WO2018028030A1 - 一种自动装箱方法及自动装箱机械手 - Google Patents

一种自动装箱方法及自动装箱机械手 Download PDF

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Publication number
WO2018028030A1
WO2018028030A1 PCT/CN2016/100714 CN2016100714W WO2018028030A1 WO 2018028030 A1 WO2018028030 A1 WO 2018028030A1 CN 2016100714 W CN2016100714 W CN 2016100714W WO 2018028030 A1 WO2018028030 A1 WO 2018028030A1
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WO
WIPO (PCT)
Prior art keywords
tray
standard
box
conveying device
standard box
Prior art date
Application number
PCT/CN2016/100714
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English (en)
French (fr)
Inventor
杨晖伟
Original Assignee
杨晖伟
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Filing date
Publication date
Application filed by 杨晖伟 filed Critical 杨晖伟
Publication of WO2018028030A1 publication Critical patent/WO2018028030A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G57/00—Stacking of articles
    • B65G57/02—Stacking of articles by adding to the top of the stack
    • B65G57/16—Stacking of articles of particular shape
    • B65G57/20—Stacking of articles of particular shape three-dimensional, e.g. cubiform, cylindrical
    • B65G57/22—Stacking of articles of particular shape three-dimensional, e.g. cubiform, cylindrical in layers each of predetermined arrangement
    • B65G57/24—Stacking of articles of particular shape three-dimensional, e.g. cubiform, cylindrical in layers each of predetermined arrangement the layers being transferred as a whole, e.g. on pallets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G61/00—Use of pick-up or transfer devices or of manipulators for stacking or de-stacking articles not otherwise provided for

Definitions

  • the invention relates to the field of conveying and packaging, in particular to an automatic packing method and an automatic packing manipulator.
  • the technical problem to be solved by the present invention is to provide a method for automatically loading a standard box having a uniform specification into a container or a container box, and a structurally reliable automatic boxing robot.
  • the present invention adopts the following technical solutions:
  • An automatic packing method comprising the following steps
  • Step 1 the standard boxes are individually entered into the tray of the automatic packing robot
  • Step 2 pushing each standard box on the infeed tray one by one to the left or right until the standard box is horizontally filled with the tray; the tray is horizontally full enough to accommodate two standard boxes;
  • Step 3 moving the tray and unboxing a plurality of standard boxes that are horizontally filled on the tray to the pallet position.
  • step 1 there is also an automatic packing robot entering the container to be loaded and performing automatic positioning:
  • the tray touches the front wall of the container box and then returns to the length of one standard box plus the distance of the total width of the tray to complete the automatic positioning.
  • the center line of the standard box is aligned with the center line of the tray one by one into the tray; in the step 2, the horizontal pushing initial The position is that the center line of the tray is offset to the left or right by half the width of one standard box;
  • step 1 When the number of standard boxes filled with trays is even, in step 1, one side of the standard box enters the tray one by one corresponding to the center line of the tray; in the step 2, the initial position of the horizontal push is the center line of the tray Offset the width of a standard box to the left or right;
  • Each standard box on the entry tray is alternately pushed horizontally to the left or right by a standard box width; when the horizontal position of the horizontal push is located on the right side of the center line of the tray, the odd-numbered horizontal push is pushed to the left, and the horizontal direction is pushed evenly Right push; when the horizontal position of the horizontal push is located on the left side of the center line of the tray, the odd cross push is pushed to the right, and the horizontal push is pushed to the left even times.
  • center line of the standard box is transported on the conveying device corresponding to the center line of the tray;
  • the standard boxes are directly entered into the trays one by one by the conveying device;
  • the standard boxes filled with trays are corrected one by one to the left or right on the conveying device by half the width of one standard box, so that the same side of the standard box corresponds to the center of the tray
  • the lines enter the tray one by one.
  • step 3 the trays filled with the standard box are first placed by the lifting, moving back and forth to the position to be palletized;
  • the rear wall of several standard boxes that are horizontally packed on the tray is integrally supported, and the tray is retracted until all the standard boxes on the tray are separated from the tray to the pallet position.
  • An automatic packing manipulator comprises a PLC control system and a frame, a conveying device, a tray and a moving system working together under the control of the PLC system; a driving device is arranged on the base of the frame, and the standard box is transported to the tray
  • the conveying device is disposed in the frame, and the front of the conveying device is provided with a tray which can be horizontally filled with two standard boxes or more, and the tray is connected to a moving system capable of driving up and down and moving back and forth;
  • the robot hand is provided with a dispensing device that can push the standard boxes delivered thereto one by one to the tray;
  • the robot hand is provided with a horizontal pushing device capable of pushing each standard box conveyed onto the tray one by one to the left or right until the horizontally filling the tray; the robot hand is further provided with the horizontally full tray A number of standard boxes are integrally taken out of the unpacking device of the tray.
  • the front end of the tray is provided with a driving sensor for realizing automatic positioning of the automatic packing robot.
  • the conveying device is divided into a second acceleration section adjacent to the rear end of the tray and a standard tank to which the outer conveying device can be transported, and can transport one of the standard boxes at intervals To the first acceleration segment on the second acceleration segment.
  • the tray is laterally divided into a middle portion of the tray, a left end of the tray, and a right end of the tray; a middle of the tray that is butted with the conveying device is provided with a pushing box gap along the length of the tray; and the horizontal pushing device is disposed below the tray
  • the utility model comprises a horizontal push box power mechanism, wherein the output end of the horizontal push box power mechanism is connected with a push box rod which pushes the standard box in the push box gap to reciprocate the upper side of the tray, and the horizontal push box power mechanism is connected.
  • the horizontal pushing and lowering mechanism that can drive the push rod rod repeatedly over/retract the upper surface of the tray.
  • a plurality of second rollers disposed along the longitudinal direction of the tray are arranged side by side, and the push box gap is left between the second rollers, and the third end of the tray and the right end of the tray are arranged in a plurality of thirds in the longitudinal direction of the tray.
  • the rollers are made side by side.
  • the conveying direction of the vertical conveying device on the conveying device is provided with a correcting gap
  • the conveying device is provided with a correcting device below
  • the correcting device includes a correcting power mechanism, and the output end of the correcting power mechanism is connected from the correcting gap
  • the dialing member of the standard box is pushed out and reciprocated left and right in the correcting gap.
  • the center line of the conveying device is the same axis or a parallel line with the center line of the tray.
  • the conveying device is divided into a second acceleration section adjacent to the rear end of the tray and a standard box to which the outer conveying device can be transported, and can transport one of the standard boxes to the second at a time.
  • a first acceleration segment on the acceleration segment, the correction direction is perpendicular to the second acceleration segment, and the correction device is disposed below the second acceleration segment.
  • the second acceleration section is a drum conveyance, comprising a plurality of first rollers disposed in a vertical second acceleration section conveying direction, and the correction gap is disposed between the plurality of first rollers.
  • the distributing device comprises two distribution racks symmetrically arranged vertically on the left and right sides of the conveying device, each of the distribution racks having four end points which can be connected in a rectangular shape, and a first sprocket is arranged at each end point.
  • the two transmission chains respectively fit the four first sprocket wheels on each of the distribution frames to form a rectangular frame, wherein at least one of the first sprocket wheels is a driving wheel that can drive the transmission chain to rotate clockwise, the first distribution bar and the second distribution
  • the rod divides the transmission chain into two equal parts, and the distribution device is positionally interchangeable and horizontally connected between the two transmission chains.
  • the conveying device is divided into a second acceleration section adjacent to the rear end of the tray and a standard tank to which the outer conveying device can be transported, and can transport one of the standard boxes to the second one at a time.
  • a first acceleration section on the acceleration section, the distribution device being disposed at the second acceleration section.
  • a left left baffle and a right baffle are respectively disposed at a rear end of the tray and a rear end of the right end of the tray, and a channel between the left baffle and the right baffle is allowed to pass through the standard box;
  • the decoupling device comprises two second front and rear moving devices respectively connected to the left baffle and the right baffle, and the second front and rear moving device on the left side is provided with a left tail which can be repeatedly extended to the right and retracted at the right end.
  • the box mechanism, the left unboxing mechanism is located in front of the left baffle, and the left end is flush with the left end of the tray; the second front and rear moving device on the right side is provided with a right unboxing mechanism that can repeatedly extend to the left and retract the left end.
  • the right unboxing mechanism is located in front of the right baffle, and the right end thereof is flush with the right end of the tray; when the right end of the left unboxing device is opposite to the left end of the right unboxing mechanism, the unboxing device is as long as the tray, and the left is off When the left end of the box device and the left end of the right unboxing mechanism are retracted, the standard box can be passed.
  • the left out of the box mechanism includes a left fixed rod fixed to the second front and rear moving device on the left side, the left fixed rod is fixed with a left cylinder that can protrude to the right; the right out of the box is fixed to the right A right fixing rod on the second front and rear moving device on the side, and a right cylinder protruding to the left of the cylinder rod is fixed on the right fixing rod.
  • the mobile system includes a first front and rear moving device that can drive the tray to move back and forth, and a main lifting system that drives the tray to move up and down; the main lifting system is provided with a main lifting power device and a main lifting power transmission mechanism, and the first front and rear moving device
  • the first forward and backward moving device and the main lifting and lowering mechanism are two groups arranged on the left and right sides of the conveying device and connected to the two sides of the tray for synchronous movement.
  • each of the first front and rear moving devices includes a front and rear moving drive mechanism and a horizontal T-shaped bracket repeatedly extended and retracted under the driving thereof, and the horizontal T-shaped bracket includes a vertical rod and a transverse direction connected with the middle portion of the vertical rod a telescopic arm; the tray is connected to the vertical rod by a connecting member;
  • the top left and right sides of the frame are respectively provided with a top end beam which can be rotated forward/reversely around the axis of the main body under the driving of the main lifting power device, and the top end beam is disposed parallel to the advancing direction of the standard box, and the main lifting power transmission mechanism
  • the top of the main beam is connected to the top beam, and the telescopic arm connected to the bottom end of the main lifting power transmission mechanism rises or falls with the forward rotation of the top beam.
  • one end of the connecting member is fixed to the tray, and the other end is vertically movable and can be positioned and connected to the vertical rod on the vertical rod.
  • the upper end of the vertical rod is provided to prevent the connecting member from sliding when it is located at the upper end of the vertical rod.
  • First tray limit device, lower end of the vertical rod A second tray limiting device is provided for preventing the connecting member from sliding downwardly from the vertical rod.
  • the middle portion of the vertical rod is provided with a third tray limiting device for ensuring that the upper surface of the tray is flush with the upper surface of the conveying device.
  • the main lifting power transmission mechanism comprises a second sprocket fixed on the top cross beam and rotating synchronously with the top cross beam, and further comprising: adapting the second sprocket and connecting on the horizontal T-shaped bracket to drive the horizontal T-shaped bracket to repeatedly rise/fall The second chain; the main lifting power device is disposed between the left and right side cross beams, and the output end thereof can drive the left and right side cross beams to rotate in the opposite direction at the same speed.
