Cushioning material holding device, forklift, and cargo handling system

Abstract

To provide such a configuration as to bring a cushioning material into close contact with a side face of a cargo on a fork.SOLUTION: A cushioning material holding device 1 is provided on a forklift so as to hold a plate-like cushioning material S. The holding device 1 includes: a slider 11 which is provided so as to be elevated / lowered together with a fork 70, and be movable in a lateral direction Y perpendicular to a horizontal projection direction X1 of the fork 70; and a holding mechanism 2 which is connected to the slider 11 so as to be rotatable around a rotation shaft 12 through the rotation shaft 12, and releasably holds the cushioning material S beside the fork 70. The holding device 1 includes a first energization member 13 which is provided so as to energize the slider 11 and the holding mechanism 2 to a direction Y2 of making the cushioning material S held by the holding mechanism 2 approach the fork 70 in the lateral direction Y, and positions the slider 11 and the holding mechanism 2 with respect to the lateral direction Y, when the holding mechanism 2 does not hold the cushioning material S.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present application relates to a buffer material holding device that releasably holds a buffer material sandwiched between packages. The present application also relates to a forklift equipped with the buffer material holding device. The present application further relates to a cargo handling system equipped with the forklift.

Background Art

[0002] As disclosed in Patent Documents 1, 2, etc., a cargo handling system for loading packages on the loading platform of a truck has been developed. After the packages are loaded on the loading platform, the truck transports the packages. In order to prevent the packages from collapsing or being damaged during transportation, a plate-shaped buffer material (sometimes called a separator) is often interposed between the packages.

[0003] In a general loading operation using a manned forklift, an operator (for example, a truck driver who works together with the forklift operator) manually props up the buffer material against the packages already loaded on the loading platform. Then, when the operator operates the forklift to load the next package, the buffer material is sandwiched between the previous package and the next package so that the buffer material is interposed between the packages without any gaps. In addition, in order to prevent the buffer material from falling down due to strong wind, the operator may hold the buffer material until immediately before loading the packages on the loading platform, but there is a risk of hand夹 accidents.

[0004] In the system of Patent Document 1, an unmanned forklift loads packages on the loading platform of a truck. In this system as well, as in the case of a manned forklift, immediately before loading, an operator manually props up the buffer material against the packages already loaded on the loading platform.

[0005] Such a method has a risk of hand夹 accidents for the operator handling the buffer material and has a problem with safety in both the case of a manned forklift and an unmanned forklift.

[0006] Patent Document 1 discloses an embodiment in which an unmanned forklift supports one load with the two forks on the left side and another load with the two forks on the right side, and transports two loads simultaneously. In this embodiment, when the unmanned forklift pauses, an operator places cushioning material between these loads supported by the forks. The unmanned forklift then shifts its forks, securing the cushioning material between the two loads. The unmanned forklift then loads these loads, along with the cushioning material, onto the platform.

[0007] This method assumes that there are four forks and that two loads are loaded together onto the truck bed. Moreover, the placement of cushioning material between the loads already loaded on the truck bed and the loads to be loaded next ultimately requires the assistance of the worker as described above.

[0008] In the system described in Patent Document 2, a transport cart moves along a rail and automatically loads cargo onto the cargo bed of a truck parked at a predetermined location. The transport cart loads the cargo onto the cargo bed one after another, ensuring that there is a certain amount of space between the cargo items. Then, an operator manually inserts cushioning material into the gaps.

[0009] To insert cushioning material after loading cargo, it is necessary to leave a gap larger than the cushioning material. However, to prevent cargo shifting or damage, it is important that the cushioning material is interposed between the cargo without any gaps. This is difficult with the method described in Patent Document 2.

[0010] Thus, there are several problems with the arrangement of cushioning materials in conventional technology. [Prior art documents] [Patent Documents]

[0011] [Patent Document 1] Japanese Patent Publication No. 2021-195195 [Patent Document 2] Japanese Patent Publication No. 2001-301984 [Overview of the project] [Problems that the invention aims to solve]

[0012] This invention provides a configuration that allows cushioning material to adhere closely to the side of the load on the fork. [Means for solving the problem]

[0013] This application provides a cushioning material holding device to be installed on a forklift for holding a plate-shaped cushioning material. The cushioning material holding device is A slider is provided so as to move up and down together with the forks of the forklift, and so as to be movable in a lateral direction perpendicular to the horizontal protrusion direction of the forks, A retaining mechanism is connected to the slider so as to be rotatable around the rotating shaft via a rotating shaft extending in the horizontal projection direction, for releasably holding the cushioning material beside the fork, The slider and the holding mechanism are provided to bias the cushioning material held by the holding mechanism toward the fork in the lateral direction, and a first biasing member is provided for positioning the slider and the holding mechanism in the lateral direction when the holding mechanism is not holding the cushioning material.

[0014] The cushioning material holding device is provided such as to bias the holding mechanism in a direction that moves the cushioning material held by the holding mechanism away from the fork in the rotational direction around the rotation axis, and may further include a second biasing member for positioning the holding mechanism with respect to the rotational direction when the holding mechanism is not holding the cushioning material.

[0015] The holding mechanism has a receiving opening into which a cushioning material is inserted. The second biasing member may position the holding mechanism such that, when the holding mechanism is not holding the cushioning material, the receiving opening faces downward and outward in a downward direction toward the forklift.

[0016] The cushioning material holding device includes a slide guide provided on the backrest of the forklift, The slider may be mounted on the slide guide so as to be slidable in the lateral direction.

[0017] The first Favoring member is, for example, a spring connected to the slide guide and the slider.

[0018] The second Favoring member is, for example, a spring connected to the slider and the holding mechanism.

[0019] Further, the present application provides a forklift, and the forklift comprises the above buffer holding device and forks for supporting a load, and a cargo handling device for integrally raising and lowering the forks and the holding mechanism.

