JP7773188B2 - system - Google Patents

Description

The present invention relates to a system for inspecting whether or not an egg is present in each seat of a tray having multiple seats.

Conventionally, there has been known a device that stacks trays with multiple storage seats in multiple layers and automatically packs them into boxes (see, for example, Patent Document 1).

Japanese Unexamined Patent Publication No. 56-7834

When packing eggs in boxes, they may be packed with all of the tray's seats filled with eggs, as shown in Patent Document 1. Also known is a trading method unique to eggs, in which eggs are packed in boxes with a fixed weight (for example, 10 kilograms or 5 kilograms).

For example, in the case of a fixed weight of 10 kilograms, all of the storage seats on the first to third trays are filled with eggs. On the other hand, the fourth tray is stacked on top of the third tray with some of the storage seats filled with eggs, but the remaining seats empty, and then shipped. In this way, the total weight of the eggs stored on the first to fourth trays is set to 10 kilograms. Note that eggs are natural products and each one weighs differently, so the number of eggs required to reach 10 kilograms is not fixed.

For example, in the case of a fixed weight of 5 kilograms, all of the seats on the first tray are filled with eggs, and the second tray is stacked on top of the first tray with some seats filled with eggs but the rest empty, and then shipped. In this way, the total weight of the eggs contained in the first and second trays is set to 5 kilograms.

When the trays are stacked and placed in a cardboard box, it is not possible to check the condition of the eggs from outside the box. Therefore, as boxing becomes more automated, there is a demand for automated inspection of the condition of the eggs on the trays before they are boxed.

The present invention therefore aims to provide a system that inspects eggs placed in each tray seat before the tray is placed in a cardboard box.

To achieve the above-mentioned objective, the present invention takes the following measures. Specifically, the system of the present invention is a system that inspects whether or not eggs are present in each of the storage seats of a tray that has multiple storage seats, and includes an inspection unit that inspects each storage seat, and a control unit that switches the inspection method in the inspection unit between inspecting one tray and inspecting other trays among the multiple trays contained in a single cardboard box.

According to the present invention, eggs placed in each tray seat can be inspected before the tray is placed in a cardboard box.

1 is an overall view of an egg tray transfer device according to an embodiment of the present invention; FIG. 1 is a plan view of one embodiment of an egg tray. FIG. 2 is a perspective view of the head portion shown in FIG. 1 . 10A and 10B are explanatory diagrams illustrating the operation of the tray holding device. FIG. 2 is an enlarged view of a main part of FIG. 1 . 1 is a flowchart showing an embodiment of a method for transferring egg trays. 1 is a flow chart illustrating an embodiment of a method for inspecting egg trays. 10 is a flowchart showing a modified example of the method for inspecting egg trays. FIG. 1 is a schematic diagram of a system including an egg tray transfer device.

The following describes an embodiment of the present invention with reference to the drawings.

The egg tray transfer device has an egg suction device 1 that detachably suctions the top surfaces of eggs E stored in egg trays T. The egg tray transfer device has a tray holding device 2 that holds egg trays T in recesses T1 formed on the outer periphery of the egg trays T. The egg tray transfer device has a moving device 3 that moves the egg suction device 1 and tray holding device 2 relative to the cardboard box G.

A tray conveying device 4 for conveying egg trays T and a cardboard conveying device 5 for conveying cardboard boxes G are provided near the moving device 3.

The tray conveying device 4 is equipped with a tray inspection device 31 (corresponding to the "inspection unit" of the present invention) that inspects whether or not eggs are present in each of the egg trays T, which have multiple egg tray seats T2, and a tray stopping device that controls the conveyance of the egg trays T based on the inspection results of the tray inspection device 31. The tray inspection device 31 can be various types of devices used in this field, such as photoelectric sensors and images.

The tray conveying device 4 is equipped with a tray supply device 33 for inner lids that supplies egg trays T for inner lids.

The egg trays T transported by the tray transport device 4 are counted by a counting unit (not shown). For example, when the moving device 3 moves between the tray transport device 4 and the cardboard box G, the count is updated and recorded. Based on the information recorded in the counting unit, information on the egg tray T that the moving device 3 will move next is known, specifically, whether it is the first egg tray T, second egg tray T, third egg tray T, fourth egg tray T, or lid tray TT.

