Cargo handling assistance device and control method for the cargo handling assistance device

Abstract

To provide a cargo handling assistance device having improved operability and a method of controlling the cargo handling assistance device.SOLUTION: A cargo handling assistance device 1 includes a raising / lowering operation unit 16, a motor unit 11, a weight detection unit 12, a position detection unit 13, a storage unit 10a, and a control unit 10. The raising / lowering operation unit 16 raises or lowers a cargo 33. The motor unit 11 drives the raising / lowering operation unit 16. The weight detection unit 12 transmits a weight value applied to the raising / lowering operation unit 16. The position detection unit 13 transmits a delivery value of a locking unit 7. The storage unit stores the weight of the locking unit 7 and the cargo 33 as a registered value. The control unit 10 has balance means 10d and automatic raising / lowering means 10c. The balance means 10d receives the weight value and the registered value, calculates a control value for reducing a difference therebetween to zero, controls the motor unit, and performs the balance control. After the delivery value reaches a preset first delivery value, when the delivery value reaches a preset second delivery value and then a predetermined time elapses, the automatic raising / lowering means 10c immediately raises or lowers the locking unit 7.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] This application is a domestic priority claim application based on the application filed on May 6, 2021. The present invention relates to a cargo handling assistance device used for manufacturing assembly, conveyance, etc. in the manufacturing field. For example, when lifting and lowering a cargo, it is balanced by the assistance of a motor and moved up and down with a slight operating force. The present invention relates to a cargo handling assistance device and a control method thereof.

Background Art

[0002] Conventionally, in factories that assemble industrial products, cargo handling devices are used to move tools, work equipment, products, semi-finished products, etc. having a large weight. Among these cargo handling devices, a cargo handling assistance device that creates a balanced state for a cargo having a large weight and generates an assisting force (assist force) so that a user can move up and down to an arbitrary height with a light operating force is partially used. Such a cargo handling assistance device that generates an assisting force performs the assistance by an electric motor, creates a balanced state, and smoothly moves the cargo by applying a small operating force to the cargo. Therefore, unlike a device that simply performs vertical movement by an electric motor, the load of the cargo and the operating force applied thereto are detected by, for example, a load detector, and an AC servo motor connected to a rotation angle detector adjusts the acceleration based on the change in weight due to the application of an external force to perform fine balance control.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Patent Document 1 discloses a technology in which a control unit maintains balance based on commands from an operating unit. When handling cargo using such a cargo handling assistance device, the operator needs to press an operating switch each time to issue an operating command. However, there was a desire to reduce the number of times this operating switch needs to be pressed, and there was room for improvement.

[0005] In view of these problems, the present invention aims to provide a cargo handling assistance device and a control method for the cargo handling assistance device that reduce the burden on workers and improve cargo handling operations. [Means for solving the problem]

[0006] A cargo handling assistance device according to one aspect of the present invention aims to achieve the above objectives, A cargo handling assist device that assists in the lifting and lowering of cargo, comprising a lifting and lowering mechanism, a motor, a weight detection unit, a position detection unit, a memory unit, and a control unit, The lifting mechanism raises and lowers the cargo by extending a suspension cable that holds the cargo in place. The motor unit drives the lifting mechanism, The weight detection unit detects the weight applied to the lifting mechanism and transmits it to the control unit. The position detection unit detects the extension value of the locking part and transmits it to the control unit. The memory unit stores the weight of the locking part and the cargo as registered values. The control unit has a balancing mechanism and an automatic lifting mechanism. The balancing mechanism receives the weight value and the registered value, calculates a control value that makes the difference between the weight value and the registered value zero, and controls the motor section to perform balance control. The automatic lifting mechanism is configured to immediately raise or lower the locking part when it detects that the payout value received from the position detection unit has reached a preset first payout value, and then reached a preset second payout value, and a predetermined time has elapsed.

[0007] Furthermore, the control unit is configured to automatically raise the locking part using an automatic lifting mechanism, and when it receives a certain weight value from the weight detection unit, it updates that certain weight value as a registered value and performs balance control.

[0008] Furthermore, the control unit is configured to lower the locking part using an automatic lifting mechanism, and when the weight value received from the weight detection unit reaches a pre-stored weight value without cargo in the memory unit, it updates the weight value without cargo as the registered value and performs balance control.

[0009] Furthermore, the control unit is configured to lower the locking part by a predetermined distance using an automatic lifting mechanism, then update the weight value received from the weight detection unit as a registered value, and perform balance control.

[0010] A control method for a cargo handling assistance device according to one aspect of the present invention aims to achieve the above objectives, A control method for a cargo handling assistance device that assists in the lifting and lowering of cargo, comprising a lifting and lowering mechanism, a motor, a weight detection unit, a position detection unit, a memory unit, and a control unit, The lifting mechanism raises and lowers the cargo by extending a suspension cable that holds the cargo in place. The motor unit drives the lifting mechanism, The weight detection unit detects the weight applied to the lifting mechanism and transmits it to the control unit. The position detection unit detects the extension value of the locking part and transmits it to the control unit. The memory unit stores the weight of the locking part and the weight of the cargo as registered values. The control unit has a balancing step and an automatic lifting step. In the balance step, the control unit receives the weight value and registered value, calculates a control value that makes the difference between the weight value and the registered value zero, and controls the motor unit to perform balance control. In the automatic lifting step, the control unit is configured to immediately raise or lower the locking part when it detects that the payout value received from the position detection unit has reached a preset first payout value, and then reached a preset second payout value, and a predetermined time has elapsed.

