Storage device and storage system

Abstract

This storage device for storing an open tray accommodating a plurality of eggs into a transport container comprises an egg suction attachment unit for suction-attaching the plurality of eggs accommodated in the open tray, a tray gripping unit for gripping the open tray, and a movement mechanism for moving the egg suction attachment unit and the tray gripping unit, wherein the movement mechanism includes: a vertical movement mechanism for vertically moving along an axis in a vertical direction; a horizontal movement mechanism for horizontally moving along an axis in a horizontal direction; and a rotational movement mechanism for performing rotational movement around an axis in the vertical direction.

Description

Storage Device and Storage System

[0001] The present invention relates to a storage device and system for storing open trays of eggs in shipping containers such as cardboard boxes.

[0002] Open trays, which do not have lids and have an open top, are containers for storing eggs. Examples of open trays include molded trays, paper trays, and PET trays. Molded trays and paper trays are made of, for example, paper or pulp, while PET trays are made of, for example, plastic. These open trays are used for storing a large number of eggs, for example, for commercial use.

[0003] Patent Document 1 discloses a moving device that is a storage device for storing open trays containing eggs in cardboard boxes, and that includes a head unit having an egg suction device and a tray holding device, and an articulated robot that moves the head unit.

[0004] Japanese Patent Application Laid-Open No. 2023-79269

[0005] However, the articulated robot has a base that is placed on the floor and an articulated arm that is attached to the base, and the storage device of Patent Document 1 tends to be large in size.

[0006] SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a compact storage device and storage system.

[0007] The storage device of the present invention is a storage device that stores an open tray containing a plurality of eggs in a transport container, and comprises: an egg adsorption section that adsorbs the plurality of eggs contained in the open tray; a tray gripping section that grips the open tray; and a movement mechanism that moves the egg adsorption section and the tray gripping section, wherein the movement mechanism comprises a vertical movement mechanism that moves up and down along a vertical axis, a horizontal movement mechanism that moves horizontally along a horizontal axis, and a rotational movement mechanism that rotates and moves around the vertical axis.

[0008] According to this configuration, the movement mechanism is composed of a vertical movement mechanism, a horizontal movement mechanism, and a rotational movement mechanism, so the installation area is smaller than that of an articulated robot, and the storage device can be made compact.

[0009] In addition, in the storage device of the present invention, the rotational movement mechanism may be connected to the egg adsorption unit and the tray gripping unit, the vertical movement mechanism may move the rotational movement mechanism up and down, and the horizontal movement mechanism may move the vertical movement mechanism horizontally.

[0010] According to this configuration, the installation area of ​​the movement mechanism can be effectively reduced.

[0011] The storage device according to the present invention may also be configured to include: a base fixed to the moving mechanism; and a cartridge including the egg adsorbing portion and the tray gripping portion, the cartridge being attachable to and detachable from the base.

[0012] According to this configuration, the egg adsorbing portion and the tray gripping portion can be attached and detached from the base as a single unit, and the egg adsorbing portion and the tray gripping portion can be easily changed depending on the type of open tray.

[0013] Furthermore, the storage unit of the present invention comprises the above-mentioned storage device; a first conveyor onto which the open trays containing eggs are transported; an inspection section arranged upstream of the first conveyor that inspects the open trays transported onto the first conveyor for defects; and a second conveyor that moves from a waiting position below the first conveyor to a connecting position downstream of the first conveyor to receive the open trays from the first conveyor when it is determined that the open trays have defects.

[0014] This configuration prevents defective open trays from being stored in the shipping container.

[0015] In addition, in the storage system of the present invention, a conveyor stopper may be installed on the second conveyor, and when it is determined that there is no defect in the open tray, the second conveyor in the standby position may position the conveyor stopper at the downstream end of the first conveyor.

[0016] According to this configuration, when it is determined that the open tray is not defective, the conveyor stopper can stop the open tray being transported by the first conveyor, and the tray gripping portion can properly grip the open tray on the first conveyor.

[0017] a perspective view showing the overall configuration of a storage system according to a first embodiment; a front view showing the overall configuration of a storage system according to the first embodiment; a three-sided view of an open tray; an exploded perspective view of a head section; a perspective view of a cartridge; a front view of a tray gripping section; a perspective view of a moving device; a perspective view of a part of a storage system; a side view of a storage system; a perspective view of a part of a storage system equipped with a manual packing section; a perspective view of a part of a storage system equipped with a manual packing section; a perspective view of an overall configuration of a storage system according to a second embodiment; a plan view showing a first example layout of an open tray processing line equipped with a storage system; a plan view showing a second example layout of an open tray processing line equipped with a storage system; an example of information about egg sizes printed on the side of a cardboard box; an example of information about egg sizes printed on the side of a cardboard box; a plan view showing another example layout of an open tray processing line equipped with a storage system;

[0018] Hereinafter, an embodiment of a storage device and a storage system will be described with reference to the drawings. Note that in each drawing, the dimensional ratios of the drawings do not necessarily match the actual dimensional ratios, and the dimensional ratios between the drawings do not necessarily match.

[0019] In the following, the XYZ coordinate system will be referred to as appropriate. Furthermore, in this specification, when a direction is expressed and a distinction is made between positive and negative directions, it is described with a positive or negative sign, such as "+X direction" and "-X direction." Furthermore, when a direction is expressed without distinguishing between positive and negative directions, it is simply described as "X direction." In other words, in this specification, when simply referring to "X direction," it includes both "+X direction" and "-X direction." The same applies to the Y direction and the Z direction. In this embodiment, the horizontal plane is parallel to the XY plane, and the vertical direction is the -Z direction.

