Transfer system, and its control method and control program

Abstract

To quickly perform a recovery work for a failure in holding or transferring an article.SOLUTION: A transfer system (1) includes: a transport unit (11) that transports an article; a transfer unit (12) that is installed at one end of the transport unit (11) and holds and transfers the article (2); a camera unit (13) that photographs the article (2) and creates a photographed image; and a control unit (15) capable of performing automatic transfer that controls the transfer unit (12) based on the photographed image and manual transfer that controls the transfer unit (12) based on an instruction from a worker (S).SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a goods transfer system in logistics, as well as its control method and control program.

Background Art

[0002] Conventionally, in logistics warehouses and the like, in order to efficiently sort and separate a large variety and quantity of goods into shipping containers by destination, a transfer system equipped with a picking device (transfer device) such as a robotic arm has been used. Regarding this type of transfer system, Patent Document 1 discloses a configuration that can perform automatic transfer in which the picking device automatically transfers goods and manual transfer in which an operator transfers goods using their own hands.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the case of the above configuration, in the above automatic transfer, if the picking device fails to hold or transfer the goods, the transfer will be switched from the automatic transfer to the manual transfer to perform the recovery work for the failure. At this time, after retreating the picking device from the dangerous space where there is a possibility of contact between the picking device and the operator, the operator will hold and transfer the goods that failed to be held or transferred by the manual transfer. And when the manual transfer is completed, after the operator retreats from the dangerous space, it will return to the automatic transfer. Thus, switching between the automatic transfer and the manual transfer takes time to ensure the safety of the operator.

[0005] One aspect of the present invention aims to realize a transfer system, etc., that can quickly recover from failures in holding or transferring articles. [Means for solving the problem]

[0006] To solve the above problems, a transfer system according to one aspect of the present invention comprises a transport unit for transporting articles, a transfer unit installed at one end of the transport unit for holding and transferring the articles, a camera unit for photographing the articles and creating an image, and a control unit for controlling the transfer unit based on the image or based on instructions from an operator.

[0007] Furthermore, another aspect of the present invention relates to a control method for a transfer system comprising: a transport unit for transporting articles; a transfer unit installed at one end of the transport unit for holding and transferring the articles; and a camera unit for photographing the articles and creating a captured image, the method comprising the step of switching between automatic transfer, which controls the transfer unit based on the captured image, and manual transfer, which controls the transfer unit based on instructions from an operator. [Effects of the Invention]

[0008] According to one aspect of the present invention, if the holding or transfer of an article fails, recovery work for the failure can be carried out quickly. [Brief explanation of the drawing]

[0009] [Figure 1] This is a perspective view showing an overview of a transfer system according to one embodiment of the present invention. [Figure 2] This is a plan view showing an overview of the above transfer system. [Figure 3] This figure shows an example of the operation of the transport unit and the transfer unit in the above transfer system. [Figure 4] This is a block diagram outlining the above transfer system. [Figure 5] This flowchart shows an example of the automatic transfer process in the control unit of the above transfer system. [Figure 6] This flowchart shows an example of the manual transfer process in the control unit described above. [Figure 7] This is a block diagram illustrating an overview of a transfer system according to another embodiment of the present invention. [Figure 8] This is a block diagram illustrating an overview of a transfer system according to another embodiment of the present invention. [Modes for carrying out the invention]

[0010] The embodiments of the present invention will be described in detail below. For the sake of convenience, components having the same function as those shown in each embodiment will be denoted by the same reference numerals, and their descriptions will be omitted as appropriate.

[0011] [Embodiment 1] One embodiment of the present invention will be described with reference to Figures 1 to 6. In the following description, for example, a transfer system is configured to transfer goods between two first and second containers. The first and second containers may each constitute a shipping container that is shipped outside the transfer system 1.

[0012] (Overview of the transfer system) Figure 1 is a perspective view showing an overview of the transfer system 1 according to this embodiment. Figure 2 is a plan view showing an overview of the transfer system 1. The transfer system 1 is used to transfer goods 2 in a logistics warehouse or the like. As shown in Figures 1 and 2, the transfer system 1 of this embodiment includes a transport unit 11, a transfer unit 12, a camera unit 13, a support frame 14, a control unit 15, and a terminal unit 16.

[0013] (Transportation section) The conveying unit 11 conveys the first container 17 and the second container 18 that contain the article 2 in the Y direction (front-rear direction, first direction). Specifically, the conveying unit 11 includes the loading conveyors 11a and 11b provided on the lower side in the Z direction, and the unloading conveyors 11c and 11d provided on the upper side in the Z direction. The first container 17 and the second container 18 are respectively conveyed to the front side in the Y direction by the loading conveyors 11a and 11b. Also, the first container 17 and the second container 18 are respectively conveyed to the rear side in the Y direction by the unloading conveyors 11c and 11d.

[0014] Furthermore, the conveying unit 11 includes a moving mechanism 11e and a housing 11f. The moving mechanism 11e sequentially moves the first container 17 from the loading conveyor 11a to the first transfer position P1, and sequentially moves the second container 18 from the loading conveyor 11b to the second transfer position P2. Also, the moving mechanism 11e sequentially moves the first container 17 arranged at the first transfer position P1 to the unloading conveyor 11c, and sequentially moves the second container 18 arranged at the second transfer position P2 to the unloading conveyor 11c. The housing 11f houses the moving mechanism 11e.