The moving device 3 has a head unit 6 equipped with an egg suction device 1 and a tray holding device 2, and a moving unit 7 that moves the head unit 6.

The moving unit 7 is exemplified as an articulated robot. The articulated robot has a base 8 placed on the floor and an articulated arm 9 attached to the base 8. The head 6 is attached to the tip of the arm 9.

The egg tray transfer device has a control device C that controls the operation of various devices such as the egg suction device 1, tray holding device 2, moving device 3, tray conveying device 4, cardboard conveying device 5, counting unit, tray inspection device 31, tray stopping device, and tray supply device 33 for inner lids.

The control device C switches the inspection method in the tray inspection device 31 between inspecting one egg tray T and inspecting other egg trays T among the multiple egg trays T contained in one cardboard box G. The control device C switches the inspection method based on information on the number of egg trays T obtained from the counting unit.

In this embodiment, the egg tray transfer device is exemplified as an egg tray storage device that stores egg trays T in a cardboard box G. It is configured to hold the egg trays T and store them in the cardboard box G with almost no gap between the outer edge of the egg trays T and the inner surface of the cardboard box G that stores the egg trays T.

Figure 2 is a plan view of an egg tray T being transported by the tray transport device 4. The egg tray T is transported to the right in Figure 2.

The egg tray T is made of a molded paper tray with recessed storage seats T2 for storing eggs E, arranged vertically and horizontally. In the illustrated example, the storage seats T2 are arranged in a grid pattern of five columns and eight columns, and protrude downward. A protrusion T3 is formed on the top surface of the egg tray T, running along the periphery of the storage seats T2. The egg tray T has a rectangular shape when viewed from above.

When the egg trays T are empty and do not contain eggs E, the egg trays T are stacked in the state shown in Figure 2. When eggs E are stored in the storage seats T2 of the egg trays T, the egg trays T are turned 180 degrees from the state shown in Figure 2 and stacked. At this time, the storage seats T2 and protrusion T3 are positioned so that the bottom surface of the upper storage seat T2 rests on the top surface of the lower protrusion T3. The protrusion T3 bulges upward so that the top surface of the egg E stored in the lower storage seat T2 is located inside the upper protrusion T3.

In this embodiment, all of the seats T2 of the egg trays T stacked in the first, second, and third tiers contain eggs E. The seats T2 of the egg tray T stacked in the fourth tier only contain some eggs E. That is, in the fourth tier, some of the seats T2 contain eggs E, but the remaining seats T2 are empty. For example, the fourth egg tray T may contain five seats T2 each with five eggs E in the first through fourth rows, only three eggs E in the five seats T2 in the fifth row, and no eggs E in the five seats T2 in the sixth through eighth rows. The sorting device 40's cumulative weight calculation function is set so that the total weight of the eggs E contained in the first through fourth tiers of egg trays T is 10 kilograms.

The outer periphery of the egg tray T is shaped so that it can be stored in the cardboard box G with almost no gap between it and the inner periphery of the cardboard box G. A finger-holding recess T1 is formed on the outer periphery of the egg tray T. This recess T1 is formed on the opposing outer periphery. One recess T1 is formed on the right hand and two on the left hand in Figure 2.

A large number of empty egg trays T, each containing no eggs E, are stacked in the same orientation. One egg tray T is removed from the stack, and an egg E is placed in the empty egg tray T's storage seat T2. As shown at the left end of the tray conveying device 4 in Figure 1, the egg tray T containing eggs E is transported to the right by the tray conveying device 4. At the right end of the tray conveying device 4, the eggs E and egg trays T are placed in a cardboard box G by the moving device 3.

An empty cardboard box G is waiting at the right end of the cardboard conveying device 5 in Figure 1. The cardboard box G is shaped to accommodate the outer periphery of the egg tray T with almost no gaps.

Eggs E stored in egg trays T are suction-held by egg suction device 1, and the egg trays T themselves are held by tray holding device 2. In this holding state, the weight of the eggs E does not exert much influence on the storage seats T2.

