Initial setting method of unmanned forklift and adjustment pallet

Abstract

To provide an initial setting method of an unmanned forklift capable of easily introducing an unmanned forklift, and suppressing the time and cost required for a test run before an official operation.SOLUTION: An initial setting method of an unmanned forklift includes the steps of mounting an adjustment pallet on a rack structure based on a preset operation program, acquiring relative positional information between the adjustment pallet and the rack structure, and calculating the deviation amount of the adjustment pallet mounted on the rack structure with respect to the rack structure based on the relative positional information. The initial setting method supports and mounts the adjustment pallet in a forward direction with the fork of the unmanned forklift when the pallet is mounted on the second and subsequent layers, and supports and mounts the adjustment pallet in the opposite direction opposed to the forward direction with the fork of the unmanned forklift when the pallet is mounted on the first layer of the rack structure.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to an initial setting method and an adjustment pallet for an unmanned forklift. [Background technology]

[0002] Patent Document 1 discloses an unmanned forklift configuration in which a pair of forks are provided with a reach-direction pallet deviation detector and a left-right direction pallet deviation detector, making it possible to detect deviations in the front-to-rear and left-right directions as well as rotational deviations of a pallet on the forks. With this configuration, deviations of the pallet relative to the forks are detected when picking up a pallet, when lowering the held pallet onto a rack or the like, or when the unmanned forklift is traveling while holding a pallet.

[0003] Furthermore, Patent Document 2 describes an initial setting method for introducing an unmanned forklift into a facility equipped with a rack structure, the initial setting method including the steps of: placing an adjustment pallet on a pallet placement section of the rack structure using the unmanned forklift based on a preset operating program; acquiring relative position information between the adjustment pallet and the rack structure using a position information acquisition section equipped in the adjustment pallet; and calculating the amount of deviation of the adjustment pallet placed on the rack structure from the pallet placement section based on the relative position information.

[0004] An unmanned forklift travels within a facility such as a warehouse or factory based on a preset operation program, and performs operations of picking up and placing pallets on a pallet placement unit set at a predetermined position. When a new unmanned forklift is introduced into a facility, initial setting information such as the movement path of the unmanned forklift and the position coordinates of the pallet placement unit must be set into the operation program. Information such as the movement path of the unmanned forklift and the position coordinates of the pallet placement unit is obtained based on design data for the facility and the racks to be installed within the facility.

[0005] However, for example, racks installed in a facility may deviate from the design data due to factors such as the accuracy of the rack's assembly and installation. For this reason, when a new unmanned forklift is introduced, a test run is conducted in which the unmanned forklift is operated based on a pre-set operating program before the unmanned forklift is officially put into operation. During this test run, the unmanned forklift actually places a pallet on the rack's pallet placement section. An operator must measure the actual placement of the placed pallet and the amount of misalignment relative to the pallet placement section, and then correct information in the operating program, such as the position coordinates of the pallet placement section, based on the measured amount of misalignment. Therefore, measuring the amount of misalignment of the placed pallet is time-consuming, which increases the time and cost required for the introduction of an unmanned forklift.

[0006] The invention described in Patent Document 2 was made to solve the above-mentioned problems, and aims to provide an initial setting method and adjustment pallet for an unmanned forklift that can easily introduce the unmanned forklift and reduce the time and cost required for test runs before official operation. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Application Publication No. 9-12297 [Patent Document 2] Japanese Patent Publication No. 2023-67706 Summary of the Invention [Problem to be solved by the invention]

[0008] As an example, the invention described in Patent Document 2 calculates the relative position information of the adjustment pallet with respect to the rack structure by detecting the distance to the beam material (rear beam material 103R) supporting one end of the adjustment pallet using a laser displacement meter (third laser displacement meter 555) that emits a laser diagonally downward toward the front side (Dx2 side) in the forward and backward direction (Dx) of the forklift when the adjustment pallet is placed on the second or third layer of the rack structure.

[0009] However, in the embodiment of the invention described in Patent Document 2, when the adjustment pallet is placed on the first layer (lower layer; floor) of the rack structure, it is not possible to obtain the distance to the rack structure using a laser displacement meter that emits a laser diagonally downward. Therefore, in order to obtain relative position information for the first layer, it is necessary to take measures such as measuring the second and third layers separately using different means.

[0010] The present disclosure has been made to solve the above-mentioned problems, and aims to provide an initial setting method and adjustment pallet for an unmanned forklift that can easily obtain relative position information when placed on the first layer as well as when placed on the second or higher layer. [Means for solving the problem]

[0011] In order to solve the above problems, the initial setting method for an unmanned forklift according to the present disclosure is an initial setting method performed using an adjustment pallet when introducing the unmanned forklift into a facility equipped with a rack structure, the adjustment pallet comprising: a pallet body that can be supported by the forks of the unmanned forklift and that can be placed on the rack structure; and a position information acquisition unit that is provided on the pallet body and acquires relative position information with respect to the rack structure when the adjustment pallet is placed on the rack structure, and when the adjustment pallet is supported in a forward direction by the forks of the unmanned forklift, the position information acquisition unit acquires relative position information with respect to the rack structure, and when the adjustment pallet is supported in a forward direction by the forks of the unmanned forklift, the position information acquisition unit and a fourth laser displacement meter that emits a laser toward the rear in the advance / retreat direction, and the initial setting method includes the steps of: placing the adjustment pallet on the rack structure by the unmanned forklift based on a preset operation program; acquiring relative position information between the adjustment pallet and the rack structure by a position information acquisition unit provided in the adjustment pallet; and calculating an amount of deviation of the adjustment pallet placed on the rack structure from the pallet placement unit based on the relative position information, wherein in the step of placing the adjustment pallet on the rack structure, when the adjustment pallet is to be placed on a second or higher layer of the rack structure, the adjustment pallet is placed while being supported in the forward direction by the forks of the unmanned forklift; and when the adjustment pallet is to be placed on the first layer of the rack structure, the adjustment pallet is placed while being supported in a reverse direction that is opposite to the forward direction by the forks of the unmanned forklift.

[0012] The adjustment pallet according to the present disclosure is an adjustment pallet used in an initial setting method when introducing an unmanned forklift into a facility equipped with a rack structure, and comprises a pallet body that can be supported by the forks of the unmanned forklift and placed on the rack structure, a replacement support attached to the pallet body, and a position information acquisition unit that is provided on the pallet body and acquires relative position information with respect to the rack structure when the adjustment pallet is placed on the rack structure, and the position information acquisition unit acquires relative position information with respect to the rack structure when the adjustment pallet is supported in a forward direction by the forks of the unmanned forklift. The pallet body is provided with a first laser displacement meter that is positioned on the rear side of the forward / backward direction of the forklift truck and emits a laser in a left-right direction that intersects with the forward / backward direction in a horizontal plane, a second laser displacement meter that is positioned on the front side of the forward / backward direction and emits a laser in the left-right direction, a third laser displacement meter that is provided at a predetermined position on the pallet body and emits a laser diagonally downward on the front side of the forward / backward direction, and a fourth laser displacement meter that emits a laser toward the rear side of the forward / backward direction, and the replacement support body has a replacement position where the third laser displacement meter that has been removed from the predetermined position can be installed upside down.