[0015] (Transfer unit) The transfer unit 12 is installed on the front end side (one end side) in the Y direction of the conveying unit 11, holds the article 2 contained in the first container 17 arranged at the first transfer position P1, and transfers it to the second container 18 arranged at the second transfer position P2. The transfer unit 12 is installed above the moving mechanism 11e and the housing 11f of the conveying unit 11 by a gantry or the like (not shown).

[0016] The transfer unit 12 includes a picking head 12a that holds the article 2, and a drive unit 12b that moves the picking head 12a up and down in the Z direction and moves the picking head 12a in two directions, the X direction and the Y direction, in a plan view. The picking head 12a is composed of, for example, one or more suction pads that adsorb the article 2. The picking head 12a adsorbs the article 2 contained in the first container 17 from above and holds the article 2 in a suspended state.

[0017] The drive unit 12b includes a fixed rail 12c, a first movable rail 12d, a second movable rail 12e, and a support arm 12f. The fixed rail 12c is installed along the X direction. The first movable rail 12d is installed along the Z direction and reciprocates in the X direction along the fixed rail 12c. The second movable rail 12e is installed along the Y direction and reciprocates in the Z direction along the first movable rail 12d.

[0018] The support arm 12f is installed along the Z direction and reciprocates in the Y direction along the second movable rail 12e. Also, a picking head 12a is attached to the lower side of the support arm 12f in the Z direction. Thereby, the transfer unit 12 can reciprocate the picking head 12a in three directions of XYZ by controlling the operation of the drive unit 12b.

[0019] Compared with a transfer unit such as a 6-axis robot, etc., the transfer unit 12 has a simple structure and is easily adaptable to a multi-row conveyor layout. Therefore, by using the transfer unit 12, the degree of freedom in the layout design of the transfer system 1 is improved.

[0020] (Camera unit) [[ID=I4]]The camera unit 13 is disposed above the transfer unit 12 and captures an article 2 to create a captured image. The camera unit 13 includes a first camera 13a and a second camera 13b. The first camera 13a captures one or more articles 2 accommodated in the first container 17 by capturing the first container 17 disposed at the first transfer position P?. The second camera 13b captures one or more articles 2 accommodated in the second container 18 by capturing the second container 18 disposed at the second transfer position P2. Note that the camera unit 13 may include a light or the like, and the first camera 13a and the second camera 13b may capture the article 2 in a state illuminated with a predetermined illuminance by a light or the like, respectively.

[0021] (Support frame) The support frame 14 is a frame that supports the camera unit 13. The support frame 14 includes support sections 14a, 14a that are installed adjacent to each other in the X direction (left-right direction, second direction) perpendicular to the Y direction with respect to the transfer unit 12 in a plan view, and beam members 14b, 14b that are installed between the support sections 14a, 14a. The first camera 13a and the second camera 13b are installed at appropriate locations on the beam member 14b on the front side in the Y direction. Note that there may be one beam member 14b or three or more.

[0022] Each of the support sections 14a-14a includes two column members 14c-14d, a girder member 14e, and a reinforcing member 14f. The column members 14c-14d are arranged in the Y direction and are fixed to the installation site of the transfer system 1 by fixing members 14g-14h. The girder member 14e and the reinforcing member 14f are erected between the column members 14c-14d.

[0023] The beam members 14b and 14b may be installed on the girder member 14e, or on the column members 14c and 14d. Furthermore, there may be two or more reinforcing members 14f, or they may be omitted. Also, if each of the support sections 14a and 14a is erected by four or more column members, the beam members 14b and 14b may be omitted. In this case, the first camera 13a and the second camera 13b should be installed at appropriate locations on the support sections 14a and 14a, respectively.

[0024] (Control unit and terminal unit) The control unit 15 controls each part of the transfer system 1 and is composed of a computer including, for example, a CPU (Central Processing Unit) and memory. The operation control of the various components is performed by having the computer execute a control program. Further details of the control unit 15 will be described later.

[0025] The terminal unit 16 is for operator S (Figure 2) to operate the transfer system 1. The terminal unit 16 has an input unit 16a such as a keyboard, touch panel, or joystick, and a display unit 16b that displays predetermined information. These control unit 15 and terminal unit 16 are examples of control equipment for the transfer system 1, and are installed outside the front guard unit 24 (described later) and on the side opposite to the side where the transfer unit 12 is provided (the front side in the Y direction) relative to the work area 25.

[0026] Specifically, the control unit 15 is connected to the transport unit 11, the transfer unit 12, the camera unit 13, and the terminal unit 16 via electrical wiring (not shown). The control unit 15 acquires predetermined information such as operating status from the transport unit 11 and the transfer unit 12, and outputs predetermined command signals such as instruction signals to the transport unit 11 and the transfer unit 12, respectively. The control unit 15 outputs predetermined instruction signals such as on / off signals to the first camera 13a and the second camera 13b of the camera unit 13, and acquires captured data from the first camera 13a and the second camera 13b, respectively. The control unit 15 receives instruction signals and the like from the terminal unit 16 in response to the operator S's operations, and transmits the information acquired from the transport unit 11, the transfer unit 12, and the camera unit 13 to the terminal unit 16.