  • the rack is further provided with a tray parking platform, and the upper surface of the tray parked on the tray parking platform is flush with the upper surface of the conveying device.
  • the automatic boxing mechanical method of the present invention adopts an automatic packing manipulator, so that the standard boxes are successively entered into the tray of the automatic packing robot, and each standard box entering the tray is horizontally left or right. Push until the horizontally full tray, move the tray and unbox the trays of several standard boxes to the pallet position; it can completely replace the labor, save manpower, fast packing speed and high efficiency.
  • the automatic loading robot has a driving device, which can drive the automatic packing robot to easily enter the container box to be loaded, and can adjust the position in the container box; the distribution device of the robot enables the standard box to enter the tray one by one accurately;
  • the horizontal pushing device arranges each standard box entering the tray one by one until the whole tray is filled, and the moving system that controls the front and rear movement of the tray moves the tray filled with the standard box to a predetermined position in the container box;
  • the unboxing device can smoothly push the standard box filled on the tray to the tray at a time to place it in a predetermined position;
  • the PLC control system has a display screen and an arithmetic system, and inputs the container box to be loaded on the display of the PLC control system.
  • the PLC control system automatically calculates the number of standard boxes that can be horizontally arranged on the tray according to the input data, automatically adjusts the initial position of the correction, the correction distance, the horizontal position of the horizontal push and the horizontal push.
  • the number of push boxes to the left or right of the box device, and the standard box code scheme can be input in the display, and each adjustment is made by the PLC control system. Coordination between the operation member, the overall standard automatic packing boxes, packing replace the manual, saving manpower.
  • the manipulator is also provided with a correcting device.
  • the correcting device pushes the standard boxes on the conveying device one by one to the center line of the corresponding tray of the center line to enter the tray, when the horizontal line is full
  • the correcting device pushes the standard boxes on the conveying device one by one to the center line of the corresponding tray on the same side of the standard box, and ensures that all the standard boxes required for filling the tray can smoothly enter the tray. in.
  • Figure 1 is a schematic view of the automatic packing robot and the container box to be loaded
  • Figure 2 is a schematic view of the standard box loading tray
  • Figure 3 is a schematic view of the overall structure of the automatic boxing robot
  • Figure 4 is a schematic diagram of the distribution of the automatic boxing robot sensor
  • Figure 5 is a schematic view of the dispensing device
  • Figure 6 is a schematic diagram of the correcting device
  • Figure 7 is a side view of the tray and mobile system settings
  • FIG. 8 is a schematic layout of the tray
  • FIG. 9 Schematic diagram of the horizontal push box
  • Figure 10 is a schematic diagram of the tray and the unboxing device
  • Figure 11 is a schematic view showing the state when the left unboxing device and the right unboxing device are extended and connected to each other.
  • Figure 12 is a schematic view showing the state in which the standard box is detached from the tray by the unboxing device
  • Figure 13 is a schematic view of the standard box being palletized below the bottommost position of the main lifting system.
  • Figure 14 is a schematic view of the standard box code ⁇ to the top position of the main lifting system.
  • Figure 15 is a schematic view of the operation of the lateral pushing device when the tray is filled with an even number of standard boxes.
  • Figure 16 is a schematic view of the operation of the lateral pushing device when the tray is filled with an odd number of standard boxes.
  • the direction in which the standard box 9 advances is defined as the front, and the left and right are left and right as shown in the drawing.
  • the front and rear walls of the standard box 9 are defined as the length of the standard box 9, and the left and right sides of the standard box 9 are defined as the width of the standard box 9, and the center line of the standard box 9 can divide the standard box 9 into two equal parts;
  • the front and rear of the tray 3 are defined as the width of the tray 3, and the left and right ends of the tray 3 are defined as the length of the tray 3, and the center line of the tray 3 can divide the tray 3 into two equal parts.
  • an automatic loading manipulator 100 includes a frame 1 with a driving device 18 at the bottom, and a conveying device 2 is arranged in the frame 1 , and a front side of the conveying device 2 is provided
  • the tray 3 is not horizontally filled with not less than two standard boxes 9, and the tray 3 is connected to the moving system 4 which can move up and down and back and forth; the rear end of the conveying device 2 can be docked with the front end of the outer conveying device 200, and the outside
  • the standard box 9 transported by the transport device 200 to the transport device 2 is pushed into the tray 3 one by one.
  • the rack 1, the transport device 2, the tray 3, and the mobile system 4 are electrically connected by a PLC control system (not shown).
  • a driving sensor 39 is provided at the front end of the tray 3.
  • the driving sensor 39 is a contact sensor, and the manipulator retreats a certain distance when the driving sensor 39 touches the front wall of the container box 7 (preferably the distance of returning the length of one standard box 9 plus the total width of the tray 3) ) achieve automatic positioning.
  • the tray 3 is preferably rectangular.
  • the outer transfer device 200 is a telescopic conveyor belt, and a movable lifting device 5 is disposed under the frame 1 to adjust the position and height of the lifting device 5 to automatically pack the robot 100. Adjusted to be flush with the bottom surface of the container box 7 to be loaded, the driving device 18 is operated, the telescopic outer conveying device 200 is gradually elongated, and the automatic packing robot 100 enters the container box 7.
  • the frame 1 includes a base 11 disposed under the conveyor 2, and the driving device 18 (the wheel with the power system in this embodiment) is disposed under the base 11 to drive the automatic boxing robot 100 to move.
  • the center line of the conveying device 2 and the center line of the tray 3 are the same axis or parallel lines, and the conveying direction of the vertical conveying device 2 on the conveying device 2 is provided with a correction gap 232, and the conveying device 2 is provided with a deviation correction
  • the device 24 includes a correcting power mechanism 243.
  • the output end of the correcting power mechanism 243 is connected with a dialing member that passes through the correcting gap 232 and can reciprocate left and right in the correcting gap 232 to push the standard box 9. 241.
  • the correcting device 24 pushes the standard boxes 9 on the conveying device 2 one by one to the center line of the tray 3 corresponding to the center line thereof, when the number of the standard boxes 9 that are horizontally filled with the trays 3 is even.
  • the correcting device 24 pushes the standard boxes 9 on the conveying device 2 one by one to the center line of the corresponding tray 3 on the same side of the standard box 9.
  • the conveying device 2 is sequentially divided into an adjacent first acceleration section 22 and a second acceleration section 23 from the rear to the front; the standard by which the first acceleration section 22 can transport the outer conveying device 200 thereto
  • the tank 9 is temporarily stored, and one of the standard tanks 9 can be transported to the second accelerating section 23 at a time; the correcting gap 232 is perpendicular to the conveying direction of the second accelerating section 23, and is disposed on the second accelerating section 23, and the correcting device 24 is disposed below the second acceleration section 23.
  • the center line of the conveying device 2 and the center line of the tray 3 are the same axis, and the outer conveying device 200 feeds the center line of the standard box 9 to the conveying device 2 corresponding to the center line of the conveying device 2, the correcting deviation
  • the device 24 is activated when the tray 3 requires an even number of standard boxes 9 to be full, and the standard box 9 running on the center line of the second acceleration section 23 pushes half of the width of the standard box 9 one by one (ie, the correcting distance).
  • the initial position means that half of the width of the standard case 9 is shifted leftward or rightward from the center line of the second acceleration section 23, and can be adjusted within the width of the second acceleration section 23.
  • the second acceleration section 23 is a roller conveyor, and includes a first roller 231 disposed in a plurality of vertical second acceleration sections 23 in a conveying direction, and a plurality of first rollers 231 are provided with a correction gap.
  • the dialing member 241 in the working state of the correcting device 24, can move to the left or right by the standard box 9 passing through the center of the second accelerating section 23, so that the standard box 9 moves to the left or right of the center line of the conveying direction.
  • the width of the box 9 is half.
  • the dial member 241 is screwed to the first ball screw 242 by left and right movements through the adapted dial holder, and the first ball screw 242 with the correcting power mechanism 243 is located at the first roller 231.
  • the lower, parallel first roller 231 is disposed.
  • the dialing member 241 can also be fixed and fixed on the sliding screw, the linear cylinder, etc., as long as the lever 241 can push the standard box 9 to the left or right to move the correction distance, and return to the initial position of the correction immediately after pushing the standard box 9. Just fine.
  • the robot is also provided with a dispensing device 25 that ensures that only one standard bin 9 enters the tray 3 at a time, preventing the standard bin 9 entering the tray 3 from being crowded or being squeezed out of the tray 3.
  • the distribution device 25 is formed in a frame shape disposed on the left and right sides of the second acceleration section 23 and is fixed to the frame 1 , and includes two vertically disposed distribution frames 251 , two transmission chains 252 , and The first distribution rod 253 and the second distribution rod 254.
  • Two distribution frames 251 are symmetrically disposed on the left and right sides of the second acceleration section 23.
  • the distribution frame 251 has four end points that can be connected in a rectangular shape, and each end point is provided with a first sprocket 255, and one transmission chain 252 is suitable.
  • the four first sprocket 255 on one distribution frame 251 forms a rectangular frame, wherein at least one first sprocket 255 is a driving wheel that can drive the transmission chain 252 to rotate clockwise, and the first distribution bar 253 and the second distribution bar 254 Horizontally connected between the two transmission chains 252, the first distribution rod 253 and the second distribution rod 254 divide the transmission chain 252 into two equal parts, that is, the transmission chain 252 runs for half a cycle, the first distribution rod 253, the first The positions of the two distribution rods 254 are interchanged.
  • a distribution sensor 256 that senses the passage of the standard box 9 is also disposed on the distribution frame 251.
  • the second distribution rod 254 is located at one end of the near tray 3 and at the lower end of the vertical portion of the transmission chain 252 (at A in FIG. 5).
  • the standard box 9 placed on the second acceleration section can be blocked from entering the tray 3.
  • the first distribution rod 253 is located at one end of the far tray 3, the upper part of the vertical portion of the transmission chain 252 (B in Fig. 5), the device to be dispensed
  • the second distribution rod 254 is moved upward to release the standard tank 9 on the second acceleration section 23, and the standard tank 9 on the second acceleration section can be pushed into the tray 3 when the first distribution rod 253 is horizontally moved forward.
  • the distribution frame 251 can be a shape that is easy to process, such as an I-shape, a rectangle, etc., and is rectangular in this embodiment.
  • the opening, stopping and conveying speeds of the outer conveying device 200, the first acceleration section 22 and the second acceleration section 23 can be individually controlled.
  • a support frame (not shown) fixed to the base 11 and capable of supporting the horizontal operation of the conveying device 2.
  • the conveying device 2 can also be a non-segmented unit, by adjusting the conveying speed of the conveying device 2 or other conventional means in the prior art, as long as it is ensured that only one standard tank 9 enters the dispensing device 25 at a time.
  • the range can be assigned.
  • the tray 3 is connected to the moving system 4, and is disposed in front of the conveying device 2 so as to be movable up and down and back and forth.
  • the moving system 4 includes a first front and rear moving device that can drive the tray 3 to move back and forth, and
  • the main lifting system 43 for driving the tray 3 up and down, the main lifting system 43 includes a main lifting power device 431 and a main lifting power transmission mechanism, and the first front and rear moving device is connected to the main lifting and lowering mechanism to synchronously move up and down with the main lifting and lowering mechanism.