Advantages of the Invention

[0011] According to the cargo handling assistance device of the present invention, it is possible to provide a cargo handling assistance device that reduces the number of times of pressing an operation switch and reduces the burden on the operator.

Brief Description of the Drawings

[0012] [Figure 1] It is a perspective configuration diagram of a cargo handling assistance device according to an embodiment of the present invention. [Figure 2] It is a perspective configuration diagram with a part of the main body device of the cargo handling assistance device according to an embodiment of the present invention omitted and a perspective view of an operation command unit. [Figure 3] It is a block configuration diagram of an electronic circuit of a cargo handling assistance device according to an embodiment of the present invention. [Figure 4] It is a schematic diagram showing an operation using the cargo handling assistance device according to an embodiment of the present invention. [Figure 5] It is a schematic diagram showing an operation using the cargo handling assistance device according to an embodiment of the present invention. [Figure 6] It is a schematic diagram showing an operation using the cargo handling assistance device according to an embodiment of the present invention. [Figure 7] It is a schematic diagram showing an operation using the cargo handling assistance device according to an embodiment of the present invention. [Figure 8] It is a schematic diagram showing an operation using the cargo handling assistance device according to an embodiment of the present invention. [Figure 9] It is a schematic diagram showing an operation using the cargo handling assistance device according to an embodiment of the present invention. [Figure 10] It is a schematic diagram showing an operation using the cargo handling assistance device according to an embodiment of the present invention. [Figure 11] It is a schematic diagram showing an operation using the cargo handling assistance device according to an embodiment of the present invention. [Figure 12] It is a flowchart of steps executed by a control unit of a cargo handling assistance device according to an embodiment of the present invention. [Figure 13] It is a time chart of a cargo handling assistance device according to an embodiment of the present invention. [Modes for carrying out the invention]

[0013] The following is a detailed description of a cargo handling assistance device according to an embodiment of the present invention, based on the drawings. Figure 1 is a perspective view of a cargo handling assistance device 1, which is an example of an embodiment of the present invention.

[0014] The cargo handling assistance device 1 comprises a main body device 2, a suspension hook 3, a link chain 4, a lifting hook 5, a grip 6, a locking part 7, and an operation command unit 20. The main body device 2 lifts and lowers the cargo 33 by locking it to the locking part 7 via the link chain 4. The lifting hook 5 is provided at the lower end of the link chain 4 that extends vertically downward from the main body device 2. The suspension hook 3 is provided on the top surface of the main body device 2. Therefore, the main body device 2 can be used by suspending it from a building beam or a movable block 41 that can move horizontally along a rail 42 for horizontal movement, as shown in Figure 4 and later.

[0015] The lifting hook 5 is a hook for handling cargo, provided at one end of the link chain 4. In this embodiment, it is a member for suspending the locking portion 7 and has a versatile shape.

[0016] The locking portion 7 is for securing the cargo 33. The locking portion 7 is made by bending a metal plate into a roughly J-shape in order to lock onto a projection provided on the upper surface of the cargo 33, and a hole for inserting a lifting hook 5 is provided at its end.

[0017] The grip 6 is a hollow cylindrical member that covers and secures the connection between the lifting hook 5 and the link chain 4. The worker can grasp the grip 6 to move the lifting hook 5 and the locking part 7 to the desired location and perform cargo handling operations.

[0018] Figure 2 is a perspective view of the cargo handling assistance device 1 of an embodiment of the present invention, with a portion of the main unit 2 omitted, and an enlarged perspective view of the operation command unit 20. The main unit 2 is equipped with a cover, and inside it are housed the control unit 10, motor unit 11, lifting operation unit 16, weight detection unit 12, position detection unit 13, etc.

[0019] The control unit 10 of the main unit 2 is equipped with a CPU (Central Processing Unit), ROM (Read Only Memory), RAM (Random Access Memory), other storage devices, and input / output devices, and controls the vertical movement of the lifting hook 5 via the link chain 4 and the lifting mechanism 16. The control unit 10 also includes a circuit that supplies electricity to the electrical and electronic components that make up the main unit 2.

[0020] The motor unit 11 is the drive source for moving the lifting hook 5 and the locking part 7 up and down. A reduction gear is attached to the load side of the motor in the motor unit 11. This motor is, for example, an AC servo motor.

