Automatic warehouse system and control method of automatic warehouse system

Abstract

The present invention relates to an automatic warehouse system and a control method thereof. In the automatic warehouse system, the influence of the operating conditions of the automatic warehouse and / or the workstation on the operating conditions of the unmanned transport vehicle is reduced. The automatic warehouse system (100) comprises: a plurality of automatic warehouses (1), a plurality of workstations (3), a driving path (R), a plurality of unmanned transport vehicles (5) and a controller (50). The driving path (R) is set to be able to access the automatic warehouse and the workstation. The unmanned transport vehicle travels on the driving path (R). The controller determines an area including at least a part of the driving path as a driving area (A1, A2) for the unmanned transport vehicle to travel, and controls the unmanned transport vehicle in a manner to transport goods between the automatic warehouse (1) and the workstation (3) belonging to the driving area. The controller (50) determines the size of the driving area for the unmanned transport vehicle to travel based on the operating conditions of at least one of the automatic warehouse or the workstation.

Description

Technical Field

[0001] The present invention relates to an automatic warehouse system having an automatic warehouse, a workstation, and a plurality of unmanned transport vehicles traveling between the automatic warehouse and the workstation, and a control method for the automatic warehouse system. Background Art

[0002] In the past, there is a known automatic warehouse system having an automatic warehouse, a workstation, and an unmanned transport vehicle for transporting goods between the automatic warehouse and the workstation (for example, see Patent Document 1). In addition, in the above-mentioned automatic warehouse system, a plurality of automatic warehouses and workstations are provided, and the technology of transporting goods between the automatic warehouse and the workstation by a plurality of unmanned transport vehicles is continuously developing.

[0003] Patent Document 1: Japanese Patent Application Laid-Open No. 11-116006

[0004] In the above-mentioned automatic warehouse system, there are cases where the operating conditions of the automatic warehouse and / or workstation change. In the existing automatic warehouse system, the area where the unmanned transport vehicle travels is predetermined and fixed. Therefore, if a transportation instruction that exceeds the transportation capacity of the goods to be carried out by the unmanned transport vehicle in a certain area is formed in the area, the transportation instruction of the goods required in the area remains unprocessed. On the contrary, when there are few transportation instructions for goods in a certain area, the number of unmanned transport vehicles that are not in operation increases, and the transportation capacity of the goods of the automatic warehouse system is not utilized.

[0005] In addition, multiple unmanned transport vehicles move between the automatic warehouse and the workstation. If the movement frequency of each unmanned transport vehicle becomes high, for example, in order to avoid collision between unmanned transport vehicles, it is necessary to move between the automatic warehouse and the workstation along a path that is not the shortest. In addition, it is necessary to wait for other unmanned transport vehicles to pass, etc., which often reduces the transportation efficiency of goods between the automatic warehouse and the workstation.

[0006] As a result, the operating conditions of the unmanned transport vehicles and the transportation efficiency of goods differ due to the high and low operating rates of the automatic warehouse and / or workstation. The automatic warehouse system cannot be used efficiently regardless of whether the operating rates of the automatic warehouse and / or workstation are high or low. Summary of the invention

[0007] The purpose of the present invention is to reduce the impact of the operating conditions of the automatic warehouse and / or workstation on the operating conditions of the unmanned transport vehicle in an automatic warehouse system having an automatic warehouse, a workstation and an unmanned transport vehicle for transporting goods between the automatic warehouse and the workstation.

[0008] Hereinafter, a plurality of embodiments will be described as means for solving the problems. These embodiments can be arbitrarily combined as needed.

[0009] An automated warehouse system according to one aspect of the present invention includes a plurality of automated warehouses, a plurality of workstations, a travel path, a plurality of unmanned transport vehicles, and a controller.

[0010] The driving route is set to be able to access multiple automatic warehouses and multiple work stations. The unmanned transport vehicle travels on the driving route.

[0011] The controller determines an area including at least a portion of a driving route as a driving area for the automated guided vehicle, and controls the automated guided vehicle to transport cargo between the automated warehouse and the workstation belonging to the driving area.

[0012] In addition, the controller determines the size of the driving area of ​​the automated guided vehicle based on the operating status of at least one of the automated warehouse or the work station.

[0013] In the above automatic warehouse system, the size of the driving area is determined based on the operating status of at least one of the automatic warehouse or the workstation, thereby reducing the impact of the operating status of the automatic warehouse and / or the workstation of the automatic warehouse system on the operating status of the unmanned transport vehicle.

[0014] The area determined by the controller may also have a plurality of reference areas. In this case, the controller may also change the size of the driving area by merging a plurality of adjacent reference areas or splitting them into reference areas based on the operating conditions of at least one of the automated warehouse or the workstation.

[0015] Thereby, the size of the traveling area can be changed by easy processing.

[0016] When setting a plurality of travel areas, the controller may determine the size of the travel area so that the operating conditions of at least one of the automated warehouses or work stations belonging to each travel area are close to each other.

[0017] By making the operating conditions of the automated warehouse and / or the workstations similar in all the travel areas, the operating conditions of the automated guided vehicles can be made uniform in all the travel areas.

