Boxing system

Abstract

To provide a boxing system that can make more effective use of a space.SOLUTION: A boxing system 1 includes: an object conveyance part 10 that conveys a plurality of objects (individual packaging boxes, etc.) to a first waiting position P1; a box molding part 20 that molds a cardboard box 90 for storing the plurality of objects; a robot 60 that packs the plurality of objects into the cardboard box 90 that is molded by the box molding unit 20 and is located at a second waiting position P2; a cardboard box conveyance part 30 that conveys the cardboard box 90 storing the plurality of objects to a third waiting position P3; and a pallet loading part 40 on which a pallet is placed for loading the cardboard boxes 90. The robot 60 not only packs the plurality of objects at the first waiting position P1 into a cardboard box 90 at the second waiting position P2 but also transfers the cardboard box 90 at the third waiting position P3 onto a pad of the pallet loading part 40.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to a packing system for packing a plurality of objects into a cardboard box. [Background technology]

[0002] There is a packing system in which a robot automatically packs multiple objects into an outer box (such as a cardboard box or case) (see Patent Document 1, etc.). In addition, there is a separate palletizing system in which a robot automatically palletizes the packed outer boxes (such as cardboard boxes) onto a pallet. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2010-285183 Summary of the Invention [Problem to be solved by the invention]

[0004] Conventionally, two systems such as those described above have been used to automate the process of packing multiple objects into cardboard boxes and palletizing the boxes onto pallets. In this case, one robot is used in the packing system that automatically packs multiple objects into cardboard boxes, and another robot is used in the separate palletizing system. Therefore, it is necessary to use at least two robots.

[0005] As described above, conventionally, two robots are required and space is required for arranging the two robots, so the space is not necessarily used effectively and there is room for improvement.

[0006] Therefore, an object of the present invention is to provide a technique that enables more effective use of space. [Means for solving the problem]

[0007] In order to solve the above problem, the packing system of the present invention comprises an object transporting unit that transports multiple objects to a first waiting position, a box molding unit that forms a cardboard box to contain the multiple objects, a robot that packs the multiple objects into the cardboard box that has been formed by the box molding unit and is located at a second waiting position, a cardboard box transporting unit that transports the cardboard box containing the multiple objects to a third waiting position, and a pallet loading unit on which a pallet for loading the cardboard box is placed, and is characterized in that the robot not only packs the multiple objects that have moved to the first waiting position into the cardboard box that is located at the second waiting position, but also transfers the cardboard box that has moved to the third waiting position onto the pallet in the pallet loading unit.

[0008] The cardboard box conveying unit may have the second waiting position, and the robot may also perform the task of moving the cardboard box molded at the molding position of the box molding unit from the molding position to the second waiting position of the cardboard box conveying unit.

[0009] The box forming section may be arranged upstream of the cardboard box transport section without being connected to the transport conveyor.

[0010] The cardboard box transport unit has a transport path that moves the cardboard box packed at the second standby position away from the robot and then moves it towards the robot, the transport path having a first sub-path, a second sub-path and a third sub-path, the first sub-path being a path that moves the cardboard box packed at the second standby position away from the robot, the second sub-path being a path that moves the cardboard box that has moved along the first sub-path to the third sub-path, and the third sub-path being a path that moves the cardboard box that has moved between the first sub-path and the second sub-path in a direction that moves it towards the robot, and the third standby position may be provided at the downstream end of the third sub-path.

[0011] The second standby position and the third standby position may be provided between the first standby position and the molding position.

[0012] The third standby position may be provided between the second standby position and the molding position.

[0013] The box mould may be positioned adjacent to the third sub-path and not adjacent to the first sub-path.

[0014] The object transporting unit may be arranged upstream of the cardboard box transporting unit, the first waiting position may be provided at the downstream end of the object transporting unit, the second waiting position may be provided at the upstream end of the cardboard box transporting unit, and the first waiting position of the object transporting unit may be provided near the second waiting position of the cardboard box transporting unit.

[0015] The first waiting position, the second waiting position, the third waiting position, and the molding position may be arranged across two adjacent sides, namely, the first side area and the second side area, of four side areas that broadly divide the periphery of the robot into four, and the pallet placing unit may be arranged in the remaining two side areas, namely, the third side area and the fourth side area, of the four side areas, and the first waiting position may be arranged in the first side area, the third waiting position may be arranged in the second side area adjacent to the first side area, the second waiting position may be arranged at a position adjacent to the first waiting position between the first waiting position and the third waiting position, and the molding position may be arranged in the second side area, and the pallet placing unit may comprise a first pallet placing unit and a second pallet placing unit each capable of placing a pallet, and the first pallet placing unit may be arranged in the third side area, and the second pallet placing unit may be arranged in the fourth side area.

[0016] The first waiting position, the second waiting position, the third waiting position, and the molding position may be arranged across two adjacent sides, the first side area and the second side area, of the four side areas that broadly divide the periphery of the robot, and the pallet placing section may be arranged in at least one of the remaining two side areas, the third side area and the fourth side area, of the four side areas.

[0017] The cardboard box transport unit may have a top sealing unit that seals the top of the cardboard box downstream of the second waiting position, and the robot may also perform the task of pushing and moving the cardboard box containing the multiple objects from the second waiting position to the top sealing unit.

[0018] The cardboard box transport unit may have a bottom sealing unit at the second waiting position that seals the bottom of the cardboard box, and the robot may move the cardboard box, which has been unfolded in the box forming unit and is open at the top and bottom, from the box forming unit to the second waiting position, the bottom sealing unit seals the bottom of the cardboard box that has been moved to the second waiting position, and the robot may pack the multiple objects into the cardboard box whose bottom has been sealed.

[0019] The first waiting position, the second waiting position, the third waiting position, and the molding position are arranged across two adjacent side areas, a first side area and a second side area, of four side areas that roughly divide the periphery of the robot into four areas, the pallet placing section includes a first pallet placing section and a second pallet placing section, each capable of placing a pallet, the first pallet placing section being arranged in a third side area adjacent to the second side area, and the second pallet placing section being arranged in a fourth side area adjacent to the first side area, the space around the robot being divided into two work spaces, a first work space including the second side area and the third side area, and a second work space including the first side area and the fourth side area, and the robot may have an operation continuation mode in which, even if a human is present in one of the two work spaces, the robot performs work in the other of the two work spaces at a low speed.

[0020] The operation continuation mode may include a mode in which the robot continues palletizing work on the second pallet loading section in the second work space at a low speed even when a human is performing pallet replacement work on the first pallet loading section in the first work space.

[0021] The object transport unit may be disposed in the second work space, and the operation continuation mode may include a mode in which the robot continues palletizing work on the first pallet placement unit in the first work space at a low speed even when a human is performing work to resolve a malfunction in the object transport unit in the second work space.

[0022] The object may be an individual packaging box, the object transport unit may have an alignment mechanism for aligning a predetermined number of objects in a row, and the robot may pack the plurality of objects into the cardboard box in units of a predetermined number or in units of an integer multiple of the predetermined number. [Effects of the Invention]

[0023] According to the present invention, one robot can perform not only the packing work but also the palletizing work, eliminating the need for two robots, thereby enabling effective use of space. [Brief explanation of the drawings]

[0024] [Figure 1] FIG. 1 is a perspective view showing a cartoning system. [Figure 2] FIG. 1 is a top view showing the cartoning system. [Figure 3] FIG. 3 is a diagram schematically illustrating a top view of FIG. 2. [Figure 4] FIG. 1 is a diagram showing the work of a robot. [Figure 5] 10A and 10B are diagrams showing how individual packaging boxes are transported by an object transport unit. [Figure 6] FIG. 10 is a diagram showing an operation in which a robot packs individual packaging boxes into cardboard boxes. [Figure 7] FIG. 10 is a diagram showing the robot pushing a cardboard box toward the top sealing section. [Figure 8] FIG. 10 is a diagram showing the state in which the cardboard box has reached the top sealing portion. [Figure 9] 10A and 10B are diagrams showing the state of transport of cardboard boxes in a cardboard box transport section. [Figure 10] FIG. 10 is a diagram showing an operation in which a robot transfers a cardboard box onto a pallet. [Figure 11] FIG. 1 shows four lateral regions, etc. [Figure 12] This is a view of Figure 3 rotated 135 degrees counterclockwise. [Figure 13]FIG. 2 is a side view of the robot hand. [Figure 14] Top view of the robot hand [Figure 15] FIG. 10 is a top view showing a modified example of a packing system. DETAILED DESCRIPTION OF THE INVENTION

[0025] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0026] <1. System Overview> Fig. 1 is a perspective view showing the packing system 1, and Fig. 2 is a top view showing the packing system 1. Figs. 3 and 4 are diagrams that schematically show the top view of Fig. 2. Fig. 3 is a diagram that mainly shows the conveying direction of cardboard boxes 90 on the cardboard box conveying section 30, and Fig. 4 is a diagram that mainly shows the work of the robot 60.

[0027] The packing system 1 is a system that packs a plurality of objects (individual packaging boxes 80 in this case) into cardboard boxes 90, and also a system that stacks (palletizes) a plurality of cardboard boxes 90, each containing a plurality of objects, on a pallet. The packing system 1 is also called a palletizing system or a caser-palletizer (system).

