Picking system

Abstract

The sorting system (100) is provided with a multi-layer sorting device (3), a second conveying device (2), and a plurality of first conveying devices (1). The multi-layer sorting device (3) has a plurality of layers of ports (31) with different heights in the vertical direction, and sorts and discharges articles (W) to a certain port (31) of the plurality of layers. The plurality of first conveying devices (1) are arranged corresponding to each of the plurality of layers of ports (31). The second conveying device (2) conveys the articles (W) received from the first conveying devices (1). The second conveying device (2) has a second conveying surface (F2) configured to be able to be lifted. In a state where the second conveying surface (F2) is located at a height corresponding to the end portion (E1) of the first conveying surface (F1) of a certain one of the plurality of first conveying devices (1), the second conveying surface (F2) receives and conveys the articles (W) discharged from the end portion (E1) of the first conveying surface (F1).

Description

TECHNICAL FIELD

[0001] The present application relates to a picking system that collects necessary articles from a plurality of articles stored. BACKGROUND

[0002] For example, in a logistics base of a seller who sells communication services, a plurality of articles are stored in advance in a logistics warehouse, and when an order is received, the purchased articles are packed for each delivery destination and sent from the logistics warehouse. In such a case, a picking system that collects necessary articles from a plurality of articles stored is used. An example of the picking system is disclosed in Japanese Patent Application Publication No. 2004-189417 (Patent Document 1). Hereinafter, in the description of the background art, the reference numerals in brackets are those of Patent Document 1.

[0003] The picking system disclosed in Patent Document 1 has a plurality of conveyors (122) as a sorting device, and the plurality of conveyors (122) have sorting trays (121) that are inclined to be movable in a direction orthogonal to a traveling direction. In the picking system, after the conveyors (122) travel to a target sorting position, the sorting trays (121) are inclined toward a recovery box (B) to discharge articles, and sorting of the articles is performed. The sorted articles are put into the recovery box (B), packed by an operator or the like, and transported to a next place.

[0004] Patent Document 1: Japanese Patent Application Publication No. 2004-189417

[0005] However, in the picking system disclosed in Patent Document 1, the recovery boxes (B) into which the sorted articles are put are provided at a plurality of positions in the traveling direction of the conveyors (122). In this case, with respect to the articles sorted into the recovery boxes (B), work sites for next work such as packing and transportation are necessary for each of the provided positions of the recovery boxes (B), which leads to dispersion of the work sites with respect to the sorted articles. SUMMARY

[0006] In view of the above-described actual situation, it is desirable to realize a picking system that enables concentration of work sites with respect to sorted articles.

[0007] The system of the present application is a picking system that collects necessary items from a plurality of items stored for shipment, characterized by comprising a multi-layer sorting device having a plurality of layers of ports having different heights in the vertical direction, discharging the items to a certain port of the plurality of layers, a second conveyance device, and a plurality of first conveyance devices provided corresponding to each of the ports of the plurality of layers, the second conveyance device conveying the items received from the first conveyance devices, each of the plurality of first conveyance devices having a first conveyance surface that receives the items discharged from the ports by the first conveyance surface and conveys the items in a state where the items are placed on the first conveyance surface in a direction away from the ports, the second conveyance device having a second conveyance surface configured to be able to be raised, the second conveyance device receiving and conveying the items discharged from the terminal end of the first conveyance surface by the second conveyance surface in a state where the second conveyance surface is positioned at a height corresponding to the terminal end of the first conveyance surface of a certain one of the plurality of first conveyance devices.

[0008] According to the present structure, the items sorted by the multi-layer sorting device and discharged from each of the plurality of ports can be received and conveyed by the first conveyance devices provided corresponding to each of the plurality of ports. Also, the plurality of items conveyed by each of the plurality of first conveyance devices can be received and conveyed by the second conveyance device. Thus, the items sorted by the multi-layer sorting device can be conveyed by the second conveyance device in order for each of the sorted item groups. Therefore, according to the present structure, the work sites used for the next work with respect to the sorted items can be concentrated at a number of specific sites that is less than the number of ports, and further, an improvement in work efficiency can be achieved.

[0009] Further features and advantages of the technology of the present disclosure will become more apparent from the following description of exemplary and non-limiting embodiments with reference to the attached drawings. BRIEF DESCRIPTION OF DRAWINGS

[0010] Figure 1 is a schematic plan view of a picking system.

[0011] Figure 2 is a perspective view showing a part of a multi-layer sorting device.

[0012] Figure 3 is a perspective view showing a part of a picking system.

[0013] Figure 4 is a width direction view of a picking system.

[0014] Figure 5 is a plan view showing a part of the operation of a picking system.

[0015] Figure 6 is a control block diagram of the order-picking system.

[0016] Figure 7 is a flowchart showing a control flow of the order-picking system.

[0017] Figure 8 is a plan view showing the order-picking system of another embodiment.

[0018] Figure 9 is a plan view showing the order-picking system of another embodiment. DETAILED DESCRIPTION

[0019] Outline structure of order-picking system

[0020] As shown in Figure 1 , the order-picking system 100 is equipped, for example, in a logistics facility owned by a business operator who conducts a communication sale, to collect necessary articles W from among a plurality of articles W stored to ship out. The order-picking system 100 collects necessary articles W from among a plurality of articles W stored in an automated warehouse, not shown, for example, to ship out. In this case, the plurality of articles W are stored in the automated warehouse in a state of being housed in containers by each category. Also, the plurality of articles W housed in the containers by each category are automatically carried out from the automated warehouse, and are separated into individual articles W in an article separating section, not shown. Thereafter, each of the plurality of articles W is individually carried. In addition, the articles W include various goods such as foodstuffs, daily necessities, and the like, for example. However, the articles W are not limited to this, and can be semi-finished products and the like used in a production line of a factory or the like.

