JP2850290B2 - Container transfer system - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a method for unloading a container carried into or out of a predetermined cargo handling place by a cargo truck from the truck or to the truck in an appropriate posture. Alternatively, the present invention relates to a transfer system capable of loading.

[0002]

2. Description of the Related Art Various types of lifting equipment such as an arm type crane and a gantry type crane are generally used for loading and unloading cargo such as containers to and from a cargo truck bed.

[0003] Conventionally used lifting / unloading equipment of this type for loading / unloading or handling is operated by a dedicated operator, so that the direction and position of the luggage are set to predetermined directions and positions. Even if it is slightly off, there is no problem in handling luggage.

[0004] However, if the unloading operation of the cargo is to be automatically executed by the robot type unmanned lifting equipment,
Unless the direction and the position of the luggage to be handled are previously set at a fixed position, it is considered that unmanned automatic handling becomes extremely difficult.

Conventionally, in handling luggage in an unmanned automatic warehouse, carts, cranes, and the like arranged for unloading and unloading luggage and transfer of loading are fully automated, and each equipment is used. An unmanned work mode automatically controlled by automatic positioning or the like has been introduced.

However, in the actual transfer operation in which a person drives a cargo truck to bring a container brought into a cargo handling area from the cargo carrier, or loads the container on the cargo carrier of the truck, the truck is stopped. Due to the variation in position, an automatic lifting device simply configured to be controlled for automatic positioning does not allow access to transfer the container to the truck bed of a misaligned truck.

On the other hand, there are various types of cargo trucks from small to large in size, and the number of containers that can be loaded varies depending on the size of the loading platform. Depending on the weight or the like of the cargo carrier, it may be different from the front or the rear of the carrier.

Therefore, a loading / unloading place for loading / unloading containers to / from the truck bed for loading / unloading of containers into / from the automatic three-dimensional warehouse is formed at a fixed position and a fixed section in one corner of the automatic three-dimensional warehouse. However, the above-mentioned variation in the driving positioning of the truck entering the place, or
Fine positioning control of the automatic lifting equipment is indispensable in response to each factor such as the large or small size of the truck bed or the difference in the position of the luggage on the bed. At present, an automatic lifting device capable of automatically performing the above-described fine positioning operation with respect to the bed of the cargo truck, or an automatic transfer system using the device is not provided.

[0009]

DISCLOSURE OF THE INVENTION In view of the above-mentioned prior art, an object of the present invention is to provide a container-like baggage that is loaded and carried at an appropriate position on a cargo bed of a cargo truck having a different size. On the other hand, or to perform an automatic transfer operation by automatically positioning the empty cargo carrier of such a cargo truck in accordance with the difference in the position or orientation of the cargo to be loaded or unloaded. It is to provide a container transfer system which can be used.

[0010]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and comprises a sensor for detecting the presence or absence of a container on a cargo truck carrier and the size of the carrier at a cargo handling location. Above the cargo handling place, a Y-axis carriage capable of moving in the length direction of the truck bed is mounted on an X-axis carriage, and a Z-axis swivel is mounted on the Y-axis carriage. A container transfer crane formed by suspending the container spreader from the swivel so as to be able to ascend and descend, and mounting a camera downward at two or four corners of a flat square on the lower surface of the cart or the container spreader is arranged. The truck of the crane is coarsely positioned in advance based on the position of the container to be loaded on the truck bed, and then the camera is used to image the truck bed, A container spreader for processing the image data of the camera to form positioning correction data for the position of the bogie and the swivel angle of the swivel base, performing corrective positioning of the bogie and the swivel base based on the correction data, and suspending and supporting the container. , And a container is suspended and placed on the cargo bed.

[0011]

[Function] Cargo trucks have various sizes of loading platforms, and the positions of containers to be loaded on them are also different. Furthermore, there are differences in the positions where such cargo trucks are operated and positioned for each truck. Even if the container transfer crane is made to automatically perform the positioning correction operation corresponding to the container loading position on the carrier, then the container is transferred to or from the carrier. It is possible to fully automate the process and greatly reduce the transfer work time.

