Stacking device

Abstract

The present invention allows for stacking trays without stopping a line of a tray carry-in part or the like even when an abnormality is detected in a tray, and comprises: 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 carried out by the tray carry-out part 4 without being stacked by the stacking part 3.

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] That is, 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 unloading section that unloads the trays that have been stacked a predetermined number of times by the stacking section, and an abnormality detection section that detects an abnormality 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 unloaded by the tray unloading section without being stacked by the stacking section.

[0008] With this stacking device, a tray in which an abnormality has been detected is removed by the tray removal unit without being stacked, allowing trays to continue stacking without stopping the line, such as the tray loading unit and tray removal unit. As a result, a predetermined number of normal trays can be stacked. Furthermore, since the line, such as the tray loading unit and tray removal unit, is not stopped when an abnormality is detected, the operating rate can be improved. Furthermore, since the operator does not need to move to the tray loading unit (the location where the abnormality was detected), labor can be saved. Furthermore, since a tray in which an abnormality has been detected is removed without being stacked, the tray in which an abnormality has been detected can be dealt with directly, improving workability. In addition, since a tray in which an abnormality has been detected is removed using the tray removal unit, the configuration for removing a tray in which an abnormality has been detected can be simplified.

[0009] It is desirable that the stacking unit transfers the tray in which an abnormality has been detected to the tray discharge unit without stacking it. With this configuration, since the tray in which an abnormality has been detected is transferred to the tray discharge unit by the stacking unit, there is no need to provide a configuration for transferring the tray in which an abnormality has been detected separately from the stacking unit.

[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, and FIG. 2 is a schematic view showing a forced ejection operation when an abnormality occurs in a tray 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 conveyor (not shown) for a subsequent process is connected to the downstream end of this tray discharge section 4, and the stacked trays T are supplied to the next process. Note that a worker can also remove the stacked trays T from the downstream end of the tray discharge section 4. Note that the tray discharge section 4 may be configured with the same conveyor as the tray load section 2.

[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 the tray T, and is an operation in which the tray T for which an abnormality has been detected is ejected by the tray ejection unit 4 without being stacked by the stacking unit 3.

[0031] Specifically, the operation is as follows: When the abnormality detection unit 5 detects an abnormality in the tray T, the tray moving unit 32 transfers the tray T with the abnormality to the tray carrying-out unit 4 without placing it on the upper surface of the stacking stage 31 or in the top row of the trays T placed on the stacking stage 31. Then, the tray carrying-out unit 4 carries out the tray T with the abnormality.

[0032] A specific example of the forced ejection operation will be described below. While a tray T is being carried in from the tray carry-in unit 2, the abnormality detection unit 5 detects an abnormality (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 transfer the abnormal tray T to the tray carry-out unit 4 (see FIG. 2(b)). As a result, only the abnormal tray T is carried out by the tray carry-out unit 4 (see FIG. 2(c)). After that, normal stacking operation is performed until an abnormality is detected in the tray T being carried in (see FIG. 2(d)).

[0033] <Effects of the Present Embodiment> According to the stacking device 100 of the present embodiment, a tray T for which an abnormality has been detected is removed by the tray removal unit 4 without being stacked. This allows for continued stacking of trays T without stopping the lines, such as the tray carry-in unit 2 and the tray removal unit 4. As a result, a predetermined number of normal trays T can be stacked. Furthermore, since the lines, such as the tray carry-in unit 2 and the tray removal unit 4, are not stopped when an abnormality is detected, the operating rate can be improved. Furthermore, since an operator does not need to move to the tray carry-in unit 2 (the location where the abnormality was detected), labor can be saved. Furthermore, since a tray T for which an abnormality has been detected is removed without being stacked, the tray T for which an abnormality has been detected can be dealt with immediately, improving operability. Additionally, since a tray T for which an abnormality has been detected is removed using the tray removal unit 4, the configuration for removing a tray T for which an abnormality has been detected can be simplified.

[0034] <Modified Embodiments of the Present Invention> The present invention is not limited to the above-described embodiments.

[0035] For example, the tray moving section 32 of the stacking section 3 is configured to transfer a tray T in which an abnormality has been detected to the tray discharge section 4, but the configuration may also include a transfer section separate from the stacking section 3 that transfers a tray T in which an abnormality has been detected to the tray discharge section 4.

[0036] Furthermore, the stacking unit 3 may be configured to stack a tray T by placing it on top of the tray T that was just loaded, as in the above embodiment, or may be configured to stack a tray T by placing it below the tray T that was just loaded. In this case, the tray T that was just loaded is lifted, and the tray T that was just loaded is placed below the lifted tray T and then lifted. Then, once a predetermined number of trays T have been lifted, the trays T are lowered, thereby stacking the predetermined number of trays T. In the stacking unit 3 configured as above, if the abnormality detection unit 5 detects an abnormality in a tray T, the stacking unit 3 does not lift the tray T with the abnormality, and the stacking unit 3 or a transfer unit separate from the stacking unit 3 transfers the tray T to the tray unloading unit 4.

[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] The tray discharge unit 4 may also have a distribution unit that distributes trays T stacked in a normal stacking operation and abnormal trays T discharged in a forced discharge operation 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 levels; a tray ejection section which ejects the trays stacked the predetermined number of levels by the stacking section; and an abnormality detection section which detects an abnormality in the trays loaded into the stacking section, wherein when the abnormality detection section detects an abnormality in the tray, the tray in respect of which an abnormality has been detected is ejected by the tray ejection section without being stacked by the stacking section.

2. The stacking device according to claim 1, wherein the stacking section transfers the tray in which an abnormality has been detected to the tray discharge section without stacking it.

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