[0021] This gearbox reduces the rotational speed of the motor to a predetermined speed. The gearbox is, for example, a harmonic drive gearbox. The harmonic drive gearbox has a wave generator, a flexspline, and a circular spline. The wave generator has an elliptical shape, with thin-walled ball bearings fitted around the outer circumference of an elliptical cam. The inner ring of the bearing is fixed to the elliptical cam, and the outer ring is elastically deformable via the balls. The flexspline has numerous external teeth formed on its outer circumference and is fitted onto the wave generator, making it elastically deformable so that the position in which it is deflected in the circumferential direction changes with the rotation of the wave generator. The circular spline is on the outer circumference side of the flexspline and has internal teeth that engage with the external teeth of the flexspline. Power is taken from the wave generator connected to the motor and transmitted as a rotational output to the output shaft 15 connected to the flexspline. By using a gearbox with minimal backlash, such as a harmonic drive gearbox, in the motor section 11, when frequently switching between forward and reverse rotation of the motor to perform vertical movement, the uncontrollable region during switching can be eliminated, resulting in smooth operation. Note that the gearbox is not limited to a harmonic drive gearbox.

[0022] The output shaft 15 is a rotating shaft that reduces its rotational speed using a reduction gear and outputs increased torque. It is connected to the lifting mechanism 16 and rotates the lifting mechanism 16 continuously in both forward and reverse directions.

[0023] The link chain 4 is a suspension cable, consisting of oval rings, each made up of a semi-circular section and a straight section connected to it, which intersect and are linked alternately. One end of the link chain 4 is connected to the suspension hook 5, and the other end (unloaded side) is stored in the chain storage section 17.

[0024] The lifting mechanism 16 includes a rotating member that rotates due to power transmission from the motor unit 11, which is the drive source. In this embodiment, the rotating member of the lifting mechanism 16 is in the shape of a hollow cylinder, connected to the output shaft 15 in the hollow portion, winds the link chain 4 around it, and winds up and unwinds the link chain 4. The position where the link chain 4 is wound is approximately vertically below the suspension hook 3 and is located close to the center of gravity of the main unit 2. The link chain 4 is fitted into a pocket groove provided on the outer cylindrical surface of the lifting mechanism 16 and wound around approximately 180 degrees. In this embodiment, the suspension rope is a link chain 4 that is connected to the suspension hook 5 and wound around the lifting mechanism 16, but it is not limited to this and a wire rope may also be used. When a wire rope is used, the lifting mechanism 16 is drum-shaped, and one end of the wire rope is fixed and wound around the rotating member.

[0025] The position detection unit 13 is connected to the non-load side of the motor unit 11. The position detection unit 13 detects the rotational angle position of the motor. The position detection unit 13 is, for example, an absolute encoder, which optically detects the rotational angle position of the motor and transmits the position value to the control unit 10 of the main unit 2. Therefore, this position detection unit 13 can detect the payout value L of the locking unit 7 from the main unit 2, that is, the lifting and lowering position of the locking unit 7.

[0026] The weight detection unit 12 is equipped with a strain generating body and strain gauges attached to the strain generating body. The strain generating body has a shape that elastically deforms so as to be able to detect the force transmitted from the link chain 4 wrapped around the lifting and lowering mechanism 16. The strain gauges are incorporated into a Wheatstone bridge circuit that converts the strain generated in the strain generating body according to the weight into an electrical signal, and the weight detection unit 12 detects the weight applied to the lifting and lowering mechanism 16 and transmits the weight value to the control unit 10 of the main unit 2.

[0027] The control unit 10 of the main unit 2 is located near the lifting and lowering mechanism 16 inside the main unit 2. The control unit 10 of the main unit 2 receives a position value (feed-out value L) from the position detection unit 13 and a weight value from the weight detection unit 12, performs calculations based on these values, and controls the motor unit 11. The electrical components, including the control unit 10 of the main unit 2, are located inside a cover to enable the main unit 2 to be used in places where it may be exposed to powder or water droplets.

[0028] In this embodiment, the position detection unit 13 is located on the non-load side of the motor unit 11, but it is not limited to this, and may be provided on the output shaft 15, which is the output of the reduction gear, or on the lifting and lowering operating unit 16, or on both. Furthermore, it is not limited to optical type, but may also be magnetic type, capacitive type, etc.

[0029] Furthermore, the weight detection unit 12 only needs to be able to detect the weight applied to the lifting and lowering unit 16, and may be a rotary type structure that detects torque from the twist of a rotating shaft provided between the reduction gear and the lifting and lowering unit 16, or a flange type or drum type structure that detects the reaction force received by the motor unit 11. Moreover, it is not limited to strain gauge type, but may also be magnetostrictive type, capacitive type, etc.

[0030] The main unit transceiver unit 14 is located on a part of the circuit board of the control unit 10 of the main unit 2. The main unit transceiver unit 14 has an electronic circuit for wireless communication with the operation command unit 20.

[0031] The control unit 20 is for remotely operating the main unit 2, and in this embodiment, it communicates via radio waves. The control unit 20 is powered by a built-in battery. The control unit 20 has, for example, a balance button 22, a holding button 23, an up button 24, and a down button 25 as operating means. Details of the operation will be described later.

[0032] Figure 3 is a block diagram of the electronic circuit of a cargo handling assistance device 1 according to an embodiment of the present invention. The cargo handling assistance device 1 is composed of a main unit 2 and an operation command unit 20.

