JP7651208B1 - Storage item transport system - Google Patents

Abstract

[Problem] To provide a stored item transport system that uses an overhead crane device to automatically transport and stack stored items such as flexi-con bags, while preventing erroneous shipping. [Solution] The stored item transport system is a system that automatically stores and retrieves stored items, and is equipped with an overhead crane device (2) that has a hand unit (5) that holds a storage rack (91) containing stored items (90), transports the storage rack held by the hand unit to a storage area and stacks it, and a management device that manages the storage address and item information in the storage area for each stored item. [Selected drawing] Figure 2

Description

Patent Law Article 30, Paragraph 2 applied. Open to the public at Yamato Transport's new warehouse preview event (Serigawa, Oyabe City, Toyama Prefecture) on April 20th and 22nd, 2023.

The present invention relates to a storage item transport system that uses an overhead crane device to automatically store and retrieve stored items such as heavy items such as FIBC bags (flexible container bags).

Technology has existed for the past in which stored items are automatically transported using overhead crane equipment. For example, JP 2004-91125 A (Patent Document 1) discloses an overhead crane equipment that is equipped with an openable hoist that directly grips the stored item, roll paper, and suspends the horizontal support frame of the roll paper hoist at four points using wire ropes.

The overhead crane device in Patent Document 1 is equipped with a first pulley that changes the direction of the wire rope extended from the drum of the hoisting device, and a second pulley that is located between the drum and the first pulley and changes the direction of the wire rope extended from the first pulley to the vertical direction. By positioning the first pulley so that the imaginary plane formed by the center lines of the front and rear wire ropes passing through the first pulley is parallel to the central axis of the drum, wear and deformation of the wire rope caused by the drum is reduced.

JP 2004-91125 A

Flexible container bags, which contain powdered or granular raw materials or products, are bulky and heavy. In addition, their shape is unstable. For this reason, while lightweight cylindrical storage items with horizontal bottom and top surfaces, such as the objects to be transported in Patent Document 1, can be stacked automatically using an overhead crane, the current situation is that the transportation and stacking of heavy, unstable-shaped flexible container bags is carried out manually and with forklifts operated by workers.

In this case, however, it is necessary to provide space in the storage area within the warehouse for forklifts to travel, so the storage area cannot be made large. In other words, dead space is generated in the storage area. In addition, when stacking FIBC bags, workers may have to work on top of the bags, which poses the risk of falling off.

In addition, when transporting FIBC bags manually in this way, it is difficult to accurately link storage locations with item information, which can lead to incorrect shipments.

The present invention has been made to solve the above problems, and its purpose is to provide a stored item transport system that uses an overhead crane device to automatically transport and stack stored items such as flexi-con bags, while preventing incorrect shipping.

A stored item transport system according to one aspect of the present invention is a stored item transport system that automatically stores and retrieves stored items, and includes an overhead crane device and a management device. The overhead crane device has a hand unit that holds storage racks that hold stored items, and transports the storage racks held by the hand unit to a storage area and stacks them. The management device manages the storage address and item information in the storage area for each stored item.

In this way, storing stored items in dedicated racks allows the items to be transported and stacked automatically. In addition, the management device manages the storage address and item information of each stored item, preventing erroneous shipment of stored items. The item information includes, for example, at least one of content identification information for identifying the manufacturer and item name, and manufacturing information for identifying the manufacturing date and lot number (production unit).

Preferably, the overhead crane device includes a pair of traveling devices that can move in the x-axis direction along a traveling rail inside the building, a traverse device that can move in the y-axis direction along a traverse rail suspended between the pair of traveling devices, and a winding device that is mounted on the traverse device and winds up and down a hanging member having a hand unit connected and fixed to its lower end. In this case, it is preferable that the management device determines a storage address that indicates a three-dimensional position when the stored item is stored. In addition, it is preferable that the control device of the overhead crane device controls the traveling devices, the traverse device, and the winding device so that the hand unit arrives at the storage address determined by the management device.

Preferably, a chain with fixed ends is provided along the traveling rail or traverse rail, and the traveling device or traverse device is provided with a drive mechanism including a sprocket that engages with the chain and a travel motor that drives the sprocket. This allows the traveling device or traverse device to be stopped at an accurate position.

Preferably, at least one of the traveling device and the traverse device is provided with a position detection means for detecting its own position. This can further improve the stopping accuracy of the traveling device or the traverse device.

Preferably, when storing items, the management device determines the storage address using an algorithm based on the empirical value of the order of items being shipped out. This allows the stored items to be transported efficiently when they are shipped out.

It is desirable for the stored item transport system to further include a calculation device that calculates the machine coordinates for the operation of the overhead crane device based on the storage address of each stored item determined by the management device, and transmits the calculated machine coordinates to the control device. This makes it possible to troubleshoot when a problem occurs.

According to the present invention, the transport and stacking of stored items can be performed automatically. As a result, it is possible to improve the amount of stored items in warehouses and ensure the safety of workers. In addition, the storage address and item information of each stored item are managed in the management device, so erroneous shipment of stored items can be prevented.

