JP2024111278A - Automated Warehouse System - Google Patents

Abstract

[Problem] One of the objectives of the present disclosure is to provide an automated warehouse system that can be flexibly configured. [Solution] An automated warehouse system 100 according to one embodiment includes a first placement section 34 and a second placement section 36 on which a loaded pallet 12 can be placed, a picking device 32 that removes load from the loaded pallet 12 placed on the first placement section 34 and moves to the second placement section 36 to create another loaded pallet, and a transport vehicle 18 that can move while autonomously changing its movement direction and moves under the picking device 32 to transport the loaded pallet 12 to the first placement section 34. [Selected Figure] Figure 1

Description

The present invention relates to an automated warehouse system.

Patent Document 1 describes a picking device that picks out items stacked on a pallet layer by layer. This picking device has a gripping device that grips items on a single-item pallet positioned at a load removal position layer by layer and transfers them to each of multiple shipping pallets positioned at a loading position, and a load transfer device that enables the gripping device to be raised and lowered relative to the shipping pallets.

JP 2002-187618 A

In an automated warehouse system, there is a process for creating a mixed pallet with multiple types of goods mixed together according to the destination's request from a single pallet that has multiple loads of the same type of goods. This process involves dividing the goods on the single pallet into specified units (hereafter referred to as "cases"), storing the divided cases, and collecting the divided and stored cases according to the destination's request to create a mixed pallet (hereafter referred to as "picking").

The picking device described in Patent Document 1 requires large-scale equipment, making it difficult to achieve a flexible configuration.

The present invention was made in consideration of these problems, and one of its objectives is to provide an automated warehouse system that can be flexibly configured.

In order to solve the above problems, an automated warehouse system according to one embodiment of the present invention includes a first placement section and a second placement section on which a loaded pallet can be placed, a picking device that removes a load from the loaded pallet placed on the first placement section and moves it to the second placement section to create another loaded pallet, and a transport vehicle that can move while autonomously changing its direction of movement and moves under the picking device to transport the loaded pallet to the first placement section.

In addition, any combination of the above components, or mutual substitution of the components or expressions of the present invention between methods, systems, etc., are also valid aspects of the present invention.

The present invention provides a flexibly configurable automated warehouse system.

FIG. 1 is a plan view illustrating an example of an automated warehouse according to an embodiment. FIG. 1 is a perspective view showing an example of an assembly in which a plurality of loads are stacked. FIG. 2 is a front view showing an example of the transport vehicle shown in FIG. 1 . FIG. 4 is a side view showing the transport vehicle of FIG. 3 . FIG. 2 is a plan view showing the picking device of FIG. 1 . FIG. 6 is a side view showing the picking device of FIG. 5 . FIG. 6 is a bottom view showing the take-out unit of the picking device of FIG. 5 . FIG. 2 is a front view showing an example of the first carriage of FIG. 1 . FIG. 2 is a front view showing an example of the second carriage of FIG. 1 . FIG. 2 is an explanatory diagram illustrating an example of a first operation of the automated warehouse of FIG. 1 . FIG. 2 is an explanatory diagram illustrating an example of a third operation of the automated warehouse in FIG. 1 .

The present invention will be described below based on a preferred embodiment with reference to the drawings. In the embodiments and modified examples, identical or equivalent components and parts are given the same reference numerals, and duplicated explanations will be omitted as appropriate. Furthermore, the dimensions of the parts in each drawing are shown enlarged or reduced as appropriate to facilitate understanding. Furthermore, some of the parts that are not important for explaining the embodiment are omitted in each drawing.

In addition, terms including ordinal numbers such as first and second are used to describe various components, but these terms are used only for the purpose of distinguishing one component from another and do not limit the components.

[Embodiment]
The overall configuration of the automated warehouse system 100 according to the embodiment will be described with reference to FIG. 1. FIG. 1 is a plan view that shows an example of the automated warehouse system 100 according to the embodiment. For convenience of explanation, as shown in the figure, an XYZ orthogonal coordinate system is defined in which a horizontal direction is the X-axis direction, a horizontal direction perpendicular to the X-axis direction is the Y-axis direction, and a direction perpendicular to both directions, i.e., a vertical direction, is the Z-axis direction. The positive directions of the X-axis, Y-axis, and Z-axis are defined as the directions of the arrows in each figure, and the negative directions are defined as the directions opposite to the arrows. Note that the X-axis direction is sometimes called the "row direction", the Y-axis direction is sometimes called the "column direction", and the Z-axis direction is sometimes called the "up-down direction". Such directional notations do not limit the configuration of the automated warehouse system 100, and the automated warehouse system 100 can be used in any configuration depending on the application.

As shown in FIG. 1, the automated warehouse system 100 includes a storage shelf 22, a picking area 30, an outgoing area 38, and a control unit 50. A first cart 14 and a second cart 16 are arranged on the storage shelf 22. A transport vehicle 18, a picking device 32, a first loading section 34, and a second loading section 36 are provided in the picking area 30. An outgoing section 40 is provided in the outgoing area 38. In the example of FIG. 1, from the viewpoint of facilitating the travel of the transport vehicle 18, the outgoing section 23, the first loading section 34, the second loading section 36, and the outgoing section 40 of the storage shelf 22, which will be described later, are arranged on the same floor Fr.