[0021] The order-picking system 100 is provided with a multilevel sorting device 3, a first carrying device 1 that carries articles W received from the multilevel sorting device 3 in a direction away from the multilevel sorting device 3, a second carrying device 2 that carries the articles W received from the first carrying device 1. In the present embodiment, the order-picking system 100 is further provided with a carrying-in device 4 that carries the articles W into the multilevel sorting device 3, and a carrying-out device 5 that carries out the articles W received from the second carrying device 2.

[0022] In the present embodiment, the plurality of articles W stored in the above-described automated warehouse in a state of being housed in containers by each category are individually separated by the above-described article separating section, are carried by the carrying-in device 4, and are delivered to the multilevel sorting device 3 to be sorted. Then, the articles W sorted by the multilevel sorting device 3 are carried by the first carrying device 1, thereafter, are delivered to the second carrying device 2, and are carried by the second carrying device 2. Further, the articles W carried by the second carrying device 2 are delivered to the carrying-out device 5, and are carried out to the outside by the carrying-out device 5.

[0023] The following describes in detail the structure of each part of the picking system 100. In addition, the direction of departure from the multi-layer sorting device 3 (more specifically, the port (intermediate port) 31 described later) is set as the departure direction X, and the direction intersecting the departure direction X when viewed from above is set as the width direction Y. The departure direction X is equivalent to the conveying direction of the article W based on the first conveying device 1. The width direction Y is a direction along the arrangement direction of the multiple columns of ports 31 described later. In the present embodiment, the width direction Y is a direction orthogonal to the departure direction X when viewed from above. That is, in the present embodiment, the departure direction X and the width direction Y are directions along the horizontal direction and are orthogonal to each other when viewed from above. In addition, in the present embodiment, the conveying direction of the article W based on the second conveying device 2 is set as a direction parallel to the width direction Y.

[0024] [Importing device]

[0025] The loading device 4 is used to load articles W into the multi-layer sorting device 3. In this embodiment, the loading device 4 sequentially loads articles W into the multi-layer sorting device 3. The articles W are then removed from the automated warehouse while being stored in containers according to their categories and individually separated in the article separation unit. In the illustrated example, the loading device 4 is configured as a conveyor. However, this configuration is not limiting and the loading device 4 may also be configured as various other transport devices, such as a transport trolley or a rooftop transporter.

[0026] [Multi-layer sorting device]

[0027] The multi-layer sorting device 3 is a device for sorting the articles W brought in from the carrying-in device 4. Figure 2 As shown, the multi-layer sorting device 3 has multiple layers of ports 31 with different heights in the vertical direction, and discharges the articles W according to a certain sorting of the multiple layers of ports 31. In the example shown in the figure, the multi-layer sorting device 3 has 8 layers of ports 31. Furthermore, in this embodiment, the multi-layer sorting device 3 has multiple columns of ports 31 with different positions in the width direction Y. That is, in this example, the multi-layer sorting device 3 has multiple ports 31 arranged in an orthogonal grid shape consisting of multiple layers and multiple columns. Here, the ports 31 can be, for example, multiple openings formed in the shell when the multi-layer sorting device 3 has a shell surrounding its outer periphery. In the case where the multi-layer sorting device 3 does not particularly have such a shell, the ports 31 can also be a hypothetical concept set corresponding to the connection portion between the multi-layer sorting device 3 and the first transport device 1.

[0028] In the present embodiment, the multi-layer sorting device 3 sorts the articles W to a certain one of the plurality of ports 31 based on order information. In this example, the multi-layer sorting device 3 discharges the articles W from the specific port 31 determined based on the order information to the first conveying device 1, thereby sorting the articles W. Note that the order information herein refers to, for example, information indicating an order (picking order) specifying the category and the number of articles W (which can be a single kind or a plurality of kinds in combination) to be shipped. Also, the multi-layer sorting device 3 discharges one or more articles W specified for each order to the port 31 different for each order, thereby sorting the articles W.

[0029] As shown in Figure 1 , in the present embodiment, the multi-layer sorting device 3 is provided with an article identifying section 30 for identifying the articles W. The multi-layer sorting device 3 sorts the articles W based on the identification result of the article identifying section 30. In this example, the article identifying section 30 is provided with a camera 30a that photographs the articles W, and is configured to perform image recognition processing on image data acquired by the camera 30a, thereby identifying the articles W. In the illustrated example, a plurality of cameras 30a are disposed at positions at which the articles W conveyed by the conveying-in device 4 can be photographed from a plurality of directions. Thus, even in a case where the posture of the articles W at the time of conveyance differs for each article W, the identification of each article W can be appropriately performed. Note that the configuration is not limited to the above, and for example, the articles W can be provided with an IC tag, a bar code, or the like (storage section) storing article information, and the article identifying section 30 can be provided with a reader (reading section) that reads the article information, and the articles W can be identified based on the article information read by the reader.

[0030] In the present embodiment, as shown in Figure 1 and Figure 3 , the multi-layer sorting device 3 is provided with a track 32 and a plurality of conveying trolleys 33 that move along the track 32. The track 32 is provided with a horizontal portion disposed in the horizontal direction (width direction Y) for each of the plurality of layers in which the ports 31 are disposed. In this example, the conveying trolleys 33 are configured to travel along the horizontal portion of the track 32, thereby conveying the articles W in the width direction Y. In addition, the track 32 can be provided with an up-and-down portion extending in the up-and-down direction and connecting the horizontal portions disposed for each of the plurality of layers. In this case, the conveying trolleys 33 are configured to be raised and lowered along the up-and-down portion of the track 32, thereby being able to move to each of the horizontal portions disposed for each of the plurality of layers. In this case, the number of the conveying trolleys 33 is not limited by the number of layers of the ports 31. Thus, for example, a smaller number of trolleys than the number of layers of the ports 31 or a larger number of trolleys can be disposed, and for example, five trolleys 33 can be disposed with respect to eight layers, or twelve trolleys 33 can be disposed with respect to eight layers. Note that, in the example shown in Figure 2 , eight trolleys 33 are disposed with respect to eight layers.