[0012]

Next, an embodiment of the present invention will be described with reference to the drawings.
FIG. 1 is a perspective view showing an outline of a handling place of the system of the present invention and a container transfer crane there, FIG. 2 is a front view of an example of an automatic three-dimensional warehouse dedicated to containers to which the present invention is applied, and FIG. FIG. 4 is a side view, FIG. 4 is a flowchart showing an operation example of the system of the present invention at the time of entry, FIG.
FIG. 3 is a functional block diagram of a drive system in an example of a container transfer crane in the system of the present invention.

2 and 3, reference numeral 1 denotes one storage compartment 1a.
An automatic three-dimensional warehouse (hereinafter, simply referred to as a warehouse 1) dedicated to containers constructed by providing a large number of storage sections 1a in multiple layers so that one or two or more containers C can be stored in the middle of the warehouse 1. An automatic stacker crane equipped with a self-propelled trolley, which is disposed in the storage area, lowers the container C of each storage section 1a to the ground or transports the container C from outside.
Is transported and lifted to the storage section 1a of the predetermined level. The lateral movement of the container C to or from each of the storage sections 1a in the warehouse 1 is performed by the self-propelled carriage 3 mounted on the stacker crane 2.

In a corner of the warehouse 1 facing the ground, a storage section 1a is not formed, and a loading / unloading station 4 is formed as a cargo handling place for loading / unloading containers by a cargo truck. On the ceiling side of the entrance / exit station 4, on the entrance side and the innermost side of the station 4, in the direction crossing the entrance / exit (hereinafter referred to as X-axis direction),
Beam members 5 and 5 are provided.

The beam members 5, 5 are provided on the beam members 5, 5, respectively.
An X-axis carriage 6X that can move along the vehicle is mounted. X
On the shaft carriage 6X, a Y formed so as to be movable in the Y-axis direction is provided.
An axle carriage 7Y is mounted. On the Y-axis trolley 7Y,
A turntable 8 that can turn around the Z axis (vertical direction with respect to the horizontal plane) is mounted thereon, and a container spreader 9 for supporting and raising and lowering the container C is mounted on the turntable 8.
It is hung up and down freely.

The container spreader 9 has a base 9a, which has a substantially rectangular shape in a plane, suspended at four corners of the turntable 8 by four sets of hoisting ropes 9b so as to be able to move up and down, and a lower surface of the base 9a. On the side, a locking claw 9c hooked on the bottom surface of the container C is provided at the lower end.
The columnar support member 9d is provided downward. Here, the locking claw 9c is rotated by a motor or the like to rotate the claw 9c.
It is formed so that the direction of c can be changed inside and outside of the lower surface of the container C. Note that the support member 9d may be formed to be extendable and contractible by a cylinder or the like.

The container spreader 9 has a claw 9c.
Is a type in which the container C is hooked and lifted at the bottom thereof, but it goes without saying that the container spreader 9 usable in the present invention may be other than the above type. For example, although not shown, the supporting rods provided at the four corners of the upper surface of the container C may be chucked and gripped by the hanging tools provided on the base 9a of the spreader 9, and the container C may be moved up and down.

In the container spreader 9, four CCD cameras 10a to 10a are provided on the lower surfaces of the four corners of the base 9a.
d is provided. Each of the cameras 10a to 10d is arranged, for example, with the imaging surface facing the four corners of the corresponding container C, and processes the images of the four corners of the container C captured by the cameras 10a to 10d, and processes the base 9a of the container spreader. Is used to create image data for determining whether the position is right above the container C or shifted. This will be described in detail later. In addition,
The cameras 10a to 10d may be provided on the lower surface of the Y-axis carriage 7Y or on the lower surface of the Y-axis carriage 6X. When the cameras 10a to 10d are mounted on these carts, a camera mounting bracket (not shown) or the like is used to prevent other components from interfering with each other within the imaging angle of view of each camera. It will be attached. Further, instead of the camera, a sensor capable of detecting the position and orientation of the container C or the position of the loading platform Tb and converting the data into an electric signal may be used. From the X-axis carriage 6X described above, the CCD cameras 10a to 10a-1
0d, the container transfer crane C used in the system of the present invention
An example of T is formed.