The storage shelf 22 can store multiple loads 10. The first loading section 34 and the second loading section 36 can each load a loading pallet carrying multiple loads 10. The picking device 32 removes the load 10 from the loading pallet 12 loaded on the first loading section 34 and moves it to the second loading section 36 to create another loading pallet 12. The transport vehicle 18 can move while autonomously changing its direction of movement, and moves under the picking device 32 to transport the loading pallet 12 to the first loading section 34. The loads 10 and the loading pallet 12 will be described later.

The control unit 50 includes an MPU (Micro Processing Unit) and other components. The control unit 50 controls the operation of the picking device 32 to pick the load 10. The control unit 50 also controls the operation of the first cart 14, the second cart 16, and the transport vehicle 18 to transport the load pallet 12 based on the results of the user's operation.

Figure 2 is a perspective view showing an assembly in which multiple loads are stacked. In this specification, one or more items contained in a case such as a cardboard box are referred to as loads 10. An empty pallet is simply referred to as a "pallet 12j." A single or multiple loads 10 placed on one pallet 12j are referred to as a "loaded pallet 12." The loaded pallet 12 refers to the combination of the pallet 12j and the loads 10 on the pallet 12j. The loaded pallet 12 may be composed of multiple stacked layers, and each layer may include multiple loads 10. In the example of Figure 2, the loaded pallet 12 includes eight loads 10 in each of three layers. The loaded pallet 12 may be the smallest unit that is entered, stored, and removed from the automated warehouse system 100. The loads 10 may be the smallest unit that is handled when picking.

The transport vehicle 18 will be described with reference to Figures 3 and 4. Figure 3 is a front view showing an example of the transport vehicle 18 in a schematic manner. Figure 4 is a side view of the transport vehicle 18. The transport vehicle 18 is a transport means that transports a load based on instructions from the control unit 50. The transport vehicle 18 functions as an automated guided vehicle (AGV) that can travel autonomously to reach the destination position by controlling the rotation and steering angle of the wheels based on the destination position and the vehicle's own position. The travel route of the transport vehicle 18 may include a preset travel route and an autonomously determined travel route.

The transport vehicle 18 is equipped with a platform 18c on which the loaded pallet 12 (hereinafter including an empty pallet 12j) is placed, and a lift mechanism 18d that raises and lowers the platform 18c. The transport vehicle 18 drives multiple wheels 18f with a motor (not shown) and travels with the loaded pallet 12 mounted. The transport vehicle 18 raises and lowers the loaded pallet 12 on the platform 18c with the lift mechanism 18d. In Figures 3 and 4, the platform 18c in the raised state is shown by a dashed line, and the platform 18c in the lowered state is shown by a solid line.

The transport vehicle 18 lifts and holds the loaded pallet 12 at the source. The transport vehicle 18 autonomously travels along a route from the source to the destination to transport the loaded pallet 12. The transport vehicle 18 unloads the loaded pallet 12 at the destination. The source and destination include, but are not limited to, the storage shelf 22, the first loading section 34, the second loading section 36, the unloading section 40, etc.

Various known guidance methods can be used for the autonomous travel of the transport vehicle 18. In this embodiment, the transport vehicle 18 is guided based on a weak induced current from an induction wire 18g embedded in the floor. The transport vehicle 18 is equipped with a safety device using sensors such as a proximity sensor and an ultrasonic distance meter to prevent collisions.

The picking device 32, the first placement section 34 and the second placement section 36 will be described with reference to Figures 1, 5 and 6. Figure 5 is a plan view showing the picking device 32. Figure 6 is a side view showing the picking device 32. In these figures, some pillars, beams and the like are omitted. The picking device 32 is provided in a picking area 30 for picking. In this embodiment, the picking area 30 is provided near the storage shelf 22. The picking area 30 is located on the same floor as the discharge section 23 of the storage shelf 22, which will be described later.

The first placement section 34 and the second placement section 36 are provided in the picking area 30 and are arranged so as to overlap with the picking device 32 in a plan view. The first placement section 34 mainly carries a loading pallet 12 (hereinafter referred to as "single pallet 12S") carrying a plurality of loads of the same type. The second placement section 36 mainly carries a loading pallet 12 (hereinafter referred to as "mixed pallet 12M") carrying a plurality of loads. The picking device 32 takes out the load 10 from the single pallet 12S before picking and transfers it to the mixed pallet 12M to create the mixed pallet 12M after picking. There is no limitation on the arrangement of the first placement section 34 and the second placement section 36, but in the example of FIG. 1, they are arranged adjacent to each other along the traveling direction (hereinafter referred to as the "entry direction") of the transport vehicle 18 in the first placement section 34 and the second placement section 36. The first placement section 34 and the second placement section 36 may be arranged adjacent to each other.

