JP7514553B2 - Egg carton transfer robot system and storage method using same - Google Patents

Description

The present invention relates to an egg carton transfer robot system that transfers egg cartons to a mobile rack, and a storage method using the same.

Once eggs are packed at the GP center, they are packed into cardboard boxes or containers, or placed on special mobile racks called roll inners.

A device for packing egg cartons is described in Patent Document 1 below. Also, a movable rack (roll inner) for storing egg cartons is known, as described in Patent Document 2 below.

The roll inners are equipped with multiple shelves, and egg cartons are placed on each shelf in a stacked state. In this state, the roll inners can be moved and displayed on the sales floor as is. For this reason, the roll inners have complex shapes and foldable parts to prevent the egg cartons from falling off the shelves.

The egg cartons are transported from the GP center to the sales floor stacked in multiple layers inside roll inners. The following features allow them to withstand being transported in a multi-layered state. Firstly, the roll inners are surrounded by fences on three sides. Secondly, the roll inners are equipped with spill guards on the loading and unloading side. The roll inners also have multiple shelves, with 4-5 egg cartons stacked per shelf (4-5 layers). And to prevent the egg cartons from sliding sideways, the egg cartons themselves are shaped to prevent the egg cartons stacked above and below from shifting sideways.

In addition, the following features are designed to increase transport efficiency. The first is to stack as many egg cartons as possible per layer of the inner roll. In other words, there is a desire to place egg cartons as close to the inside of the fence as possible, and as close to the bottom of the shelves as possible. This is because the egg cartons are packed tightly on the shelves and restrained by each other, preventing them from moving significantly from their designated positions, thereby preventing the eggs from cracking during transport. Furthermore, the second feature is that the shelves and fences are foldable so that they can be stored compactly when not in use.

JP 2018-177325 A Utility Model Registration No. 3209255

The task of storing egg containers in the movable rack (roll inner) described in Patent Document 2 is performed manually, and automation has not yet been achieved.

When loading egg cartons onto the top shelf of the roll inner, the upper part is an open space, so loading can be done with almost the same movements as in Patent Document 1. However, when loading egg cartons onto other shelves, the above-mentioned factors (obstacles for the robot head) prevent automation.

When trying to store egg cartons in roll inners, complex movements are required to ensure that the egg cartons do not hit obstacles, and the folded parts must be unfolded, so there is an issue that the technology disclosed in Patent Document 1, which uses robots instead of human labor, cannot be applied as is.

The present invention therefore aims to provide an egg carton transfer robot system that solves the problems of the conventional technology, and a storage method using the same.

The egg carton transfer robot system of the present invention comprises a robot head, a robot arm, and a control unit. The robot head comprises a gripping unit that grips an egg carton. The robot arm is capable of changing the position and orientation of the robot head. The control unit controls the movement of the robot head and the robot arm, and moves the egg carton gripped by the gripping unit to the space below a foldable shelf provided on a movable rack.

The storage method using the egg carton transfer robot system of the present invention includes the steps of placing a mobile rack within reach of the robot head in the egg carton transfer robot system described above, positioning the robot head at a predetermined location on the egg carton to grasp the egg carton, moving the egg carton grasped by the robot head into space, and positioning the lower end of the moved egg carton inside the protrusion on the lower tier.

The present invention provides an egg carton transfer robot system that automatically transfers egg cartons to a mobile rack, and a storage method using the same.

The above and other objects, features, aspects and advantages of the present invention will become apparent from the following detailed description of the present invention taken in conjunction with the accompanying drawings.

FIG. 1 is a side view showing an egg carton transfer robot system according to an embodiment of the present invention. FIG. 2 is a side view showing the egg pack transferring robot system according to the embodiment. FIG. 2 is an enlarged side view illustrating a storage method using the egg carton transfer robot system of the embodiment. FIG. 11 is a plan view illustrating a storage method using the egg carton transfer robot system of the embodiment. FIG. 11 is a plan view illustrating a storage method using the egg carton transfer robot system of the embodiment. FIG. 13 is a side view showing an operation of pulling out a shelf using the egg carton transfer robot system of the embodiment. FIG. 13 is a side view showing an operation of pulling out a shelf using the egg carton transfer robot system of the embodiment. FIG. 2 is a diagram corresponding to FIG. 1 and illustrating a modified example of the present invention. FIG. 9 is a side view of FIG. 8 . FIG. 10 is a view corresponding to FIG. 1 and showing another modified example of the present invention. FIG. 11 is a side view of FIG. FIG. 4 is a diagram corresponding to FIG. 3 and showing a modified example of the present invention.