At the loading / unloading station 4, a truck space Ts in which a cargo truck T for transporting the container C is located is formed on one side of the floor surface, and a truck bed is provided in a space beside the truck space Ts. T
b, a conveyor table or a loading tray TF (hereinafter simply referred to as a loading tray TF) for transferring the container C to the stacker crane 2 or transferring the container C in the opposite direction is arranged alongside the space Ts. The container transfer crane CT uses the spreader 9 to move the truck T entering the truck space Ts at the loading / unloading station 4.
In this case, automatic reloading of containers C, that is, automatic transfer, is performed between the loading platform Tb and the receiving platform TF.

The track space T of the station 4
There are several types of cargo tonnage, from large (for example, 11 ton load) to small (for example, 4 ton load). C may be stacked two times, and the positioning of such trucks T of different vehicle sizes in the space Ts is considerably coarse in view of the positioning accuracy of the container transfer crane CT. Since the positioning of the container spreader 9 in the container transfer crane CT needs to be performed in consideration of the size of the truck T, the position of the container on the loading platform, and the like, the present invention uses a unique method for this positioning method. I have.

First, the truck space Ts is provided with a carrier sensor for determining the size of the carrier Tb of the truck T entering the truck space Ts. Here, as an example, when the distance between the rear end surface of the truck carrier Tb and the terminal surface of this space Ts reaches a predetermined value, the carrier end sensor 11 for outputting a stop signal such as light emission / sound.
a and a cargo bed front sensor 11b for measuring the distance to the front end of the truck cargo bed Tb are provided on the rear wall surface of the truck space Ts.

When an ultrasonic sensor is used for the sensors 11a and 11b, the loading platform front sensor 11b is located at the rear surface of the driver's cabin of the truck T (that is, at the front end of the loading platform Tb).
By way of example, the distance from the rear wall of the space Ts to the front end of the carrier Tb can be measured by irradiating an ultrasonic wave and the reflected wave thereof, and if the distance obtained by the sensor 11a is subtracted from this distance, the carrier Tb can be measured. The total length is determined, and therefore, the number of tons of the truck is determined based on the length data of the loading platform Tb (hereinafter referred to as the loading platform data). The types of the sensors 11a and 11b and the arrangement positions of the sensors 11a and 11b in the present invention are not limited to those in the above example. The point is that any device capable of measuring the size (length) of the loading platform Tb of the truck T is sufficient. For example, a camera, an infrared sensor, or the like can be used. Further, it is desirable to provide a marker made of a material that reflects or absorbs signals such as light, sound waves, and radio waves on the side of the loading platform Tb in accordance with the type and type of sensor used.

On the other hand, in the track space Ts, as shown in FIG.
Is provided for indicating the package of the truck T driven by the driver or the crew.
Here, on the display screen 12P, as shown in FIG.
The number of containers C loaded on the large truck T, or in the case of the small truck T, the container C is located in front of the loading platform Tb, or
Pictograms (pictograms) 12a to 12d indicating whether they are to be loaded in the middle or at the rear are displayed at the same time, and the driver or the like displays any of the corresponding displays 12a to 1d.
When the user touches 2d, an output to that effect (hereinafter referred to as package data) is made.

The platform data measured by the sensors 11a and 11b and the package data of the package display input stage 12 are processed in the control of the container spreader 9 described later. Hereinafter, an example of an actual unloading operation of the container C will be described with reference to FIGS. 1 to 3 and FIGS.