[0027] (guard) In the transfer system 1 of this embodiment, the transfer unit 12 performs an operation to move the picking head 12a back and forth in the three directions of X, Y, and Z. For this reason, as shown in Figures 1 and 2, a guard is provided around the transfer unit 12 to significantly reduce the possibility of workers S coming into contact with the transfer unit 12 from a safety standpoint. Specifically, in this embodiment, the guard consists of a lateral guard unit 21, a front guard unit 24, and a rear guard unit 41, which are provided sequentially from the control equipment side toward the rear in the Y direction.

[0028] (Side guard section) As shown in Figures 1 and 2, each of the support sections 14a, 14a includes a lateral guard section 21 that separates the transfer section 12 from the outside in the X direction. The lateral guard section 21 includes a transparent plate 22 and a frame member 23 that holds the transparent plate 22. This prevents people, including workers S, from entering from the X direction and coming into contact with the transfer section 12, thereby improving the safety of the transfer system 1.

[0029] Furthermore, since each of the support sections 14a and 14a is provided with a lateral guard section 21, there is no need to newly provide a guard section on the outside of the support sections 14a and 14a in the X direction to separate the transfer section 12 from the outside in the X direction. As a result, the transfer system 1 can be made more space-saving.

[0030] Incidentally, since the two support parts 14a·14a are installed adjacent to the transfer unit 12 in the X direction, they are also adjacent to the housing 11f of the transport unit 11, which is located below the transfer unit 12 in the Z direction. Therefore, in this embodiment, the lateral guard part 21 is omitted in the lower region of the support part 14a, that is, the region facing the housing 11f. This reduces the area where the lateral guard part 21 is provided. On the other hand, the housing 11f prevents the worker S from entering from below the support part 14a and coming into contact with the transfer unit 12. In other words, the housing 11f acts as a partition between the transfer unit 12 and the outside in the X direction in the lower region of the support part 14a.

[0031] (Front guard section) As shown in Figures 1 and 2, in the transfer system 1, a front guard section 24 is provided to separate the work area 25, which is set on the opposite side of the transport section 11 from the transfer section 12 in a plan view, from the outside. The front guard section 24 is connected to two support sections 14a, 14a.

[0032] The work area 25 is a space for manual transfer, in which worker S holds and moves the item 2. In other words, the transfer system 1 of this embodiment is capable of both automatic transfer, in which the transfer unit 12 holds and automatically moves the item 2, and manual transfer, in which worker S enters the work area 25, holds and moves the item 2. The front guard unit 24 is provided around the work area 25, adjacent to the work area 25.

[0033] Specifically, the front guard section 24 includes a plurality of fixed guard sections 26 and a movable guard section 27 connected together. The fixed guard section 26 includes a transparent plate 31 and a frame member 32 that holds the transparent plate 31. The lower corner of the frame member 32 in the Z direction is fixed to the installation location of the transfer system 1 by a fixing member 26a. In addition, the fixed guard sections 26, 26 on the rear side in the Y direction are connected to the front side in the Y direction of the support sections 14a, 14a, respectively.

[0034] The movable guard section 27 constitutes an entrance / exit door for workers S to the work area 25, and includes a fixed frame member 33 and a movable member 34 provided within the fixed frame member 33. The lower corner of the fixed frame member 33 in the Z direction is fixed to the installation location of the transfer system 1 by a fixed member 33a. The movable member 34 is rotatably provided with respect to the fixed frame member 33 via a hinge member (not shown) or the like. The movable member 34 includes a transparent plate 35 and a frame member 36 that holds the transparent plate 35.

[0035] As a result, it is possible to prevent people, including worker S, from inadvertently entering the work area 25 and coming into contact with the transfer unit 12, thereby improving the safety of the transfer system 1. Furthermore, since the front guard unit 24 is provided adjacent to the work area 25, it is possible to suppress the increase in the installation space required for the transfer system 1 due to the provision of the front guard unit 24.

[0036] Furthermore, if the transfer system 1 is only capable of automatic transfer, the work area 25 may be set as a monitoring area for a supervisor to monitor the transfer unit 12. Alternatively, the work area 25 may be omitted. In this case, the front guard unit 24 should be provided adjacent to the transfer unit 12 on the front side in the Y direction of the transfer unit 12.

[0037] (Rear guard section) As shown in Figures 1 and 2, the transfer system 1 is provided with rear guard sections 41 and 41 adjacent to the front end of the transport section 11 in the Y direction in the X direction, and separating the front end from the outside in the X direction. The rear guard section 41 includes a transparent plate 42 and a frame member 43 that holds the transparent plate 42. The front side of the rear guard sections 41 and 41 in the Y direction is connected to the rear side of the support sections 14a and 14a in the Y direction. In addition, the lower corner of the frame member 43 in the Z direction is fixed to the installation location of the transfer system 1 by a fixing member 43a. Furthermore, reinforcing members 44 and 45 are provided between the rear guard sections 41 and 41.

[0038] This prevents people, including worker S, from entering from the transport section 11 and coming into contact with the transfer section 12, thereby improving the safety of the transfer system 1. Furthermore, since the rear guard section 41 is provided adjacent to the transport section 11, it is possible to suppress the increase in the installation space required for the transfer system 1 due to the provision of the rear guard section 41.