1 is a plan view of a warehouse equipped with an overhead crane apparatus according to an embodiment of the present invention. 1 is a side view showing a main part of an overhead crane apparatus according to an embodiment of the present invention. 1 is a side view showing a main part of an overhead crane apparatus according to an embodiment of the present invention. 1 is a plan view showing a schematic diagram of a traverse device of an overhead crane apparatus according to an embodiment of the present invention; 5 is a perspective view showing a schematic connection state between a lower end of a hanging member hanging down from a traverse device and a hand unit in the embodiment of the present invention. FIG. 3 is a perspective view showing a schematic configuration of a lower end portion of a hand unit according to an embodiment of the present invention. FIG. 4 is a cross-sectional view showing a schematic configuration of an upper end portion of a hand unit in the embodiment of the present invention. FIG. 11 is a side view showing a schematic configuration example of a connecting member that connects a lower end portion of the hanging member and a hand portion. FIG. FIG. 2 is a diagram illustrating a drive mechanism of a traverse device according to an embodiment of the present invention. FIG. 2 is a diagram illustrating a drive mechanism of a traveling device according to an embodiment of the present invention. FIG. 2 is a schematic diagram showing a configuration example of a position detection unit according to the embodiment of the present invention. 2 is a block diagram showing a schematic functional configuration of a management device provided in the flexible container bag transport system according to the embodiment of the present invention. FIG.

The embodiment of the present invention will be described in detail with reference to the drawings. Note that the same or corresponding parts in the drawings are given the same reference numerals and their description will not be repeated.

In this embodiment, a FIBC transport system is described that automatically transports and stacks FIBC bags using an overhead crane device. The FIBC transport system includes an overhead crane device that transports FIBC bags stored in a dedicated rack to a storage area in a warehouse, and a management device that manages the storage address and item information for each FIBC bag in the storage area.

<About the overhead crane device>
(General configuration)
First, a schematic configuration of an overhead crane system 1 according to the present embodiment will be described with reference to Figures 1 to 3. Figure 1 is a plan view of a warehouse equipped with an overhead crane system 1 according to the present embodiment. Figures 2 and 3 are side views showing the main parts of the overhead crane system 1. In Figure 1, the depth direction of the warehouse as seen from the entrance/exit E is shown as the x-axis direction, and the width direction of the warehouse as seen from the entrance/exit E is shown as the y-axis direction. The x-axis direction and the y-axis direction are perpendicular to each other on a horizontal plane. The z-axis direction shown in Figures 2 and 3 corresponds to the up-down direction (vertical direction).

The warehouse has a loading/unloading station AR1 facing the entrance/exit E, and a storage area AR2 located at the rear of the loading/unloading station AR1. It also has an operation area AR3 near the entrance/exit E. The storage area AR2 occupies most of the interior space of the warehouse.

The overhead crane device 1 includes a pair of running rails 11, 11 extending in the x-axis direction, a pair of running devices (hereinafter referred to as "saddles") 2, 2 that can move in the x-axis direction along the running rails 11, 11, a pair of lateral rails 22, 22 that are suspended between the pair of saddles 2 and extend in the y-axis direction, a lateral device (hereinafter referred to as "trolley") 3 that can move along the y-axis direction straddling the lateral rails 22, 22, a winding device 4 mounted on the trolley 3 and winding up and down the hanging member 43, and a hand unit 5 that is connected and fixed to the lower end of the hanging member 43. It also includes a control device that controls the saddle 2, trolley 3, and winding device 4. The control device is realized by a PLC (Programmable Logic Controller) or the like installed in the warehouse.

As shown in FIG. 2, the trolley 3 is a self-propelled mobile device that includes a carriage body 35 having wheels 34 that fit on each of a pair of lateral rails 22, 22, and a drive mechanism 30 that moves the carriage body 35 linearly in the y-axis direction. The lateral rails 22 are formed on a girder 23 that receives the load of the trolley 3, and the load received by the girder 23 is supported by the saddle 2. As shown in FIG. 10 described later, the saddle 2 is also a self-propelled mobile device that includes a carriage body 21 having wheels that fit on the running rails 11, and a drive mechanism 20 that moves the carriage body 21 linearly in the x-axis direction.

The ceiling crane device 1 can adjust the planar position (xy coordinates) of the hand unit 5 by adjusting the x-axis position of the saddle 2 and the y-axis position of the trolley 3, and can adjust the height (z coordinate) of the hand unit 5 by adjusting the length of winding of the hanging member 43 by the winding device 4 mounted on the trolley 3. The hand unit 5 rises and falls between the working height at which it grips the FIBC bag 90 and the retraction height, which is the upper limit of the lift. The hand unit 5 positioned at the retraction height is shown by a solid line in Figure 3.