[0028] Here, an individual box 80 (in other words, a small box having a rectangular parallelepiped shape) is exemplified as an object to be packed into the individual box 80. Various products (medicines, cosmetics, food, daily necessities, etc.) can be packed inside the individual box 80.

[0029] In the packing system 1, a plurality of individual packaging boxes 80 are packed in an aligned state into one cardboard box 90. For example, 24 individual packaging boxes 80 aligned in two rows (six boxes in each row) are packed into one cardboard box 90. Furthermore, a plurality of cardboard boxes 90 that have been similarly packed are stacked on a pallet in a predetermined manner (block stacking, brick stacking, pinhole stacking, etc.). For example, 24 cardboard boxes 90 are stacked on a pallet in four rows (six boxes in each row) using block stacking.

[0030] As shown in FIGS. 1 and 2, the boxing system 1 includes an object transport unit 10, a box forming unit 20, a cardboard box transport unit 30, a pallet placing unit 40, and a robot 60.

[0031] The object conveying unit 10 is a conveying unit that conveys objects (here, individual packaging boxes 80) to a first standby position P1 (see FIG. 3). The first standby position P1 is a standby position for the individual packaging boxes 80 in preparation for a packing operation in which the individual packaging boxes 80 are packed into cardboard boxes 90. The first standby position P1 is also referred to as a packing position for the individual packaging boxes 80. The first standby position P1 is provided inside the object conveying unit 10 (the downstream end of the object conveying unit 10). In the object conveying unit 10, the individual packaging boxes 80 are conveyed to the first standby position P1 in a state where they are aligned in a row in groups of a predetermined number (for example, six boxes). The object conveying unit 10 is also referred to as an individual box alignment unit because it has a mechanism (alignment mechanism) that aligns a predetermined number of objects (individual packaging boxes 80) in a row.

[0032] The box forming unit 20 is a processing unit equipped with a device (box former) that forms a cardboard box 90 (also referred to as an outer box) for containing multiple objects (also referred to as workpieces). The device (box former) is a device that assembles folded cardboard boxes 90 into a box shape. The cardboard box 90 formed at a predetermined position (also referred to as a forming position) P0 (see FIG. 3) of the box forming unit 20 is transferred by the robot 60 from the forming position P0 of the box forming unit 20 to a second standby position P2 (see FIG. 3) of the cardboard box conveying unit 30. The forming position P0 is a position within the box forming unit 20 where a folded cardboard box is opened and formed. The second standby position P2 is a position where the cardboard box 90 waiting for the boxing operation is placed (a standby position for the cardboard box 90 for the boxing operation) and is also a packing position for the cardboard box 90.

[0033] The cardboard box conveying unit 30 is a conveying unit that conveys cardboard boxes 90 containing (packaged with) a plurality of objects (individual packaging boxes 80) from a second standby position P2 to a third standby position P3 (see FIG. 3). In the cardboard box conveying unit 30, the cardboard boxes 90 are conveyed in the longitudinal direction of the cardboard boxes 90. The third standby position P3 is a position where the cardboard boxes 90 waiting for the palletizing operation are placed, and is a standby position for the cardboard boxes 90 intended for the palletizing operation. The second standby position P2 and the third standby position P3 are provided within the cardboard box conveying unit 30. The second standby position P2 is provided at the upstream end of the cardboard box conveying unit 30, and the third standby position P3 is provided at the downstream end of the cardboard box conveying unit 30.

[0034] The cardboard box conveying unit 30 is disposed downstream of the object conveying unit 10. In other words, the object conveying unit 10 is disposed upstream of the cardboard box conveying unit 30. The first standby position P1 of the object conveying unit 10 and the second standby position P2 of the cardboard box conveying unit 30 are disposed close to (near) each other. This allows the work of packing the individual boxes 80 (at the first standby position P1) into the cardboard boxes 90 (at the second standby position P2) to be carried out efficiently.

[0035] When a plurality of objects (packaging boxes 80) are packed into a cardboard box 90 at the second standby position (packing position) P2, the cardboard box 90 is transported by the cardboard box transport section 30 to the third standby position P3.

[0036] Specifically, the cardboard box conveying section 30 has a conveying path that moves the cardboard box 90, which has completed packing work at the second waiting position P2, away from the robot 60 (to the right in Figure 3), and then changes its direction of travel (movement direction) twice (upward and leftward in Figure 3) before moving closer to the robot 60 (to the left in Figure 3).

[0037] Specifically, the cardboard box transport section 30 includes a transport conveyor 31 (three roller conveyors 31a, 31b, 31c) for cardboard boxes (see FIG. 3). The bottom sealing section 32 (described below) and the three roller conveyors 31a, 31b, 31c form a U-shaped transport path when viewed from above.

[0038] The U-shaped transport path is made up of three sub-paths (first to third sub-paths).

[0039] The first sub-path is a path along which cardboard boxes 90 that have completed the packing process at second standby position P2 are temporarily moved in a direction away from robot 60 (toward the right in FIG. 3). The first sub-path is configured with a bottom sealing unit 32 (described below) and a roller conveyor 31a. Cardboard boxes 90 are moved on the first sub-path from bottom sealing unit 32 (second standby position P2) to weight measuring unit 34.

[0040] The second sub-path is a path that connects the downstream end of the first sub-path and the upstream end of the third sub-path. The second sub-path is configured with a roller conveyor 31b. Cardboard boxes 90 that have moved along the first sub-path are moved to (the upstream end of) the third sub-path via the second sub-path. In other words, the second sub-path is a path that moves cardboard boxes 90 that have moved along the first sub-path to the third sub-path.

[0041] The third sub-path is arranged parallel to the first sub-path. The third sub-path is a path along which the cardboard boxes 90 are moved in the opposite direction (toward the robot 60) (leftward in FIG. 3) to the conveying direction along the first sub-path (rightward in FIG. 3), and is configured with a roller conveyor 31c. The cardboard boxes 90 are moved on the third sub-path from the upstream end of the third sub-path to the downstream end (third standby position P3) of the third sub-path. The second standby position P2 is provided at the upstream end of the first sub-path (the position of the bottom sealing unit 32), and the third standby position P3 is provided at the downstream end of the third sub-path. The third standby position P3 can also be expressed as being provided at the end (downstream end) of the U-shaped conveying path (not in the middle (on the roller conveyor 31b) of the U-shaped conveying path) (more specifically, at the end (left end side in FIG. 3) of the roller conveyor 31c).

[0042] The cardboard box conveying unit 30 also includes a bottom sealing unit 32 that seals the bottom of the cardboard box 90, and a sealing unit 33 (also referred to as a top sealing unit) that seals the top of the cardboard box 90. The bottom sealing unit 32 is located at the second standby position P2, and the top sealing unit 33 is located downstream of the second standby position P2. The second standby position P2 is also provided with a support member (a frame with a partially open area corresponding to the bottom) that supports the bottom of the cardboard box 90 when sealing the bottom, and the roller conveyor 31a (not located at the second standby position P2) is located downstream of the second standby position P2. The cardboard box conveying unit 30 also includes a weight measuring unit 34 (see FIG. 3). The weight measuring unit 34 is located downstream of the top sealing unit 33.

[0043] The pallet placement section 40 is an area where a pallet 41 for loading cardboard boxes 90 (a pallet 41 onto which the cardboard boxes 90 are loaded) is placed. In the packing system 1 according to this embodiment, two pallets 41 (41a, 41b) can be used in parallel (in parallel). Specifically, the pallet placement section 40 includes a first pallet placement section 40a having an area for placing one pallet 41a, and a second pallet placement section 40b having an area for placing the other pallet 41b.

[0044] The robot 60 is configured as, for example, a vertically articulated robot. A robot hand 67 is attached to the end of the robot 60 via a docking section 67b (connection section) (see also Figures 13 and 14). The robot 60 has six drive axes (six rotary joints), and can freely change the position and posture (six degrees of freedom in total) of the end of the robot (and therefore the robot hand 67) within its range of motion.

[0045] The robot 60 has six rotational joints, from the first rotational joint to the sixth rotational joint, arranged in this order from the base portion of the robot 60 toward the hand portion. The first rotational joint is a rotational joint that can rotate around an axis vertical to the base, and the second rotational joint and the third rotational joint are two rotational joints that can rotate around horizontal axes. The fourth rotational joint is a rotational joint that can rotate around an axis parallel to the extension direction of the link on the hand side of the third rotational joint. The fifth rotational joint is a rotational joint that can rotate around an axis perpendicular to the rotational axis of the fourth rotational joint. The sixth rotational joint is a rotational joint that can rotate around an axis perpendicular to both the rotational axis of the fourth rotational joint and the rotational axis of the fifth rotational joint.

[0046] 13 and 14, the hand main body 67a of the robot hand 67 has a generally thin plate shape and a generally rectangular shape (a generally thin rectangular parallelepiped shape). Note that Fig. 13 is a side view (front view) of the robot hand 67, and Fig. 14 is a top view of the robot hand 67. Figs. 13 and 14 show a state in which the hand main body 67a is in a horizontal state (a state in which the main surface of the thin plate-like hand main body 67a extends horizontally).