[0013] The adjustment pallet according to the present disclosure is an adjustment pallet used in an initial setting method when introducing an unmanned forklift into a facility equipped with a rack structure, and comprises a pallet body that can be supported by the forks of the unmanned forklift and placed on the rack structure, a replacement support attached to the pallet body, and a position information acquisition unit that is provided on the pallet body and acquires relative position information with respect to the rack structure when the adjustment pallet is placed on the rack structure, and the position information acquisition unit acquires relative position information with respect to the rack structure when the adjustment pallet is supported in a forward direction by the forks of the unmanned forklift. a first laser displacement meter arranged rearward in the forward / backward direction of the unmanned forklift relative to the rack structure, and emitting a laser in a left-right direction intersecting the forward / backward direction in a horizontal plane; a second laser displacement meter arranged forward in the forward / backward direction, and emitting a laser in the left-right direction; a third laser displacement meter provided at a predetermined position on the pallet body, and emitting a laser diagonally downward on the forward side in the forward / backward direction; and a fourth laser displacement meter that emits a laser toward the rear side in the forward / backward direction, and the pallet body is provided with a scale member extending along the forward / backward direction. [Effects of the Invention]

[0014] According to the initial setting method for an unmanned forklift and the adjustment pallet of the present disclosure, relative position information can be easily obtained when the forklift is placed on the first layer in addition to when the forklift is placed on the second or higher layer. [Brief explanation of the drawings]

[0015] [Figure 1] 1 is a plan view showing a schematic configuration of an unmanned transport forklift system in a facility to which an initial setting method for an unmanned forklift, an adjustment pallet, and an adjustment system for an unmanned forklift according to an embodiment of the present disclosure are applied. FIG. [Figure 2] FIG. 2 is a side view of the rack equipment installed in the facility. [Figure 3] FIG. 2 is a plan view of the rack equipment. [Figure 4]FIG. 2 is a plan view showing an adjustment pallet constituting the adjustment system of the unmanned forklift. [Figure 5] FIG. 2 is a side view showing an adjustment pallet constituting the adjustment system of the unmanned forklift. [Figure 6] FIG. 10 is a cross-sectional view showing the adjustment pallet supported by the forks of an unmanned forklift. [Figure 7] 10A and 10B are diagrams illustrating the process of acquiring the relative position of the adjustment pallet with respect to the rack structure when placing goods on the second or third layer of the rack structure. [Figure 8] 10A and 10B are diagrams illustrating the process of acquiring the relative position of the adjustment pallet with respect to the forklift when picking up goods from the second or third layer of the rack structure. [Figure 9] 10A and 10B are diagrams illustrating a process for acquiring the relative position of an adjustment pallet with respect to a rack structure when placing an item on the first layer of the rack structure. [Figure 10] 10A and 10B are diagrams illustrating the process of acquiring the relative position of the adjustment pallet with respect to the forklift when picking up goods from the first layer of the rack structure. [Figure 11] FIG. 10 is a diagram showing the configuration of a unit including a third laser displacement meter. [Figure 12] FIG. 2 is a front view showing an adjustment pallet constituting the adjustment system of the unmanned forklift. [Figure 13] FIG. 2 is a side view showing an adjustment pallet constituting the adjustment system of the unmanned forklift. [Figure 14] FIG. 10 is a diagram showing the reference position and replacement position of the third laser displacement meter. [Figure 15] 10A and 10B are diagrams illustrating a process for acquiring the relative position of an adjustment pallet with respect to a rack structure when placing an item on the first layer of the rack structure. [Figure 16] FIG. 2 is a plan view showing an adjustment pallet constituting the adjustment system of the unmanned forklift. DETAILED DESCRIPTION OF THE INVENTION

[0016] Hereinafter, embodiments for carrying out the initial setting method for an unmanned forklift and the adjustment pallet according to the present disclosure will be described with reference to the accompanying drawings. However, the present disclosure is not limited to these embodiments.

[0017] First Embodiment (Configuration of unmanned forklift system) Prior to describing the unmanned forklift adjustment system according to the present disclosure, an automated guided forklift system (AGF) 1 to which the unmanned forklift adjustment system is applied will be described. As shown in FIG. 1 , facilities in which the unmanned forklift system 1 is installed include, for example, warehouses, factories, commercial facilities, and cargo handling facilities. In warehouses, for example, various items loaded on pallets are stored. In factories, for example, various parts and materials loaded on pallets are transported between processes within the factory. In commercial facilities, for example, products loaded on pallets are displayed on product shelves. In cargo handling facilities, for example, cargo loaded on pallets is temporarily stored and sorted for delivery to its destination. Here, the pallets may include containers that can be transported by the unmanned forklift.

[0018] In the unmanned transport forklift system 1, an unmanned forklift 2 automatically travels along a predetermined route R set within a facility, and transports various items loaded on a pallet 5 within the facility. The unmanned transport forklift system 1 comprises one or more unmanned forklifts 2 that can travel along the route R, and a system controller 3.

[0019] (Rack structure configuration) Such a facility is provided with rack structures 100 on which pallets 5, which can carry items, parts, merchandise, cargo, etc., can be placed. A plurality of rack structures 100 are arranged along the route R of the unmanned forklift 2. As shown in FIG. 2, the rack structures 100 are configured, for example, in multiple layers, one above the other. As shown in FIGS. 2 and 3, the rack structure 100 includes a plurality of support columns 102 provided on a floor surface F, and beam members 103 installed between adjacent support columns 102. The support columns 102 and the beam members 103 are formed, for example, from steel frames.

[0020] The multiple support pillars 102 are arranged at predetermined intervals in the direction in which the path R extends in a horizontal plane (hereinafter, this direction will be referred to as the left-right direction Dy). The multiple support pillars 102 are arranged in pairs, with a front support pillar 102F and a rear support pillar 102R, at intervals in the forward-backward direction Dx, which is perpendicular to the left-right direction Dy in which the path R extends in the horizontal plane. The front support pillar 102F is arranged on a rear side Dx1 close to the path R in the forward-backward direction Dx. The rear support pillar 102R is arranged on a front side Dx2 away from the path R in the forward-backward direction Dx.

[0021] In this embodiment, the beams 103 are arranged in multiple layers at intervals in the up-down direction Dv of the rack structure 100, for example. The beams 103 include a front beam 103F, a rear beam 103R, and a side beam 103S. The front beam 103F extends in the left-right direction Dy and connects adjacent front columns 102F together. The rear beam 103R extends in the left-right direction Dy and connects adjacent rear columns 102R together. The side beam 103S extends in the forward-backward direction Dx and connects adjacent front beams 103F and rear beams 103R together. In the upper layer 100t of the rack structure 100, each column 102 extends higher than the front beams 103F, rear beams 103R, and side beams 103S.

[0022] The rack structure 100 is provided with a plurality of pallet placement sections S. Each pallet placement section S is capable of mounting a pallet 5. The pallet placement sections S are set on beam members 103. In this embodiment, the pallet placement sections S are arranged in three upper and lower layers, namely, an upper layer 100t (hereinafter also referred to as the "third layer"), a middle layer 100m (hereinafter also referred to as the "second layer"), and a lower layer 100b (hereinafter also referred to as the "first layer") in the vertical direction Dv of the rack structure 100. In the pallet placement sections S set in the upper layer 100t and middle layer 100m in the vertical direction Dv of the rack structure 100, the pallet 5 is placed across the upper surfaces of the front beam member 103F and the rear beam member 103R. An auxiliary beam (not shown) extending in the forward / backward direction Dx may be provided between the front beam 103F and the rear beam 103R. In the pallet placement section S set in the lower layer 100b of the rack structure 100 in the up-down direction Dv, the pallet 5 is placed directly on the floor surface F. In the pallet placement section S set in the lower layer 100b of the rack structure 100, the floor surface F as the pallet placement section S functions as part of the rack structure 100.

[0023] 3, in this embodiment, two pallet placement units S are set side by side in the left-right direction Dy between the front columns 102F and the rear columns 102R that are adjacent in the left-right direction Dy in each of the upper and lower three floors of the rack structure 100. That is, in each of the upper floor 100t, middle floor 100m, and lower floor 100b of the rack structure 100, a pallet placement unit SL on the left side Dy1 in the left-right direction Dy (left side as viewed from the path R side) and a pallet placement unit SR on the right side Dy2 in the left-right direction Dy (right side as viewed from the path R side) are arranged between the front columns 102F and the rear columns 102R that are adjacent in the left-right direction Dy.

[0024] (Configuration of unmanned forklift) As shown in FIGS. 2 and 3, the unmanned forklift 2 includes a forklift body 21, a pair of forks 22, and a forklift control unit . The forklift body 21 is configured to be able to travel along a route R within the facility under the control of the forklift control unit 23. The forklift body 21 travels along the route R either as a guideless type, in which the forklift body 21 travels while recognizing the position of the unmanned forklift 2 itself within the facility using a gyro or laser, or as a guided type, in which the forklift body 21 travels along a guide laid along the route R.

