handling system according to claim 1.

5. The loading vehicle is a sensor for detecting a detection object that determines the amount of movement of the transfer device by the side shift device; The side shift device is configured to move the transfer device based on the database while the vehicle body is traveling or after the vehicle body has stopped traveling and before the sensor detects the detection target.

2. The cargo handling system according to claim 1.

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