[0047] Adsorption sections (vacuum adsorption sections) 68a, 68b, and 68c facing laterally (and outward) are provided on the peripheral edge of the hand attachment section side (upper surface side) of hand main body 67a. Adsorption sections 68a and 68b are provided on the long side sides of hand main body 67a, which has a substantially rectangular shape, and adsorption section 68c is provided on the short side sides of hand main body 67a. Adsorption sections 68a, 68b, and 68c are used to adsorb the inner surface of cardboard box 90 and hold cardboard box 90, for example.

[0048] Furthermore, a plurality of (e.g., 30 in total) downward-facing suction units (vacuum suction units) 68d are provided on the object side (bottom surface side) of the hand main body 67a, divided into a plurality of rows (e.g., five rows). In each row, a predetermined number (e.g., six) of suction units 68d are arranged along the longitudinal direction of the hand main body 67a. The plurality of suction units 68d are used to suction the upper surfaces of the plurality of individual boxes 80 to hold the plurality of individual boxes 80, etc.

[0049] The robot 60 performs a task (operation) of packing a plurality of objects (packaging boxes 80) that have moved to the first standby position P1 into (the inside of) a cardboard box 90 that is located at the second standby position P2 near the first standby position P1 (FIG. 4) (see arrow B2 in FIG. 4). The robot 60 also performs a task of transferring (palletizing) the cardboard box 90 that has moved to the third standby position P3 onto the pallet 41 of the pallet placement unit 40 (see arrow B4 in FIG. 4).

[0050] That is, in the packing system 1, the robot 60 not only packs multiple objects into cardboard boxes 90, but also transfers (loads) the cardboard boxes 90 from the third standby position P3 onto the pallets 41 of the pallet placement unit 40 (palletizing work). Therefore, it is not necessary to provide separate robots for the packing work and the palletizing work. In short, it is not necessary to provide two robots, and only one robot is required. Therefore, it is possible to improve space efficiency (space saving).

[0051] The robot 60 also performs the task of moving the (empty) cardboard box 90 (before being packed) from the molding position P0 of the box molding unit 20 to the second standby position P2 of the cardboard box conveying unit 30 (see arrow B1 in FIG. 4). The robot 60 also performs the task of pushing the packed cardboard box 90 from the second standby position P2 to the box sealing unit 33 (see arrow B3 in FIG. 4).

[0052] The controller 70 is configured to include an overall control unit, a robot controller, etc. The overall control unit is a control unit that controls the entire packing system. The robot controller is a control unit that controls the robot 60, and is a control unit at a lower level than the overall control unit. The controller 70 is also configured to include a memory unit and an operation unit 75 (see Figure 1), etc. The memory unit is configured with a storage device such as a hard disk drive (HDD) and / or a solid state drive (SSD). The operation unit 75 is equipped with an input unit that accepts various inputs (setting operation inputs, etc.) from the user 99, and an output unit (display output unit, audio output unit, etc.) that output various information.

[0053] The controller (also referred to as a control unit) 70 is configured by a computer system (also simply referred to as a computer) equipped with one or more hardware processors (for example, a central processing unit (CPU) and a graphics processing unit (GPU)). The controller 70 performs various processes by executing, in the CPU or the like, a predetermined software program (hereinafter simply referred to as a program) stored in a storage unit (a non-volatile storage unit such as a ROM and / or a hard disk). The program (more specifically, a group of program modules) (also referred to as a "program product") may be recorded on a portable storage medium such as a USB memory, read from the storage medium, and installed on the computer. Alternatively, the program may be downloaded via a communication network or the like and installed on the computer.

[0054] 2. Configuration and Operation of Object Conveying Unit 10 The object conveying section 10 includes a conveyor (more specifically, two belt conveyors 11 and 12) for conveying the individual boxes 80 (objects), direction changers 13 and 14, a push-out section 15, a buffer area section 16, a pressure plate 17, a waiting area section 18, and photoelectric sensors 19a and 19b (see FIG. 5). Note that FIG. 5 is a diagram showing how the individual boxes 80 are conveyed by the object conveying section 10.

[0055] The conveying direction of the upstream belt conveyor 11 is perpendicular to the conveying direction of the downstream belt conveyor 12. The upstream belt conveyor 11 conveys each individual box 80 in the vertical direction in Figure 5, and the downstream belt conveyor 12 conveys each individual box 80 in the horizontal direction in Figure 5.

[0056] The belt conveyor 11 transports the individual packaging boxes 80 one by one (in the vertical direction in FIG. 5) supplied from a supply unit (not shown) further upstream. A stopper (guide unit) 11e is provided at the downstream end of the belt conveyor 11. As multiple individual packaging boxes 80 are transported one by one on the belt conveyor 11 toward the downstream end, the multiple individual packaging boxes 80 gradually accumulate in a line in the vertical direction in FIG. 5 (the conveying direction of the belt conveyor 11) at a predetermined position (to the right of the push-out unit 15) near the downstream end. When the photoelectric sensor 19a detects that a predetermined number of individual packaging boxes 80 (for example, six) have accumulated, the plate-shaped push-out unit 15 moves toward the right in FIG. 5 (toward the belt conveyor 12 arranged downstream of the belt conveyor 11). 5 as its longitudinal direction, the extrusion surface (right surface) of the plate-shaped extrusion unit 15 pushes the side surface (left surface) of a predetermined number of individual packaging boxes 80 aligned in a row, thereby pushing the predetermined number of individual packaging boxes 80 aligned in a row onto the right-side belt conveyor 12.

[0057] In this way, the belt conveyor 11 is provided with an alignment mechanism (packaging box alignment unit) that aligns a plurality of packaging boxes 80 in a row in groups of a predetermined number (for example, six boxes).

[0058] By using the direction changers 13 and 14, the orientation of the individual box 80 can be changed (converted) as needed during transport on the belt conveyor 11. The direction changer 13 can change the orientation of the individual box 80 by 90 degrees in a horizontal plane (between a vertical orientation and a horizontal orientation), and the direction changer 14 can change the orientation of the individual box 80 by 90 degrees in a vertical plane (between a horizontal position and an upright position). Figure 5 illustrates an example in which the orientation of the individual box 80 is changed from a vertical orientation to a horizontal orientation (by the direction changer 13).

[0059] The belt conveyor 12 transports a predetermined number of packaging boxes 80 aligned in a row to the right in Fig. 5 (toward the downstream side of the belt conveyor 12). In the belt conveyor 12, a waiting area 18 is provided downstream of a buffer area 16. The (predetermined number of) individual packaging boxes 80 in each row move via the buffer area 16 to a first waiting position P1 (a packing position for the individual packaging boxes 80) within (the leading end of) the waiting area 18.

[0060] Specifically, a buffer area 16 is provided at a position (near the center of the belt conveyor 12 in the conveying direction) where the individual boxes 80 in each row have advanced a certain distance from the left end (upstream end) of the belt conveyor 12. A pressure plate 17 (for clamping) is provided at the leading end (right end) of the buffer area 16 (and at the bottom in FIG. 5). Guide portions 12b and 12c are provided along the conveying direction of the belt conveyor 12 on one of both sides (the top side in FIG. 5) of the conveying path of the belt conveyor 12. When the individual boxes 80 in the leading row move close to the pressure plate 17, the pressure plate 17 moves slightly upward in the vertical direction in FIG. 5 (a direction perpendicular to the conveying direction) to temporarily hold the individual boxes 80 in the leading row (both ends in the vertical direction in FIG. 5) sandwiched between the pressure plate 17 and the guide portion 12b (at the top of FIG. 5). As a result, the individual boxes 80 in the leading row are neatly aligned (in a single row) with the gaps between the individual boxes 80 in the vertical direction reduced. Furthermore, while the individual boxes 80 in the leading row are being held, the individual boxes 80 in the leading row (and the individual boxes 80 in the following rows) do not move in the conveying direction (even if the belt conveyor 12 is driven).

[0061] A photoelectric sensor 19b (see FIG. 3) is provided at the rear end side within the waiting area 18. The controller 70 determines whether to maintain or release the holding state by the pressure plate 17 depending on whether the light from the photoelectric sensor 19b is blocked. If the light is blocked, the holding state of the row of individual boxes 80 continues, and the row of individual boxes 80 does not move. On the other hand, if the light is not blocked, the holding state is released, and the row of individual boxes 80 is transported to the waiting area 18.

[0062] By repeating this operation (temporarily holding and releasing using the pressure plate 17) for each row of individual boxes 80, each row of individual boxes 80 (a predetermined number of individual boxes 80) is transported sequentially on the belt conveyor 12 to the waiting area 18. A stopper 12e (described later) is provided at the front of the waiting area 18, and the individual boxes 80 in the front row advance within the waiting area 18 until they come into contact with the stopper 12e and stop. Then, when several subsequent rows of individual boxes 80 have accumulated in the waiting area 18, the light of a photoelectric sensor 19b provided at the rear end of the waiting area 18 is blocked by the individual boxes 80 in the rear row.

[0063] When this interruption is detected by the photoelectric sensor 19b, the controller 70 determines that the waiting area 18 is full (that is, a predetermined number of individual packaging boxes 80 (for example, 36 boxes = 6 boxes per row × 6 rows) have accumulated). The controller 70 maintains the state in which the individual packaging boxes 80 in the first row in the buffer area 16 are held using the pressure plate 17. This stops the entry of individual packaging boxes 80 into the waiting area 18.