[0025] The pair of forks 22 is provided on the forklift body 21 so as to be able to move up and down in the vertical direction Dv. The pair of forks 22 can be inserted into fork insertion portions (not shown) formed in the pallet 5. Under the control of the forklift control unit 23, the unmanned forklift 2 lifts the pair of forks 22 with the pair of forks 22 inserted into the fork insertion portions (not shown), thereby holding the pallet 5 on the pair of forks 22.

[0026] The forklift control unit 23 controls the operation of the unmanned forklift 2 based on a preset operation program. The forklift control unit 23 is capable of transmitting and receiving data to and from the system controller 3 via wireless communication means such as a wireless LAN (Local Area Network). The forklift control unit 23 receives commands from the system controller 3 via the wireless communication means, including position information of the pallet placement unit S, which is the loading position for loading a pallet 5 onto the forks 22 or the unloading position for the pallet 5 loaded on the forks 22. Here, the position information of the pallet placement unit S is coordinate information or the like that indicates the position of the pallet placement unit S.

[0027] Based on a command received from the system controller 3, the forklift control unit 23 moves the forklift body 21 along the route R toward the pallet placement unit S, which is the loading or unloading position. The forklift control unit 23 operates the forks 22 at the pallet placement unit S, which is the loading or unloading position, to load the pallet 5 onto the forks 22 or unload the pallet 5 onto the pallet placement unit S. When loading or unloading onto the pallet placement unit S, the unmanned forklift 2 moves forward or backward relative to the rack structure 100 in a direction (forward / backward direction Dx) that intersects with the extension direction of the route R within the horizontal plane.

[0028] (Configuration of the unmanned forklift adjustment system) The unmanned forklift adjustment system is applied when the above-mentioned unmanned forklift 2 and unmanned transport forklift system 1 are newly introduced into a facility. The unmanned forklift adjustment system comprises an adjustment pallet 50 and a processing terminal. The basic configuration of the unmanned forklift adjustment system is the same as the invention described in Patent Document 2 (JP 2023-67706 A), so a detailed explanation will be omitted here.

[0029] (Adjustment palette configuration) As shown in Figs. 4 and 5, the adjustment pallet 50 includes a pallet body 51 and a position information acquisition unit 53. The pallet body 51 is rectangular in plan view, and has the same size in plan view as the pallet used in the unmanned transport forklift system 1. The pallet body 51 has insertion holes 52 into which the forks 22 of the unmanned forklift 2 are inserted. This allows the pallet body 51 to be supported by the forks 22 of the unmanned forklift 2. The pallet body 51 can be placed on the pallet placement section S of the rack structure 100.

[0030] The position information acquisition unit 53 is provided on the pallet main body 51. The position information acquisition unit 53 acquires relative position information between the adjustment pallet 50 and the rack structure 100 when the adjustment pallet 50 is placed on the pallet placement unit S. The position information acquisition unit 53 also acquires relative position information between the adjustment pallet 50 and the unmanned forklift 2 when the adjustment pallet 50 is supported by the forks 22 of the unmanned forklift 2. In this embodiment, the position information acquisition unit 53 includes a first laser displacement meter 551, a second laser displacement meter 552, an intermediate laser displacement meter 553, a third laser displacement meter 555, and a fourth laser displacement meter 556, and a data transmission unit 56. In the following description, when the first laser displacement meter 551, the second laser displacement meter 552, the intermediate laser displacement meter 553, the third laser displacement meter 555, and the fourth laser displacement meter 556 are collectively referred to simply as "laser displacement meter."

[0031] The laser displacement meter measures the distance to the rack structure 100 by irradiating a laser onto a part of the rack structure 100. On the rack structure 100 side, a reflecting portion (not shown) that reflects the laser emitted from the laser displacement meter is set on each pallet placement portion S. This reflecting portion is set, for example, on a part of the surface of the front support 102F or the rear support 102R. When the laser emitted from the laser displacement meter 55 is irradiated onto the surfaces of the front support 102F or the rear support 102R, the laser is reflected by the surfaces of the front support 102F or the rear support 102R toward the laser displacement meter. In this case, the surfaces of the front support 102F or the rear support 102R function as a reflecting portion by reflecting the laser emitted from the laser displacement meter 55. Furthermore, as a reflecting portion, a reflector made of a laser-reflecting material may be attached to a predetermined position of the rack structure 100 by, for example, a magnet when initializing the unmanned forklift 2.

[0032] In this embodiment, the first laser displacement meter 551, the second laser displacement meter 552, and the intermediate laser displacement meter 553 are arranged on both sides of the pallet body 51 in the left-right direction Dy, respectively.

[0033] The first laser displacement meter 551 is disposed on the rear side Dx1 (side closer to the route R) of the pallet body 51 in the advancing / retreating direction Dx of the unmanned forklift 2 relative to the rack structure 100. The second laser displacement meter 552 is disposed on the front side Dx2 (side away from the route R) of the pallet body 51 in the advancing / retreating direction Dx. The intermediate laser displacement meter 553 is disposed between the first laser displacement meter 551 and the second laser displacement meter 552 on the pallet body 51. The intermediate laser displacement meter 553 is disposed at a position biased toward the first laser displacement meter 551 relative to the second laser displacement meter 552 in the advancing / retreating direction Dx.

[0034] The first laser displacement meter 551, the second laser displacement meter 552, and the intermediate laser displacement meter 553 each emit a laser in the left-right direction Dy relative to the pallet body 51 and detect a part of the rack structure 100 located in the left-right direction Dy. The first laser displacement meter 551, the second laser displacement meter 552, and the intermediate laser displacement meter 553 detect a laser reflected by a reflecting portion provided on a support 102 (front support 102F, rear support 102R) that is part of the rack structure 100. When the first laser displacement meter 551, the second laser displacement meter 552, and the intermediate laser displacement meter 553 detect a laser reflected by a reflecting portion, they each detect a distance to the reflecting portion. In this embodiment, the reflecting portions are arranged, for example, on the front support 102F, the rear support 102R, and the rear beam member 103R. The reflecting portions are arranged on the side surfaces of the front support 102F and the rear support 102R that face the pallet placement portion S in the left-right direction Dy.

[0035] The first laser displacement meter 551, the second laser displacement meter 552, and the intermediate laser displacement meter 553 detect the reflecting parts located on the front support 102F and the rear support 102R located on the sides in the left-right direction Dy when the adjustment pallet 50 is loaded onto the pallet loading section S by the unmanned forklift 2.

[0036] For example, if the positional deviation of the adjustment pallet 50 relative to the pallet mounting section S in the forward / backward direction Dx is small, only the first laser displacement meter 551 detects the reflective portion of the front support 102F, and the laser of the second laser displacement meter 552 and the intermediate laser displacement meter 553 passes through without hitting the front support 102F and the rear support 102R.

[0037] For example, if the adjustment pallet 50 is significantly misaligned toward the forward side Dx2 (away from the path R) in the forward / backward direction Dx relative to the pallet mounting section S, only the second laser displacement meter 552 detects the reflecting portion of the rear support 102R, and the laser of the first laser displacement meter 551 and the intermediate laser displacement meter 553 passes through without hitting the front support 102F.

[0038] For example, if the adjustment pallet 50 is significantly misaligned toward the rear side Dx1 (path R side) in the forward / backward direction Dx relative to the pallet mounting section S, only the intermediate laser displacement meter 553 detects the reflecting part of the front support 102F, and the laser passes through the first laser displacement meter 551 and the second laser displacement meter 552 without hitting the front support 102F or the rear support 102R.

[0039] The third laser displacement meter 555 emits a laser beam obliquely downward toward a second side Dx2 in the forward / backward direction Dx of the unmanned forklift 2 relative to the rack structure 100. The third laser displacement meter 555 is disposed, for example, on the bottom of the pallet main body 51. Two third laser displacement meter 555 are disposed at an interval in the left-right direction Dy. When the laser beam emitted obliquely downward toward the second side Dx2 in the forward / backward direction Dx is reflected by a reflector attached to the rear beam member 103R so as to face the rear side Dx1 in the forward / backward direction Dx, each third laser displacement meter 555 detects the distance to the reflector.