Below, an example of an egg pack transfer robot system 10 according to an embodiment will be described with reference to Figures 1 to 7. The egg pack transfer robot system 10 transfers multiple transported egg packs P onto a mobile rack (hereinafter referred to as a "roll inner R").

The roll inner R comprises multiple foldable shelves R1. The shelves R1 can be changed between a use state where they are pulled out to the front and a storage state where they are folded and positioned at the back. Above each shelf R1 in the use state, a storage space R2 is formed in which egg packs P are stored. Egg packs P are stacked one above the other in the storage space R2. The roll inner R further comprises a fence R3 arranged around the shelf R1, a spill guard R4 provided on the side edge of the shelf R1, a shelf support (not shown) provided inside the fence R3, and casters (not shown).

Egg cartons P come in a variety of sizes and shapes. The figure shows a 10-egg carton P called a "flat pack," which has a flat top surface P1. The egg carton P has protrusions P2 on the top surface. The protrusions P2 are provided, for example, at each corner of the top surface P1. The protrusions P2 prevent the egg cartons P stacked on top from shifting out of position.

The egg carton transfer robot system 10 comprises a robot head 1, a robot arm 2, and a control unit 3.

The robot head 1 includes a gripping unit 11. The gripping unit 11 grips multiple egg packs P. The gripping unit 11 can hold, for example, three egg packs P that are adjacent in the horizontal direction. The gripping unit 11 is composed of multiple suction members 12. Each suction member 12 suctions the top surface P1 side of the egg pack P with the lid closed. Each suction member 12 is connected to a vacuum mechanism (not shown). Each suction member 12 has a bellows structure that can expand and contract in the vertical direction. Each egg pack P is held by multiple suction members 12 (for example, six). Note that each egg pack P may be held by four suction members 12, and any arrangement of the suction members 12 may be used as long as the adsorbed egg pack P does not tilt more than necessary.

The robot arm 2 is capable of changing the position and posture of the robot head 1. The robot arm 2 moves the robot head 1 between the temporary waiting area 8 and the roll inner R. The robot arm 2 may be a conventional multi-joint robot that can be operated arbitrarily, such as a six-axis vertical multi-joint robot. In addition, the robot arm 2 may be a variety of robots or devices that can move the robot head 1 arbitrarily along the X-axis, Y-axis, and Z-axis. The temporary waiting area 8 is provided downstream of the conveying device 9, and a packaging device (not shown) that places eggs in packs is located upstream of the conveying device 9.

The control unit 3 controls the movements of the robot head 1 and the robot arm 2. The control unit 3 is composed of a dedicated computer or a general-purpose computer, including a CPU, internal memory, an input/output interface, and an AD conversion unit. The functions of the control unit 3 are fulfilled by the cooperation of the CPU and its peripheral devices according to the program stored in the internal memory.

The control unit 3 moves the egg pack P held by the gripping unit 11 into the space below the foldable shelf R1 provided on the roll inner R. The control unit 3 positions the tip 21 of the robot arm 2 at a location shifted toward one end in the longitudinal direction from the center of gravity of the egg pack P held by the gripping unit 11, and moves the egg pack P. The control unit 3 moves the egg pack P so as to avoid interference between the egg pack P held by the robot head 1 and an obstacle. Here, an "obstacle" is, for example, a protrusion P2 provided on an egg pack P previously stacked on the roll inner R, or a folded shelf R1 that exists above the space where multiple egg packs P are stacked. The control unit 3 also unfolds the foldable shelf R1.