[0033] The control unit 10 of the main unit 2 controls the entire main unit 2. The control unit 10 of the main unit 2 includes a drive circuit that drives the motor unit 11. The control unit 10 of the main unit 2 receives the weight value applied to the lifting operation unit 16 from the weight detection unit 12, and the position value of the rotation angle of the motor unit 11 from the position detection unit 13, and transmits and receives signals with the main unit transmitting / receiving unit 14. The main unit transmitting / receiving unit 14 and the control unit 10 of the main unit 2 are connected by a wire, and transmit and receive signals at high speed with extremely short time intervals. The control unit 10 includes a storage unit 10a and a calculation unit 10b, and the calculation unit 10b includes an automatic lifting / lowering means 10c and a balancing means 10d. The storage unit 10a may be located inside the control unit 10, or it may be located outside the control unit 10.

[0034] The main unit's transceiver unit 14 communicates wirelessly with the operation command transceiver unit 26 of the operation command unit 20. The main unit's transceiver unit 14 and the operation command transceiver unit 26 are composed of electronic circuits that perform wireless communication and have a radio wave transmitter and receiver, as well as possibly having a CPU (Central Processing Unit), ROM (Read Only Memory), RAM (Random Access Memory), etc.

[0035] The operation command control unit 21 controls the entire operation command unit 20. The operation command control unit 21 receives operation commands from each operation means (operation buttons) and transmits the operation command signal to the operation command transmission / reception unit 26. The operation command transmission / reception unit 26 then wirelessly transmits the operation command received from the operation command control unit 21 to the main unit transmission / reception unit 14. This signal containing the command is accompanied by identification information of the operation command unit 20, which is used to pair the operation command unit 20 with the main unit 2.

[0036] Next, the roles of each operation button, which is an operating means provided in the operation command unit 20, will be explained. Each operation button is, for example, a momentary push switch, which turns ON while pressed and self-returns OFF when released. When an operator presses the balance button 22, a balance command is transmitted from the operation command unit 20, and the control unit 10 of the main unit 2 receives this and proceeds to balance control. That is, when the balance button 22 is pressed, the control unit 10 of the main unit 2 has the weight detection unit 12 detect the weight value applied to the lifting operation unit 16, and stores the output weight value as a registered weight in the storage unit 10a. Then, the balance means 10d calculates a control value that makes the difference between the registered weight and the weight applied to the lifting operation unit 16 zero, and controls the motor unit 11. In this invention, this control is called balance control, and the state of the locking unit 7 and the cargo 33 during this balance control is called the balance state. In other words, balance control is the process by which the control unit 10 of the main unit 2 calculates control values ​​so that the tension of the link chain 4 caused by the registered weight is the same as the tension of the link chain 4 caused by the weight detected by the lifting operation unit 16, and controls the motor unit 11 accordingly. If the operator applies a vertically downward external force to the locking part 7 or the cargo 33 during this balance control, the weight applied to the lifting operation unit 16 increases. Therefore, the control unit 10 of the main unit 2 calculates control values ​​to bring this closer to the registered weight and controls the motor unit 11 in the direction of unwinding the link chain 4, causing the locking part 7 and the cargo 33 to descend. On the other hand, if the operator applies a vertically upward external force to the locking part 7 or the cargo 33 during this balance control, the weight applied to the lifting operation unit 16 decreases. Therefore, the control unit 10 of the main unit 2 calculates control values ​​to bring this closer to the registered weight and controls the motor unit 11 in the direction of winding up the link chain 4, causing the locking part 7 and the cargo 33 to rise. When the operator stops applying external force, the weight detected by the weight detection unit 12 becomes equal to the registered weight, and the locking unit 7 and the cargo 33 become stationary. This control value includes, for example, acceleration.

[0037] On the other hand, when the operator presses the holding button 23, the control unit 10 of the main unit 2 receives a holding command and controls the motor unit 11 to hold the lifting mechanism 16 in its current position, that is, to maintain the lifting position of the lifting hook 5 and the locking mechanism 7.

[0038] When the operator presses the up button 24 or down button 25, the control unit 10 of the main unit 2 receives this and controls the motor unit 11 to raise or lower the lifting hook 5. By continuously pressing the up button 24 or down button 25, the operator can continuously raise and lower the lifting hook 5 and the locking part 7 using the motor unit 11. Regardless of whether the main unit 2 is in the holding state or the balancing state, when the operator presses the up button 24 or down button 25, it will raise or lower, and when the operator releases the pressed up button 24 or down button 25, it returns to the holding state.

[0039] Figures 4 to 11 are schematic diagrams illustrating a series of work states in which an operator handles cargo 33 using the cargo handling assistance device 1 according to an embodiment of the present invention. Figure 12 is a flowchart of the operations performed by the control unit 10 of the main unit 2 of the cargo handling assistance device 1 according to an embodiment of the present invention. The movement of the locking part 7 and the cargo 33, and each control step performed by the control unit 10 of the main unit 2 at that time, will be explained using Figures 4 to 12.

[0040] In Figure 4, the rail 42 is a track rail installed horizontally on the ceiling or the like within the work area. The movable block 41 is a member that can move substantially horizontally along the rail 42 and is connected to the suspension hook 3 to suspend the main device 2. Therefore, the movable block 41 allows the suspension hook 3 and below to move freely in the horizontal direction.

