Stacking device

Abstract

The present invention is capable of stacking trays without stopping a line of a tray carry-in part etc. even if an abnormality is detected in a tray and includes: a tray carry-in part 2 for carrying in trays T containing a plurality of eggs E; a stacking part 3 for stacking a predetermined number of trays T carried in by the tray carry-in part 2; a tray carry-out part 4 for carrying out the predetermined number of trays T stacked by the stacking part 3; and an abnormality detection part 5 for detecting an abnormality in a tray T carried into the stacking part 3. When the abnormality detection part 5 detects an abnormality in a tray T, the tray T in which the abnormality has been detected is arranged in the uppermost stage by the stacking part 3 and carried out by the tray carry-out part 4, regardless of whether the predetermined number of trays T have been stacked or not.

Description

Stacking device

[0001] The present invention relates to a stacking device for stacking trays containing a plurality of eggs.

[0002] As shown in Patent Document 1, this type of stacking device includes an input conveyor for loading trays, a stacking and transport mechanism for stacking the trays, and an output conveyor for transporting the stacked trays. The stacking and transport mechanism stacks trays at the receiving position of the input conveyor either directly onto the stacking position of the output conveyor or on top of other trays placed at that position. The predetermined number of stacked trays are then transported by the output conveyor.

[0003] However, if trays with defects such as missing eggs (contents missing) are stacked, problems will occur in subsequent processes. For this reason, an abnormality detection unit that detects abnormalities in trays is installed on the carry-in conveyor, and when an abnormality is detected by the abnormality detection unit, the carry-in conveyor is stopped and the tray with the defect is removed.

[0004] However, each time an abnormality is detected, a worker must move to the carry-in conveyor, remove the defective tray, and then restart the conveyor, which is time-consuming for the worker.Furthermore, because the carry-in conveyor must be stopped and restarted each time an abnormality is detected, the operating rate of the stacking device decreases.

[0005] Japanese Patent Application Laid-Open No. 2002-284349

[0006] Therefore, the present invention has been made to solve the above problems, and its objective is to enable trays to be stacked without stopping the line, such as the tray loading section, even if an abnormality in the tray is detected.

[0007] In other words, the stacking device of the present invention comprises a tray loading section that loads trays containing a plurality of eggs, a stacking section that stacks the trays loaded by the tray loading section a predetermined number of times, a tray discharge section that loads the trays that have been stacked the predetermined number of times by the stacking section, and an abnormality detection section that detects abnormalities in the trays loaded into the stacking section, and is characterized in that when the abnormality detection section detects an abnormality in the tray, the tray in which an abnormality has been detected is placed in the topmost tier by the stacking section and is discharged by the tray discharge section, regardless of whether the trays have been stacked the predetermined number of times.

[0008] With this stacking device, a tray in which an abnormality has been detected is placed on the top shelf and removed, allowing trays to continue being stacked without stopping the line, such as the tray loading section and tray unloading section. Furthermore, since the line, such as the tray loading section and tray unloading section, is not stopped when an abnormality is detected, the operating rate can be improved. Furthermore, there is no need for an operator to move to the tray loading section and remove the tray with the abnormality from the tray loading section, saving time and effort. Furthermore, since the tray in which an abnormality has been detected is placed on the top shelf, the tray in which the abnormality has been detected can be dealt with while it is still stacked, improving workability.

[0009] It is desirable that the stacking unit stacks the trays by placing the tray carried in by the tray carrying-in unit on top of the tray carried in just before. With this configuration, the stacking unit stacks the carried-in tray by placing it on top of the tray carried in just before. Therefore, there is no need to change the stacking operation even if an abnormality is detected in the tray. Furthermore, with this configuration, it is only necessary to change the control content of the existing stacking device.

[0010] According to the present invention configured in this manner, even if an abnormality in a tray is detected, it is possible to stack trays without stopping the line such as the tray loading section.

