Tray storage equipment

Abstract

The present invention stores stacked trays using relatively low-strength egg trays, such as American trays. A storage shelf 4 comprises a plurality of storage support portions 41 for supporting the lower surface of a tray T, wherein at least one of the plurality of storage support portions 41 supports a projection portion row T2x composed of a single row of a projection portion T2 along the insertion and removal direction on the lower surface of the tray T, or a recessed portion T2y formed between the projection portion rows T2x. A transfer device 5 comprises at least one conveyance support portion 51 for supporting the lower surface of the tray T, wherein the at least one conveyance support portion 51 supports a portion different from a portion supported by the plurality of storage support portions 41 on the lower surface of the lowermost tray T.

Description

Tray storage equipment

[0001] The present invention relates to a tray storage facility.

[0002] One example of conventional tray storage equipment is an automated warehouse that stores tray groups (also referred to as stacked trays) stacked by a stacking device, as shown in Patent Document 1. This automated warehouse has an inlet port through which the tray groups are carried in, a plurality of storage shelves that store the tray groups carried in at the inlet port, an outlet port through which the tray groups stored in the storage shelves are carried out, and transportation means such as a stacker crane that carries the tray groups from the inlet port into the storage shelves and carries the tray groups stored in the storage shelves out to the outlet port.

[0003] Furthermore, Patent Document 2 discloses a special tray suitable for storage in an automated warehouse. This tray has five rows and six columns of egg-receiving recesses for accommodating eggs, and the bottom of the tray is formed with reinforcing ribs in a grid pattern that connect the tips of the egg-receiving recesses. These reinforcing ribs prevent the tray from bending when eggs are stored inside or when the trays are stacked.

[0004] JP 2016-179893 A JP 2008-127082 A

[0005] Some storage shelves in automated warehouses that use the above-mentioned special trays are configured to support only both widthwise ends of the stacked trays, as shown in Figure 8. Specifically, the storage shelf has two support beams corresponding to both widthwise ends of the stacked trays, and supports both widthwise ends of the bottom tray of the stacked trays.

[0006] However, when stacked trays made of general-purpose trays such as American trays are stored in a storage shelf with the above-described configuration, the widthwise center of the stacked trays will bend, making it difficult to store the stacked trays safely.In the worst case scenario, the bending of the stacked trays may cause them to come off the support beams and fall off the storage shelf.

[0007] The present invention has been made to solve the above problems, and aims to store stacked trays using trays with relatively low strength, such as American trays.

[0008] That is, the tray storage facility according to the present invention is a tray storage facility in which stacked trays each containing eggs are loaded into a storage shelf by a transfer device and are loaded out of the storage shelf by the transfer device, wherein the tray has a plurality of egg accommodating sections formed in rows and columns on the top surface thereof and a plurality of protruding sections formed on the bottom surface thereof that protrude downwards corresponding to each of the plurality of egg accommodating sections, and the transfer device loads and unloads the stacked trays into and out of the storage shelf such that the row or column direction of the plurality of egg accommodating sections in the bottommost tray of the stacked trays faces the storage shelf, and the storage shelf is secured by the transfer device. The transfer device has a plurality of storage support parts extending along the loading / unloading direction and supporting the underside of the lowest tray, at least one of the plurality of storage support parts supporting a row of protrusions consisting of a single row of protrusions along the loading / unloading direction on the underside of the lowest tray or a recess formed between adjacent rows of protrusions, and the transfer device has at least one transport support part extending along the loading / unloading direction and supporting the underside of the lowest tray, and the at least one transport support part supports a part of the underside of the lowest tray that is different from the part supported by the plurality of storage support parts.

[0009] In this tray storage facility, at least one of the storage shelf's multiple storage support members supports the protruding portion row or the recessed portion between adjacent protruding portion rows on the underside of the stacked trays, thereby supporting portions other than both ends of the stacked trays and preventing sagging of the stacked trays stored in the storage shelf. As a result, stacked trays using relatively weak egg trays, such as American trays, can be stored in the tray storage facility (e.g., an automated warehouse). Furthermore, at least one transport support member of the transfer device supports portions of the stacked trays' underside that are different from the portions supported by the multiple storage support members, allowing for smooth loading and unloading of the stacked trays. Furthermore, if at least one transport support member is configured to support portions of the stacked trays' underside other than both widthwise ends, sagging of the stacked trays can be prevented even during transport.