[0039] Furthermore, in this embodiment, the front guard section 24, the side guard section 21, and the rear guard section 41 are provided with transparent plates 22, 31, 35, and 42 as effective guards. This allows the operator S of the transfer system 1 to monitor the transport section 11 and the transfer section 12 from outside the transfer system 1 as a supervisor. Note that fences, nets, or other types of guards may be used instead of the transparent plates 22, 31, 35, and 42.

[0040] (Operation of the transfer and transport sections) In the transfer system 1 configured as described above, the control unit 15 first instructs the loading conveyors 11a and 11b of the transport unit 11 to load the first container 17 and the second container 18 from the rear in the Y direction to the front in the Y direction, and continues this process. The control unit 15 also instructs the unloading conveyors 11c and 11d of the transport unit 11 to unload the first container 17 and the second container 18 from the front in the Y direction to the rear in the Y direction, and continues this process.

[0041] Next, the control unit 15 instructs the moving mechanism 11e of the transport unit 11 to move the first container 17 and the second container 18. As a result, the moving mechanism 11e moves the transported first container 17 and the second container 18 to the first transfer position P1 and the second transfer position P2, respectively. Next, the control unit 15 instructs the transfer unit 12 to transfer based on the images of the first container 17 and the second container 18 taken by the camera unit 13. As a result, the transfer unit 12 holds the article 2 contained in the first container 17 at the first transfer position P1 and transfers it to the second container 18 at the second transfer position P2.

[0042] Next, the control unit 15 instructs the moving mechanism 11e of the transport unit 11 to move the first container 17. As a result, the moving mechanism 11e moves the first container 17 from the first transfer position P1 to the unloading conveyor 11c, and moves the next first container 17 that has been loaded to the first transfer position P1. The first container 17 that has been moved to the unloading conveyor 11c is unloaded to the rear in the Y direction.

[0043] The control unit 15 repeatedly issues movement instructions for the first container 17 and transfer instructions, thereby filling the second container 18 with the required items 2. The control unit 15 then issues movement instructions for the first container 17 and the second container 18 to the movement mechanism 11e of the transport unit 11. This moves the first container 17 from the first transfer position P1 to the discharge conveyor 11c, and the second container 18 from the second transfer position P2 to the discharge conveyor 11d. The first container 17, which has been moved to the discharge conveyor 11c, and the second container 18, which has been moved to the discharge conveyor 11d, are then discharged to the rear in the Y direction.

[0044] Figure 3 shows an example of the operation of the transport unit 11 and the transfer unit 12. First, as shown in operation 1001 of Figure 3, the first movable rail 12d moves in the X direction on the fixed rail 12c so that the picking head 12a comes into contact with the item 2a to be transferred in the first container 17 at the first transfer position P1, the second movable rail 12e moves downward in the Z direction on the first movable rail 12d, and the support arm 12f moves in the Y direction on the second movable rail 12e.

[0045] Next, as shown in operation 1002 of Figure 3, the picking head 12a sucks up the article 2a and the second movable rail 12e moves upward in the Z direction on the first movable rail 12d, so that the picking head 12a holds the article 2a and moves upward in the Z direction. Next, as shown in operation 1003 of Figure 3, the first movable rail 12d moves in the X direction on the fixed rail 12c and the support arm 12f moves in the Y direction on the second movable rail 12e, so that the picking head 12a moves the article 2a from its proper place in the second container 18 at the second transfer position P2 to a position upward in the Z direction.

[0046] Next, as shown in operation 1004 of Figure 3, the second movable rail 12e moves downward in the Z direction along the first movable rail 12d so that the picking head 12a places the item 2a in the appropriate position, and the picking head 12a releases its grip on the item 2a. At this time, the moving mechanism 11e of the transport unit 11 moves the first container 17 at the first transfer position P1 to the unloading conveyor 11c, and moves the next first container 17 that has been loaded to the first transfer position P1.

[0047] Then, as shown in operation 1005 of Figure 3, the second movable rail 12e moves upward in the Z direction along the first movable rail 12d in order for the picking head 12a to transfer the next item 2 to be transferred. At this time, the movement mechanism 11e of the transport unit 11 completes the transfer of the first container 17 to the unloading conveyor 11c, and at the same time, the transfer of the next first container 17 to the first transfer position P1 is completed.

[0048] (Details of the control unit and terminal unit) Figure 4 is a block diagram illustrating the overview of the transfer system 1 of this embodiment. In this embodiment, in addition to the automatic and manual transfer described above, manual transfer is possible in which the transfer unit 12 holds and transfers the item 2 when the operator S gives instructions to the terminal unit 16. Note that the control of the transport unit 11 is omitted in Figure 4.

[0049] As described above, the camera unit 13 photographs the first container 17 at the first transfer position P1 and the second container 18 at the second transfer position P2 to create an image. The camera unit 13 transmits the image data showing the above image to the control unit 15 and the terminal unit 16.

[0050] The terminal unit 16 includes an input unit 16a, a display unit 16b, and a notification unit 16c. The input unit 16a receives the above instruction entered by the operator S and creates instruction data indicating the instruction. The input unit 16a transmits the created instruction data to the control unit 15.