The egg suction device 1 holding eggs E and the tray holding device 2 holding egg trays T are moved above an empty cardboard box G by the moving device 3. Because the moving device 3 has a head unit 6 of an articulated robot, the movement of the head unit 6 moves the eggs E and egg trays T from above the cardboard box G into the cardboard box G. Then, when the egg suction device 1 and the tray holding device 2 release their hold, the eggs E and egg trays T are stored in the cardboard box G.

When the cardboard box G is full of eggs E and egg trays T stored in multiple layers, it is transported to the left side of Figure 1 by the cardboard box transport device 5. The cardboard box G is then packed and shipped.

The egg trays T stored in the cardboard box G are stacked with each tier rotated 180 degrees. The bottom surface of the storage seat T2 of the egg tray T on the tier above rests on the top surface of the protrusion T3 on the top surface of the egg tray T. The 180-degree rotation is achieved by rotating the head unit 6.

Figure 3 is a detailed drawing of the head portion 6.

The head unit 6 is provided at the tip of the arm unit 9 of the articulated robot. The head unit 6 has an egg suction device 1 and a tray holding device 2.

The head unit 6 has a base plate 10 that is rotatably mounted on the tip of the arm unit 9. The base plate 10 is approximately rectangular, and a connection portion 11 with the arm unit 9 is provided in the center of the base plate 10. Tray holding devices 2 are provided on the upper surface of both the left and right sides of this base plate 10. An egg suction device 1 is provided on the underside of the base plate 10.

The tray holding device 2 and egg suction device 1 are separable, making maintenance easy.

The tray holding device 2 has a holding member 12 that holds the egg trays T. The holding member 12 is attached to a holding member moving device 13 that is provided on the upper surface of the base plate 10. The holding member 12 is composed of a rod-shaped member. The holding member moving device 13 is composed of a cylinder. A cylinder rod 15 is movably provided in the center of a cylinder body 14 that is fixed to the upper surface on both the left and right sides of the base plate 10, and guide rods 16 are provided on both sides of the cylinder rod 15. The tips of the cylinder rod 15 and the guide rod 16 are connected by a head plate 17. The upper end of the rod-shaped holding member 12 is fixed to the head plate 17.

The surface of the retaining member 12 is provided with an engaging portion (not shown) that engages with the outer periphery of the recess T1 of the egg tray T. The engaging portion is composed of a concave-convex portion. The concave-convex portion is composed of a screw. The diameter of the retaining member 12, which is composed of a threaded rod, is smaller than the depth of the recess T1 of the egg tray T. In other words, the retaining member 12 is configured to be inserted into and removed from the recess T1 by moving it up and down. After insertion, the retaining member moving device 13 moves it toward the surface of the recess T1 of the egg tray T, and the engaging portion presses against and holds the surface of the recess T1. In this embodiment, as shown in Figure 2, the recess T1 of the egg tray T has one on the right side and two on the left side, so the retaining members 12 are also arranged to fit this, with one on one side and two on the other side.

The egg suction device 1 is detachably attached to the base plate 10 by egg suction device attachment parts 19 provided on both the front and rear sides of the base plate 10. The egg suction device 1 has a tray 20 with a peripheral wall that is the same shape as the base plate 10, and this tray 20 is airtightly attached to the underside of the base plate 10 by the egg suction device attachment parts 19 to form an airtight chamber. On the underside of the tray 20, suction pads 21 are provided in the same number as the storage seats T2 so that they can suction the top faces of the eggs E stored in the storage seats T2 of the egg tray T. A ventilation pipe (not shown) is provided in the tray 20, passing through it, and a bellows-shaped suction pad 21 is provided at the lower end of the ventilation pipe.

The airtight chamber formed by the substrate 10 and the tray 20 is connected to a vacuum device (not shown) via a connection portion 11 formed on the top surface of the substrate 10.

Next, the detailed operation of the egg suction device 1 and tray holding device 2 will be explained. The distance between the outer edge of the egg tray T and the inner surface of the cardboard box G is almost zero, or the egg tray T is slightly larger. The distance between the edge of the most recessed part of the finger hook recess T1 and the inner surface of the cardboard box G is 11 mm. The diameter of the holding member 12 is 6 mm. The stroke of the cylinder of the holding member moving device 13 on the side where two holding members 12 are provided is 40 mm. The stroke of the cylinder of the holding member moving device 13 on the side where one holding member 12 is provided is 15 mm. Note that these distance, diameter, and stroke values can be changed depending on the type of tray T.