As shown in Figures 2 and 3, the hand unit 5 is configured to be able to grasp and open a rack 91 in which FIBC bags 90 are stored. FIBC bags 90 usually have a height of over 1 meter and can weigh more than 1 ton. In addition, their shape is unstable. FIBC bags 90 are stored in dedicated racks 91 that can be stacked, enabling automatic transportation and stacking using the ceiling crane device 1. In the following description, the rack 91 that stores FIBC bags 90 is referred to as the "FIBC storage rack 91."

As an example, the FIBC storage rack 91 includes a bottom surface 911 arranged in a lattice pattern, four square pillars (vertical bars) 912 provided at the four corners of the bottom surface 911, and two upper and lower rows of horizontal bars 913 connecting adjacent square pillars 912. No horizontal bars 913 are arranged on the front side, which is the insertion port for the FIBC bag 90, but only on both side surfaces and the back surface. The FIBC storage rack 91 also includes legs 914 that support the bottom surface 911 from below.

A total of four legs 914 are provided on the extension line of the square pillars 912. The bottom surface of the legs 914 is provided with an upwardly recessed recess 916 (Figure 6). The upper end of the square pillar 912 of the lower FIBC storage rack 91 fits into the recess 916 of the upper FIBC storage rack 91. This allows the FIBC storage racks 91 to be stacked stably, so that multiple FIBC storage racks 91 (for example, up to four) can be stacked in the storage area AR2 shown in Figure 1.

Even if the FIBC bag 90 is stored in the FIBC storage rack 91, the FIBC storage rack 91 is huge and heavy. The winding device 4 and hand unit 5 of the overhead crane device 1 according to this embodiment are configured to properly grip the FIBC storage rack 91 when entering and leaving the warehouse, and to transport the gripped FIBC storage rack 91 in a safe state. In addition, the drive mechanisms 20, 30 of the saddle 2 and trolley 3 are configured to stop the device at an accurate position. The configuration of each part of the overhead crane device 1 will be described in detail below.

(Configuration of the winding device)
The configuration of the winding device 4 will be described with reference to Figures 4 and 5. Figure 4 is a schematic plan view of the winding device 4 mounted on the trolley 3. Figure 5 is a perspective view showing a schematic connection state between the lower end of the hanging member 43 and the hand unit 5. For ease of understanding, the movement direction (x-axis direction) of the trolley 3 is also referred to as the front-rear direction, and the extension direction (y-axis direction) of the rotation shaft 32 perpendicular to the x-axis direction on a horizontal plane is also referred to as the left-right direction. Also, the left side of the paper surface of Figure 4 is referred to as the front of the trolley 3.

As shown in FIG. 4, the winding device 4 includes rotating shafts 42a, 42b arranged at a distance from each other in the front-rear direction, reels 45a, 45b connected and fixed to both ends of the front rotating shaft 42a (left side of the drawing), reels 46a, 46b connected and fixed to both ends of the rear rotating shaft 42b (right side of the drawing), and a lifting and lowering drive means for driving the rotating shafts 42a, 42b. Two hanging members 43a, 43b are wound around each of the front reels 45a, 45b. Two hanging members 43c, 43d are wound around each of the rear reels 46a, 46b.

The lifting/lowering drive means preferably includes two motors (hereinafter referred to as "lifting/lowering motors") 41a, 41b that individually drive the rotating shafts 42a, 42b. The lifting/lowering motors 41a, 41b are typically servo motors. The lifting/lowering drive means preferably includes a speed reducing mechanism that reduces the rotation of the servo motors. The lifting/lowering motor 41a is located forward of the moving motor 31, and the lifting/lowering motor 41b is located rearward of the moving motor 31. The rotating shafts 42a, 42b of the winding device 4 are not limited to being parallel to the rotating shaft 32 of the moving motor 31, but may be perpendicular to the rotating shaft 32.

The winding device 4 simultaneously rotates (forward and reverse) the front and rear reels 45a, 45b, 46a, and 46b by simultaneously driving the two lifting motors 41a and 41b, and winds up and down the four (two pairs) hanging members 43a, 43b, 43c, and 43d. In this way, by separately providing the lifting motor 41a for rotating the front reels 45a and 45b and the lifting motor 41b for rotating the rear reels 46a and 46b, the four hanging members 43a, 43b, 43c, and 43d can be stably raised and lowered. As shown in FIG. 4, in a plan view, the total of four reels 45a, 45b, 46a, and 46b are aligned in both the x-axis direction and the y-axis direction.

In this embodiment, the suspension members 43a, 43b, 43c, and 43d are not made of typical wires, but are made of belt members (metal belts) that are thin metal plates (see FIG. 5). The belt members are typically steel belts. In the following description, the suspension members 43 (43a, 43b, 43c, and 43d) are referred to as steel belts 43. The steel belt 43 has a constant width W. The thickness of the steel belt 43 is 1/10 or less of the width W.