The configuration of the first placement section 34 and the second placement section 36 is not limited, but the placement sections in this embodiment have multiple placement tables arranged on either side of the entrance path for the transport vehicle 18 to enter. In the example of FIG. 1, the first placement section 34 has two placement tables 34p arranged at a distance in the vehicle width direction of the transport vehicle 18, and the second placement section 36 has two placement tables 36p arranged at a distance in the vehicle width direction of the transport vehicle 18.

From the viewpoint of smooth entry and exit of the transport vehicle 18, the placement platforms 34p and 36p are configured as follows. The distance between the two placement platforms 34p and the distance between the two placement platforms 36p are set to a width equal to the width of the transport vehicle 18 plus a specified margin. The height of the placement platforms 34p, 36p is set to be higher than the placement platform portion 18c in the lowered state and lower than the placement platform portion 18c in the raised state. The front-to-rear length (length in the entry direction) of the placement platforms 34p, 36p is set to be a length equal to the length of the transport vehicle 18 plus a specified margin.

The picking device of this embodiment picks up the load 10 from above the first loading section 34, and loads the load onto the second loading section 36 from above the second loading section 36. In the example of FIG. 1, the picking device 32 includes a so-called gantry-type crane mechanism. The picking device 32 includes a pair of vertical beams 32e, a cross beam 32k, a crane cart 32d, a hanging section 32j, and a removal unit 32h. The pair of vertical beams 32e are provided spaced apart on both sides in the Y-axis direction in the upper space of the picking area 30. Both ends of the vertical beams 32e are supported by the upper ends of the vertical columns 32g.

The cross beam 32k is a rail-like structure extending in the Y-axis direction, and is suspended between a pair of vertical beams 32e. The cross beam 32k is configured to be self-propelled on the vertical beams 32e in the X-axis direction. The cross beam 32k is sometimes called a crane girder. The crane cart 32d is a cart that is self-propelled on the cross beam 32k in the Y-axis direction. The crane cart 32d is sometimes called a trolley cart. The hanging part 32j can hang the removal unit 32h from the crane cart 32d and move it up and down in the Z-axis direction. The hanging part 32j can also rotate the removal unit 32h horizontally. The removal unit 32h is provided at the tip of the hanging part 32j, and is configured to be able to lift the load 10.

The picking device 32 supports the removal unit 32h so that it can move freely in the horizontal direction (X-axis direction, Y-axis direction). The picking device 32 also supports the removal unit 32h so that it can move up and down (Z-axis direction).

The removal unit 32h will now be described. FIG. 7 is a bottom view showing the removal unit 32h. The removal unit 32h has a generally rectangular shape when viewed from the bottom. On the bottom surface of the removal unit 32h, a plurality of suction sections 32s are arranged in a matrix in the X-axis direction and the Y-axis direction. Each of the plurality of suction sections 32s generates a suction force by sucking in air. The magnitude of the suction force of the suction sections 32s can be adjusted. Each of the suction sections 32s may be divided into a plurality of sections.

The suction unit 32s is configured to be switchable between an ON state in which it generates an adhesive force capable of adsorbing the load 10, and an OFF state in which it generates virtually no adhesive force. The OFF state includes not only a completely non-generating state, but also a state in which it generates an adhesive force so small that it cannot adsorb the load 10. The removal unit 32h adjusts the adhesive forces of the multiple suction units 32s to adsorb and hold all the loads 10 on one layer. The removal unit 32h can also adjust the area in which the adhesive force is generated to selectively adsorb and hold one or more loads 10 on one layer.

In place of or in addition to the suction section 32s, the removal unit 32h may have a clamping mechanism (not shown) that clamps the load 10 horizontally.

The storage shelf 22 will be described with reference to FIG. 1. The storage shelf 22 is a shelf section capable of storing multiple loads 10. The configuration of the storage shelf 22 is not particularly limited as long as it is capable of containing and storing multiple loads 10. The storage shelf 22 includes multiple storage sections 24 arranged along the X-axis direction and the Y-axis direction. Each storage section 24 is configured to be capable of storing loads 10. In particular, the storage shelf 22 can store single-loading pallets 12S, mixed-loading pallets 12M, and empty pallets 12j in each storage section 24.

This embodiment includes N levels (N is an integer equal to or greater than 1, for example, 3) of storage shelves 22 arranged in layers one above the other. FIG. 1 shows the first level of storage shelves 22 closest to floor Fr. In the second level and above, the Nth level of storage shelves 22 is arranged above the N-1th level of storage shelves 22. The storage shelves 22 of each level may have a similar configuration. In particular, each level of storage shelves 22 is provided with one or more sets of first carts 14 and second carts. Also, a lifting means (not shown) may be provided for lifting and lowering the first cart 14 with or without load 10 between the multiple levels of storage shelves 22.

The storage shelf 22 is provided with a first rail 26 as a running path for the first carriage 14 and a second rail 28 as a running path for the second carriage 16. The first rail 26 extends in the Y-axis direction on the storage shelf 22. The first carriage 14 is a transport means capable of running under each storage section 24. The second rail 28 extends in the X-axis direction adjacent to the storage shelf 22.

