Manufacturing method of mast structure

Abstract

To provide a mast structure that can be reassembled quickly with excellent reproducibility.SOLUTION: A mast structure (10) includes a mast (20), a guide rail, a connecting plate (6), and a positioning plate (7). The mast (20) is divided into an upper mast (21) and a lower mast (22). The guide rail guides an elevating body that is raised / lowered along the mast. The coupling plate (6) is provided with a fitting portion (60). The positioning plate (7) is provided with a fitted portion (70) to be fitted to the fitting portion (60) of the connecting plate (6).SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a mast structure, an article conveying device, and a method for manufacturing a mast structure.

Background Art

[0002] Conventionally, there has been an article conveying device provided with a dividable mast. For example, Patent Document 1 describes a loading and unloading device provided with a post that can be divided into an upper post and a lower post. The loading and unloading device of Patent Document 1 attaches an upper flange to the lower end of the upper post and a lower flange to the upper end of the lower post, and then connects the upper flange of the upper post and the lower flange of the lower post to assemble and connect the upper post and the lower post.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, the post of Patent Document 1 has a problem that it takes time to connect the upper post and the lower post.

[0005] One aspect of the present invention aims to provide a mast structure, an article conveying device, and a method for manufacturing a mast structure that can quickly and reproducibly reassemble a mast.

Means for Solving the Problems

[0006] To solve the above problems, a mast structure according to one aspect of the present invention comprises a mast divided into an upper mast and a lower mast positioned below the upper mast; a guide rail for guiding a lifting body that moves up and down along the mast, the guide rail divided into an upper guide rail laid on the upper mast and a lower guide rail laid on the lower mast; and a connecting plate fixed to the upper mast and the lower mast respectively for connecting the upper mast and the lower mast. The connecting plate is provided with a fitting portion. The structure further comprises a positioning plate attached to the lower mast, the positioning plate having a fitted portion that fits with the fitting portion of the connecting plate when the upper mast and the lower mast are connected.

[0007] To solve the above problems, a method for manufacturing a mast structure according to one aspect of the present invention comprises a mast divided into an upper mast and a lower mast disposed below the upper mast, and a guide rail for guiding a lifting body that moves up and down along the mast, the guide rail being divided into an upper guide rail and a lower guide rail, and the method for manufacturing a mast structure comprises a temporary assembly step, a disassembly step and a reassembly step.

[0008] The temporary assembly step includes: assembling the mast by fixing a connecting plate to the upper mast and the lower mast by bolting so that it spans the upper mast and the lower mast; laying the upper guide rail on the upper mast; laying the lower guide rail on the lower mast; adjusting the relative positions of the upper guide rail laid on the upper mast and the lower guide rail laid on the lower mast with the mast assembled, and then attaching the positioning plate to the lower mast with the fitting portion of the positioning plate fitted into the fitting portion of the connecting plate; a first positioning step of inserting the first pin through the first communication hole communicating between the connecting plate and the upper mast; and a second positioning step of inserting the second pin through the second communication hole communicating between the positioning plate and the lower mast. The dismantling step includes releasing the bolt fastening of the connecting plate to the lower mast to separate the upper mast and the lower mast. The reassembly step includes reassembling the mast by fastening the connecting plate to the lower mast with bolts, while the fitting portion of the positioning plate is fitted into the fitting portion of the connecting plate. [Effects of the Invention]

[0009] According to one aspect of the present invention, the mast structure can be reassembled quickly and reproducibly. [Brief explanation of the drawing]

[0010] [Figure 1] This figure shows the overall configuration of a stacker crane according to an embodiment of the present invention. [Figure 2] This is a perspective view of the first connecting plate and positioning plate connected to the mast according to the embodiment. [Figure 3] This is a front view of the first connecting plate and positioning plate according to the embodiment. [Figure 4] This is a front view of the second connecting plate according to the embodiment. [Figure 5] This is a front view of the third connecting plate according to the embodiment. [Figure 6] This is a cross-sectional view of the upper mast and upper guide rail according to the embodiment. [Figure 7] This is a cross-sectional view of the lower mast and lower guide rail according to the embodiment. [Figure 8] This is a cross-sectional view showing the protrusion of the first connecting plate that engages with the recess of the mast according to the embodiment. [Figure 9] This flowchart shows the process for manufacturing the mast structure according to the embodiment. [Figure 10] This figure shows the upper mast during the dismantling step in Figure 9. [Modes for carrying out the invention]

[0011] Hereinafter, a stacker crane 1 according to Embodiment 1 of the present invention will be described with reference to Figures 1 to 10.