[0010] It is desirable that two of the plurality of storage support parts support both end portions of the underside of the lowest tray in the width direction perpendicular to the insertion / removal direction. With this configuration, the plurality of storage support parts support both end portions of the stacked trays in the width direction and the middle portion between them, thereby enabling stable support of the stacked trays.

[0011] It is desirable that the at least one transport support member has a protrusion that fits into an uneven surface formed on the underside of the lowest tray. This configuration can prevent the stacked trays from shifting relative to the transport support member when the stacked trays are transported by the transfer device. This can, for example, increase the transport speed when transporting the stacked trays.

[0012] According to the present invention configured as described above, stacked trays using egg trays having a relatively low strength, such as American trays, can be stored.

[0013] FIG. 1 is a plan view schematically showing the configuration of a tray storage facility (automated warehouse) according to one embodiment of the present invention. (a) is a plan view, (b) is a side view seen from the row direction, and (c) is a side view seen from the column direction, showing trays of the same embodiment. FIG. 2 is a perspective view showing the storage shelf and the transport support part of the transfer device of the same embodiment. FIG. 3 is a front view showing the positional relationship between the storage support part of the storage shelf and the transport support part of the transfer device of the same embodiment. FIG. 4 is a front view showing the positional relationship between the storage support part of the storage shelf and the transport support part of the transfer device of a modified embodiment. FIG. 5 is a front view showing the positional relationship between the storage support part of the storage shelf and the transport support part of the transfer device of the modified embodiment. FIG. 6 is a schematic view showing the configuration of the transport support part of the modified embodiment. FIG. 7 is a perspective view showing the configuration of a conventional storage shelf.

[0014] An embodiment of a tray storage facility 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 designated by the same reference numerals, and their description will be omitted where appropriate.

[0015] <Configuration of Tray Storage Facility 100> As shown in FIG. 1, the tray storage facility 100 of this embodiment is an automated warehouse that stores stacked trays ST received through an inlet gate 2 in storage shelves 4 by a transfer device 5.

[0016] A sorting system 11 is arranged upstream of the automated warehouse 100, and a packaging system 12 is arranged downstream of the automated warehouse 100. The sorting system 11, the automated warehouse 100, and the packaging system 12 form a sorting and packaging system.

[0017] This sorting and packaging system is installed in a GP center. Raw eggs E are brought into the GP center from the center's own farm or farms around the country, and raw eggs E are transported to the grading system 11 from neighboring farms via a raw egg conveyor. These raw eggs E are then sorted by grade for each lot by the sorting system 11 and stored in the automated warehouse 100 by "variety (e.g., white, size M from XX farm)" for inventory management. In response to orders from supermarkets and the like around the country, eggs E are shipped from the automated warehouse 100, packaged in containers by the packaging system 12, and shipped and managed as "egg products (XX eggs)."

[0018] Specifically, the automated warehouse 100 is equipped with a plurality of inbound gates 2, a plurality of outbound gates 3, a plurality of storage shelves 4 for storing stacked trays ST, and a transfer device 5 for moving the stacked trays ST between the inbound gates 2, the outbound gates 3, and the storage shelves 4.

[0019] An incoming transfer section 6, such as a conveyor, is connected to each of the multiple incoming gates 2, and transports stacked trays ST to the incoming gate 2. Each incoming transfer section 6 is provided with a stacking device 10 that stacks trays T containing eggs E in a vertical direction. Furthermore, upstream of the stacking device 10 in the incoming transfer section 6, a sorting system 11 is provided that sorts the eggs E, for example, by weight, and stores them in trays T.

[0020] Each of the multiple outgoing gates 3 is connected to an outgoing transport unit 7, such as a conveyor, that transports the stacked trays ST to a packaging system 12. The packaging system 12 has a de-stack device 12a that de-stacks the stacked trays ST transported by the outgoing transport unit 7 into individual trays T, and a packaging device 12b located downstream of the de-stack device 12a. The packaging device 12b transfers eggs E contained in the trays T into containers P, such as egg packs, and packs the eggs E into the containers P.