To hold egg trays T and adsorb eggs E on the tray conveying device 4 in Figure 1, the head unit 6 is positioned above the egg tray T and then lowered so that the holding members 12 of the tray holding device 2 are positioned within the recesses T1 of the egg tray T. The suction pads 21 of the egg suction device 1 adsorb the top surfaces of the eggs E to hold them. The holding members 12 move the two cylinder rods 15 inward by 40 mm, and one cylinder rod 15 is moved inward by 15 mm, holding the egg tray T at the engaging portions of the holding members 12 on both the left and right sides. In this state, as shown in Figure 4, the egg tray T is pushed downward slightly by the holding members 12 on both the left and right sides, and the eggs E are held by the suction pads 21 of the egg suction device 1, so their weight does not act significantly on the egg tray T.

The head unit 6 is moved upward, then moved above an empty cardboard box G on the cardboard conveying device 5, and then lowered to move the egg tray T and eggs E into the cardboard box G. The egg suction means 1 releases the eggs E from suction. The holding member 12 moves one cylinder rod 15 outward 15 mm, disengaging the engaging portion of the holding member 12 from the egg tray T. The head unit 6 is moved 5 mm to the left, disengaging the engaging portions of the two holding members 12 from the egg tray T. The head unit 6 is then raised and moved out of the cardboard box G.

In this embodiment, a 10 mm diameter nut is fixed to the lower end of the threaded rod that serves as the holding member 12 to prevent the egg tray T from accidentally falling.

Figure 6 is a flowchart of an egg tray transfer method using an egg tray transfer device.

The egg tray transfer method includes steps S2, S6, S10, and S14 of suction-holding eggs E stored in egg trays T with the egg suction device 1, steps S3, S7, S11, and S15 of holding the egg trays T with the tray holding device 2, and steps S4, S8, S12, and S16 of moving the eggs E and egg trays T relative to the cardboard box G with the moving device 3.

To explain the storage method in more detail, an empty cardboard box G is placed (Step S1). The egg suction device 1 picks up eggs E for the first tier (Step S2). The tray holding device 2 holds the recessed portion T1 of the egg tray T for the first tier (Step S3). The moving device 3 moves the egg suction device 1 and tray holding device 2 to the cardboard box G (Step S4). The holding of the first tier tray and egg suction are released (Step S5).

The eggs E for the second tier are picked up (Step S6). The tray T for the second tier is held (Step S7). After rotating the head unit 6 of the moving device 3, the egg suction device 1 and tray holding device 2 are moved to the cardboard box G (Step S8). The holding of the second tier tray and egg suction are released (Step S9).

The eggs E for the third tier are picked up (Step S10). The tray T for the third tier is held (Step S11). It is moved to the cardboard box G (Step S12). The holding of the third tier tray and the egg suction are released (Step S13).

The eggs E for the fourth tier are picked up (Step S14). The tray T for the fourth tier is held (Step S15). The head unit 6 is rotated and moved to the cardboard box G (Step S16). The holding of the fourth tier tray and the egg suction are released (Step S17).

The above operations are repeated until the cardboard box G is full, at which point the egg tray TT for the inner lid is held by the tray holding device 2 (step S18). It is then moved to the cardboard box G (step S19). The egg tray TT for the inner lid is released from its hold (step S20).

The completed cardboard box G is discharged by the cardboard conveying device 5 (step S21).

Note that steps S2 and S3, steps S6 and S7, steps S10 and S11, and steps S14 and S15 are not limited to this order, and may be performed in reverse or simultaneously.

Next, we will explain the flowchart in Figure 7. Figure 7 is a flowchart of an egg tray inspection method using a system that inspects whether or not an egg E is present in each storage seat T2 of an egg tray T.

The egg tray inspection method in tray inspection device 31 switches between inspection of one egg tray T and inspection of other egg trays T based on information on the number of egg trays T obtained from the counting unit. Specifically, for egg trays T on the first to third tiers, tray inspection device 31 inspects all of the storage seats T2 on the egg tray T, but for egg trays T on the fourth tier, tray inspection device 31 does not inspect any of the storage seats T2 on the egg tray T.