The steel belt 43 is wound cylindrically around each reel 45a, 45b, 46a, 46b. This makes it possible to prevent the winding from becoming erratic or collapsing, which can occur when using a general wire rope as the suspension member. This prevents the hand unit 5 from shifting or tilting in the position height (z coordinate). In addition, since no lubricating oil is required, as is necessary when using a wire rope, problems such as the flexi-con bag 90 becoming dirty due to dripping of lubricating oil can be eliminated. In addition, the pulley diameter for winding the steel belt 43 can be made compact.

Each reel 45a, 45b, 46a, 46b has a winding portion 47 around which the steel belt 43 is wound, and annular flange portions 48 located at both ends. The width W of the steel belt 43 is approximately equal to the winding width of each reel 45a, 45b, 46a, 46b. This allows the winding state of the steel belt 43 to be maintained better. Therefore, the hand unit 5 can be raised and lowered while being kept straight and horizontal.

As shown in FIG. 2, when the hand unit 5 is lowered, i.e., when the steel belt 43 is wound down, the front reels 45a, 45b and the rear reels 46a, 46b rotate in a direction facing each other when viewed from the side (when viewed in the x-axis direction). In the example of FIG. 2, the insertion holes 350 through which the front steel belts 43a, 43b pass are provided rearward (toward the center) from the rotation shaft 42a of the reels 45a, 45b, and the insertion holes 350 through which the rear steel belts 43c, 43d pass are provided forward (toward the center) from the rotation shaft 42b of the reels 46a, 46b.

As shown in FIG. 5, the lower ends of the four steel belts 43 are fixed to the upper end of the hand unit 5 via a connecting member 6. The connecting members 6 are provided at multiple locations (four locations) corresponding to the positions of the four reels 45a, 45b, 46a, and 46b. Specifically, the connecting members 6 are provided directly below the positions where the steel belts 43 are pulled out from each reel (the positions of the insertion holes 350). This allows each of the steel belts 43 lowered downward from the trolley 3 to be maintained in a straight state (vertical state). In other words, the four steel belts 43a, 43b, 44a, and 44b can be raised and lowered while maintaining a parallel state in both the x-axis direction and the y-axis direction.

(Configuration of hand section)
The configuration of the hand unit 5 will be described with reference to Figures 2 and 5. The hand unit 5 has a main body 50 that holds the entire FIBC storage rack 91 from above, and multiple pairs of clamp pins 53 that are provided at the lower end of the main body 50 and support the bottom surface 911 of the FIBC storage rack 91 from below.

The main body 50 is formed in an inverted U-shape when viewed from the front side (e.g., one side in the x-axis direction) and is composed of an upper end frame 51 assembled in a rectangular shape when viewed from above, and a pair of side frames 52 hanging down from both sides of the upper end frame 51. The clamp pin 53 advances and retreats horizontally (e.g., in the y-axis direction) between a protruding position where it protrudes inward from the lower end 52a of the side frame 52, and a concealed position where it does not protrude from the lower end 53a.

The clamp pins 53 are located in a concealed position in a free state (when not gripping the FIBC storage rack 91), and are placed in a protruding position when gripping the FIBC storage rack 91. As shown in FIG. 6, the multiple pairs of clamp pins 53 contact the underside of the bottom portion 911 of the FIBC storage rack 91. This allows the FIBC storage rack 91 to be supported from below. For example, two pairs of clamp pins 53 are provided.

In order for the hand unit 5 to stably hold the FIBC storage rack 91, it is desirable that the pair of side frames 52 of the main unit 50 contact or are close to both side surfaces (e.g., cross bars 913) of the FIBC storage rack 91. It is also desirable that the upper end frame 51 of the main unit 50 contact or are close to the upper end of the FIBC storage rack 91 (e.g., square pillars 912 or cross bars 913 on the upper side). The main unit 50 may have a fitting portion that fits into the square pillars 912 or cross bars 913 of the FIBC storage rack 91 from the side or above (not shown). This reduces the risk of the FIBC storage rack 91 falling off the hand unit 5 even when the FIBC storage rack 91 held by the hand unit 5 is raised or lowered.

As shown in FIG. 5, the hand unit 5 has a centering mechanism 54 that absorbs horizontal positional deviation with respect to the FIBC storage rack 91 to be grasped. The centering mechanism 54 is provided on both of the pair of side frames 52 and has an inward groove 540 that receives the square pillar 912 of the FIBC storage rack 91. The groove 540 has an upper groove with a constant groove width and a lower groove whose groove width increases toward the bottom. As a result, even if the position of the FIBC storage rack 91 and the position of the hand unit 5 in a plan view are slightly misaligned in the x-axis direction (or y-axis direction), the positional deviation can be corrected during the descent of the hand unit 5 by lowering the steel belt 43. In other words, the hand unit 5 can center the FIBC storage rack 91 and accurately grasp it.

The upper frame 51 of the hand unit 5 is provided with a lock pin (convex portion) 55 that protrudes upward. Multiple lock pins 55 (for example, four) are provided on the upper frame 51. The lock pins 55 will be described with reference to FIG. 7. As shown in FIG. 7(A), the carriage body 35 of the trolley 3 is provided with a pin receiver holder 36 corresponding to the position where the lock pin 55 is arranged. The pin receiver holder 36 has a through hole that extends in the vertical direction or a recessed portion that is recessed upward.