[0041] A structure 30 is located vertically below the cargo handling assistance device 1. The structure 30 has a first surface 30a and a second surface 30b. The first surface 30a is lower in the vertical direction than the second surface 30b. A conveyor 31 is placed on the first surface 30a, and cargo 33 is transported on the conveyor 31 in the depth direction shown in Figure 4. On the other hand, a bottomed container 32 is placed on the second surface 30b. The container 32 is a storage container that can hold multiple cargo 33. Here, we will explain the procedure for moving the cargo 33 that has been transported on the conveyor 31 into the container 32.

[0042] In Figure 12, when the worker turns on the power switch (not shown) of the main unit 2 while the power to the cargo handling assistance device 1 is initially off, the control unit 10 of the main unit 2 starts up, executes step S101, and proceeds to step S102. In step S101, the control unit 10 of the main unit 2 holds the lifting mechanism 16 in its current position (holding mode). In step S102, if the control unit 10 of the main unit 2 determines that the lift button 24 or the lower button 25 has been pressed, it executes step S103. In step S103, the control unit 10 of the main unit 2 operates the lifting mechanism 16 to raise or lower the locking mechanism 7, returns to step S101, and holds it in that position. When the operator continuously presses the up button 24 or down button 25 of the operation command unit 20, the control unit 10 of the main unit 2 continues step S103 to raise or lower the lifting hook 5 and the locking part 7.

[0043] If the control unit 10 of the main unit 2 determines in step S102 that the up button 24 or the down button 25 has not been pressed, it proceeds to step S104.

[0044] In step S104, the control unit 10 of the main unit 2 determines that the balance button 22 has not been pressed and returns to step S101 to maintain the holding state. In step S104, the control unit 10 of the main unit 2 determines that the balance button 22 has been pressed and proceeds to step S105. That is, when the operator presses the balance button 22 while the cargo 33 is not suspended, i.e., without cargo, the control unit 10 of the main unit 2 receives the weight value W1 applied to the weight detection unit 12 in step S105, stores this as a registered value, and proceeds to step S106. This weight value W1 is the weight without cargo, and is the weight detected by the weight detection unit 12 when the cargo 33 is not locked to the locking unit 7.

[0045] In step S106, the control unit 10 of the main unit 2 starts load-handling-free balance control (balancing step) based on the registered value of "no load-handling-free" stored in the memory unit 10a, and proceeds to step S107. That is, the balancing means 10d within the control unit 10 executes this balancing step. In this state, the operator can grasp the grip 6 and freely raise and lower the locking part 7, so the operator moves it until the payout value L of the tip of the locking part 7 becomes smaller than a predetermined first payout value L1a. This state is shown in Figure 4. The payout value L refers to the vertical distance from the bottom surface B of the main unit 2 to the tip of the locking part 7.

[0046] Step S107 of the control unit 10 of the main unit 2 continues until the extension value of the tip of the locking part 7 becomes smaller than a predetermined first extension value L1a. If the control unit 10 of the main unit 2 determines in step S107 that the extension value L of the tip of the locking part 7 has become smaller than a predetermined first extension value L1a, it proceeds to step S108.

[0047] In step S108, the control unit 10 of the main unit 2 sets a flag to enable the automatic lifting function and proceeds to step S109.

[0048] Step S109 of the control unit 10 of the main unit 2 continues until the extension value L of the tip of the locking part 7 is greater than a predetermined second extension value L2a and this is maintained for a predetermined time, i.e., n seconds. The value n of this predetermined time can be set by the work manager or worker in the control unit 10 according to the content of the cargo handling work. If the control unit 10 of the main unit 2 determines in step S109 that the extension value L of the tip of the locking part 7 is greater than a predetermined second extension value L2a and this has been maintained for a predetermined time, i.e., n seconds (Yes), it proceeds to step S110. That is, the worker operates the grip 6 to lower the locking part 7 below at least the position of the second extension value L2a shown in Figure 5 and maintains this for n seconds. Then, in step S110, the control unit 10 of the main unit 2 performs automatic lifting (automatic lifting step) and proceeds to step S111. That is, the automatic lifting means 10c in the control unit 10 performs this automatic lifting step. The worker releases their hand from grip 6 once the automatic lifting process begins and waits until the automatic lifting is complete.

[0049] The control unit 10 of the main unit 2 performs the automatic lifting in step S110 as follows: The control unit 10 of the main unit 2 commands the motor unit 11 to rotate the locking part 7 in the direction of raising, and the lifting operation unit 16 winds up the link chain 4. Then, when the weight value received from the weight detection unit 12 becomes approximately a certain weight value, a stop command is issued to the motor unit 11 (Figure 6). The automatic lifting is then completed, and the flag for enabling the automatic lifting function is turned off. When the weight value received from the weight detection unit 12 becomes approximately a certain weight value, it means that the cargo 33 is suspended in mid-air.

[0050] In step S111, the control unit 10 of the main unit 2 stores the weight value W2 received from the weight detection unit 12 and proceeds to step S112. In step S112, the control unit 10 of the main unit 2 performs balance control based on the weight value W2 and proceeds to step S113. That is, at this time, the control unit 10 of the main unit 2 performs balance control with the load in place. After this, the operator can grasp the grip 6 and freely raise and lower the locking part 7 and the load 33, so the operator moves the locking part 7 until the extension value L of the tip of the locking part 7 becomes smaller than a predetermined third extension value L3.