[0064] Thereafter, when a predetermined number of rows (number of rows to be packed in one packing operation: for example, two rows) of individual boxes 80 are moved (removed) from the first standby position P1 (on the belt conveyor 12) by the packing operation, the subsequent rows of individual boxes 80 in the standby area 18 move toward the first standby position P1 downstream (right side) in the conveying direction. When the photoelectric sensor 19b in the standby area 18 is unblocked again in response to this movement, the individual boxes 80 resume entering the standby area 18. In detail, the clamping state (holding state) by the pressure plate 17 in the buffer area 16 is released, and the individual boxes 80 in the leading row in the buffer area 16 proceed toward the standby area 18.

[0065] By such operations, multiple rows of individual packaging boxes 80 wait in an aligned state in the waiting area 18. In particular, a predetermined number of rows (for example, two rows) of individual packaging boxes 80 on the leading row side in the waiting area 18 wait at the first waiting position P1 to be picked up by the robot 60.

[0066] At the end of the belt conveyor 12, a stopper 12e and an alignment bar (rod) 12d are provided.

[0067] The stopper 12e is disposed at the end of the belt conveyor 12, extending in a direction (also referred to as the width direction of the belt conveyor 12) perpendicular to the conveying direction of the belt conveyor 12. The stopper 12e prevents the individual boxes 80 in the leading row from moving further (progressing beyond the end position of the belt conveyor 12), and the individual boxes 80 in the leading row stop in a state where they are neatly aligned along the extension direction of the stopper 12e (the width direction of the belt conveyor 12).

[0068] The alignment bar 12d is arranged along the conveying direction of the belt conveyor 12 on both sides of the conveying path of the belt conveyor 12 opposite the guide portion 12c (lower side in FIG. 5) (normally spaced apart from the individual boxes 80). The alignment bar 12d moves toward the guide portion 12c (upward in FIG. 5) (at a predetermined timing) when multiple rows of individual boxes 80 (including a predetermined number of rows of individual boxes 80) are present in the waiting area 18. As a result, the alignment bar 12d presses the multiple rows of individual boxes 80 toward the guide portion 12c, and the multiple rows of individual boxes 80 are sandwiched between the alignment bar 12d and the guide portion 12c. As a result, the lengths of the individual boxes 80 in each row in the width direction of the belt conveyor 12 are aligned, and the predetermined number of rows (e.g., two rows) of individual boxes 80 are positioned and arranged in predetermined positions in the waiting area 18 (the upper right area of ​​the waiting area 18). Then, on condition that positioning is completed (and the cardboard boxes 90 are present at the second standby position P2, etc.), the robot 60 starts the packing work (the work of packing a predetermined number of rows of individual boxes 80 into the cardboard boxes 90). After the start of the packing work (immediately after suction by the suction section 68d, etc.) or before the start of the packing work (when positioning is completed, etc.), the alignment bar 12d returns to its original position (a position separated from the individual boxes 80).

[0069] 3. Box Forming Section 20, Cardboard Box Conveying Section 30, and Pallet Placing Section 40 As described above, the box forming unit 20 includes a device (box former) that forms the cardboard box 90. For example, in the cardboard box supply unit 20b (see FIG. 2) of the box forming unit 20, a large number of cardboard boxes 90 are pre-arranged in a folded (two sides at a time) (upright) state. One of the four sides of the folded cardboard box 90 is then sucked by a suction unit of the box former and pulled out toward the front, whereby the cardboard box 90 is deformed (molded) into a rectangular shape via a parallelogram (as viewed from above). In this way, the folded state of the cardboard box 90 is released. The deformed cardboard box 90 is present at the forming position P0 (see FIG. 5), with both the top and bottom of the cardboard box 90 open.

[0070] The cardboard box 90 formed at the forming position P0 of the box molding unit 20 is transferred by the robot 60 from the forming position P0 to the second standby position P2 of the cardboard box conveying unit 30. Specifically, the suction units 68a, 68b, and 68c of the robot hand 67 suction (vacuum suction) the inner surface (body) of the cardboard box 90 to hold the cardboard box 90. More specifically, the suction units 68a and 68b suction the inner surfaces of the long sides of the cardboard box 90 (which has a rectangular shape in top view), and the suction unit 68c suctions the inner surfaces of the short sides of the cardboard box 90. In this holding state, the robot 60 once lifts the cardboard box 90 to remove it from the box molding unit 20, moves it above the second standby position P2 of the cardboard box conveying unit 30, and then lowers it to place it at the second standby position P2 (see arrow B1 in FIG. 5, etc.). When the cardboard box 90 is removed from the molding position P0, the box molding section 20 starts molding the next cardboard box 90.

[0071] When a cardboard box 90 with both the top and bottom open is placed at the second waiting position P2, the bottom sealing section 32 folds the four flaps on the bottom (lower surface) side of the cardboard box 90 to form the bottom surface and seals the bottom surface (performs a bottom sealing).

[0072] Here, the sealing of the bottom is not performed in the box forming unit 20, but is performed in the bottom sealing unit 32 provided in the cardboard box conveying unit 30, but is not limited to this. For example, the box forming unit 20 may fold four flaps on the bottom (lower surface) side of the cardboard box 90 to form the bottom and seal the box. In this way, the cardboard box 90 formed by the box forming unit 20 may be formed into a box shape with both the top and bottom open (without sealing the bottom), or may be formed into a box shape with the bottom (lower) sealed.

[0073] On the condition that the sealing of the bottom surface of the cardboard box 90 at the second standby position P2 is completed, the robot 60 starts the work of packing the cardboard box 90 (the cardboard box 90 whose bottom surface has been sealed). Specifically, the robot 60 picks up a predetermined number of rows (for example, two rows) of individual packaging boxes 80 that have been waiting at the first standby position P1 and packs them into the cardboard box 90 at the second standby position P2 (see arrow B2 in Figure 6 etc.). Note that Figure 6 is a diagram showing the work of the robot 60 packing the individual packaging boxes 80 into the cardboard box 90.

[0074] More specifically, the robot 60 holds the plurality of individual packaging boxes 80 (for example, two rows (12 boxes in total)) at the first standby position P1 by suction (vacuum suction) of the plurality of suction portions 68d (see FIG. 13 , etc.) of the robot hand 67. In this holding state, the robot 60 lifts the plurality of individual packaging boxes 80 from the first standby position P1, moves them above the second standby position P2, and then lowers them to place them inside the cardboard box 90 at the second standby position. During the period from lifting to lowering, the robot 60 rotates the rotary joint closest to the hand to change the orientation of the robot hand 67 and simultaneously change the orientation of the plurality of individual packaging boxes 80 by 90 degrees, and then moves the plurality of individual packaging boxes 80. As a result, the plurality of individual packaging boxes 80 are packed into the cardboard box 90 in the orientation of the cardboard box 90. Thereafter, the robot 60 releases the suction state of the plurality of suction portions 68d, and then lifts the robot hand 67 out of the cardboard box 90.

[0075] This operation is repeated a number of times corresponding to the number of rows (layers) of the individual boxes 80 in the cardboard box 90. For example, two rows of the individual boxes 80 (in the case of six individual boxes 80 per row, a total of 12 individual boxes 80 in the two rows) are stacked in two rows (two layers) and packed into the cardboard box 90. In this case, the robot 60 performs the operation of picking up an integer multiple (twice) of a predetermined number (six) of individual boxes 80 (for example, 12 boxes) at a time and packing them into the cardboard box 90, twice (for two rows). As a result, a total of 24 individual boxes 80 (= 12 boxes × 2 times) are packed into the cardboard box 90.

[0076] Here, the individual packaging boxes 80 are stacked in two layers within the cardboard box 90, but this is not limiting. For example, the individual packaging boxes 80 may be stacked in three or more layers within the cardboard box 90, or (conversely) a single layer of packaging boxes 80 may be configured. Furthermore, the individual packaging boxes 80 are picked up by the robot hand 67 in units of two rows (a total of 12 boxes), but this is not limiting. For example, the individual packaging boxes 80 may be picked up by the robot hand 67 in units of three rows (or units of three or more rows) and packed, or conversely, they may be picked up and packed in units of one row (in other words, in units of a predetermined number of boxes (e.g., six boxes) within one row), etc.

[0077] In this way, the robot 60 may pack multiple (e.g., 24) objects into the cardboard box 90 in predetermined numbers (e.g., 6), or may pack an integer multiple of the predetermined number into the cardboard box 90.

[0078] When the packing operation into a predetermined number (for example, 24 boxes) of cardboard boxes 90 is completed, the robot 60 closes one flap on the upstream short side of the four flaps that stand upright and surround the upper opening of the cardboard box 90. Specifically, the robot 60 closes the one flap by pushing it with the side of the hand main body 67a of the robot hand 67 from the upstream side of the cardboard box 90 (the left side in FIG. 6).