[0011] 1 is a front view showing a configuration of a stacking device according to an embodiment of the present invention, a schematic diagram showing a forced ejection operation when an abnormality occurs in the first tier in the same embodiment, and a schematic diagram showing a forced ejection operation when an abnormality occurs in the second tier or later in the same embodiment.

[0012] An embodiment of a stacking device according to the present invention will be described below with reference to the drawings. Note that, for ease of understanding, all of the drawings shown below are drawn in a schematic manner with appropriate omissions or exaggerations. Identical components are given the same reference numerals, and their descriptions will be omitted where appropriate.

[0013] <Configuration of Stacking Device 100> The stacking device 100 of this embodiment stacks a predetermined number (for example, six) of trays T each containing a plurality of eggs E.

[0014] Here, the tray T is an American tray made of synthetic resin having egg trays arranged in 5 rows and 6 columns, for example, but various other trays such as a pulp mold tray can also be used.

[0015] Specifically, as shown in FIG. 1, the stacking device includes a tray loading section 2, a stacking section 3, a tray unloading section 4, an abnormality detection section 5, and a control section 6.

[0016] The tray loading section 2 loads trays T containing a plurality of eggs E into the stacking section 3. Specifically, the tray loading section 2 is a belt conveyor for transporting the trays T.

[0017] A conveyor (not shown) from a previous process is connected to the upstream end of this tray loading section 2, and trays T containing eggs E are supplied thereto. Note that a worker can also supply trays T containing eggs E to the upstream end of the tray loading section 2.

[0018] The stacking unit 3 stacks a predetermined number (e.g., six) of trays T carried in by the tray carrying-in unit 2. The stacking unit 3 of this embodiment stacks the trays T carried in by the tray carrying-in unit 2 by placing the tray T on top of the tray T carried in immediately before.

[0019] Specifically, the stacking section 3 has a stacking stage 31 on which trays T are placed and stacked, a tray moving section 32 that moves the trays T from the tray loading section 2 to the stacking stage 31 to stack the trays T, and a stacking tray moving section 33 that moves the trays T that have been stacked a predetermined number of times on the stacking stage 31 to the tray unloading section 4.

[0020] The tray moving unit 32 supports and lifts the peripheral edge of the tray T, thereby moving the tray T to the upper surface of the stacking stage 31 or to the topmost tray of the trays T placed on the stacking stage 31.

[0021] The stacking tray moving unit 33 has a push-out member (not shown) that pushes out the stacked trays T to the tray discharge unit 4. The moving mechanism of the push-out member of the stacking tray moving unit 33 may be configured using the moving mechanism of the tray moving unit 32. Note that the stacking tray moving unit 33 may be configured to move the stacked trays T from the stacking stage 31 to the tray discharge unit 4 by lifting them up.

[0022] Here, the stacking stage 31 may be configured to descend by one tray each time a tray T is stacked by the tray moving unit 32. In this case, the stacking stage 31 descends until a predetermined number of trays T are stacked, and then rises to its initial position after the predetermined number of trays T have been stacked. In this state, the stacking tray moving unit 33 pushes the stacked trays T to move them to the tray discharge unit 4. The initial position is a height position that is approximately the same as the height position of the belt conveyor of the tray discharge unit 4.

[0023] Furthermore, in the case where the trays T can be stacked by changing the orientation of one of the trays T by, for example, 90 degrees in the horizontal direction, the stacking unit 3 has a function of rotating the tray T in the horizontal direction. Alternatively, the tray loading unit 2 may have a function of rotating the tray T in the horizontal direction.

[0024] The tray discharge unit 4 discharges the trays T stacked in a predetermined number of layers by the stacking unit 3 from the stacking unit 3. Specifically, the tray discharge unit 4 is a belt conveyor for transporting the stacked trays T.

[0025] A downstream end of the tray discharge section 4 is connected to a conveyor (not shown) for a subsequent process, and the stacked trays T are supplied to the next process. Note that an operator can also remove the stacked trays T from the downstream end of the tray discharge section 4.