[0018] The controller may determine the ratio of the number of automated warehouses to the number of work stations that transport goods to and from the unmanned transport vehicle and that belong to the travel area so that the ratio becomes larger in a larger travel area before and after the size of the travel area is changed.

[0019] Thus, when a large travel area is set due to a low operating rate of an automated warehouse and / or a work station, the number of work stations in operation can be reduced in accordance with the low operating rate.

[0020] The driving area may also include a first driving area and a second driving area that are adjacent to each other.

[0021] In this case, the controller may also determine the work station that is closest to the second driving area among the work stations belonging to the first driving area, and the work station that is closest to the first driving area among the work stations belonging to the second driving area as the first work station and the second work station, respectively, so as to control the unmanned transport vehicle to transport goods between the first work station and the second work station and the automatic warehouse.

[0022] This allows the same operator to operate the workstations belonging to the two travel areas. As a result, the number of operators to be arranged in the automated warehouse system can be reduced.

[0023] Each automatic warehouse may also have a conveying device for conveying goods in the automatic warehouse. In this case, the controller may also reduce the travel area when the operation rate of the conveying devices in the multiple automatic warehouses is high, and increase the travel area when the operation rate of the conveying devices in the multiple automatic warehouses is low.

[0024] This can reduce the impact caused by the operating conditions of the automated warehouse, and improve the efficiency of storage and warehousing of the automated warehouse system.

[0025] The controller may also reduce the driving area when the operation rate of the plurality of unmanned transportation vehicles is high, and increase the driving area when the operation rate of the plurality of unmanned transportation vehicles is low.

[0026] This can improve the efficiency of cargo transportation by the unmanned transport vehicle and the efficiency of storage and retrieval in the automatic warehouse system.

[0027] Another aspect of the present invention is a method for controlling an automatic warehouse system. The automatic warehouse system includes a plurality of automatic warehouses, a plurality of workstations, a travel path configured to access the plurality of automatic warehouses and the plurality of workstations, and a plurality of unmanned transport vehicles traveling on the travel path. The method for controlling the automatic warehouse system includes the following steps.

[0028] The step of determining an area including at least a portion of the travel route as a travel area for the automated guided vehicle to travel.

[0029] The step of controlling the unmanned transport vehicle in such a manner that cargo is transported between an automatic warehouse and a work station belonging to a driving area.

[0030] In the above control method, the size of the travel area is determined based on the operating status of at least one of the automated warehouse or the work station.

[0031] In the control method, the size of the driving area is determined based on the operating status of at least one of the automated warehouse or the workstation, thereby reducing the impact of the operating status of the automated warehouse and / or the workstation of the automated warehouse system on the operating status of the unmanned transport vehicle.

[0032] Since the influence of the operating conditions of the automatic warehouse and / or workstation on the operating conditions of the unmanned conveyor can be reduced, the automatic warehouse system can be used with the same high efficiency even if the operating conditions of the automatic warehouse and / or workstation change. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a schematic plan view of the entire automatic warehouse system according to the first embodiment.

[0034] Figure 2 This is an enlarged top view of a portion of the automated warehouse system.

[0035] Figure 3 It is a block diagram showing the control structure of an automatic warehouse system.

[0036] Figure 4 This is a flowchart showing the operation of the automatic warehouse system.

[0037] Figure 5 This is a diagram showing an example of a case where a small travel area is determined in an automated warehouse system.

[0038] Figure 6 This is a diagram showing an example of a case where a large travel area is determined in an automated warehouse system.

[0039] Figure 7 This is a diagram showing an example of determination of a work station according to the third embodiment. DETAILED DESCRIPTION

[0040] 1. First Implementation

[0041] (1) Overall structure of the automated warehouse system

[0042] use Figure 1 as well as Figure 2 The automated warehouse system 100 will be described. Figure 1 This is a schematic plan view of the entire automatic warehouse system 100 according to the first embodiment. Figure 2 It is a top view which enlarges a part of the automatic warehouse system 100.

[0043] The automatic warehouse system 100 is a system including a plurality of automatic warehouses 1, a plurality of workstations 3, and a plurality of unmanned transport vehicles 5. The automatic warehouse system 100 is configured in various factories, logistics bases, etc. In the automatic warehouse system 100, goods are put into the automatic warehouse 1 from the workstation 3, and goods are taken out of the automatic warehouse 1 from the workstation 3. When the goods are put into or taken out of the automatic warehouse 1, the goods are transported between the workstation 3 and the automatic warehouse 1. The transportation of the goods is performed by a plurality of unmanned transport vehicles 5.

[0044] In the following description, the X direction (arrow X direction) is the arrangement direction of the plurality of automatic warehouses 1, the Y direction (arrow Y direction) is the direction perpendicular to the X direction on the horizontal plane, and the Z direction (arrow Z) is the vertical direction.

[0045] (2) Automated Warehouse

[0046] The automated warehouse 1 automatically stores goods transported by the unmanned transport vehicle 5 and automatically carries out the stored goods. The automated warehouse 1 includes a shelf 11 , a stacker crane 13 , an inbound conveyor 15 , and an outbound conveyor 17 .

