Automatic adsorption loading assist device

Abstract

To provide a technique relating to the configuration of an automatic adsorption loading assist device aimed at ensuring safety, reducing the labor of operators and saving the labor of the operators and relating to a safety ensuring method and a drive control method for safely and efficiently carrying out a process of moving and loading heavy paper bags or the like.SOLUTION: An automatic adsorption loading assist device assists a process of conveying paper bags or the like in a form in which holding force is increased by a synergistic effect of mechanical restraining force of a holding hand and adsorption-based restraining force utilizing a suction function of suction pads. Specifically, the device has a function that stably holds paper bags or the like packaging heavy starch or the like in an unstable shape, and conveys them from a predetermined storage position to a predetermined transport position, automatically applies an adhesive during the conveying process, and assists loading in a stable form.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to the configuration of an automatic suction loading assist device and to the technology related to the work assistance method, control method, and safety assurance method in each process for safely and efficiently transporting and orderly loading heavy items such as paper bags. [Background technology]

[0002] In order to transport paper bags or the like packed with powder materials such as starch, it is common to use dedicated equipment such as a forklift to load them onto a transport pallet.

[0003] Generally, the paper bags in question are heavy and unstable in shape, so the work requires heavy labor and high levels of caution from the workers. Because the bags are heavy, it is an extremely dangerous job if the load collapses.

[0004] The automatic suction loading assist device is equipped with a suction pad and holding hand on a robot arm, and has functions for holding, transporting, loading and ensuring safety for paper bags and other items, making it possible to assist each process of loading them onto transport pallets safely and efficiently, thereby reducing the labor required for workers, improving the efficiency of throughput times in each process and complementing safety assurance tasks.

[0005] Because it uses an electric air suction mechanism and an electric robot arm, it is possible to reduce noise during loading and unloading operations and improve the working environment caused by flammable fuel compared to support devices such as forklifts that use flammable fuel.

[0006] Since the system is built around control by electrical signals, it is important to have an automatic suction loading assist function that can easily integrate with safety sensor signals and remotely control the functions of holding, transporting, and loading paper bags, etc., thereby complementing the labor required for each process. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Patent Publication No. 2023-125848 [Patent Document 2] Patent Publication No. 2022-098172 [Patent Document 3] Patent Publication No. 2022-092237 [Patent Document 4] Patent Publication No. 2023-548539 [Patent Document 5] Patent Publication No. 2022-079576 [Patent Document 6] Patent Publication No. 2021-118203 [Patent Document 7] Patent Publication No. 2023-158273 [Patent Document 8] Patent Publication No. 2022-056344 Summary of the Invention [Problem to be solved by the invention]

[0008] The equipment used to move and load paper bags packed with powder materials such as starch from an accumulation area (pallets and belt conveyors, etc.) to a transportation area (pallets) is heavy and large in shape, and because it is in a paper bag state, it requires a lifting mechanism for transporting and loading heavy objects, and tends to be large and heavy. Currently, in order to operate larger and heavier equipment, operations are often carried out using large equipment such as forklifts that use flammable fuel as a power source.

[0009] The maneuverability of large equipment requires dedicated operators, and the loading process takes time and requires many operators to monitor the safety of the loading condition.

[0010] The present invention solves the above-mentioned problems and provides the configuration of an automatic suction loading assist device that is safe and reduces the labor required by operating personnel, and provides technology related to a safety method and drive control method for safely and efficiently moving and loading heavy items such as paper bags. [Means for solving the problem]

[0011] The present invention, which solves the above-mentioned problems, is an automatic suction loading assist device. By adopting an automatic suction assist system consisting of an automatic transport arm with automatic suction and automatic restraint functions and an automatic adhesive application function that automatically applies adhesive, it is possible to efficiently, safely and reliably move powder materials packed in heavy and unstable-shaped paper bags, etc. from a storage state to a transportation state and load them in an orderly manner.

[0012] As shown in Figure 1, the automatic suction loading assist device is composed of a suction pad (a), holding hand (b), transport arm (c), device control unit (d) including power supply function, transport arm control unit (e), suction control unit (f), vision sensor units (g1) and (g2), vision sensor control unit (h) and adhesive application unit (i).The device itself has the function of holding and transporting paper bags, etc., and applying adhesive, allowing for efficient and safe loading.