Referring to the flowchart of FIG. 4, a driver or the like who came to the warehouse 1 with the container C loaded on the truck T enters the loading mode display input means 12 at the entrance of the truck space Ts of the loading / unloading station 4. , Any of the displays 12a to 12d is selected, and the track T is put in the space Ts in the back. At this time, the sensor 11a operates to detect the retreat limit position of the track T, thereby completing the retreat position of the track T in the space Ts (step S1 in FIG. 4). Next, loading tray T
Step S determines whether or not container C remains on F
It is checked in step 2 that if the container C remains, it is determined that the container C is abnormal and the stacker crane 2 executes the processing, and a standby command is output to the container transfer crane CT (steps S3 and S4). When the process ends, the process returns to the step S2. On the other hand, the Y-axle truck 7Y of the container spreader 9 moves in the Y-axis direction according to the package data of the package display input means 12 (step S5). The direction and amount of the movement are determined by the display contents 12 a to 1 in the input means 12.
2d, that is, the direction and the amount set in advance corresponding to the packing style. This is the coarse positioning of the container spreader 9 corresponding to the size of the truck T and the package.

When the above coarse positioning is completed, the size of the carrier Tb (the size of the truck) is checked by the sensors 11a and 11b (step S6), and then the CCD camera 10a provided on the transfer crane CT.
10 to 10d image the four corners of the container C of the loading platform Tb (Step S7). The imaging data of each of the cameras 10a to 10d is converted into, for example, data on the XY coordinates of the corner vertices of the four corners of the container, and this is converted to the container C at the proper position.
Is compared with the XY coordinate data of the corner vertex in step S8 and displayed on the monitor of the display unit 13;
-The displacement amount and the displacement angle of the container C on the Y coordinate are calculated, and the X and Y axis carriages 6X, 7Y,
Then, the swivel 8 is driven at a low speed, and the position and the direction of the container spreader 9 are matched with the container C on the loading platform Tb (step S9). The images captured by the cameras 10a to 10d are displayed on a monitor screen of the display unit 13.

When the rotation and positioning of the container spreader 9 are completed, the rope 9b hanging the base 9a is lowered (step S10). At this time, the claw 9 of the spreader 9
Since c is directed outward, when the support member 4d descends and the claw 9c reaches the floor of the loading platform Tb, the torque of the motor lowering the cable body 9b decreases, which is detected by the current value. Is done. When the decrease in the torque of the motor is detected, the lowering of the spreader 9 is stopped, and the pawl 9c is inserted into the lower surface side of the container C, for example, by a half turn (steps S11 and S11).
12).

When the claws 9c enter the bottom surface of the container C, the rope 9b is pulled up to suspend the container C in the air.
While returning the spreader 9 rotated and positioned with respect to the container C on the loading platform Tb to the original posture, the bogie 6 of each axis is returned.
The X and 7Y motors are driven to position the spreader 9 on which the container C is suspended, just above the loading tray TF. Here, since the receiving tray TF is positioned at the fixed position, the positioning of the spreader 9 suspending the container C is performed with respect to the receiving tray TF at the fixed position (step S13).

Container spreader 9 for receiving table TF
Is completed, the base 9 of the spreader 9 is
The rope 9b suspending a is lowered, and the suspended container C is placed on the receiving platform TF. Container C is receiving TF
The fact that the motor has reached the upper position is detected by the current detection that the torque of the motor of the hoist that is winding down the rope 9b is reduced (step S14).

When the container C is placed on the loading tray TF, the container 9 is transferred from the truck bed Tb to the stacker crane 2 by rotating the claws 9c of the spreader 9 outward to raise the base 9a. The transfer of the container C on the receiving tray TF is completed (step S14). As described above, the transfer from the loading platform Tb to the receiving platform TF when the number of containers C loaded on the truck is one is completed, and the bogies 6X and 7Y of the respective axes of the container spreader 9 return to the respective origin positions. Then, the apparatus enters a standby state for the next container transfer.
If there are two containers C, the package display input means 12
Is determined in step S15, and the operation returns to step 2.