[0012] [Stacker Crane] Figure 1 shows the overall configuration of a stacker crane 1 according to Embodiment 1. As shown in Figure 1, the stacker crane 1 comprises a mast structure 10, a connecting section 30, a lifting body 40, and a traveling section 50. The mast structure 10 includes a pair of masts 20, a first connecting plate 6, a second connecting plate 6A (see Figure 4), a third connecting plate 6B (see Figure 5), a positioning plate 7, and a guide rail 9 (see Figure 6). The stacker crane 1 is an example of an article conveying device.

[0013] A pair of masts 20 are erected on the upper part of the running section 50, spaced apart in the running direction (X direction in Figure 1) and aligned vertically (Z direction in Figure 1). Each mast 20 is formed from a vertically elongated hollow member. Each mast 20 is configured to be separable into an upper mast 21 and a lower mast 22. The lower mast 22 is positioned below the upper mast 21.

[0014] The connecting part 30 is installed at the upper end of the mast structure 10. Specifically, the connecting part 30 connects the upper ends of the respective upper masts 21 of the pair of masts 20 to each other. The lifting body 40 is supported by the pair of masts 20 and moves up and down along the masts 20. The lifting body 40 is configured to be able to grip the article G.

[0015] The lifting body 40 has a transfer device 41, a guide block 42, a pair of upright parts 43, and an article placement part 44. The transfer device 41 transfers the article G to be conveyed between the transfer target locations. Examples of the transfer target locations include an article storage shelf provided at a position separated in the Y direction (FIG. 2) orthogonal to the X direction in plan view from the traveling route R, and a transfer location with a conveying device such as a conveyor. The article placement part 44 is a member for placing the article G and connects the lower ends of the pair of upright parts 43 to each other.

[0016] The pair of upright parts 43 are arranged spaced apart in the arrangement direction of the pair of masts 20. Belts B are connected to the upper and lower ends of each upright part 43. The lifting body 40 moves up and down along the mast 20 in a state where the guide block 42 is guided by the guide rail 9 (see FIG. 6) when the belt B is wound by the lifting motor M2. In addition, guide rollers may be provided on the side surface of the lifting body 40 on the mast 20 side, and the lifting body 40 may be configured to move up and down along the mast 20 when the guide rollers are guided by the guide rail 9. Also, a chain may be used instead of the belt B.

[0017] On each mast 20, a first connecting plate 6, a second connecting plate 6A, a third connecting plate 6B, and a positioning plate 7 are respectively attached to the connecting portion between the upper mast 21 and the lower mast 22. Specifically, the first connecting plate 6, the second connecting plate 6A, and the third connecting plate 6B are fixed to the upper mast 21 and the lower mast 22 respectively and connect the upper mast 21 and the lower mast 22. The positioning plate 7 is attached to the lower mast 22.

[0018] The traveling unit 50 travels along the traveling route R. The traveling unit 50 supports the traveling wheels W1 and W2 that roll on the traveling route R. The traveling wheel W1 is provided at the front end of the traveling unit 50 and is driven by the traveling motor M1. The traveling wheel W2 is provided at the rear end of the traveling unit 50 so as to be freely rotatable.

[0019] [Connecting Plate and Positioning Plate] Next, the first connecting plate 6, the second connecting plate 6A, the third connecting plate 6B, and the positioning plate 7 will be described in detail with reference to FIGS. 2 to 5.