[0047] The shelves 11 are arranged in pairs with the Y direction as the longitudinal direction and facing each other at a distance in the X direction. The shelves 11 have a plurality of cargo loading sections for loading and storing cargo in the X direction and the Z direction. Thus, the shelves 11 can store cargo in a matrix in the X direction and the Z direction.

[0048] The stacker crane 13 (an example of a conveying device) conveys goods in the automatic warehouse 1. The stacker crane 13 includes a traveling trolley that can travel along a traveling track 13A, and a lifting platform that can be raised and lowered along a mast on the traveling trolley and is provided with a transfer device. The traveling track 13A is arranged to extend along the Y direction between two shelves 11 opposite to the X direction in the automatic warehouse 1. The traveling trolley travels along the traveling track 13A, so that the stacker crane 13 can transport goods between the cargo loading part of the shelf 11 and the inbound conveyor 15 and the outbound conveyor 17 described later. In addition, the stacker crane 13 can transfer goods with respect to the cargo loading part of the shelf 11, the inbound conveyor 15, and the outbound conveyor 17 using the transfer device provided on the lifting platform.

[0049] The stacker crane 13 is not particularly limited, and various known stacker cranes can be used. As a transfer device installed on a lift table and performing cargo transfer, for example, a rear hook type that hooks the rear end of the cargo to take it in, a clamp type that clamps both sides of the cargo to hold and transfer it, a fork type that lifts and transfers the cargo by a sliding fork, or a front hook type that hooks the front end of the cargo to take it in can be used.

[0050] The inbound conveyor 15 is a device that conveys the cargo transported by the unmanned transport vehicle 5 to the vicinity of the rack 11. The inbound conveyor 15 includes a main conveyor 15A and an auxiliary conveyor 15B.

[0051] The main conveyor 15A carries the goods conveyed by the auxiliary conveyor 15B, and conveys the goods toward the vicinity of the shelf 11. The goods conveyed to the vicinity of the shelf 11 are conveyed by the stacker crane 13, and are loaded and stored in a predetermined goods loading section. The type or structure of the main conveyor 15A is not particularly limited. As the main conveyor 15A, various conveyors such as a belt conveyor, a chain conveyor, or a roller conveyor can be used.

[0052] The auxiliary conveyor 15B is disposed at the end of the main conveyor 15A in the Y direction, and conveys the cargo transferred from the unmanned transport vehicle 5 to the main conveyor 15A.

[0053] In this embodiment, the unmanned transport vehicle 5 drills into the lower part of the auxiliary conveyor 15B, and the conveyor body of the auxiliary conveyor 15B picks up the goods from the unmanned transport vehicle 5, thereby transferring the goods between the unmanned transport vehicle 5 and the main conveyor 15A. For example, the auxiliary conveyor 15B is raised and lowered to pick up the goods loaded on the unmanned transport vehicle 5, or the lifter installed on the unmanned transport vehicle 5 and loaded with goods is lowered, so that the goods can be transferred from the lifter to the auxiliary conveyor 15B.

[0054] The outgoing conveyor 17 is a device that conveys the cargo transported by the stacker crane 13 for outgoing cargo to the arrival position of the unmanned transport vehicle 5. The outgoing conveyor 17 includes a main conveyor 17A and an auxiliary conveyor 17B.

[0055] The cargo transported by the stacker crane 13 is transferred and placed on the main conveyor 17A. The main conveyor 17A conveys the placed cargo toward the sub-conveyor 17B. For example, various conveyors such as a belt conveyor, a chain conveyor, or a roller conveyor can be used as the main conveyor 17A.

[0056] The auxiliary conveyor 17B is disposed at an end portion of the main conveyor 17A in the Y direction, and transfers the cargo conveyed by the main conveyor 17A to the unmanned transport vehicle 5 .

[0057] In this embodiment, the unmanned transport vehicle 5 enters the lower part of the auxiliary conveyor 17B, and the auxiliary conveyor 17B lowers the conveyor body carrying the cargo toward the unmanned transport vehicle 5 , thereby transferring the cargo from the auxiliary conveyor 17B to the unmanned transport vehicle 5 .

[0058] (3) Operation station

[0059] The plurality of workstations 3 are arranged at predetermined intervals in the Y direction relative to the plurality of automated warehouses 1 and arranged in parallel in the X direction. The workstations 3 are workstations for picking goods for storage or outbound storage. Workers or picking robots for picking goods are arranged at the workstations 3.

[0060] Furthermore, a space is provided near the work station 3 for the unmanned transport vehicle 5 to be carried into the work station 3 to stand by.

[0061] like Figure 1 As shown, a conveyor 33 is provided on the side of each work station 3. The conveyor 33 joins at a position away from the work station 3 in the Y direction. The conveyor 33 conveys the goods picked up in the work station 3 to the outside.

[0062] As a method of conveying the items picked up at the work station 3 by the conveyor 33 , there is a method of picking up items for each delivery address at the work station 3 and conveying them to the outside by the conveyor 33 .