[0051] Step S113 of the control unit 10 of the main unit 2 continues until the extension value L of the tip of the locking part 7 becomes smaller than a predetermined first extension value L1b. If the control unit 10 of the main unit 2 determines in step S113 that the extension value L of the tip of the locking part 7 has become smaller than a predetermined first extension value L1b (Figure 7) (Yes), it proceeds to step S114.

[0052] In step S114, the control unit 10 of the main unit 2 sets the flag for enabling the automatic unloading function and proceeds to step S115. The automatically unloaded cargo 33 basically needs to be unloaded. Therefore, although the flag for enabling the automatic unloading function has been cleared after the automatic unloading is complete, the control unit 10 of the main unit 2 is in a waiting state to set the flag for enabling the automatic unloading function, which is the next step to be performed.

[0053] As shown in Figure 8, the operator operates the grip 6 to move the main unit 2 to a position near the vertically above the container 32. Since the friction between the moving block 41 and the rail 42 is small, the main unit 2 and the entire assembly can be easily moved to the position shown in Figure 8 by the operator applying a horizontal force to the grip 6. The operator then operates the grip 6 to gradually lower the cargo 33 to the position where it will be placed on the container 32 (Figure 9). Of course, from the state shown in Figure 7, the operator can also proceed to the state shown in Figure 9 by applying a horizontal force to the grip 6 while also applying a downward vertical force.

[0054] Step S115 of the control unit 10 of the main unit 2 continues until the extension value L of the tip of the locking part 7 is greater than a predetermined second extension value L2b and this is maintained for a predetermined time, i.e., m seconds. The value m of this predetermined time can also be set by the work manager or worker in the control unit 10 according to the content of the cargo handling work. If the control unit 10 of the main unit 2 determines in step S115 that the extension value L of the tip of the locking part 7 is greater than a predetermined second extension value L2b and this has been maintained for a predetermined time, i.e., m seconds (Yes), it proceeds to step S116. That is, the worker operates the grip 6 to lower the locking part 7 to a position at least below the second extension value L2b shown in Figure 9 and maintains this position for m seconds. Then, in step S116, the control unit 10 of the main unit 2 performs automatic unloading (automatic lifting step) and proceeds to step S105. That is, the automatic lifting means 10c in the control unit 10 performs this automatic lifting step. The worker releases their hands from grip 6 when automatic unloading begins and waits for the automatic unloading to complete.

[0055] Here, we will explain in detail what the control unit 10 of the main unit 2 does in step S116. The control unit 10 of the main unit 2 commands the motor unit 11 to rotate in the direction of lowering the locking part 7, and the lifting and lowering operation unit 16 unwinds the link chain 4. The conditions under which the motor unit 11 stops are, for example, one of the following:

[0056] Example Condition 1: The control unit 10 of the main unit 2 lowers the locking part 7 to the motor unit 11 by a predetermined distance, and then proceeds to step S105 when the weight value received from the weight detection unit 12 reaches a certain weight value. This predetermined distance can be set by the work manager or worker in the control unit 10 depending on the content of the cargo handling work.

[0057] Example Condition 2: The control unit 10 of the main unit 2 lowers the locking part 7 until the weight value received from the weight detection unit 12 reaches the weight without cargo stored in the storage unit 10a, and proceeds to step S105. The weight without cargo is the weight detected by the weight detection unit 12 when no cargo is locked to the locking part 7. The weight without cargo stored in the storage unit 10a can be set in the control unit 10 by the work manager or worker registering in advance that no cargo 33 is suspended from the locking part 7.

[0058] Therefore, as shown in Figure 10, the locking part 7 is lowered to a position (extension value Lc) where it can be released from the cargo 33. The worker then grips the grip 6 again to release the locking part 7 from the cargo 33 and moves it vertically upward (Figure 11).

[0059] When the operator presses the hold button 23, the raise button 24, or the lower button 25, the control unit 10 of the main unit 2 treats this as an interrupt process and returns to step S101, and the cargo handling assistance device 1 enters the hold state.

[0060] Figure 13 is an example of a schematic chart showing the relationship between the control mode of the cargo handling assist device 1 and the transitions of the payout value of the locking unit 7, the registered weight used for balancing, and the detected weight, with the horizontal axis being the time axis, in a cargo handling assist device 1 according to an embodiment of the present invention. From top to bottom, Figure 13 shows the pressed state of the balance button 22, the control mode of the control unit 10, the flag state for automatic lifting and automatic unloading, the payout value of the locking unit 7 (the vertical axis downwards is positive, as in Figures 4 to 11), the registered value stored in the memory unit 10a, and the detected weight detected by the weight detection unit 12 and received by the control unit 10.

[0061] Next, we will explain the work process shown in Figures 4 to 11, the flowchart in Figure 12, and the chart in Figure 13.