[0020] Further, the present application provides an automatically drivable forklift, and the forklift comprises the above buffer holding device, forks for supporting a load, a cargo handling device for integrally raising and lowering the forks and the holding mechanism and shifting them in the lateral direction, and a control unit for controlling the operation of the forklift according to a work instruction related to cargo handling.

[0021] Furthermore, the present application provides a cargo handling system comprising the above automatically drivable forklift, and automatically driving the forklift so that the forklift loads a load onto the loading platform of a transport vehicle parked in a predetermined parking area according to a work instruction related to cargo handling. The control unit of the forklift after placing the load on the forks, temporarily stops the forklift at a predetermined temporary stop position away from the side of the rear part of the loading platform of the transport vehicle parked in the parking area, In response to the instruction to resume operation, the forklift, with the cushioning material held by the holding mechanism, is driven from the temporary stop position to the cargo bed of the transport vehicle. The aforementioned cargo is loaded onto the cargo bed next to the cargo already loaded on the cargo bed, and, When loading the aforementioned cargo onto the cargo bed, the holding mechanism releases the cushioning material and sandwiches the cushioning material between the aforementioned cargo and the previously placed cargo. This controls the operation of the forklift. [Brief explanation of the drawing]

[0022] [Figure 1] Figure 1 schematically shows an example of a cushioning material holding device. [Figure 2] Figure 2 shows a magnified view of the cushioning material holding device in Figure 1. [Figure 3] Figure 3 is a view of the cushioning material holding device shown in Figure 1 from a downward oblique angle. [Figure 4] Figure 4 is a diagram illustrating the operation of the cushioning material holding device shown in Figure 1. [Figure 5] Figure 5 is a diagram illustrating the operation of the cushioning material holding device shown in Figure 1. [Figure 6] Figure 6 is a diagram illustrating a preferred arrangement of the holding mechanism. [Figure 7] Figure 7 schematically shows an example of a non-actuator type holding mechanism. [Figure 8] Figure 8 shows how the cushioning material is inserted into the holding mechanism shown in Figure 7. [Figure 9] Figure 9 is a diagram illustrating how the cushioning material is held by the holding mechanism shown in Figure 7. [Figure 10] Figure 10 is a diagram illustrating how the cushioning material is held by the holding mechanism shown in Figure 7. [Figure 11] Figure 11 is a diagram illustrating the cargo handling operation of a forklift using the holding mechanism shown in Figure 7. [Figure 12] Figure 12 schematically shows an example of an actuator-type holding mechanism. [Figure 13]Figure 13A is a plan view of the retaining mechanism of Figure 12 with the second clamper (movable clamper) in the open position, and Figure 13B is a plan view of the retaining mechanism of Figure 12 with the second clamper in the clamped position. [Figure 14] Figure 14A is a front view of Figure 13A, and Figure 14B is a front view of Figure 13B. [Figure 15] Figures 15A and 15B illustrate upper stoppers, respectively. [Figure 16] Figures 16A and 16B illustrate examples of cushioning material sensors, respectively. [Figure 17] Figure 17 is a block diagram showing the configuration related to the actuator control unit. [Figure 18] Figure 18 is a diagram illustrating the cargo handling operation of a forklift using the holding mechanism shown in Figure 12. [Figure 19] Figure 19 shows a portion of the work area of ​​the example cargo handling system. [Figure 20] Figure 20 is a schematic block diagram of an example of an autonomous forklift. [Modes for carrying out the invention]

[0023] The following describes exemplary embodiments of the present invention with reference to the attached drawings. Note that the components shown in the drawings do not necessarily represent exact dimensions or proportions, but merely depict their function or operation.

[0024] Figure 1 schematically shows a cushioning material holding device 1 according to one example. The cushioning material holding device 1 is attached to a forklift 7 (Figure 19) as an attachment and holds a plate-shaped cushioning material S in a releaseable manner. The forklift 7 may be a manned or unmanned forklift. The forklift 7 is equipped with forks 70 for supporting the load W. Here, the load W refers to the pallet P and all the items placed on it. The forklift 7 supports the load W by inserting the forks 70 into the pallet P and scooping it up. In Figure 1, four forks 70 are shown, but the number is, of course, not limited.

[0025] In Figure 1, the horizontal projection direction of the fork 70 is denoted as X1, and the lateral direction perpendicular to this horizontal projection direction X1 is denoted as Y(Y1,Y2). The horizontal projection direction X1 is sometimes referred to as the front of the forklift 7, and the lateral direction Y is sometimes referred to as the left-right direction of the forklift 7.

[0026] The cushioning material holding device 1 comprises a slide guide 10, a slider 11 provided on the slide guide 10 so as to be movable in the lateral direction Y, a rotating shaft 12 attached to the slider 11 and extending from the slider 11 in a horizontal projection direction X1, and a holding mechanism 2 connected to the slider 11 via the rotating shaft 12 so as to be rotatable around the rotating shaft 12.

[0027] The slide guide 10 is attached to the backrest 71. Therefore, the holding mechanism 2 and the forks 70 are raised and lowered together by the lifting operation of the forklift 7, and are also shifted together in the lateral direction Y by the side shift operation. In order to move the holding mechanism 2 and the forks 70 together, the slide guide 10 may be attached not only to the backrest 71, but also to other members such as finger bars or lift brackets.

[0028] As shown in Figure 2, the slide guide 10 includes, for example, two side frames 100 spaced apart in the lateral direction Y, and two upper and lower guide bars 101 that span across the side frames 100 and extend in the lateral direction Y. The slider 11 is slidably mounted on the guide bars 101. This allows the slider 11 to move in the lateral direction Y between the side frames 100.