[0063] Alternatively, there is a method in which, for example, a portion of multiple goods for the same delivery address is picked up at multiple workstations 3 and transported to the outside via a conveyor 33, and then the multiple goods are aggregated to the same delivery address outside the transportation destination.

[0064] (4) Unmanned transport vehicle

[0065] The plurality of unmanned transport vehicles 5 are vehicles for transporting cargo and can travel unmanned. The unmanned transport vehicles 5 travel on a predetermined travel route R. The unmanned transport vehicles 5 transport cargo by loading cargo on a cargo loading portion provided on the top of the unmanned transport vehicles 5 and moving.

[0066] like Figure 1 as well as Figure 2 As shown, the travel path R is formed in a grid shape by a plurality of paths extending in the X direction and a plurality of paths extending in the Y direction between the automatic warehouse 1 and the workstation 3. In addition, the travel path R extends through the auxiliary conveyors 15B and 17B. In the travel path R, a label displaying an identification code such as a QR code (registered trademark) is arranged at the intersection of the path extending in the X direction and the path extending in the Y direction.

[0067] The automated transport vehicle 5 moves while detecting the identification code between the automated warehouse 1 and the workstation 3. After the automated transport vehicle 5 detects the identification code while moving, it determines whether to change the moving direction at the intersection where the identification code is arranged based on the detected identification code.

[0068] For example, the identification code configured on the driving path R and the information indicating the direction to move from the intersection where the identification code is configured are associated with the driving instruction of the unmanned transportation vehicle 5. In addition, the determination of whether the moving direction should be changed at the intersection can be performed by the unmanned transportation vehicle 5, and the unmanned transportation vehicle 5 can also inquire of the controller 50 described later whether to change the moving direction every time it reaches the intersection.

[0069] If it is determined that the moving direction is changed at the intersection, the unmanned transport vehicle 5 turns at the intersection and changes the moving direction before starting to go straight. On the other hand, if it is determined that the moving direction is not changed at the intersection, it keeps going straight. In this way, the unmanned transport vehicle 5 can go straight and turn as needed between the automatic warehouse 1 and the workstation 3, and move on the grid-shaped driving path R.

[0070] In the present embodiment, it is possible to transport both incoming and outgoing cargoes using a single unmanned transport vehicle 5 .

[0071] Specifically, the unmanned transport vehicle 5 that transports the incoming goods from the work station 3 moves along the travel path R in the auxiliary conveyor 15B and enters the auxiliary conveyor 15B of the incoming conveyor 15 from the front. Then, the auxiliary conveyor 15B picks up the incoming goods.

[0072] Then, the unmanned transport vehicle 5 that has picked up the goods moves along the travel path R from the auxiliary conveyor 15B of the inbound conveyor 15 to the auxiliary conveyor 17B of the outbound conveyor 17 from the front or side. Then, the outbound goods are loaded onto the unmanned transport vehicle 5 by the auxiliary conveyor 17B. The unmanned transport vehicle 5 loaded with goods exits from the front of the auxiliary conveyor 17B and delivers the goods toward the work station 3.

[0073] As described above, by using a single unmanned transport vehicle 5 to perform both transport of incoming cargo and outgoing cargo, the unmanned transport vehicle 5 can efficiently perform transport of cargo.

[0074] Each of the plurality of automated transport vehicles 5 can only travel in a predetermined area (referred to as travel areas A1, A2) of the entire travel path R. Figure 5 , Figure 6 )) moves on the driving path within. The determination of the driving areas A1 and A2 will be described in detail later.

[0075] In this embodiment, the unmanned transport vehicle 5 is driven by a travel motor 5B ( Figure 3 ) An AGV (Automatic Guided Vehicle) that drives by rotating its wheels. Alternatively, the unmanned transport vehicle 5 may be, for example, an overhead crane or a rail-guided vehicle.

[0076] In addition, in addition to configuring identification codes at the intersections of the paths, the driving path R can also be constructed by other methods, such as a method in which the driving path R is constructed by a magnetic tape (magnetic guidance method) or a method in which the driving path R is constructed by a track (rail-guided method).

[0077] (5) Control structure

[0078] use Figure 3 The control structure of the automatic warehouse system 100 will be described. Figure 3 : is a block diagram showing the control structure of the automatic warehouse system 100.

[0079] The automatic warehouse system 100 has a controller 50 as a control structure of the automatic warehouse system 100. The controller 50 is a computer system having a processor (e.g., CPU), a storage device (e.g., ROM, RAM, HDD, SSD, etc.), and various interfaces (e.g., A / D converter, D / A converter, communication interface, etc.). The controller 50 performs various control operations of the automatic warehouse system 100 by executing a program stored in a storage unit (corresponding to a part or all of the storage area of ​​the storage device).

[0080] The controller 50 may be composed of a single processor, but may also be composed of a plurality of independent processors for each control.

[0081] A part or all of the functions of the controller 50 may be realized as a program executable by a computer system constituting the controller 50. In addition, a part of the functions of each element of the control unit may be constituted by a special IC.