The operation example for storing the container C loaded on the cargo truck in the warehouse 1 has been described above. Next, the container C is extracted from the storage section 1a of the warehouse 1 by the stacker crane 2. A case where the container C is transferred to the cargo truck T will be described based on the flowchart of FIG.

The operation of storing the container C in the predetermined storage section 1a by the stacker crane 2 or taking out the container C from the predetermined storage section 1a, and the control for that, are performed by a stacker crane in a known three-dimensional warehouse. Since this is the same as the case, it is omitted here.

The container C taken out of the storage section 1a by the stacker crane 2 is transferred from the stacker crane 2 to the receiving table TF of the loading / unloading station 4;
The spreader 9 of the container transfer crane CT is the loading table TF
The container C transferred from the stacker crane 2 above is transferred to the carrier Tb of the cargo truck T.

As described above, the truck T on which the container C is loaded has various sizes, and the stop position is also shifted. For this reason, the personnel such as the driver of the truck T can use the displays 12a to 12d of the display input means 12 to
The size of the empty truck and the loading position are designated, and the empty truck T is positioned back to the track space Ts (step P1). Receiving platform TF in step P2
The presence or absence of the container C is checked, and if the container C exists, the container spreader 9
The carriages 6X and 7Y of each axis are driven toward the carrier Tb side (step P3) to perform coarse positioning with respect to the truck carrier Tb, where the CCD cameras 10a to 10b are positioned.
d causes the surface of the loading platform Tb to be imaged (step P4). When the container C is not on the receiving tray TF, an output to that effect is made in Step P2. Therefore, in Step P5, the container transfer crane CT is put on standby, and the stacker crane 2 is operated to activate the predetermined container C. Extraction and transfer to the receiving table TF are performed.

The loading platform Tb by the cameras 10a to 10d
When the floor surface of the truck carrier Tb is completely imaged on the imaging surfaces of all the cameras 10a to 10d in the imaging of
This position data of the spreader 9 is the loading position for the loading platform Tb. On the other hand, if some of the cameras 10a
If the image of the floor surface of the loading platform of the truck T has not been completely captured on the imaging surface of 10 to 10d, it is determined that the predetermined positioning of the truck T has not been performed, and the carriage 7Y of the Y-axis is moved (step P6). ), Correction positioning is performed until it is determined in step P7 that the floor surface of the loading platform Tb has completely entered the imaging surfaces of all the cameras 10a to 10d, and this position data is used as loading platform loading position data. If the loading platform Tb still does not enter the cameras 10a to 10d, an abnormality process is performed (step P8). The images of the loading platform Tb of the cameras 10a to 10d are displayed on the monitor screen 13.

After teaching the loading position data of the container spreader 9 to the truck bed, the spreader 9 moves right above the receiving stand TF on which the container C is placed and returns (step P9), and the container C is suspended. The raising operation starts (step P10).

Here, since the receiving table TF is at a fixed position,
The operation of lifting and suspending the container C thereon by the container spreader 9 is performed according to a preset program.

The container C suspended by the spreader 9
Is driven right above the truck bed Tb by driving the carriages 6X, 7Y and the swivel base 8 of each axis of the spreader 9 according to the positioning data previously taught (step P11). Thereafter, the base 9a of the spreader 9 is lowered, and when it is detected that the torque of the drive source motor has decreased, the lowering of the base 9a is stopped, and the pawl 9c is rotated outward, whereby the spreader 9 The loading of the container C onto the truck bed Tb is completed (step P12).

When the base 9a of the spreader 9 with the claws 9c turned outward is pulled up and the axes 6X and 7Y of the respective axes return to the origin positions, the spreader 9 is in the standby position for the next transfer. If two containers C are loaded, step P
2 and the above-mentioned transfer operation is repeated (step P13).

The container transfer crane C for automatically transferring the container C from the truck bed Tb to the receiving bed TF or automatically transferring the container C from the receiving bed TF to the truck bed Tb.
The drive system of T is formed as shown in FIG. 6 as an example, and this point will be described below.