[0013] The power supply function of this device is activated by the start-up control operation of the device control unit (d), which then activates the motor that operates the transfer arm (c). In this case, the built-in self-test (BIT) function makes it possible to detect abnormalities before they occur, and if an obstacle is visually detected by the vision sensor (g2) attached to the transport arm (c), the device control unit (d) sends a stop signal to stop each drive motor.

[0014] As shown in Figure 2, the transport arm (c) recognizes the storage position and shape of the paper bags, etc. from a vision sensor such as a 3D camera, and performs path generation control to compensate for the difference between the position information of the transport arm (c) and the position information of the paper bags, etc. to be transported, thereby enabling trajectory control of the transport arm (c).

[0015] A motor is started to rotate the transport arm (c) in the optimal direction, and the holding hand (b) is directed to the optimal position for paper bags, etc. As shown in Figure 3, deviation information is generated from the target shape information, target position information, and holding hand position information from the vision sensors (g1) and (g2), and the transport arm (c) is used to control path generation, and the drive motor for the holding hand (b) is activated in six directions along three axes: pitch, roll, and yaw, so that the paired left and right holding hands (b) can hold paper bags, etc. from both sides.

[0016] As the holding hand (b) is driven, the suction pump is activated from the suction control unit (f), which sucks in air and appropriately operates the operating direction of the suction wind direction variable louver (53), allowing the suction pad (a) to adhere to a paper bag or the like. At this time, as shown in Figure 4, in order to operate the variable suction air direction louver (53) appropriately, the device control unit (d) can transmit a signal indicating the suction pump operating capacity and the time synchronization maintained by the holding hand (b) based on the position information from the vision sensor (g2) and the load deviation information from the load sensors (12) attached to the left and right of the holding hand (b).

[0017] The suction from the suction pad (a) effectively utilizes the breathability of the paper bag, etc., and by utilizing the perforated suction port (51) as shown in Figure 1-5 to suck the packed powder material, the paper bag, etc. is sucked uniformly from the inside toward the suction pad, so that it can adhere to the suction pad (a) in a more stable state than when only the outer paper bag is sucked.

[0018] As shown in Figure 5, the suction pad has two pairs of suction hoses (54) that correspond to the length of the paper bags, etc., and is equipped with variable airflow louvers (53) that can finely adjust the suction direction, and can finely adjust the suction force in the direction of weight deviation based on information from a load sensor attached to the holding hand (b). In order to increase the suction force in the direction of the excess weight, the suction force of the suction hose (54) in that direction is increased and the variable airflow direction louver (53) in the suction direction is also used to strengthen the suction force.

[0019] Paper bags and other items held by the holding hand (b) of the automatically driven transport arm (c) are adsorbed by a suction pad, allowing them to be transported reliably and stably from the storage pallet to the transport pallet.

[0020] In the process of moving paper bags, etc. from a storage pallet to a transport pallet, position information is received from the control unit (d), and a program that passes through the upper level of the adhesive application unit automatically applies adhesive to the underside of the paper bags, etc. at the application position. The adhesive application process can be carried out automatically during the transport process from storage pallets to transport pallets, making it possible to improve work efficiency and reduce labor.

[0021] The adhesive application process allows the upper and lower paper bags, etc. to form a stronger stacked state when loaded onto a transport pallet, reducing risk factors such as cargo collapse and contributing to improved safety.

[0022] The conveying arm (c) is rotated 360 degrees horizontally by a turntable incorporated in the holding part of the conveying arm (c) that receives position information signals from the device control unit (d). The arm has a trim function that allows for fine adjustments, allowing it to rotate in the optimal direction relative to the storage pallet or conveyor carrying the paper bags or other items to be transported.

[0023] By rotating the transport arm in the optimal direction, the suction pad (a) and holding hand (b) are directed to the optimal position relative to the paper bag, etc., and the paper bag, etc. is held in the optimal state.

[0024] The vision sensor (g1) monitors the entire loading process of paper bags, etc., controlled by the vision sensor operation control unit (h), and the vision sensor (g2) equipped on the transport arm (c) processes image information acquired by the vision sensor (g1) and monitors obstacles to the rotation of the transport arm, thereby enabling safe transport of paper bags, etc.