[0082] The controller 50 can wirelessly communicate with the travel control unit 5A of each unmanned transport vehicle 5 and transmit a travel command of each unmanned transport vehicle 5 to the travel control unit 5A. The travel control unit 5A controls the travel motor 5B of the unmanned transport vehicle 5 based on the travel command to control the movement of the unmanned transport vehicle 5 .

[0083] The travel control unit 5A is a computer system having a processor (eg, CPU), a storage device (eg, ROM, RAM, HDD, SSD, etc.), and various interfaces (eg, A / D converter, D / A converter, communication interface, etc.).

[0084] The controller 50 can communicate with each inbound conveyor 15 (main conveyor 15A, auxiliary conveyor 15B) and each outbound conveyor 17 (main conveyor 17A, auxiliary conveyor 17B) in a wireless or wired manner to control the transportation of goods by the inbound conveyor 15 and the outbound conveyor 17.

[0085] Furthermore, the controller 50 can communicate with the stacker crane 13 in a wireless or wired manner to control the storage of goods into the rack 11 and the removal of goods from the rack 11 by the stacker crane 13 .

[0086] (6) Operation of the automatic warehouse system

[0087] Below, use Figure 4 The operation of the automatic warehouse system 100 having the above-described configuration will be described. Figure 4 1 is a flowchart showing the operation of the automatic warehouse system 100 .

[0088] Figure 4 The processing shown in the flowchart is executed by the controller 50. Figure 4 All of the processing shown in the flowchart may be executed by a program stored in the storage device of the controller 50 , or part of the processing may be executed by the program and the remaining part may be executed by hardware constituting the controller 50 .

[0089] in addition, Figure 4 A portion of the processing shown in the flowchart (and related processing) may be executed by the controller 50, and the remaining portion may also be executed by other controllers.

[0090] When the automatic warehouse system 100 starts to operate, the driving areas A1 and A2 of the unmanned transport vehicle 5 are first determined. The driving areas A1 and A2 include at least a portion of the driving path R, and determine the range within which the unmanned transport vehicle 5 belonging to the driving areas A1 and A2 can move. In addition, any one of the multiple automatic warehouses 1 and any one of the multiple workstations 3 belong to the determined driving areas A1 and A2. That is, in the present embodiment, all the automatic warehouses 1 belong to any one of the driving areas A1 and A2, and there is no automatic warehouse 1 that does not belong to any of the driving areas A1 and A2. Specifically, the driving areas A1 and A2 are determined as follows.

[0091] In step S1, when determining the travel areas A1 and A2, the controller 50 determines the operating status of the automatic warehouse system 100. In the present embodiment, the operating status of the automatic warehouse system 100 is the operating rate of the stacker crane 13 of the automatic warehouse 1. The operating rate of the stacker crane 13 can be determined based on, for example, scheduling data that records information related to the entry and exit of goods.

[0092] For example, when a large amount of information on storage and unloading is recorded in the scheduling data within a specified time range, it is determined that the operating rate of the stacker crane 13 of the automated warehouse 1 is high. On the other hand, when a small amount of information on storage and unloading is recorded within the specified time range, it is determined that the operating rate of the stacker crane 13 is low.

[0093] The operating status of the automated warehouse system 100 is not limited to the operating rate of the stacker crane 13 of the automated warehouse 1 , and may be, for example, the operating rate of the automated transport vehicle 5 in the travel areas A1 and A2 .

[0094] The judgment criteria for whether the operating rate of the stacker crane 13 or the unmanned transport vehicle 5 of the automatic warehouse system 100 is high or low (for example, the threshold value for judging the operating rate of "high" or "low") can be appropriately determined according to the scale of the automatic warehouse system 100, the transportation capacity of the stacker crane 13 or the unmanned transport vehicle 5, etc.

[0095] When the overall operation rate of the stacking cranes 13 of the plurality of automated warehouses 1 is high (or the overall operation rate of the unmanned transport vehicles 5 in the driving areas A1 and A2 is high) (“high operation rate” in step S1), the controller 50 performs the following operations in step S2: Figure 5 As shown, the driving route R is divided into a plurality of small driving areas A1. Figure 5 1 is a diagram showing an example of a case where a small travel area A1 is determined in the automatic warehouse system 100. In this case, workers are arranged at all of the plurality of work stations 3.

[0096] Furthermore, “the overall operation rate is high” means that most stacker cranes 13 or unmanned transport vehicles 5 perform actions for transporting goods at a relatively high frequency, and there are almost no stacker cranes 13 or unmanned transport vehicles 5 that do not perform such actions at all or perform such actions at a low frequency, or there are no stacker cranes 13 or unmanned transport vehicles 5 at all.

[0097] exist Figure 5 In the example shown, the driving route R is divided into four small driving areas A1, each of which includes three workstations 3 and 7 or 8 groups of automatic warehouses 1. The number of unmanned transport vehicles 5 belonging to each driving area A1 is roughly the same. Figure 5 In FIG. 1 , the automatic storage system 1 belonging to one driving area A1 is surrounded by a single-point chain line, and the work station 3 of one driving area A1 is surrounded by a dotted line.