Next, an example of a storage method using the egg carton transfer robot system 10 will be described. First, the roll inner R is placed within the range that the robot head 1 can reach. The roll inner R has the shelf R1 on which the egg cartons P are transferred in a usable state, and the shelf R1 above it is in a stored state.

In the conveying device 9, egg packs P conveyed from the upstream side are collected in the temporary waiting area 8. When, for example, three egg packs P are gathered in the temporary waiting area 8, the transfer operation is started.

First, the control unit 3 moves the robot head 1 above the collected egg packs P. At that time, the control unit 3 positions the tip 21 of the robot arm 2 at a position shifted toward one end in the longitudinal direction from the center of gravity of the egg pack P gripped by the gripping unit 11. The robot head 1 is also positioned at a predetermined location on the egg pack P to grip the egg pack P. Specifically, the tip 21 of the robot arm 2 has a rotation center positioned at a position shifted from the center of gravity of the egg pack P. The tip 21 of the robot arm 2 and the robot head 1 are positioned above the egg pack P. The underside of the robot head 1 is equipped with a gripping unit 11 that adsorbs a portion of the egg pack P containing 10 eggs, corresponding to six eggs from the longitudinal direction, on the upper surface of the egg pack P. In other words, the robot head 1 supports the egg pack P in a cantilevered state.

The control unit 3 then moves the egg pack P grasped by the robot head 1 to the storage space R2 in the inner roll R. The control unit 3 slides the egg pack P to avoid interference between the egg pack P grasped by the robot head 1 and an obstacle.

Then, as shown in FIG. 3, the lower end of the moved egg pack P is positioned inside the protrusion P2 of the lower tier. The control unit 3 releases its grip on the egg pack P.

The storage space R2 inside the roll inner R, through which the egg packs P are moved, includes a space (the back space) surrounded by the top surfaces of the previously stacked egg packs P and the bottom surfaces of the shelves R1 in the stored state. As shown in FIG. 4, when moving the egg packs P to the back space, the tip 21 of the robot arm 2 and the robot head 1 are positioned on the side away from the back fence R3 (the front side). The egg packs P are then placed vertically in the back space.

In addition, when the egg packs P are moved to the storage space R2 in the inner roll R in which the egg packs P are placed sideways, the tip 21 of the robot arm 2 and the robot head 1 are positioned on the side away from the side fence R3 (towards the center), as shown in FIG. 5.

After transferring one level of the shelf R1, the control unit 3 unfolds the foldable shelf R1 as shown in Figures 6 and 7. That is, the foldable shelf R1 is unfolded from the stored state to the used state using the same robot head 1 used when transferring the egg cartons P. Specifically, the control unit 3 unfolds the foldable shelf R1 by having the gripper 11 adsorb the shelf R1 and then moving the robot head 1 forward in that state. The shelf R1 in the stored state covers only a portion of the upper part of the lower storage space R2, while the unfolded shelf R1 in the used state covers the entire upper part of the lower storage space R2.

As described above, the egg pack transfer robot system 10 according to this embodiment includes a robot head 1, a robot arm 2, and a control unit 3. The robot head 1 includes a gripping unit 11 that grips an egg pack P. The robot arm 2 is capable of changing the position and posture of the robot head 1. The control unit 3 controls the movement of the robot head 1 and the robot arm 2. The control unit 3 also moves the egg pack P gripped by the gripping unit 11 to the space below a foldable shelf R1 provided on the roll inner R. This solves the problems with the conventional technology and allows the egg pack P to be automatically transferred to a mobile rack.

The control unit 3 positions the tip 21 of the robot arm 2 at a location shifted toward one end in the longitudinal direction from the center of gravity of the egg pack P gripped by the gripping unit 11, and moves the egg pack P. The control unit 3 also moves the egg pack P so as to avoid interference between the egg pack P gripped by the robot head 1 and the protrusions P2 and shelf boards R1 on the egg packs P previously loaded on the inner roll R. Therefore, even in the special situation of loading egg packs P onto the inner roll R, automation is possible.

The control unit 3 unfolds the foldable shelf R1, making it possible to load multiple shelves R1 using a single robot.