[0020] FIG. 2 is a perspective view of the first connecting plate 6, the second connecting plate 6A, and the positioning plate 7 in a state of being connected to the mast 20. As shown in FIG. 2, a rectangular notch 60 is formed on the lower side surface of the first connecting plate 6. The notch 60 corresponds to the fitting portion.

[0021] Also, a rectangular protrusion 70 is provided on the upper side surface of the positioning plate 7. The protrusion 70 corresponds to the fitting portion that fits with the notch 60 of the first connecting plate 6 when the upper mast 21 and the lower mast 22 are connected.

[0022] Furthermore, the second connecting plate 6A is fixed to the side surface adjacent to the side surface of the mast 20 where the first connecting plate 6 is disposed. The second connecting plate 6A is a rectangular plate-like member.

[0023] FIG. 3 is a front view of the first connecting plate 6 and the positioning plate 7. As shown in FIG. 3, the first connecting plate 6 is a rectangular plate-like member and has a plurality of first through holes 61 and a plurality of first connecting holes 62. Bolts 81 are inserted into the first through holes 61. First pins 83 are inserted into the first connecting holes 62. The first pins 83 are made of spring pins or the like. The length d1 in the width direction of the first connecting plate 6, that is, the X direction in FIG. 1, is shorter than the outer diameter D of the mast 20.

[0024] The positioning plate 7 has a plurality of second through holes 71 and a plurality of second communication holes 72. Bolts 82 are inserted through the second through holes 71. Second pins 84 are inserted through the second communication holes 72. The second pins 84 are made of spring pins or the like.

[0025] Figure 4 is a front view of the second connecting plate 6A. Figure 5 is a front view of the third connecting plate 6B. As shown in Figure 4, the second connecting plate 6A has a plurality of first through holes 61A and a plurality of first communication holes 62A. Bolts 81 are inserted through the first through holes 61A. First pins 83 are inserted through the first communication holes 62A. The widthwise length d2 of the second connecting plate 6A is shorter than the widthwise length d1 of the first connecting plate 6.

[0026] As shown in Figure 5, the third connecting plate 6B is a rectangular plate-shaped member and has a plurality of first through holes 61B and a plurality of first communication holes 62B. The widthwise length d3 of the third connecting plate 6B is shorter than the widthwise length d1 of the first connecting plate 6 and the widthwise length d2 of the second connecting plate 6A.

[0027] A bolt 81 is inserted through the first through hole 61B. A first pin 83 is inserted through the first connecting hole 62B. The third connecting plate 6B is fixed by bolts 81B to the side of the mast 20 to which the first connecting plate 6 is fixed and to the adjacent side (see Figure 6).

[0028] Figure 6 is a cross-sectional view of the upper mast 21 and upper guide rail 91. Figure 7 is a cross-sectional view of the lower mast 22 and lower guide rail 92. The guide rail 9 shown in Figures 6 and 7 guides the lifting body 40 as it moves up and down along the mast 20. The lifting body 40 is positioned on the guide rail 9 via guide blocks 42 so as to be movable in the vertical direction.

[0029] The guide rail 9 is composed of an upper guide rail 91 and a lower guide rail 92. As shown in Figure 6, the upper guide rail 91 is laid on the upper mast 21 and fixed by bolts 85. The upper guide rail 91 extends along the direction of extension of the upper mast 21 (the Z direction in Figure 1).

[0030] Furthermore, as shown in Figure 7, the lower guide rail 92 is laid on the lower mast 22 and fixed by bolts 86. The lower guide rail 92 extends along the direction of extension of the lower mast 22 (the Z direction in Figure 1).

[0031] Figure 8 is a cross-sectional view showing the protrusion 63 of the first connecting plate 6 that engages with the recess 23 of the mast 20. As shown in Figure 8, the first connecting plate 6 has a protrusion 63 that projects toward the upper mast 21. The protrusion 63 extends along the direction of extension of the first connecting plate 6, that is, along the vertical direction in Figure 3.

[0032] The mast 20 is provided with a recess 23 that engages with a protrusion 63 of the first connecting plate 6. The recess 23 is provided so as to extend along the extending direction of the first connecting plate 6, i.e., the Z direction in Figure 1. This makes it easy to position the mast 20 and the first connecting plate 6.