The first cart 14 will be described with reference to FIG. 8. FIG. 8 is a front view showing an example of the first cart 14. The first cart 14 drives a plurality of wheels 14f by a motor (not shown) and travels on the first rail 26 in the Y-axis direction with the loading pallet 12 mounted thereon. The first cart 14 raises and lowers the loading pallet 12 on the loading platform 14c by the lift mechanism 14d. In FIG. 8, the loading platform 14c in the raised state is shown by a dashed line, and the loading platform 14c in the lowered state is shown by a solid line. The first cart 14 can lower the loading pallet 12 to the storage section 24. The first cart 14 can lift and support the loading pallet 12 from the storage section 24. The first cart 14 can get on and off the second cart 16.

The second cart 16 will be described with reference to Figure 9. Figure 9 is a front view showing an example of the second cart 16, with the first cart 14 mounted on it. The second cart 16 is a transport means that drives multiple wheels 16f by a motor (not shown) and travels on the second rail 28 in the X-axis direction. The second cart 16 can transport the first cart 14 with a loading pallet 12 mounted on it or when it is empty.

The storage shelf 22 transports the cargo 10 brought into the loading section (not shown) to a designated storage section 24 by the first cart 14 and the second cart 16 for storage. The storage shelf 22 transports the cargo 10 stored in the designated storage section 24 to the unloading section 23 by the first cart 14 and the second cart 16 for unloading.

As shown in FIG. 1, the storage shelf 22 has an unloading section 23 as an exit for unloading the loaded pallet 12. The unloading section 23 is configured to allow the first trolley 14 and the transport vehicle 18 to enter. The unloading section 23 is provided with a first rail 26 for the first trolley 14 to enter. That is, the first trolley 14 enters the unloading section 23, unloads the loaded pallet 12, and exits. Next, the transport vehicle 18 enters the unloading section 23 and exits while holding the loaded pallet 12. The reverse is also possible. That is, the unloading section 23 functions as a transfer section that transfers the loaded pallet 12 between the first trolley 14 and the transport vehicle 18. From this, the unloading section 23 can be said to be an entrance and exit of the storage shelf 22.

The configuration of the discharge section 23 is not limited, but the discharge section 23 in this embodiment has multiple platforms arranged on either side of the entrance path through which the transport vehicle 18 enters. In the example of FIG. 1, the discharge section 23 has two platforms 23p arranged at a distance in the vehicle width direction of the transport vehicle 18.

In order to facilitate the entry and exit of the transport vehicle 18, the distance between the two platforms 23p is set to the width of the transport vehicle 18 plus a specified margin, and the height of the platforms 23p is set to be higher than the platform portion 18c in the lowered state and lower than the platform portion 18c in the raised state. The front-to-rear length of the platform 23p (length in the entry direction) is set to be the length of the transport vehicle 18 plus a specified margin.

The unloading section 40 will be described with reference to FIG. 1. The unloading section 40 is a platform for unloading the picked mixed pallet 12M to the destination. There are no limitations on the configuration of the unloading section 40, but the unloading section 40 of this embodiment has multiple platforms arranged on either side of the entrance path for the transport vehicle 18 to enter. In the example of FIG. 1, the unloading section 40 has two platforms 40p arranged at a distance in the vehicle width direction of the transport vehicle 18. The two platforms 40p can be configured in the same way as the two platforms 34p of the first loading section 34.

The operation of the automated warehouse system 100 configured as described above will now be described. In this operation, the transport vehicle 18 autonomously travels to the destination along the induction wire 18g while detecting the induced current of the induction wire 18g. Furthermore, when the transport vehicle 18 approaches the target platform, it uses the detection results of a sensor that detects the platform to correct its own position relative to the platform and travels while maintaining an appropriate gap with the platform. Examples of sensors that detect the platform include laser sensors and image sensors. Furthermore, when the transport vehicle 18 completes its operation, it moves to a specified standby position and waits there.

(First Action)
The first operation is a transfer operation. An example of the first operation will be described with reference to Fig. 10. Fig. 10 is an explanatory diagram for explaining the first operation. The first operation is a transfer operation in which the transport vehicle 18 transfers the single pallet 12S stored in the storage shelf 22 to the first placement section 34 based on a command from the control section 50 (hereinafter simply referred to as a "command").

(1) In the first operation, first, the first cart 14 and the second cart 16 transport the single pallet 12S stored in a specified storage section 24 of the storage shelf 22 to the discharge section 23. During this process, the first cart 14 loads the single pallet 12S on the elevated loading platform 14c and enters the discharge section 23 (FIG. 10(a)). After entering the discharge section 23, the first cart 14 lowers the loading platform 14c to lower the single pallet 12S onto the loading platform 23p of the discharge section 23. After lowering the single pallet 12S, the first cart 14 exits the discharge section 23 and moves into the storage shelf 22.