[0079] At this time, the robot 60 drives each joint (e.g., three joints on the tip side) to change the posture of the robot hand 67 (the posture of the thin-plate-shaped hand main body 67a) from a horizontal state (see FIG. 1, etc.) to an upright state. Specifically, the robot hand 67, which has been pulled up (moved upward) from inside the cardboard box 90, is rotated 90 degrees around an axis (imaginary axis) parallel to the direction of travel of the roller conveyor 31a. More specifically, the posture of the hand main body 67a is changed so that the upper and lower surfaces (of the hand main body 67a) in the horizontal state become the left and right surfaces (surfaces on the left side (upper side in FIG. 2) with respect to the direction of travel of the roller conveyor 31a) in the upright state, respectively. Furthermore, the posture of the hand main body 67a is changed so that, of the four sides of the approximately rectangular hand main body 67a, two side surfaces corresponding to the shorter sides are positioned forward and rearward, and two side surfaces corresponding to the longer sides are positioned upward and downward. Then, the robot 60 closes the one flap (the flap on the upstream short side) by pushing the one flap (the flap on the upstream short side) with one side surface (one side surface of the hand main body 67a) on the front side corresponding to the short side (from the left side in Figure 6).

[0080] Furthermore, the robot 60 changes the position and posture of the hand and pushes the side surface under the one flap (the side surface of the body of the cardboard box 90) with the side surface of the hand main body 67a (from the left side of FIG. 6) (see the white arrow in FIG. 7), thereby pushing the cardboard box 90 from the second standby position P2 toward the top sealing unit 33. In response to this action, the cardboard box 90 slides on the cardboard box transport unit 30 and moves toward the top sealing unit 33 (the upstream end of the roller conveyor 31a) (see arrow B3 in FIGS. 7 and 8). FIG. 7 is a diagram showing the robot 60 pushing the cardboard box 90 toward the top sealing unit 33. FIG. 8 is a diagram showing the cardboard box 90 reaching the top sealing unit 33.

[0081] In this way, the robot 60 performs the top sealing assistance task of the cardboard box 90 (specifically, the task of closing one flap and pushing the cardboard box 90 from the second standby position P2 to the top sealing section 33).

[0082] The top sealing unit 33 performs top sealing work and the like on the cardboard box 90 that has been moved to the top sealing unit 33. Specifically, the top sealing unit 33 closes the flap on the downstream short side and the remaining two flaps (the left and right (long side) flaps in the direction of travel), and seals the top of the cardboard box 90.

[0083] Then, the cardboard box 90 is transported from the top sealing unit 33 to the weight measuring unit 34 (see Figures 3 and 9, etc.) in accordance with the drive of the roller conveyor 31a. Note that Figure 9 is a diagram showing the state in which the cardboard box 90 is transported by the cardboard box transport unit 30.

[0084] The weight measuring unit 34 measures the weight of the cardboard box 90 .

[0085] If the measured value (weight value) of the cardboard box 90 is not within the standard range (smaller than a predetermined value, etc.), it is determined that the number of individual packaging boxes 80 contained in the cardboard box 90 is less than the specified value (an abnormality has occurred). In this case, the cardboard box 90 is transported to a defective product transport path (not shown) connected to the cardboard box transport unit 30 (roller conveyor 31a).

[0086] On the other hand, if the measured value (weight value) of the cardboard box 90 is within the reference range (e.g., equal to or greater than a predetermined value), it is determined that the number of individual packaging boxes 80 contained in the cardboard box 90 satisfies the specified value (normal). In this case, the cardboard box 90 is moved to the roller conveyor 31c via the roller conveyor 31b. Specifically, the cardboard box 90 on the weight measuring unit 34 is pushed upward in FIG. 9 by the pusher plate 36 (see FIG. 9), passes through the roller conveyor 31b, and is moved toward the roller conveyor 31c (more specifically, the right end side of the roller conveyor 31c in FIG. 2). The cardboard box 90 is then transported by the roller conveyor 31c and continues along the transport direction of the roller conveyor 31c (to the left in FIG. 2) until it reaches the third standby position P3 (see FIG. 9, etc.).

[0087] Furthermore, when the cardboard box 90 is moved from the second waiting position P2 to the top sealing section 33 (no longer present at the second waiting position P2) (see Figure 8, etc.), the robot 60 performs the task of moving the next cardboard box 90 from the box molding section 20 (molding position P0) to the second waiting position P2.

[0088] When a sensor (not shown) installed near the third standby position P3 detects that the cardboard box 90 transported by the roller conveyor 31c has reached the third standby position P3, the cardboard box 90 is transferred by the robot 60 onto the pallet 41 in the pallet placement section 40 (see arrow B4 in FIG. 10, etc.). FIG. 10 is a diagram showing the operation of the robot 60 transferring the cardboard box 90 onto the pallet 41.

[0089] The roller conveyor 31c also functions as a buffer area for the sealed cardboard boxes 90. A maximum of several (for example, four) cardboard boxes 90 can be placed on the roller conveyor 31c.

[0090] Thereafter, the above-described operations (preparation of molded cardboard boxes 90 (arrow B1), packing into cardboard boxes 90 (arrow B2), assisting in top sealing (arrow B3, etc.), and transferring to a pallet (arrow B4)) (see FIG. 4) are repeatedly performed. In this way, a predetermined number of cardboard boxes 90 are loaded onto the pallet 41. For example, 24 cardboard boxes 90 are loaded on the pallet 41 in four tiers (six boxes per tier) in block stacking.

[0091] Furthermore, once the predetermined number (e.g., 24 boxes) of cardboard boxes 90 have been loaded onto the pallet 41a of one pallet loading section 40a (see solid arrow B4 in FIG. 10), loading onto the pallet 41b of the other pallet loading section 40b (see dashed arrow B4 in FIG. 10) begins. Thereafter, the same operation is repeated, with boxes being loaded alternately onto the two pallet loading sections 40a, 40b. The pallet 41 loaded with the predetermined number of cardboard boxes 90 is moved to another location as needed by a forklift or the like. The forklift or the like can access the pallet loading sections 40a, 40b from the outer periphery of the packing system 1. In detail, the forklift etc. can access the pallet placement section 40a from the rear side (upper side in Figure 10) and left side (including area R9 (Figure 12) (described later)) of the pallet placement section 40a as viewed from the robot 60, and can access the pallet placement section 40b from the right side (including area R9) of the pallet placement section 40b as viewed from the robot 60.

[0092] In such a boxing system 1, the robot 60 performs the following tasks within a time interval T1 during which a predetermined number (e.g., 24) of individual packaging boxes 80 are placed at the first standby position P1: preparing the cardboard boxes 90 (arrow B1), packing the boxes into the cardboard boxes 90 (arrow B2), assisting in top-side sealing (arrow B3, etc.), and transferring the boxes to a pallet (arrow B4). For example, if the transport interval between individual packaging boxes 80 in the object transport unit 10 is 3 seconds, the 24 individual packaging boxes 80 are lined up at the first standby position P1 at intervals of 72 (=3*24) seconds. The robot 60 performs these four tasks (see arrows B1, B2, B3, and B4) within this time interval T1 (e.g., 72 seconds).

[0093] Furthermore, the robot 60 performs these four tasks, for example, in the following order: packing into the cardboard box 90a (arrow B2), assisting in sealing the top of the cardboard box 90a (arrow B3, etc.), preparation for the next cardboard box 90b (arrow B1), and transfer (another sealed cardboard box 90z) to the pallet 41 (arrow B4). However, this is not limitative, and the tasks may be performed in another order, for example, packing into the cardboard box 90a (arrow B2), assisting in sealing the top of the cardboard box 90a (arrow B3, etc.), transfer (another sealed cardboard box 90z) to the pallet 41 (arrow B4), and preparation for the cardboard box 90b next to the cardboard box 90a (arrow B1).

[0094] <4. Layout> 2, 3, 4, 11, etc. (top views), in a top view, a robot 60 is provided near the center of the packing system 1, and an object transport unit 10, a cardboard box transport unit 30, a box forming unit 20, and a pallet placement unit 40 are provided (counterclockwise) to surround the robot 60. In other words, the object transport unit 10, the cardboard box transport unit 30, the box forming unit 20, and the pallet placement unit 40 are provided in the peripheral area of ​​the robot 60 (more specifically, in the area adjacent to the robot 60).

[0095] Specifically, among the four lateral areas E1 to E4 (see FIG. 11) of the robot 60, the belt conveyor 12 of the object transport unit 10 and the roller conveyor 31a of the cardboard box transport unit 30 are arranged in a straight line in the first lateral area E1 (the area on the lower side in FIG. 11, etc.). The first standby position P1 of the belt conveyor 12 is provided near (adjacent to) the second standby position P2 of the cardboard box transport unit 30.

[0096] 11 is a diagram showing four lateral regions E1 to E4. The four lateral regions E1 to E4 are regions (four lateral regions on the top, bottom, left, and right in FIGS. 3 and 11) obtained by roughly dividing the periphery (360 degrees) of the robot 60 into four directions (approximately 90 degrees each). The second lateral region E2 is adjacent to the first lateral region E1 and the third lateral region E3, and the third lateral region E3 is adjacent to the second lateral region E2 and the fourth lateral region E4. The fourth lateral region E4 is adjacent to the third lateral region E3 and the first lateral region E1, and the first lateral region E1 is adjacent to the fourth lateral region E4 and the second lateral region E2.