The lock pin 55 and the pin receiver holder 36 constitute a fixing means for fixing the hand part 5, which has been raised to the upper end by winding up the steel belt 43, to the trolley 3. As shown in FIG. 7(B), when the hand part 5 is raised to the upper end, the lock pin 55 fits into the pin receiver holder 36. This causes the hand part 5 to be integrated with the trolley 3 (locked state). As will be described in detail later, horizontal movement of the trolley 3 is possible only when the hand part 5 is fixed to the trolley 3, and horizontal movement of the trolley 3 is not possible when the hand part 5 is not fixed to the trolley 3 (when the hand part 5 is suspended from the steel belt 43).

In the example of FIG. 7, the outer peripheral surface 550 of the lock pin 55 is a tapered surface. Also, the inner peripheral surface 360 of the through hole or recess of the pin receiver holder 36 is a tapered surface with a larger diameter on the lower side. This allows the lock pin 55 to be pushed into the pin receiver holder 36 until the outer peripheral surface 550 of the lock pin 55 tightly contacts the inner peripheral surface 360 of the pin receiver holder 36, so that the hand unit 5 can be securely fixed to the trolley 3.

The configuration of the fixing means is not limited to the configuration shown in FIG. 7, and it is sufficient that the hand unit 5 is fixed to a predetermined position on the trolley 3 at the raised end. For example, a recess may be provided on the hand unit 5 side, and the fitting portion on the trolley 3 side may be a protrusion such as a lock pin.

(Configuration of connecting member)
The structure of the connecting member 6 that connects the lower end of the steel belt 43 to the hand unit 5 will be described with reference to FIG.

The connecting member 6 includes, for example, a belt side member 61 fixed to the lower end of the steel belt 43, a hand side member 62 fixed to the hand unit 5, and a vibration absorbing means 63 provided between the two members 61, 62. The belt side member 61 has, for example, a rod member 61a whose upper end is connected to the lower end of the steel belt 43, and an annular flange portion 61b provided at the lower end of the rod member 61a. The hand side member 62 is, for example, formed of an annular member that protrudes laterally from the upper end frame 51 of the hand unit 5 and through which the longitudinal center portion of the rod member 61a passes.

The vibration absorbing means 63 is composed of a spring that can expand and contract in the vertical direction, and is provided between the annular member serving as the hand side member 62 and the flange portion 61b. This makes it possible to absorb the vibration (shock) applied to the hand portion 5 when winding of the steel belt 43 is completed (when the hand portion 5 reaches the raised end). As a result, it is possible to prevent the FIBC storage rack 91 held by the hand portion 5 from shifting position due to shock, or the FIBC storage rack 91 from falling. Alternatively, it is possible to prevent the FIBC bag 90 from falling off the FIBC storage rack 91.

(Trolley drive mechanism)
The drive mechanism 30 of the trolley 3 will be described with reference to Figures 4 and 9. Figure 9 is a diagram showing a schematic diagram of the drive mechanism 30 of the trolley 3. As shown in Figure 4, a chain 24 extending in the front-rear direction (y-axis direction) is disposed on each transverse rail 22. Both ends of the chain 24 are fixed in a tensioned state.

The drive mechanism 30 includes a travel motor 31 mounted on the carriage body 35, and power transmission means 33, 33 provided on both the left and right sides of the carriage body 35. The power transmission means 33 includes a drive sprocket 33a and two driven sprockets 33b that are coaxially connected to a rotating shaft 32 that is rotated (forward and reverse) by the travel motor 31, and these sprockets 33a, 33b are configured to mesh with the chain 24. In this way, the drive mechanism 30 includes sprockets 33a, 33b that mesh with the chain 24, and the travel motor 31 that drives one sprocket 33a.

The trolley 3 moves forward and backward (in the y-axis direction) by itself while pulling the chain 24. This makes it less likely for slippage to occur than in a drive method in which the wheels 34 are directly rotated by the travel motor 31, and therefore prevents positional deviation when stopped. In other words, by providing the trolley 3 with the power transmission means 33, the trolley 3 can be stopped at an accurate position in the y-axis direction.

(Saddle drive mechanism)
The drive mechanism 20 of the saddle 2 also has a power transmission means similar to the drive mechanism 30 of the trolley 3. Specifically, as shown in Fig. 10, the drive mechanism 20 includes a travel motor 24 mounted on the carriage body 21 and a power transmission means 25 provided on a side (one side) of the carriage body 21. The power transmission means 25 includes a drive sprocket 25a and two driven sprockets 25b that are coaxially coupled to a rotating shaft 24a that is rotated (forward and reverse) by the travel motor 24, and these sprockets 25a, 25b are configured to mesh with a chain 12 arranged on the traveling rail 11.

As a result, the saddle 2 also moves left and right (x-axis direction) by itself while pulling the chain 12, so the saddle 2 can be stopped at an accurate position in the x-axis direction.