[0021] The plurality of storage shelves 4 store the received stacked trays ST by type. Each storage shelf 4 may be configured to store one stacked tray ST or multiple (e.g., three) stacked trays ST. The specific configuration of the storage shelf 4 will be described later.

[0022] The transfer device 5 transfers stacked trays ST from the incoming gate 2 to the storage shelf 4, and transfers stacked trays ST from the storage shelf 4 to the outgoing gate 3. In this embodiment, the transfer device 5 is configured with a stacker crane that can move up and down and left and right. This stacker crane is controlled by the management device CTL. The transfer device 5 then moves the stacked trays ST received at each incoming gate 2 to the storage shelf 4 for storage by type. The transfer device 5 also moves the stacked trays ST stored in each storage shelf 4 to each outgoing gate 3 for outgoing.

[0023] <Characteristics of the Tray Storage Facility (Automated Warehouse)> The tray T of this embodiment is a general-purpose tray known as an American tray, and as shown in Figure 2, has a rectangular shape in plan view, a plurality of egg accommodating sections T1 formed in a matrix on the top surface, and a plurality of protruding sections T2 formed on the bottom surface that protrude downward and correspond to each of the egg accommodating sections T1. These protruding sections T2 form the bottoms of the egg accommodating sections T1.

[0024] Specifically, the tray T has a plurality of egg containing sections T1 arranged in 5 rows and 6 columns, and can contain a total of 30 eggs E. In addition, on the bottom surface of the tray T, in addition to a plurality of protrusions T2 corresponding to the plurality of egg containing sections T1, protrusions T2 are also provided outside the protrusions T2 in the first row and outside the protrusions T2 in the fifth row. In other words, on the bottom surface of the tray T, a plurality of protrusions T2 are arranged in 7 rows and 6 columns.

[0025] That is, as shown in Figure 2(a), when viewed from the side in the row direction of the plurality of egg accommodating units T1, the tray T has a configuration in which five egg accommodating units T1 and seven protrusions T2 are visible, and the seven protrusions T2 form repeated recesses and protrusions on the underside of the tray T. As shown in Figure 2(b), when viewed from the side in the column direction of the plurality of egg accommodating units T1, the tray T has a configuration in which six egg accommodating units T1 and six protrusions T2 are visible, and the six protrusions T2 form repeated recesses and protrusions on the underside of the tray T.

[0026] The transfer device 5 moves the stacked trays ST into and out of the storage shelf 4 so that the row direction or column direction of the plurality of egg accommodating sections T1 in the lowest tray T of the stacked trays ST faces the storage shelf 4. The transfer device 5 of this embodiment moves the stacked trays ST into and out of the storage shelf 4 so that the row direction of the plurality of egg accommodating sections T1 in the lowest tray T faces the storage shelf 4. In other words, five egg accommodating sections T1 are lined up on the storage shelf 4 side (leading edge) of the lowest tray T (five leading edge, see FIG. 2(b)).

[0027] 3 and 4, each storage shelf 4 has a so-called comb-like shape and includes a plurality of storage support portions 41 that support the underside of the lowest tray T. Each storage support portion 41 is linear and extends along the loading / unloading direction of the transfer device 5. The plurality of storage support portions 41 are arranged side by side in the width direction perpendicular to the loading / unloading direction.

[0028] Specifically, as shown in Fig. 4, at least one of the plurality of storage support portions 41 supports a protrusion row T2x (see Fig. 2(b)) consisting of one row of protrusions T2 along the insertion / removal direction on the underside of the lowest tray T, or a recess T2y (see Fig. 2(b)) formed between adjacent protrusion rows T2x. In this embodiment, there are four storage support portions 41 arranged along the width direction, and the two innermost storage support portions 41 each support a different protrusion row T2x (the third and fifth rows from the left).

[0029] Of the four storage support portions 41, the two outer storage support portions 41 support both widthwise ends of the underside of the bottommost tray T. In this embodiment, the two outer storage support portions 41 support the outermost protrusion rows T2x (the first and seventh rows from the left). When the stacked trays ST are supported by these four storage support portions 41, a space is formed between the four storage support portions 41 below the bottommost tray T.