[0040] The third laser displacement meter 555, which is disposed on the left side Dy1 in the left-right direction Dy of the pallet body 51, is configured to emit a laser along a plane including the end face of the left side Dy1 of the pallet body 51. Similarly, the third laser displacement meter 555, which is disposed on the right side Dy2 in the left-right direction Dy, is configured to emit a laser along a plane including the end face of the right side Dy2 of the pallet body 51. As shown in FIG. 4 , the third laser displacement meter 555 may be formed as a unit together with a support member so that it can be easily attached to and detached from the pallet body 51. In this case, the unit PI includes the third laser displacement meter 555 and a displacement meter support member 51a for supporting the third laser displacement meter 555. This displacement meter support member 51a is attached to the pallet body 51 via, for example, a screw.

[0041] The fourth laser displacement meter 556 measures the amount of positional deviation of the adjustment pallet 50 relative to the unmanned forklift 2 when the adjustment pallet 50 is unloaded, by irradiating a laser onto a part of the unmanned forklift 2. The fourth laser displacement meter 556 is disposed on the rear side Dx1 of the pallet body 51 in the forward / backward direction Dx, and emits a laser toward the rear side Dx1 in the forward / backward direction Dx.

[0042] As described above, when the adjustment pallet 50 is supported in the forward direction by the forks 22 of the unmanned forklift 2, the first laser displacement meter 551 is positioned on the rear side Dx1 of the forward / backward direction Dx of the unmanned forklift 2 relative to the rack structure 100, and emits a laser in the left-right direction Dy that intersects with the forward / backward direction Dx in the horizontal plane. Similarly, when the adjustment pallet 50 is supported in the forward direction by the forks 22 of the unmanned forklift 2, the second laser displacement meter 552 is positioned on the forward side Dx2 in the forward / backward direction Dx and emits a laser in the left-right direction Dy. Furthermore, when the adjustment pallet 50 is supported in the forward direction by the forks 22 of the unmanned forklift 2, the third laser displacement meter 555 emits a laser beam obliquely downward on the forward side Dx2 in the forward / backward direction Dx. Furthermore, when the adjustment pallet 50 is supported in the forward direction by the forks 22 of the unmanned forklift 2, the fourth laser displacement meter 556 emits a laser beam toward the rear side Dx1 in the forward / backward direction Dx. 4 and 5, and specifically, the direction in which the first laser displacement meter 551 is located on the rear side Dx1 in the advancing / retreating direction Dx of the unmanned forklift 2, and the direction in which the second laser displacement meter 552 is located on the front side Dx2 in the advancing / retreating direction Dx of the unmanned forklift 2. In other words, the "forward direction" is the direction in which the third laser displacement meter 555 emits a laser beam downward on the front side Dx2 in the advancing / retreating direction Dx of the unmanned forklift 2, and the direction in which the fourth laser displacement meter 556 emits a laser beam toward the rear side Dx1 in the advancing / retreating direction Dx of the unmanned forklift 2. The "reverse direction" described below is the direction opposite to the "forward direction."

[0043] The data transmission unit 56 outputs data indicating the distance detected by each of the laser displacement meters as relative position information between the adjustment pallet 50 and the rack structure 100. The data transmission unit 56 transmits the relative position information to a predetermined processing terminal (not shown) via wireless communication such as a wireless LAN.

[0044] (Configuration of unmanned forklift and its relationship with the adjustment pallet) Next, the relationship between the configuration of the unmanned forklift and the adjustment pallet will be described with reference to FIG.

[0045] The fourth laser displacement meter 556 and the first laser displacement meter 551 each measure the distance to the unmanned forklift-side reference position display unit 90 as relative position information between the adjustment pallet 50 and the unmanned forklift 2. The unmanned forklift-side reference position display unit 90 is set on the unmanned forklift 2 and indicates the unmanned forklift-side reference position of the unmanned forklift 2. In this embodiment, a forward-facing surface 91, a lateral surface 92, and an upper forward-facing surface 95 are set as the unmanned forklift-side reference position display unit 90.

[0046] The forward surface 91 is set on the forks 22 of the unmanned forklift 2. Each fork 22 of the unmanned forklift 2 is formed in an L-shape when viewed in the width direction (left-right direction Dy) of the forklift body 21. Each fork 22 has a pallet support part 22a that is inserted into the insertion hole 52 of the pallet body 51, and a fork base part 22b that extends upward from the base end of the pallet support part 22a and is supported on the forklift body 21 so as to be able to rise and fall. The forward surface 91 serving as the unmanned forklift-side reference position indicator 90 is a surface of the fork base part 22b that faces the forward side Dx2 in the forward / backward direction Dx.

[0047] Furthermore, the forklift body 21 of the unmanned forklift 2 is provided with a plate-shaped reflecting member 93 on the straddle leg 21s that extends along the floor surface. The reflecting member 93 rises upward from the straddle leg 21s. A lateral surface 92 serving as the unmanned forklift-side reference position indicator 90 is formed on the reflecting member 93 so as to face the left-right direction Dy.

[0048] The fourth laser displacement meter 556 and the first laser displacement meter 551 detect a part of the unmanned forklift 2 in order to measure the amount of positional deviation of the adjustment pallet 50 relative to the unmanned forklift 2 when the item is picked up.

[0049] The fourth laser displacement meter 556 measures the distance to the forward faces 91 of the pair of forks 22 by irradiating the laser onto the forward faces 91 serving as the unmanned forklift-side reference position indicators 90 along the rear side Dx1 in the forward / backward direction Dx. In the first embodiment, a pair of fourth laser displacement meter 556 is arranged at an interval in the left-right direction Dy to match the pair of forks 22. From the difference in the distance to the forward faces 91 of the forks 22 measured by the pair of fourth laser displacement meter 556, it is also possible to detect a rotational deviation of the adjustment pallet 50 about the vertical axis relative to the unmanned forklift 2.

[0050] The first laser displacement meter 551 emits a laser beam toward the right side Dy2 in the left-right direction Dy, and measures the distance to the lateral surface 92 of the reflecting member 93 serving as the unmanned forklift side reference position display unit 90.

[0051] The fourth laser displacement meter 556 and the first laser displacement meter 551 respectively detect the laser reflected by the forward surface 91 and the lateral surface 92 of the unmanned forklift side reference position display unit 90. When the fourth laser displacement meter 556 and the first laser displacement meter 551 respectively detect the laser reflected by the forward surface 91 and the lateral surface 92, they detect the distance to the forward surface 91 and the lateral surface 92.

[0052] When obtaining relative position information of the adjustment pallet 50 with respect to the unmanned forklift 2, the fourth laser displacement meter 556 and the first laser displacement meter 551 are configured to operate in a state in which the adjustment pallet 50 is supported by the forks 22 of the unmanned forklift 2. For this reason, the forks 22 may be equipped with a pallet sensor (not shown) that detects that the adjustment pallet 50 has been picked up.

[0053] Furthermore, in the forklift body 21 of the unmanned forklift 2 according to the first embodiment, the straddle legs 21s that extend along the floor surface are further provided with plate-shaped reflective members 94. The reflective members 94 rise obliquely upward from the straddle legs 21s. An upper front surface 95 serving as the unmanned forklift-side reference position indicator 90 is formed on the reflective member 94 so as to face obliquely upward and to the forward side Dx2 in the forward / backward direction Dx.

[0054] (Procedure for initial setup of unmanned forklift) Next, the procedure of the initial setting method for the unmanned forklift according to the first embodiment will be described with reference to FIGS.

[0055] FIG. 7 is a diagram illustrating a process for acquiring the relative position of the adjustment pallet with respect to the rack structure when placing an article on the second or third layer of the rack structure. FIG. 8 is a diagram illustrating the process of acquiring the relative position of the adjustment pallet with respect to the forklift when picking up goods from the second or third layer of the rack structure. FIG. 9 is a diagram illustrating a process for acquiring the relative position of the adjustment pallet with respect to the rack structure when placing an article on the first layer of the rack structure. FIG. 10 is a diagram illustrating a process for acquiring the relative position of the adjustment pallet with respect to the forklift when picking up goods from the first layer of the rack structure.