Because the saddle 2 and trolley 3 are equipped with the above-mentioned drive mechanisms 20, 30, the trolley 3 can be stopped at a desired planar position (xy coordinates). As a result, the hand unit 5, which moves integrally with the trolley 3, can be transported to a desired planar position (xy coordinates).

(Position detection means)
In order to improve the accuracy of the stopping position of the trolley 3, it is desirable that the saddle 2 and the trolley 3 are equipped with a position detection means for detecting their own positions. Fig. 11 is a schematic diagram showing an example of the configuration of the position detection means 37 mounted on the trolley 3.

As shown in FIG. 11, the position detection means 37 includes a camera that faces the code tape 26 attached along the longitudinal direction (y-axis direction) of the lateral rail 22. The position detection means 37 reads the code information (e.g., QR Code (registered trademark)) displayed on the code tape 26 with the camera to detect its own position. The detected position information is sent to the control device and used for feedback control of the movement motor 31 by the control device. A similar position detection means is also provided in the saddle 2. This allows the trolley 3 to be stopped at the desired position easily and with high accuracy.

(Overview of overhead crane operation)
Next, an overview of the operation of the ceiling crane apparatus 1 when the flexible container bag 90 is loaded into and unloaded from the warehouse will be described.

When a FIBC bag 90 is stored, the control device of the overhead crane device 1 picks up the FIBC storage rack 91 placed at the loading/unloading station AR1 and controls its transport to a specified storage location in the storage area AR2. The storage address is information indicating a three-dimensional position, and is represented, for example, by a number in the x-axis direction, a number in the y-axis direction, and a number in the z-axis direction (tier number). The "number" is not limited to numbers, and may include letters and symbols.

The control device of the overhead crane device 1 first controls the movement of the saddle 2 and trolley 3, and moves the trolley 3 (hand unit 5) onto the loading/unloading station AR1. It is desirable for the control device to operate the saddle 2 and trolley 3 simultaneously (in parallel) and move the trolley 3 diagonally.

With the trolley 3 stopped directly above the FIBC storage rack 91 to be picked up, the steel belt 43 is slowly wound down and the hand unit 5 is lowered to the height of the FIBC storage rack 91 to be picked up. The hand unit 5 is preferably provided with a detection means for checking the FIBC storage rack 91 when it is lowered (not shown). The control device protrudes the multiple pairs of clamp pins 53 to grip the FIBC storage rack 91 with the hand unit 5, then slowly winds up the steel belt 43, raises the hand unit 5 to the upper end, and secures it to the trolley 3.

After the hand unit 5 is locked, the control device again controls the movement of the saddle 2 and the trolley 3 so that the hand unit 5 (trolley 3) arrives at the horizontal position (xy coordinates) corresponding to the specified storage address. Because the FIBC storage rack 91 is large and heavy, the movement speed of the saddle 2 and the trolley 3 is set to a slow speed.

After the trolley 3 is stopped at the correct planar position (xy coordinates), the steel belt 43 is slowly wound down. Specifically, the hand unit 5 is lowered to a position height (z coordinate) corresponding to the specified storage address. After the hand unit 5 has stopped at the correct position height, the clamp pin 53 is retracted to the concealed position, and the FIBC storage rack 91 is released. This allows the FIBC storage rack 91 to be placed at the desired storage address in the storage area AR2. The FIBC storage rack 91 is placed on the floor of the storage area AR2, or is stacked on top of an already placed FIBC storage rack 91.

When the FIBC bag 90 is unloaded, the control device of the overhead crane device 1 picks up the FIBC storage rack 91 placed in the designated storage location in the storage area AR2 and controls its transport to the loading/unloading station AR1. When unloading, the overhead crane device 1 performs the reverse operation from when it was loaded.

Specifically, the control device of the overhead crane device 1 controls the movement of the saddle 2 and the trolley 3 so that the empty hand unit 5 (trolley 3) arrives at a horizontal position (xy coordinates) corresponding to the specified storage address. In an empty hand unit 5, the clamp pin 53 is located in the concealed position. Even when the empty hand unit 5 is transported, the hand unit 5 is fixed to the trolley 3.

After the trolley 3 is stopped at the correct planar position (xy coordinates), the steel belt 43 is slowly wound down. Specifically, the hand unit 5 is lowered to a position height (z coordinate) corresponding to the specified storage address. After the hand unit 5 has stopped at the correct position height, the multiple pairs of clamp pins 53 protrude inward and grip the FIBC storage rack 91. Once the hand unit 5 has gripped the FIBC storage rack 91, the steel belt 43 is slowly wound up, and the hand unit 5 is raised to the upper end and fixed to the trolley 3.

If another FIBC storage rack 91 is stacked on top of the FIBC storage rack 91 to be picked up, the upper FIBC storage rack 91 is moved to an evacuation area near the storage area AR2 before the target FIBC storage rack 91 is picked up.