To explain the inspection method in more detail, when an egg tray T arrives, if that egg tray T is one of the egg trays T stacked in the first to third tiers (step S31), the control device C controls the tray inspection device 31 to inspect all of the storage seats T2 (step S32). The tray inspection device 31 inspects the egg trays T one row at a time as they are transported by the tray transport device 4.

If an abnormality is found in the inspection of step S32 (step S33), for example, if egg E is not detected in the storage seat T2 where egg E should be stored, the process proceeds to step S34. In step S34, the control device C issues an error notification. The control device C also activates the tray stopping device. The tray stopping device stops the tray conveying device 4 and does not release the stopper 32.

Then, eggs E are replenished in the corresponding egg holding seat T2 (step S35), and, for example, when the restart button is pressed manually, the process proceeds to step S37. If no abnormalities are found in the inspection in step S32 (step S33), the process also proceeds to step S37.

On the other hand, if in step S31 the egg tray T is the fourth tier, the tray inspection device 31 is controlled not to inspect any of the storage seats T2 on the egg tray T (step S36). Then, the process proceeds to step S37. In step S37, the stopper 32 is released, and the egg tray T is moved to the next process, i.e., toward the egg tray transfer device.

Repeat the above steps.

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

<Modification (Fig. 8)>
A flowchart of the egg tray inspection method may be as shown in Figure 8. Specifically, the system shown in Figure 8 that inspects whether or not eggs E are present in each seat T2 of an egg tray T inspects a fractional number of egg trays T (e.g., the fourth egg tray T) based on row-controlled information (hereinafter referred to as "hole information").

First, hole information for each row is obtained (step S41). The hole information may be obtained from the sorting device or may be input in advance into the control device C. The sorting device places eggs E into egg trays T so that the total weight reaches 10 kg based on the weighed egg weight, and then sends the egg trays T in order to the tray inspection device 31. The hole information is information about which hole (receiving seat T2) in each egg tray T the sorting device has released the eggs E into. In particular, for the fourth egg tray T, for example, five eggs E have been released into each of the five receiving seats T2 in rows 1 to 4, and no eggs E have been released into the five receiving seats T2 in rows 5 to 8.

After that, when an egg tray T arrives, if that egg tray T is one of the trays stacked in the first to third tiers (step S42), the control device C controls the tray inspection device 31 to inspect all of the storage seats T2 (step S43). The tray inspection device 31 inspects the egg trays T one row at a time as they are transported by the tray transport device 4.

On the other hand, if the egg tray T is stacked in the fourth tier in step S42, the tray inspection device 31 is controlled not to inspect some of the storage seats T2 on the egg tray T (step S44). Specifically, the tray inspection device 31 performs inspection based on the hole information obtained from the sorting device. For example, the tray inspection device 31 inspects the first to fourth rows, but does not inspect the fifth to eighth rows.

If an abnormality is found in the inspections of steps S43 and S44 (step S45), for example, if egg E is not detected in seat T2 where egg E should be, the process proceeds to step S46. In step S46, control device C issues an error notification. Control device C also activates the tray stopping device. The tray stopping device stops the tray conveying device 4 and does not release stopper 32.

Then, eggs E are replenished in the corresponding egg holding seat T2 (step S47), and, for example, when the restart button is pressed manually, the process proceeds to step S48. If no abnormalities are found in the inspections of steps S43 and S44 (step S45), the process also proceeds to step S48.

In step S48, the stopper 32 is released and the egg tray T is moved to the next process, i.e., toward the egg tray transfer device.

Repeat the above steps.

<Other Modifications>
In another modified example, a system equipped with an egg tray transfer device is equipped with a weight checker 41, and controls the tray conveying device 4 so as not to stop based on the inspection results of the tray inspection device, and if an abnormality occurs, eggs are replenished to the tray T at the weight checker 41 portion. The weight checker 41 measures the weight of the entire cardboard box G after it has been packed using the system of this embodiment. In Figure 9, reference numeral 40 denotes a sorting device, and reference numeral 42 denotes a sealing device for closing the lid of the cardboard box G.