[0056] (Place luggage on the second and third floors) First, with reference to FIG. 7, a process for acquiring the relative position of the adjustment pallet 50 with respect to the rack structure 100 when placing goods on the second or third layer of the rack structure 100 will be described. When placing an item on the second or third layer of the rack structure 100, the operator supports the adjustment pallet 50 in the "forward direction" and then places it on the pallet placement section S of the second or third layer. The state after being placed in this manner is as shown in Figure 7. In other words, the adjustment pallet 50 is placed on the pallet placement section S of the second or third layer of the rack structure 100 in the forward direction. The process in this case is as described in Patent Document 2 (JP 2023-67706 A). That is, the first laser displacement meter 551 measures the distance to the front support 102F (not shown in FIG. 7), and the third laser displacement meter 555 measures the distance to the rear beam 103R.

[0057] (Picking up from the second and third floors) Next, with reference to FIG. 8, a process for acquiring the relative position of the adjustment pallet 50 with respect to the unmanned forklift 2 when picking up goods from the second or third layer of the rack structure 100 will be described. When removing an item from the second or third layer of the rack structure 100, the operator removes the adjustment pallet 50 placed in the "forward direction." The state after removal in this manner is as shown in Figure 8. In other words, the adjustment pallet 50 is supported in the forward direction by the forks 22 of the unmanned forklift 2. The process in this case is as described in Patent Document 2 (JP 2023-67706 A). That is, the first laser displacement meter 551 measures the distance to the reflecting member 93 having the lateral surface 92 (FIG. 6), and the fourth laser displacement meter 556 measures the distance to the forward surface 91 of the fork 22 (in FIG. 8, the fork 22 is in a position (upper side) immediately after picking up the goods, so the first laser displacement meter 551 and the reflecting member 93 are not in an opposing positional relationship, but in reality, the fork 22 is subsequently lowered to bring the first laser displacement meter 551 and the reflecting member 93 into an opposing positional relationship).

[0058] (Place luggage on the first floor) Next, with reference to FIG. 9, a process for acquiring the relative position of the adjustment pallet 50 with respect to the rack structure 100 when placing an article on the first layer of the rack structure 100 will be described. When placing an item on the first layer of the rack structure 100, the operator supports the adjustment pallet 50 in the "reverse direction" and then places it on the pallet placement section S (floor surface F) of the first layer. The state after being placed in this manner is as shown in Figure 9. In other words, the adjustment pallet 50 is placed on the pallet placement section S of the first layer of the rack structure 100 in the reverse direction. Because the adjustment pallet 50 is placed in the reverse direction, the second laser displacement meter 552 is located on the rear side Dx1 in the forward / backward direction Dx. With this arrangement, the second laser displacement meter 552 measures the distance to the front support 102F (not shown in FIG. 7). Furthermore, because the adjustment pallet 50 is placed in the opposite direction, the fourth laser displacement meter 556 emits a laser toward the forward side Dx2 in the advance / retract direction Dx. Therefore, the fourth laser displacement meter 556 measures the distance to a reflector P attached to the rack structure 100 so that the fourth laser displacement meter 556 is positioned on the forward side Dx2 in the advance / retract direction Dx. Here, the reflector P may be a blank sheet of paper or the like that is temporarily fixed with a magnet at the back of the first layer of the rack structure 100 (on the forward side Dx2).

[0059] (Picking up from the first layer) Next, with reference to FIG. 10, a process for acquiring the relative position of the adjustment pallet 50 with respect to the unmanned forklift 2 when picking up goods from the first layer of the rack structure 100 will be described. When removing an item from the first layer of the rack structure 100, the operator removes the adjustment pallet 50 placed in the "reverse direction." The state after removal in this manner is as shown in Figure 10. In other words, the adjustment pallet 50 is supported in the reverse direction by the forks 22 of the unmanned forklift 2. Because the adjustment pallet 50 is supported in the reverse direction, the second laser displacement meter 552 is located on the rear side Dx1 in the forward / backward direction Dx. With this arrangement, the second laser displacement meter 552 measures the distance to the reflecting member 93 having the lateral surface 92 (FIG. 6). Furthermore, because the adjustment pallet 50 is supported in the reverse direction, the third laser displacement meter 555 emits a laser beam downward toward the rear side Dx1 in the forward / backward direction Dx. With this arrangement, the third laser displacement meter 555 measures the distance to the reflecting member 94 having an upper forward surface 95 (FIG. 6).

[0060] As described above, in the initial setting method for the unmanned forklift according to the first embodiment, when the adjustment pallet 50 is placed on the first layer (when placed on the floor surface F), it is placed in the opposite orientation to when placed on the second or higher layer. By doing so, it is possible to obtain the amount of deviation in both the forward / backward direction (Dx) and the left / right direction (Dy) when placed on the first layer without changing the configuration of the adjustment pallet 50. The same applies to obtaining the amount of deviation from the unmanned forklift 2 when picking up goods from each layer.

[0061] Second Embodiment An initial setting method for an unmanned forklift according to the second embodiment will be described with reference to FIGS.

[0062] First, the specific configuration of the unit PI will be described with reference to Fig. 11. The unit PI is a unit provided to facilitate attachment and detachment of the third laser displacement meter 555 to the pallet body 51 and adjustment of the irradiation direction.

[0063] Specifically, as shown in FIG. 11, the unit PI includes a third laser displacement meter 555, a displacement meter support member 51a, and an angle adjustment member 51b. The third laser displacement meter 555 is fixed to the angle adjustment member 51b with a screw (not shown) or the like. The angle adjustment member 51b is screwed to the surface of the displacement gauge support member 51a extending in the up-down direction Dv at a center position O and an adjustment position T. An elongated hole is cut in the displacement gauge support member 51a at a position corresponding to the adjustment position T, in the shape of an arc centered on the center position O, and the irradiation angle can be changed (adjusted) by changing the adjustment position T of this elongated hole. The displacement gauge support member 51a has a screw hole Q on a surface extending in the left-right direction Dy, and is fixed to the pallet main body 51 with a screw through this screw hole Q.

[0064] Next, the configuration of an adjustment pallet 50 according to a second embodiment will be described with reference to FIGS. The adjustment pallet 50 according to the second embodiment differs from the first embodiment in that it includes a replacement support 51c.

[0065] 12 and 13, a replacement support 51c is provided on the pallet body 51 of the adjustment pallet 50. The replacement support 51c is configured so that a flat surface (mounting surface SF) is located near the center of the pallet body 51 in the forward / backward direction Dx, at a position higher in the up-down direction Dv than the top surface of the pallet body 51. Note that the replacement support 51c according to the second embodiment has a hollowed-out structure in the center so as not to interfere with other devices installed near the center of the top surface of the pallet body 51, but other embodiments are not limited to this configuration. In the second embodiment, the position where the third laser displacement meter 555 is installed so as to emit a laser diagonally downward on the forward side Dx2 of the forward / backward direction Dx, as shown in Figures 12 and 13, is defined as the "default position" of the third laser displacement meter 555.

[0066] As shown in Fig. 14, the mounting surface SF of the replacement support 51c allows the unit PI, which has been removed from its predetermined position, to be replaced while being turned upside down. Here, the position on the mounting surface SF where the unit PI can be attached upside down is defined as the "replacement position." The third laser displacement meter 555 of the unit PI installed at the "replacement position" emits a laser beam diagonally upward on the forward side Dx2 in the forward / backward direction Dx. As described above, the replacement support body 51c has a replacement position where the third laser displacement meter 555, which has been removed from its predetermined position, can be attached upside down.

[0067] Next, with reference to FIG. 15, a process of acquiring the relative position of the adjustment pallet 50 with respect to the rack structure 100 in the second embodiment when placing an article on the first layer of the rack structure 100 will be described.