[0031] In the present embodiment, each of the conveyance vehicles 33 is provided with a discharge conveyor 34 that supports the article W from below and discharges the article W from the port 31. The discharge conveyor 34 moves the article W in the left-right direction (in the present example, the direction of departure X) with reference to the advancing direction (in the present example, the width direction Y) of the conveyance vehicle 33. Figure 1 In the example shown, the ports 31 are arranged on both sides with reference to the advancing path of the conveyance vehicles 33 in the advancing direction of the conveyance vehicles 33. Also, the discharge conveyors 34 are capable of discharging the articles W with reference to each of the ports 31 arranged on both sides.

[0032] [First conveyance device]

[0033] The first conveyance device 1 is a device for conveying the articles W sorted by the multi-layer sorting device 3. The first conveyance device 1 is provided in correspondence with each of the ports 31 of the multi-layer. In the present embodiment, a plurality of first conveyance devices 1 are arranged in the width direction Y in a manner corresponding to each of the ports 31 of the multi-column on each of the layers of the multi-layer. Figure 1 In the example shown, the first conveyance devices 1 are each provided with a plurality of regions on both sides with reference to the advancing path of the conveyance vehicles 33 in the advancing direction of the conveyance vehicles 33.

[0034] As shown in Figure 3 Each of the plurality of first conveyance devices 1 has a first conveyance surface Fl, receives the article W discharged from the port 31 by means of the first conveyance surface Fl, and conveys the article W in the direction of departure X from the port 31 in a state placed on the first conveyance surface Fl.

[0035] As shown in Figure 1 and Figure 4 In the present embodiment, the first conveyance device 1 discharges the articles W to the second conveyance device 2 in units of groups Gw of a plurality of articles W per order. The number of articles W constituting one group Gw differs for each order. For example, there are cases in which one group Gw is constituted by one article W depending on the order.

[0036] In the present embodiment, the first conveyance device 1 is provided with an upstream conveyance section 11 and a downstream conveyance section 12. The upstream conveyance section 11 and the downstream conveyance section 12 are configured to be arranged in line in the direction of departure X and convey the articles W in the direction of departure X, respectively. The upstream conveyance section 11 and the downstream conveyance section 12 are configured as conveyors that act independently of each other.

[0037] The upstream conveyance section 11 functions as an article storage section for storing articles W to be discharged to the second conveyance device 2. The upstream conveyance section 11 sequentially receives the articles W from the multistory sorting device 3 to store them until a set of all the articles W, i.e., an article group Gw, specified for each order is collected. In addition, the collection of the article group Gw means the collection of all the articles W constituting the article group Gw. The upstream conveyance section 11 conveys the article group Gw to the downstream conveyance section 12 when the article group Gw for each order is collected. In the present embodiment, the upstream conveyance section 11 is provided with a stopper 111 disposed at the downstream end in the conveyance direction. The stopper 111 is configured to change its state to a closed state in which the conveyance path from the upstream conveyance section 11 to the downstream conveyance section 12 is closed, and an open state in which the conveyance path is open. The upstream conveyance section 11 conveys the articles W in the direction X away while the stopper 111 is in the closed state. Thus, the upstream conveyance section 11 restricts the movement of the articles W at the downstream end and stores them. After that, when the article group Gw for each order is collected, the stopper 111 is made to be in the open state, and the article group Gw is conveyed to the downstream conveyance section 12.

[0038] The downstream conveyance section 12 functions as an article discharge section for discharging the articles W to the second conveyance device 2. The downstream conveyance section 12 discharges the articles W to the second conveyance device 2 in units of the article group Gw conveyed from the upstream conveyance section 11. In the present embodiment, the downstream conveyance section 12 discharges the articles W to the second conveyance device 2 in a state where the second conveyance surface F2 of the second conveyance device 2 is located at a height corresponding to the terminal end portion El of the first conveyance surface Fl. In addition, in the present example, as shown in FIG. 8, the downstream conveyance section 12 is configured to discharge the articles W to a certain region A in which the articles W have not been placed, among a plurality of regions A hypothetically set on the second conveyance surface F2 of the second conveyance device 2. Figure 5 Figure 5 Thus, the article groups Gw for a plurality of orders can be conveyed in parallel by the second conveyance device 2.

[0039] [Second conveyance device]

[0040] The second conveyance device 2 is a device for conveying the articles W received from the first conveyance device 1. Figure 1 In the example shown in FIG. 9, the second conveyance device 2 is disposed on both sides with respect to the traveling path of the conveyance cart 33, based on the traveling direction of the conveyance cart 33. Between the second conveyance device 2 and the conveyance path of the conveyance cart 33 in the direction X away, a plurality of first conveyance devices 1 are disposed in line in the width direction Y.

[0041] As shown in FIG. 10, the second conveyance device 2 is provided with a plurality of conveyance sections 21. The conveyance sections 21 are disposed in line in the direction X away with respect to the traveling path of the conveyance cart 33. The conveyance sections 21 are configured to convey the articles W in the direction X away while the articles W are placed on the second conveyance surface F2 of the second conveyance device 2. Figure 3 ​As shown, the second conveyance device 2 has a second conveyance surface F2 configured to be able to be raised and lowered, and in a state in which the second conveyance surface F2 is positioned at a height corresponding to the terminal portion E1 of the first conveyance surface Fl of a certain one of the plurality of first conveyance devices 1, the second conveyance device 2 receives and conveys the article W that is discharged from the terminal portion E1 of the first conveyance surface Fl by means of the second conveyance surface F2. In the present embodiment, the second conveyance device 2 conveys the article W in a state in which the article W is placed on the second conveyance surface F2, and conveys the article W in the width direction Y. In the present example, the second conveyance device 2 conveys the article W in units of the article group Gw for each order.