[0020] Storage System First Embodiment A storage system 1 includes a storage device 2 , a carry-in section 3 , a storage section 4 , a first conveyor 5 , a second conveyor 6 , a third conveyor 7 , and an unloading section 8 .

[0021] The storage system 1 is controlled by a main control unit (not shown) provided in a management system that manages the storage system 1. The storage system 1 may also be controlled by an individual control unit provided separately. The main control unit and the individual control unit may be realized, for example, by a dedicated circuit, firmware, or a combination of hardware such as a processor and memory with a program that defines a control procedure.

[0022] The storage device 2 includes a head unit 21 and a moving mechanism 26 that moves the head unit 21. As shown in FIG. 2 , the storage device 2 stores open trays T containing eggs that are carried onto the first conveyor 5 in cardboard boxes C (an example of a transport container) in the storage unit 4. The open trays T are trays that do not have lids and have an open top, such as molded trays made from pulp, paper trays made from paper, or PET trays made from plastic. In this embodiment, the transport container is a cardboard box, but is not limited to this and may be any container, such as a plastic container.

[0023] As shown in FIG. 3 , the open tray T has an egg placement portion T1, a peripheral portion T2, and a cutout portion T3. The egg placement portion T1 has multiple recesses, each of which holds one egg. The peripheral portion T2 is provided to surround the egg placement portion T1. The cutout portion T3 is a depression extending from the peripheral portion T2 toward the center of the open tray T, forming a space into which a person's fingers can be inserted. The open tray T can be carried by a person inserting their fingers into the cutout portion T3. As an example, the open tray T has two cutout portions T3 on one short side and one cutout portion T3 on the other short side. Note that the open tray T shown in FIG. 3 is merely an example, and the number of recesses on the egg placement portion T1 and the locations and / or number of the cutout portions T3 are not limited to this example.

[0024] As shown in Fig. 4, the head unit 21 includes a base 22 and a cartridge 23 that is detachable from the base 22. The base 22 is fixed to a movement mechanism 26 and moved by the movement mechanism 26. The base 22 has a generally U-shaped cross section, and a pair of guide grooves 221, 221 extending in the Y direction are formed on the inner surface. The base 22 also includes a first pipe 222. The first pipe 222 is connected to a vacuum blower 223 (see Fig. 2) via a suction pipe (not shown).

[0025] The cartridge 23 has a pair of guide plates 231 extending in the Y direction, and the guide plates 231 are guided in the Y direction by guide grooves 221 in the base 22. This allows the cartridge 23 to be attached to and detached from the -Y direction side of the base 22. The cartridge 23 also has a locking mechanism 232 for fixing the cartridge 23 to the base 22, and a cartridge side plate 232a for supporting the locking mechanism 232. The cartridge side plate 232a may have an opening for distinguishing the type of cartridge 23.

[0026] As shown in Figures 4 and 5, the cartridge 23 includes an egg suction portion 24 and a tray gripping portion 25. That is, the egg suction portion 24 and the tray gripping portion 25 are integrally configured as the cartridge 23. This allows different cartridges 23 to be prepared according to the type of open tray T, making it possible to easily change the egg suction portion 24 and the tray gripping portion 25 according to the type of open tray T. The base 22 may include a tool confirmation sensor 225 for confirming the type of cartridge 23. The tool confirmation sensor 225 may be a photoelectric sensor, a proximity sensor, or the like. For example, as shown in Figure 4, when two tool confirmation sensors 225 are provided, four types of cartridges 23 can be distinguished by the presence or absence of an opening in the cartridge side plate 232a facing the tool confirmation sensor 225.

[0027] Egg suction unit 24 suctions a plurality of eggs contained in open tray T. Egg suction unit 24 has a plurality of bellows-shaped suction pads 241, and each suction pad 241 suctions a single egg. The plurality of suction pads 241 are arranged in a row and attached to suction ducts 243. Egg suction unit 24 also has second pipes 242 connected to the plurality of suction ducts 243. Second pipes 242 have connecting portions 242a (see FIG. 5) that are connected to connecting portions 222a (see FIG. 4) of first pipes 222 of base 22. When vacuum blower 223 sucks air through first pipes 222 and second pipes 242, the eggs are suctioned by suction pads 241, and when vacuum blower 223 exhausts the air, the eggs are detached from suction pads 241. The suction duct 243 is detachably attached to a suction duct base 244 that is integrated with the second pipe 242, making cleaning easy even if egg liquid gets inside the suction pad 241 or the suction duct 243.

[0028] As shown in FIG. 5, the tray gripping portion 25 includes a pair of claw members 251, 251 that are inserted into the cutout portion T3 of the open tray T. The claw member 251 has a long plate shape. As shown in FIG. 6, the claw member 251 has a locking portion 251a at its tip. The locking portion 251a has multiple V-shaped grooves formed in parallel. The claw member 251 also has a pin 251b at its base end. The claw member 251 is rotatably held by a claw holding bracket 252.

[0029] The tray gripping portion 25 also includes a box-shaped cam 253. Arc-shaped cam grooves 253a are formed on both side surfaces of the box-shaped cam 253 in the X direction. The pin 251b of the claw member 251 can move along the cam groove 253a. As a result, when the box-shaped cam 253 moves up and down relative to the claw holding bracket 252, the pin 251b moves along the cam groove 253a, and the tips of the pair of claw members 251, 251 open and close. When the pair of claw members 251, 251 is inserted into the notch portion T3 of the open tray T in the closed state, the pair of claw members 251, 251 is then opened, and the locking portion 251a locks onto the edge of the notch portion T3.