  • the first front and rear moving device and the main lifting and lowering mechanism are two groups disposed on the left and right sides of the conveying device 2 and connected to the two sides of the tray 3 for synchronous movement.
  • each of the first front and rear moving devices includes a front and rear moving drive mechanism 413 and a horizontal T-shaped bracket 41 repeatedly extended and retracted under the driving thereof.
  • the horizontal T-shaped bracket 41 includes a vertical rod 412 and a vertical rod
  • the transverse telescopic arm 411 is connected to the middle portion 412; the tray 3 is detachably connected to the vertical rod 412 by a connecting member 42.
  • One end of the connecting member 42 is fixed to the tray 3, and the other end is vertically movable and can be locatingly connected to the vertical rod 412 on the vertical rod 412.
  • the upper end of the vertical rod 412 is provided with the connecting member 42 at the upper end of the vertical rod 412.
  • the first tray limiting device 4121 that slides down, the lower end of the vertical rod 412 is provided with a second tray limiting device 4122 for preventing the connecting member 42 from sliding downwardly from the vertical rod 412, and the middle portion of the vertical rod 412 is provided with the upper surface of the securing tray 3
  • a third tray stopper 4123 that is flush with the upper surface of the conveying device 2.
  • the main lifting system, the first front and rear moving device and the connecting member 42 cooperate to drive the tray 3 between the bottom surface of the container box 7 and the lowest end of the main lifting system 43, and at the highest end of the main lifting system 43 and the container box 7.
  • a standard box 9 is placed between the top surfaces.
  • the top left and right sides of the frame 1 are respectively provided with a top end beam 121 which can be rotated forward/reversely around the axis of the main driving device 431, and the top end beam 121 is parallel to the advancement of the standard box 9.
  • the top of the main lifting power transmission mechanism is disposed on the top end beam 121, and the bottom end can drive the horizontal T-shaped bracket 41 to move up and down with the telescopic arm 411.
  • the main lifting power transmission mechanism is fixed on the top end beam 121.
  • the main lifting power The device 431 is disposed between the left and right top end beams 121 by the prior art. When the main lifting power device 431 is in operation, the top end beams 121 on both sides are reversely rotated at the same speed.
  • the telescopic arm 411 is sleeved with a sliding seat 414, and the front and rear moving driving mechanism 413 mounted on the sliding seat 414 can drive the horizontal T-shaped bracket 41 to retract and retract under the command of the PLC control system, and the second chain 433
  • the end of the sliding seat 414 is connected to the telescopic arm 411.
  • the connection of the sliding seat 414 to the telescopic arm 411 may be a screw nut pair or a rack and pinion pair, or may be a chain drive or a synchronous belt drive.
  • a timing belt is preferably used. transmission.
  • the main lifting system 43 and the first front and rear moving device can adopt various methods such as pneumatic, hydraulic, motor, gear, and the like in the prior art, as long as the vertical up and down movement of the tray 3 can be realized.
  • the robot hand is provided with a horizontal pushing box device 31 which can vertically discharge a plurality of standard boxes 9 which are respectively conveyed onto the tray 3, and the robot hand is further provided.
  • a plurality of standard boxes 9 which are horizontally filled on the tray 3 can be completely taken out of the unboxing device 32 of the tray 3 in parallel, and a tray reset sensor 38 is disposed below the tray 3 on the frame 1 to ensure the upper tray 3 in the boxed state.
  • the surface is flush with the upper surface of the delivery device 2, preferably the tray reset sensor 38 is a proximity switch.
  • the tray 3 can be parked on the rack 1 in the boxed state.
  • the length of the tray 3 can be reasonably set according to the needs, and can be the same as the width of the container to be loaded, or half of the width of the container to be loaded, or one third of the width of the container to be loaded, as long as it can ensure no less than two
  • the standard box 9 just fills it up. In this embodiment, as shown in FIG. 8 and FIG.
  • the length of the tray 3 is the same as the width of the container box 7 to be loaded, and is divided into a middle portion 33 of the tray, a left end 34 of the tray, and a right end 35 of the tray; and the docking with the conveying device 2
  • a pushing box gap 331 is arranged on the middle portion 33 of the tray along the longitudinal direction of the tray 3; the horizontal pushing box device 31 is disposed below the tray 3, and includes a lateral pushing box power mechanism 315, and the output end of the lateral pushing box power mechanism 315 is connected high.
  • the push box rod 311 of the standard box 9 is pushed and reciprocated in the push box gap 331, and the horizontal push box power mechanism 315 is connected to the pushable push box rod 311 repeatedly over/retracting the tray 3
  • the upper surface is pushed on the lifting mechanism 312.
  • the traverse initial position of the lateral pushing device 31 can be reasonably set in the area of the middle portion 33 of the tray.
  • the horizontal pushing initial position refers to a position at which the lateral pushing device 31 is ready to push the first standard box 9 entering the tray 3.
  • the horizontal position of the lateral pushing device 31 is shifted from the middle of the tray 3 to the left or right by half the width of the standard box 9, when the standard box 9 is arranged.
  • the horizontal pushing initial position of the lateral pushing device 31 is the width of one standard box 9 moving from the center of the tray 3 to the left or right, and the horizontal position of the horizontal pushing is located on the right side of the center line of the tray 3.
  • the horizontal pushing and lowering mechanism 312 is a first linear cylinder
  • the middle portion 33 of the tray is formed by a plurality of second rollers disposed along the longitudinal direction of the tray 3, and a push box is left between the second rollers.
  • the gap 331, the lateral pushing device 31 is disposed below the second roller.
  • the push rod rod 311 is connected to the second ball screw 313 through an adapter thread that can move left and right through the base of the push rod rod, and the second ball screw 313 of the lateral push box power mechanism 315 is provided.
  • the second ball screw 313 is connected along the longitudinal direction of the tray 3, and the second ball screw 313 is connected to the cylinder rod which can be vertically expanded and contracted by the first linear cylinder.
  • the push box rod 311 extends beyond the second drum when the first linear cylinder 312 is jacked up, and can be moved left and right by the second ball screw 313 to push the standard box 9 located in the middle portion 33 of the tray to the left end 34 of the tray or the right end of the tray. 35.
  • the push box lever 311 is lowered to leave a static space of the standard box 9 until the last standard box is transported to the tray 3.
  • the tray left end 34 and the tray right end 35 are preferably formed by arranging a plurality of third rollers in the longitudinal direction of the vertical tray 3, and the resistance is small, and the standard box placed on the third roller can be easily pushed away.
  • the left baffle 342 is vertically disposed at the rear of the left end 34 of the tray, and the right baffle 352 is vertically disposed at the rear of the right end 35 of the tray, and a space between the left baffle 342 and the right baffle 352 is left.
  • the standard box 9 is adapted to pass through the passage.
  • the arrangement 32 includes two second forward and backward moving devices 323 respectively connected to the left flap 342 and the right flap 352.
  • the second front and rear moving device 323 on the left side is provided with a left end that can be repeatedly extended to the right and retracted.
  • the detaching mechanism 321 is located at the front of the left baffle 342, the left end of which is flush with the left end of the tray 3, and the second front and rear moving device 323 of the right side is provided with a left end which can be repeatedly extended to the left and retracted.
  • the right unboxing mechanism 322, the right detaching mechanism 322 is located in front of the right baffle 352, and the right end thereof is flush with the right end of the tray 3; as shown in FIG.
  • the left detachment in the process of loading the standard box 9 into the tray 3, the left detachment
  • the right end of the box mechanism 321 and the left end of the right detaching mechanism 322 are in a retracted state, that is, the conveying device 2 and the middle portion 33 of the tray are unblocked; as shown in FIG. 11, in the state of the preliminary pushing box, the right end of the left detaching mechanism 321 Extending from the left end of the right detaching mechanism 322, the two are connected, so that the detaching device 32 is equal in length to the tray 3, as shown in FIG. 12, simultaneously activating the second front and rear moving device 323 and the first front and rear moving device.
  • the box device 32 always bears against all the standard boxes 9 on the tray 3, the first front and rear moving device belt
  • the movable tray 3 is retracted, and a plurality of standard boxes 9 arranged laterally on the tray 3 are pushed all the way to the weight position.
  • the second front and rear moving device 323 is a second linear cylinder fixed to the left baffle 342 and the right baffle 352, respectively, and the left unboxing mechanism 321 includes a left fixed on the cylinder rod of the second linear cylinder on the left side.
  • the fixing rod 3211, the left end of the left fixing rod 3211 is flush with the left end of the tray 3, the right end does not exceed the right end of the left baffle 342, and the left fixing rod 3211 is fixed with a left cylinder 3212 that can protrude to the right, and the right deboxing
  • the mechanism 322 includes a right fixing rod 3221 fixed on the cylinder rod of the second linear cylinder on the right side, the right end of the right fixing rod 3221 is flush with the right end of the tray 3, the left end does not exceed the left end of the right flap 352, and the left fixing rod 3221
  • a right cylinder 3222 extending from the cylinder rod to the left is fixed, and when the left cylinder 3212 and the right cylinder 3222 are synchronously extended, the cylinder rods of the left cylinder 3212 and the right cylinder 3222 are in contact with each other.
  • the left unboxing mechanism 321 , the right detaching mechanism 322 , and the second front and rear moving device 323 may also be other conventional methods in
  • the tray parking table 36 is disposed below the tray 3 on the rack 1. After the height of the tray parking table 36 is placed on the tray 3, the tray reset sensor 38 just detects the tray 3.
  • the PLC control system has an input system, a display screen and an arithmetic system.
  • the length, width and height of the container box 7 to be loaded and the standard box 9 are input, and the PLC control system automatically calculates the tray 3 based on the input data.
  • the number of standard bins 9 that can be horizontally arranged each time, the initial position of the correcting deviation of the correcting device 24, the correcting distance, the initial position of the lateral pushing of the lateral pushing device 31, and the number of pushing the box to the left or right by the lateral pushing device 31 are automatically adjusted.
  • a standard box 9 weight scheme can also be set, and the automatic boxing robot 100 automatically performs the entire line palletizing according to the weight scheme.
  • the palletizing scheme is an arrangement scheme of the placement order of the standard boxes 9 in the container box 7.
  • the number of the trays 3 is 6 in the standard box 9.
  • the horizontal position of the lateral pushing device 31 is half of the width of the standard box 9 from the middle of the tray 3 to the right. The packing method of the robot 100 will be described.
  • Step 1 automatic positioning of the automatic boxing robot 100
  • the height of the lifting device 5 is adjusted to be flush with the bottom surface of the container box 7, the driving device 18 is activated, and the automatic loading robot 100 enters the container box 7.
  • the driving sensor 39 at the front end of the tray 3 touches the front box wall of the container box 7,
  • the automatic loading robot 100 retreats a predetermined distance, and the predetermined distance is preferably a length of one standard box 9 plus the total width of the tray 3, and the driving sensor 39 is closed;
  • Step 2 the standard box 9 is entered into the tray 3 one by one;
  • the forklift or other handling device transports the entire standard tank 9 to the rear side section of the outer conveyor 200, and adjusts the conveying speeds of the first acceleration section 22, the second acceleration section 23, and the outer conveyor 200 to coordinate the standard box 9 manually.
