JP4122967B2 - Forklift selection support device, forklift selection support method, and forklift selection support program - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a forklift selection support device, a forklift selection support method, and a program thereof.
[0002]
[Prior art]
A battery forklift without exhaust gas is used for indoor transportation such as a warehouse. In order to build a transport system that arranges a large number of shelves in the warehouse and stores the goods that are carried from the outside to the shelves, or transports the stored goods to the place of delivery, the daily transport work It is necessary to select a battery forklift that can perform this.
[0003]
As a method for selecting a battery forklift, for example, Japanese Utility Model Laid-Open No. 6-59917 discloses a quick reference table in which the number of cycles by lift and the number of cycles by battery capacity are plotted on the vertical axis and the average travel distance is plotted on the horizontal axis. Is described for each model of the battery forklift to facilitate the selection of the model.
[0004]
By the way, to determine the required number of battery forklifts when the amount of work per day is decided, calculate the cycle time (time required for one warehousing and evacuation work) of the warehousing and unloading work of luggage. There is a need to. Further, in order to determine whether or not the capacity of the battery is appropriate, it is necessary to calculate the power consumption by the warehousing work and the warehousing work.
[0005]
For this reason, the battery forklift catalog describes the cycle time and power consumption for a standard route.
FIG. 10 (A) is a diagram illustrating an example of a transportation route described in a catalog of a conventional battery forklift.
[0006]
Move the battery forklift from point A to point C in FIG. 10 (A) with no load, push out the reach, raise it 2m, lower it, tilt it forward, pull in the reach, and from point C via point D to point A Return to the point. Assuming that this work is one cycle, the number of hours of continuous operation is shown as data.
[0007]
[Patent Document 1]
Japanese Utility Model Publication No. 6-59917 (abstract, paragraphs 0007, 0008)
[0008]
[Problems to be solved by the invention]
However, the usage conditions of each user are different, and calculating the cycle time and power consumption suitable for the usage conditions of each individual user only by describing the standard route and its power consumption as described above. I can't.
[0009]
For example, when the actual package transport route is a route as shown in FIG. 10B, that is, when the load is empty, the vehicle retreats from the point A to the point B, switches back and moves forward to the point C. After pushing out, scooping, and pulling in the reach, move backward to point D, then turn right at point E and advance to point A.
[0010]
There was no means for calculating the cycle time of the traveling pattern as described above and the power consumption when the operation was repeated. Therefore, it is difficult to determine how many battery forklifts are necessary to perform the loading / unloading work desired by the user.
An object of the present invention is to enable accurate selection of a forklift.
[0011]
[Means for Solving the Problems]
Selection supporting device for a forklift of the present invention, warehousing located in work area using a forklift, unloading position, based on the layout information indicating the storage position, the wire forming means for forming a conductor showing a movement path of the forklift, the Based on the total value of the horizontal distance of the conducting wire, the total value of the vertical distance of the conducting wire, and the number of turns in the conducting wire, the warehousing cycle time required to transport the luggage from the warehousing position to the storing position, and the luggage A cycle time calculation means for calculating a delivery cycle time required for transporting the container from the storage position to the delivery position, the receipt cycle time calculated by the cycle time calculation means, the delivery cycle time, and the number of receipts per day Estimating means for estimating the number of forklifts required based on the number of warehouses per day Obtain.
[0012]
According to this invention, since the warehousing cycle time and the warehousing cycle time can be calculated for an arbitrary transportation route, the number of forklifts necessary for executing a predetermined number of warehousing operations and warehousing operations is estimated. can do.
Furthermore, it has power consumption calculation means for calculating power consumption due to the warehousing operation and the warehousing operation based on the conducting wire, and the estimating means includes the warehousing cycle time, the warehousing cycle time, and the power consumption in the warehousing operation and the warehousing operation. The number of necessary forklifts may be estimated based on the number of times of warehousing per day and the number of times of warehousing per day.
[0013]
By configuring in this way, it is possible to calculate the capacity of the battery necessary for executing the designated number of warehousing and unloading operations and to estimate the number of forklifts necessary from the battery capacity. Thereby, the number of forklifts can be estimated more accurately in consideration of the capacity of the battery.