[0029] The slide guide 10 is located on the upper surface of the backrest 71 at the lateral Y end (the Y1 end in this example), and the holding mechanism 2 is located at the tip of the rotating shaft 12 that extends forward X1 from the slider 11. As a result, the holding mechanism 2 is located forward X1 from the backrest 71 and outside (towards Y1) from the outermost fork 70, as shown in Figure 1. Therefore, when the holding mechanism 2 holds the cushioning material S, the cushioning material S is located to the side of the fork 70. When the load W is supported by the fork 70, the held cushioning material S faces the side of the load W.

[0030] Since the holding mechanism 2 is connected to the slider 11 via the rotation axis 12, it can move laterally in the Y direction together with the slider 11. The specific configuration of the holding mechanism 2 will be described later.

[0031] As shown in Figure 2, the cushioning material holding device 1 further includes a first biasing member 13 and a second biasing member 14.

[0032] The first biasing member 13 biases the slider 11 and the holding mechanism 2 in the direction (Y2 in this example) where the cushioning material S held by the holding mechanism 2 approaches the fork 70, and positions the slider 11 and the holding mechanism 2 with respect to the lateral direction Y when the holding mechanism 2 is not holding the cushioning material S.

[0033] In this example, the first biasing member 13 is a spring, more specifically a tension spring, which is connected to the slider 11 and the slide guide 10 (its Y2-side side frame 100) and biases the slider 11 by pulling it in direction Y2. As a result, when the cushioning material S is not held, the slider 11 and the holding mechanism 2 are positioned closer to direction Y2 within their range of motion in the lateral direction Y.

[0034] The second biasing member 14 biases the cushioning material S held by the holding mechanism 2 in the direction away from the fork 70 (direction R1 in this example) within the rotational direction R (R1, R2) around the rotation axis 12. As a result, the second biasing member 14 positions the holding mechanism 2 with respect to the rotational direction R when the holding mechanism 2 is not holding the cushioning material S.

[0035] In this example, the second biasing member 14 is a spring, more specifically a tension spring, connected to the slider 11 (its mounting portion 110) and the holding mechanism 2 (its mounting portion 21), and positions the holding mechanism 2 by pulling it in direction R1 against its own weight. If the second biasing member 14 were not present, the holding mechanism 2 would hang vertically from the rotation axis 12 due to its own weight.

[0036] As shown in Figure 3, the holding mechanism 2 has a downward-facing receiving opening 20 into which the cushioning material S is inserted. As described later, worker C (Figure 19) stands next to the forklift 7 and inserts the cushioning material S into the receiving opening 20 from below, allowing the holding mechanism 2 to hold it. Because the second biasing member 14 positions the holding mechanism 2 with respect to the rotational direction R, when the cushioning material S is not being held, the receiving opening 20 faces downwards and outwards from the forklift 7 (Y1 in this example), in a downward-sloping direction d (Figure 2).

[0037] As shown in Figure 4, worker C inserts the cushioning material S into the receiving opening 20 from below and holds it in the holding mechanism 2, then releases his hand from the cushioning material S. As shown in Figures 4 and 5, due to the weight of the cushioning material S, the holding mechanism 2 and the held cushioning material S rotate vertically downward around the rotation axis 12, i.e., in direction R2, against the biasing force of the second biasing member 14. At the same time as this rotational movement, the slider 11 and the holding mechanism 2 are pulled in direction Y1 against the biasing force of the first biasing member 13 and move, and the cushioning material S stabilizes in contact with the side of the load W, as shown in Figure 5.

[0038] In the stable state shown in Figure 5, the cushioning material S is biased in direction Y2 by the first biasing member 13, so that the cushioning material S is pressed against the load W and in close contact with the side surface of the load W. To achieve this operation, the biasing force of the first and second biasing members 13 and 14 (i.e., the spring constants of both springs in this example) is appropriately set considering the weight of the cushioning material S.

[0039] For example, the position of the side of the load W on the fork 70 may vary each time due to differences in the width of the load W or the insertion position of the fork 70 into the pallet P. With the above configuration, even if the position of the side of the load W on the fork 70 is different, the lateral displacement Y can be absorbed, and the cushioning material S can be brought into close contact with the side of the load W.

[0040] The forklift 7 can transport the load W to the loading platform 80 (Figure 19) of the transport vehicle 8 with the cushioning material S in close contact with the load W. This eliminates the need for worker C to prop the cushioning material S against load W' (Figure 6) already placed on the loading platform 80, thereby eliminating the risk of finger pinching. Furthermore, the close contact reduces the risk of the cushioning material S interfering with adjacent loads W' during loading, and the risk of the cushioning material S flapping in strong winds.

[0041] As described later, the forklift 7 places the load W onto the loading platform 80, and the cushioning material S is placed between the loads W. Normally, the front row of the loading platform 80 does not have the cushioning material S in between. As shown in Figure 6, in the non-holding state, it is preferable to position the holding mechanism 2 with the first biasing member 13 so that it does not protrude beyond the sides of the load W supported by the forks 70, taking into account the size of the load W. This makes it possible to avoid interference between the front wall 800 of the loading platform 80 and the holding mechanism 2.

[0042] The mounting height of the holding mechanism 2 is determined considering the height of the load W being transported by the forklift 7. The holding mechanism 2 is positioned higher than the top surface of the load W on the forks 70, thus avoiding interference with the load W. Therefore, the holding mechanism 2 is positioned higher than "the height of the forks 70 + the height of the load W," and depending on the size of the load W, it may be at or above the height of the worker C.

[0043] As shown in Figure 6, if the holding mechanism 2 is pulled inward from the side of the load W, it is thought that it will be difficult for worker C to insert the cushioning material S into the receiving opening 20 (Figure 3). However, as mentioned above, when the holding mechanism 2 is not holding the cushioning material S, it is tilted outward by the second biasing member 14, and its receiving opening 20 faces diagonally downward d. Therefore, it is easier for worker C to insert the cushioning material S.