[0068] When placing an item on the first layer of the rack structure 100, the operator supports the adjustment pallet 50 in the forward direction, moves the third laser displacement meter 555 (unit PI) from the "default position" to the "replacement position," and places it on the first-layer pallet placement section S (floor surface F). The state after being placed in this manner is as shown in FIG. 15. That is, when the adjustment pallet 50 is placed on the first-layer pallet placement section S, the third laser displacement meter 555 emits a laser beam from the upper surface of the replacement support 51c toward the forward side Dx2 in the advance / retract direction Dx and obliquely upward. With this configuration, the third laser displacement meter 555 measures the distance to the rear beam 103R, which is located above and forward side Dx2 in the advance / retract direction Dx. Furthermore, the first laser displacement meter 551 measures the distance to the front support 102F (not shown in FIG. 15) in the same way as when it is placed on the second or third floor in the first embodiment (FIG. 7).

[0069] In the initial setting method according to the second embodiment, the process of acquiring relative position information between the adjustment pallet 50 and the unmanned forklift 2 is as follows. That is, in the process of acquiring relative position information between the adjustment pallet 50 and the unmanned forklift 2, the operator retrieves the adjustment pallet 50 placed in the "forward direction" on the first layer of the rack structure 100 (see FIG. 15), and therefore, it is possible to acquire relative position information with the unmanned forklift 2 in the same procedure as when retrieving an item from the second or third layer in the first embodiment. Therefore, in the initial setting method according to the second embodiment, the operator does not need to install a reflective member 94 (FIG. 6) having an upper forward surface 95 on the unmanned forklift 2.

[0070] On the other hand, when placing an item on the second or third layer and obtaining relative position information between the adjustment pallet 50 and the rack structure 100, and when removing an item from the second or third layer and obtaining relative position information between the adjustment pallet 50 and the unmanned forklift 2, the same procedures as in the first embodiment are used. In other words, when placing an item on the second or third layer of the rack structure 100, the operator supports the adjustment pallet 50 in the forward direction, installs the third laser displacement meter 555 (unit PI) in the "default position," and places it on the pallet placement section S on the second or third layer.

[0071] As described above, in the initial setting method for the unmanned forklift according to the second embodiment, in the step of placing the adjustment pallet 50 on the rack structure 100, if the adjustment pallet 50 is to be placed on the second or higher layer of the rack structure 100, the third laser displacement meter 555 is installed in the "default position" and placed on the rack structure 100, and if the adjustment pallet 50 is to be placed on the first layer of the rack structure 100, the third laser displacement meter 555 is installed in the "replacement position" and placed on the rack structure 100. By adopting this configuration, even when placed on the first layer of the rack structure 100, relative position information with respect to the rack structure 100 can be obtained by measuring the distance to the rear beam member 103R, which is located diagonally above the front side Dx2 in the forward / backward direction Dx.

[0072] Third Embodiment An initial setting method for an unmanned forklift according to the third embodiment will be described with reference to FIG.

[0073] First, the configuration of the adjustment pallet 50 according to the third embodiment will be described. As shown in FIG. 16 , an adjustment pallet 50 according to the third embodiment is characterized in that, in addition to the configuration of the adjustment pallet 50 according to the first embodiment, the pallet main body 51 is provided with a scale member 51d extending along the forward / backward direction Dx. Specifically, the scale member 51d is installed so as to extend along each of the left end face Dy1 and the right end face Dy2 of the pallet main body 51 in the left-right direction Dy. The scale member 51d is installed so as to protrude at least further rearward Dx1 than the end face of the pallet main body 51 on the rearward side Dx1 in the forward / backward direction Dx. The scale member 51d is graduated at intervals of, for example, ···, −8 mm, −5 mm, −3 mm, 0 mm, +3 mm, +5 mm, +8 mm, +10 mm, +12 mm, ···, and the like. The 0 mm position (reference position) of the scale member 51d may be aligned with the end face on the rear side Dx1 in the advance / retract direction Dx of the pallet main body 51, and a negative scale may be provided on the portion protruding toward the rear side Dx1. The scale member 51d may be detachable from the pallet main body 51 via a magnet, for example.

[0074] Next, a process of acquiring the relative position of the adjustment pallet 50 with respect to the rack structure 100 in the case where an article is placed on the first layer of the rack structure 100 in the third embodiment will be described. 16 shows a state in which the adjustment pallet 50 is placed on the first layer (floor surface F) of the rack structure 100 as viewed from above. In the third embodiment, a marking line L extending in the left-right direction Dy from the front surface (reference surface 102Fm) of the front support 102F is provided in advance on the floor surface F. Then, the operator reads the position of the marking line L from the scale of the scale member 51d of the adjustment pallet 50 placed on the first layer. This allows information on the relative position between the adjustment pallet 50 and the rack structure 100 when placed on the first layer to be obtained.

[0075] As described above, in the initial setting method for the unmanned forklift according to the third embodiment, when the forklift is placed on the first layer of the rack structure, the operator acquires, via the scale member 51d, the relative position of the adjustment pallet 50 in the forward / backward direction Dx with respect to the reference position of the rack structure 100 (the marking line L extending parallel to the reference surface 102Fm). Then, via the second laser displacement meter 552, the operator acquires the distance to the front support 102F located in the left-right direction Dy of the adjustment pallet 50. By doing so, it is possible to obtain relative position information when the substrate is placed on the first layer through a simpler and more reliable process compared to the first and second embodiments.

[0076] As a modification of the third embodiment, for example, the following may be performed. That is, in the modified example, the marking line L does not necessarily have to be provided, and the positional relationship between the scale member 51d and the reference surface 102Fm may be visually measured. Alternatively, the operator may wear AR (Augmented Reality) glasses or the like and acquire an image including the scale member 51d and the front support column 102F through the AR glasses. In this case, the relative position in the forward / backward direction Dx may be calculated through image processing by the AR glasses and provided to the operator.

[0077] In the above-described embodiments, the rack structure 100 has been described as having a three-layer structure including a lower layer 100b (first layer), a middle layer 100m (second layer), and an upper layer 100t (third layer), but this is not limited to this in other embodiments. That is, the rack structure 100 according to another embodiment may have a four or more layer structure. In this case, the step of acquiring relative position information for the fourth layer or higher may be equivalent to the step of acquiring relative position information for the second and third layers described in the above-described embodiments.

[0078] <Additional Notes> The initial setting method and adjustment pallet of the unmanned forklift 2 described in each of the above-described embodiments can be understood, for example, as follows.

[0079] (1) An initial setting method for an unmanned forklift according to a first aspect is an initial setting method performed using an adjustment pallet (50) when introducing an unmanned forklift (2) into a facility equipped with a rack structure (100), the adjustment pallet comprising: a pallet body that can be supported by the forks of the unmanned forklift and that can be placed on the rack structure; and a position information acquisition unit (53) that is provided on the pallet body and acquires relative position information with respect to the rack structure when the adjustment pallet is placed on the rack structure, the position information acquisition unit comprising: a first laser displacement meter (551) that is arranged on the rear side of the advancing / retreating direction of the unmanned forklift relative to the rack structure when the adjustment pallet is supported in the forward direction by the forks of the unmanned forklift; a second laser displacement meter (552) that is arranged on the front side of the advancing / retreating direction and emits a laser in the left-right direction; and a third laser displacement meter (553) that emits a laser diagonally downward on the front side of the advancing / retreating direction. and a fourth laser displacement meter (556) that emits a laser toward the rear side in the forward / backward direction, and the initial setting method includes the steps of: placing the adjustment pallet on the rack structure by the unmanned forklift based on a preset operation program; acquiring relative position information between the adjustment pallet and the rack structure by the position information acquisition unit provided in the adjustment pallet; and calculating the amount of deviation of the adjustment pallet placed on the rack structure with respect to the rack structure based on the relative position information, wherein in the step of placing the adjustment pallet on the rack structure, when the adjustment pallet is to be placed on a second or higher layer of the rack structure, the adjustment pallet is placed while being supported in the forward direction by the forks of the unmanned forklift, and when the adjustment pallet is to be placed on the first layer of the rack structure, the adjustment pallet is placed while being supported in a reverse direction that is opposite to the forward direction by the forks of the unmanned forklift.