[0014]
Further, the cycle time calculating means may calculate a cycle time of picking for transporting a part of a load from a shelf to a delivery position or an operation for refilling a part of the load.
By comprising in this way, the cycle time of loading / unloading and the cycle time of picking (or replenishment) can be calculated, and the number of required forklifts can be estimated from those calculation results.
[0015]
The calculation of the warehousing cycle time and the warehousing cycle time is, for example, calculating the total value of the horizontal distance and the total distance of the vertical distance indicating the transportation route from the warehousing position to the storage position, and further turning at a right angle from the conductive line. Calculate the number of times, multiply the time required for the turn by the number of turns, calculate the total time required for the right-angled turn, and add the times.
[0016]
Conductor creating means corresponds to, for example, a drawing function of the CAD tool support apparatus 11 of Figure 1, the cycle time calculating means corresponds to the cycle time calculation tools CAD tools, power consumption calculation means, CAD tools Corresponds to the power consumption calculation tool.
[0017]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is an explanatory diagram of functions of a battery forklift selection support device 11 having a battery forklift cycle time and power consumption calculation tool.
[0018]
The battery forklift selection support device (hereinafter referred to as support device) 11 is constituted by, for example, a portable personal computer and has a CPU, a memory, and a hard disk (storage device). The support device 11 stores a CAD tool (program) including a battery forklift cycle time and power consumption calculation tool in a storage device.
[0019]
The CAD tool has an interactive input screen. The building information such as the size of the customer's building, the arrangement of the shelves, the loading / unloading position of the baggage, the load information such as the size and weight of the baggage, the user When the type of forklift recommended is entered, a conductor showing the overall layout and the route of cargo transport from the storage position of the battery forklift to the storage position of the shelf or the route of transport of luggage from the storage position of the shelf to the delivery position is created. Is done. And the cycle time and power consumption of loading / unloading are calculated based on the created conducting wire. In addition, the number of forklifts required for the daily loading / unloading work is estimated from the calculated loading / unloading cycle time, the number of loading / unloading times per day, the number of warehouses per day, the working time per day, etc. The number of units and the overall layout are output from the CAD tool as proposal materials.
[0020]
FIG. 2 is a flowchart illustrating processing contents of the CAD tool according to the embodiment. The CPU of the support device 11 creates a layout diagram showing the shelves for storing the luggage, the loading / unloading positions, etc. from the inputted building information (FIG. 2, S11).
Next, based on the above layout diagram, a forklift conducting wire indicating a route for transporting the cargo from the storage position of the battery forklift to the predetermined storage position of the shelf or from the predetermined storage position of the shelf to the storage position is created (FIG. 2). S12).
[0021]
When the conducting wire is created, the total value of the distances of the horizontal portions of the conducting wire is calculated (FIG. 2, S13). Further, the total value of the distances of the vertical portions of the conducting wire is calculated (FIG. 2, S14). Further, it is calculated how many times the conducting wire is turned at a right angle (FIG. 2, S15).
The parameter table (hereinafter referred to as a parameter table) 21 for calculating the cycle time and power consumption shown in FIG. 4 includes a switchback required time Tsb and power consumption Wsb at that time, a required time Ttv during right-angle turning and power consumption at that time. Wtv, time required for acceleration Tda and power consumption Wda at that time, time required for constant speed driving Tds and power consumption Wds at that time, time required for deceleration Tdd and power consumption Wdd at that time, turning with loading ( The required time Ttwa (at the time of approach) and the power consumption Wtwa at that time, the required time Ttwd at the time of product turning (at the time of departure), the power consumption Wtwd at that time, etc. are set as fixed values.
[0022]
The load handling time Tpck for picking is set by the user when the load handling time Twkr at the shelf and the load handling time Twks at the loading / unloading site (entry / exit position) are set. The parameter table 21 is provided with two types of tables for each forklift model: a case of traveling with a load of 70% and a case of traveling with no load.
[0023]
Based on the corresponding parameters in the parameter table 21, the CPU of the support device 11 calculates the warehousing operation cycle time, which is the time required to transport the luggage from the warehousing position to the predetermined storage position on the shelf, and the power consumption at that time. Calculation is performed (FIG. 2, S16).