[0062] First, with the cargo handling assistance device 1 powered off, when the worker turns on the power switch (not shown) of the main unit 2, the control unit 10 of the main unit 2 starts up, and the control unit 10 of the main unit 2 executes step S101 to perform position holding. Therefore, the mode of the cargo handling assistance device 1 is set to holding mode. At this time, nothing is locked to the locking part 7, so if the worker does not apply any external force, the weight detection unit 12 detects the weight value W1.

[0063] Next, when the operator presses the balance button 22 (time t1), the control unit 10 of the main unit 2 proceeds to Yes in step S104, and in step S105, the storage unit 10a stores the weight value W1 detected by the weight detection unit 12 as the registered value. In this embodiment, the registered value when the power to the cargo handling assistance device 1 is turned off is carried over as the registered value when it is restarted, so the registered value is W1 from the time of startup.

[0064] The control unit 10 of the main unit 2 enters load-free balancing mode from time t1. The operator holds the grip 6 and attempts to raise the locking part 7 until the payout value L of the locking part 7 becomes smaller than the first payout value L1a. As a result, the weight value applied to the weight detection unit 12 decreases, so the control unit 10 of the main unit 2 winds up the locking part 7 so that the weight value detected by the weight detection unit 12 becomes the registered weight W1, and the detected weight becomes approximately W1. Here, the dashed line of the detected weight around time t2 in Figure 13 indicates the net weight due to the operator applying a vertically upward external force. In order for the operator to determine whether the payout value L of the locking part 7 is smaller than the first payout value L1a, the relative positional relationship may be displayed on the bottom surface of the main unit 2 using a display unit with a light-emitting diode or the like, or by an audible notification. Other variations include providing a display unit on the control unit 20 or grip 6, or providing a vibrating component on the control unit 20 or grip 6 to notify the operator.

[0065] The control unit 10 of the main unit 2 sets a flag to activate the automatic lifting function at time t2 when the payout value L of the locking part 7 becomes smaller than the first payout value L1a. Subsequently, the worker grasps the grip 6 and applies an external force vertically downward to pull down the locking part 7, so the payout value L of the locking part 7 increases, and the weight value applied to the weight detection unit 12 increases. The control unit 10 of the main unit 2 then pays out the locking part 7 so that the weight value detected by the weight detection unit 12 becomes the registered weight W1, so the detected weight is approximately W1. The dashed line in the detected weight shows the net weight due to the vertically downward external force applied by the worker.

[0066] The worker grasps the grip 6 and brings the locking part 7 to the locking part of the cargo 33 and stops it. Then, in step S109, the control unit 10 of the main unit 2 detects that the payout value L of the locking part 7 has exceeded the second payout value L2a (time t3) and has continued for a predetermined time of n seconds, and performs automatic lifting in step S110. As a result, the weight applied to the weight detection unit 12 gradually increases. When the weight value W2 received from the weight detection unit 12 becomes approximately constant, the control unit 10 of the main unit 2 issues a stop command to the motor unit 11, ending the automatic lifting and turning off the flag for enabling the automatic lifting function (time t5). In step S111, the control unit 10 of the main unit 2 stores the weight value W2 at this time as a registered value in the storage unit 10a, and from time t5, performs cargo handling balance control in step S112. Thus, from time t5, the control unit 10 enters cargo handling balance mode.

[0067] Next, the worker grasps the grip 6 and raises the locking part 7, so the payout value L of the locking part 7 decreases, and the weight value applied to the weight detection unit 12 also decreases. However, the control unit 10 of the main unit 2 winds up the locking part 7 so that the weight value detected by the weight detection unit 12 becomes the registered weight W2, so the detected weight remains approximately W2.

[0068] Eventually, when the worker extends the locking part 7 to a first extension value L1b, the control unit 10 of the main unit 2 sets a flag to activate the automatic unloading function at time t6, when the extension value L of the locking part 7 becomes smaller than the first extension value L1b. To help the worker determine whether the extension value L of the locking part 7 is smaller than the first extension value L1b, the main unit 2 may display the relative position using a display unit with a light-emitting diode or the like, or by providing an audible notification. Other variations include providing a display unit on the operation command unit 20 or grip 6, or providing a vibrating member on the operation command unit 20 or grip 6 to inform the worker. The worker then moves the cargo handling assistance device 1 horizontally to a position vertically above the container 32 (corresponding to the period from time t6 to time t7). When the operator grasps the grip 6 and begins to lower the locking part 7 (time t7), the extension value L of the locking part 7 increases, and the weight value applied to the weight detection unit 12 also increases. Here again, the control unit 10 of the main unit 2 extends the locking part 7 so that the weight value detected by the weight detection unit 12 becomes the registered weight W2, so the detected weight remains approximately W2.

[0069] As shown in Figure 9, the operator moves the cargo 33 to the vicinity of the placement surface of the container 32. Then, in step S115, the control unit 10 of the main unit 2 detects that the payout value L of the locking part 7 has exceeded the second payout value L2b (time t8) and has continued for a predetermined time of m seconds, and in step S116, it executes automatic unloading. Therefore, the weight value detected by the weight detection unit 12 decreases as the cargo 33 comes into contact with the container 32. Then, when the weight value received from the weight detection unit 12 becomes approximately constant W1, the control unit 10 of the main unit 2 terminates the automatic unloading and turns off the flag for enabling the automatic unloading function (time t10).