[0080] (2) The initial setting method for an unmanned forklift according to a second aspect is the initial setting method for an unmanned forklift described in (1), wherein the step of acquiring relative position information between the adjustment pallet and the rack structure includes, when the adjustment pallet is placed on the second or higher layer of the rack structure, acquiring the distance to a rear beam member located below the adjustment pallet in the forward / backward direction through the third laser displacement meter (555), and acquiring the distance to a front support column located in the left / right direction of the adjustment pallet through the first laser displacement meter (551); and, when the adjustment pallet is placed on the first layer of the rack structure, further includes, when the adjustment pallet is placed on the first layer of the rack structure, acquiring the distance to a reflector provided on the rack structure located in the forward / backward direction of the adjustment pallet through the fourth laser displacement meter (556), and acquiring the distance to a front support column located in the left / right direction of the adjustment pallet through the second laser displacement meter (552).

[0081] (3) The initial setting method for an unmanned forklift according to the third aspect is the initial setting method for an unmanned forklift described in (1) or (2), which acquires relative position information of the unmanned forklift when supported by the forks of the unmanned forklift, and further includes the steps of: using the unmanned forklift to pick up the adjustment pallet based on a preset operating program; acquiring relative position information between the adjustment pallet and the unmanned forklift using the position information acquisition unit provided in the adjustment pallet; and calculating the amount of deviation of the adjustment pallet with respect to the unmanned forklift based on the relative position information between the adjustment pallet and the unmanned forklift.

[0082] (4) The initial setting method for an unmanned forklift according to a fourth aspect is the initial setting method for an unmanned forklift described in (3), and in the step of acquiring relative position information between the adjustment pallet and the unmanned forklift, if the cargo is picked up from the second or higher layer of the rack structure, the step of acquiring the distance from the forward-facing surface of the fork of the unmanned forklift through the fourth laser displacement meter (556) and the step of acquiring the distance from a reflective member having a lateral surface attached to the unmanned forklift through the first laser displacement meter (551); and in the case of picking up from the first layer of the rack structure, the step of acquiring the distance from the reflective member having an upward forward-facing surface attached below the rear side of the unmanned forklift in the forward / backward direction through the third laser displacement meter (555) and the step of acquiring the distance from the reflective member having the lateral surface through the second laser displacement meter (552).

[0083] (5) An adjustment pallet according to a fifth aspect is an adjustment pallet used in an initial setting method when an unmanned forklift is introduced into a facility equipped with a rack structure, and comprises a pallet body that can be supported by the forks of the unmanned forklift and placed on the rack structure, a replacement support attached to the pallet body, and a position information acquisition unit that is attached to the pallet body and acquires relative position information with respect to the rack structure when the adjustment pallet is placed on the rack structure, and the position information acquisition unit acquires the forward movement of the unmanned forklift relative to the rack structure when the adjustment pallet is supported in a forward direction by the forks of the unmanned forklift. The pallet body is provided with a first laser displacement meter (551) that is arranged on the rear side in the retreat direction and emits a laser in a left-right direction that intersects with the advance / retract direction in a horizontal plane, a second laser displacement meter (552) that is arranged on the front side in the advance / retract direction and emits a laser in the left-right direction, a third laser displacement meter (555) that is provided at a predetermined position on the pallet body and emits a laser diagonally downward on the front side in the advance / retract direction, and a fourth laser displacement meter (556) that emits a laser toward the rear side in the advance / retract direction, and the replacement support body has a replacement position where the third laser displacement meter (555) that has been removed from the predetermined position can be installed upside down.

[0084] (6) A sixth aspect of the present invention relates to an initial setting method for an unmanned forklift, which is performed using the adjustment pallet described in (5) when introducing an unmanned forklift into a facility equipped with a rack structure, and includes the steps of: placing the adjustment pallet on the rack structure by the unmanned forklift based on a preset operation program; acquiring relative position information between the adjustment pallet and the rack structure by a position information acquisition unit equipped in the adjustment pallet; and calculating, based on the relative position information, the amount of deviation of the adjustment pallet placed on the rack structure relative to the rack structure. In the step of placing the adjustment pallet on the rack structure, if the adjustment pallet is to be placed on a second or higher layer of the rack structure, the third laser displacement meter is installed at the predetermined position and placed on the rack structure, and if the adjustment pallet is to be placed on the first layer of the rack structure, the third laser displacement meter is installed at the replacement position and placed on the rack structure.

[0085] (7) An adjustment pallet according to a seventh aspect is an adjustment pallet used in an initial setting method when an unmanned forklift is introduced into a facility equipped with a rack structure, and includes a pallet body that can be supported by the forks of the unmanned forklift and placed on the rack structure, and a position information acquisition unit that is provided on the pallet body and acquires relative position information with respect to the rack structure when the adjustment pallet is placed on the rack structure, and the position information acquisition unit acquires relative position information of the unmanned forklift with respect to the rack structure when the adjustment pallet is supported in a forward direction by the forks of the unmanned forklift. The pallet body is provided with a first laser displacement meter (551) that is arranged on the rear side of the advancing / retreating direction of the lift and emits a laser in a left-right direction that intersects with the advancing / retreating direction in a horizontal plane, a second laser displacement meter (552) that is arranged on the front side of the advancing / retreating direction and emits a laser in the left-right direction, a third laser displacement meter (555) that is provided at a predetermined position on the pallet body and emits a laser diagonally downward on the front side of the advancing / retreating direction, and a fourth laser displacement meter (556) that emits a laser toward the rear side of the advancing / retreating direction, and the pallet body is provided with a scale member that extends along the advancing / retreating direction.

[0086] (8) An initial setting method for an unmanned forklift according to an eighth aspect is an initial setting method performed using the adjustment pallet described in (7) when introducing an unmanned forklift into a facility equipped with a rack structure, and includes the steps of: placing the adjustment pallet on the rack structure by the unmanned forklift based on a preset operation program; acquiring relative position information between the adjustment pallet and the rack structure by a position information acquisition unit equipped in the adjustment pallet; and calculating a deviation amount of the adjustment pallet placed on the rack structure relative to the rack structure based on the relative position information; wherein the step of acquiring the relative position information between the adjustment pallet and the rack structure When the adjustment pallet is placed on the second or higher layer of the rack structure, the adjustment pallet includes a step of acquiring the distance to a rear beam member located below the front side of the adjustment pallet in the forward / backward direction through the third laser displacement meter (555), and a step of acquiring the distance to a front support column located in the left / right direction of the adjustment pallet through the first laser displacement meter (551), and when the adjustment pallet is placed on the first layer of the rack structure, the adjustment pallet includes a step of acquiring the relative position of the adjustment pallet in the forward / backward direction with respect to a reference position of the rack structure through the scale member, and a step of acquiring the distance to a front support column located in the left / right direction of the adjustment pallet through the second laser displacement meter (552). [Explanation of symbols]

[0087] 1. Automated transport forklift system 2...Unmanned forklift 3...System controller 21...Forklift body 22...Fork 23...Forklift control unit 50...Adjustment palette 51...Pallet body 51a...Displacement gauge support member 51b...Angle adjustment member 51c…Replacement support 51d...Scale material 52...insertion hole 53...Location information acquisition unit 551...First laser displacement meter (laser displacement meter) 552...Second laser displacement meter (laser displacement meter) 553...Intermediate laser displacement meter (laser displacement meter) 555...Third laser displacement meter (laser displacement meter) 556...Fourth laser displacement meter (laser displacement meter) 56...Data transmission unit 100...Rack structure 100b...Lower floor (1st floor) 100m...Middle layer (2nd layer) 100t...Upper floor (3rd floor) 102…post 102F…Front support 102R…rear support 103...Beam material 103F...Front beam material 103R...Rear beam material 103S...Side beam material Dv…Vertical direction Dx…Advance / retreat direction Dx1…Back side Dx2...front side Dy…Left and right direction Dy1…Left side Dy2…Right side F…Floor surface R...Route S...Pallet placement section L...marking line