  • the standard tank 9 enters the middle of the conveyor 2 by the outer conveyor 200.
  • the speeds of the first acceleration section 22, the second acceleration section 23, and the outer conveyor 200 are preferably adjusted such that the outer conveyor 200 continues to operate, the first acceleration section 22 is intermittently operated, and the outer conveyor 200 sends the standard tank 9 to the first acceleration.
  • the first acceleration section 22 just transports the temporarily stored standard tank 9 to the second acceleration section 23.
  • the second distribution rod 254 of the dispensing device 25 stops at A, the first distribution rod 253 stops at B, the first acceleration section 22, the second acceleration section 23, and the outer conveyor 200 Operation, when the distribution sensor 256 senses that the first standard tank 9 passes the point B, the second acceleration section 23 continues to operate, the first acceleration section 22 stops working; the first standard tank 9 moves to the second position that is located at point A. Until the distribution rod 254 is intercepted, the sensor to be dispensed 256 senses that the standard tank 9 is intercepted by the second distribution rod 254 (the distribution sensor 256 determines that the standard tank 9 has been intercepted by the second distribution rod 254 as being intercepted from signal to no signal.
  • the distribution device 25 starts to work, the transmission chain 252 rotates clockwise, drives the second distribution rod 254 to rise first and then moves horizontally backward, the first distribution rod 253 first descends and then moves horizontally forward, and the first distribution rod 253 will be the standard box. 9 propelling the tray 3, the first distribution rod 253 stops at A, the second distribution rod 254 stops at B, and the first acceleration section 22 starts to run while the first distribution rod 253 horizontally pushes the first standard tank 9.
  • the second standard box 9 follows the first distribution rod 253 and stops on the second acceleration section 23, A first distribution of the rod 253 is located to intercept, repeat the cycle, ensure that only one standard tank 9 pushed onto the tray 3;
  • Step 3 each of the standard boxes 9 that sequentially enter the same position on the tray 3 are pushed to the left or right one by one to the horizontally filled trays 3;
  • the standard box 9 is fed into the tray 3 from the middle of the second acceleration section 23, the center line of the standard box 9 corresponds to the center line of the tray 3, and the horizontal pushing initial position of the lateral pushing box 31 is from the tray 3.
  • the middle is shifted to the right by half of the width of one standard box 9.
  • the lateral pushing device 31 stops the width of the first standard box 9 to the left and then stops after the second standard box is fed into the tray 3.
  • the push box device 31 stops the second standard box by shifting the width of one standard box to the right, and after the third standard box is fed into the tray 3, the lateral push box device 31 shifts the third standard box to the left by a standard.
  • the third standard box pushes the first standard box to continue to move one position to the left, and so on, until the fourth standard box is traversed. Thereafter, the push box lever 311 is lowered to leave a static space of the standard box 9, and the fifth standard box is transported to the tray 3, and the entire tray 3 is filled.
  • the horizontal position of the lateral pushing device 31 is a standard box moving from the center of the tray 3 to the right.
  • the width of 9, the one side of the standard box 9 (the left side of the standard box 9 in this embodiment) is fed into the tray 3 along the center line of the second acceleration section 23, and the lateral pushing device 31 is laterally pushed as shown in FIG. Box process.
  • the horizontal pushing device 31 stops the first standard box 9 by shifting the width of one standard box to the left, and after the second standard box is fed into the tray 3, the lateral pushing unit 31 shifts the second standard box to the right.
  • the lateral pushing device 31 pushes the third standard box to the left. Move the width of a standard box. During the movement of the third standard box to the left, the third standard box pushes the first standard box to continue moving to the left one box, leaving a standard box of static space, 4th The standard boxes are transported onto the tray 3, and the entire tray 3 is filled.
  • Step 4 moving the tray 3 and pushing a plurality of standard boxes 9 horizontally full on the tray 3 to the pallet position;
  • the main lifting system 43 drives the tray 3 up by a suitable distance (to prevent the friction between the tray 3 and the tray parking table 36 from causing the standard box 9 to fall, preferably 10 cm), before the telescopic arm 411 Stretching, the tray 3 is moved forwardly out of the tray parking table 36.
  • the front end of the tray 3 is adjacent to the front box wall of the container box 7 or the side wall of the first column of the standard standard box 9.
  • the main lifting system 43 drives the telescopic arm 411 and is equipped with The tray 3 of the standard box 9 is lowered to the bottom of the container box 7 or above the standard box 9 which has been palletized;
  • the second front and rear moving device 323 and the first front and rear moving device are activated, and the unboxing device 32 always holds all the standard boxes 9 on the tray 3 as a whole, and the telescopic arm 411 is retracted, and the tray 3 is driven back until the standard box 9 is completely Get out of the tray 3.
  • the main lifting system 43 drives the horizontal T-shaped bracket 41 and the tray 3 to rise above the tray parking table 36 by a suitable distance (preferably 10 cm), and the tray 3 is retracted directly above the tray parking table by the telescopic arm 411, and then the main lifting System 43 drives tray 3 down and placed on the tray docking station.
  • a suitable distance preferably 10 cm
  • the standard box 9 is palletized and the container box 7 is lower than the bottom end of the bottommost end of the main lifting system 43: as shown in FIG. 13, when the tray 3 is stopped on the tray parking table 36, the standard box 9 is loaded, and then loosened.
  • the third tray limiting device, the connecting member 42 is movable relative to the vertical rod 412, and the main lifting system 43 is activated to drive the horizontal T-shaped bracket 41 to rise until the tray 3 is located at the second tray limiting device 4122; preferably, the tray 3
  • the process of loading the standard box 3 and adjusting the relative position of the connecting member 42 and the horizontal T-shaped bracket 41 is performed simultaneously; then, the operations of 4.1, 4.2, and 4.3 are performed, and the standard box 9 is palletized on the bottom surface of the container box 7.
  • the standard box 9 yards the normal position between the bottom surface and the top surface of the container box 7: when the tray 3 is stopped on the tray parking table 36 and the standard box 9 is loaded, the connecting member 42 is movable relative to the vertical rod 412, and the main lifting is started.
  • the system 43 drives the horizontal T-shaped bracket 41 to descend until the tray 3 is located at the third tray limiting device, and opens the third tray stopper fixing tray 3; preferably, the tray 3 is loaded with the standard box 3 and the adjusting connector 42 and the transverse T
  • the process of the relative positions of the brackets 41 is simultaneously performed; then, the operations of 4.1, 4.2, and 4.3 are performed, and the standard box 9 is palletized on the bottom surface of the container box 7.
  • the process of repeating the normal position between the bottom surface and the top surface of the standard box 9 yards of the container box 7 is repeated until the palletizing of the standard box 9 at all normal positions in the same column is completed.
  • the standard box 9 is smashed into the container box 7 at a position higher than the top end of the main lifting system 43: as shown in FIG. 14, when the tray 3 is stopped at the parking table loading standard box 9, the third tray limiting device is released, and the connecting member 42 is relatively movable relative to the vertical rod 412, the main lifting system 43 is activated to drive the horizontal T-shaped bracket 41 to descend, so that the tray 3 is located at the top end of the vertical rod 412, and the first tray limiting device 4121 is activated to prevent the tray 3 from sliding down, preferably, the tray 3
  • the process of loading the standard box 9 and adjusting the relative position of the connecting member 42 and the horizontal T-shaped bracket 41 is performed simultaneously; then, the operations of 4.1, 4.2, and 4.3 are performed, and the standard box 9 is smashed into the container box 7 and is higher than the main lifting system 43.
  • the position of the top end, at this point, the automatic packing robot 100 completes the palletizing of a list of standard boxes 9.
  • the driving device 18 drives the automatic packing robot 100 to retreat the distance of one standard box 9, and performs the palletizing of the next standard box, so that the cycle is repeated until the packing operation of the entire container box 7 is completed.