[0024]
Further, based on the lead wire for the delivery operation and various parameters in the parameter table 21, the delivery operation cycle time, which is the time required to transport the cargo from the predetermined position on the shelf to the delivery position, and the power consumption at that time are calculated. Calculate (FIG. 2, S17).
Next, the cycle time and power consumption of the picking operation are calculated based on the parameters related to the picking operation in the parameter table 21 (FIG. 2, S18).
[0025]
FIG. 3 is a detailed flowchart of the process of calculating the cycle time and power consumption in steps S16 to S18 in FIG.
First, the corresponding parameter table 21 is searched using the model of the forklift to be used as a key, and the maximum traveling speed Rmax, the traveling acceleration time Tds, the traveling current Ida, and the maximum lifting speed Pmax set in the parameter table 21 are searched. Then, fixed values such as the vertical acceleration time Tlua and the vertical current Ila are acquired (FIG. 3, S21). The above fixed values are stored in the parameter table 21 of FIG.
[0026]
In the next step S22, the following calculations (1) to (5) are performed, and a numerical value not given as a fixed value is calculated.
Specifically, the time required to travel a predetermined distance by dividing the value obtained by subtracting the acceleration distance (Rmax × Tda / 2) from the travel distance L obtained from the distance calculation of the lead wire by the maximum travel speed Rmax. Tds is calculated (calculation of S22, (1)).
[0027]
The power consumption Wds is calculated by multiplying the required time Tds when traveling at a constant speed over the distance L obtained by the calculation of (1) above and the current consumption Ids during constant speed traveling (S22, (2)). Calculation).
Next, a value obtained by subtracting the acceleration distance (Pmax × Tlua / 2) from the lifting height V is divided by the maximum ascent speed Pmax to calculate a required time Tlus when the lift is raised at a constant speed (S22, Calculation of (3)).
[0028]
Next, the power consumption Wlus at the time of increase is calculated by multiplying the required time Tlus when the lift obtained by the above calculation (3) is increased and the current consumption Ilus at the time of increase (S22, (4)). ▼ calculation).
Next, the cargo lifting height V is divided by the maximum climbing speed Pmax to calculate the required time Tldd when descending (calculation of S22, (5)).
[0029]
Next, the warehousing operation cycle time is calculated using the numerical values of the parameter table 21 and the calculation formula defined for each operation (FIG. 3, S23). The warehousing operation cycle time is calculated from the following formula.
ΣT = NL [Twks] + FL [Tsb + Tda + Tds + Tdd + n × Ttv + Ttwa
+ Tlua + Tlus + Topt1 + Topt2 + Twkr] + NL [Tldd + Ttwd + Tda
+ Tds + Tdd + n × Ttv + Ttwa]
In the above formula, FL [] indicates the work time when there is a load (load of 70% of the rated value), and NL [] indicates the work time when there is no load.
[0030]
Next, the power consumption at the time of warehousing is calculated using the numerical value of the parameter table 21, the value calculated in step S22, and the calculation formula (FIG. 3, S24). The power consumption of the warehousing operation is calculated from the following formula.
ΣW = NL [Wwks] + FL [Wsb + Wda + Wds + Wdd + n × Wtv + Wtwa
+ Wlua + Wlus + Wopt1 + Wopt2 + Wwkr] + NL [Wldd + Wtwd + Wda
+ Wds + Wdd + n × Wtv + Wtwa]
Next, the shipping operation cycle time, the shipping operation power consumption, the picking cycle time, and the picking power consumption are calculated in the same procedure as A and B in steps S24 and S25 (FIG. 3, S25).
[0031]
Here, a specific example of the process of calculating the cycle time and power consumption in steps S23 to S25 will be described with reference to FIGS.
FIG. 5 is a diagram showing a lead wire for the warehousing operation of the forklift 33. When the position of the cargo handling area (entry / exit position) 31 and the shelf 32 in the building is designated, the CAD tool creates a conductive wire 34 connecting the predetermined storage position of the cargo handling area 31 and the shelf 32, which is the entry point. The CAD tool calculates the warehousing operation cycle time and the power consumption by creating the conducting wire 34 and then calculating the distance of the straight line portion of the conducting wire 34 and the number of times of turning at right angles.