[0030] In this embodiment, as shown in Figure 3, the base ends of the four storage support sections 41 (the ends opposite the side where the contents are inserted and removed) are fixed to a cross member 42, which is in turn fixed to two support columns 43 erected on the left and right sides at the rear. Furthermore, the tip ends of the two outer storage support sections 41 are fixed to two support columns 44 erected on the left and right sides at the front. In other words, the two outer storage support sections 41 are doubly supported beams supported at two points, the front end and the rear end, and the two inner storage support sections 41 are cantilevered beams supported at one point, the rear end. Note that the fixing structure of the four storage support sections 41 is not limited to this, and various structures are possible.

[0031] Corresponding to the structure of this storage shelf 4, the transfer device 5 has a so-called comb-like shape, as shown in Figures 3 and 4, and has multiple transport support parts 51 that support the underside of the lowest tray T. The transfer device 5 of this embodiment is configured to have three transport support parts 51. Each transport support part 51 is linear and extends along the loading / unloading direction. The multiple transport support parts 51 are also arranged side by side in the width direction perpendicular to the loading / unloading direction.

[0032] 4, the plurality of transport support portions 51 support portions of the underside of the lowest tray T that are different from the portions supported by the plurality of storage support portions 41. In this embodiment, the configuration has three transport support portions 51 along the width direction, and the three transport support portions 51 each support a different protrusion row T2x (the second row, fourth row, and sixth row from the left). In other words, the three transport support portions 51 support the protrusion row T2x that is not supported by the four storage support portions 41.

[0033] In this embodiment, the base ends (the ends opposite the side where the material is inserted and removed) of the three transport support parts 51 are fixed to a slide member 50 that moves horizontally by a horizontal drive part (not shown) of the transfer device 5, as shown in Figure 3.

[0034] Next, the operation of the transfer device 5 for inserting and removing the stacked trays ST into and from the storage shelf 4 will be briefly described.

[0035] When storing stacked trays ST in the storage shelves 4, the transfer device 5 receives the stacked trays ST from the receiving gate 2 and moves to the front of the desired storage shelf 4. The transfer device 5 then moves the slide member 50 toward the storage shelf 4. At this time, the multiple transport support members 51 of the transfer device 5 slide to be inserted between the multiple storage support members 41 of the storage shelf 4. After moving the stacked tray ST into the storage shelf 4, the transfer device 5 moves the multiple transport support members 51 downward to transfer the stacked tray ST onto the multiple storage support members 41. Here, because the two inner storage support members 41 are cantilevered, they do not interfere with the transfer operation, such as the sliding movement of the multiple transport support members 51. The transfer device 5 then moves the slide member 50 to the opposite side of the storage shelf 4, moving the multiple transport support members 51 out of the storage shelf 4, and moves to a predetermined standby position or to the receiving gate 2 to transfer the next stacked tray ST.

[0036] When removing a stacked tray ST from a storage shelf 4, the transfer device 5 moves to the front of the desired storage shelf 4. The transfer device 5 then moves the slide member 50 toward the storage shelf 4. At this time, the multiple transport support parts 51 of the transfer device 5 slide to be inserted between the multiple storage support parts 41 of the storage shelf 4 so as not to come into contact with the stacked tray ST. The transfer device 5 then moves the multiple transport support parts 51 upward to transfer and lift the stacked tray ST onto the multiple transport support parts 51. The transfer device 5 then moves the slide member 50 to the opposite side from the storage shelf 4 to move the multiple transport support parts 51 out of the storage shelf 4. After moving the stacked tray ST out of the storage shelf 4, the transfer device 5 moves to the delivery gate 3 and transfers the stacked tray ST to the delivery gate 3.

[0037] In addition, the configuration may be such that multiple transport support sections 51 are inserted between multiple storage support sections 41 so as to contact the underside of the stacked tray ST, and the stacked tray ST is transferred to the multiple transport support sections 51 at the same time as the multiple transport support sections 51 are inserted into the multiple storage support sections 41.

[0038] <Effects of this embodiment> According to the tray storage equipment 100 of this embodiment, at least one of the multiple storage support parts 41 of the storage shelf 4 supports the protrusion row T2x or the recessed part T2y between adjacent protrusion row T2x on the underside of the stacked tray ST, thereby supporting parts of the stacked tray ST other than both ends and preventing bending of the stacked tray ST stored on the storage shelf 4. As a result, it is possible to store stacked trays ST using trays T with relatively low strength, such as American trays, in the automated warehouse 100.