Abstract

一种自动装箱方法，包括以下步骤：使标准箱（9）逐个进入自动装箱机械手的托盘（3）上；将每一个进入托盘（3）上的标准箱（9）逐个向左或向右横推，直到所述标准箱（9）横向排满托盘（3）；所述托盘（3）上横向摆满时恰好可容纳大于或等于两个标准箱（9）；移动托盘（3）并将托盘（3）上横向排满的若干个标准箱（9）整体脱箱到码垛位置处；同时公开了一种自动装箱机械手，包括在PLC系统控制下配合工作的机架（1）、输送装置（2）、托盘（3）、移动系统（4）；所述机架（1）的底座上装有行车装置（18），机架（1）内设有输送装置（2），输送装置（2）的前方设有可横向摆满大于等于两个标准箱（9）的托盘（3），托盘（3）连接在可带动其上下、前后移动的移动系统（4）上；机械手上还设有分配装置（25）和脱箱装置（32），完全代替人工，装箱速度快，节省人力。

Description

一种自动装箱方法及自动装箱机械手 技术领域
本发明涉及输送装箱领域，特别涉及一种自动装箱方法及自动装箱机械手。
背景技术
随着世界贸易的全球化，集装箱在国际运输中发挥着重要的作用，对于生产厂家或商家，必须将包装好成箱的产品装入集装箱或货柜箱内，现有技术中通常采取人工搬运、摆箱的方式完成装箱工作，劳动量大、工作效率低。
发明内容
本发明要解决的技术问题是提供一种可代替人工将规格统一的标准箱自动化地装入集装箱或货柜箱中的方法及一种结构可靠的自动装箱机械手。
为解决上述技术问题，本发明采用以下技术方案：
一种自动装箱方法，包括以下步骤
步骤1，使标准箱逐个进入自动装箱机械手的托盘上；
步骤2，将每一个进入托盘上的标准箱逐个向左或向右横推，直到所述标准箱横向排满托盘；所述托盘上横向摆满时恰好可容纳大于或等于两个标准箱；
步骤3，移动托盘并将托盘上横向排满的若干个标准箱整体脱箱到码垛位置处。
优选地，在步骤1之前还有自动装箱机械手进入待装货柜箱并进行自动定位：
所述托盘触碰到货柜箱的前壁后再退回一个标准箱的长度加上托盘总宽度的距离完成自动定位。
更优选地，当排满托盘的标准箱的个数为奇数时，所述步骤1中，所述标准箱的中心线对准托盘的中心线逐个进入托盘；所述步骤2中，横推初始位置为托盘中心线向左或向右偏移一个标准箱宽度的一半；
当排满托盘的标准箱的个数为偶数时，所述步骤1中，所述标准箱的一个侧面对应托盘的中心线逐个进入托盘；所述步骤2中，横推初始位置为托盘中心线向左或向右偏移一个标准箱的宽度；
每一个进入托盘上的标准箱被交替的向左或向右横推一个标准箱的宽度；当横推初始位置位于托盘中心线右侧时，奇数次横推向左推动，偶数次横推向右推动；当横推初始位置位于托盘中心线左侧时，奇数次横推向右推动，偶数次横推向左推动。
进一步地，所述标准箱的中心线对应托盘的中心线在输送装置上输送；
当排满托盘的标准箱的个数为奇数时，所述标准箱由输送装置直接逐个进入托盘；
当排满托盘的标准箱的个数为偶数时，所述标准箱在输送装置上被逐个向左或向右纠偏一个标准箱宽度的一半，使所述标准箱的同一个侧面对应托盘的中心线逐个进入托盘。
更进一步地，步骤3中，首先将排满标准箱的托盘通过升降、前后移动放置到待码垛位置处；
将托盘上横向排满的若干个标准箱的后壁整体顶住，托盘后退，直至托盘上所有标准箱脱离托盘码垛到码垛位置处。
一种自动装箱机械手，包括PLC控制系统、以及在PLC系统控制下配合工作的机架、输送装置、托盘、移动系统；所述机架的底座上装有行车装置，将标准箱输送到托盘上的输送装置设置在机架内，输送装置的前方设有可横向摆满大于等于两个标准箱的托盘，托盘连接在可带动其上下、前后移动的移动系统上；
所述机械手上设有可将输送到其上的标准箱逐个推送到托盘上的分配装置；
所述机械手上设有可将每一个输送到托盘上的标准箱逐个向左或向右横推、直到横向排满托盘的横向推箱装置；机械手上还设有可使托盘上横向排满的若干个标准箱整体脱出托盘的脱箱装置。
优选地，所述托盘的前端设有实现自动装箱机械手自动定位的行车感应器。
进一步地，所述输送装置分为与托盘后端相邻的第二加速段以及可将外传送装置输送到其上的标准箱暂存、且能间隔性地每次将一个所述标准箱输送到第二加速段上的第一加速段。
更进一步地，所述托盘横向分为托盘中部、托盘左端、托盘右端；与输送装置对接的所述托盘中部上沿托盘长度方向设有推箱间隙；所述横向推箱装置设置于托盘的下方，包括横向推箱动力机构，横向推箱动力机构的输出端连有高出托盘上表面时在所述推箱间隙中左右往复运动推动标准箱的推箱杆，所述横向推箱动力机构连接在可带动推箱杆反复超出/缩回托盘上表面的横推升降机构上。
其中，所述托盘中部沿托盘长度方向设置的若干个第二滚筒并排而成，第二滚筒之间留有所述推箱间隙，所述托盘左端及托盘右端垂直托盘长度方向设置若干个第三滚筒并排而成。
更优选地，所述输送装置上垂直输送装置的输送方向设有纠偏间隙，输送装置的下方设有纠偏装置，纠偏装置包括纠偏动力机构，纠偏动力机构的输出端连有从所述纠偏间隙中穿出、且可在所述纠偏间隙中左右往复运动推动标准箱的拨件。
所述输送装置的中心线与所述托盘的中心线为同一轴线或互为平行线。
进一步地，所述输送装置分为与托盘后端相邻的第二加速段以及可将外传送装置输送到其上的标准箱暂存、且能每次将一个所述标准箱输送到第二加速段上的第一加速段，所述纠偏间隙垂直第二加速段的输送方向设置于第二加速段上，所述纠偏装置设置于第二加速段的下方。
所述第二加速段为滚筒输送，包括若干个垂直第二加速段输送方向设置的第一滚筒，若干个第一滚筒之间设有所述纠偏间隙.
其中，所述分配装置包括对称竖直设置于输送装置左右两侧的两个分配架，每个所述分配架具有四个可连成矩形的端点，每个端点处均设置第一链轮，两个传动链分别适配每一个分配架上的四个第一链轮形成矩形框，其中至少一个第一链轮是可带动传动链顺时针转动的主动轮，第一分配杆、第二分配杆将所述传动链分成相等的两份、分配装置转动时可位置互换地、水平连接于两个传动链之间。
也可以，所述输送装置分为与托盘后端相邻的第二加速段以及可将外传送装置输送到其上的标准箱暂存、且能每次将一个所述标准箱输送到第二加速段上的第一加速段，所述分配装置设置于第二加速段处。
优选地，所述托盘左端、托盘右端的后方分别设置竖直的左挡板、右挡板，左挡板与右挡板之间留有宽度可容标准箱适配通过的通道；
所述脱箱装置包括分别连接在左挡板、右挡板上的两个第二前后移动装置，左侧的第二前后移动装置上设有右端可反复向右伸出、缩回的左脱箱机构，左脱箱机构位于左挡板的前方，其左端与托盘的左端平齐；右侧的第二前后移动装置上设有左端可反复向左伸出、缩回的右脱箱机构，右脱箱机构位于右挡板的前方，其右端与托盘的右端平齐；左脱箱装置的右端与右脱箱机构的左端相向伸出对接时，使脱箱装置与托盘等长，左脱箱装置的左端与右脱箱机构的左端缩回时，可容标准箱通过。
更优选地，左脱箱机构包括固定在左侧的第二前后移动装置上的左固定杆，左固定杆上固定有气缸杆可向右伸出的左气缸；右脱箱机构包括固定在右侧的第二前后移动装置上的右固定杆，右固定杆上固定有气缸杆向左伸出的右气缸。
所述移动系统包括可带动托盘前后移动的第一前后移动装置、以及带动托盘上下移动的主升降系统；主升降系统设有主升降动力装置及主升降动力传动机构，所述第一前后移动装置连接在主升降传动机构上随主升降传动机构同步上下运动，所述第一前后移动装置、主升降传动机构为设置于输送装置左右两侧、且连接于托盘两侧同步运动的两组。
进一步地，每个所述第一前后移动装置包括前后移动驱动机构及在其带动下反复伸出、缩回的横T形支架，横T形支架包括竖杆以及与竖杆中部连接的横向的伸缩臂；所述托盘通过连接件可升降地连接在竖杆上；
所述机架的左右两侧顶部分别设有可在主升降动力装置驱动下绕自身轴心正转/反转的顶端横梁，顶端横梁平行标准箱的前进方向设置，所述主升降动力传动机构的顶部连接在顶端横梁上，连接在主升降动力传动机构底端的伸缩臂随顶端横梁的正转反转而上升或下降。
更进一步地，所述连接件的一端与托盘固定，另一端可升降地、且可在竖杆上定位地连接在竖杆上，竖杆的上端设有防止连接件位于竖杆上端时下滑的第一托盘限位装置，竖杆的下端 设有防止连接件向下滑出竖杆的第二托盘限位装置，竖杆的中部设有确保托盘的上表面与输送装置的上表面平齐的第三托盘限位装置。
所述主升降动力传动机构包括固定在顶端横梁上随顶端横梁同步转动的第二链轮，还包括适配第二链轮、连接在横T形支架上可带动横T形支架反复上升/下降的第二链条；主升降动力装置设置在左右两侧顶端横梁之间，其输出端可带动左右两侧顶端横梁以相同速度反向转动。
最优选地，所述机架上还设有托盘停放台，停放于托盘停放台上的托盘的上表面与输送装置的上表面平齐。
与现有技术相比，本发明的自动装箱机械方法采用自动装箱机械手，使标准箱逐个进入自动装箱机械手的托盘上，将每一个进入托盘上的标准箱逐个向左或向右横推，直到横向排满托盘，移动托盘并将托盘若干个标准箱整体脱箱到码垛位置处；可完全代替人工，节省人力，装箱速度快、效率高。
所述自动装箱机械手带有行车装置，可带动自动装箱机械手轻松进入待装货柜箱，且可在货柜箱内调整位置；机械手的分配装置，使得标准箱能依次逐个准确地进入托盘中；所述横向推箱装置将每一个进入托盘的标准箱逐个的横向排开，直到排满整个托盘，控制托盘前后上下运动的移动系统将装满标准箱的托盘送到货柜箱内的预定位置；脱箱装置可将托盘上排满的标准箱一次性平稳推下托盘，使其放置于预定位置；PLC控制系统带有显示屏及运算系统，在PLC控制系统的显示器上输入待装货柜箱与标准箱的长、宽、高，PLC控制系统根据输入的数据，自动计算出托盘上每次可横向排列的标准箱的个数，自动调整纠偏初始位置、纠偏距离、横推初始位置以及横向推箱装置向左或向右的推箱次数，且可在显示器中输入标准箱码垛方案，利用PLC控制系统调整各部件之间协调运行，整体实现标准箱的自动装箱，取代人工装箱，节约人力。机械手还设有纠偏装置，当横向排满托盘的标准箱的个数为奇数时，纠偏装置将输送装置上的标准箱逐个推动至其中心线对应托盘的中心线进入托盘上，当横向排满托盘的标准箱的个数为偶数时，纠偏装置将输送装置上标准箱逐个推动至标准箱的同一侧对应托盘的中心线进入托盘中，确保排满托盘需要的所有标准箱均能顺利进入托盘中。
附图说明
下面结合附图和具体实施方式对本发明作进一步详细地解释。
图1是自动装箱机械手与待装货柜箱整体示意图
图2是标准箱装上托盘的示意图
图3是自动装箱机械手整体结构示意图
图4是自动装箱机械手感应器分布示意图
图5是分配装置示意图
图6是纠偏装置示意图
图7是托盘与移动系统设置侧视示意图
图8是托盘详细布局示意图
图9横向推箱装置示意图
图10是托盘与脱箱装置示意图
图11是左脱箱装置与右脱箱装置相向伸出而相接时的状态示意图
图12是标准箱被脱箱装置顶住脱离托盘的状态示意图
图13是标准箱被码垛到低于主升降系统最底端位置的示意图