[0098] In this way, when the overall operating rate of the stacker cranes 13 of multiple automatic warehouses 1 is high, that is, when the frequency of goods entering and leaving the warehouse is high, the efficiency of goods entering and leaving the warehouse can be improved by enabling movement only in a small driving area A1, and making the automatic warehouse 1, work station 3 and unmanned transport vehicle 5 belonging to the small driving area A1 responsible for multiple entries and exits.

[0099] In addition, by enabling the unmanned transport vehicle 5 to move only in a small travel area A1, the distance that the unmanned transport vehicle 5 moves between the automated warehouse 1 and the workstation 3 and the number of turns that the unmanned transport vehicle 5 makes at the intersection of the paths can be reduced. As a result, the efficiency of transporting goods by the unmanned transport vehicle 5 can be improved, and the efficiency of warehousing and unloading of the automated warehouse system 100 can be improved.

[0100] On the other hand, when the operation rates of the stacking cranes 13 of the plurality of automated warehouses 1 are low as a whole (or when the operation rates of the unmanned transport vehicles 5 in the driving areas A1 and A2 are equally low) (“low operation rate” in step S1), the controller 50 performs the following operations in step S3: Figure 6 As shown, the driving route R is divided into large driving areas A2. Figure 6 1 is a diagram showing an example of a case where a large driving area A2 is determined in the automated warehouse system 100 .

[0101] Furthermore, “the overall operation rate is low” means that most stacker cranes 13 or unmanned transport vehicles 5 perform actions for transporting goods at a low frequency or do not perform them at all, and there are almost no stacker cranes 13 or unmanned transport vehicles 5 that perform such actions at a high frequency or do not exist at all.

[0102] exist Figure 6 In the example shown, the driving route R is divided into two large driving areas A2, each of which includes 14 or 15 groups of automated warehouses 1. The number of unmanned transport vehicles 5 belonging to each driving area A2 is roughly the same before and after the driving area is changed. Figure 6 In FIG. 1 , the automated warehouse 1 belonging to one driving area A2 is surrounded by a dashed line, and the workstation 3 belonging to one driving area A2 and being used (ie, where goods are transported by the unmanned transport vehicle 5 ) is surrounded by a dotted line.

[0103] In this way, when the operating rates of the stacking cranes 13 of multiple automatic warehouses 1 are equally low, that is, when the frequency of goods entering and leaving the warehouse is low, by enabling the unmanned transport vehicle 5 to move in a large driving area A2 that includes more automatic warehouses 1, the impact of the frequency of goods entering and leaving the warehouse (the operating status of the automatic warehouse system 100) on the operating status of the unmanned transport vehicle 5 can be reduced.

[0104] like Figure 6 As shown by the dotted line, when a large driving area A2 is set, workers are deployed at three workstations 3 adjacent to one driving area A2. That is, before and after the driving area is changed, the number of workstations 3 belonging to one driving area is almost unchanged, while the number of automated warehouses 1 belonging to one driving area A2 increases.

[0105] In other words, the controller 50 determines the ratio of the number of automatic warehouses 1 to the number of workstations 3 that transport goods between the unmanned transport vehicles 5 and the driving areas A1 and A2 so that the ratio becomes larger in the larger driving area A2 before and after the sizes of the driving areas A1 and A2 are changed.

[0106] Thus, when a large travel area A2 is set due to a low operating rate of the automated warehouse 1 and / or the workstations 3, the number of operating workstations 3 can be reduced in accordance with the low operating rate.

[0107] In addition, Figure 6 In the example shown, three work stations 3 among the six work stations 3 belonging to each travel area A2 are used, but the present invention is not limited to this, and the number (ratio) of the work stations 3 used may be arbitrary.

[0108] Furthermore, in this embodiment, the controller 50 merges two adjacent small driving areas A1 to generate the above-mentioned large driving area A2. Figure 5 The two adjacent running areas A1 on the left side in the X direction are combined to generate the running area A2, and the two adjacent running areas A1 on the right side in the X direction are combined to generate the running area A2.

[0109] When the small driving areas are combined to generate a large driving area, three or more adjacent small driving areas may be combined. That is, when generating a large driving area, the number of small driving areas to be combined may be arbitrary.

[0110] In this way, by combining the small driving areas A1 to generate the large driving area A2, the size of the driving areas A1 and A2 can be changed by easy processing. The driving area of ​​the minimum unit used to generate the large driving area A2 is particularly called a "reference area". In this embodiment, the small driving area A1 is the reference area.

[0111] Since the reference area is the running area A1 , when the set running area is switched from the large running area A2 to the small running area A1 , the controller 50 divides the large running area A2 into the reference areas to set the running area A1 .

[0112] The number of automated warehouses 1 and workstations 3 belonging to the reference area is determined based on, for example, the number of automated warehouses 1 that can transport the goods in the quantity that can be processed at one workstation 3 without stagnation.