The storage method using the egg pack transfer robot system 10 includes the steps of placing the inner roll R within the reach of the robot head 1, positioning the robot head 1 at a predetermined location on the egg pack P to grasp the egg pack P, moving the egg pack P grasped by the robot head 1 into space, and positioning the lower end of the moved egg pack P inside the protrusion P2 of the lower tier. This storage method solves the problems of the conventional technology and allows the egg packs P to be automatically transferred to the inner roll R. In addition, the stacked egg packs P can withstand the movement of the inner roll R without significant misalignment.

Note that the present invention is not limited to the above-described embodiments.

The arrangement of egg packs P in the inner roll R is not limited to that shown in the figure. For example, egg packs P may be arranged vertically on the front side of the inner roll R in the same way as on the back side.

The gripping unit 11 is not limited to the suction type. For example, the robot head 1 shown in Figs. 8 and 9 has a gripping unit 13 that grips an egg pack P from the side. The gripping unit 13 grips an egg pack P containing 10 eggs by wrapping around almost the entire egg pack P along the longitudinal direction. The gripping unit 13 releases the gripping state by retreating to the position shown by the two-dot chain line in Fig. 9.

10 and 11, the robot head 1 is provided with a gripping unit 14 that grips the egg pack P from above and below. The gripping unit 14 grips the egg pack P containing 10 eggs by wrapping almost the entire egg pack P along the longitudinal direction. Specifically, the gripping unit 14 is provided with a support member 15 and a cooperating member 16. The support member 15 is arranged on the underside of the egg pack P. The support member 15 is, for example, rod-shaped, and is arranged in a recess P3 on the underside that has unevenness according to the shape of the eggs, and is contained within the recess P3. The cooperating member 16 cooperates with the support member 15 to prevent the egg pack P from tilting or swaying significantly. The cooperating member 16 is, for example, plate-shaped, and is arranged on the top surface P1 of the egg pack P. The shape and location of the cooperating member 16 are not limited to those shown in the figures. The gripping state is released by retreating to the position shown by the two-dot chain line in FIG. 11, for example. Also, as shown in FIG. 10, the tip 21 of the robot arm 2 may be located to the side of the egg carton P.

Even if the gripping portion 11 is of the suction type, the shape, number, and arrangement of the suction members 12 are not limited to those shown in the figure. It is preferable that the suction members 12 have a shape, number, and arrangement that can prevent the egg pack P from tilting or swaying significantly.

The egg packs P are not limited to flat packs. For example, as shown in FIG. 12, they may be "regular packs" in which the lid has projections and recesses formed to conform to the shape of the eggs. In the case of regular packs, the lower and upper tiers are stacked with a shift of half an egg. The protrusions P2 are convex parts provided on the lid that conform to the shape of the eggs. The protrusions P2 prevent the egg packs P stacked on top from shifting out of position. Furthermore, the egg packs P are not limited to packs containing 10 eggs.

The step of unfolding the foldable shelf R1 may be performed using a device other than the robot that transfers the egg cartons P.

The embodiments disclosed herein are illustrative and are not intended to be limiting. The present invention is defined by the claims rather than the scope described above, and is intended to include all modifications within the meaning and scope of the claims.

The present invention can be used in an egg carton transfer robot system that transfers egg cartons to a mobile rack, and in a storage method using the same.

10... Egg pack transfer robot system 1... Robot head 11, 13, 14... Gripper 2... Robot arm 3... Control unit P... Egg pack R... Roll inner (mobile rack)
R1: Foldable shelf R2: Storage space

Claims (2)

A robot head having a gripper that horizontally grips an egg carton;
a robot arm capable of changing the position and posture of the robot head;
A control unit is provided for controlling the movement of the robot head and the robot arm,
The control unit moves the egg pack horizontally held by the gripping unit to a storage space above the egg packs previously stacked on a movable rack,
The egg carton transfer robot system further moves the egg carton horizontally toward the space below the foldable shelf board in the stored state provided on the mobile rack. The egg pack transfer robot system of claim 1, wherein the control unit moves the egg pack by positioning the tip of the robot arm at a location shifted toward one end in the longitudinal direction from the center of gravity of the egg pack gripped by the gripping unit.

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