[0042] In the present embodiment, the second conveyance surface F2 is arranged in the width direction Y in a manner that follows the terminal portions E1 of the plurality of first conveyance surfaces Fl that are arranged in the width direction Y, on each of the plurality of layers. In the present example, the second conveyance surface F2 is arranged over the entire area of the arrangement region of the terminal portions E1 of the plurality of first conveyance surfaces Fl that are arranged in the width direction Y, on each of the plurality of layers. Thus, the second conveyance device 2 is able to receive the article W from all of the plurality of first conveyance devices 1 arranged in the width direction Y, on each of the plurality of layers. Also, the second conveyance device 2 raises and lowers the second conveyance surface F2, whereby the second conveyance device 2 is able to receive the article W from all of the first conveyance devices 1 arranged in the width direction Y, on all of the plurality of layers, and convey the received article W in the width direction Y.

[0043] As shown in FIG. 1, the first conveyance device 1 has a first conveyance surface Fl that is arranged in the width direction Y, and conveys the article W in the width direction Y. In the present example, the first conveyance device 1 conveys the article W in units of the article group Gw for each order. Figure 5As shown, in the present embodiment, a plurality of regions A are hypothetically set on the second conveyance surface F2 of the second conveyance device 2. The setting of the regions A and the control of the first conveyance device 1 and the second conveyance device 2 based on the regions A are performed by the overall control device Ct, the first conveyance control section Cl, and the second conveyance control section C2 described later. Each region A is set to a width capable of placing a single or a plurality of articles W constituting the article group Gw. In the illustrated example, the length of the width direction Y of each region A is set to be equal to the size of the width direction Y of the first conveyance device 1. The second conveyance device 2 moves the second conveyance surface F2 (region A) intermittently by the length of the width direction Y of the region A each time, or continuously without stopping. Also, the downstream conveyance section 12 of the first conveyance device 1 discharges the article group Gw to a certain region A of the regions A set on the second conveyance surface F2 in which the article group Gw is not placed. At this time, in order to reduce the possibility that a plurality of article groups Gw of different orders are mixed with each other on the second conveyance surface F2, it is preferable to control the downstream conveyance section 12 so that the article group Gw is not discharged with respect to a region A adjacent to a region A in which the article group Gw is already placed. For example, it is also possible to control so that the discharge of the article group Gw is not performed with respect to only a region A adjacent to a region A in which the article group Gw is placed. That is, it is also possible to perform the discharge of the article group Gw at an interval of one region A. Furthermore, it is also possible to control so that the discharge of the article group Gw is not performed with respect to a region A adjacent to a region A adjacent to a region A in which the article group Gw is placed. That is, it is also possible to perform the discharge of the article group Gw at an interval of two regions A. Figure 5 In the present embodiment, an example in which the case of performing the discharge of the article group Gw at an interval of one region A and the case of performing the discharge of the article group Gw at an interval of two regions A coexist is shown. In addition, it is also possible to perform only one of the control of performing the discharge of the article group Gw at an interval of one region A and the control of performing the discharge of the article group Gw at an interval of two regions A. Furthermore, it is also possible to perform the control of discharging the article group Gw at an interval of three or more regions A.

[0044] As Figure 4As shown, in this embodiment, the second transport devices 2 are provided on each of the left and right sides of the transport trolley 33's travel path, relative to the direction of travel of the transport trolley 33. Because the second transport devices 2 have a second transport surface F2 configured to be raised and lowered as described above, even if there are fewer second transport devices 2 than the number of levels on which the first transport devices 1 are provided, the second transport devices 2 can receive articles W from the first transport devices 1 on each level of multiple layers. However, this is not limiting to such a configuration; the second transport devices 2 may be provided on each level of multiple layers where the first transport devices 1 are provided. For example, one second transport device 2 may be provided on each level, thereby providing a total of the same number of second transport devices 2 as the number of levels on which the first transport devices 1 are provided.

[0045] In this embodiment, the second transport device 2 is configured as a trough-type conveyor (see FIG. 1 ) in which the center portion 20 of the second transport surface F2 of the cross section perpendicular to the transport direction of the article W of the second transport device 2 is recessed relative to the side portions 21, 21. Figure 4 ). Thus, during the transport of articles W by the second transport device 2, the articles W can be positioned closer to the center portion 20 of the second transport surface F2. This prevents the articles W from being transported from the second transport surface F2 in the left or right direction relative to the transport direction. Furthermore, as described above, in this embodiment, the second transport device 2 transports articles W in order-based article groups Gw. Therefore, when an article group Gw consists of multiple articles W, the multiple articles W constituting the article group Gw can be transported while being gathered in the center portion 20 of the second transport surface F2.

[0046] like Figure 1 As shown, in this embodiment, the second transport device 2 transports the article group Gw received from the first transport device 1 in the width direction Y and discharges it to the unloading device 5. In this example, a storage container B that receives and stores the articles W discharged from the second transport device 2 is arranged below the end E2 of the second transport surface F2 in the width direction Y. In the example shown in the figure, a plurality of storage containers B are sequentially transported in a state of being placed on the transport surface F5 of the unloading device 5. For example, Figure 4 As shown, the second conveying device 2 raises and lowers its second conveying surface F2, placing the article group Gw into the container B placed on conveying surface F5 while aligning the height of the conveying surface F5 of the unloading device 5, more specifically, the height of the container B placed on conveying surface F5. At this point, the unloading device 5 is preferably controlled to stop conveying the container B, into which the article group Gw is to be placed, or to reduce the conveying speed. This allows for the appropriate placement of the article group Gw into the container B.

[0047] like Figure 1 and Figure 3As shown, in the present embodiment, the second conveying device 2 has a narrowing portion 22 that narrows the arrangement range of the group Gw of articles on the second conveying surface F2 in a direction orthogonal to the conveying direction (here, the direction X of departure).