[0113] After setting the driving areas A1 and A2, the controller 50 issues a command in step S4 to start the storage and retrieval of goods in the automatic warehouse system 100. Specifically, the controller 50 issues a command to allow the transportation of goods by the unmanned transport vehicle 5 belonging to the driving areas A1 and A2 within the set driving areas A1 and A2, and to perform storage and retrieval of goods between the automatic warehouse 1 and the work station 3 belonging to the set driving areas A1 and A2.

[0114] By executing the above steps S1 to S4, the sizes of the driving areas A1 and A2 are determined based on the operating conditions of the stacker crane 13 of the automatic warehouse 1 of the automatic warehouse system 100, and the influence of the operating conditions of the automatic warehouse 1 on the operating conditions of the unmanned transport vehicle 5 can be reduced. As a result, even if the operating conditions of the automatic warehouse 1 change, the automatic warehouse system 100 can be used with the same high efficiency.

[0115] (7) Modification 1

[0116] In the above embodiment, the sizes of the travel areas A1 and A2 are determined based on the operating conditions of the stacker crane 13 of the automated warehouse 1. However, as a first modification, the sizes of the travel areas A1 and A2 may be determined based on the operating conditions of the auxiliary conveyors 15B and 17B of the automated warehouse 1.

[0117] For example, when goods are accumulated in the auxiliary conveyor 17B for outbound delivery, the travel area of ​​the automatic warehouse 1 including the auxiliary conveyor 17B can be reduced to improve the outbound delivery capacity of the travel area, thereby eliminating the accumulation of outbound goods.

[0118] (8) Modification 2

[0119] In the above-described embodiment and Modification 1, the sizes of the travel areas A1 and A2 are determined based on the operating conditions of the automated warehouse 1 . However, as Modification 2, the sizes of the travel areas A1 and A2 may be determined based on the operating conditions of the workstation 3 .

[0120] For example, the size of the travel areas A1 and A2 can be determined based on the number of operating workstations 3 (the number of workstations 3 where operators are deployed). For example, when the number of operating workstations 3 is large, the size of the travel areas A1 and A2 can be reduced, thereby improving the ability to enter and exit the warehouse.

[0121] The sizes of the travel areas A1 and A2 can be determined based on the status of cargo handling at the work station 3. For example, if unprocessed cargo is stagnant at the work station 3, the sizes of the travel areas A1 and A2 to which the work station 3 belongs can be increased to eliminate the cargo stagnation.

[0122] Furthermore, for example, even when the size of the travel areas A1 and A2 is not changed, or when the travel area is enlarged, if there is another work station 3 belonging to the travel area, the handling of the goods can be transferred to the other work station 3, thereby preventing the goods from being stranded.

[0123] Furthermore, the sizes of the travel areas A1 and A2 can be determined based on both the operating conditions of the automated warehouse 1 and the operating conditions of the workstations 3. In this case, the contribution rates of the operating conditions of the automated warehouse 1 and the workstations 3 to the sizes of the travel areas A1 and A2 can be adjusted by focusing on the operating conditions of the automated warehouse 1 or the workstations 3.

[0124] Furthermore, for example, in the automated warehouse system 100 , the travel areas A1 and A2 may be determined based on the number of workers performing work, that is, based on the number of operable work stations 3 .

[0125] 2. Second Implementation

[0126] In the first embodiment described above, the sizes of the travel areas A1 and A2 are set to be substantially the same, based on the premise that the operation rates of the plurality of automated warehouses 1 are substantially equal as a whole.

[0127] However, this is not limited to this. When multiple driving areas are set, and the operating rates of the automatic warehouses 1 are different, the size of the driving area can be determined in a way that the operating conditions of at least one of the automatic warehouses 1 or work stations 3 belonging to each driving area are close.

[0128] The above “determine the size of the driving area so that the operating conditions are close” includes both determining the size of a driving area so that the operating conditions are simply the same or approximately the same, and making the difference in the operating conditions in each of the plurality of driving areas generated after merging the small driving area A1 smaller.

[0129] For example, the size of the driving area to which the automatic warehouse 1 and / or the work station 3 with a high operating rate belongs can be reduced, and the size of the driving area to which the automatic warehouse 1 and / or the work station 3 with a low operating rate belongs can be increased. In this way, by making the operating conditions of the automatic warehouse 1 and / or the work station 3 close in all driving areas, the operating conditions of the unmanned transport vehicle 5 can be made consistent in all driving areas.

[0130] 3. Third Implementation

[0131] When the driving path R is divided into multiple driving areas, such as Figure 7As shown, the controller 50 can also set the adjacent driving areas as the first driving area A21 and the second driving area A22, and determine the work station 3 closest to the second driving area among the work stations 3 belonging to the first driving area A21, and the work station 3 closest to the first driving area among the work stations 3 belonging to the second driving area A22 as the first work station 31 and the second work station 32, respectively, so that the unmanned transport vehicle 5 can transport goods between the first work station 31 and the second work station 32 and the automatic warehouse 1.

[0132] Figure 7 This is a diagram showing an example of determination of a work station according to the third embodiment.

[0133] Thereby, for example, one operator or one picking robot can operate the work stations 3 belonging to two travel areas. As a result, the number of operators or picking robots arranged in the automatic warehouse system 100 can be reduced.