[0070] The control unit 10 of the main unit 2 immediately switches to a balanced mode without cargo handling at a weight value W1 after automatic unloading.

[0071] The worker grasps the grip 6 and releases the locking part 7 from the cargo 33, raising the locking part 7 until its extension value L reaches the first extension value L1a (time t11). Consequently, the extension value of the locking part 7 decreases, and the weight value applied to the weight detection unit 12 also decreases. The same process is then repeated. As shown in Figure 13, the worker only presses the balance button 22 once, significantly reducing the burden on the worker. Furthermore, if the control unit 10 is set to start in load-free balance mode when the power of the cargo handling assistance device 1 is turned on, cargo handling operations can be performed without operating any buttons at all.

[0072] As described above, the present invention provides a cargo handling assistance device and a control method thereof that improves operator operability by reducing the frequency of pressing the operation buttons through the automatic lifting and automatic unloading functions of the cargo handling assistance device.

[0073] Although the present invention has been described based on preferred embodiments, the present invention is not limited to the embodiments described above, and various modifications are possible without departing from the spirit of the invention. [Industrial applicability]

[0074] One example of the application of this invention is its use in material handling machinery that assists in the movement of cargo. [Explanation of symbols]

[0075] 1: Cargo handling assistance device 2: Main unit 3: Hanging hook 4: Link chain (suspension rope) 5: Hooks for hanging equipment 6: Grip 7: Locking part 10: Control Unit (Main Unit Control Unit) 10a: Storage section 10b: Arithmetic section 10c: Automatic lifting mechanism 10d: Balancing method 11: Motor section 12: Weight detection unit 13: Position detection unit 14: Main unit transceiver 15: Output shaft 16: Lifting mechanism 17: Chain storage compartment 20: Operation command section 21: Operation Command Control Unit 22: Balance Button 23: Hold button 24: Up button 25: Down button 26: Operation command transmission / reception unit 30: Structure 30a: First surface 30b: Second side 31: Conveyor 32: Container 33: Cargo handling equipment 41: Moving Block 42: Rail

Claims

1. A cargo handling assist device that assists in the lifting and lowering of cargo, comprising a lifting and lowering mechanism, a motor, a weight detection unit, a position detection unit, a memory unit, and a control unit, The lifting mechanism extends a suspension cable to hold the cargo in place, thereby raising and lowering the cargo. The motor unit drives the lifting and lowering mechanism, The weight detection unit detects the weight value applied to the lifting mechanism and transmits it to the control unit. The position detection unit transmits to the control unit if it detects at least one of the following as an extension value based on the distance the locking portion has been extended: a preset first extension value, a predetermined extension value smaller than the first extension value, or a preset second extension value larger than the first extension value. The storage unit stores the weight of the locking part and the weight of the cargo as registered values. The control unit includes a balancing means and an automatic lifting means. The balancing means receives the weight value and the registered value, calculates a control value that makes the difference between the weight value and the registered value zero, and controls the motor unit to perform balance control. The automatic lifting means is A cargo handling assistance device that immediately raises or lowers the locking part when it is detected that the payout value received from the position detection unit has reached the first payout value from the predetermined payout value, and then reached the second payout value, and a predetermined time has elapsed.

2. The control unit, The cargo handling assistance device according to claim 1, wherein the automatic lifting means automatically raises the locking portion, and when a certain weight value is received from the weight detection unit, the certain weight value is updated as the registered value, and the balance control is performed.

3. The control unit, The cargo handling assistance device according to claim 1 or 2, wherein the locking portion is lowered by the automatic lifting means, and when the weight value received from the weight detection unit reaches a weight value without cargo that has been previously stored in the storage unit, the weight value without cargo is updated as the registered value, and the balance control is performed.

4. The cargo handling assistance device according to claim 1 or 2, wherein the control unit lowers the locking portion by a predetermined distance using the automatic lifting means, updates the weight value received from the weight detection unit as the registered value, and performs the balance control.

5. A control method for a cargo handling assistance device that assists in the lifting and lowering of cargo, comprising a lifting and lowering mechanism, a motor, a weight detection unit, a position detection unit, a memory unit, and a control unit, The lifting mechanism extends a suspension cable to hold the cargo in place, thereby raising and lowering the cargo. The motor unit drives the lifting and lowering mechanism, The weight detection unit detects the weight value applied to the lifting mechanism and transmits it to the control unit. The position detection unit transmits to the control unit if it detects at least one of the following as an extension value based on the distance the locking portion has been extended: a preset first extension value, a predetermined extension value smaller than the first extension value, or a preset second extension value larger than the first extension value. The storage unit stores the weight of the locking part and the weight of the cargo as registered values, The control unit has a balancing step and an automatic lifting step. In the balancing step, the control unit receives the weight value and the registered value, calculates a control value that makes the difference between the weight value and the registered value zero, and controls the motor unit to perform balancing control. A control method for a cargo handling assist device, wherein in the automatic lifting step, the control unit detects that the payout value received from the position detection unit has reached the first payout value from a predetermined payout value, and then reached the second payout value, and a predetermined time has elapsed, and immediately raises or lowers the locking part.

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