[0051] The display unit 16b displays the captured images from the camera unit 13 in real time. This allows the operator S to give instructions to the control unit 15 while referring to the captured images. Furthermore, the display unit 16b displays in real time both the captured image of the source item 2 at the first transfer position P1 and the captured image of the destination item 2 at the second transfer position P2. This allows the operator S to refer to both the captured image of the source item 2 and the captured image of the destination item 2, making it easier to control the transfer unit 12.

[0052] Furthermore, the captured images displayed on the display unit 16b are created using the same cameras (first camera 13a and second camera 13b) as the captured images acquired by the image acquisition unit 15a of the control unit 15. Therefore, there is no need to provide a new camera for creating the captured images displayed on the display unit 16b. However, the captured images displayed on the display unit 16b and the captured images acquired by the image acquisition unit 15a of the control unit 15 may be created using different cameras.

[0053] The notification unit 16c provides notifications to the worker S based on notification instruction data acquired from the control unit 15. Examples of notifications provided by the notification unit 16c include flashing using a light-emitting element, outputting sound using a speaker, displaying information using the display unit 16b, and transmitting information to the worker S's mobile terminal using a wireless communication device.

[0054] The control unit 15 includes an image acquisition unit 15a, an image processing unit 15b, an instruction acquisition unit 15c, and a drive control unit 15d. In the automatic transfer described above, the image acquisition unit 15a, the image processing unit 15b, and the drive control unit 15d are used, while in the manual transfer described above, the instruction acquisition unit 15c and the drive control unit 15d are used.

[0055] The image acquisition unit 15a acquires image data of the articles 2 contained in the first container 17 and the second container 18 from the camera unit 13. The image acquisition unit 15a sends the acquired image data to the image processing unit 15b.

[0056] The image processing unit 15b performs image processing on the captured image to acquire transfer data for transferring the item 2a. The image processing unit 15b sends the acquired data to the drive control unit 15d.

[0057] Specifically, the image processing unit 15b performs image processing on the captured image to extract images of the articles 2 contained in the first container 17 and the second container 18, and identifies the X and Y coordinates of the articles 2 (hereinafter referred to as "XY coordinates"). Since the above image processing is publicly known, its explanation will be omitted. Next, based on the identified XY coordinates of the articles 2, the image processing unit 15b selects the XY coordinates of the article 2a to be transferred in the first container 17 and identifies the XY coordinates of the position where the article 2a will be placed in the second container 18. Then, the image processing unit 15b sends the XY coordinate data of the article 2a to be transferred and the XY coordinate data of the position to be placed as described above to the drive control unit 15d as transfer data.

[0058] The instruction acquisition unit 15c acquires instruction data from the terminal unit 16. Examples of instructions indicated by the instruction data include a movement instruction to move the picking head 12a in the X or Y direction, a holding instruction and a release instruction for the item 2a to be transferred, and an instruction to switch between automatic transfer and manual transfer. The instruction acquisition unit 15c sends the acquired instruction data to the drive control unit 15d.

[0059] The drive control unit 15d controls the drive unit 12b so that the picking head 12a holds and transfers the item 2. The operation of the drive control unit 15d differs between the automatic transfer and the manual transfer.

[0060] (Automatic transfer process) Figure 5 is a flowchart showing an example of the automatic transfer process in the control unit 15. As shown in Figure 5, first the image acquisition unit 15a waits until it acquires image data from the camera unit 13 (S11).

[0061] When the image acquisition unit 15a acquires the data of the captured image (YES in S11), the image processing unit 15b performs image processing on the captured image to extract images of the articles 2 contained in the first container 17 and the second container 18, and to identify the XY coordinates of the articles 2 (S12). Next, based on the identified XY coordinates of the articles 2, the image processing unit 15b selects the XY coordinates of the article 2a to be transferred in the first container 17 and identifies the XY coordinates of the position where the article 2a will be placed in the second container 18 (S13). Next, the drive control unit 15d instructs the drive unit 12b to move the picking head 12a to the XY coordinates of the article 2a to be transferred (S14).

[0062] Next, the drive control unit 15d instructs the drive unit 12b to hold the article 2a (S15). At this time, the drive unit 12b first moves the picking head 12a downward in the Z direction (downwards). When the picking head 12a and the article 2a come into contact, the drive unit 12b stops the movement and the picking head 12a attracts and holds the article 2a. Then, the drive unit 12b moves the picking head 12a upward in the Z direction (upwards). Alternatively, instead of instructing the drive unit 12b to hold the article 2a, the drive control unit 15d may instruct the drive unit 12b to perform the above operation related to holding the article 2a.

[0063] Next, the drive control unit 15d determines whether the picking head 12a is holding the item 2a (S16). This can be determined by whether the picking head 12a is adsorbing the item 2a. If the item 2a is being held (YES in S16), the drive control unit 15d instructs the drive unit 12b to move the picking head 12a to the XY coordinates described above (S17).

[0064] Next, the drive control unit 15d instructs the drive unit 12b to release the article 2a (S18). At this time, the drive unit 12b first lowers the picking head 12a. When the picking head 12a reaches near the bottom of the second container 18, the drive unit 12b stops the movement and terminates the suction of the article 2a by the picking head 12a. As a result, the article 2a is released from the picking head 12a and placed in the second container 18. Then, the drive unit 12b raises the picking head 12a. After that, the process returns to step S11 and the automatic transfer process is repeated. Alternatively, instead of instructing the drive unit 12b to release the article 2a, the drive control unit 15d may instruct the drive unit 12b to perform the above action related to the release of the article 2a.