(2) The transport vehicle 18 travels toward the discharge section 23 with the loading platform 18c lowered (FIG. 10(b)). After entering the discharge section 23, the transport vehicle 18 raises the loading platform 18c to lift the single pallet 12S and exits the discharge section 23 (FIG. 10(c)).

(3) After leaving the discharge section 23, the transport vehicle 18 travels toward the first loading section 34 (Figure 10 (d)).

(4) After the transport vehicle 18 enters the first loading section 34, it lowers the loading platform 18c and places the single pallet 12S on the loading platform 34p of the first loading section 34 (Figure 10(e)). After the single pallet 12S has been lowered, the transport vehicle 18 exits the first loading section 34.

(5) The transport vehicle 18 repeats this first operation in accordance with the shipping plan, and transfers the single pallets 12S of different types of loads 10 to different first loading sections 34. By operating in this manner, single pallets 12S carrying different types of loads 10 are placed on multiple first loading sections 34.

(Second Action)
The second operation is a picking operation. An example of the second operation of the picking device 32 will be described with reference to Fig. 6. As described above, the second operation is an operation of removing the loads 10 from the single-loading pallet 12S placed on the first loading section 34 based on a command corresponding to the shipping plan, and creating a mixed-loading pallet 12M on the second loading section 36 for shipping to a destination such as a retail store. In Fig. 6, the first type of loads 10-A are shown with dashed hatching, the second type of loads 10-B are shown with solid hatching, and the third type of loads 10-C are shown in white without hatching.

(1) The transport vehicle 18 places an empty pallet 12j for creating a mixed pallet 12M on the second loading section 36 of the picking area 30. During this process, the transport vehicle 18 transports the pallet 12j from a pallet storage area (not shown) that stores the pallet 12j to a specified second loading section 36.

(2) The picking device 32 removes the required number of the first type of cargo 10-A from the single-loading pallet 12S and places them on the pallet 12j of the second loading section 36.
(3) The picking device 32 also picks up the required number of second type loads 10-B from another single-loading pallet 12S and places them on top of the first type loads 10-A on the pallet 12j.
(4) The picking device 32 also removes the required number of third type loads 10-C from yet another single-loading pallet 12S and places them on top of the second type loads 10-B on the pallet 12j.
(5) In this manner, the picking device 32 stacks multiple types of cargo 10 corresponding to the shipping plan on the pallet 12j to create a mixed pallet 12M.

(Third Action)
The third operation is a preparation operation for unloading. An example of the third operation will be described with reference to FIG. 11. FIG. 11 is an explanatory diagram for explaining the third operation. The third operation is an operation of transferring the mixed pallet 12M of the second placement section 36 to the unloading section 40 by the transport vehicle 18 based on a command. The third operation may be performed by the transport vehicle 18 that performed the first operation, or may be performed by a transport vehicle 18 different from the transport vehicle 18 that performed the first operation. In this example, the third operation is performed by the transport vehicle 18 that performed the first operation. In other words, one transport vehicle 18 performs the first operation and the third operation.

(1) The transport vehicle 18 travels toward the second mounting portion 36 with the mounting platform portion 18c lowered (FIG. 11(a)).
(2) After entering the second loading section 36, the transport vehicle 18 raises the loading platform 18c to lift the mixed pallet 12M, then exits the second loading section 36 and travels toward the unloading section 40 (Figure 11 (b)).

(3) When the transport vehicle 18 enters the unloading section 40, it lowers the loading platform 18c and places the mixed pallet 12M on the loading platform 40p of the unloading section 40 (Figure 11 (c)). After unloading the mixed pallet 12M, the transport vehicle 18 exits the unloading section 40 and repeats the third operation according to the shipping plan.

(4) The mixed pallet 12M unloaded at the delivery section 40 is loaded onto a truck using a transport means such as a forklift and shipped to the destination.

In this way, by transporting the mixed pallets 12M to the unloading section 40 by the transport vehicle 18, even if the timing of the end of picking varies, the pallets can be transported by the transport vehicle 18 in the order in which the picking was completed, which provides greater flexibility in unloading compared to conveyors, etc.

(Fourth Action)
The fourth operation is an operation of recovering the empty pallet. As a result of the second operation, the empty pallet 12j after picking remains on the first loading section 34. The fourth operation is an operation of recovering the pallet 12j remaining on the first loading section 34 by the transport vehicle 18 based on a command.

In the fourth operation, the transport vehicle 18, with the platform 18c lowered, enters the first loading section 34, lifts up the pallet 12j, exits the first loading section 34, travels toward a designated pallet storage area, and lowers the pallet 12j into the pallet storage area.

A dedicated storage area may be provided as a pallet storage area, but in this embodiment, a part of the storage shelf 22 is used. In this case, the transport vehicle 18 transports the pallet 12j to the storage shelf 22. For example, the pallet 12j is transported to the discharge section 23, transferred to the first cart 14, and transported to the specified storage section 24 by the first cart 14 and the second cart 16.