[0044] Instead of the above example of applying tension with the second biasing member 14 (spring, etc.) to tilt the holding mechanism 2 (receiving opening 20), for example, the center of gravity of the holding mechanism 2 may be adjusted, and if necessary, weights may be added so that the receiving opening 20 is tilted by its own weight.

[0045] Next, the exemplary holding mechanism 2 will be described. Figure 7 is a view of the non-actuator type holding mechanism 2 from a direction X2 opposite to the horizontal protrusion direction X1, and Figure 8 is a perspective view showing the whole. Note that some components of the cushioning material holding device 1 (for example, biasing members 13, 14) may be omitted from the illustration (the same applies hereafter).

[0046] The holding mechanism 2 includes a holder 30. In this example, the holder 30 is configured in a substantially U-shape, with the side facing the horizontal projection direction X1 being open. The holder 30 may be composed of a single component or a combination of multiple components. The holder 30 is connected to the rotation axis 12, allowing the holding mechanism 2 to rotate around the rotation axis 12. Although not shown in the figure, a second biasing member 14 is connected to its mounting portion 21.

[0047] As shown in Figure 7, the holder 30 has a first plane 301 and a second plane 302 that are spaced apart from each other and facing each other. The lower ends of the first plane 301 and the second plane 302 define a receiving opening 20 for inserting the cushioning material S from below between the first plane 301 and the second plane 302. In Figure 7, the portion 303 defining the first plane 301 and the portion 304 defining the second plane 302 are hatched. These portions 303 and 304 are parts that extend in the horizontal projection direction X1 from the base end portion 300 connected to the rotating shaft 12, as shown in Figure 8.

[0048] As shown in Figure 7, the first plane 301 and the second plane 302 face each other in a wedge shape. That is, the first plane 301 and the second plane 302 form a wedge shape that narrows toward the socket 20, and the distance between them gradually decreases toward the socket 20.

[0049] Furthermore, the holding mechanism 2 includes a rolling member 31 supported by the holder 30 so as to be able to roll on the second plane 302 in directions approaching and moving away from the receiving opening 20. In this example, the rolling member 31 is a roller. For example, the roller can roll on the second plane 302 by being supported along the second plane 302 by a shaft extending horizontally in the direction X (Figure 8) of the roller, provided on the holder 30 (e.g., its base end portion 300) in a guide body (not shown). Its range of motion is indicated by arrow e. The rolling member 31 is not limited to a roller, as long as it has a circumferential surface that enables it to roll on the second plane 302. Two or more rolling members may be arranged coaxially.

[0050] When the cushioning material S is not being held, the rolling member 31 is at its lowest point within its range of motion, i.e., the position closest to the receiving opening 20, due to its own weight. The rolling member 31 is positioned so that the upper end of the cushioning material S makes contact with it when the cushioning material S is inserted from below through the receiving opening 20.

[0051] As shown in Figure 8, worker C holds the cushioning material S and inserts it from below through the receiving opening 20 between the first plane 301 (part 303) and the second plane 302 (part 304) (see arrow f). At this time, the rolling member 31 is pushed up by the cushioning material S and rolls upward along the second plane 302, so that the cushioning material S is positioned between the rolling member 31 and the first plane 301, as shown in Figure 9.

[0052] From there, when worker C presses the cushioning material S against the rolling member 31 and pulls it downward (see arrow g in Figure 9), the rolling member 31 rolls downward on the second plane 302. However, due to the wedge shape of both planes 301 and 302, when pulled down to a certain extent, the rolling member 31 and the cushioning material S become tightly attached to each other and sandwiched between the first plane 301 and the second plane 302, as shown in Figure 10.

[0053] In the state shown in Figure 10, there is no gap for the rolling member 31 to roll further toward the receiving opening 20. Therefore, even if worker C tries to pull the cushioning material S further down, the rolling member 31, which is in close contact with it, rotates in direction h and tries to move downward (but does not actually move downward), which pushes the cushioning material S further toward the first plane 301, and as a result the cushioning material S cannot be pulled down any further. In this way, the cushioning material S is prevented from coming out of the receiving opening 20 and is held in place.

[0054] If worker C releases their hand in this state, the situation will be as shown in Figure 11. The weight of the cushioning material S acts in a direction that would cause the cushioning material S to come out of the receiving opening 20, but for the same reasons as described above, the cushioning material S is held in place by being sandwiched between the rolling member 31 and the first plane 301, and does not come out.

[0055] Naturally, to prevent the cushioning material S from slipping through, the coefficient of friction on the surface of the rolling member 31 (roller) and the wedge angle of both planes 301 and 302 are set appropriately in advance, taking into account the characteristics of the cushioning material S, such as its material and weight.

[0056] The release of the cushioning material S is explained. As shown in Figure 11, worker C holds the cushioning material S in the holding mechanism 2 so that it extends below the pallet P. The forklift 7 travels to the front of the loading platform 80 and positions the load W on the forks 70 so that there is a certain amount of space between it and the load W' already loaded on the loading platform 80 (hereinafter referred to as the existing load), and positions the cushioning material S facing the side of the existing load W'. At this time, the height of the lower end of the pallet P on the forks 70 is lower than the height of the upper end of the pallet P of the existing load W, and the lower end of the cushioning material S is not in contact with the loading platform 80.

[0057] Next, the forklift 7 uses the cargo handling device 74 (Figure 19) to side-shift the forks 70 and the holding mechanism 2 toward the existing load W' in direction Y1. As a result, the cushioning material S comes into contact with the side of the existing load W', and the cushioning material S is interposed between the loads W and W'.