[0026] The abnormality detection unit 5 detects abnormalities in the trays T carried in by the tray carrying-in unit 2. The abnormality detection unit 5 in this embodiment is provided above the tray carrying-in unit 2 and detects any eggs that have fallen out of the trays T being carried in. An abnormality signal detected by the abnormality detection unit 5 is sent to the control unit 6.

[0027] The control unit 6 controls the tray loading unit 2, stacking unit 3, and tray unloading unit 4 to perform normal stacking and forced ejection operations. The control unit 6 is configured by a computer having a CPU, memory, input / output interface, AD converter, etc. The control unit 6 may be configured by a physically integrated computer, or may be configured by physically separate computers.

[0028] <Normal Stacking Operation> The normal stacking operation is an operation that is performed when the abnormality detection unit 5 does not detect any abnormality in the tray T, and is an operation in which the trays T that are transported sequentially are stacked in a predetermined number of layers and then carried out.

[0029] Specifically, the operation is as follows: The tray moving unit 32 places the tray T, which has been carried into a predetermined receiving position by the tray carrying-in unit 2, on the upper surface of the stacking stage 31 or on the topmost tray T placed on the stacking stage 31. When this operation is repeated a predetermined number of times (e.g., six times), a predetermined number of trays T (e.g., six) are stacked on the stacking stage 31. Thereafter, the stacked tray moving unit 33 moves the stacked trays T to the tray carrying-out unit 4, for example, by pushing them. Then, the tray carrying-out unit 4 carries out the stacked trays T.

[0030] <Forced ejection operation> The forced ejection operation is an operation performed when the abnormality detection unit 5 detects an abnormality in a tray T, and is an operation in which the tray T in which an abnormality has been detected is placed on the top shelf and removed, regardless of whether the trays T are stacked a predetermined number of times.

[0031] Specifically, the operation is as follows: When the abnormality detection unit 5 detects an abnormality in a tray T, the tray moving unit 32 places the tray T with the abnormality on the upper surface of the stacking stage 31 or in the topmost tier of trays T placed on the stacking stage 31. After this operation, the stacking tray moving unit 33 moves the tray T on the stacking stage 31 to the tray ejection unit 4, for example, by pushing it. Then, the tray ejection unit 4 ejects the tray T with the abnormality or the stack of trays T with the abnormal tray T placed in the topmost tier.

[0032] A specific example of the forced ejection operation will be described below. (1) When an abnormality occurs in the first tray T (see FIG. 2): While this tray T is being carried in from the tray carry-in unit 2, the abnormality is detected by the abnormality detection unit 5 (see FIG. 2(a)). The control unit 6 then receives the abnormality signal. The control unit 6 controls the tray moving unit 32 of the stacking unit 3 to move the abnormal tray T to the top surface of the stacking stage 31 (see FIG. 2(b)). The control unit 6 then controls the stacking tray moving unit 33 of the stacking unit 3 to move the abnormal tray T from the stacking stage 31 to the tray ejection unit 4 (see FIG. 2(c)). As a result, only the abnormal tray T is ejected by the tray ejection unit 4. During this forced ejection operation, the tray carry-in unit 2 and the tray ejection unit 4 operate in the same manner as in the normal stacking operation. Thereafter, the normal stacking operation is performed until an abnormality is detected in the tray T being carried in.

[0033] (2) When an abnormality occurs in a tray T in the second to sixth stages (see FIG. 3 , here the fifth stage) While this tray T is being carried in from the tray carry-in unit 2, the abnormality is detected by the abnormality detection unit 5 (see FIG. 3( a)). The control unit 6 then receives the abnormality signal. The control unit 6 controls the tray moving unit 32 of the stacking unit 3 to move the tray T with the abnormality to the stacking stage 31. The tray moving unit 32 then stacks the tray T with the abnormality on the top stage of the trays T already stacked on the stacking stage 31 (see FIG. 3( b)). The control unit 6 then controls the stacked tray moving unit 33 of the stacking unit 3 to move the stacked tray T with the abnormal tray T at the top from the stacking stage 31 to the tray carry-out unit 4 (see FIG. 3( c)). As a result, the stacked tray T with the abnormal tray T at the top stage is carried out by the tray carry-out unit 4. In this forced ejection operation, the tray loading section 2 and the tray unloading section 4 operate in the same manner as in the normal stacking operation. After that, the normal stacking operation is continued until an abnormality in the loaded tray T is detected.