[0025] By operating an electric motor that extends and retracts the arm part equipped on the transport arm (c), the suction pad (a) and holding hand (b) can be moved to the optimal position for the paper bag, etc., and can approach the paper bag, etc.

[0026] By using a vision sensor (g1) installed in a location that can monitor the area where paper bags, etc. are transferred from the storage pallet to the transport pallet and a wearable camera (11) installed on the transport arm, abnormal approach and contact can be prevented, thereby making it possible to safely carry out the processes of holding, moving and loading paper bags, etc.

[0027] The device control unit (d) is composed of a processing unit that processes information from various vision sensors (g1) (g2), a display unit that transmits the processed information to the operating personnel, and an operation unit for inputting various operations.

[0028] The processing unit calculates the deviation direction and deviation distance from the positional difference during the process of transporting paper bags, etc., based on the position information (latitude and longitude) from the GPS (Global Positioning System) device equipped on the transport arm (c) and the position information of the storage pallet and transport pallet, controls the electric motor that drives the transport arm (c), and performs processing to control the operating distance of the extension and contraction of the transport arm (c).

[0029] The device control unit (d) has a BIT function that controls electrical signals and automatically determines connections with various sensor information, and an operation stick that switches to manual mode and stops operation in an emergency.

[0030] This transmits operational information to the electric motor indicating the optimal direction of movement of the transport arm (c), and drives the electric motor in the optimal direction.

[0031] The transfer arm (c) is directed to the optimum position and extends to a position where it can hold paper bags, etc., by driving an electric motor.

[0032] The holding hand (b) extended to the holding position checks the distance and holding angle to the paper bag, etc. using a wearable camera (11), and directs the holding hand (b) to the optimal position using a 3-axis, 6-direction (pitch, roll, yaw) rotation motor equipped on the arm that holds the holding hand (b).

[0033] With the holding hand (b) pointed in the direction detected by the vision sensor (g2) as the optimal position, the opposing holding hand on the opposite corner is operated in the closing direction to hold the paper bag or the like from both sides. In order to synchronize the holding state and suck with the suction pad (a), the suction pump is activated by a control signal from the suction control unit (f), and the paper bag or the like is also sucked and held by the suction pad (a).

[0034] The holding state of the paper bag or the like held by the suction pad (a) and holding hand (b) is detected by a load sensor (11) attached to the holding hand, and if any deviation in the holding state occurs, the suction capacity of the suction pad (a) is controlled by a variable louver (53) installed between the suction pump and the suction pad to control the amount of suction deviation and hold the bag in the optimal position.

[0035] The paper bag or the like is suctioned by the suction pad (a) and mechanically restrained by the holding hand (b), so that the paper bag or the like is held stably and securely.

[0036] With the paper bag or the like held by the suction pad (a) and the holding hand (b), the transport arm (c) is rotated from the storage pallet orientation to the transport pallet orientation.

[0037] As the conveying arm (c) rotates while holding the paper bag or the like, it stops temporarily above the adhesive application section (i) as shown in Figure 6, and adhesive is sprayed from the adhesive application gun (63) of the adhesive application section (i) onto the bottom of the paper bag or the like in response to a coating agent spray control signal from the device control section (d). At this time, when the jetting is optimal, a jetting control signal is transmitted from the control unit (d) to the adhesive application unit (i) based on the deviation angle information of the transport arm (c) and visual information from the vision sensor (g) equipped on the transport arm (c).

[0038] The automatic adhesive application section (i) is equipped with an infrared sensor (62) at a position where it can detect paper bags, etc., and automatically measures the optimum time to start and stop spraying the adhesive, transmits the time information to the adhesive application control device, and transmits an adhesive spray start / stop control signal to the adhesive tank (64).

[0039] After the process of spraying the adhesive and applying it to the bottom of the paper bag or the like is completed, the transport arm (c) is rotated and directed toward the transport pallet.

[0040] The transport arm (c) directed towards the transport pallet holds paper bags or the like in the loading location, and the electric motor equipped on the transport arm (c) is driven to move the holding hand (b) to the optimal position.