[0058] Next, the forklift 7 uses the cargo handling device 74 to lift down the forks 70 and the holding mechanism 2, placing the load W onto the loading platform 80. At this time, the lower end of the cushioning material S comes into contact with the loading platform 80, causing the cushioning material S to receive an upward force and be displaced upward relative to the holding mechanism 2, thereby releasing the fixing of the rolling member 31. Consequently, the holding of the cushioning material S is released.

[0059] Next, as the forklift 7 moves backward (in the X2 direction), the forks 70 exit the holes in the pallet P. Since the holder 30 is open at the X1 end, the cushioning material S can remain in place between the loads W and W'. As a result, the cushioning material S is positioned between the loads W and W' without any gaps.

[0060] The loading operation of the cargo W described above is performed by the operator controlling the forklift 7 in the case of a manned forklift, and by the control unit 75 (Figure 20) that controls the automatic operation of the forklift 7 controlling the movement of the forklift 7 and the movement of the forks 70 in the case of an unmanned forklift.

[0061] This example of a holding mechanism 2 can hold the cushioning material S without using a dedicated actuator for holding the cushioning material S. Moreover, it has the advantage that the cushioning material S can be released naturally during the loading operation, and the cushioning material S can be placed without any gaps between the loads W and W'.

[0062] In this example, it is necessary to hold the cushioning material S so that it protrudes by an appropriate amount from the bottom edge of the pallet P. To facilitate this, it is preferable that the holding mechanism 2 is equipped with an over-insertion prevention stopper 32, which the upper end of the cushioning material S abuts against when the cushioning material S is inserted from below through the receiving opening 20, as shown only in Figure 10. The over-insertion prevention stopper 32 is attached to the holder 30. The worker C holds the cushioning material S in the holding mechanism 2 by inserting the cushioning material S until it hits the over-insertion prevention stopper 32 and then pulling it down. This ensures that the amount of cushioning material S inserted by the worker C is always constant, and the state shown in Figure 11 can be stably created.

[0063] Next, another example of a holding mechanism 2 will be described. Figures 12 to 14 show an actuator-type holding mechanism 2. In Figure 13, the cushioning material S is hatched for differentiation.

[0064] The holding mechanism 2 includes a base 40. As shown in Figure 12, the base 40 is configured in a substantially U-shape in this example, with the side facing the horizontal projection direction X1 being open. Although not shown, the base 40 is connected to the slider 11 via a rotating shaft 12, similar to the holder 30 in the previous example, and is also biased by a second biasing member 14.

[0065] Furthermore, the holding mechanism 2 includes a pair of first clampers 41 and second clampers 42 facing each other, and an actuator 43 for moving the second clamper 42 relative to the first clamper 41.

[0066] The clampers 41 and 42 are used to hold the cushioning material S in place. These clampers 41 and 42 define the receiving opening 20 (Figure 14A) into which the cushioning material S is inserted. The first clamper 41 is attached and fixed to the inside of the roughly U-shaped base 40. The first clamper 41 may be a separate part from the base 40 or integrally formed with it.

[0067] The second clamper 42 is located inside the substantially U-shaped base 40 and faces the first clamper 41. The second clamper 42 is attached to the base 40 via a link 44, which allows it to move closer to and further away from the first clamper 41.

[0068] In this example, actuator 43 is a linear actuator, more specifically a cylinder, which moves the second clamper 42 by moving its movable part, the rod. Actuator 43 is supported on the base 40 so that it can operate on the base 40. The second clamper 42 is connected to the movable part (rod) of actuator 43 via a link 44.

[0069] When actuator 43 moves the second clamper 42 furthest from the first clamper 41, the distance between these clampers 41 and 42 is greater than the width of the cushioning material S, so the cushioning material S can be inserted from below through the receiving opening 20 between the clampers 41 and 42 (Figures 13A and 14A). This position of the second clamper 42 is defined as the open position.

[0070] On the other hand, when the actuator 43 is activated and moves the second clamper 42 from the open position toward the first clamper 41, the inserted cushioning material S can be clamped between the first clamper 41 and the second clamper 42 (Figures 13B and 14B). Hereafter, this position of the second clamper 42 will be referred to as the clamping position.

[0071] The actuator 43 is not limited to a linear actuator such as a cylinder; other actuators, such as a motor, may be used. Furthermore, the connection between the actuator 43 and the second clamper 42 is not limited to a link 44; any configuration may be adopted depending on the type of actuator and the overall configuration of the holding mechanism 2.

[0072] Furthermore, the holding mechanism 2 includes one or more upper end stoppers 45 against which the upper end of the cushioning material S abuts when the cushioning material S is inserted from below through the receiving opening 20 between the first clamper 41 and the second clamper 42.

[0073] In this example, two upper stoppers 45 are provided, spaced apart along the horizontal direction X. Each upper stopper 45 consists of a guide portion 450 extending in the vertical direction and a hook-shaped receiving portion 451 that is continuously provided above the guide portion 450 and receives the upper end of the cushioning material S. The upper stoppers 45 are attached to the second clamper 42, and the guide portion 450 extends upward from the second clamper 42. The upper stoppers 45 may also be attached to the first clamper 41 or the base 40.

[0074] As shown in this example, it is preferable that the guide portion 450 is located on the inside of the forklift 7 (and therefore on the Y2 side) of the gap between the clampers 41 and 42 into which the cushioning material S is inserted. As described above, the worker C stands beside the forklift 7 and inserts the cushioning material S into the holding mechanism 2 (receiving opening 20) which is tilted diagonally outward. When the guide portion 450 is located on the inside, as shown in Figure 15A, it is ensured that when the cushioning material S is inserted, it hits the guide portion 450 and is guided into the receiving portion 451 (see arrow i). If the guide portion 450 is on the opposite side, as shown in Figure 15B, there is a possibility that the cushioning material S will not enter the receiving portion 451.