[0033] [Method for manufacturing mast structures] Next, the manufacturing method of the mast structure 10 will be described with reference to Figures 9 and 10. Figure 9 is a flowchart showing the flow of the manufacturing method of the mast structure 10.

[0034] As shown in Figure 9, in the manufacturing method of the mast structure 10 of this embodiment, a temporary assembly step (S1), a disassembly step (S2), and a reassembly step (S3) are performed in order.

[0035] The preliminary assembly step S1 is carried out by workers in the manufacturing plant of the stacker crane 1. In the preliminary assembly step S1, the mast assembly process is performed first. In the mast assembly process, with the lower surface of the upper mast 21 and the upper surface of the lower mast 22 in contact, the first connecting plate 6 is positioned to straddle the upper mast 21 and the lower mast 22.

[0036] Next, as shown in Figure 6, bolts 81 are inserted through each of the first through holes 61 in the first connecting plate 6, each of the through holes 21a in the upper mast 21, and each of the through holes 22a in the lower mast 22, thereby fixing the first connecting plate 6 to the upper mast 21 and lower mast 22 by bolt fastening. At this time, by engaging the protrusions 63 of the first connecting plate 6 with the recesses 23 of the mast 20, the fixing work of the first connecting plate 6 to the mast 20 can be performed efficiently.

[0037] Furthermore, bolts 81 are inserted through each of the first through holes 61A in the second connecting plate 6A, each of the through holes 21a in the upper mast 21, and each of the through holes 22a in the lower mast 22, thereby fixing the second connecting plate 6A to the upper mast 21 and lower mast 22 by bolt fastening.

[0038] Furthermore, bolts 81 are inserted through each of the first through holes 61B of the third connecting plate 6B, each of the through holes 21a of the upper mast 21, and each of the through holes 22a of the lower mast 22, thereby fixing the third connecting plate 6B to the upper mast 21 and lower mast 22 by bolt fastening. In this way, the mast 20 is assembled by making fine adjustments to the upper mast 21 and lower mast 22 to prevent distortion or other issues.

[0039] After the mast assembly process, the upper guide rail laying process and the lower guide rail laying process are carried out. In the upper guide rail laying process, the upper guide rail 91 is laid on the upper mast 21. In the lower guide rail laying process, the lower guide rail 92 is laid on the lower mast 22.

[0040] After the upper guide rail laying process and the lower guide rail laying process, an adjustment process is carried out. In the adjustment process, with the mast 20 assembled, the relative positions of the upper guide rail 91 laid on the upper mast 21 and the lower guide rail 92 laid on the lower mast 22 are adjusted. Once this adjustment is complete, the upper guide rail 91 is fixed to the upper mast 21 with bolts 85, and the lower guide rail 92 is fixed to the lower mast 22 with bolts 86.

[0041] After the adjustment process, the positioning plate mounting process is performed. In the positioning plate mounting process, the positioning plate 7 is attached to the lower mast 22 with bolts 82 while the protruding portion 70 of the positioning plate 7 is fitted into the notch 60 of the first connecting plate 6. This ensures that the positioning plate 7 is securely fixed to the lower mast 22.

[0042] Next, in the upper mast 21, first communication holes (not shown) are provided at positions corresponding to each of the first communication holes 62 of the first connecting plate 6. Then, in the first positioning step, the first pins 83 are inserted through each of the first communication holes 62 of the first connecting plate 6 and each of the first communication holes of the upper mast 21.

[0043] Furthermore, the first pin 83 is inserted through the first communication hole 62A of the second connecting plate 6A and the first communication hole (not shown) of the upper mast 21. Also, the first pin 83 is inserted through the first communication hole 62B of the third connecting plate 6B and the first communication hole (not shown) of the upper mast 21.

[0044] After the first positioning step, a second positioning step is performed. In the second positioning step, a second pin 84 is inserted through each second communication hole 72 of the positioning plate 7 and each second communication hole (not shown) of the lower mast 22.