[0041] At this time, the holding hand (b) is directed to the optimal position by a 3-axis, 6-direction (pitch, roll, yaw) rotation motor equipped on the transfer arm (c).

[0042] At the same time, the GPS position information equipped on the transport arm (c) and the position information of the transport pallet are corrected, and the presence or absence of obstacles is confirmed using the vision sensor equipped on the transport arm (c) and the wearable camera (11) equipped on the holding hand (b), ensuring safe loading.

[0043] When the holding hand (b) moves to the optimal position, the holding hand opens in both directions, the suction function of the suction pad (a) is stopped in synchronization, and the paper bags, etc. are loaded from the holding hand (b) onto a transport pallet.

[0044] The process of neatly loading heavy items such as paper bags onto transport pallets requires a lot of labor, but the labor burden can be significantly reduced by automatically loading paper bags that have been coated with adhesive in an automatic adhesive application unit.

[0045] The present invention, which solves the above problems, provides a configuration for an automatic suction loading assist device and a control method for safely and efficiently transporting and loading paper bags and the like. [Effects of the Invention]

[0046] The present invention safely and efficiently moves heavy and unstable paper bags and other items from storage pallets to transport pallets and stacks them in an orderly manner using an electric system, thereby reducing labor compared to work performed using conventional heavy equipment. In particular, this will contribute to labor-saving and manpower-saving work processes and safety in response to the 2024 problem in the logistics industry. The recent application of robotic arms has made it possible to improve the efficiency of throughput (production lead time) and support safe loading by providing a function that complements the shortening of takt time (process work time), which contributes to a reduction in working hours in the logistics industry and also makes it possible to reduce the labor and manpower required for logistics work related to loading operations. [Brief explanation of the drawings]

[0047] [Figure 1] FIG. 2 is a schematic diagram of an automatic suction loading assist device. [Figure 2] FIG. 10 is a schematic diagram of transfer arm operation control. [Figure 3] FIG. 10 is a schematic diagram of holding hand control. [Figure 4] FIG. 10 is a schematic diagram of air suction louver operation control. [Figure 5] FIG. 2 is a schematic diagram of a suction pad. [Figure 6] FIG. 1 is a schematic diagram of an automatic adhesive application device. [Industrial Applicability]

[0048] In the future, by utilizing cognitive functions such as generative artificial intelligence with more detailed image recognition functions and multi-layered vision sensors, it will be possible to operate it as an autonomous automatic suction loading assist device, which will enable further labor and manpower savings. Furthermore, by making the transport arms and other components smaller and lighter, they can be made into portable devices such as vehicle-mounted devices, which will enable loading and unloading operations inside and outside logistics cargo vehicles, as well as outdoor transport and loading operations, thereby contributing to greater efficiency in logistics operations.In addition, by attaching holding hands and suction pads that can be used for loading disaster prevention and safety materials such as sandbags, the devices can be used for a wide variety of transport and loading operations. [Explanation of symbols]

[0049] (a) Suction pad (b) Holding hand (c) Transfer arm (d) Device control unit (e) Transfer arm control unit (f) Suction control unit (g1)(g2) Vision sensor (h) Vision sensor operation control unit (i) Adhesive application unit 11 Wearable camera 12 Load sensor 13 Imaging position setting signal 14 Vision sensor acquisition information and operation control signal 15. Transfer arc operating area information signal 16. Transfer arm control signal 17 Transfer arm position control signal 18 Holding hand open / close control signal 19 Weight information signal 20 Suction control information 21 Suction pad lift signal 22 suction control signal 23 suction deflection louver control signal 51 Perforated suction port 52 Adhesive cushioning material 53 Variable airflow direction louver 54 suction hose 61 adhesive application device 62 application operation sensor 63 adhesive application gun 64 Adhesive tank 65 Adhesive application controller 66 Application operation control signal 67 Adhesive application amount control signal

Claims

1. The automatic suction loading assist device has the function of stably holding paper bags packed with starch or other materials, which are heavy and have unstable shapes, and transporting them from a designated storage position to a designated transportation position, and also automatically applying adhesive during the transportation process to assist in loading in a stable form.