[0075] The holding mechanism 2 includes a cushioning material sensor 46 for detecting when the upper end of the cushioning material S reaches the upper end stopper 45. In this example, the cushioning material sensor 46 turns ON when it detects that the upper end of the cushioning material S has reached and entered the receiving portion 451. Multiple cushioning material sensors 46 are provided, one for each upper end stopper 45 (Figure 12).

[0076] The cushioning sensor 46 may be either non-contact or contact-type. For example, the cushioning sensor 46 in Figure 16A is a photoelectric switch that projects light 460 from the outside of the receiving portion 451 through a hole into the inside, and turns ON when the cushioning material S enters the receiving portion 451 and blocks the light 460. As another example, the cushioning sensor 46 in Figure 16B may be a contact-type switch with a contact 461 positioned on the inner top surface of the receiving portion 451, and turns ON when the cushioning material S enters the receiving portion 451 and presses against the contact 461.

[0077] As shown in Figure 17, the cushioning material holding device 1 includes an actuator control unit 50 (composed of, for example, a control circuit) for controlling the actuator 43. The actuator control unit 50 is electrically connected to a cushioning material sensor 46 provided for each upper end stopper 45. The actuator control unit 50 is also electrically connected to the actuator 43 and can determine the position of the second clamper 42 based on signals from the actuator 43.

[0078] The actuator control unit 50 operates the actuator 43 to move the second clamper 42 from the open position to the clamped position only when all cushioning material sensors 46 detect cushioning material S (only when all cushioning material sensors 46 are turned ON).

[0079] In other words, the actuator control unit 50 will not operate the actuator 43 to move the second clamper 42 to the clamped position if at least one cushioning sensor 46 does not detect the cushioning material S. In the example shown in Figure 12, if one cushioning sensor 46 is ON but the other cushioning sensor 46 is OFF, the actuator control unit 50 will keep the second clamper 42 in the open position.

[0080] With this configuration, when worker C inserts the cushioning material S from below between the clampers 41 and 42 and presses it against the upper stopper 45 (receiving portion 451), the actuator 43 is activated, and the inserted cushioning material S is held in place by the clampers 41 and 42. As a result, even if worker C releases the cushioning material S, the cushioning material S is held in place by the holding mechanism 2 and adheres tightly to the side of the load W (Figure 18).

[0081] Thanks to the upper stopper 45 and the cushioning material sensor 46, the operator C can avoid overinserting the cushioning material S and can maintain it at the appropriate height.

[0082] If worker C inserts the cushioning material S but its orientation is incorrect, at least one of the cushioning material sensors 46 will remain OFF. On the other hand, if worker C inserts the cushioning material S in the correct orientation, all of the cushioning material sensors 46 will turn ON, and the cushioning material S will be held in place. Therefore, the cushioning material S can be held by the holding mechanism 2 at the appropriate height and in the appropriate orientation.

[0083] In this regard, unlike the example, three or more upper stoppers 45 and cushioning material sensors 46 may be provided. Alternatively, one upper stopper 45 may be provided in the horizontal direction X, and multiple cushioning material sensors 46 may be provided at intervals in the horizontal direction X relative to this one upper stopper 45.

[0084] Furthermore, if any of the cushioning material sensors 46 turn OFF while the actuator control unit 50 is moving the second clamper 42 from the open position to the clamped position, the actuator control unit 50 determines that the posture of the cushioning material S has been disrupted and stops moving to the clamped position. For example, in this case, the actuator control unit 50 returns the second clamper 42 to the open position. This allows the worker C to redo the insertion work of the cushioning material S.

[0085] As shown in Figure 17, the cushioning material holding device 1 may be equipped with an indicator 51. When all sensors are ON and the actuator 43 receives a signal indicating that the second clamper 42 is in the clamping position, the actuator control unit 50 determines that the cushioning material S is being held and displays information indicating this on the indicator 51. For example, the indicator is an LED that lights up green when the cushioning material S is being held. This allows worker C to easily understand that the cushioning material S is being properly held by the holding mechanism 2 and to release their hand from the cushioning material S with confidence.

[0086] In the case of a manned forklift: When the cushioning material S is being held, the actuator control unit 50 responds to a release instruction from the operator operating the control unit 72 (Figure 17) by the operator by activating the actuator 43 to move the second clamper 42 to the open position and release the holding of the cushioning material S. The control unit 72 may be, for example, a button or lever, located in the driver's seat of the forklift 7.

[0087] In the case of an unmanned forklift: When the forklift 7 loads the load W on the forks 70 onto the loading platform 80, the actuator control unit 50 operates the actuator 43 at a predetermined timing to move the second clamper 42 to the open position and release the holding of the cushioning material S.

[0088] As an example, as shown in Figure 18, when the forklift 7 loads cargo W onto the loading platform 80 next to the already placed cargo W', it leaves a gap of about 50-60 mm between the held cushioning material S and the already placed cargo W. This gap can be detected by sensors such as the environmental sensor 76 (Figure 20), such as the LiDAR of the unmanned forklift. Next, the forklift 7 releases the cushioning material S and drops it onto the loading platform 80 between cargo W and the already placed cargo W', detaching it from the holding mechanism 2. Next, the forklift 7 uses the cargo handling device 74 to side-shift the forks 70 toward the already placed cargo W, thereby sandwiching the cushioning material S between cargo W and W'. Next, the forklift 7 uses the cargo handling device 74 to lift down the forks 70 and place cargo W on the loading platform 80. Finally, the forklift 7 reverses to remove the forks 70 from the pallet P.

[0089] This allows the cushioning material S to be placed without any gaps between the loads W and W' when loading the load W onto the loading platform 80. The operation of the forklift 7 is performed by a control unit 75, which includes an actuator control unit 50. In the case of a manned forklift, the operator controls the forklift 7 to perform the above operation.