[0045] In the temporary assembly step S1 described above, the mounting positions of the first connecting plate 6, the second connecting plate 6A, the third connecting plate 6B, and the positioning plate 7 to the mast 20 can be determined when the mast 20 is properly assembled and the relative positions of the upper guide rail 91 and the lower guide rail 92 are adjusted.

[0046] After the preliminary assembly step S1, a test run of the stacker crane 1 is performed. Once the test run is complete, the dismantling step S2 is performed. In the dismantling step S2, first, the bolts 81 that secure the lower mast 22 to the first connecting plate 6, the bolts 81A that secure the lower mast 22 to the second connecting plate 6A, and the bolts 81B that secure the lower mast 22 to the third connecting plate 6B are loosened. In this way, the bolt fastenings of the first connecting plate 6, the second connecting plate 6A, and the third connecting plate 6B to the lower mast 22 are released.

[0047] At this time, the bolts 82 that secure the lower mast 22 and the positioning plate 7 should not be loosened. This ensures that the position of the positioning plate 7 on the lower mast 22 is maintained in the appropriate position.

[0048] Then, by sliding the lower mast 22 downwards, the upper mast 21 and the lower mast 22 are separated, as shown in Figure 10. At this time, the first connecting plate 6, the second connecting plate 6A, and the third connecting plate 6B remain attached to the upper mast 21.

[0049] In this way, by separating the upper mast 21 and the lower mast 22 in the dismantling step S2, the mast structure 10 can be easily transported to the site where the automated warehouse or the like, in which the stacker crane 1 is used, is located.

[0050] After the dismantling step S2, the reassembly step S3 is performed. In the reassembly step S3, the process of reassembling the mast structure 10 at the site is carried out. Specifically, first, the lower mast 22 is moved toward the upper mast 21, and the upper surface of the lower mast 22 is brought into contact with the lower surface of the upper mast 21.

[0051] Subsequently, the protruding portion 70 of the positioning plate 7 is fitted into the notch 60 of the first connecting plate 6. This allows for precise positioning of the upper mast 21 and the lower mast 22.

[0052] Then, in this fitted state, the first connecting plate 6 is fixed to the lower mast 22 with bolts 81, the second connecting plate 6A is fixed to the lower mast 22 with bolts 81A, and the third connecting plate 6B is fixed to the lower mast 22 with bolts 81B. This ensures that the first connecting plate 6 is securely fixed to the upper mast 21 and the lower mast 22.

[0053] Next, the relative positions of the upper guide rail 91 laid on the upper mast 21 and the lower guide rail 92 laid on the lower mast 22 are checked. According to the present invention, it is possible to reassemble the mast 20 with good reproducibility, but if there is a misalignment in the relative positions of the upper guide rail 91 and the lower guide rail 92, the relative positions are adjusted.

[0054] If it is confirmed that the relative positions described above are not misaligned, the upper guide rail 91 is fixed to the upper mast 21 with bolts 85, and the lower guide rail 92 is fixed to the lower mast 22 with bolts 86. In this way, the mast 20 can be efficiently and properly reassembled at the site.

[0055] As shown in Figure 2, with the stacker crane 1 of Embodiment 1 described above, the upper mast 21 and lower mast 22 can be accurately positioned by fitting the protruding portion 70 of the positioning plate 7 into the notch 60 of the first connecting plate 6. This allows for quick and reproducible reassembly of the mast 20 on site. Therefore, smooth raising and lowering of the lifting body 40 along the guide rail 9 can be easily reproduced during reassembly.

[0056] In particular, since the widthwise length d1 of the first connecting plate 6 is shorter than the outer diameter D of the mast 20, the upper mast 21 and the lower mast 22 can be connected without increasing the outer diameter D of the mast 20.

[0057] Furthermore, first pins 83 are inserted through each first communication hole 62 of the first connecting plate 6 and each first communication hole of the upper mast 21, and second pins 84 are inserted through each second communication hole 72 of the positioning plate 7 and each second communication hole of the lower mast 22. This prevents misalignment of the first connecting plate 6 relative to the upper mast 21 and misalignment of the positioning plate 7 relative to the lower mast 22.