[0039] In this embodiment, the stacked trays ST can be smoothly taken in and out because at least one transport support part 51 of the transfer device 5 supports a part of the underside of the stacked trays ST that is different from the part supported by the plurality of storage support parts 41. Furthermore, if at least one transport support part 51 is configured to support a part of the underside of the stacked trays ST other than both ends in the width direction, it is possible to prevent the stacked trays ST from bending even when the stacked trays ST are being transported.

[0040] <Modified Embodiments of the Present Invention> The present invention is not limited to the above-described embodiments.

[0041] For example, the transfer device 5 may be configured to load and unload the stacked trays ST into and from the storage shelf 4 so that the row direction of the plurality of egg accommodating sections T1 in the lowest tray T faces the storage shelf 4. In other words, six egg accommodating sections T1 are lined up on the storage shelf 4 side (leading edge) of the lowest tray T (six leading edges, see FIG. 2(c)).

[0042] Furthermore, although the storage support portion 41 and the transport support portion 51 in the above embodiment support the protrusion row T2x of the lowest tray T, they may also support the recesses T2y formed between adjacent protrusion rows T2x.

[0043] 5 is a possible combination of the number and arrangement of storage support units 41 and the number and arrangement of transport support units 51 at the front of the stacker 5. The combinations shown below may be configured such that the storage support units 41 and the transport support units 51 are interchangeable. In the above embodiment, the storage support units 41 and the transport support units 51 may also be interchangeable.

[0044] 5(a) shows a configuration in which the storage shelf 4 has three storage support parts 41, the storage support parts 41 on both sides support the first and seventh protrusion rows T2x at both ends of the lowest tray T, and the central storage support part 41 supports the fourth protrusion row T2x. Also, the transfer device 5 has two transport support parts 51, one of which supports the second and third protrusion rows T2x, and the other of which supports the fifth and sixth protrusion rows T2x.

[0045] 5(b) shows a configuration in which the storage shelf 4 has four storage support parts 41, the storage support parts 41 on both sides support the first and seventh protrusion rows T2x at both ends of the lowest tray T, and the central storage support part 41 supports the third and fifth protrusion rows T2x. Also, the transfer device 5 has six transport support parts 51, and each transport support part 51 supports a recess T2y formed between the protrusion rows T2x.

[0046] 5(c) shows a configuration in which the storage shelf 4 has three storage support parts 41, the storage support parts 41 on both sides support the first and seventh protrusion rows T2x at both ends of the lowest tray T, and the central storage support part 41 supports the fourth protrusion row T2x. Also, the transfer device 5 has four transport support parts 51, and each transport support part 51 supports a recess T2y formed between the protrusion rows T2x.

[0047] 6 is a possible combination of the number and arrangement of storage support units 41 and the number and arrangement of transport support units 51 at the front of the six. The combinations shown below may be configured such that the storage support units 41 and the transport support units 51 are interchangeable.

[0048] 6(a) shows a configuration in which the storage shelf 4 has three storage support parts 41, the storage support parts 41 on both sides support the first and sixth protrusion rows T2x at both ends of the lowest tray T, and the central storage support part 41 supports the recess T2y formed between the third and fourth protrusion rows T2x. Also, the transfer device 5 has two transport support parts 51, one of which supports the second and third protrusion rows T2x, and the other of which supports the fourth and fifth protrusion rows T2x.

[0049] 6(b) shows a configuration in which the storage shelf 4 has three storage support parts 41, the storage support parts 41 on both sides support the outer parts of the protrusion rows T2x at both ends of the lowest tray T, and the central storage support part 41 supports the recess T2y formed between the third and fourth protrusion rows T2x. Also, the transfer device 5 has two transport support parts 51, one of which supports the first to third protrusion rows T2x, and the other of which supports the fourth to sixth protrusion rows T2x.

[0050] 6(c) shows a configuration in which the storage shelf 4 has three storage support parts 41, the storage support parts 41 on both sides support the outer parts of the protrusion rows T2x at both ends of the lowest tray T, and the central storage support part 41 supports the recess T2y formed between the third and fourth protrusion rows T2x. Also, the transfer device 5 has four transport support parts 51, and each transport support part 51 supports the recess T2y formed between the protrusion rows T2x.