[0065] On the other hand, if the item 2a is not being held (NO in S16), the drive control unit 15d determines whether the number of times the item 2a has not been held consecutively has reached a predetermined number (S19). If the number is less than the predetermined number (NO in S19), the process returns to step S15 and the holding of the item 2a is repeated. On the other hand, if the number has reached the predetermined number (YES in S19), the drive control unit 15d determines that it has failed to hold the item 2a and sends notification instruction data to the notification unit 16c of the terminal unit 16 instructing it to notify the system of this failure (S20).

[0066] Subsequently, the drive control unit 15d terminates the automatic transfer process and moves on to the manual transfer process. This allows for an automatic switch from automatic transfer to manual transfer. Furthermore, the notification allows the operator S to recognize the need to perform a manual transfer.

[0067] (Variations of the automatic transfer process) Note that the automatic transfer process is not limited to the example shown in Figure 5. For example, if the control unit 15 detects a failure to hold or transfer item 2a while performing the normal automatic transfer process (S11-S15, S17, S18), it may terminate the normal automatic transfer process, send notification instruction data to the notification unit 16c of the terminal unit 16 instructing notification of the failure, and then proceed to the manual transfer process.

[0068] (Manual transfer process) Figure 6 is a flowchart showing an example of the manual transfer process in the control unit 15. As shown in Figure 6, the instruction acquisition unit 15c waits until it acquires instruction data from the input unit 16a of the terminal unit 16 (S31). When the instruction acquisition unit 15c acquires the instruction data (YES in S31), the drive control unit 15d determines whether the instruction indicated by the instruction data is the switching instruction (S32).

[0069] If the above switching instruction is given (YES in S32), the drive control unit 15d terminates the manual transfer process and moves to the automatic transfer process. This allows the operator S to switch between the automatic transfer and the manual transfer.

[0070] If the above switching instruction is not given (NO in S32), the drive control unit 15d controls the drive unit 12b according to the instruction data indicated above (S33). Then, the process returns to step S31 and the above manual transfer process is repeated.

[0071] Specifically, if the above instruction is a movement instruction, the drive control unit 15d instructs the drive unit 12b to move the picking head 12a by a predetermined amount in the X or Y direction. As a result, the operator S can move the picking head 12a directly above the item 2a that failed to be held or transferred, or directly above the position where the item 2a will be placed, by giving the above movement instruction to the input unit 16a of the terminal unit 16.

[0072] Furthermore, if the above instruction is a hold instruction, the drive control unit 15d instructs the drive unit 12b to hold the item 2a to be transferred. The operation of the drive unit 12b in this case is the same as in step S15 of Figure 5. Furthermore, if the above instruction is a release instruction, the drive control unit 15d instructs the drive unit 12b to release the item 2a. The operation of the drive unit 12b in this case is the same as in step S18 of Figure 5.

[0073] In this way, by inputting the above-mentioned move instruction, hold instruction, and release instruction into the input unit 16a of the terminal unit 16, the operator S can have the transfer unit 12 hold and transfer the item 2a that was held or failed to transfer during automatic transfer. In other words, the operator S can perform the recovery operation for the failure. Once the recovery operation for the failure is completed, the operator S can return to the automatic transfer process by inputting the above-mentioned switch instruction into the input unit 16a of the terminal unit 16.

[0074] As described above, even if the control unit 15 fails to hold or transfer the item 2a in automatic transfer, which controls the transfer unit 12 based on the XY coordinates (position) of the item 2a to be transferred, it can switch to manual transfer, which controls the transfer unit 12 based on the instructions of the operator S, and perform the recovery work for the failure. Therefore, as in the case of switching from automatic transfer to manual transfer, there is no need to move the transfer unit 12 out of a hazardous space where the transfer unit 12 and the operator S may come into contact, so the recovery work for the failure can be performed quickly.

[0075] Furthermore, the operator S only needs to input movement instructions in the XY direction (two directions) into the input unit 16a, and does not need to input movement instructions in the Z direction (up and down direction) into the input unit 16a. As a result, control of the transfer unit 12 becomes easier. Note that if the control unit 15 can execute movement instructions in the Z direction to the transfer unit 12, the operator S may be able to input movement instructions in the Z direction into the input unit 16a.

[0076] [Embodiment 2] Another embodiment of the present invention will be described with reference to Figure 7. In this embodiment, in addition to the automatic and manual transfer described above, manual transfer is possible in which the transfer unit 12 holds and transfers the item 2 when the worker S visually inspects the item 2 and gives instructions to the terminal unit 16. For this reason, it is desirable that the terminal unit 16 be a terminal device that the worker S can carry, such as a tablet or smartphone.

[0077] Figure 7 is a block diagram illustrating the overview of the transfer system 1 of this embodiment. The transfer system 1 shown in Figure 7 differs from the transfer systems 1 shown in Figures 1 to 6 in that it omits the configuration for transmitting the captured image data from the camera unit 13 to the terminal unit 16, but the other configurations and processes are the same.