[0048] The narrowing portion 22 has a pair of guide members 221 arranged apart in a direction orthogonal to the conveying direction of the second conveying device 2 (the direction X of departure). The pair of guide members 221 is fixed immovably to the second conveying surface F2. Thus, the articles W conveyed on the second conveying surface F2 come into contact with the pair of guide members 221 from the upstream side in the conveying direction. The pair of guide members 221 is arranged so that the interval between the members in the direction X of departure narrows toward the downstream side in the conveying direction of the second conveying device 2. Thus, the pair of guide members 221 can come into contact with the articles W that make up the group Gw of articles and cause the articles W to flow toward the downstream side. Also, the pair of guide members 221 can narrow the arrangement range of the group Gw of articles made up of a plurality of articles W conveyed on the second conveying surface F2 toward the central side in the direction orthogonal to the conveying direction. With the narrowing portion 22 having such a pair of guide members 221, for example, the plurality of articles W that make up the group Gw of articles can be aligned in a row in the conveying direction of the second conveying device 2 after passing through the narrowing portion 22. By so arranging, the plurality of articles W that make up the group Gw of articles can be put into the storage container B one at a time.

[0049] [Conveying-out device]

[0050] The conveying-out device 5 is a device for conveying the articles W outward. In the present embodiment, the conveying-out device 5 has a conveying surface F5 with which a plurality of storage containers B are sequentially conveyed in a state of being supported from below. In the illustrated example, the conveying-out device 5 is configured as a conveyor. However, the conveying-out device 5 is not limited to such a structure and can be configured as various conveying devices such as a conveying cart.

[0051] [Control configuration of picking system]

[0052] Next, the control configuration of the picking system 100 will be described. Figure 6 is a block diagram showing the control configuration of the picking system 100.

[0053] As Figure 6As shown, the sorting system 100 is provided with an overall control device Ct that comprehensively manages storage, transport, and the like of the articles W within the system. The overall control device Ct is configured to be able to communicate in a wired or wireless manner between each of a transport-in control section C4 that controls the operation of the transport-in device 4, a sorting control section C3 that controls the operation of the multi-layer sorting device 3, a first transport control section Cl that controls the operation of the first transport device 1, a second transport control section C2 that controls the operation of the second transport device 2, and a transport-out control section C5 that controls the operation of the transport-out device 5. The overall control device Ct, the transport-in control section C4, the first transport control section Cl, the second transport control section C2, and the transport-out control section C5 are each provided with, for example, a processor such as a microcomputer, a peripheral circuit such as a memory, and the like. Furthermore, each function is realized through the cooperation of these hardware and a program executed on the processor such as a computer.

[0054] In the present embodiment, the sorting control section C3 is configured to be able to acquire the recognition result of the article recognition section 30 and control the operation of the multi-layer sorting device 3 in a manner that sorts the articles W based on the recognition result.

[0055] Furthermore, in the present embodiment, the first transport control section Cl includes an upstream side control section Cl l that controls the operation of the upstream side transport section 11, and a downstream side control section C12 that controls the operation of the downstream side transport section 12 (see also Figure 4 ). In the present example, the upstream side control section Cl l controls the driving and stopping of the conveyor section of the upstream side transport section 11, and controls the open / close state of the stopper 111. Furthermore, the downstream side control section C12 controls the driving and stopping of the conveyor section of the downstream side transport section 12.

[0056] Next, the control flow of the sorting system 100 will be described mainly with reference to Figure 7 . Figure 7 is a flowchart that shows part of the control flow of the sorting system 100.

[0057] In the sorting system 100, first, the recognition of the articles W is performed (Step #1). In the present embodiment, the article recognition section 30 performs the recognition of the articles W transported in by the transport-in device 4. As described above, in the present example, the recognition of the category or the like of the articles W is performed by image recognition of the camera 30a (see Figure 1 ).

[0058] Next, the sorting of the articles W is performed based on the recognition result of the article recognition section 30 (Step #2). The sorting of the articles W is performed as described above with reference to Figure 5As shown in the figure above, the multi-layer sorting device 3 discharges the articles W through one of the multiple ports 31 to the first transport device 1 corresponding to the port 31. In this example, the sorting process of the articles W also includes selecting a specific port 31 from the multiple ports 31 as the sorting destination based on the order information and the identification result of the article W by the article identification unit 30.

[0059] Next, it is determined whether the article group Gw indicated by the order information is stored in the upstream conveying section 11 of the first conveying device 1 (specifically, whether all the articles W constituting the article group Gw are stored) (step #3). If the article group Gw has not been stored (step #3; no), wait until the article group Gw is stored (step #4). If it is determined that the article group Gw indicated by the order information is stored in the upstream conveying section 11 (step #3; yes), preparations are made to discharge the article group Gw to the second conveying device 2 (step #5). Specifically, if Figure 5 As shown in the center figure, the stopper 111, which had been closing the conveyance path from the upstream conveyor 11 to the downstream conveyor 12, is opened, thereby opening the conveyance path and conveying the article group Gw from the upstream conveyor 11 to the downstream conveyor 12. If the downstream conveyor 12 is not in a state capable of discharging the article group Gw to the second conveying device 2 (step #6; No), it stops driving and stands by in a state ready for discharge (step #5).

[0060] Next, when the article group Gw is in a state capable of being discharged relative to the second conveying device 2 (step #6; yes), the article group Gw is discharged from the downstream conveying section 12 to the second conveying device 2 (step #7). Here, the state capable of being discharged relative to the second conveying device 2 refers to the following state: the downstream conveying section 12 (the terminal end E1 of the first conveying surface F1) serving as the discharge source of the article group Gw is set as the target downstream conveying section 12A, the second conveying surface F2 of the second conveying device 2 is located at a height corresponding to the target downstream conveying section 12A, and the area A of the second conveying surface F2 capable of carrying the article group Gw is located at a position corresponding to the target downstream conveying section 12A. More specifically, the state in which the second conveying surface F2 of the second conveying device 2 is located at a height corresponding to the target downstream conveying section 12A refers to the following state: Figure 4 As shown, the second conveying surface F2 of the second conveying device 2 is located at a predetermined height below the first conveying surface F1 of the downstream conveying section 12A. In this case, the difference between the second conveying surface F2 and the first conveying surface F1 is, for example, smaller than the height of the article W. Furthermore, the state in which the area A of the second conveying surface F2 capable of carrying the article group Gw is located at a position corresponding to the downstream conveying section 12A is a state in which the area A, which has not yet carried the article group Gw, is located adjacent to the terminal end E1 of the first conveying surface F1 of the downstream conveying section 12A.