2. This automatic suction loading assist device is characterized by sucking powder material inside paper bags, etc. from a suction pad pressed against the paper bags, etc., via a suction hose from an air suction device, and stably holding the paper bags, etc., sucked onto the suction pad in synchronization with the holding function of the holding hand.

3. An automatic suction loading assist device equipped with a suction hose and suction pad that calculates the optimal suction amount of the suction pad in the control unit based on the weight and weight distribution of paper bags, etc., and controls the appropriate suction amount.

4. The automatic suction loading assist device is characterized by the fact that the suction hose is composed of two suction hoses, one on the left and one on the right, making it easy to control the optimal suction amount, and that it sucks and holds paper bags and the like in a balanced manner.

5. This automatic suction loading assist device is characterized by a mechanism that is equipped with a louver inside the suction hose that can control the suction wind direction and wind speed, and calculates the weight center of gravity and balance of paper bags, etc. from load information from a load sensor equipped on the holding hand, thereby demonstrating optimal suction capacity for paper bags, etc.

6. The automatic suction loading assist device is characterized by the fact that the suction pad has a mesh-like porous surface over the entire adhesive surface to uniformly suction and hold cloth bags, etc., and is equipped with a frame structure all around to maintain strength, as well as a central pad to prevent bending of paper bags, etc. and to suction them horizontally.

7. An automatic suction loading assist device that works in conjunction with the suction pad's suction operation to operate the two-way holding hands from an open state to a contracted state, holding paper bags and other items from two directions, and transporting them in a safe and stable manner using a suction mechanism and mechanical restraint mechanism.

8. An automatic suction loading assist device that has the function of detecting the three-dimensional shape and loading status of paper bags, etc. on the storage pallet and loading conveyor using a vision sensor that utilizes a three-dimensional camera (hereinafter referred to as a "3D camera") installed in a location that can monitor the area where paper bags, etc. are transferred from the storage pallet to the transport pallet, and a vision sensor that utilizes a 3D camera installed on the transport arm, and transmitting shape information and distance information to a control unit.

9. The automatic suction loading assist device has a transport arm control program that processes information on paper bags, etc. transmitted from the vision sensor, as well as position information and operation information of the automatic suction loading assist device, and controls the drive of the transport arm in multiple dimensions, including rotation drive, front / back / left / right drive, and lift / lower drive, to approach the paper bags, etc., held by the suction pad in the optimal state.

10. This automatic suction loading assist device has the function of monitoring the distance from the vision sensor to the installation position and the installation status above the transport pallet, transmitting information on the distance and installation status to the control unit, and using the transport arm and suction pad to optimally drive paper bags, etc. in six directions (pitch, roll, and yaw) along three axes.

11. An automatic suction loading assist device that has the function of applying adhesive by utilizing a spray mechanism using compressed air from an adhesive tank at the optimal position for the adhesive application unit during the process of moving the transport arm from a storage pallet to a transport pallet in cooperation with the transport arm's operation control program.

12. This automatic suction loading assist device has the function of automatically calibrating the position of the holding hand and the position of the adhesive application unit while paper bags, etc. are restrained by the holding hand and moving them to the optimal position using a wearable camera attached to the holding hand, thereby applying adhesive to the underside of the paper bags, etc. in a short time while they are being moved from the storage pallet to the transport pallet.

13. An automatic suction loading assist device that has a function to detect passing objects using infrared light installed in the adhesive application device, and synchronizes the time when adhesive is sprayed based on the time information when paper bags, etc. pass above the adhesive application device, thereby generating time control to effectively apply adhesive.

14. An automatic suction loading assist device that has a vision sensor installed in a location that can monitor the area where paper bags, etc. are transferred from a storage pallet to a transport pallet, and a vision sensor installed on the transport arm, or a function that operates the transport arm to transport paper bags, etc. to the top of the transport pallet set by a program. In addition, the automatic suction loading assist device has the function of generating an emergency stop signal and halting operation if an obstacle is detected by the vision sensor.

15. An automatic suction loading assist device that moves to the optimal loading position using a transport arm, stops air suction from the suction pad in response to a signal from the device control unit, and changes the holding hand from a restrained state to a released state in time with the suction stop function, utilizing the adhesive function of the adhesive applied by the automatic adhesive applicator to orderly load paper bags, etc.

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