[0058] [Other Embodiments] In the embodiment described above, the first connecting plate 6 is provided with a notch 60 as a fitting portion and the positioning plate 7 is provided with a protrusion 70 as a fitted portion, but the embodiment is not limited to this. For example, the first connecting plate 6 may be provided with a protrusion and the positioning plate 7 may be provided with a notch.

[0059] The stacker crane 1 in the above-described embodiment has two pairs of first connecting plates 6 and positioning plates 7 for one mast 20, but is not limited to this. The stacker crane 1 only needs to have at least one pair of connecting plates and positioning plates.

[0060] Furthermore, although the stacker crane 1 is assumed to have six connecting plates, consisting of two first connecting plates 6, two second connecting plates 6A, and two third connecting plates 6B, it is sufficient for it to have at least one connecting plate.

[0061] Furthermore, in the embodiment described above, the protrusion 63 of the first connecting plate 6 is assumed to extend along the vertical direction, but the invention is not limited to this, and the first connecting plate 6 may have multiple protrusions provided at predetermined intervals in the vertical direction. In this case, the mast 20 only needs to have multiple recesses formed therein that engage with the protrusion 63 of the first connecting plate 6. With this configuration, the first connecting plate 6 can be reassembled onto the mast 20 efficiently.

[0062] Furthermore, in the embodiments described above, the stacker crane 1 is provided with a pair of masts 20, but it is not limited to this. The stacker crane 1 may be provided with at least one mast 20, or even just one mast 20.

[0063] 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 this disclosure. [Explanation of symbols]

[0064] 1. Stacker crane 6. First connecting plate 6A Second connecting plate 6B Third connecting plate 7 Positioning plate 10 Mast Structures 20 Mast 21 Upper mast 22 Lower mast 30 Connecting part 40 Lifting mechanism 50 Running section 60 Notch (fitting part) 61, 61A, 61B 1st through hole 62, 62A, 62B 1st communication hole 70 Projection part (mated part) 71 Second through hole 72 2nd communication hole 83. Pin 1 84. Pin 2 9 Guide rails 91 Upper guide rail 92 Lower guide rail S1 Temporary Assembly Step S2 Dismantling Steps S3 Reassembly Step

Claims

[Claim 1] A method for manufacturing a mast structure comprising a mast divided into an upper mast and a lower mast positioned below the upper mast, and a guide rail for guiding a lifting body that moves up and down along the mast, the guide rail being divided into an upper guide rail and a lower guide rail, It comprises a temporary assembly step, a disassembly step, and a reassembly step. The mast has a recess that extends in the vertical direction, The upper mast and the lower mast are connected by a connecting plate fixed to the mast, which has a protrusion that extends outwards from the mast, and the protrusion engages with the recess of the mast. The aforementioned temporary assembly step is The process of assembling the mast involves fixing a connecting plate to the upper mast and the lower mast by bolting it so that it spans the upper mast and the lower mast, The process of laying the upper guide rail on the upper mast, The process of laying the lower guide rail on the lower mast, With the mast assembled, the relative positions of the upper guide rail laid on the upper mast and the lower guide rail laid on the lower mast are adjusted, and then the positioning plate is attached to the lower mast with the fitting portion provided on the upper side of the positioning plate fitted into the fitting portion provided on the lower side of the connecting plate. A first positioning step involves inserting a first pin into a first communication hole that connects the connecting plate and the upper mast, The process includes a second positioning step of inserting a second pin into a second communication hole that communicates with the positioning plate and the lower mast, The aforementioned dismantling step is, The process includes separating the upper mast and the lower mast by releasing the bolt fastening of the connecting plate to the lower mast while the connecting plate remains attached to the upper mast and the bolt fastening of the positioning plate to the lower mast is not loosened, The aforementioned reassembly step is, A method for manufacturing a mast structure, comprising the step of reassembling the mast by fastening the connecting plate to the lower mast with bolts, while fitting the receiving portion of the positioning plate attached to the lower mast into the fitting portion of the connecting plate attached to the upper mast.

Images