[0090] In each of the above examples, the cushioning material holding device 1 (holding mechanism 2) is installed on the left side (Y1 side) of the forklift 7, but it may also be installed on the right side (Y2 side) of the forklift 7. When installed on the Y2 side, the configuration should be symmetrical to the above examples. Furthermore, the holding mechanism 2 may be installed on both sides. This depends on the design of the cargo handling system.

[0091] Next, we will illustrate a cargo handling system for loading cargo W onto the cargo bed 80 of a transport vehicle 8 using an autonomous forklift 7 (unmanned forklift) equipped with a cushioning material holding device 1. Note that in the following, configurations similar to those in Patent Document 1 will not be described.

[0092] Figure 19 partially shows the work area 9 of the forklift 7. The work area 9 is provided with a parking area 90 for a manned transport vehicle 8 to park. The transport vehicle 8 is, for example, a truck and is equipped with a cargo bed 80 and a driver's cab 81. The cargo bed 80 is located behind the driver's cab 81. The cargo bed 80 is, for example, a wing type, and its wings (not shown) on both sides rotate and open, opening up both sides. This allows the forklift 7 to load cargo W onto the cargo bed 80 from both the left and right sides of the transport vehicle 8.

[0093] The forklift 7 loads the cargo W onto the loading platform 80 from front to back. When loading cargo W onto the loading platform 80, the forklift 7 places a cushioning material S between the cargo W and the previously placed cargo W' (Figures 11 and 18). To achieve this, the position of the cushioning material holder 1 relative to the forklift 7 is considered. For example, in Figure 19, the mounting position of the cushioning material holder 1 is reversed between the forklift 7 responsible for the right side of the loading platform 80 (upper side of the figure) and the forklift 7 responsible for the left side of the loading platform 80 (lower side of the figure). In addition, the cushioning material holder 1 may be provided on both sides of the forklift 7 so that the forklift 7 can handle loading operations from both sides of the loading platform 80.

[0094] As shown in Figure 20, the forklift 7 is equipped with a travel device 73 and a cargo handling device 74. The travel device 73 consists of a travel motor, drive wheels, etc., and moves the forklift 7. The cargo handling device 74 includes a lift mechanism, a shift mechanism, etc., and can raise and lower the forks 70 and the holding mechanism 2 as a single unit, and can also be side-shifted (i.e., moved laterally in the Y direction).

[0095] The forklift 7 is equipped with a control unit 75 and an environmental sensor 76. The control unit 75 is a computing device and includes a computing circuit such as a CPU (Central Processing Unit). The control unit 75 controls the operation of the forklift 7 by executing a program stored in a storage medium.

[0096] The environmental sensor 76 is used for the automatic operation of the forklift 7. The control unit 75 estimates its own position in the work area 9 based on the detection by the environmental sensor 76, and controls the travel device 73 and the cargo handling device 74 based on its own position, and operates the forklift 7 and forks 70 according to the work instructions related to cargo handling (received from the cargo handling system server).

[0097] For example, a laser guidance system may be employed in which the vehicle estimates its own position and performs automatic driving using a laser scanner (e.g., 2D-LiDAR (Light Detection And Ranging)) as an environmental sensor 76 that projects laser light into the surroundings, and multiple reflectors placed in the work area 9. Alternatively, a SLAM (Simultaneous Localization and Mapping) guidance system may be employed in which the vehicle estimates its own position and performs automatic driving using SLAM technology with a distance measuring sensor (e.g., laser rangefinder, stereo camera, depth camera, 3D-LiDAR) as an environmental sensor 76 that measures the distance to surrounding objects. As these technologies are well known, their explanation will be omitted.

[0098] In Figure 20, the configuration shown by the dashed line represents the configuration when the above-described actuator-type holding mechanism 2 is adopted. Here, the actuator control unit 50 can be considered as part of the control unit 75.

[0099] The following describes an example of the cargo handling system's operation.

[0100] Before loading, the driver drives the transport vehicle 8, which has a large number of cushioning materials S loaded on its cargo bed 80, to the parking area 90. Then, the worker C (for example, the driver of the transport vehicle 8) moves all the cushioning materials S to the rear of the cargo bed 80, as shown in Figure 19.

[0101] Then, the forklift 7 begins loading the cargo onto the transport vehicle 8's cargo bed 80. The following operations of the forklift 7 are performed by the control unit 75. First, the forklift 7 travels to a loading area (not shown), similar to Patent Document 1, and places the cargo W on the forks 70.

[0102] Next, the forklift 7 drives to a predetermined stopping position 91 and stops. This stopping position 91 is located to the side of the rear of the cargo bed 80 of the transport vehicle 8 which is parked in the stopping area 90. In this example, the stopping positions 91 are provided on both the left and right sides of the cargo bed 80. The forklift 7 stops so that the cushioning material holding device 1 faces the cargo bed 80. The distance from the cargo bed 80 to the stopping position 91 should be sufficient for worker C to work, for example, 2 to 3 meters.

[0103] Next, worker C takes one of the cushioning materials S that had been placed at the rear of the loading platform 80 and places it in the cushioning material holding device 1 (holding mechanism 2) of the temporarily stopped forklift 7 as described above. The cushioning material S is in close contact with the side of the load W. As mentioned above, it is not necessary to hold the cushioning material S when loading the load W to the very front of the loading platform 80.

[0104] Next, worker C operates the work indicator 92 shown in Figure 20 to send a restart command to the control unit 75 of the forklift 7. The work indicator 92 is, for example, a terminal carried by worker C or a button installed on the wall 93 of the work area 9, and is configured to transmit a restart command to the control unit 75 wirelessly when operated by the worker. Alternatively, the work indicator 92 may be installed in a predetermined location on the forklift 7 that is easy for worker C to operate.

[0105] In response to receiving a command to resume operation, the control unit 75 restarts the automatic operation of the forklift 7. The forklift 7 travels from the temporary stop position 91 to the loading platform 80 along the path indicated by arrow j in Figure 19 and stops.