After the hand unit 5 is locked, the control device again controls the movement of the saddle 2 and trolley 3, moving the trolley 3 (hand unit 5) at a low speed from the storage area AR2 to the loading/unloading station AR1. When the trolley 3 arrives at the loading/unloading station AR1, the steel belt 43 is slowly wound down to release the FIBC storage rack 91. At the loading/unloading station AR1, FIBC storage racks 91 may also be stacked on top of FIBC storage racks 91 already placed thereon.

In this way, the control device of the ceiling crane device 1 controls the movement of the saddle 2 and trolley 3 (only) when the hand unit 5 is fixed at the raised end by winding up the steel belt 43. In other words, the saddle 2 and trolley 3 are not moved when the hand unit 5 is suspended by the steel belt 43 (when not fixed by the lock pin 55). This makes it possible to prevent the hand unit 5 from swinging when the saddle 2 or trolley 3 moves. It also makes it possible to prevent the hand unit 5 from colliding with the FIBC storage racks 91 stacked high in the storage area AR2. Therefore, the FIBC bags 90 can be transported safely.

<Regarding the management device>
Fig. 11 is a block diagram showing a schematic functional configuration of a management device provided in the FIBC transport system according to this embodiment. As shown in Fig. 11, in this embodiment, the FIBC transport system includes a management device 100, a calculation device 200, and a control device (hereinafter referred to as a "crane control device") 300 for the overhead crane device 1. The management device 100 and the calculation device 200 are information processing devices having a processor and a memory unit. The memory unit of the management device 100 stores a warehousing program, a warehousing program, inventory master information, and control data for the operation of the overhead crane device 1. The memory unit of the calculation device 200 stores a calculation program for calculating machine coordinates for the operation of the overhead crane device 1.

As shown in FIG. 11, a calculation device 200 is interposed between the management device 100 and the crane control device 300, and these devices 100, 200, and 300 are independent subsystems, so that when a problem occurs, it can be quickly isolated.

The management device 100 executes the storage program when a warehousing schedule for FIBC bags 90 is input via the operation panel 9. The warehousing schedule information includes item information and the number of items to be stored for the FIBC bags 90. The item information includes at least content-specific information for identifying the manufacturer and item name, and may include manufacturing information for identifying the manufacturing date and lot number (production unit). The management device 100 determines the storage address (storage location in three-dimensional space) of the FIBC bags 90 according to a "storage address optimization algorithm" defined in the warehousing program. The storage address optimization algorithm is an address determination algorithm that is defined in consideration of optimal shipping (for example, calculated based on the experience of past shipping operations and the characteristics of the stored items).

For example, when multiple FIBC bags 90 of the same item are received, the management device 100 assigns storage addresses to store them together in the same location according to a storage address optimization algorithm. Desirably, storage addresses in the same tower (addresses differing only in the stage number) are assigned. By ensuring that FIBC bags 90 of different items are not stored in the same tower (same horizontal position), extra operations such as reloading FIBC storage racks 91 can be eliminated when retrieving the items.

The storage address of each FIBC bag 90 is stored in the inventory master storage unit and the control data storage unit. The inventory master storage unit stores the storage address, the date of entry, and item information in association with the identification number of the FIBC bag 90. The inventory master storage unit further stores quality control information for identifying the quality of each item (for example, whether or not it is defective).

The management device 100 executes the outgoing program when the outgoing schedule of FIBC bags 90 is input via the operation panel 9. The shipping schedule information includes the type of FIBC bags 90 and the number of items to be shipped. It may also include the scheduled outgoing date. The management device 100 determines the FIBC bags 90 to be shipped according to the "outgoing optimization algorithm" defined in the outgoing program, and determines the outgoing order of the FIBC bags 90 scheduled to be shipped on the same day. The outgoing optimization algorithm is an algorithm for realizing first-in, first-out, prevention of erroneous shipments (items), and prevention of erroneous shipments based on quality control information of the FIBC bags 90. The identification numbers and outgoing order of the FIBC bags 90 to be shipped are stored in the control data storage unit.

The management device 100 automatically determines the operation method of the ceiling crane device 1 on the working day based on the information stored in the control data storage unit. If only control data for entering the warehouse is stored, it determines it as a "warehouse entry only operation", and if only control data for retrieval is stored, it determines it as a "warehouse exit only operation". If both control data for entering the warehouse and control data for retrieval are stored, it determines it as a "warehouse entry and exit simultaneous operation".

"Simultaneous loading and unloading operation" means that on the way back from a loading operation (the operation of transporting (loading) a FIBC bag 90 picked up at loading/unloading station AR1 to storage area AR2), the overhead crane device 1 is moved so that the FIBC bag 90 to be unloaded is picked up at storage area AR2 and returned to loading/unloading station AR1. By enabling such simultaneous loading and unloading operations, it is possible to compensate for the slow transport speed.

The management device 100 transmits the determined operation method to the computing device 200 together with the control data stored in the control data storage unit.