图14是标准箱码垛到高于主升降系统最顶端位置的示意图
图15是托盘上排满偶数个标准箱时横向推箱装置工作示意图
图16是托盘上排满奇数个标准箱时横向推箱装置工作示意图
具体实施方式
为了描述方便，如图1、图2中文字所示为参考，以标准箱9前进的方向定义为前，图示中所示左、右为左、右。将标准箱9前后壁之间定义为标准箱9的长，标准箱9左右两侧之间定义为标准箱9的宽，标准箱9的中心线可将标准箱9分成左右均等的两份；将托盘3前后之间定义为托盘3的宽，将托盘3左右两端之间定义为托盘3的长，托盘3的中心线可将托盘3分成左右均等的两份。
如图1、图3、图4所示，一种自动装箱机械手100，包括底部装有行车装置18的机架1，机架1内设有输送装置2，输送装置2的前方设有可横向摆满不少于两个标准箱9的托盘3，托盘3连接在可带动其上下、前后移动的移动系统4上；输送装置2的后端可与外传送装置200的前端对接，将外传送装置200输送到输送装置2上的标准箱9逐个推送入托盘3中，所述机架1、输送装置2、托盘3、移动系统4通过PLC控制系统(图中未示出)电通讯连接，实现相互之间协调运行。托盘3的前端设有行车感应器39。优选地，行车感应器39为接触式感应器，在行车感应器39触碰到货柜箱7的前壁时机械手后退一定距离(优选为退回一个标准箱9的长度加上托盘3总宽度的距离)实现自动定位。托盘3优选为矩形。
如图1所示，本实施例中，外传送装置200为伸缩输送带，机架1的下方设有可移动的升降装置5，调整升降装置5的位置及高度，可将自动装箱机械手100调整到与待装货柜箱7的底面平齐对接，行车装置18运行，可伸缩的外传送装置200逐渐拉长，自动装箱机械手100进入货柜箱7内。
所述机架1包括设置于输送装置2下方的底座11，行车装置18(本实施例中为带有动力系统的车轮)设置于底座11下方，可带动自动装箱机械手100运动。
所述输送装置2的中心线与托盘3的中心线为同一轴线或互为平行线，所述输送装置2上垂直输送装置2的输送方向设有纠偏间隙232，输送装置2的下方设有纠偏装置24，纠偏装置24包括纠偏动力机构243，纠偏动力机构243的输出端连有从所述纠偏间隙232中穿出、且可在所述纠偏间隙232中左右往复运动推动标准箱9的拨件241。当横向排满托盘3的标准 箱9的个数为奇数时，纠偏装置24将输送装置2上的标准箱9逐个推动至其中心线对应托盘3的中心线，当横向排满托盘3的标准箱9的个数为偶数时，纠偏装置24将输送装置2上标准箱9逐个推动至标准箱9的同一侧对应托盘3的中心线。
如图3所示，所述输送装置2自后向前依次分为相邻的第一加速段22、第二加速段23；第一加速段22可将外传送装置200输送到其上的标准箱9暂存，且能每次将一个所述标准箱9输送到第二加速段23上；所述纠偏间隙232垂直第二加速段23的输送方向设置于第二加速段23上，纠偏装置24设置于第二加速段23的下方。本实施例中，所述输送装置2的中心线与托盘3的中心线为同一轴线，外传送装置200将标准箱9的中心线对应输送装置2的中心线送入输送装置2，所述纠偏装置24在托盘3需要偶数个标准箱9才能排满时启动，将运行在第二加速段23中心线上的标准箱9逐个向左或向右推动标准箱9宽度的一半(即纠偏距离)后随即返回到纠偏初始位置，使所述标准箱9的同一侧沿托盘3的中心线进入托盘3中，确保排满托盘3需要的所有标准箱9均能顺利进入托盘3中；所述纠偏初始位置是指自第二加速段23的中心线向左或向右偏移标准箱9宽度的一半，可在第二加速段23的宽度范围内调节。当托盘3需要奇数个标准箱9才能排满时，标准箱9的中心线对应第二加速段23的中心线送入托盘3中，纠偏装置24不启动，停放于不妨碍标准箱9通过的一侧。
如图5、图6所示，所述第二加速段23为滚筒输送，包括若干个垂直第二加速段23输送方向设置的第一滚筒231，若干个第一滚筒231之间设有纠偏间隙232，纠偏装置24工作状态下，拨件241可顶住通过第二加速段23中心的标准箱9向左或向右移动，使得标准箱9偏离输送方向的中心线向左或向右移动标准箱9宽度的一半。实施例中，拨件241通过适配的拨件固定座可左右移动地螺纹连接在第一滚珠丝杆242上，带有纠偏动力机构243的所述第一滚珠丝杆242位于第一滚筒231下方、且平行第一滚筒231设置。拨件241也可适配固定在滑动丝杠、直线气缸等上，只要能实现拨杆241能向左或向右推动标准箱9移动纠偏距离、且在推标准箱9后即刻返回纠偏初始位置即可。
所述机械手还设有确保每次仅有一个标准箱9进入托盘3的分配装置25，防止进入托盘3的标准箱9拥挤或被挤下托盘3。
如图5所示，所述分配装置25为设置于第二加速段23左右两侧的框架形，固定于机架1上，包括两个竖直设置的分配架251、两个传动链252以及第一分配杆253、第二分配杆254。两个分配架251对称设置于第二加速段23的左右两侧，所述分配架251具有四个可连成矩形的端点，每个端点处均设置第一链轮255，一个传动链252适配一个分配架251上的四个第一链轮255形成矩形框，其中至少一个第一链轮255是可带动传动链252顺时针转动的主动轮，第一分配杆253、第二分配杆254水平地连接于两个传动链252之间，第一分配杆253、第二分配杆254将所述传动链252分成相等的两份，即传动链252每运行半周，第一分配杆253、第二分配杆254的位置互换。分配架251上还设有可感应标准箱9通过的分配感应器256。初始状态下，第二分配杆254位于近托盘3一端、传动链252竖直部分的下端(图5中A处)， 可阻挡置于第二加速段上的标准箱9进入托盘3，相应地，第一分配杆253位于远托盘3一端、传动链252竖直部分的上部(图5中B处)，待分配装置25启动时，第二分配杆254向上运行，放行第二加速段23上的标准箱9，第一分配杆253水平向前运行时可将第二加速段上的标准箱9推进托盘3。所述分配架251可为工字型、矩形等方便加工的形状，本实施例中为矩形。
所述外传送装置200、第一加速段22和第二加速段23的开启、停止及输送速度均可单独控制。输送装置2的下方设有固定于底座11上、可支撑输送装置2水平运行的支撑架(图中未示出)。所述输送装置2也可为不分段的整体，可以通过调整输送装置2的输送速度或现有技术中其他常规方式，只要能保证每次只有一个标准箱9进入所述分配装置25的分配范围进行分配即可。
如图7和图3所示，托盘3连接在移动系统4上，可上下、前后移动地设置于输送装置2的前方，移动系统4包括可带动托盘3前后移动的第一前后移动装置、以及带动托盘3上下移动的主升降系统43，主升降系统43包括主升降动力装置431及主升降动力传动机构，所述第一前后移动装置连接在主升降传动机构上随主升降传动机构同步上下运动，所述第一前后移动装置、主升降传动机构为设置于输送装置2左右两侧、且连接于托盘3两侧同步运动的两组。
实施例中，每个所述第一前后移动装置包括前后移动驱动机构413及在其带动下反复伸出、缩回的横T形支架41，横T形支架41包括竖杆412以及与竖杆412中部连接的横向的伸缩臂411；所述托盘3通过连接件42可升降地连接在竖杆412上。
所述连接件42的一端与托盘3固定，另一端可升降地、且可在竖杆412上定位地连接在竖杆412上，竖杆412的上端设有防止连接件42位于竖杆412上端时下滑的第一托盘限位装置4121，竖杆412的下端设有防止连接件42向下滑出竖杆412的第二托盘限位装置4122，竖杆412的中部设有确保托盘3的上表面与输送装置2的上表面平齐的第三托盘限位装置4123。主升降系统、第一前后移动装置及连接件42共同作用，可带动托盘3可在货柜箱7底面与主升降系统43的最低端之间、以及在主升降系统43的最高端与货柜箱7顶面之间装标准箱9。
本实施例中，所述机架1的左右两侧顶部分别设有可在主升降动力装置431驱动下绕自身轴心正转/反转的顶端横梁121，顶端横梁121平行标准箱9的前进方向设置，主升降动力传动机构的顶部设置在顶端横梁121上，底端可带动横T形支架41上下运动地与伸缩臂411连接，具体地，主升降动力传动机构包括固定在顶端横梁121上随顶端横梁121同步转动的第二链轮432，以及适配第二链轮432、连接在横T形支架41上可带动横T形支架41反复上升/下降的第二链条433，主升降动力装置431通过现有技术的方式设置在左右两个顶端横梁121之间，主升降动力装置431工作时带动两侧的顶端横梁121以相同速度反向转动。实施例中，所述伸缩臂411上套接有滑动座414，安装在滑动座414上的前后移动驱动机构413在PLC控制系统指令下可带动横T形支架41前后伸缩运动，第二链条433的末端连接在滑动座414上，所述滑动座414与伸缩臂411的连接形式可以是丝杆螺母副或齿轮齿条副，也可以是链条传动或同步带传动，本实施例优选使用同步带传动。
主升降系统43、第一前后移动装置可采用现有技术中气动、液压、电机、齿轮等各种方式，只要能够实现带动托盘3平稳的上下、前后运动即可。
如图3、图4、图8、图9所示，机械手上设有可将每一个输送到托盘3上的若干个标准箱9逐个横向排开的横向推箱装置31，机械手上还设有可使托盘3上横向排满的若干个标准箱9整体平行脱出托盘3的脱箱装置32，机架1上托盘3的下方设有托盘复位感应器38，确保装箱状态下托盘3的上表面与输送装置2的上表面为同一平面，优选地，托盘复位感应器38为接近开关。装箱状态下，托盘3可停放在机架1上。
托盘3的长度可根据需要合理设置，可与待装货柜箱宽度相同，或为待装货柜箱宽度的一半，或为待装货柜箱宽度的三分之一，只要确保可容不少于两个标准箱9恰好将其排满即可。本实施例中，如图8、图9所示，托盘3的长度与待装货柜箱7的宽度相同，分为托盘中部33、托盘左端34、托盘右端35；与输送装置2对接的所述托盘中部33上沿托盘3长度方向设有推箱间隙331；所述横向推箱装置31设置于托盘3的下方，包括横向推箱动力机构315，横向推箱动力机构315的输出端连有高出托盘3上表面时在所述推箱间隙331中左右往复运动推动标准箱9的推箱杆311，所述横向推箱动力机构315连接在可带动推箱杆311反复超出/缩回托盘3上表面的横推升降机构312上。