[0078] In this embodiment, the terminal unit 16 does not need to display the captured image of the item 2. Furthermore, the worker S only needs to be in a position where they can visually see the item 2 in the transfer unit 12, such as outside the work area 25, the side guard unit 21, and the front guard unit 24.

[0079] [Embodiment 3] Other embodiments of the present invention will be described with reference to Figure 8.

[0080] Figure 8 is a block diagram illustrating the overview of the transfer system 1 of this embodiment. The transfer system 1 shown in Figure 8 differs from the transfer system 1 shown in Figures 1 to 6 in that it is further provided with a communication unit CS, information is exchanged between the control unit 15 and the terminal unit 16 via the communication unit CS, and instead of the camera unit 13 directly transmitting captured image data to the terminal unit 16, it transmits it to the terminal unit 16 via the image acquisition unit 15a and the communication unit CS. The other configurations are the same. A communication network NT may also be provided in the transfer system 1 of this embodiment along with the communication unit CS.

[0081] The communication unit CS is responsible for sending and receiving information. The communication unit is equipped with communication devices such as a transmit / receive circuit. Specifically, the communication unit CS transmits the captured image data received from the image acquisition unit 15a of the control unit 15 to the display unit 16b of the terminal unit 16, and transmits the instruction data received from the input unit 16a of the terminal unit 16 to the instruction acquisition unit 15c of the control unit 15.

[0082] In this embodiment, even if the worker S is located away from the transfer unit 12, they can hold and transfer the item 2a by referring to the captured image of the item 2a displayed on the display unit 16b. As a result, even if the worker S is in a remote location, they can perform the recovery work for the failure described above.

[0083] [Examples of implementation using software] The function of the transfer system 1 (hereinafter referred to as "device") is a program that causes the device to function as a computer, and can be realized by a program that causes each control block of the device (particularly each part included in the control unit 15) to function as a computer.

[0084] In this case, the device includes a computer having at least one control device (e.g., a processor) and at least one storage device (e.g., memory) as hardware for executing the program. By executing the program using this control device and storage device, the functions described in each of the embodiments are realized.

[0085] The above program may be recorded on one or more computer-readable recording media, not temporary ones. These recording media may or may not be provided by the above device. In the latter case, the program may be supplied to the above device via any wired or wireless transmission medium.

[0086] Furthermore, some or all of the functions of each of the above control blocks can also be realized by logic circuits. For example, an integrated circuit in which logic circuits functioning as each of the above control blocks are formed is also included in the scope of the present invention. In addition, it is also possible to realize the functions of each of the above control blocks by, for example, a quantum computer.

[0087] Furthermore, each process described in the above embodiments may be performed by AI (Artificial Intelligence). In this case, the AI ​​may operate on the control device described above, or it may operate on other devices (for example, an edge computer or a cloud server).

[0088] 〔summary〕 As described above, the transfer system according to embodiment 1 of the present invention comprises a transport unit for transporting articles, a transfer unit installed on one end of the transport unit for holding and transferring the articles, a camera unit for photographing the articles and creating captured images, and a control unit capable of performing automatic transfer, which controls the transfer unit based on the captured images, and manual transfer, which controls the transfer unit based on instructions from an operator.

[0089] According to the above configuration, even if the control unit fails to hold or transfer an item during automatic transfer, which controls the transfer unit based on an image of the item, it can switch to manual transfer, which controls the transfer unit based on the operator's instructions, and perform recovery work for the failure. Therefore, as in the case of switching from automatic transfer to manual transfer, there is no need to move the transfer unit out of a hazardous space where the transfer unit and the operator may come into contact, so the recovery work for the failure can be performed quickly.

[0090] The transfer system according to aspect 2 of the present invention may further include, in aspect 1 above, an input unit into which the operator's instructions are input, and a display unit that displays the captured image. In this case, even if the operator cannot directly see the item, they can perform the recovery work for the failure by referring to the captured image of the item displayed on the display unit and inputting instructions to the input unit.

[0091] The transfer system according to embodiment 3 of the present invention may further include a communication unit that transmits the captured image data to the display unit and receives instruction data indicating the instruction from the input unit, as in embodiment 2 above. In this case, even an operator who is separated from the transfer unit can hold and transfer the article by referring to the captured image of the article displayed on the display unit.

[0092] In the transfer system according to embodiment 4 of the present invention, in embodiments 2 and 3 above, the camera unit may photograph both the source and destination of the article, and the display unit may display both the image of the source and the image of the destination. In this case, the operator can refer to both the image of the source and the image of the destination, making it easier to control the transfer unit.

[0093] In the transfer system according to aspect 5 of the present invention, in aspects 2 and 3 described above, the captured image used by the control unit and the captured image displayed by the display unit may be created by the same camera. In this case, there is no need to provide a new camera to create the captured image displayed on the display unit.

[0094] In the transfer system according to aspect 6 of the present invention, in aspects 2 and 3 described above, the captured image used by the control unit and the captured image displayed by the display unit may be created by different cameras.

[0095] In the transfer system according to embodiment 7 of the present invention, in embodiments 1 to 6 described above, if the transfer unit fails to hold or transfer the article a predetermined number of times during automatic transfer, the system may switch to manual transfer. In this case, the system can automatically switch from automatic transfer to manual transfer.