[0106] Next, the forklift 7 loads the load W onto the loading platform 80. The specific operation by which the forklift 7 loads the load W onto the loading platform 80, while releasing the hold of the cushioning material S and sandwiching the cushioning material S between the load W and the previously placed load W', is as described above regarding the non-actuator type and the holding mechanism 2 in the actuator direction.

[0107] The cargo handling system repeats the above operation of the forklift 7 until a predetermined number of cargo W has been loaded. In this example, loading to the left and right sides of the loading platform 80 is performed simultaneously, and worker C moves around the rear of the loading platform 80 to install the cushioning material S. The worker's movement is indicated by arrow k.

[0108] In this cargo handling system, thanks to the cushioning material holding device 1, the process of placing the cushioning material S between the cargo W and W' during loading onto the loading platform 80 is automated. There is no need for worker C to be nearby when the forklift 7 is loading, eliminating the risk of worker C getting their hands caught or coming into contact with the cushioning material. Worker C can remain within the roughly U-shaped area 94 around the rear of the loading platform 80, without intersecting the movement of the forklift 7, allowing for safe and efficient work.

[0109] Because the cushioning material S is attached to the side of the transport vehicle 8, it is unnecessary to temporarily move the cushioning material S from the cargo bed 80 to another location.

[0110] In the case of the actuator-type holding mechanism 2, if at least one cushioning sensor 46 turns OFF when traveling from the temporary stop position 91 to the loading platform 80, there is a high probability that the cushioning material S will be in an improper position as it is about to slip off, or that it will have completely come out of the holding mechanism 2. In this case, the control unit 75 may stop the automatic operation of the forklift 7 and notify the operator C of the situation using an audio (warning sound) and / or a display (such as the illumination of a warning color) from an alarm device not shown.

[0111] When loading is performed using a manned forklift, the operator controls the forklift 7 in the same manner as the automated driving operation described above. After worker C attaches the cushioning material S, they send a signal to the operator, who then resumes driving the forklift 7 upon receiving the signal. Because the area 94 is small, the risk of contact accidents between worker C and the manned forklift is also reduced.

[0112] Although preferred embodiments of the present invention have been described above, the present invention is not limited to the above embodiments. [Explanation of Symbols]

[0113] 1 Cushioning material holding device 10 Slide Guide 11 Sliders 12 Rotation axes 13. First biasing member (e.g., a spring) 14. Second biasing member (e.g., a spring) 2 Retention mechanism 20 socket 7 Forklift 70 Forks 75 Control Unit 8 Transport vehicles 80 cargo bed 90 Parking area for transport vehicles 91 Stopping position for forklifts C Worker d Diagonally downward direction R rotation direction S Cushioning material W luggage W' Already left luggage X1 Fork horizontal projection direction Y (horizontal direction)

Claims

1. A cushioning material holding device installed on a forklift to hold a plate-shaped cushioning material, A slider is provided so as to move up and down together with the forks of the forklift, and so as to be movable in a lateral direction perpendicular to the horizontal protrusion direction of the forks, A retaining mechanism is connected to the slider so as to be rotatable around the rotating shaft via a rotating shaft extending in the horizontal projection direction, for releasably holding the cushioning material beside the fork, The slider and the holding mechanism are provided to bias the cushioning material held by the holding mechanism toward the fork in the lateral direction, and a first biasing member is provided for positioning the slider and the holding mechanism in the lateral direction when the holding mechanism is not holding the cushioning material. Cushioning material holding device.

2. The holding mechanism is provided such as to bias the holding mechanism in a direction away from the fork in the rotational direction of the rotation axis, and further comprises a second biasing member for positioning the holding mechanism with respect to the rotational direction when the holding mechanism is not holding the cushioning material. The cushioning material holding device according to claim 1.

3. The holding mechanism has a receiving opening into which a cushioning material is inserted. The second biasing member positions the holding mechanism such that, when the holding mechanism is not holding the cushioning material, the receiving opening faces downward and outward from the forklift. The cushioning material holding device according to claim 2.

4. The forklift is equipped with a slide guide on its backrest, The slider is mounted on the slide guide so as to be slidable in the lateral direction. The cushioning material holding device according to claim 1.

5. The first biasing member is a spring connected to the slide guide and the slider. The cushioning material holding device according to claim 4.

6. The second biasing member is a spring connected to the slider and the holding mechanism. The cushioning material holding device according to claim 2.

7. It is a forklift, The cushioning material holding device according to claim 1 and Forks for supporting the luggage, A cargo handling device comprising the fork and the holding mechanism which are raised and lowered together, forklift.

8. An autonomous forklift, A cushioning material holding device according to claim 1, Forks for supporting the luggage, A cargo handling device that integrally raises and lowers the fork and the holding mechanism and shifts them laterally, The system includes a control unit that controls the operation of the forklift in accordance with work instructions related to cargo handling, forklift.

9. A cargo handling system comprising a forklift as described in claim 8, wherein the forklift is automatically driven to load cargo onto the cargo bed of a transport vehicle parked in a predetermined parking area in accordance with work instructions related to cargo handling, The control unit of the forklift is After placing the cargo on the forks, the forklift is temporarily stopped at a predetermined stopping position located to the side of the rear of the cargo bed of the transport vehicle parked in the parking area. In response to the instruction to resume operation, the forklift, with the cushioning material held by the holding mechanism, is driven from the temporary stop position to the cargo bed of the transport vehicle. The aforementioned cargo is loaded onto the cargo bed next to the cargo already loaded on the cargo bed, and, When loading the aforementioned cargo onto the cargo bed, the holding mechanism releases the cushioning material and sandwiches the cushioning material between the aforementioned cargo and the previously placed cargo. Controlling the operation of the forklift, Cargo handling system.

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