Claims

1. An initial setting method using an adjustment pallet when introducing an unmanned forklift into a facility equipped with a rack structure, The adjustment palette is a pallet body that can be supported by the forks of the unmanned forklift and placed on a rack structure; a position information acquisition unit provided on the pallet body and configured to acquire relative position information with respect to the rack structure when the pallet body is placed on the rack structure, The location information acquisition unit When the adjustment pallet is supported in the forward direction by the forks of the unmanned forklift, a first laser displacement meter that is disposed on the rear side of the rack structure in a direction in which the unmanned forklift truck advances and retreats, and that emits a laser in a left-right direction that intersects with the direction in which the unmanned forklift truck advances and retreats within a horizontal plane; a second laser displacement meter that is disposed on the front side in the forward / backward direction and emits a laser in the left-right direction; a third laser displacement meter that emits a laser beam diagonally downward toward the front side in the forward / backward direction; a fourth laser displacement meter that emits a laser toward the rear side in the advance / retract direction; It is equipped with The initial setting method includes: placing the adjustment pallet on the rack structure by the unmanned forklift truck based on a preset operation program; acquiring relative position information between the adjustment pallet and the rack structure by the position information acquisition unit included in the adjustment pallet; calculating a deviation amount of the adjustment pallet placed on the rack structure relative to the rack structure based on the relative position information; Including, In the step of placing the adjustment pallet on the rack structure, When placing the adjustment pallet on the second or higher layer of the rack structure, the adjustment pallet is supported in the forward direction by the forks of the unmanned forklift and placed thereon; When placing the adjustment pallet on the first layer of the rack structure, the adjustment pallet is supported by the forks of the unmanned forklift in a reverse direction that is a direction opposite to the forward direction and placed thereon. How to set up an unmanned forklift.

2. In the step of acquiring relative position information between the adjustment pallet and the rack structure, When placed on the second or higher layer of the rack structure, A step of acquiring a distance to a rear beam material located below the front side of the adjustment pallet in the forward / backward direction using the third laser displacement meter; acquiring a distance between the adjustment pallet and a front support column located in the left-right direction of the adjustment pallet through the first laser displacement meter; Including, When placed on the first layer of the rack structure, acquiring, via the fourth laser displacement meter, a distance to a reflector provided on the rack structure that is positioned forward in the advancing / retreating direction of the adjustment pallet; Obtaining a distance between the adjustment pallet and a front support column located in the left-right direction of the adjustment pallet through the second laser displacement meter; Including, The method for initializing an unmanned forklift according to claim 1.

3. The position information acquisition unit of the adjustment pallet further acquires relative position information with respect to the unmanned forklift when the adjustment pallet is supported by the forks of the unmanned forklift, a step of loading the adjustment pallet with the unmanned forklift truck based on a preset operation program; acquiring relative position information between the adjustment pallet and the unmanned forklift by the position information acquisition unit included in the adjustment pallet; calculating a deviation amount of the adjustment pallet with respect to the unmanned forklift based on relative position information between the adjustment pallet and the unmanned forklift; The method for initializing an unmanned forklift according to claim 1 or 2, further comprising:

4. In the step of acquiring relative position information between the adjustment pallet and the unmanned forklift, When cargo is taken from the second or higher layer of the rack structure, Obtaining a distance to a forward surface of a fork of the unmanned forklift through the fourth laser displacement meter; acquiring a distance to a reflective member having a lateral surface provided on the unmanned forklift through the first laser displacement meter; Including, When loading from the first layer of the rack structure, acquiring, via the third laser displacement meter, a distance to a reflecting member provided below the rear side of the unmanned forklift in the forward / backward direction and having an upper forward-facing surface; acquiring a distance to the reflecting member having the lateral surface through the second laser displacement meter; Including, The method for initializing an unmanned forklift according to claim 3.

5. An adjustment pallet used in an initial setting method when introducing an unmanned forklift into a facility equipped with a rack structure, a pallet body that can be supported by the forks of the unmanned forklift and placed on a rack structure; A replacement support member installed on the pallet body; a position information acquisition unit provided on the pallet body and acquiring relative position information with respect to the rack structure when the pallet body is placed on the rack structure; Equipped with The location information acquisition unit When the adjustment pallet is supported in the forward direction by the forks of the unmanned forklift, a first laser displacement meter that is disposed on the rear side of the rack structure in a direction in which the unmanned forklift truck advances and retreats, and that emits a laser in a left-right direction that intersects with the direction in which the unmanned forklift truck advances and retreats within a horizontal plane; a second laser displacement meter that is disposed on the front side in the forward / backward direction and emits a laser in the left-right direction; a third laser displacement meter provided at a predetermined position on the pallet body and emitting a laser diagonally downward toward the front side in the advancing / retreating direction; a fourth laser displacement meter that emits a laser toward the rear side in the advance / retract direction; Equipped with the replacement support has a replacement position at which the third laser displacement meter removed from the predetermined position can be attached upside down, Adjustment palette.

6. 6. An initial setting method using the adjustment pallet according to claim 5 when introducing an unmanned forklift into a facility equipped with a rack structure, comprising: placing the adjustment pallet on the rack structure by the unmanned forklift truck based on a preset operation program; acquiring relative position information between the adjustment pallet and the rack structure by the position information acquisition unit included in the adjustment pallet; calculating a deviation amount of the adjustment pallet placed on the rack structure relative to the rack structure based on the relative position information; Including, In the step of placing the adjustment pallet on the rack structure, When the laser displacement sensor is to be placed on the second or higher layer of the rack structure, the third laser displacement sensor is installed at the predetermined position and placed on the rack structure; When the laser displacement meter is to be placed on the first layer of the rack structure, the third laser displacement meter is installed at the replacement position and placed on the rack structure. How to set up an unmanned forklift.

7. An adjustment pallet used in an initial setting method when introducing an unmanned forklift into a facility equipped with a rack structure, a pallet body that can be supported by the forks of the unmanned forklift and placed on a rack structure; a position information acquisition unit provided on the pallet body and acquiring relative position information with respect to the rack structure when the pallet body is placed on the rack structure; Equipped with The location information acquisition unit When the adjustment pallet is supported in the forward direction by the forks of the unmanned forklift, a first laser displacement meter that is disposed on the rear side of the rack structure in a direction in which the unmanned forklift truck advances and retreats, and that emits a laser in a left-right direction that intersects with the direction in which the unmanned forklift truck advances and retreats within a horizontal plane; a second laser displacement meter that is disposed on the front side in the forward / backward direction and emits a laser in the left-right direction; a third laser displacement meter provided at a predetermined position on the pallet body and emitting a laser diagonally downward toward the front side in the advancing / retreating direction; a fourth laser displacement meter that emits a laser toward the rear side in the advance / retract direction; Equipped with The pallet body includes a scale member extending along the forward / backward direction. Adjustment palette.

8. 10. An initial setting method performed using the adjustment pallet according to claim 7 when introducing an unmanned forklift into a facility equipped with a rack structure, comprising: placing the adjustment pallet on the rack structure by the unmanned forklift truck based on a preset operation program; acquiring relative position information between the adjustment pallet and the rack structure by the position information acquisition unit included in the adjustment pallet; calculating a deviation amount of the adjustment pallet placed on the rack structure relative to the rack structure based on the relative position information; Including, In the step of acquiring relative position information between the adjustment pallet and the rack structure, When placed on the second or higher layer of the rack structure, A step of acquiring a distance to a rear beam material located below the front side of the adjustment pallet in the forward / backward direction using the third laser displacement meter; acquiring a distance between the adjustment pallet and a front support column located in the left-right direction of the adjustment pallet through the first laser displacement meter; Including, When placed on the first layer of the rack structure, acquiring a relative position of the adjustment pallet in the forward / backward direction with respect to a reference position of the rack structure through the scale member; Obtaining a distance between the adjustment pallet and a front support column located in the left-right direction of the adjustment pallet through the second laser displacement meter; Including, How to set up an unmanned forklift.

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