[0030] The tray gripping unit 25 also includes a stationary slide rod 254 that guides the box-shaped cam 253 in the up-down direction, and a pressing member 255 that is movable up and down relative to the claw holding bracket 252. The pressing member 255 presses the upper end of the box-shaped cam 253 with a protrusion 255a of the pressing member 255. The pressing member 255 is also pressed down by an air cylinder 224 (see FIG. 4) fixed to the outer surface of the base 22. When the air cylinder 224 presses down the pressing member 255, the protrusion 255a is pressed down together with the box-shaped cam 253, thereby changing the pair of claw members 251, 251 from the closed state to the open state. The box-shaped cam 253 is pressed upward by a spring 253b, and when the air cylinder 224 is released from the downward pressure, the box-shaped cam 253 moves upward, and the claw members 251, 251 close.

[0031] As shown in Figure 7, the movement mechanism 26 includes a rotational movement mechanism 27 that rotates the head unit 21 around the Z-axis, an up-down movement mechanism 28 that moves the head unit 21 up and down along the Z-axis, and a horizontal movement mechanism 29 that moves the head unit 21 horizontally along the X-axis.

[0032] The rotational movement mechanism 27 is coupled to the upper surface of the base 22 and rotates the base 22 about an axis in the Z direction. The rotational movement mechanism 27 is, for example, a rotary actuator. The rotational movement mechanism 27 can stop the base 22 at three positions: a first position (position shown in FIG. 7 ) where the longitudinal direction of the base 22 is parallel to the X direction; a second position rotated 90° to the right from the first position; and a third position rotated 90° to the left from the first position. For example, when the base 22 is in the first position, the tray gripper 25 grips an open tray T, the base 22 is rotated to the second position, and the gripped open tray T is stored in the cardboard box C. Then, the base 22 is rotated back to the first position, the tray gripper 25 grips the next open tray T, the base 22 is rotated to the third position, and the gripped open tray T is stored in the cardboard box C. In this way, multiple open trays T can be stacked in the cardboard box C while being alternately inverted.

[0033] The vertical movement mechanism 28 is connected to the rotational movement mechanism 27 and moves the rotational movement mechanism 27 up and down. The vertical movement mechanism 28 is, for example, a ball screw 281. The ball screw 281 includes a vertical screw shaft 282 extending in the Z direction and a nut 283 threadedly engaged with the vertical screw shaft 282. The rotational movement mechanism 27 is connected to the lower end of the vertical screw shaft 282. The nut 283 is rotatably supported on a table 284. The nut 283 is rotated via a belt by a servo motor 285 fixed to the table 284. As a result, by rotating the nut 283 with the servo motor 285, the vertical screw shaft 282 is moved in the Z direction relative to the table 284, and as a result, the rotational movement mechanism 27 can be moved in the Z direction. The vertical movement mechanism 28 includes a guide shaft 286 extending in the Z direction to prevent the vertical screw shaft 282 from rotating relative to the table 284. The guide shaft 286 and the vertical screw shaft 282 are connected by a connecting plate 286a. A suction pipe (not shown) extending in the Z direction is disposed between the guide shaft 286 and the vertical screw shaft 282, and the suction pipe moves up and down together with the guide shaft 286 and the vertical screw shaft 282. The suction pipe is fixed to the connecting plate 286a.

[0034] The horizontal movement mechanism 29 is connected to the vertical movement mechanism 28 and moves the vertical movement mechanism 28 horizontally. The horizontal movement mechanism 29 is, for example, a feed screw 291. The feed screw 291 includes a horizontal screw shaft 292 extending in the X direction and a nut 293 threadedly engaged with the horizontal screw shaft 292. The horizontal screw shaft 292 is rotated by a servo motor 295 fixed to a top plate 294 (see FIG. 1). The nut 293 is fixed to the upper surface of the table 284. The table 284 is placed on the top plate 294 via a linear guide 296 (see FIG. 1) and is slidable in the X direction relative to the top plate 294. As a result, by rotating the horizontal screw shaft 292 using the servo motor 295, the nut 293 is moved in the X direction relative to the top plate 294, and as a result, the table 284 (vertical movement mechanism 28) can be moved in the X direction.

[0035] As shown in FIG. 8 , the carry-in unit 3 includes a roller conveyor capable of transporting in the +Y direction, and carries empty cardboard boxes C to the storage device 2. A box-making machine (not shown) is disposed upstream of the carry-in unit 3, and the carry-in unit 3 is continuous with the box-making machine. The carry-in unit 3 transports empty cardboard boxes C assembled by the box-making machine to a standby position below the storage device 2. The carry-in unit 3 may include a box transfer mechanism 31 that transfers empty cardboard boxes C in the +X direction. After transporting the cardboard boxes C to the standby position, the box transfer mechanism 31 transports the cardboard boxes C to the storage unit 4. The box transfer mechanism 31 may be driven by a narrow conveyor that can be raised and lowered and disposed in the gap between the rollers of the roller conveyor, or an air cylinder disposed in a position that does not interfere with the cardboard boxes C. In addition, when the storage system 1 has a layout as shown in Figure 13 (described later), the loading section 3, storage section 4, and unloading section 8 are arranged in a straight line in the +Y direction, so it is not necessary to have a box transfer mechanism 31 that transfers the cardboard box C in the +X direction.

[0036] The storage unit 4 is equipped with a roller conveyor capable of transporting in the +X direction, and transports the cardboard box C received from the carry-in unit 3. The storage unit 4 is equipped with a first detection sensor 41. The first detection sensor 41 detects whether the cardboard box C has arrived above the storage unit 4. The first detection sensor 41 may be, for example, a load sensor or an optical sensor, but is not limited to these.

[0037] The storage section 4 is provided with a retaining portion 42. The retaining portion 42 comes into contact with the flap of the cardboard box C to restrain the cardboard box C from moving.