[0034] <Effects of this embodiment> According to the stacking device 100 of this embodiment, a tray T for which an abnormality has been detected is placed on the top tier and removed, so that stacking of trays T can continue without stopping the lines, such as the tray carry-in unit 2 and the tray carry-out unit 4. Furthermore, because the lines, such as the tray carry-in unit 2 and the tray carry-out unit 4, are not stopped when an abnormality is detected, the operating rate can be improved. Furthermore, there is no need for an operator to move to the tray carry-in unit 2, so that work can be saved. Furthermore, because the tray T for which an abnormality has been detected is placed on the top tier, the tray T for which an abnormality has been detected can be dealt with while it is still stacked, improving workability.

[0035] <Modified Embodiments of the Present Invention> The present invention is not limited to the above-described embodiments.

[0036] For example, in addition to the above-described embodiment, the stacking method of the stacking unit may be any method as long as the tray T in which an abnormality has been detected is placed on the top tier. That is, in a normal stacking operation, a tray T is placed below the tray T that was just loaded, and when an abnormality is detected in a tray T, the tray T in which the abnormality has been detected is placed on the top tier of the trays T that are already stacked.

[0037] Furthermore, although the abnormality detection unit 5 in the above embodiment detects eggs falling out of the tray T, it may also be configured to detect abnormalities in the eggs E contained in the tray T (for example, cracked eggs, broken eggs, dirty eggs, etc.).

[0038] Furthermore, the abnormality detection unit 5 may detect an abnormality in the tray T during transport in the tray carry-in unit 2, or may detect an abnormality in the tray T stopped at, for example, a predetermined receiving position in the tray carry-in unit 2. Furthermore, the abnormality detection unit 5 may detect an abnormality in the tray T being moved by the tray moving unit 32 of the stacking unit 3.

[0039] Furthermore, the tray T may be configured to have an alarm unit that notifies the operator when the abnormality detection unit 5 detects an abnormality in the tray T or when a forced ejection operation is performed on the abnormal tray T. The alarm unit may be configured to emit sound, light, or display on a screen.

[0040] In addition, the tray discharge section 4 may have a distribution section that distributes trays T stacked by normal stacking operation and trays T with abnormalities that have been discharged by forced discharge operation or stacked trays T with abnormal trays T at the top, to different paths.

[0041] Furthermore, the present invention is not limited to the above-described embodiment, and it goes without saying that various modifications are possible without departing from the spirit of the present invention.

[0042] According to the present invention, even when an abnormality in a tray is detected, it is possible to stack trays without stopping the line such as the tray loading section.

[0043] 100: Stacking device E: Eggs T: Tray 2: Tray loading section 3: Stacking section 4: Tray unloading section 5: Abnormality detection section 6: Control section

Claims

1. A stacking device comprising: a tray loading section which loads a tray containing a plurality of eggs; a stacking section which stacks the trays loaded by the tray loading section a predetermined number of tiers; a tray ejection section which ejects the trays stacked the predetermined number of tiers by the stacking section; and an abnormality detection section which detects abnormalities in the trays loaded into the stacking section, wherein when the abnormality detection section detects an abnormality in the tray, the tray in which the abnormality has been detected is placed in the top tier by the stacking section and ejected by the tray ejection section, regardless of whether the trays have been stacked the predetermined number of tiers.

2. A stacking device as described in claim 1, wherein the stacking section stacks the trays by placing the trays brought in by the tray loading section on top of the tray that was brought in immediately before.

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