[0097] Furthermore, in the second side area E2 (the area to the right in FIG. 11 and other figures) of the four side areas E1 to E4 of the robot 60, the roller conveyor 31c (particularly the third standby position P3) of the cardboard box conveying section 30 and the box forming section 20 (particularly the forming position P0) are arranged. Of the three sub-paths that form the U-shaped conveying path in the cardboard box conveying section 30, the box forming section 20 is arranged adjacent to the cardboard box conveying section 30 (specifically the third sub-path) along the third sub-path (roller conveyor 31c) that includes the terminal end (third standby position P3) of the cardboard box conveying section 30. Specifically, the box forming section 20 is arranged adjacent to the third sub-path, not adjacent to the first sub-path.

[0098] Furthermore, pallet placement units 40a and 40b are arranged in the remaining two lateral areas of the four lateral areas E1 to E4 of the robot 60, namely, a third lateral area E3 (upper area in FIG. 3) and a fourth lateral area E4 (left area in FIG. 3). Specifically, in FIG. 3, pallet placement unit 40a is arranged above the robot 60 (third lateral area E3), and pallet placement unit 40b is arranged to the left of the robot 60 (fourth lateral area E4). Pallet placement units 40a and 40b are arranged in directions that differ by 90 degrees from each other with the robot 60 as the base point, and are arranged in a so-called L-shape (including robot 60).

[0099] The roller conveyor 31a is provided in a range spanning both the first side area E1 and the second side area E2, and the roller conveyor 31b is provided in the second side area E2. The box molding section 20 is provided in a range spanning both the second side area E2 and the third side area E3. The belt conveyor 11 is provided in the fourth side area E4, and the belt conveyor 12 is provided in a range spanning both the fourth side area E4 and the first side area E1. The belt conveyor 12 is provided along the left side (left edge) of the pallet placement section 40b as viewed from the robot 60, and the belt conveyor 11 is provided on the far side of the pallet placement section 40b as viewed from the robot 60 (stretching from directly behind to the left rear). In other words, the pallet placement unit 40b is provided between the robot 60 and the belt conveyor 11 (specifically, on the upstream side of the belt conveyor 11).

[0100] The first standby position P1, the second standby position P2, the third standby position P3, and the molding position P0 are located within the working range of the robot 60 (and also within the peripheral area (more specifically, the adjacent area) of the robot 60). In Figure 2 and other figures, the working range of the robot 60 is shown as a circular area surrounded by a dashed line.

[0101] Furthermore, these positions P1, P2, P3, and P0 are located within a range extending from the first lateral area E1 (the lower area in Figure 3) to the second lateral area E2 (the right area in Figure 3) of the four lateral areas E1 to E4 into which the area around the robot 60 is broadly divided (extending across the adjacent first lateral area E1 and second lateral area E2).

[0102] Specifically, the first standby position P1 is located in a first lateral area E1 (downward in FIG. 3) of the robot 60, and the third standby position P3 and the molding position P0 (the position where the cardboard box 90 molded in the box molding section 20 is located) are located in a second lateral area E2 (rightward area in FIG. 3) of the robot 60. The second standby position P2 is located between (in the direction of) the first standby position P1 and the third standby position P3, and is located in the first lateral area E1 and / or the second lateral area E2.

[0103] Furthermore, the molding position P0 of the box molding unit 20 is arranged between the first standby position P1 and the second standby position P2 and the third standby position P3. In other words, the second standby position P2 and the third standby position P3 are arranged between the first standby position P1 and the molding position P0 (around the robot 60). Furthermore, the molding position P0 is arranged between the second standby position P2 and the third standby position P3. In other words, the third standby position P3 is provided between the molding position P0 and the second standby position P2.

[0104] These positions P1, P2, P3, and P0 are concentrated in a range that spans only two side areas (the first side area E1 and the second side area E2) out of the four side areas E1 to E4 that are roughly divided around the robot 60. Therefore, it is possible to realize a compact system layout while making it possible to arrange the pallet placement unit 40 in at least one of the other two side areas (the third side area E3 and the fourth side area E4).

[0105] Furthermore, the two pallet placement units 40 are located within a range extending from the third lateral area E3 to the fourth lateral area E4 (a range extending from the top to the left in FIG. 3), and positions P1, P2, P3, and P0 are located within a range extending from the first lateral area E1 to the second lateral area E2 (a range extending from the bottom to the right in FIG. 3). In other words, positions P1, P2, P3, and P0 are located on opposite sides of the robot 60 from the two pallet placement units 40. This effectively separates the pallet placement units 40 (40a, 40b), which are areas where humans (workers) often enter, from other areas, allowing for appropriate cooperative operations between humans and robots.

[0106] Note that Fig. 12 is a diagram obtained by rotating Fig. 11 (and Fig. 3, etc.) 135 degrees counterclockwise. The first lateral area E1 of the robot 60 corresponds to the upper right area (of the robot 60) in Fig. 12. In Fig. 12, the second lateral area E2 corresponds to the upper left area, the third lateral area E3 corresponds to the lower left area, and the fourth lateral area E4 corresponds to the lower right area.

[0107] <5. Collaborative work between robots and humans> In the packing system 1, the area around the robot 60 (particularly the movable area of ​​the robot 60 (see the dashed circular area)) is roughly divided into a left half area R1 and a right half area R2 in FIG. 12. The left half area R1 is an area including the second lateral area E2 and the third lateral area E3, and the right half area R2 is an area including the first lateral area E1 and the fourth lateral area E4. The left half area R1 includes the first pallet placement unit 40a and the box molding unit 20, and the right half area R2 includes the second pallet placement unit 40b and the object conveying unit 10. The cardboard box conveying unit 30 is disposed across both areas R1 and R2. The left half area R1 is also referred to as the first working space, and the right half area R2 is also referred to as the second working space. In other words, the space around the robot 60 (particularly the space near the periphery) is roughly divided into a first working space R1 and a second working space R2.

[0108] When the robot 60 transfers the cardboard box 90 from the third standby position P3 to the pallet 41a in the first pallet loading section 40a, it moves counterclockwise from the third standby position P3 (around the center of rotation of the base of the robot 60) so as not to pass over the pallet 41b.

[0109] When the robot 60 transfers the cardboard box 90 from the third standby position P3 to the pallet 41b in the second pallet loading section 40b, the robot 60 moves clockwise from the third standby position P3 (around the center of rotation of the base of the robot 60) so as not to pass over the pallet 41a.

[0110] The packing system 1 takes into consideration cooperative work between the robot 60 and humans. Specifically, it has an operation continuation mode in which, even if a human is present in one of the two work spaces (first work space R1 and second work space R2), the robot 60 continues working in the other of the two work spaces. In the operation continuation mode, (in principle) the robot is prohibited from working in one of the spaces (human work is permitted), and the robot works (continues) in the other space at a low speed (slower than the normal operating speed of the robot 60 (when no human is present)). In the operation continuation mode, it is possible to continue the robot work in one space while ensuring the safety of the human in the other space.

[0111] The operation continuation mode (also referred to as the low-speed mode) is initiated by a start command from a worker (human) and terminated by a stop command from the worker. The start command and the end command are given by inputting operations on the operation panel of the controller 70. The input command specifies a robot work prohibited space (human work space) or a robot work continuation space in addition to the start command for the operation continuation mode. In addition, in response to the end command, the robot 60 returns to work at a normal speed (a faster operating speed than in the low-speed mode).

[0112] The operation continuation mode has two sub-modes (first mode and second mode) depending on which of the two regions R1 and R2 human work is permitted in (which region low-speed operation is continued in).

[0113] The first mode is a mode in which human work is permitted in the first workspace R1 (left half area in FIG. 12) (a mode in which the robot work continues at a low speed in the second workspace R2), while the second mode is a mode in which human work is permitted in the second workspace R2 (right half area in FIG. 12) (a mode in which the robot work continues at a low speed in the first workspace R1).

[0114] For example, in the first mode, human work is permitted in the first workspace R1, but robot work is prohibited in the first workspace R1. In the first mode, the robot work continues (in principle) at low speed only in the second workspace R2 (the right half area of ​​FIG. 12). The first mode is also referred to as a mode in which low-speed operation is continued only in the right half area (second workspace) R2.

[0115] Specifically, while a human (worker) is performing the task of replacing the pallets 41a in the first pallet placement unit 40a in the left half area (first work space) R1 (including the task of moving the pallet 41a to another location using a forklift or the like and the task of placing the next pallet 41a on the first pallet placement unit 40a), the robot 60 can continue the palletizing task in the right half area (second work space) R2. Specifically, the robot 60 can continue the task of transferring the cardboard boxes 90 clockwise from the third standby position P3 to the pallets 41b in the second pallet placement unit 40b at a low speed. Note that this operation continuation mode assumes that no human is working near the third standby position P3, and the robot 60 is allowed to pass through the left half area (first work space) R1 near the third standby position P3 (clockwise from the third standby position P3).

[0116] In the second mode, human work is permitted in the second workspace R2, but robot work is prohibited in the second workspace R2. In the second mode, robot work continues (in principle) at low speed only in the first workspace R1 (the left half area of ​​FIG. 12). The second mode is also referred to as a mode in which low-speed operation continues only in the left half area (first workspace) R1.