[0061] Next, the article group Gw is transported in the width direction Y by the 2nd conveying device 2, and the article group Gw is dropped into the storage container B placed on the conveying surface F5 of the conveying-out device 5 (Step #7). Specifically, the 2nd conveying device 2 drops the article group Gw into the storage container B placed on the conveying surface F5 in a state where the 2nd conveying surface F2 is raised to the height of the conveying surface F5 of the conveying-out device 5. Then, the article group Gw dropped into the storage container B is conveyed out to the outside by the conveying-out device 5.

[0062] 〔Other Embodiments〕

[0063] Next, other embodiments of the sorting system will be described.

[0064] (1) In the above-described embodiments, the following example has been described: the 2nd conveying surface F2 of the 2nd conveying device 2 is configured to be arranged over the entire area of the arrangement area of the terminal portions El of the plurality of 1st conveying surfaces Fl arranged in the width direction Y. However, it is not limited to this example, and the 2nd conveying surface F2 of the 2nd conveying device 2 can be arranged in an area of a part of the arrangement area of the terminal portions El of the above-described plurality of 1st conveying surfaces Fl. In this case, for example, it can be configured that the plurality of 2nd conveying devices 2 are arranged in the width direction Y so that the 2nd conveying surfaces F2 of the plurality of 2nd conveying devices 2 are arranged over the entire area of the arrangement area of the terminal portions El of the above-described plurality of 1st conveying surfaces Fl as a whole.

[0065] (2) In the above-described embodiments, the following example has been described: the storage container B that receives and stores the article W discharged from the 2nd conveying device 2 is arranged on the conveying surface F5 of the conveying-out device 5. However, it is not limited to this example, and the storage container B can not be arranged on the conveying surface F5 of the conveying-out device 5. In this case, for example, it can be configured that the conveying-out device 5 conveys the article W in a state where the article W is directly supported from below by the conveying surface F5.

[0066] (3) In the above-described embodiments, the following example has been described: the 2nd conveying device 2 is configured as a trough-type conveyer in which the central portion 20 of the 2nd conveying surface F2 is recessed with respect to the both side portions 21, 21. However, it is not limited to this example, and the 2nd conveying device 2 can be configured as a conveyer having a flat 2nd conveying surface F2. Further, the 2nd conveying device 2 is not limited to the belt-type conveyer as illustrated, and can be a roller-type conveyer or the like.

[0067] (4) In the above-described embodiment, the example in which the upstream conveyance section 11 is provided with the stopper 111 that restricts movement of the article W, whereby the articles W are accumulated to the order-specified article group Gw (specifically, to the accumulation of all the articles W that constitute the article group Gw) was described. However, the example is not limited to this, and the upstream conveyance section 11 can not be provided with the stopper 111. In this case, the upstream conveyance section 11 can be configured to, for example, accumulate the articles W to the order-specified article group Gw by controlling driving and stopping.

[0068] (5) In the above-described embodiment, the example in which the first conveyance device 1 is configured to discharge the articles W to the second conveyance device 2 as a unit of the article group Gw for each order was described, but is not limited to this. For example, the first conveyance device 1 can be configured to convey the articles W in a state of a single article W each time the articles W are discharged from the port 31 by the multi-layer sorting device 3. In this case, a mechanism for gathering the article group Gw for each order can be provided to the second conveyance device 2 or the conveyance-out device 5, or control for gathering the article group Gw for each order can be performed.

[0069] (6) In the above-described embodiment, the example in which one first conveyance device 1 is configured to accumulate the article group Gw for each order to discharge to the second conveyance device 2 was described, but is not limited to this. The article group Gw for one order can be collected by a plurality of first conveyance devices 1 to be shared in parts to be discharged to the second conveyance device 2. For example, in a case where one order is an article group Gw constituted by 10 articles W, the 10 articles W can be collected by a plurality of first conveyance devices 1 to be shared in parts (for example, to be shared five by five by two first conveyance devices 1 that are continuous in the width direction Y) to be discharged to the second conveyance device 2. In this case, the plurality of articles W that constitute the article group Gw for one order can be gathered at the second conveyance device 2 or the conveyance-out device 5. For example, the discharge timing of the articles W discharged from the plurality of first conveyance devices 1 can be controlled in a manner that the article groups Gw discharged from the plurality of first conveyance devices 1 are continuously conveyed at the second conveyance device 2 in parts. In the above-described example, for example, a total of 10 articles W of five articles W discharged from one of the two first conveyance devices 1 and five articles W discharged from the other can be discharged to the adjacent regions A of the second conveyance surface F2.

[0070] (7) In the above-described embodiment, the example in which the second conveying surface F2 of the second conveying device 2 is arranged in the width direction Y so as to follow the terminal portions E1 of the plurality of first conveying surfaces Fl was described, but the present application is not limited to this, and the second conveying surface F2 can be arranged in a direction intersecting the width direction Y. For example, the second conveying surface F2 can be arranged in the separation direction X. In these cases, the end portion on the upstream side in the conveying direction of the second conveying surface F2 can be connected to the terminal portion E1 of the first conveying surface Fl. Also, the second conveying device 2 can be configured to be movable in the width direction Y in addition to the vertical direction, and the end portion on the upstream side in the conveying direction of the second conveying surface F2 can be positioned at a position corresponding to the terminal portion E1 of the first conveying surface Fl of a certain one of the plurality of first conveying devices 1, and the article W discharged from the first conveying surface Fl can be received by the second conveying surface F2 and conveyed. Alternatively, the same number of second conveying devices 2 as the first conveying devices 1 arranged in the width direction Y can be arranged in the width direction Y.