[0096] In the transfer system according to embodiment 8 of the present invention, in embodiments 1 to 7 above, the control unit may switch between the automatic transfer and the manual transfer based on a switching instruction from the operator indicating the switch. In this case, the operator can switch between the automatic transfer and the manual transfer.

[0097] In the transfer system according to aspect 9 of the present invention, in aspects 1 to 8 above, the transfer unit may include a picking head for holding the article and a drive unit for raising and lowering the picking head and moving the picking head in two directions in a plan view. In this case, the operator only needs to input the movement in the two directions, making it easy to control the transfer unit.

[0098] A control method for a transfer system according to embodiment 10 of the present invention is a control method for a transfer system comprising: a transport unit for transporting articles; a transfer unit installed on one end of the transport unit for holding and transporting the articles; and a camera unit for photographing the articles and creating an image, the method including a step of switching between automatic transfer, which controls the transfer unit based on the image, and manual transfer, which controls the transfer unit based on instructions from an operator. In this case, the same effects as in embodiment 1 are achieved.

[0099] Each aspect of the present invention may be implemented by a computer. In this case, a control program for the transfer system, which enables the computer to implement the transfer system and its control method by operating the computer as each part and each step (software element) of the transfer system and its control method, and a computer-readable recording medium on which the program is recorded, also fall within the scope of the present invention.

[0100] The present invention is not limited to the embodiments described above, and various modifications are possible within the scope of the claims. Embodiments obtained by appropriately combining the technical means disclosed in different embodiments are also included in the technical scope of the present invention. [Explanation of Symbols]

[0101] 1. Transfer System 2, 2a Goods 11 Conveying section 11a, 11b Conveyor for loading / unloading 11c, 11d Conveyor for unloading 11e Moving mechanism 11f cabinet 12 Transfer Section 12a picking head 12b Drive unit 12c fixed rail 12d First movable rail 12e Second movable rail 12f Support Arm 13 Camera Section 13a Camera 1 13b Second Camera 14 Support Frame 14a Support part 15 Control Unit 15a Image acquisition unit 15b Image Processing Unit 15c Instruction acquisition part 15d Drive control unit 16 Terminal section 16a Input section 16b Display section 16th century Hochi Department 17 1st container 18 Second container 21 Side guard section 24 Front guard section 25 Work Area 26 Fixed guard section 27 Movable guard section 41 Rear guard section

Claims

1. A conveying unit for transporting goods, A transfer unit is installed on one end of the transport unit and holds and transfers the article, A camera unit that photographs the aforementioned item and creates an image, The system includes a control unit capable of performing automatic transfer, which controls the transfer unit based on the captured image, and manual transfer, which controls the transfer unit based on the operator's instructions. The aforementioned transfer unit is, A picking head for holding the aforementioned article, The unit includes a drive unit that raises and lowers the picking head and moves the picking head in two directions in a plan view, In the manual transfer described above, the control unit shall Based on the operator's instruction to move the picking head in the two directions, the drive unit is controlled to move the picking head. A transfer system that controls the drive unit so that the picking head automatically moves up and down to hold the item based on an instruction from the worker to hold the item.

2. An input unit into which the operator's instructions are entered, The transfer system according to claim 1, further comprising a display unit for displaying the captured image.

3. The transfer system according to claim 2, further comprising a communication unit that transmits the data of the captured image to the display unit and receives instruction data indicating the instruction from the input unit.

4. The camera unit photographs both the source and destination of the item being transferred. The transfer system according to claim 2 or 3, wherein the display unit displays both the image captured at the transfer source and the image captured at the transfer destination.

5. The transfer system according to claim 2 or 3, wherein in the camera unit, the captured image used by the control unit and the captured image displayed by the display unit are created by the same camera.

6. The transfer system according to claim 2 or 3, wherein in the camera unit, the captured image used by the control unit and the captured image displayed by the display unit are created by different cameras.

7. The transfer system according to any one of claims 1 to 3, wherein the control unit switches to manual transfer if the transfer unit fails to hold or transfer the article a predetermined number of times during automatic transfer.

8. The transfer system according to any one of claims 1 to 3, wherein the control unit switches between the automatic transfer and the manual transfer based on a switching instruction from the operator indicating a switch.

9. In the manual transfer, the control unit shall Furthermore, the transfer system according to any one of claims 1 to 3, wherein the drive unit controls the picking head to be raised or lowered based on the operator's instruction to raise or lower the picking head.

10. A transfer system comprising: a transport unit for transporting articles; a transfer unit installed at one end of the transport unit for holding and transferring the articles; and a camera unit for photographing the articles and creating captured images, wherein the transfer unit includes a picking head for holding the articles; and a drive unit for raising and lowering the picking head and moving the picking head in two directions in a plan view, and a control method for the transfer system, The first step includes switching between automatic transfer, which controls the transfer unit based on the captured image, and manual transfer, which controls the transfer unit based on instructions from the operator. In the aforementioned manual transfer, A second step involves controlling the drive unit to move the picking head based on the operator's instruction to move the picking head in the two directions, A method for controlling a transfer system, comprising: a third step of controlling the drive unit so that the picking head automatically moves up and down to hold the item based on an instruction from the operator to hold the item.

11. A control program for causing a computer to perform the first step, the second step, and the third step in the control method for a transfer system according to claim 10.

Images