In this modified egg tray inspection method, if an abnormality is found in the inspections described in steps S32, S42, S44, etc. (step S45), control device C performs a cueing process. The cueing process changes the egg tray transfer method using the egg tray transfer device from the series of egg tray transfer methods shown in Figure 6.

For example, if an abnormality is found in the second egg tray T, the control device C controls the egg tray transfer device to move the second egg tray T to a cardboard box G, and controls the cardboard conveying device 5 to send the cardboard box G downstream while it is still incomplete. When this cardboard box G reaches the weight checker 41, an abnormality is detected and it is stopped.

Next, control device C controls cardboard conveying device 5 to set a new empty cardboard box G. Control device C controls the egg tray transfer device to place the third egg tray T and the fourth egg tray T in the first and second tiers of the cardboard box G, respectively. From this state, control device C controls cardboard conveying device 5 to send the cardboard box G downstream while it is still incomplete. This cardboard box G also detects an abnormality when it reaches weight checker 41, and is stopped.

Meanwhile, a new empty cardboard box G and the first egg tray T to be placed in are prepared in the egg tray transfer device, completing the loading operation.

With this arrangement, if the tray inspection device detects an abnormality, there is no need to stop the egg tray T in a location where it is difficult to replenish eggs, such as on the tray conveying device 4. Furthermore, correction work for the egg tray T can be carried out in a location with relatively ample space, such as where the weight checker 41 is located.

<Other Modifications>
The shape of the egg tray T and the number and arrangement of the receiving seats T2 are not limited to those shown in the drawing. The tray T is not limited to a molded tray made of paper, and may be a tray made of plastic.

The number of egg trays T contained in a cardboard box G is not limited to four. For example, the present invention can also be applied to a box in which the total weight of the eggs E contained in the first and second egg trays T is set to 5 kilograms and traded.

The moving device 3 is not limited to an articulated robot, but may also be one that moves the head unit 6 in multiple directions in both horizontal and vertical planes.

Furthermore, the recess T1 formed on the outer periphery of the egg tray T is not limited to being for finger placement, but may be any recess that allows the egg tray holding device 2 to operate within the recess T1. While the concave and convex portions of the engagement part are shown as being made up of screws, they may also be saw-tooth shaped. The holding member moving device 13 is not limited to being a cylinder, and may also be solenoid or motor-driven.

As yet another variation, the system of this embodiment can be used to check whether the egg trays T have reached the egg tray transfer device in the correct order from the sorting device. All but the fourth egg tray must be fully loaded in the storage seat T2. Therefore, if an unfilled egg tray T is detected at a time other than when the fourth egg tray should arrive, the control device C may be configured to issue an error.

The scope of the present invention is indicated by the claims, not by the above description, and includes all modifications that are equivalent in meaning to and within the scope of the claims.

REFERENCE SIGNS LIST 1 Egg suction device 2 Tray holding device 3 Moving device 4 Tray conveying device 5 Cardboard conveying device 6 Head section 7 Moving section 8 Base section 9 Arm section 10 Base plate 11 Connection section 12 Holding member 13 Holding member moving device 14 Cylinder body 15 Cylinder rod 16 Guide rod 17 Head plate 19 Egg suction device mounting section 20 Tray 21 Suction pad 31 Tray inspection device 32 Stopper 33 Tray supply device for inner lid 40 Sorting device 41 Weight checker 42 Sealing device C Control device E Egg G Cardboard box T Egg tray T1 Recessed section T2 Receiving seat T3 Protruding section TT Egg tray for inner lid

Claims (2)

A system for inspecting whether or not eggs are present in each of the trays that are provided with a plurality of trays and are automatically packed into cardboard boxes,
an inspection unit that inspects each accommodation seat;
Among the multiple trays contained in one cardboard box,
an inspection of one tray;
Inspection of the top tray where eggs are stored in part of each seat .
a control unit for switching an inspection method in the inspection unit ;
The control unit
In the uppermost tray, the inspection method in the inspection unit is switched so that inspection is not performed on all of the accommodation seats; or
In the top tray, the inspection method in the inspection unit is switched so as to inspect a portion of each seat based on hole information indicating which seat on the tray the eggs were released toward . a counting unit that counts the number of trays transported to the inspection unit,
The control unit, based on the tray number information obtained from the count unit,
The system of claim 1 , wherein the inspection method is switched.