[0071] (8) In the above-described embodiment, the example in which a plurality of imaginary regions A for the downstream-side conveying section 12 (first conveying device 1) to discharge the articles W to the second conveying device 2 were provided on the second conveying surface F2 was described. However, the present application is not limited to this, and the second conveying surface F2 can be provided with one region A. Figure 3 In the example shown, each region A is provided as an imaginary region without providing a member or the like to separate the adjacent regions A. However, the present application is not limited to this, and the region A can be provided, for example, as shown in Figure 8 In the example shown, the second conveying surface F2 is provided with the cross members 23 at regular intervals in the conveying direction (width direction Y), and the adjacent regions A are separated by the cross members 23. In this case, the cross members 23 can protrude upward from the second conveying surface F2, and can be arranged in a direction orthogonal when viewed from above with respect to the conveying direction of the second conveying device 2. Thus, it is possible to suppress the articles W placed on the second conveying surface F2 from falling over and moving outside the specified region A, and it is possible to reduce the possibility of the plurality of article groups Gw of different orders being mixed with each other on the second conveying surface F2.

[0072] (9) In the above-described embodiment, the example in which the first conveying device 1 was configured as a conveyor that operates independently of the other conveyors, and was provided with the upstream-side conveying section 11 and the downstream-side conveying section 12 arranged in the separation direction X was described. However, the present application is not limited to this example, and the first conveying device 1 can be configured, for example, as shown in Figure 9As shown, the first conveying device 1 is configured of one conveyor (conveying section). In this case, preferably, the first conveying device 1 is provided with at least one of a first detection sensor S1 that detects the article W at a first set position P1 on the first conveying surface Fl, a second detection sensor S2 that detects the article W at a second set position P2 on the first conveying surface Fl, and a third detection sensor S3 that detects the article W at a third set position P3 on the first conveying surface Fl. Figure 9 In the example shown, the first set position P1, the second set position P2, and the third set position P3 are arranged in this order from the upstream side to the downstream side in the conveying direction (the direction of departure X) on the first conveying surface Fl. The first set position P1 is set at an end region on the upstream side in the conveying direction of the first conveying surface Fl, and the first detection sensor S1 detects the presence or absence of the article W that is to be fed from the multistage sorting device 3 to the first conveying device 1. The third set position P3 is set at an end region on the downstream side in the conveying direction of the first conveying surface Fl, and the third detection sensor S3 detects the article W that is to be fed from the first conveying device 1 to the second conveying device 2. For example, in the case where the feeding of the article W to the second conveying device 2 is to be performed at an unintended timing, the conveying of the article W by the first conveying device 1 can be stopped on the basis of the detection of the article W by the third detection sensor S3. Further, the second set position P2 is set between the first set position P1 and the third set position P3 in the conveying direction of the first conveying surface Fl, and is set at a position close to the third set position P3, and the second detection sensor S2 detects the state of the article W that is conveyed by the first conveying device 1 before the article W reaches the third set position P3. For example, in order to perform the feeding of the article W to the second conveying device 2 at an appropriate timing, in the case where the first conveying device 1 is temporarily stopped before the article W is fed to the second conveying device 2, in the case where the article W is detected by the second detection sensor S2, the article W can be extended beyond the stop position and a warning or the like (notification of an alarm sound or the like) can be performed. In addition, the first conveying device 1 can be provided with three or more conveyors (conveying sections) that are independent of each other, without being limited to the example described above.

[0073] (10) Furthermore, the structures disclosed in the above-described embodiments can be applied in combination with the structures disclosed in other embodiments, as long as there is no contradiction. The embodiments disclosed in this specification are merely illustrative in all respects. Therefore, various changes can be appropriately made within the scope of the gist of the present application.

[0074] 〔Summary of the above-described embodiments〕

[0075] Hereinafter, the sorting system described in the above will be described.

[0076] A picking system that collects necessary items from a plurality of items stored for shipment, characterized by comprising a multi-layer sorting device that has a plurality of layers of ports having different heights in the vertical direction, discharges the items to a certain one of the ports of the plurality of layers, a second conveyance device that conveys the items received from the first conveyance devices, and a plurality of first conveyance devices that are provided corresponding to each of the ports of the plurality of layers, each of the plurality of first conveyance devices having a first conveyance surface that receives the items discharged from the ports and conveys the items in a state where the items are placed on the first conveyance surface in a direction away from the ports, the second conveyance device having a second conveyance surface that is configured to be able to be raised and lowered, receives the items discharged from the terminal end of the first conveyance surface in a state where the second conveyance surface is positioned at a height corresponding to the terminal end of the first conveyance surface of a certain one of the plurality of first conveyance devices, and conveys the items.

[0077] According to the present structure, the items sorted by the multi-layer sorting device and discharged from each of the plurality of ports can be received and conveyed by the first conveyance devices provided corresponding to each of the plurality of ports. Also, the plurality of items conveyed by each of the plurality of first conveyance devices can be received and conveyed by the second conveyance device. Thus, the items sorted by the multi-layer sorting device can be conveyed by the second conveyance device in order for each sorted item group. Therefore, according to the present structure, the work sites used for the next work with respect to the sorted items can be concentrated at a number of specific sites that is less than the number of ports, and further, an improvement in work efficiency can be achieved.

[0078] Here, preferably, the multi-layer sorting device sorts the items to a certain one of the plurality of ports based on order information, and the first conveyance devices discharge the items to the second conveyance device in units of item groups that are collections of the items for each order.

[0079] According to the present structure, the plurality of items can be sorted with respect to each of the plurality of ports based on order information, and the sorted plurality of items can be conveyed by the second conveyance device in units of item groups that are collections of the items for each order. Therefore, according to the present structure, the items can be conveyed by the second conveyance device in units of item groups sorted with respect to each order. Thus, the next work can be performed for each item group, and an improvement in work efficiency can be achieved.