[0038] The storage section 4 is provided with a stopper plate 43. The stopper plate 43 moves up and down in the Z direction between adjacent rollers to permit or prohibit the transport of the cardboard box C.

[0039] The first conveyor 5 includes a belt conveyor 50 capable of conveying in the +X direction, and is continuous with, for example, an egg-packing machine (not shown) located upstream. The first conveyor 5 receives open trays T containing eggs from the egg-packing machine.

[0040] The first conveyor 5 is equipped with a conveyor stopper 51. The conveyor stopper 51 stops the open tray T being transported by the belt conveyor 50. The first conveyor 5 may be equipped with a tray arrival confirmation sensor 51a that confirms that the open tray T has arrived at a position where it abuts against the conveyor stopper 51. The tray arrival confirmation sensor 51a is fixed to the inner surface of an inclined guide 61, which will be described later.

[0041] The storage system 1 also includes an inspection unit 52 arranged upstream of the first conveyor 5. The inspection unit 52 includes a second detection sensor 53, an inspection trigger sensor 54, and an inspection means 55. The inspection unit 52 may also include an upstream conveyor 56 arranged upstream of the belt conveyor 50.

[0042] The second detection sensor 53 detects an open tray T being carried onto the belt conveyor 50. The second detection sensor 53 may be, for example, a load sensor, an optical sensor, an ultrasonic sensor, or a capacitance sensor, but is not limited to these. When an optical sensor is used as the second detection sensor 53, the optical sensor is disposed on the side of the upstream conveyor 56 and emits light in the Y direction (see FIG. 9 ).

[0043] The inspection trigger sensor 54 detects a protrusion T11 (see FIG. 3 ) when viewed from the side of the egg placement portion T1 of the open tray T being carried onto the belt conveyor 50. The inspection trigger sensor 54 may be, for example, an optical sensor, an ultrasonic sensor, or a capacitance sensor, but is not limited to these. When an optical sensor is used as the inspection trigger sensor 54, the optical sensor is disposed on the side of the upstream conveyor 56, lower than the second detection sensor 53, and emits light in the Y direction (see FIG. 9 ).

[0044] The inspection means 55 is disposed above the second detection sensor 53. When the second detection sensor 53 detects an open tray T and the inspection trigger sensor 54 detects the protrusion T11, the inspection means 55 inspects the open tray T for defects. The inspection means 55 is, for example, an image sensor that photographs the open tray T row by row. Based on the images captured by the inspection means 55, the main control unit determines whether the eggs in the open tray T are damaged and whether eggs are contained in all rows of the open tray T in the Y direction (or whether eggs are not contained in the open tray T). Note that the inspection means 55 is not limited to an image sensor. The inspection means 55 may also be a load sensor, an optical sensor, an ultrasonic sensor, a capacitance sensor, a millimeter-wave radar sensor, or the like. When an optical sensor is used as the inspection means 55, the optical sensors are disposed above the upstream conveyor 56 and in the same number as the number of rows of the open tray T (the number of egg seats in the Y direction), and irradiate light in the Z direction. The light is irradiated onto the top of the eggs contained in the open tray T. This allows the open trays T to be inspected row by row to see if there are eggs in the entire row or if there are no eggs in the entire row. If the second detection sensor 53 is ON and an inspection NG signal is ON from the inspection means 55, the main control unit determines that the tray is defective and stores this as a defective tray. Taking into account the response speed of the inspection means 55, the judgment may be made by offsetting the difference in response speed (delay).

[0045] When an open tray T that has been determined to be free of defects in the inspection arrives at the detection position of the tray arrival confirmation sensor 51a, the main control unit controls the storage device 2 to lift the open tray T on the belt conveyor 50 and store it in a cardboard box C on the storage unit 4.

[0046] On the other hand, when an open tray T determined to be defective in the inspection arrives at the detection position of the tray arrival confirmation sensor 51a, the main control unit moves the second conveyor 6 in the X direction from below the first conveyor 5. More specifically, the main control unit moves the second conveyor 6 so that it is continuous with the first conveyor 5. At this time, the belt conveyor 50 is temporarily stopped until the first conveyor 5 and the second conveyor 6 are continuous with each other. By temporarily stopping, the open tray T is prevented from falling.

[0047] The second conveyor 6 has a conveyor base 6a that is movable in the X direction. The conveyor base 6a is moved by an air cylinder or the like (not shown). The second conveyor 6 moves between a standby position below the first conveyor 5 (position shown in FIG. 8) and a connecting position downstream of the first conveyor 5.

[0048] A conveyor stopper 51 is erected at the downstream end (+X direction end) of the conveyor base 6a. As a result, when the second conveyor 6 is in the standby position, the conveyor stopper 51 is located at the downstream end of the belt conveyor 50 and stops the open tray T being transported by the belt conveyor 50. On the other hand, when the second conveyor 6 moves to the connecting position, the conveyor stopper 51 moves together with the conveyor base 6a and moves away from the downstream end of the belt conveyor 50.

[0049] The second conveyor 6 is equipped with a roller conveyor 60 capable of conveying in the +X direction. The downstream end (+X end) of the roller conveyor 60 is supported on the conveyor base 6a so as to be rotatable up and down. The upstream end (-X end) of the roller conveyor 60 is equipped with a guide protrusion 60a that protrudes laterally.

[0050] An inclined guide 61 is provided on each side of the second conveyor 6 in the Y direction. The inclined guide 61 is a stationary plate with a guide hole 61a formed therein. The guide hole 61a guides the guide protrusion 60a of the roller conveyor 60. The front end (+X direction end) of the guide hole 61a is higher than the other parts. Therefore, the roller conveyor 60 is horizontal in the standby position, while in the coupled position, the guide protrusion 60a is raised and the front is lowered (see Figure 9).