横向推箱装置31的横推初始位置可在托盘中部33的区域内合理设置。所述横推初始位置是指横向推箱装置31准备推动第一个进入托盘3的标准箱9时所处的位置。当标准箱9排满托盘3的数量为奇数时，横向推箱装置31的横推初始位置为从托盘3的中间向左或向右偏移半个标准箱9的宽度，当标准箱9排满托盘3的数量为偶数时，横向推箱装置31的横推初始位置为从托盘3的中心向左或向右移动一个标准箱9的宽度，当横推初始位置位于托盘3中心线右侧时，横向推箱装置31的奇数次推箱向左推动，偶数次推箱向右推动，左右交替；当横推初始位置位于托盘3中心线左侧时，横向推箱装置31的奇数次推箱向右推动，偶数次推箱向左推动，确保最终标准箱9摆满整个托盘3。本实施例中，所述横推升降机构312为第一直线气缸，所述托盘中部33由沿托盘3长度方向设置的若干个第二滚筒并排而成，第二滚筒之间留有推箱间隙331，横向推箱装置31设置于第二滚筒的下方。如图8、图9所示，推箱杆311通过推箱杆底座可左右移动的适配螺纹连接在第二滚珠丝杆313上，设有横向推箱动力机构315的第二滚珠丝杆313沿托盘3长度方向设置，第二滚珠丝杆313通过丝杆支架314连接在第一直线气缸可上下伸缩的气缸杆上。推箱杆311在第一直线气缸312顶起时超出第二滚筒，可在第二滚珠丝杆313的带动下左右移动，将位于托盘中部33的标准箱9推到托盘左端34或托盘右端35，直到完成倒数第二个标准箱9的横推后，推箱杆311下降，留出一个标准箱9的静空位，待最后一个标准箱输送到托盘3上。托盘左端34及托盘右端35优选为垂直托盘3长度方向设置若干个第三滚筒并排而成，阻力小，置于第三滚筒上的标准箱可被轻松推走。
如图10-图12所示，托盘左端34的后方竖直设置左挡板342，托盘右端35的后方竖直设置右挡板352，左挡板342与右挡板352之间留有可容标准箱9适配通过的通道。所述脱箱装 置32包括分别连接在左挡板342、右挡板352上的两个第二前后移动装置323，左侧的第二前后移动装置323上设有右端可反复向右伸出、缩回的左脱箱机构321，左脱箱机构321位于左挡板342的前方，其左端与托盘3的左端平齐；右侧的第二前后移动装置323上设有左端可反复向左伸出、缩回的右脱箱机构322，右脱箱机构322位于右挡板352的前方，其右端与托盘3的右端平齐；如图10所示，在标准箱9装入托盘3的过程中，左脱箱机构321的右端和右脱箱机构322的左端均处于缩回状态，即输送装置2与托盘中部33之间畅通；如图11所示，预备推箱状态下，左脱箱机构321的右端与右脱箱机构322的左端相向伸出，两者相接，使得脱箱装置32与托盘3等长，如图12所示，同时启动第二前后移动装置323及第一前后移动装置，脱箱装置32始终顶住托盘3上的所有标准箱9，第一前后移动装置带动托盘3后退，将托盘3上横向排列的若干个标准箱9整体推至跺码位置。
具体地，第二前后移动装置323为分别固定在左挡板342、右挡板352上的第二直线气缸，左脱箱机构321包括固定在左侧的第二直线气缸的气缸杆上的左固定杆3211，左固定杆3211的左端与托盘3的左端平齐，右端不超出左挡板342的右端，左固定杆3211上固定有气缸杆可向右伸出的左气缸3212，右脱箱机构322包括固定在右侧的第二直线气缸的气缸杆上的右固定杆3221，右固定杆3221的右端与托盘3的右端平齐，左端不超出右挡板352的左端，左固定杆3221上固定有气缸杆向左伸出的右气缸3222，当左气缸3212、右气缸3222同步相向伸出时，左气缸3212及右气缸3222的气缸杆相接。所述左脱箱机构321、右脱箱机构322、第二前后移动装置323也可为现有技术中的其他常规方式。
优选地，机架1上托盘3的下方设置托盘停放台36，托盘停放台36的高度以托盘3放上后，托盘复位感应器38恰好检测到托盘3为准。
所述自动装箱机械手100进行装箱时，可按以下方法进行：
PLC控制系统带有输入系统、显示屏及运算系统，在PLC控制系统中输入待装货柜箱7以及标准箱9的长、宽、高，PLC控制系统根据输入的数据，自动计算出托盘3上每次可横向排列的标准箱9的个数，自动调整纠偏装置24的纠偏初始位置、纠偏距离、横向推箱装置31的横推初始位置、横向推箱装置31向左或向右推箱次数，在PLC控制系统中还可以设置标准箱9跺码方案，自动装箱机械手100根据跺码方案自动进行整行码垛。所述码垛方案即标准箱9在货柜箱7中的摆放顺序的排列方案。
本实施例，以标准箱9排满托盘3的数量为5个，横向推箱装置31的横推初始位置为从托盘3的中间向右移动标准箱9宽度的一半为例，对自动装箱机械手100的装箱方法进行描述。
步骤1，自动装箱机械手100的自动定位；
调整升降装置5的高度与货柜箱7的底面齐平，启动行车装置18，自动装箱机械手100进入货柜箱7，待托盘3前端的行车感应器39触碰到货柜箱7的前箱壁后，自动装箱机械手100后退预定距离，预定距离优选为一个标准箱9的长度加上托盘3的总宽度，行车感应器39关闭；
步骤2，使标准箱9逐个进入托盘3上；
叉车或其他搬运装置将整垛标准箱9运送到外传送装置200的后侧段，调整第一加速段22、第二加速段23、外传送装置200的输送速度协调配合，人工将标准箱9搬上外传送装置200，标准箱9由外传送装置200进入输送装置2的中间。第一加速段22、第二加速段23、外传送装置200的速度优选调整为：外传送装置200持续运行，第一加速段22间隔运行，外传送装置200将标准箱9送上第一加速段22时，第一加速段22恰好将其上暂存的标准箱9输送到第二加速段23上。
如图5所示，初始状态下，分配装置25的第二分配杆254停在A处，第一分配杆253停于B处，第一加速段22、第二加速段23、外传送装置200运行，当分配感应器256感应到第一个标准箱9通过B点，第二加速段23继续运行，第一加速段22停止工作；第一个标准箱9运动到被位于A点的第二分配杆254拦截为止，待分配感应器256感应到标准箱9被第二分配杆254拦截(分配感应器256从有信号到无信号即判定标准箱9已被第二分配杆254拦截为已拦截)；分配装置25开始工作，传动链252顺时针转动，带动第二分配杆254先上升再水平向后运动，第一分配杆253先下降再水平向前运动，第一分配杆253将标准箱9推进托盘3，第一分配杆253停在A处，第二分配杆254停于B处，在第一分配杆253水平推第一个标准箱9的同时，第一加速段22启动运行，第二个标准箱9尾随第一分配杆253停在第二加速段23上，被位于A处第一分配杆253拦截，如此重复循环，确保每次只有一个标准箱9被推到托盘3上；
步骤3，将每一个依次进入托盘3上同一位置的标准箱9逐个向左或向右推至横向排满托盘3；
如图16所示，标准箱9由第二加速段23的中间送入托盘3，标准箱9的中心线对应托盘3的中心线，横向推箱装置31的横推初始位置为从托盘3的中间向右偏移一个标准箱9宽度的一半，横向推箱装置31将第一个标准箱9向左推移一个标准箱的宽度后停止，待第二个标准箱送入托盘3上后，横向推箱装置31将第二个标准箱向右推移一个标准箱的宽度后停止，待第三个标准箱送入托盘3上后，横向推箱装置31将第三个标准箱向左推移一个标准箱的宽度，在第三个标准箱向左运动的过程中，第三个标准箱推动第一个标准箱继续向左运动一个箱位，如此循环往复，直到完成第四个标准箱的横移后，推箱杆311下降，留出一个标准箱9的静空位，待第5个标准箱输送到托盘3上，整个托盘3被排满。
该步骤中，当标准箱9排满托盘3的数量为偶数(4个)时，如图15所示，横向推箱装置31的横推初始位置为从托盘3的中心向右移动一个标准箱9的宽度，标准箱9的一侧(本实施例中为标准箱9的左侧)沿第二加速段23中心线送入托盘3中，横向推箱装置31按图15所示进行横向推箱工序。横向推箱装置31将第一个标准箱9向左推移一个标准箱的宽度后停止，待第二个标准箱送入托盘3上后，横向推箱装置31将第二个标准箱向右推移一个标准箱的宽度后停止，待第三个标准箱送入托盘3上后，横向推箱装置31将第三个标准箱向左推 移一个标准箱的宽度，在第三个标准箱向左运动的过程中，第三个标准箱推动第一个标准箱继续向左运动一个箱位，留出一个标准箱的静空位，第4个标准箱输送到托盘3上，整个托盘3被排满。
步骤4，移动托盘3并将托盘3上横向排满的若干个标准箱9整体推放到码垛位置处；
4.1将排满标准箱9的托盘3通过升降、前后移动到需码垛位置；
当托盘3排满标准箱9后，主升降系统43带动托盘3上升合适距离(为防止托盘3与托盘停放台36之间发生摩擦导致标准箱9掉落，优选为10cm)，伸缩臂411前伸，带动托盘3向前移出托盘停放台36，托盘3的前端紧邻货柜箱7的前箱壁或前一列已码好的标准箱9的侧壁，主升降系统43带动伸缩臂411及装有标准箱9的托盘3下降到货柜箱7的底部或同列已码垛好的标准箱9的上方；
4.2将托盘3上横向排满的若干个标准箱9整体推下；
同时启动第二前后移动装置323和第一前后移动装置，脱箱装置32始终将托盘3上所有的标准箱9整体顶住，同时伸缩臂411缩回，带动托盘3后退，直到标准箱9完全脱离托盘3。
4.3将托盘3移动到装箱位置处；
主升降系统43带动横T形支架41及托盘3上升到高出托盘停放台36合适距离(优选为10cm)，托盘3在伸缩臂411的带动下退回至托盘停放台的正上方，然后主升降系统43带动托盘3下降并放置于托盘停放台上。
本实施例中，首先将标准箱9码垛货柜箱7低于主升降系统43最底端的底面上：如图13所示，托盘3停在托盘停放台36上装载标准箱9时，松开第三托盘限位装置，连接件42相对竖杆412为可活动状态，启动主升降系统43带动横T形支架41上升，直到托盘3位于第二托盘限位装置4122处；优选地，托盘3装载标准箱3及调整连接件42与横T形支架41相对位置的过程同时进行；然后进行4.1、4.2、4.3的动作，将标准箱9码垛货柜箱7的底面上。
将标准箱9码垛货柜箱7的底面与顶面之间的正常位置：托盘3停在托盘停放台36上装载标准箱9时，连接件42相对竖杆412为可活动状态，启动主升降系统43带动横T形支架41下降，直到托盘3位于第三托盘限位装置处，开启第三托盘限位装置固定托盘3；优选地，托盘3装载标准箱3及调整连接件42与横T形支架41相对位置的过程同时进行；然后进行4.1、4.2、4.3的动作，将标准箱9码垛货柜箱7的底面上。重复进行标准箱9码垛货柜箱7的底面与顶面之间的正常位置的工序，直到完成同一列中所有正常位置处标准箱9的码垛。
将标准箱9码垛到货柜箱7中高于主升降系统43最顶端的位置：如图14所示，托盘3停在停放台装载标准箱9时，松开第三托盘限位装置，连接件42相对竖杆412为可活动状态，启动主升降系统43带动横T形支架41下降，使托盘3位于竖杆412的顶端，启动第一托盘限位装置4121防止托盘3下滑，优选地，托盘3装载标准箱9及调整连接件42与横T形支架41相对位置的过程同时进行；然后进行4.1、4.2、4.3的动作，将标准箱9码垛到货柜箱7中高于主升降系统43最顶端的位置，至此，自动装箱机械手100完成一列标准箱9的码垛。
在PLC系统控制下，行车装置18带动自动装箱机械手100后退一个标准箱9的距离，进行下一列标准箱的码垛，如此重复循环，直到完成整个货柜箱7的装箱工作。

Claims (23)

  1. 一种自动装箱方法，其特征在于，包括以下步骤
    步骤1，使标准箱(9)逐个进入自动装箱机械手的托盘(3)上；
    步骤2，将每一个进入托盘(3)上的标准箱(9)逐个向左或向右横推，直到所述标准箱(9)横向排满托盘(3)；所述托盘(3)上横向摆满时恰好可容纳大于或等于两个标准箱(9)；