In addition, in the fourth operation, the transport vehicle 18 may transport the pallet 12j from the first loading section 34 to the second loading section 36 that has been emptied by the third operation.

(Fifth Action)
The fifth operation is an operation for recovering the intermediate pallet. The second operation leaves a single-loading pallet 12S (hereinafter referred to as an "intermediate pallet") on the first loading section 34, on which some of the loads 10 have been removed and the remaining loads 10 have been stacked. For example, when the loads 10 on the intermediate pallet are not required in the immediate shipping plan and it is desired to place a single-loading pallet 12S for other types of loads 10 on the first loading section 34, the fifth operation can free up the first loading section 34. The fifth operation is an operation for recovering the intermediate pallet remaining on the first loading section 34 by the transport vehicle 18 based on a command.

In the fifth operation, the transport vehicle 18, with the loading platform 18c lowered, enters the first loading section 34, lifts up the intermediate pallet, exits the first loading section 34, travels toward a designated intermediate pallet storage area, and deposits the pallet 12j into the intermediate pallet storage area.

A dedicated storage area may be provided as the intermediate pallet storage area, but in this embodiment, a part of the storage shelf 22 is used. In this case, the transport vehicle 18 transports the intermediate pallet j to the storage shelf 22. For example, the intermediate pallet j is transported to the discharge section 23, transferred to the first cart 14, and transported to the specified storage section 24 by the first cart 14 and the second cart 16.

In addition, in the fifth operation, the transport vehicle 18 may transport a single pallet 12S, from which the load 10 has not yet been removed, to the storage shelf 22, instead of an intermediate pallet.

Furthermore, according to the fifth operation, for example, for a single-loading pallet 12S with low demand, only the necessary amount of load 10 can be removed, and the remainder can be temporarily evacuated from the first loading section 34, and a single-loading pallet 12S with high demand can be brought into the first loading section 34.

(Sixth Action)
The sixth operation is an operation for recovering the mixed pallet 12M. There are cases where it is desired to temporarily recover the mixed pallet 12M from the second placement section 36 or the outgoing section 40. For example, when a shipping plan is changed, the sixth operation can vacate the second placement section 36 or the outgoing section 40. The sixth operation is an operation for recovering the mixed pallet 12M from the second placement section 36 or the outgoing section 40 by the transport vehicle 18 based on a command.

In the sixth operation, the transport vehicle 18, with the loading platform 18c lowered, enters the second loading section 36 or the unloading section 40, lifts up the mixed pallet 12M, exits the second loading section 36 or the unloading section 40, travels toward the designated mixed pallet 12M storage area, and unloads the pallet 12j into the mixed pallet 12M storage area.

(Seventh Action)
The seventh operation is an operation in which, based on a command, the transport vehicle 18 transports the loaded pallet 12 from the receiving section (not shown) to the storage shelf 22. For example, the loaded pallet 12 is unloaded from the truck to the receiving section by a transport means such as a forklift, the loaded pallet 12 from the receiving section is transported to the unloading section 23 by the transport vehicle 18, the loaded pallet 12 is transferred to the first cart 14, and the loaded pallet 12 is transported to a predetermined storage section 24 by the first cart 14 and the second cart 16.

A dedicated storage area may be provided as a place to store the mixed pallets 12M, but in this embodiment, a part of the storage shelf 22 is used. In this case, the transport vehicle 18 transports the mixed pallet 12M to the storage shelf 22. For example, the mixed pallet 12M is transported to the discharge area 23, transferred to the first cart 14, and transported to a specified storage area 24 by the first cart 14 and the second cart 16. Note that the mixed pallets 12M include unfinished pallets as well as completed pallets.

The above is an explanation of the first to seventh operations. This is merely an example, and various modifications are possible.

A separate transport vehicle 18 may be provided for each operation. Also, the transport vehicle 18 may perform multiple operations in a time-sharing manner. Depending on the size of the warehouse and the volume of cargo handled, one or more transport vehicles 18 may be provided.

As described above, this embodiment has a first path between the storage shelf 22 and the first placement section 34, a second path between the first placement section 34 and the second placement section 36, a third path between the second placement section 36 and the delivery area 38, and a fourth path between the delivery area 38 and the storage shelf. A single transport vehicle 18 may transport a loaded pallet along one of the first, second, third, and fourth paths, or a single transport vehicle 18 may transport a loaded pallet along at least two of these four paths, or multiple transport vehicles 18 may share the transport of a loaded pallet along these four paths. This can be flexibly configured according to the size and operating conditions of the warehouse.

The transport vehicle 18 may be configured to be able to travel on the storage shelves 22, and the transport vehicle 18 may be configured to function in the same way as the first trolley 14. With this configuration, the same type of transport vehicle 18 can be used as long as the design of the route of the transport vehicle 18 (for example, the rail structure, its width, and the structure of the receiving part) is the same. In this case, when multiple transport vehicles 18 are used in the entire system including the storage shelves 22 and the picking area 30, the arrangement of the transport vehicles 18 can be flexibly operated.