[0051] The third conveyor 7 is equipped with a roller conveyor 70 capable of transporting in the X direction. As shown in FIG. 9 , the roller conveyor 70 is coupled to the roller conveyor 60 when the second conveyor 6 is in the coupled position. That is, when an open tray T is determined to be defective, the second conveyor 6 moves to the coupled position, and the roller conveyor 60 is coupled to the belt conveyor 50 and the roller conveyor 70. As a result, the open tray T determined to be defective is transported from the belt conveyor 50 to the roller conveyor 60, and then from the roller conveyor 60 to the roller conveyor 70. Furthermore, by connecting the conveyors in the event of an equipment malfunction, conventional manual packing work can be performed. A conveyor (not shown) for transporting open trays T determined to be defective may be disposed downstream of the roller conveyor 70.

[0052] The main control unit detects whether a predetermined number of open trays T have been stored in the cardboard box C (i.e., whether the cardboard box C is full). As an example, the main control unit counts the number of times stacked by the storage device 2, and determines that the cardboard box C is full when the count reaches a predetermined number, and determines that the cardboard box C is not full when the count does not reach the predetermined number. The storage device 2 stores open trays T in the cardboard box C until the main control unit detects that the cardboard box C is full. When the main control unit detects that the cardboard box C is full, the storage unit 4 transports the cardboard box C to the discharge unit 8. Furthermore, when an open tray T determined to be defective by inspection by the inspection means 55 is ejected, the ejected open tray T is also counted as part of the predetermined number, and the cardboard box C is transported to the discharge unit 8 with the number of ejected open trays T less. The storage device 2 may place an empty open tray T containing no eggs on top of the open tray T containing eggs at the top surface of the cardboard box C. The empty open tray T functions as a lid for the open tray T containing eggs at the top surface, thereby preventing damage to the eggs.

[0053] The discharge section 8 is adjacent to the storage section 4 and includes discharge section free rollers 82 that receive cardboard boxes C transported from the storage section 4 in the X direction, a roller conveyor 80 that transports the cardboard boxes C in the Y direction, and a discharge detection sensor 81 that detects cardboard boxes C transported from the storage section 4 or cardboard boxes C packed by other devices or people. When the discharge detection sensor 81 detects that a cardboard box C has been transported from the storage section 4, the discharge section free rollers 82 descend below the roller conveyor 80, and the cardboard box C is transferred to the roller conveyor 80 and transported in the Y direction. Furthermore, if a cardboard box C packed by other devices or people is detected, the discharge section free rollers 82 temporarily stop and, once the cardboard box C has been confirmed to have passed, the cardboard box is discharged. Although not shown, in this embodiment, a weight checker is disposed downstream of the discharge section 8 to measure the weight of the cardboard box C stored in the open tray T and adjust the weight as necessary. The weight checker can also detect cardboard boxes C that do not contain the required number of open trays T. A box sealing machine is located downstream of the weight checker, and a palletizer is located downstream of the box sealing machine. The discharge section 8 continues to the weight checker and transports cardboard boxes C containing open trays T to the weight checker.

[0054] As shown in Figures 10 and 11, the storage system 1 may include a manual packing section 9 adjacent to the discharge section 8. The manual packing section 9 includes a liftable work table 90 on which cardboard boxes C can be placed during manual packing, and manual packing section free rollers 91 for receiving cardboard boxes C transported from the discharge section 8. In the event of an equipment malfunction, the roller conveyors 60 and 70 that transport the open trays T can be connected to transport the open trays T to the roller conveyor 70, allowing conventional manual packing work to be performed in the manual packing section 9. Under normal circumstances, as shown in Figure 10, the work table 90 is used in a raised position, and cardboard boxes C are transported from the discharge section 8 to a subsequent process. When a cardboard box C that is not full and has been determined to be defective by the inspection means 55 is to be transported, the work table 90 is lowered as shown in FIG. 11 to cause the manual stuffing section free rollers 91 to protrude, and the cardboard box C is transported to the work table 90. When the transport is confirmed by the transport detection sensor 81, the work table 90 is raised as shown in FIG. 10, allowing the cardboard box C to be placed on the work table 90. The open tray T that has been determined to be defective and transported to the roller conveyor 70 is then corrected, packed into a cardboard box C waiting on the work table 90, and then manually pushed into the discharge section 8 for transport to a subsequent process. Although not shown, defects discovered by the inspection means 55 may be automatically transported to the discharge section 8 after being corrected by a robot or the like, by correcting any excess or deficiency and replacing any defective eggs.

[0055] Second Embodiment The second embodiment has the same configuration as the first embodiment except for the configuration described below, and therefore the commonalities will be omitted and differences will be mainly described. Note that in the second embodiment, elements having substantially the same configuration or substantially the same function (action) as the parts described in the first embodiment are represented, and their description will not be repeated.

[0056] The movement mechanism 26 includes a rotational movement mechanism 27 that rotates the head unit 21 around the Z-axis, an up-down movement mechanism 28 that moves the head unit 21 up and down along the Z-axis, and a horizontal movement mechanism 29 that moves the head unit 21 horizontally along the X-axis.

[0057] The up-down movement mechanism 28 is a ball screw spline 287. The ball screw spline 287 includes a ball screw spline shaft 288 extending in the Z direction and a ball screw nut 289 that screws onto the ball screw spline shaft 288. The head portion 21 is fixed to the lower end of the ball screw spline shaft 288. The ball screw nut 289 is rotated by the servo motor 285 via a belt. Thus, by rotating the ball screw nut 289 with the servo motor 285, the ball screw spline shaft 288 is moved in the Z direction, and as a result, the head portion 21 can be moved in the Z direction.