[0080] Further, preferably, a direction intersecting the aforementioned direction of departure when viewed from above is set as a width direction, the aforementioned multi-layer sorting device has a plurality of rows of the aforementioned ports having different positions in the aforementioned width direction, a plurality of the aforementioned first conveyance devices are arranged in the aforementioned width direction in a manner corresponding to each of the aforementioned ports of the aforementioned plurality of rows on each of the aforementioned multi-layers, the aforementioned second conveyance surface is arranged in the aforementioned width direction in a manner following the terminal portions of the plurality of the aforementioned first conveyance devices arranged in the aforementioned width direction on each of the aforementioned multi-layers, and the aforementioned second conveyance device conveys the aforementioned articles in the aforementioned width direction.

[0081] According to the present structure, articles sorted by the multi-layer sorting device with respect to the ports of each of the multi-layers and the plurality of rows can be received by the first conveyance devices provided corresponding to each of the plurality of ports and conveyed in the direction of departure, and a plurality of articles conveyed by each of the plurality of first conveyance devices can be received by the second conveyance device and conveyed in the width direction. At this time, the second conveyance surface is arranged in the width direction in a manner following the terminal portions of the plurality of first conveyance devices arranged in the width direction, so the articles conveyed by the plurality of first conveyance devices can be efficiently received by the second conveyance surface of the second conveyance device. Further, the installation space of the second conveyance device can be suppressed to be small.

[0082] Further, preferably, the aforementioned second conveyance surface is arranged on each of the aforementioned multi-layers so as to cover the entire area of the arrangement region of the terminal portions of the plurality of aforementioned first conveyance devices arranged in the aforementioned width direction.

[0083] According to the present structure, all of the plurality of first conveyance devices arranged in the width direction are targeted, and the articles discharged from all of the first conveyance devices can be received by the second conveyance surface of the second conveyance device and conveyed.

[0084] Further, preferably, the aforementioned second conveyance device conveys the aforementioned articles in a state placed on the aforementioned second conveyance surface, and a housing container that receives and houses the aforementioned articles discharged from the aforementioned second conveyance device is arranged below with respect to the end portion of the aforementioned second conveyance surface in the aforementioned width direction.

[0085] According to the present structure, the articles conveyed by the second conveyance device can be dropped into the housing container at the end portion of the second conveyance surface. Therefore, the work sites for the next work with respect to the sorted articles can be concentrated around the end portion of the second conveyance surface. Thus, an improvement in work efficiency can also be achieved.

[0086] Further, preferably, the aforementioned second conveyance device is a slot conveyor having a shape in which the central portion of the aforementioned second conveyance surface in a cross section orthogonal to the direction of conveyance of the aforementioned articles based on the second conveyance device is recessed with respect to the both side portions.

[0087] According to the present structure, in the conveyance of the article by the second conveyance device, the article can be brought closer to the central portion side of the second conveyance surface. Thus, in the conveyance of the article by the second conveyance device, the article can be restrained from protruding from the second conveyance surface. Further, in the case where the articles after sorting are conveyed by the second conveyance device in accordance with each article group, the article group can be conveyed in a state where the article group is gathered at the central portion of the second conveyance surface. Thus, the improvement of the work efficiency in the case where the next work is performed for each article group is easily achieved.

[0088] Industrial applicability

[0089] The technology of the present application can be utilized in a sorting system that collects necessary articles from a plurality of articles to be stored and delivers the articles.

[0090] Explanation of reference numerals

[0091] 100: sorting system

[0092] 1: first conveyance device

[0093] F1: first conveyance surface

[0094] E1: terminal portion

[0095] 2: second conveyance device

[0096] F2: second conveyance surface

[0097] E2: end portion

[0098] 20: central portion

[0099] 21: side portion

[0100] 3: multi-layer sorting device

[0101] 31: port

[0102] B: containing container

[0103] W: article

[0104] Gw: article group

[0105] X: direction of departure

[0106] Y: width direction

Claims

1. A picking system that collects necessary items from a plurality of stored items and sends them out of the warehouse, characterized in that: Equipped with a multi-layer sorting device, a second transport device, and multiple first transport devices, The multi-layer sorting device has multiple layers of ports with different heights in the vertical direction, and the articles are sorted and discharged into one of the multiple layers of the ports. The plurality of first transport devices are provided corresponding to each of the plurality of ports. The second transport device receives the article from the first transport device and transports it. Each of the plurality of first transport devices has a first transport surface, receives the articles discharged from the port via the first transport surface, and transports the articles in a direction away from the port while being placed on the first transport surface. The second conveying device has a second conveying surface that can be raised and lowered. When the second conveying surface is positioned at a height corresponding to the terminal end of the first conveying surface of any one of the plurality of first conveying devices, the articles discharged from the terminal end of the first conveying surface are received and conveyed by the second conveying surface. The direction intersecting the aforementioned separation direction when viewed from above is defined as the width direction. The multi-layer sorting device has a plurality of rows of ports at different positions in the width direction. The plurality of first transport devices are arranged in the width direction in each of the plurality of layers so as to correspond to each of the plurality of rows of ports. The second conveying surface is arranged in the width direction in each of the plurality of layers so as to be along the terminal ends of the plurality of first conveying surfaces arranged in a row in the width direction. The second transport device transports the article in the width direction.

2. The picking system according to claim 1, wherein: The multi-layer sorting device sorts the items to one of the plurality of ports based on the order information. The first transport device discharges the articles in article groups, which are a collection of a plurality of articles per order, to the second transport device.

3. The picking system according to claim 1 or 2, characterized in that: The second conveying surface is arranged over the entire area of ​​the arrangement region of the terminal ends of the plurality of first conveying surfaces in each of the plurality of layers, and the plurality of first conveying surfaces are arranged so as to be aligned in the width direction.

4. The picking system according to claim 1 or 2, characterized in that: The second transport device transports the article while placing it on the second transport surface. A storage container for receiving and storing the articles discharged from the second transport device is arranged below an end portion of the second transport surface in the width direction.

5. The picking system according to claim 1 or 2, characterized in that: The second transport device is a trough-type conveyor having a shape in which a center portion of the second transport surface in a cross section perpendicular to a transport direction of the article by the second transport device is recessed relative to both side portions.

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