The arithmetic device 200 calculates the machine coordinates for operating the overhead crane device 1 based on the received information. The arithmetic device 200 provides the calculated machine coordinates to the crane control device 300. The crane control device 300 includes a servo amplifier that operates the above-mentioned travel motor 31 and lift motors 41a, 41b. The crane control device 300 drives the travel motor 31 and lift motors 41a, 41b based on the received machine coordinates.

During the storage operation, the overhead crane device 1 transports the FIBC bag 90 to the optimal storage address determined according to the storage address optimization algorithm. Since the storage address is determined taking into account optimal shipping as described above, it is possible to (as much as possible) avoid the need to reload the stacked FIBC bags 90 during the shipping operation.

The computing device 200 also calculates the operating time of the overhead crane device 1 based on the calculated machine coordinates. This allows the operator to accurately know the operating time of the overhead crane device 1, allowing the operator to perform other tasks during automatic operation.

The management device 100 preferably receives the calculation results of the machine coordinates and operation time from the computing device 200, and stores the movement history of the contents (stored items) packed in the flexi-con bag 90 as an inventory history. By allowing the user who has entrusted the stored items to check the inventory history, the reliability of the stored items can be improved.

As described above, in this embodiment, the management device 100 manages (at least) the storage address and item information of each FIBC bag 90, making it possible to prevent erroneous shipment of FIBC bags 90. Furthermore, when a FIBC bag 90 is received, the management device 100 determines the storage address using a storage address optimization algorithm based on the empirical value of the order of shipment, making it possible to transport the FIBC bag 90 efficiently when it is shipped out.

The storage address optimization algorithm can be determined according to the type of contents of the FIBC bag 90 (for example, agricultural products such as rice, industrial products such as resin pellets, civil engineering and construction materials such as sand, etc.). In order to achieve more efficient loading and unloading, it is desirable to have the AI learn the shipping history of the FIBC bag 90 and update the storage address optimization algorithm.

In this embodiment, an example is shown in which the stored item to be transported by the ceiling crane device 1 is a flexi-con bag, but the above-mentioned technology can also be applied to cases in which items other than flexi-con bags (heavy items) are transported and stacked.

The embodiments disclosed herein should be considered to be illustrative and not restrictive in all respects. The scope of the present invention is indicated by the claims rather than the above description, and it is intended to include all modifications within the meaning and scope of the claims.

1 Ceiling crane device, 2 Travel device (saddle), 3 Traverse device (trolley), 4 Winding device, 5 Hand section, 6 Connecting member, 9 Operation panel, 11 Travel rail, 12, 24 Chain, 20, 30 Drive mechanism, 22 Traverse rail, 24, 31 Travel motor, 25, 33 Power transmission means, 25a, 25b, 33a, 33b Sprocket, 26 Cord tape, 34 Wheel, 36 Pin receiving holder, 37 Position detection means, 41a, 41b Lifting motor, 43, 43a, 43b, 43c, 43d, 44a, 44b Suspension member (steel belt), 45a, 45b, 46a, 46b Reel, 53 Clamp pin, 54 Centering mechanism, 55 Lock pin, 61 Belt side member, 62 Hand side member, 63 Vibration absorbing means, 90 FIBC bag, 91 rack (FIBC storage rack), 100 management device, 200 calculation device, 300 crane control device (PLC), AR1 loading/unloading station, AR2 storage area, AR3 operation area, W width.

Claims (4)

A storage item transport system that automatically stores and retrieves stored items,
a ceiling crane device having a hand unit that grips a storage rack that contains storage items, and transports the storage rack gripped by the hand unit to a storage area and stacks it;
a management device for managing storage addresses and item information in the storage area for each storage item;
The overhead crane device includes a pair of traveling devices that are movable in the x-axis direction along a traveling rail inside a building, a traverse device that is movable in the y-axis direction along a traverse rail that is stretched between the pair of traveling devices, and a winding device that is mounted on the traverse device and winds up and down a suspended member having a lower end connected and fixed to the hand unit,
The management device determines a storage address indicating a three-dimensional position when the storage item is stored,
The overhead crane device further includes a control device that controls the traveling device, the traverse device, and the winding device so that the hand unit arrives at a storage address determined by the management device,
A chain having fixed ends is provided along the traveling rail and the traverse rail,
The running device and the traverse device include a drive sprocket located on one side of the chain in the vertical direction , two driven sprockets located on the other side of the chain in the vertical direction with the drive sprocket between them, and a movement motor that drives the drive sprocket, and a drive mechanism is provided that is configured so that the drive sprocket and the two driven sprockets mesh with the chain . 2. The stored item transport system according to claim 1 , wherein at least one of the traveling device and the traversing device is provided with a position detection means for detecting its own position. 2. The stored item transportation system according to claim 1 , wherein the management device determines the storage address when the stored item is received using an algorithm based on an empirical value of the order of items being shipped out. The stored item transportation system of claim 1, further comprising an arithmetic device that calculates machine coordinates for operation of the ceiling crane device based on the storage address of each stored item determined by the management device, and transmits the calculated machine coordinates to the control device.

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