[0058] The rotational movement mechanism 27 rotates the ball screw spline shaft 288. The rotational movement mechanism 27 is, for example, a rotary actuator. The rotational movement mechanism 27 rotates the ball screw spline shaft 288 via, for example, a belt.

[0059] According to the configuration of the second embodiment, there is no need for the guide shaft 286 as in the first embodiment. Furthermore, since the suction piping can be formed inside the ball screw spline shaft 288, the suction piping can be simplified.

[0060] [Open Tray Processing Line] <First Layout Example> FIG. 13 is a plan view showing a first layout example of an open tray processing line provided with a storage system 1. As shown in FIG.

[0061] The open tray processing line 100a includes a repacking device 101, a box former 102, a weight checker 103, an automatic capping machine 104, a box sealing machine 105, a 90° rotating conveyor 106, a printer 107, and a small palletizer 108. The open tray processing line 100a is controlled by a main control unit (not shown) that is provided in a management system that manages the open tray processing line 100a.

[0062] Eggs produced in the chicken coop are washed, dried, and then moved to temporary containers for storage. The repacking device 101 is equipped with a tray supply unit 101a, which separates and supplies stacked empty open trays one by one. The repacking device 101 transfers eggs from the temporary containers to the empty open trays. The open trays T containing multiple eggs are transported to the storage system 1.

[0063] The box former 102 assembles cardboard boxes into a box shape and glues the bottom surface with tape, hot melt, staples, etc. The cardboard boxes C are transported by the box receiving conveyor 102a to the loading section 3 of the storage system 1. In this example, the loading section 3, storage section 4, and unloading section 8 of the storage system 1 are aligned in a row.

[0064] The weight checker 103 measures the weight of the cardboard box C storing the open tray T. If the weight of the cardboard box C storing the open tray T is less than a predetermined weight (for example, 10 kg), the cardboard box C is sorted by the NG sorting conveyor 103a to the NG conveyor 103b.

[0065] The automatic lid putting machine 104 places an empty open tray T containing no eggs on top of the topmost open tray T in the cardboard box C. The automatic lid putting machine 104 is equipped with a tray supply unit 104a, which separates and supplies the stacked empty open trays T one by one. The empty open tray T functions as a lid for the topmost open tray T. The automatic lid putting machine 104 may be equipped with multiple tray supply units 104a. The setup time can be reduced by selecting the tray supply unit 104a to be used in accordance with the open tray T to be processed.

[0066] The sealing machine 105 seals the top surface of the transported cardboard box C by adhesive tape, hot melt, staples, or the like.

[0067] The 90° rotating conveyor 106 rotates the cardboard box C by 90° in a horizontal plane.

[0068] The printer 107 prints information related to the eggs on the side of the cardboard box C.

[0069] The small palletizer 108 stacks the cardboard boxes C on a pallet or a cart.

[0070] <Second Layout Example> FIG. 14 is a plan view showing a second layout example of an open tray processing line provided with a storage system 1.

[0071] The open tray processing line 100b includes a sorting device 109, a box former 102, a weight checker 103, an automatic capping machine 104, a box sealing machine 105, a 90° rotating conveyor 106, a printer 107, and a palletizer 110. The open tray processing line 100b is controlled by a main control unit (not shown) provided in a management system that manages the open tray processing line 100b. The open tray processing line 100b includes multiple storage systems 1a, 1b, and 1c.

[0072] The sorting device 109 has a plurality of stations 109a, 109b, and 109c, and for example, sorts open trays T containing small eggs to station 109a, open trays T containing medium eggs to station 109b, and open trays T containing large eggs to station 109c. The open trays T from stations 109a, 109b, and 109c are transported to the first conveyors 5 of storage systems 1a, 1b, and 1c, respectively. Conveyors corresponding to the upstream conveyor 56 may be arranged between stations 109a, 109b, and 109c and the first conveyor 5, respectively, and stations 109a, 109b, and 109c may also have the function of the upstream conveyor 56.

[0073] The box former 102 assembles the cardboard boxes into a box shape and adheres the bottom surface with tape, hot melt, staples, etc. The cardboard boxes C are transported to the storage system 1 by the box receiving conveyor 102a.

[0074] In this example, the loading section 3 of each of the storage systems 1a, 1b, and 1c is formed by a single continuous conveyor. The unloading section 8 of each of the storage systems 1a, 1b, and 1c is also formed by a single continuous conveyor. Therefore, the loading section 3 may include stopper plates 3a, 3b, and 3c, and the unloading section 8 may include stopper plates 8a, 8b, and 8c.

[0075] The main control unit can control the transport of empty cardboard boxes C and the transport of full cardboard boxes C by raising and lowering the stopper plates 3a, 3b, 3c and stopper plates 8a, 8b, 8c.

[0076] For example, in storage system 1b, once packing of open trays T containing medium-sized eggs into cardboard boxes C is completed, the cardboard boxes C are transported from storage section 4 to discharge section 8. Next, in storage system 1b, empty cardboard boxes C are transported from carry-in section 3 to storage section 4. Next, by lowering stopper plate 3a, the empty cardboard boxes C are transported from carry-in section 3 of storage system 1a to carry-in section 3 of storage system 1b. Next, by raising stopper plate 3a, the empty cardboard boxes C are transported to carry-in section 3 of storage system 1a. Similarly, in storage system 1c, once the empty cardboard boxes C are transported from carry-in section 3 to storage section 4, by lowering stopper plate 3b, the empty cardboard boxes C are transported from carry-in section 3 of storage system 1b to carry-in section 3 of storage system 1c. In this way, empty cardboard boxes C are appropriately supplied to the carry-in sections 3 of each of storage systems 1a, 1b, and 1c.