In FIG. 6, an X-axis carriage 6X and a Y-axis carriage 7
Y includes servo motors 6a and 7a, speed reducers 6b and 7b connected to the wheels of each bogie, and servo controllers 6c and 7c each having a positioning function on each axis. In this case, the current position data of each of the X and Y axes is detected by encoders 6d and 7d provided on the motors 6a and 7a, and the detected data is fed back to a position calculation unit (not shown) of the servo control units 6c and 7c. Is formed.

On the other hand, the turntable 8 includes a servomotor 8a as a turning drive source, a speed reducer 8b connected to a turntable, and a servo control unit 8c having an angle positioning function. The current turning angle data of the table 8 is stored in the motor 8
The signal is detected by the encoder 8d provided at the position (a) and is fed back to the servo controller 8c.

The lifting drive of the container spreader 9, which is suspended from the turntable 8 by a cable body 9b, has a servo motor 9e and a speed reducer 9f connected to a winding drum, and a torque detection and positioning function. It is formed by the servo controller 9g. The motor 9e has an encoder 9h.
Is provided to detect the elevation position data.

Each of the driving systems described above includes a CCD camera 10a.
Each of the data from the storage platforms 11a, 11b and the display input means 12 is processed by the image recognition controller 14 and the sequence control unit 15, and the drive is controlled by the sequence control based on the command data from the central control unit 16.

[0045]

As described above, the present invention is directed to an operation of lowering a container from a cargo truck or a container being loaded on the cargo carrier, in which a large variation in the size of the cargo platform and positioning to the transfer position is likely to occur. Has been automated inside a multi-storey warehouse, so conventional luggage systems that can automatically move large packages loaded on trucks such as containers into and out of an auto multi-storey warehouse almost unattended. No breakthrough effect can be obtained.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an outline of a cargo handling place of the system of the present invention and a container transfer crane there.

FIG. 2 is a front view of an example of an automatic three-dimensional warehouse dedicated to containers to which the present invention system is applied.

FIG. 3 is a side view of FIG. 2;

FIG. 4 is a flowchart showing an operation example at the time of storage of the system of the present invention.

FIG. 5 is a flowchart showing an operation example at the time of retrieval of the system of the present invention.

FIG. 6 is a functional block diagram of a drive system in an example of the container transfer crane in the system of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Automatic warehouse 2 Stacker crane 3 Self-propelled truck of a stacker crane 4 Loading / unloading station 5 Beam member 6X X-axis cart 7Y Y-axis cart 8 Z-axis swivel base 9 Container spreader 10a-10d CCD camera 11a, 11b Carrier sensor 12 Package Display and input means 13 Display part T Cargo truck Tb Carrier TF Cargo carrier CT Container transfer crane

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-51-7655 (JP, A) JP-A-54-132172 (JP, U) (58) Fields investigated (Int. Cl. ⁶ , DB name) B66C 13/00-15/06

Claims (1)

(57) [Claims] 1. A sensor for detecting the presence or absence of a container on a cargo truck bed and the size of the cargo bed at a cargo handling place, and capable of moving in the longitudinal direction of the cargo bed of the truck above the cargo handling place. The Y-axis truck that has been mounted on the X-axis truck,
A Z-axis swivel is mounted on the Y-axle, a container spreader is suspended from the swivel so as to be able to move up and down, and cameras are provided at two to four corners of a plane square on the lower surface of the bogie or the container spreader. A crane for container transfer formed by mounting the container downward is arranged, and the truck of the crane is based on the size of the truck bed obtained from the detection signal of the sensor and the position of the container to be loaded on the bed. After the coarse positioning is performed in advance, the camera is used to capture an image of the truck bed, and the image data of each camera is processed to form positioning correction data for the position of the bogie and the turning angle of the swivel table. The trolley and the swivel unit are corrected and positioned by this, and the container spreader supporting and suspending the container is lowered, and the container is suspended on the loading platform. Container transfer system, characterized in that it is placed in.