For example, when four transport vehicles 18 are operated, all of the transport vehicles 18 can be used in the storage shelf 22 at one time, or two of the four transport vehicles 18 can be used in the storage shelf 22 and the remaining two transport vehicles 18 can be used in the picking area 30. Also, if there is a tendency for the transport vehicles 18 used in the picking area 30 to be insufficient, the transport vehicles 18 (for example, one vehicle) used in the storage shelf 22 can be used in the picking area 30 as support, or vice versa, allowing for flexible system operation.

The features of the automated warehouse system 100 of this embodiment configured as described above will be described. This embodiment is equipped with a storage shelf 22, a first placement section 34, a second placement section 36, a transport vehicle 18, and a picking device 32, so that picking, which removes goods 10 from a single-loading pallet 12S and creates a mixed-loading pallet 12M, can be achieved with a small number of steps.

In addition, according to this embodiment, the size of the first placement section 34, the second placement section 36, and the picking device 32 can be selected according to the size of the warehouse and the amount of cargo handled, so the automated warehouse system can be configured flexibly. When the size of the warehouse or the amount of cargo handled changes, the number and operating form of the transport vehicles 18 can be changed to flexibly accommodate the change. In addition, depending on the size of the warehouse and the amount of cargo handled, a flexible response can be provided by extending the vertical beams 32e and cross beams 32k of the crane mechanism, adding movable bodies of the crane mechanism, adding an unloading section 23, adding a first placement section 34, or adding a second placement section.

Furthermore, according to this embodiment, the load 10 removed from the single pallet 12S is loaded directly onto the mixed pallet 12M. Therefore, compared to a method in which the load 10 removed from the single pallet 12S is divided into multiple cases and stored in a separate space, and the cases stored in the separate space are loaded onto the mixed pallet, space efficiency is improved because a separate space for storing the cases is not used. Also, because the removal of the load 10 and the loading onto the mixed pallet 12M are performed in an integrated manner, productivity is improved and equipment costs can be reduced compared to a method in which separation and loading are performed separately.

In addition, according to this embodiment, the travel route of the transport vehicle 18 can be easily changed by replacing the guide wire 18g.

This embodiment may also include a separate transport vehicle that moves the mixed pallet 12M from the second loading section 36 to the outgoing area 38. In this case, the throughput of the warehouse can be improved.

In addition, in this embodiment, the mixed pallet 12M can be moved from the second placement section 36 to the outgoing area 38 by the transport vehicle 18 used in the first operation. In this case, capital investment can be reduced.

In addition, in this embodiment, the transport vehicle 18 can transport the empty pallet 12j from the first loading section 34. In this case, the mechanism for transporting the empty pallet 12j can be omitted.

In addition, in this embodiment, an empty pallet 12j can be transported to the second loading section 36 by the transport vehicle 18. In this case, the mechanism for transporting the empty pallet 12j can be omitted.

In addition, in this embodiment, the transport vehicle 18 can move the single pallet 12S or the single pallet 12S with some of the loads 10 removed from the first loading section 34 to the storage shelf 22. In this case, the first loading section 34 can be used effectively.

In addition, in this embodiment, the discharge section 23, the first loading section 34, the second loading section 36, and the delivery section 40 have multiple platforms arranged on either side of the entrance path through which the transport vehicle 18 enters. In this case, the discharge section 23, the first loading section 34, the second loading section 36, and the delivery section 40 can be simply configured.

In addition, in this embodiment, the unloading section 23, the first loading section 34, the second loading section 36, and the delivery section 40 of the storage shelf 22 are arranged on the same floor Fr. In this case, the step on the travel path of the transport vehicle 18 is small, so the transport vehicle 18 can travel easily.

Above, examples of the embodiments of the present invention have been described in detail. All of the above-mentioned embodiments merely show specific examples of how to put the present invention into practice. The contents of the embodiments do not limit the technical scope of the present invention, and many design changes such as changing, adding, or deleting components are possible within the scope of the idea of the invention defined in the claims. In the above-mentioned embodiments, the contents for which such design changes are possible are explained with notations such as "in the embodiment" and "in the embodiment", but this does not mean that design changes are not permitted for contents without such notations. Furthermore, hatching in the drawings does not limit the material of the hatched object.

(Modification)
The following describes the modified examples. In the drawings and description of the modified examples, the same or equivalent components and members as those in the embodiment are denoted by the same reference numerals. Descriptions that overlap with the embodiment will be omitted as appropriate, and the description will focus on configurations that differ from the embodiment.

In the description of the embodiment, an example has been shown in which the automated warehouse system 100 executes the first to seventh operations, but this is not limiting. It is not essential to execute all of the first to seventh operations, and the automated warehouse system 100 only needs to execute the first and second operations.

In the description of the embodiment, an example has been shown in which the storage shelf 22 has the first cart 14 and the second cart 16, but this is not limited to this. For example, the storage shelf 22 may not have one or both of the first cart 14 and the second cart 16.