[0117] Specifically, while a human (worker) is performing work to resolve a defect that has occurred in the object transport unit 10 from outside the object transport unit 10 (upper right side of FIG. 12) in the right half area (second work space) R2, the robot 60 can continue the palletizing work in the left half area (first work space) R1. An example of a defect resolution work is work to resolve an abnormal alignment of the individual boxes 80 (work to align the individual boxes 80 that protrude from the row).

[0118] Furthermore, while a human (worker) is performing the task of replacing the pallets 41b on the pallet placement unit 40b in the right half area (second work space) R2 (including the task of moving the pallets 41b to another location using a forklift or the like), the robot 60 can continue the palletizing task in the left half area (first work space) R1. Specifically, the robot 60 can continue the task of transferring the cardboard boxes 90 counterclockwise from the third standby position P3 to the pallets 41a in the first pallet placement unit 40a at a low speed.

[0119] In this packing system 1, the robot 60 is controlled not to enter area R9 (see FIG. 12) within its movement range. Area R9 is an area sandwiched between pallet placement units 40a and 40b, and is an area on the outer periphery (away from the robot 60) of the closest position between pallet placement units 40a and 40b. This allows a person to pass through area R9 (including a part of the first workspace R1) within the robot's working range when accessing the pallet 41b on pallet placement unit 40b in the second mode. Similarly, in the first mode, a person to access the pallet 41a on pallet placement unit 40a is allowed to pass through area R9 (including a part of the second workspace R2) within the robot's working range.

[0120] Furthermore, the operation continuation mode may be initiated by a start operation (such as an input operation on the operation panel of the controller 70) by an operator (human) as described above, but is not limited to this. For example, when the transfer of a predetermined number of cardboard boxes 90 onto the pallet placement unit 40a is completed, the first mode (an operation continuation mode in which human work is permitted in the first work space R1 and robot work continues at a low speed in the second work space R2) may be automatically initiated. Similarly, when the transfer of a predetermined number of cardboard boxes 90 onto the pallet placement unit 40b is completed, the second mode (an operation continuation mode in which human work is permitted in the second work space R2 and robot work continues at a low speed in the first work space R1) may be automatically initiated. In this way, the replacement operation of a pallet for which palletizing has been completed can be automatically initiated (without any particular operation), and subsequently, new palletizing onto the other pallet can be automatically initiated.

[0121] <6. Effects of the embodiment> In the packing system 1, the robot 60 not only packs multiple objects into cardboard boxes 90, but also transfers (palletizes) the cardboard boxes 90 from the third standby position P3 onto the pallets 41 of the pallet placement unit 40. Therefore, it is not necessary to provide separate robots for the packing work and the palletizing work. In short, it is not necessary to provide two robots, and only one robot is required. Therefore, it is possible to improve space efficiency (space saving).

[0122] Furthermore, the cardboard box 90 formed at the forming position P0 of the box forming section 20 is transferred by the robot 60 to the second standby position P2 of the cardboard box conveying section 30.

[0123] This eliminates the need to provide a transport path area (area for arranging a transport conveyor, etc.) from the box forming unit 20 to the second standby position P2 (packing position), thereby improving space efficiency.

[0124] Furthermore, it is not necessarily required to dispose the box forming unit 20 upstream of the cardboard box conveying unit 30. This increases the degree of freedom in the positioning of the box forming unit 20. As a result, it is possible to improve space efficiency.

[0125] For example, in this embodiment, the box molding unit 20 is disposed within the working range of the robot 60 in an area not connected to the upstream portion of the cardboard box conveying unit 30 (such as the bottom sealing unit 32 at the second standby position P2) by a conveyance path such as a conveyor (i.e., an enclave separated from (the conveyance path of) the cardboard box conveying unit 30). In other words, the box molding unit 20 fulfills the role of supplying molded cardboard boxes 90 to the upstream portion of the cardboard box conveying unit 30 in a manner not connected to the upstream portion of the cardboard box conveying unit 30 (the second standby position P2) via a conveyance path. Specifically, the box molding unit 20 is disposed to the side (upper side in FIG. 2 ) (in a direction perpendicular to the conveyance direction of the cardboard box conveying unit 30) of the cardboard box conveying unit 30 (more specifically, the third standby position P3 at the most downstream of the cardboard box conveying unit 30), along the roller conveyor 31c downstream of the cardboard box conveying unit 30. The box forming unit 20 is arranged in a state where it is not (directly) connected to the second standby position P2 (the upstream part of the cardboard box conveying unit 30) by the transfer conveyor. The box forming unit 20 is arranged adjacent to the cardboard box conveying unit 30 itself, but is arranged away from the upstream part of the cardboard box conveying unit 30.

[0126] This allows the object conveying unit 10 to be located upstream of the cardboard box conveying unit 30, and the object conveying unit 10 and the cardboard box conveying unit 30 to be located close to each other (particularly the first standby position P1 and the second standby position P2 to be located close to each other). This in turn makes it possible to improve the efficiency of the boxing work (reduce the time required). Furthermore, the box forming unit 20 (the unit that supplies cardboard boxes 90 to the cardboard box conveying unit 30) can be located in an appropriate area other than the upstream side of the cardboard box conveying unit 30 (for example, a side area of ​​the cardboard box conveying unit 30).

[0127] Furthermore, the cardboard box transport unit 30 has a transport path along which the cardboard box 90 packed by the robot 60 at the second standby position P2 first moves away from the robot 60, then changes direction and moves toward the robot 60 (returning to the vicinity of the robot 60). More specifically, the cardboard box transport unit 30 has a U-shaped transport path. A third standby position P3 is provided at the downstream end (terminal end) of the U-shaped transport path. The robot 60 then performs a palletizing operation of transferring the cardboard box 90 from the third standby position P3 onto a pallet 41.

[0128] In this way, the cardboard box 90 packed by the robot 60 at the second standby position P2 is moved by the cardboard box conveying unit 30 in a direction away from the robot 60, and then brought closer to the robot 60 again to the third standby position P3 within the working range of the robot 60. The cardboard box 90 is then moved by the robot 60 from the third standby position P3 onto the pallet 41. In this way, since not only the second standby position P2 but also the third standby position P3 are located near the robot 60, it is possible to effectively perform not only the packing work but also the palletizing work by a single robot 60. In particular, the third standby position P3 is located in an area adjacent to the robot 60 (neighborhood area). Therefore, it is possible to improve the working efficiency of the robot 60 (efficiency of the palletizing work).

[0129] Furthermore, positions P1, P2, P3, and P0 are concentrated within a range that spans only two adjacent side areas (the first side area E1 and the second side area E2) of the four side areas E1 to E4 that are roughly divided around the robot 60. This makes it possible to arrange the pallet placement unit 40 in at least one of the other two side areas (the third side area E3 and the fourth side area E4), while still achieving a compact system arrangement. In particular, it is possible to achieve a compact packing system 1 while ensuring sufficient space around the robot 60 for the arrangement of two pallets.

[0130] Furthermore, the pallet placement unit 40 is disposed in the third side area E3 and the fourth side area E4, and positions P1, P2, P3, and P0 are concentrated in a range spanning the first side area E1 and the second side area E2 among the four side areas. This makes it possible to prevent interference between the robot 60 and the cardboard boxes 90 on the pallet 41 of the pallet placement unit 40 when the robot 60 accesses any of positions P0, P1, P2, and P3.

[0131] For example, let us assume that molding position P0 is located higher (in the third side area E3) than the position shown in FIG. 3 (the second side area E2). In this case, near the line connecting molding position P0 and the center of the base of robot 60, cardboard boxes 90 stacked up to a high (vertical) position (for example, up to the highest level) on pallet 41a may interfere with robot 60 moving toward molding position P0. However, by not having position P0 in the third side area E3 or the fourth side area, such interference can be avoided. The same applies to the other positions P1, P2, and P3.

[0132] Furthermore, the U-shaped conveying path corresponding to roller conveyors 31b and 31c also functions as a buffer area (an area that is originally required to a certain extent) for waiting for palletizing work. Therefore, the provision of roller conveyors 31b and 31c hardly reduces space efficiency (or reduces space efficiency). In particular, the third standby position P3 at the end of the U-shaped path is located close to the second standby position P2 at the start of the U-shaped path. This prevents the path length of the conveying path corresponding to roller conveyor 31b (and thus the cardboard box conveying unit 30) from increasing (e.g., increasing to an area larger than the required buffer area), thereby enabling a compact system configuration.

[0133] Furthermore, the cardboard box 90 moves on the roller conveyors 31a and 31c along the longitudinal direction of the cardboard box 90. In other words, the conveying direction of the roller conveyors 31a and 31c is the longitudinal direction of the cardboard box 90, and the conveying direction of the roller conveyor 31b is the lateral direction of the cardboard box 90. Therefore, it is possible to shorten the path length (the vertical length in FIG. 2) of the roller conveyor 31b in the U-shaped cardboard box conveying section 30, and thus to position the second standby position P2 and the third standby position P3 close to each other.