    步骤3，移动托盘(3)并将托盘(3)上横向排满的若干个标准箱(9)整体脱箱到码垛位置处。
  2. 如权利要求1所述的自动装箱方法，其特征在于，在步骤1之前还有自动装箱机械手进入待装货柜箱并进行自动定位：
    所述托盘(3)触碰到货柜箱的前壁后再退回一个标准箱(9)的长度加上托盘(3)总宽度的距离完成自动定位。
  3. 如权利要求1或2所述的自动装箱方法，其特征在于，
    当排满托盘(3)的标准箱(9)的个数为奇数时，所述步骤1中，所述标准箱(9)的中心线对准托盘(3)的中心线逐个进入托盘(3)；所述步骤2中，横推初始位置为托盘中心线向左或向右偏移一个标准箱(9)宽度的一半；
    当排满托盘(3)的标准箱(9)的个数为偶数时，所述步骤1中，所述标准箱(9)的一个侧面对应托盘(3)的中心线逐个进入托盘(3)；所述步骤2中，横推初始位置为托盘中心线向左或向右偏移一个标准箱(9)的宽度；
    每一个进入托盘(3)上的标准箱(9)被交替的向左或向右横推一个标准箱(9)的宽度；当横推初始位置位于托盘(3)中心线右侧时，奇数次横推向左推动，偶数次横推向右推动；当横推初始位置位于托盘(3)中心线左侧时，奇数次横推向右推动，偶数次横推向左推动。
  4. 如权利要求3所述的标准箱的自动装箱方法，其特征在于，所述标准箱(9)的中心线对应托盘(3)的中心线在输送装置(2)上输送；
    当排满托盘(3)的标准箱(9)的个数为奇数时，所述标准箱(9)由输送装置(2)直接逐个进入托盘(3)；
    当排满托盘(3)的标准箱(9)的个数为偶数时，所述标准箱(9)在输送装置(2)上被逐个向左或向右纠偏一个标准箱(9)宽度的一半，使所述标准箱(9)的同一个侧面对应托盘(3)的中心线逐个进入托盘(3)。
  5. 如权利要求1或2所述的自动装箱方法，其特征在于，步骤3中，首先将排满标准箱(9)的托盘(3)通过升降、前后移动放置到待码垛位置处；
    将托盘(3)上横向排满的若干个标准箱(9)的后壁整体顶住，托盘(3)后退，直至托盘(3)上所有标准箱(9)脱离托盘(3)码垛到码垛位置处。
  6. 一种自动装箱机械手，其特征在于，包括PLC控制系统、以及在PLC系统控制下配合工作的机架(1)、输送装置(2)、托盘(3)、移动系统(4)；所述机架(1)的底座(11)上装有行车装置(18)，将标准箱(9)输送到托盘(3)上的输送装置(2)设置在机架(1)内，输送装置(2)的前方设有可横向摆满大于等于两个标准箱(9)的托盘(3)，托盘(3)连接在可带动其上下、前后移动的移动系统(4)上；
    所述机械手上设有可将输送到其上的标准箱(9)逐个推送到托盘(3)上的分配装置(25)；
    所述机械手上设有可将每一个输送到托盘(3)上的标准箱(9)逐个向左或向右横推、直到横向排满托盘(3)的横向推箱装置(31)；机械手上还设有可使托盘(3)上横向排满的若干个标准箱(9)整体脱出托盘(3)的脱箱装置(32)。
  7. 如权利要求6所述的自动装箱机械手，其特征在于，所述托盘(3)的前端设有实现自动装箱机械手自动定位的行车感应器(39)。
  8. 如权利要求6所述的自动装箱机械手，其特征在于，所述输送装置(2)分为与托盘(3)后端相邻的第二加速段(23)以及可将外传送装置(200)输送到其上的标准箱(9)暂存、且能间隔性地每次将一个所述标准箱(9)输送到第二加速段(23)上的第一加速段(22)。
  9. 如权利要求6所述的自动装箱机械手，其特征在于，所述托盘(3)横向分为托盘中部(33)、托盘左端(34)、托盘右端(35)；与输送装置(2)对接的所述托盘中部(33)上沿托盘(3)长度方向设有推箱间隙(331)；所述横向推箱装置(31)设置于托盘(3)的下方，包括横向推箱动力机构(315)，横向推箱动力机构(315)的输出端连有高出托盘(3)上表面时在所述推箱间隙(331)中左右往复运动推动标准箱(9)的推箱杆(311)，所述横向推箱动力机构(315)连接在可带动推箱杆(311)反复超出/缩回托盘(3)上表面的横推升降机构(312)上。
  10. 如权利要求9所述的自动装箱机械手，其特征在于，所述托盘中部(33)沿托盘(3)长度方向设置的若干个第二滚筒并排而成，第二滚筒之间留有所述推箱间隙(331)，所述托盘左端(34)及托盘右端(35)垂直托盘(3)长度方向设置若干个第三滚筒并排而成。
  11. 如权利要求6所述的自动装箱机械手，其特征在于，所述输送装置(2)上垂直输送装置(2)的输送方向设有纠偏间隙(232)，输送装置(2)的下方设有纠偏装置(24)，纠偏装置(24)包括纠偏动力机构(243)，纠偏动力机构(243)的输出端连有从所述纠偏间隙(232)中穿出、且可在所述纠偏间隙(232)中左右往复运动推动标准箱(9)的拨件(241)。
  12. 如权利要求11所述的自动装箱机械手，其特征在于，所述输送装置(2)的中心线与所述托盘(3)的中心线为同一轴线或互为平行线。
  13. 如权利要求6所述的自动装箱机械手，其特征在于，所述输送装置(2)分为与托盘(3)后端相邻的第二加速段(23)以及可将外传送装置(200)输送到其上的标准箱(9)暂存、且能每次将一个所述标准箱(9)输送到第二加速段(23)上的第一加速段(22)，所述纠 偏间隙(232)垂直第二加速段(23)的输送方向设置于第二加速段(23)上，所述纠偏装置(24)设置于第二加速段(23)的下方。
  14. 如权利要求13所述的自动装箱机械手，其特征在于，所述第二加速段(23)为滚筒输送，包括若干个垂直第二加速段(23)输送方向设置的第一滚筒(231)，若干个第一滚筒(231)之间设有所述纠偏间隙(232).
  15. 如权利要求6所述的自动装箱机械手，其特征在于，所述分配装置(25)包括对称竖直设置于输送装置(2)左右两侧的两个分配架(251)，每个所述分配架(251)具有四个可连成矩形的端点，每个端点处均设置第一链轮(255)，两个传动链(252)分别适配每一个分配架(251)上的四个第一链轮(255)形成矩形框，其中至少一个第一链轮(255)是可带动传动链(252)顺时针转动的主动轮，第一分配杆(253)、第二分配杆(254)将所述传动链(252)分成相等的两份、分配装置(25)转动时可位置互换地、水平连接于两个传动链(252)之间。
  16. 如权利要求6所述的自动装箱机械手，其特征在于，所述输送装置(2)分为与托盘(3)后端相邻的第二加速段(23)以及可将外传送装置(200)输送到其上的标准箱(9)暂存、且能每次将一个所述标准箱(9)输送到第二加速段(23)上的第一加速段(22)，所述分配装置(25)设置于第二加速段(23)处。
  17. 如权利要求9所述的自动装箱机械手，其特征在于，所述托盘左端(34)、托盘右端(35)的后方分别设置竖直的左挡板(342)、右挡板(352)，左挡板(342)与右挡板(352)之间留有宽度可容标准箱(9)适配通过的通道；
    所述脱箱装置(32)包括分别连接在左挡板(342)、右挡板(352)上的两个第二前后移动装置(323)，左侧的第二前后移动装置(323)上设有右端可反复向右伸出、缩回的左脱箱机构(321)，左脱箱机构(321)位于左挡板(342)的前方，其左端与托盘(3)的左端平齐；右侧的第二前后移动装置(323)上设有左端可反复向左伸出、缩回的右脱箱机构(322)，右脱箱机构(322)位于右挡板(352)的前方，其右端与托盘(3)的右端平齐；左脱箱装置(32)的右端与右脱箱机构(322)的左端相向伸出对接时，使脱箱装置(32)与托盘(3)等长，左脱箱装置(32)的左端与右脱箱机构(322)的左端缩回时，可容标准箱(9)通过。
  18. 如权利要求17所述的自动装箱机械手，其特征在于，左脱箱机构(321)包括固定在左侧的第二前后移动装置(323)上的左固定杆(3211)，左固定杆(3211)上固定有气缸杆可向右伸出的左气缸(3212)；右脱箱机构(322)包括固定在右侧的第二前后移动装置(323)上的右固定杆(3221)，右固定杆(3221)上固定有气缸杆向左伸出的右气缸(3222)。
  19. 如权利要求6所述的自动装箱机械手，其特征在于，所述移动系统(4)包括可带动托盘(3)前后移动的第一前后移动装置、以及带动托盘(3)上下移动的主升降系统(43)；主升降系统(43)设有主升降动力装置(431)及主升降动力传动机构，所述第一前后移动装置连接在主升降传动机构上随主升降传动机构同步上下运动，所述第一前后移动装置、主升降传动机构为设置于输送装置(2)左右两侧、且连接于托盘(3)两侧同步运动的两组。
  20. 如权利要求19所述的自动装箱机械手，其特征在于，每个所述第一前后移动装置包括前后移动驱动机构(413)及在其带动下反复伸出、缩回的横T形支架(41)，横T形支架(41)包括竖杆(412)以及与竖杆(412)中部连接的横向的伸缩臂(411)；所述托盘(3)通过连接件(42)可升降地连接在竖杆(412)上；
    所述机架(1)的左右两侧顶部分别设有可在主升降动力装置(431)驱动下绕自身轴心正转/反转的顶端横梁(121)，顶端横梁(121)平行标准箱(9)的前进方向设置，所述主升降动力传动机构的顶部连接在顶端横梁(121)上，连接在主升降动力传动机构底端的伸缩臂(411)随顶端横梁(121)的正转反转而上升或下降。
  21. 如权利要求20所述的自动装箱机械手，其特征在于，所述连接件(42)的一端与托盘(3)固定，另一端可升降地、且可在竖杆(412)上定位地连接在竖杆(412)上，竖杆(412)的上端设有防止连接件(42)位于竖杆(412)上端时下滑的第一托盘限位装置(4121)，竖杆(412)的下端设有防止连接件(42)向下滑出竖杆(412)的第二托盘限位装置(4122)，竖杆(412)的中部设有确保托盘(3)的上表面与输送装置(2)的上表面平齐的第三托盘限位装置(4123)。
  22. 如权利要求20所述的自动装箱机械手，其特征在于，所述主升降动力传动机构包括固定在顶端横梁(121)上随顶端横梁(121)同步转动的第二链轮(432)，还包括适配第二链轮(432)、连接在横T形支架(41)上可带动横T形支架(41)反复上升/下降的第二链条(433)；主升降动力装置(431)设置在左右两侧顶端横梁(121)之间，其输出端可带动左右两侧顶端横梁(121)以相同速度反向转动。
  23. 如权利要求6～22所述的自动装箱机械手，其特征在于，所述机架(1)上还设有托盘停放台(36)，停放于托盘停放台(36)上的托盘(3)的上表面与输送装置(2)的上表面平齐。
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