[0032]
The warehousing operation refers to the following operation. After loading the cargo at the loading place 31 at the position x0 in FIG. 5 and switching back to the position x1 in FIG. 5, the direction is changed to a right angle, and the right turns at the position x3 to the position x4 in front of the shelf 32. Moving. Then, the lift is lifted to load the pallet on which the luggage on the shelf 32 is loaded, and after returning to the loading place 31 after being stored in the shelf 32. The cycle time during the warehousing operation can be calculated by the following formula.
[0033]
ΣT = NL [Twks] + FL [Tsb + Tda + Tds + Tdd + n × Ttv + Ttwa
+ Tlua + Tlus + Topt1 + Topt2 + Twkr] + NL [Tldd + Ttwd + Tda
+ Tds + Tdd + n × Ttv + Ttwa]
In the brackets [], Twks is the load handling time at the loading station 31, Tsb is the switchback time, Tda is the acceleration travel time, Tds is the constant speed travel time, Tdd is the deceleration travel time, and n is the number of turns at right angles. Ttv is the right turn time, Ttwa is the load turn time when approaching, Twd is the load turn time when leaving, Tlua is the rise time when climbing up, Tlus is the rise time when climbing at a constant speed, Topt1 is the time required for option operation 1 (reach in, reach out, etc.), Topt2 is the time required for option operation 2 (attachment operation, etc.), Twkr is the load handling time on the shelf, Tldd is the descent time when descending at a constant speed, Ttwd indicates the loading turn time when leaving.
[0034]
The warehousing operation cycle time for transporting the cargo from the warehousing position to an arbitrary position on the shelf 32 can be calculated by the above formula.
The power consumption of the warehousing operation can also be calculated by the following formula, in the same manner as the above cycle time calculation method.
[0035]
ΣW = NL [Wwks] + FL [Wsb + Wda + Wds + Wdd + n × Wtv + Wtwa
+ Wlua + Wlus + Wopt1 + Wopt2 + Wwkr] + NL [Wldd + Wtwd + Wda + Wds
+ Wdd + n × Wtv + Wtwa]
In the above formula, Wwks in parentheses [] is the power consumption during handling at the loading site 31, Wsb is the power consumption during switch bag, Wda is the power consumption during acceleration travel, and Wds is the power consumption during constant speed travel. , Wdd is the power consumption during deceleration, Wlua is the power consumption during acceleration, Wlus is the power consumption during constant speed increase, Wopt1 is the power consumption for option operation 1, Wopt2 is the power consumption for option operation 2, and Wwkr is the shelf Power consumption at the time of handling in 32, Wldd is the power consumption at the time of constant speed descent, Wtwd is the power consumption of product turning at the time of approach, and Wtwd is the power consumption of product turning at the time of separation.
[0036]
The power consumption of the warehousing operation can be calculated by the above formula.
Next, FIG. 6 is a figure which shows the conducting wire of the forklift at the time of unloading operation | movement. A lead 34 shown in FIG. 6 is created by the CAD tool, and the cycle time and power consumption are calculated based on the lead 34. The conducting wire 34 in FIG. 6 is the same as the conducting wire 34 in the warehousing operation in FIG.
[0037]
The unloading operation refers to an operation of leaving the cargo handling area 31, moving to a predetermined position on the shelf 32, and loading the cargo to the cargo handling area 31.
The shipping operation cycle time can be calculated by the following formula.
ΣT = NL [Tsb + Tda + Tds + Tdd + n × Ttv + Ttwa + Tlua + Tlus
+ Topt1 + Topt2 + Twkr] + FL [Tldd + Ttwd + Tda + Tds + Tdd
+ N × Ttv + Ttwa + Twks]
The shipping operation cycle time can be calculated by the above formula.
[0038]
The power consumption ΣW for the leaving operation can be expressed as follows.
ΣW = NL [Wsb + Wda + Wds + Wdd + n × Wtv + Wtwa + Wlua + Wlus
+ Wopt1 + Wopt2 + Wwkr] + FL [Wldd + Wtwd + Wda + Wds + Wdd
+ N × Wtv + Wtwa + Wwks]
The power consumption of the leaving operation can be calculated from the above formula.
[0039]
Next, FIG. 7 is a diagram showing a lead wire for a picking (or replenishing) operation of the forklift 33.