[0134] The robot 60 also performs the task of pushing and moving a cardboard box 90 containing a plurality of individual packaging boxes 80 from the second standby position P2 to the top sealing unit 33. This eliminates the need to provide the cardboard box conveying unit 30 with a mechanism for moving the cardboard box from the second standby position P2 to the top sealing unit 33. Therefore, it is possible to simplify the drive mechanism of the cardboard box conveying unit 30.

[0135] <7. Modifications, etc.> Although the embodiment of the present invention has been described above, the present invention is not limited to the above-described contents.

[0136] For example, in the above-described embodiment, the second standby position P2 and the third standby position P3 may be reversed. In other words, the U-shaped cardboard box conveying section 30 may be provided upside down in FIG. 3, etc.

[0137] Furthermore, in the above-described embodiment, two pallet placement units 40a, 40b are provided, but this is not limited thereto, and only one of the two pallet placement units 40a, 40b may be provided. FIG. 15 is a top view showing a packing system 1 (also referred to as 1B) according to such a modified example. For example, as shown in FIG. 15, only a single pallet placement unit 40a may be provided (only in the third lateral area E3). Furthermore, the conveying path length of the object conveying unit 10 (particularly the path length of the belt conveyor 12) may be shorter than that of the above-described embodiment (see FIG. 3, etc.). This makes it possible to realize a more compact packing system 1. However, this is not limited thereto, and conversely, only a single pallet placement unit 40b may be provided (only in the fourth lateral area E4).

[0138] Furthermore, the packing system 1 (also referred to as 1A) according to the embodiment and the packing system 1B according to the modified example differ in the presence or absence of the pallet placement section 40b and the path length of the belt conveyor 12, but have a common configuration in other respects. Therefore, it is possible to standardize or modularize the packing system.

[0139] Furthermore, in the above-described embodiment, the robot 60 performs the four tasks described above (see arrows B1, B2, B3, and B4 in FIG. 4, etc.), but is not limited to this. For example, the robot 60 may perform three tasks (see arrows B1, B2, and B4) excluding the assisting task of sealing the top of the cardboard box 90a (arrow B3, etc.). Alternatively, the robot 60 may perform two tasks (see arrows B2 and B4) excluding the preparation task (arrow B1) of the cardboard box 90a.

[0140] In the above-described embodiments, the individual packaging box 80 is exemplified as the target object, but the present invention is not limited to this. For example, the target object may be a product having a shape other than a rectangular parallelepiped (a product having a special shape). In this case, the robot hand 67 suitable for handling the product (the robot hand 67 having a separate handling unit instead of the suction unit 68d) may be used to pack the product into the cardboard box 90.

[0141] In the above-described embodiment, a predetermined number of individual packaging boxes 80 are aligned in a row in the object transport section 10, and multiple rows of individual packaging boxes 80 are packed together in the cardboard box 90, but this is not limiting. For example, the individual packaging boxes 80 may be supplied one by one to the first standby position P1, and the individual packaging boxes 80 may be packed one by one in the cardboard box 90. However, from the viewpoint of efficiency, it is preferable that two or more individual packaging boxes 80 are packed together (collectively) in the cardboard box 90 at one time. [Explanation of symbols]

[0142] 1,1A,1B Packaging System 10 Object transport section 11,12 Belt conveyor 20 Box molding section 30 Cardboard box transport section 31a, 31b, 31c Roller conveyor 32 Bottom sealing part 33 Top sealing section (sealing section) 40, 40a, 40b Pallet placement section 41a, 41b Palette 60 Robot 67 Robot Hand 68a, 68b, 68c, 68d Adsorption part 70 Controller 75 Operation section 80 individual boxes 90 Cardboard Box

Claims

1. an object transport unit that transports a plurality of objects to a first standby position; a box molding unit that molds a cardboard box for storing the plurality of objects; a robot that packs the plurality of objects into the cardboard box that has been formed by the box forming unit and is present at a second standby position; a cardboard box transport unit that transports the cardboard box containing the plurality of objects to a third standby position; a pallet placement section on which a pallet for loading the cardboard boxes is placed; Equipped with The robot In addition to the work of packing the plurality of objects moved to the first standby position into the cardboard box present at the second standby position, A boxing system characterized in that the system also performs the task of transferring the cardboard box that has moved to the third standby position onto the pallet of the pallet placement section.

2. the cardboard box conveying unit has the second standby position, 2. The boxing system according to claim 1, wherein the robot also performs the task of moving the cardboard box formed at the forming position of the box forming unit from the forming position to the second waiting position of the cardboard box conveying unit.

3. 3. The box packing system according to claim 2, wherein the box forming section is disposed upstream of the cardboard box transport section without being connected to a transport conveyor.

4. the cardboard box transport unit has a transport path along which the cardboard box packed at the second standby position is first moved in a direction away from the robot and then moved in a direction toward the robot, the transport path includes a first sub-path, a second sub-path, and a third sub-path; the first sub-path is a path along which the cardboard boxes packed at the second standby position are temporarily moved in a direction away from the robot, the second sub-path is a path for moving the cardboard box that has moved on the first sub-path to the third sub-path, the third sub-path is a path along which the cardboard box that has moved along the first sub-path and the second sub-path moves in a direction approaching the robot, 4. The cartoning system according to claim 3, wherein the third waiting position is provided at a downstream end of the third sub-path.

5. 5. The cartoning system according to claim 4, wherein the second standby position and the third standby position are provided between the first standby position and the molding position.

6. 5. The cartoning system according to claim 4, wherein the third waiting position is provided between the second waiting position and the molding position.

7. 5. The cartoning system of claim 4, wherein the box forming section is positioned adjacent to the third sub-path and not adjacent to the first sub-path.

8. the object transport unit is disposed upstream of the cardboard box transport unit, the first standby position is provided at a downstream end of the object transport unit, the second standby position is provided at the upstream end of the cardboard box conveying section, 8. The boxing system according to claim 7, wherein the first standby position of the object transporting unit is provided near the second standby position of the cardboard box transporting unit.

9. the first standby position, the second standby position, the third standby position, and the molding position are provided across a first side area and a second side area, which are two adjacent sides of four side areas that roughly divide the periphery of the robot into four areas, the pallet placement units are provided in the remaining two side areas of the four side areas, that is, a third side area and a fourth side area, the first standby position is provided in the first side area, the third standby position is provided in the second side region adjacent to the first side region, the second standby position is provided at a position adjacent to the first standby position between the first standby position and the third standby position, the molding position is provided in the second side region; the pallet placement unit includes a first pallet placement unit and a second pallet placement unit, each capable of placing a pallet thereon; the first pallet placement section is provided in the third side area, 9. The cartoning system according to claim 8, wherein the second pallet rest is provided in the fourth side area.

10. the first standby position, the second standby position, the third standby position, and the molding position are provided across a first side area and a second side area, which are two adjacent sides of four side areas that roughly divide the periphery of the robot into four areas, 3. The box packing system according to claim 2, wherein the pallet placement section is provided in at least one of the remaining two side areas, namely, a third side area and a fourth side area, of the four side areas.

11. the cardboard box conveying unit has a top sealing unit that seals the top surface of the cardboard box, the top sealing unit being located downstream of the second standby position; 3. The boxing system according to claim 2, wherein the robot also performs the task of pushing the cardboard box containing the plurality of objects from the second standby position to the top sealing section.

12. the cardboard box conveying unit has a bottom sealing unit at the second standby position that seals the bottom of the cardboard box, the robot moves the cardboard box, which has been unfolded in the box molding unit and is open at the top and bottom, from the box molding unit to the second standby position; the bottom sealing unit seals the bottom of the cardboard box that has been moved to the second standby position, 3. The boxing system according to claim 2, wherein the robot packs the plurality of objects into the cardboard box whose bottom surface has been sealed.

13. the first standby position, the second standby position, the third standby position, and the molding position are provided across a first side area and a second side area, which are two adjacent side areas among four side areas that roughly divide the periphery of the robot into four areas, the pallet placement unit includes a first pallet placement unit and a second pallet placement unit, each capable of placing a pallet thereon; the first pallet placement section is provided in a third side area adjacent to the second side area, the second pallet placement section is provided in a fourth side area adjacent to the first side area, a peripheral space of the robot is divided into two workspaces: a first workspace including the second lateral area and the third lateral area; and a second workspace including the first lateral area and the fourth lateral area; 3. The case packing system according to claim 2, wherein the robot has an operation continuation mode in which, even if a human being is present in one of the two work spaces, the robot performs work in the other of the two work spaces at a low speed.

14. 14. The boxing system according to claim 13, wherein the operation continuation mode includes a mode in which the robot continues palletizing work to the second pallet placement section in the second work space at a low speed even when a human is performing pallet replacement work on the first pallet placement section in the first work space.

15. the object transport unit is disposed in the second working space, 14. The packing system according to claim 13, wherein the operation continuation mode includes a mode in which the robot continues palletizing work on the first pallet placement section in the first work space at a low speed even when a human is performing work to resolve a malfunction in the object transport section in the second work space.

16. the object is an individual packaging box, the object transport unit has an alignment mechanism that aligns a predetermined number of objects in a line; 16. The packing system according to claim 1, wherein the robot packs the plurality of objects into the cardboard box in units of a predetermined number or in units of an integer multiple of the predetermined number.

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