[0077] Furthermore, for example, if packing into cardboard boxes C in storage system 1a and packing into cardboard boxes C in storage system 1b are completed almost simultaneously, the stopper plate 8a can be raised to temporarily stop the transfer of cardboard boxes C from storage system 1a. This prevents cardboard boxes C being transferred from storage system 1a from coming into contact with cardboard boxes C being transferred from storage system 1b.

[0078] The weight checker 103 measures the weight of the cardboard box C storing the open tray T. If the weight of the cardboard box C storing the open tray T is less than a predetermined weight (for example, 10 kg), the cardboard box C is sorted by the NG sorting conveyor 103a to the NG conveyor 103b.

[0079] The automatic lid insertion machine 104 places an empty open tray T containing no eggs on top of the topmost open tray T in the cardboard box C. The automatic lid insertion machine 104 is equipped with a tray supply unit 104a, which separates and supplies the stacked empty open trays T one by one. The empty open tray T functions as a lid for the topmost open tray T. In this example, multiple tray supply units 104a are provided to supply different open trays T for different egg sizes. The automatic lid insertion machine 104 may also be equipped with a box imaging unit 104b. The box imaging unit 104b identifies the contents of the open tray T based on the shape, identification color, egg placement unit T1, number of eggs, etc., and supplies the corresponding open tray T from the tray supply unit 104a selected based on the identification results.

[0080] The sealing machine 105 seals the top surface of the transported cardboard box C by adhesive tape, hot melt, staples, or the like.

[0081] The 90° rotating conveyor 106 rotates the cardboard box C by 90° in a horizontal plane.

[0082] The printer 107 prints information related to the eggs on the side of the cardboard box C.

[0083] The palletizer 110 stacks the cardboard boxes C on multiple pallets or carts. The palletizer 110 is equipped with, for example, an articulated robot. The palletizer 110 may also be equipped with a box identification unit 110a that reads information printed on the cardboard boxes C by the printer 107. The box identification unit 110a assigns destination information based on the read information. At this time, if there is no destination or the printed information cannot be read, the cardboard box C is evacuated. The palletizer 110 selects a corresponding pallet or cart from multiple pallets or carts according to the destination information assigned by the box identification unit 110a, and stacks the cardboard boxes C on it.

[0084] The storage device and storage system are not limited to the configurations of the above-described embodiments, nor are they limited to the above-described effects. Furthermore, the storage device and storage system can, of course, be modified in various ways without departing from the spirit of the present invention. For example, the configurations and methods of the above-described embodiments may be arbitrarily adopted and combined.

[0085] (1) In the storage system 1 according to the above embodiment, the main control unit is configured to determine whether the eggs in the open tray T are damaged and whether eggs are contained in all rows in the Y direction of the open tray T (or whether no eggs are contained in the open tray T) based on the image captured by the inspection means 55. However, the storage system 1 is not limited to this configuration. The main control unit may be configured to determine the orientation of the open tray T based on the image captured by the inspection means 55. If the orientation of the open tray T is opposite to the desired orientation, the open tray T cannot be properly stacked on the cardboard box C. The orientation of the open tray T is determined, for example, by the location and / or number of the cutout portions T3.

[0086] If the orientation of the open tray T is opposite to the desired orientation, the open tray T may be transferred from the belt conveyor 50 to the roller conveyor 60, and then from the roller conveyor 60 to the roller conveyor 70. The open tray T transferred to the roller conveyor 70 may be reversed and then manually packed.

[0087] Furthermore, if the orientation of the open tray T is opposite to the desired orientation, the tray gripper 25 may grip the open tray T and store it in the cardboard box C. In this case, the rotational movement mechanism 27 is configured to stop the base 22 at three positions: a first position where the longitudinal direction of the base 22 is parallel to the X direction; a second position rotated 90° to the right from the first position; and a third position rotated 90° to the left from the first position; as well as a fourth position rotated 180° from the first position. If it is determined that the orientation of the open tray T is opposite to the desired orientation, the base 22 is first rotated to the fourth position, the tray gripper 25 grips the open tray T, and then the base 22 is rotated to the second or third position, and the gripped open tray T is stored in the cardboard box C.

[0088] (2) Regarding the open tray T, an open tray T having a substantially rectangular outer shape has been exemplified. However, this is not limiting and an open tray having a substantially square outer shape may also be used. Square open trays are known to have egg seats (recesses on which eggs are placed) arranged in 5 rows and 6 columns, each capable of accommodating 30 eggs, or in 6 rows and 6 columns, each capable of accommodating 36 eggs. Unlike rectangular open trays, when stacking square open trays containing eggs, the trays are typically rotated 90° at intervals. When packing such square open trays into cardboard boxes C using the storage system 1, the rotational movement mechanism 27 simply positions the base 22 at two points: a first position where the tray grippers 25 are located in front of and behind the open tray in the traveling direction; and a second position rotated 90° to the right or left from the first position. Specifically, for example, the tray gripping unit 25 may repeat an operation of gripping an open tray at the first position and packing it into a cardboard box C in the same orientation, and an operation of gripping an open tray at the first position, lifting it up, changing its orientation to the second position, and then packing it into a cardboard box C. Of course, depending on the open tray to be processed, the tray gripping unit 25 may repeat an operation of gripping an open tray at the second position and packing it into a cardboard box C in the same orientation, and an operation of gripping an open tray at the second position, changing its orientation to the first position, and then packing it into a cardboard box C.