In the description of the embodiment, an example has been shown in which the picking device 32 is supported from the ceiling side by a gantry-type crane mechanism, but the present invention is not limited to this. For example, the picking device may be supported by an articulated robot or a support means of a different configuration. In addition, the picking device may be attached to a side wall on the side and supported from the side.

In the description of the embodiment, an example has been shown in which the picking operation removes loads 10 from a collection of loads 10 of the same type (single-loading pallet 12S) to create a collection of multiple types of loads 10 (mixed-loading pallet 12M), but the present invention is not limited to this. The picking operation may include an operation of removing loads 10 from a collection of multiple types of loads 10, or may create a collection of loads 10 of the same type using the removed loads 10. In addition, the collection of loads 10 of the same type created by picking may be shipped out of the warehouse.

In the description of the embodiment, an example was given in which the transport vehicle 18 is guided based on an induced current in an electric wire installed on the floor, but the transport vehicle 18 may employ a different guidance method. Methods for guiding the transport vehicle 18 include a method using lines drawn on the floor, a method using facility shapes such as walls and shelves using a laser scanner, a method using light and a reflector, a method using radio waves and an RFID (Radio Frequency Identifier), a method using a magnetic signal from a magnetic tape installed on the floor, a method using radio waves from a beacon, and a combination of these methods.

The transport vehicle 18 may also be configured to recognize its own vehicle position and autonomously travel to a destination position based on the recognition result and the stored map information. The transport vehicle 18 may be equipped with various methods for recognizing its own vehicle position. For example, the transport vehicle 18 may recognize its own vehicle position using multiple reflectors installed in a warehouse and a laser scanner mounted on the transport vehicle. For example, the positions of the multiple reflectors may be stored on the map of the transport vehicle. In this case, the transport vehicle 18 can recognize at least three reflectors with a laser scanner and identify its own vehicle position based on the principle of triangulation by referring to the position information of the reflectors stored on the map.

The transport vehicle 18 may also be configured to correct its own vehicle position information in order to improve driving accuracy. For example, the transport vehicle 18 may use an image sensor to recognize images of floors, walls, equipment, etc., and correct its own vehicle position based on the recognition results. The transport vehicle 18 may also correct its own vehicle position based on the amount of wheel rotation determined from the detection results of an encoder that detects the rotation of the wheels. The transport vehicle 18 may also correct its own vehicle position based on the detection results of an acceleration sensor such as a gyro.

In the description of the embodiment, an example was shown in which the transport vehicle 18 is provided separately from the first cart 14, but this is not limited to this. As an example, the first cart 14 traveling on the storage shelf 22 may function as the transport vehicle 18 itself. For example, the first rail 26 of the lowest level of the storage shelf 22 may be connected to the rail of the placement section of the picking area 30, and the first cart 14 may move the single pallet 12S directly to the picking area 30. This rail connection relationship may be provided in accordance with the number of placement sections lined up in the X-axis direction of the picking area 30. In this case, a linked system can be constructed in which each storage shelf 22 can directly access the placement section of the picking area 30.

In addition, the picking area 30 may be provided with another transport means having the same function as the second cart 16 and capable of transporting the first cart 14. In this case, the above-mentioned linkage system can be constructed by providing at least one rail between the storage shelf 22 and the picking area 30 without providing rails corresponding to all of the multiple placement sections. In addition, by using this other transport means and the first cart 14, it is possible to selectively control which of the multiple placement sections a single pallet is to be brought into. In addition, from the viewpoint of constructing the above-mentioned linkage system in a compact manner, it is preferable that the picking area 30 and the storage shelf 22 are adjacent to each other, and it is even more preferable that they are structurally integrated. In this case, the transport path between the picking area 30 and the storage shelf 22 can be shortened.

In the description of the embodiment, an example has been shown in which the transport vehicle 18 moves under the picking device 32 to transport the loaded pallet 12, but this is not limited to the above. The transport vehicle 18 may be configured to move alongside the picking device 32. In this case, the travel route of the transport vehicle 18 can be flexibly set.

In the description of the embodiment, an example has been shown in which the placement table 34p of the first placement section 34 and the placement table 36p of the second placement section 36 are separated from each other, but this is not limiting. The placement table 34p and the placement table 36p may be connected to each other or may be formed integrally.

Each of these modified examples provides the same effects as the embodiment.

Any combination of the above-described embodiments and modifications is also useful as an embodiment of the present invention. A new embodiment resulting from the combination has the combined effects of each of the combined embodiments and modifications.

10 load, 12 loaded pallet, 12M mixed pallet, 12S single pallet, 18 transport vehicle, 18g induction wire, 22 storage shelf, 23 discharge section, 32 picking device, 34 first placement section, 36 second placement section, 40 delivery section, 50 control section, 100 automated warehouse system.

Claims (1)

a first placement section and a second placement section on which a loaded pallet can be placed;
a picking device that picks out a load from a load pallet placed on the first placement section and moves the load to the second placement section to create another load pallet;
a transport vehicle that can move while autonomously changing a moving direction and moves under the picking device to transfer the loaded pallet to the first placement section;
An automated warehouse system equipped with:

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