Picking is an operation of transporting a part of the luggage stored in the pallet of the shelf 32 to the loading site 31. In addition, replenishment is an operation of replenishing the cargo from the loading site 31 to the pallet of the shelf 32 in reverse to picking.
[0040]
Define the picking cycle as follows: An empty pallet is placed on the lift at the loading station 31 at the position x0 in FIG. 7, the pallet is lowered at the position x2 in front of the shelf 32, and switched back to the position x3. The vehicle moves forward to the position x4, pulls out the pallet from the shelf 32, lowers the pallet on which the load is placed, and the operator places the load on the pallet on the empty pallet. The pallet on which the load was placed is returned to the original shelf 32, and the pallet placed below is placed on the lift and carried to the loading site 31.
[0041]
The cycle time during the picking operation can be expressed by the following equation.
ΣT = NL [Twks] + NL [Tsb + Tda + Tds + Tdd + n × Ttv + Twks
+ Tsb + Ttwa + Tlua + Tlus + Topt1 + Topt2 + Twkr] + FL [Tldd
+ Ttwd] + Tpck + FL [Tlua + Tlus + Ttwa + Topt1 + Topt2 + Twkr]
+ NL [Tldd + Ttwd + Tsb + Twks] + FL [Tsb + Tda + Tds + Tdd
+ N × Ttv + Ttwa + Twks]
The picking operation cycle time is calculated by the above formula.
[0042]
The power consumption ΣW of the picking operation can be expressed by the following equation, for example.
ΣW = NL [Wwks] + NL [Wsb + Wda + Wds + Wdd + n × Wtv + Twks
+ Wsb + Wtwa + Wlua + Wlus + Wopt1 + Wopt2 + Wwkr] + FL [Wldd + Wtwd] + FL [Wlua + Wlus + Wtwa + Wopt1 + Wopt2 + Wwkr]
+ NL [Wldd + Wtwd + Wsb + Wwks] + FL [Wsb + Wda + Wds + Wdd + n × Wtv + Wtwa + Wwks]
The power consumption of the picking operation is calculated from the above formula.
[0043]
The result obtained by multiplying the warehousing cycle time obtained as described above and the number of times of warehousing per day, the result of multiplying the number of times of warehousing cycle time and the number of warehousing per day, and the picking cycle time and the number of times of picking per day are multiplied. Total the results to calculate the daily forklift operating hours.
[0044]
Also, the required number of forklifts is calculated by dividing the actual operating time of the daily forklift by the daily work time (for example, 8 hours).
Furthermore, the result of multiplying the power consumption of the warehousing cycle by the number of times of warehousing per day, the result of multiplying the power consumption of the warehousing cycle by the number of times of warehousing per day, and the result of multiplying the power consumption of the picking cycle and the number of picking times per day To calculate the actual power consumption of a forklift truck for one day.
[0045]
Further, the average power consumption of the battery is calculated by dividing the actual power consumption of the daily forklift by the working time of the day. If the average battery current consumption is known, the continuous operation time of one forklift can be calculated based on the given work conditions from the battery capacity and the battery discharge characteristics. From this continuous operation time, it is possible to estimate how many forklifts can work for one day, or whether or not the battery needs to be replaced during one day of work.
[0046]
Next, FIG. 8 is a diagram showing the lead wire 42 for picking operation of the picker.
The picker picking cycle time is defined as follows. 8 lifts an empty pallet at the loading area 31 and moves without changing direction, lifts the picker at the position X1 in front of the shelf 32, moves the load from the shelf 32 to the pallet, and loads the load onto the pallet. It is the time until it is transported to the cargo handling area 31 in a state of being in an open state.
[0047]
The picker picking cycle time can be expressed by the following equation.
ΣT = NL [Tda + Tds + Tdd + n × Ttv + Tlua + Tlus + Topt1 + Topt2]
+ Tpck + FL [Tldd + Tda + Tds + Tdd + n × Ttv + Ttwa + Twks]
The picker picking cycle time can be calculated from the above equation.
[0048]
The power consumption can be calculated from the same calculation formula and the parameter table 21.
Next, FIG. 9 is a diagram showing a parameter table 51 for a vehicle mainly carrying goods such as a battery towing car.