[0089] (3) In the storage system 1 according to the above embodiment, the main control unit is configured to move the second conveyor 6 from a standby position below the first conveyor 5 to a connecting position downstream of the first conveyor 5 (to move the second conveyor 6 so as to be continuous with the first conveyor 5) when an open tray T determined to be defective arrives at the detection position of the tray arrival confirmation sensor 51a. However, the storage system 1 is not limited to this configuration. For example, the main control unit may be configured to control the storage device 2 to lift the open tray T on the belt conveyor 50 and transfer it to the roller conveyor 70 when an open tray T determined to be defective arrives at the detection position of the tray arrival confirmation sensor 51a.

[0090] (4) In the open tray processing line according to the above embodiment, the printer 107 prints information related to the eggs on the side of the cardboard box C. Here, the information related to the eggs is the size of the eggs, etc. For example, the egg size is printed on the side of the cardboard box C in the form shown in FIGS. 15A and 15B. In the example of FIG. 15A, a mark is printed on the letter M, and in the example of FIG. 15B, a mark is printed below the letter M, both of which indicate that medium-sized eggs are stored in the cardboard box C.

[0091] The box identification unit 110a reads the information printed on the cardboard box C by the printer 107 and assigns information about the transfer destination based on the read information. The box identification unit 110a is, for example, an image sensor that acquires an image and reads the information printed on the cardboard box C from the acquired image. In the example shown in FIG. 15A, the box identification unit 110a sets an inspection area for each cell in the table and determines the size based on the cell with a mark. In the example shown in FIG. 15B, the box identification unit 110a searches for characters of the target size (LL, L, M, S, etc.) and determines whether or not there is a mark below them.

[0092] Furthermore, the box identification unit 110a may read information printed on or attached to the cardboard box C in advance, in addition to the information printed on the cardboard box C by the printer 107. The information printed on or attached to the cardboard box C may be, for example, the brand name of eggs. The box identification unit 110a reads the brand name from the acquired image and assigns information about the transfer destination based on the read brand name.

[0093] 16, the box identifying unit 110a can also read information printed on (including information printed or attached to) the cardboard boxes C fed from the conveyor 111. The cardboard boxes C may be fed onto the conveyor 111 manually, for example.

[0094] 1: Storage system 1a: Storage system 1b: Storage system 1c: Storage system 2: Storage device 3: Loading section 4: Storage section 5: First conveyor 6: Second conveyor 6a: Conveyor base 7: Third conveyor 8: Loading section 9: Manual packing section 21: Head section 22: Base 23: Cartridge 24: Egg suction section 25: Tray gripping section 26: Movement mechanism 27: Rotational movement mechanism 28: Up / down movement mechanism 29: Horizontal movement mechanism 31: Box transfer mechanism 41: First detection sensor 42: Holding section 43: Stopper plate 50: Belt conveyor 51: Conveyor stopper 51a: Tray arrival confirmation sensor 52: Inspection section 53: Second detection sensor 54 : Inspection trigger sensor 55 : Inspection means 56 : Upstream conveyor 60 : Roller conveyor 60a : Guide protrusion 61 : Inclined guide 61a : Guide hole 70 : Roller conveyor 80 : Roller conveyor 81 : Discharge detection sensor 82 : Discharge section free roller 90 : Work table 91 : Manual filling section free roller 221 : Guide groove 222 : First piping 222a : Connection section 223 : Vacuum blower 224 : Air cylinder 225 : Tool confirmation sensor 231 : Guide plate 232 : Locking mechanism 232a : Cartridge side plate 241 : Suction pad 242 : Second piping 242a : Connection section 251 : Claw member 251a : Locking section 251b : Pin 252 : Claw holding bracket 253 : Box-shaped cam 253a : Cam groove 253b : Spring 254 : Slide rod 255 : Pressing member 255a : Projection 281 : Ball screw 282 : Vertical screw shaft 283 : Nut 284 : Table 285 : Servo motor 286 : Guide shaft 287 : Ball screw spline 288 : Ball screw spline shaft289: Ball screw nut 291: Feed screw 292: Horizontal screw shaft 293: Nut 294: Top plate 295: Servo motor 296: Linear guide C: Cardboard box T: Open tray T1: Egg placement portion T11: Convex portion T2: Peripheral portion T3: Notch portion

Claims

1. A storage device for storing an open tray containing a plurality of eggs in a transport container, comprising: an egg adsorption section for adsorbing the plurality of eggs contained in the open tray; a tray gripping section for gripping the open tray; and a moving mechanism for moving the egg adsorption section and the tray gripping section, wherein the moving mechanism comprises a vertical movement mechanism for moving up and down along a vertical axis, a horizontal movement mechanism for moving horizontally along a horizontal axis, and a rotational movement mechanism for rotating movement around the vertical axis.

2. A storage device as described in claim 1, wherein the rotational movement mechanism is connected to the egg adsorption section and the tray gripping section, the vertical movement mechanism moves the rotational movement mechanism vertically, and the horizontal movement mechanism moves the vertical movement mechanism horizontally.

3. The storage device according to claim 1, comprising: a base fixed to the moving mechanism; and a cartridge including the egg adsorption portion and the tray gripping portion, the cartridge being attachable to and detachable from the base.

4. A storage system comprising: a storage device as claimed in claim 1; a first conveyor onto which the open trays containing eggs are transported; an inspection unit disposed upstream of the first conveyor for inspecting the open trays transported onto the first conveyor for defects; and a second conveyor which, when it is determined that the open trays are defective, moves from a waiting position below the first conveyor to a connecting position downstream of the first conveyor to receive the open trays from the first conveyor.

5. The storage system according to claim 4, wherein a conveyor stopper is provided on the second conveyor, and when it is determined that there is no defect in the open tray, the second conveyor in the waiting position positions the conveyor stopper at the downstream end of the first conveyor.

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