[0051] Furthermore, although the transfer device 5 in the above embodiment is configured to have a plurality of transport support parts 51, it is sufficient to have at least one transport support part 51. For example, in a configuration having two storage support parts, it is conceivable to configure the stacking trays so that each side is supported by two storage support parts, and the inside (center) of these is supported by one transport support part 51. Furthermore, a base plate may be provided on the underside of the plurality of transport support parts 51, so that the plurality of transport support parts 51 are configured as an integrated unit.

[0052] Furthermore, as shown in FIG. 7 , at least one transport support member 51 of the transfer device 5 may have a protrusion 52 that fits into an irregularity formed on the underside of the lowest tray T. For example, the protrusion 52 may be a continuous ridge formed along the pull-out direction, or may be formed intermittently to fit between the protrusions T2. FIG. 7 shows an example in which each transport support member 51 has protrusions 52 formed to sandwich the protrusion row T2x from both the left and right sides. This configuration allows the stacked trays ST to be stably supported on the transport support member 51, preventing the stacked trays ST from shifting relative to the transport support member 51 when the stacked trays ST are transported by the transfer device 5. This allows, for example, a faster transport speed when transporting the stacked trays ST.

[0053] Furthermore, the incoming-side conveying section 6 connected to the incoming gate 2 and / or the outgoing-side conveying section 7 connected to the outgoing gate 3 may be configured to convey the stacked trays ST while supporting not only both widthwise ends of the underside of the stacked trays ST but also portions other than both ends, similar to the storage shelf 4. Specifically, the incoming-side conveying section 6 and / or the outgoing-side conveying section 7 may be configured to have a plurality of parallel chain conveyors. Each chain conveyor supports the protrusion row T2x of the lowest tray T or the recess T2y formed between the protrusion rows T2x.

[0054] Furthermore, although the tray storage facility 100 in the above embodiment is an automated warehouse, it may also be a facility other than an automated warehouse in which stacked trays ST are carried in and out of the storage shelves 4 by a transfer device 5. Furthermore, although the automated warehouse in the above embodiment stores eggs E after being sorted by the sorting system 11, it is not limited to this and may be, for example, an automated warehouse used upstream of the sorting system 11, that is, an automated warehouse for storing raw eggs.

[0055] 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.

[0056] According to the present invention, stacked trays using egg trays with relatively low strength, such as American trays, can be stored.

[0057] REFERENCE SIGNS LIST 100: Tray storage facility (automated warehouse) E: Egg T: Tray T1: Egg storage section T2: Protrusion T2x: Protrusion row T2y: Recess ST: Stacked tray 4: Storage shelf 41: Storage support section 5: Transfer device 51: Transport support section 52: Protrusion

Claims

1. A tray storage facility in which stacked trays containing eggs are carried into a storage shelf by a transfer device and carried out of the storage shelf by the transfer device, wherein the trays have a plurality of egg accommodating sections formed in rows and columns on their upper surfaces and a plurality of protrusions formed on their lower surfaces that protrude downward corresponding to each of the plurality of egg accommodating sections, the transfer device moves the stacked trays into and out of the storage shelf so that the row or column direction of the plurality of egg accommodating sections in the lowest tray of the stacked trays faces the storage shelf, the storage shelf has a plurality of storage support sections that extend along the loading and unloading direction of the transfer device and support the underside of the lowest tray, and at least one of the plurality of storage support sections supports a protrusion row consisting of a single row of protrusions along the loading and unloading direction on the underside of the lowest tray, or a recess formed between adjacent rows of protrusions, the transfer device has at least one transport support section that extends along the loading and unloading direction and supports the underside of the lowest tray, The tray storage facility, wherein the at least one transport support section supports a portion of the underside of the lowest tray that is different from the portion supported by the plurality of storage support sections.

2. A tray storage facility as described in claim 1, wherein two of the plurality of storage support sections support both ends of the width direction perpendicular to the insertion / removal direction on the underside of the lowest tray.

3. A tray storage facility as described in claim 1 or 2, wherein said at least one transport support portion has a protrusion that fits into an unevenness formed on the underside of said lowest tray.

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