[0049]
The difference between the parameter table 51 of FIG. 9 and the parameter table 21 of FIG. 4 is that the towing vehicle does not perform operations such as lifting, lowering, and turning with a load. It is not set.
The present invention is not limited to the embodiment described above, and can be configured as follows.
(A) The present invention is not limited to the case where the loading / unloading places described in the embodiment are the same, but can also be applied to transport systems having different loading / unloading places.
[0050]
【The invention's effect】
According to the present invention, the number of forklifts required for warehousing work, warehousing work, etc. can be estimated more accurately. Further, the number of necessary forklifts can be accurately estimated from the necessary battery capacity by calculating the power consumption of those operations.
[Brief description of the drawings]
FIG. 1 is an explanatory diagram of a tool for calculating the number of forklifts and power consumption.
FIG. 2 is a diagram showing a flowchart for calculating a conductor, cycle time, and power consumption.
FIG. 3 is a diagram illustrating a flowchart for calculating a cycle time and power consumption.
FIG. 4 is a diagram showing a parameter table.
FIG. 5 is a diagram showing a lead wire for a warehousing operation.
FIG. 6 is a diagram showing a lead wire for a leaving operation.
FIG. 7 is a diagram showing a conducting wire for a picking operation.
FIG. 8 is a diagram showing a lead wire for picking operation of the picker.
FIG. 9 is a diagram showing a parameter table for a towing vehicle.
FIG. 10 is an explanatory diagram of loading / unloading work.
[Explanation of symbols]
11 Battery Forklift Selection Support Device 21 Parameter Table 31 Loading Box 32 Shelf 33 Battery Forklift

Claims (3)

Conductor creation means for creating a conductor showing a moving path of the forklift based on layout information indicating a storage position, a delivery position, and a storage position at a work place where the forklift is used ;
Based on the total value of the horizontal distance of the conducting wire, the total value of the vertical distance of the conducting wire, and the number of turns in the conducting wire , the warehousing cycle time required to transport the load from the warehousing position to the storing position, and A cycle time calculating means for calculating a delivery cycle time required for transporting the package from the storage position to the delivery position;
Based on the conducting wire, power consumption calculating means for calculating power consumption in the warehousing operation and the warehousing operation;
Based on the warehousing cycle time and the warehousing cycle time calculated by the cycle time calculating means, the power consumption in the warehousing operation and the warehousing operation calculated by the power consumption calculating means , the number of times of warehousing per day, and the number of times of warehousing per day A forklift selection support device comprising an estimation means for estimating the number of forklifts required. Based on the layout information indicating the warehousing position, the warehousing position, and the storage position at the work place where the forklift is used , create a conductor that indicates the movement path of the forklift,
Based on the total value of the horizontal distance of the conducting wire, the total value of the vertical distance of the conducting wire, and the number of turns in the conducting wire , the warehousing cycle time required to transport the load from the warehousing position to the storing position, and Calculate the delivery cycle time required to transport the package from the storage position to the delivery position,
Based on the conducting wire, the power consumption in the warehousing operation and the warehousing operation is calculated,
Forklift selection support method for estimating the number of forklifts required based on the calculated warehousing cycle time and warehousing cycle time, power consumption in the calculated warehousing operation and warehousing operation , the number of warehousing operations per day, and the number of warehousing operations per day . Computer
A conductor creation means for creating a conductor showing a movement path of the forklift based on layout information indicating a storage position, a delivery position, and a storage position in a work place where the forklift is used;
Based on the total value of the horizontal distance of the conducting wire, the total value of the vertical distance of the conducting wire, and the number of turns in the conducting wire, the warehousing cycle time required to transport the load from the warehousing position to the storing position, and A cycle time calculating means for calculating a delivery cycle time required for transporting the package from the storage position to the delivery position;
Power consumption calculation means for calculating power consumption in the warehousing operation and the warehousing operation based on the conducting wire,
Based on the warehousing cycle time and the warehousing cycle time calculated by the cycle time calculating means, the power consumption in the warehousing operation and the warehousing operation calculated by the power consumption calculating means, the number of times of warehousing per day, and the number of times of warehousing per day An estimation means for estimating the number of forklifts required,
Forklift selection support program to function as

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