[0134] For example, the following operation is repeated, i.e., while working at one work station, the goods are left at another work station. When a certain amount of goods are left at the other work station, the operator or the picking robot moves to the other work station, thereby enabling one operator or one picking robot to operate work stations belonging to different driving areas.

[0135] 4. Common matters in implementation methods

[0136] The first to third embodiments described above have the following structures and functions in common.

[0137] An automatic warehouse system 100 (an example of an automatic warehouse system) includes: multiple automatic warehouses 1 (an example of multiple automatic warehouses), multiple work stations 3 (an example of multiple work stations), a driving path R (an example of a driving path), multiple unmanned transport vehicles 5 (an example of multiple unmanned transport vehicles) and a controller 50 (an example of a controller).

[0138] The driving route R is provided so as to be able to access a plurality of automated warehouses 1 and a plurality of workstations 3 . The unmanned transport vehicle 5 travels on the driving route R.

[0139] The controller 50 determines an area including at least a portion of the driving path R as the driving area A1, A2 (an example of a driving area) where the unmanned transport vehicle 5 travels, and controls the unmanned transport vehicle 5 to transport goods between the automatic warehouse 1 and the work station 3 belonging to the driving area A1, A2.

[0140] Furthermore, the controller 50 determines the size of the travel areas A1 and A2 in which the automated transport vehicle 5 travels, based on the operating status of at least one of the automated warehouse 1 and the workstation 3 .

[0141] In the automated warehouse system 100, the sizes of the travel areas A1 and A2 are determined based on the operating conditions of at least one of the automated warehouse 1 and the workstation 3. This can reduce the impact of the operating conditions of the automated warehouse 1 and / or the workstation 3 of the automated warehouse system 100 on the operating conditions of the automated transport vehicle 5.

[0142] 5. Other Implementation Methods

[0143] Although a plurality of embodiments of the present invention have been described above, the present invention is not limited to the above embodiments, and various modifications can be made without departing from the spirit of the invention. In particular, the plurality of embodiments and modifications described in this specification can be arbitrarily combined as needed.

[0144] (A) In the first embodiment, the size of the reference area, which is the minimum unit of the running area, is the same as the size of the small running area A1. However, the present invention is not limited to this, and the reference area may be smaller than the small running area A1.

[0145] (B) The size of the travel area may be changed in real time based on the operational status of the automated warehouse system 100 that changes over time.

[0146] (C) When a specific automated guided vehicle 5 belongs to different driving areas before and after the size of the driving area is changed, the automated guided vehicle 5 may automatically move to the driving area to which it belongs after the size of the driving area is changed.

[0147] (D) The automated warehouse 1 may be, for example, a shuttle warehouse having a shuttle vehicle that is provided on each level of the shelves 11 and moves along the length direction of the shelves 11 to transport goods.

[0148] (E) There may be an automated storage 1 that does not belong to any of the travel areas A1 and A2. For example, an automated storage 1 whose operation rate is substantially 0 may not belong to any of the travel areas A1 and A2.

[0149] (F) The travel path R in the vicinity of the workstation 3 that is not used in the automated warehouse system 100 may not be included in any of the travel areas A1 and A2.

[0150] Possibility of industrial application

[0151] The present invention can be widely applied to automatic warehouse systems.

[0152] Description of Reference Numerals

[0153] 100…Automatic warehouse system, 1…Automatic warehouse, 3…Work station, 31…First work station, 32…Second work station, 33…Conveyor, 5…Unmanned transport vehicle, 5A…Driving control unit, 5B…Driving motor, 11…Shelf, 13…Stacking crane, 13A…Driving track, 15…Inbound conveyor, 15A…Main conveyor, 15B…Auxiliary conveyor, 17…Outbound conveyor, 17A…Main conveyor, 17B…Auxiliary conveyor, 50…Controller, A1, A2…Driving area, A21…First driving area, A22…Second driving area, R…Driving path.

Claims

1. An automatic warehouse system, comprising: Multiple automated warehouses; Multiple work stations; A driving path, which is configured to access the plurality of automated warehouses and the plurality of work stations; A plurality of unmanned transport vehicles, which travel on the above-mentioned travel path; and a controller that determines an area including at least a portion of the driving path as a driving area for the unmanned transport vehicle, and controls the unmanned transport vehicle in a manner that transports goods between the automatic warehouse and the work station belonging to the driving area, The controller changes the size of the driving area based on the operating conditions of the automated warehouse that change over time. Each automatic warehouse has a conveying device for conveying goods in the automatic warehouse. The controller reduces the travel area when the operation rate of the conveying devices in the plurality of automated warehouses is high, and increases the travel area when the operation rate of the conveying devices in the plurality of automated warehouses is low.

2. The automatic warehouse system according to claim 1, in, The above area has multiple reference areas. The controller changes the size of the driving area by merging a plurality of adjacent reference areas or splitting the driving area into the reference areas based on the operating conditions of the automated warehouse that change over time.

3. The automatic warehouse system according to claim 1, in, When setting the plurality of driving areas, the controller determines the sizes of the driving areas so that the operating conditions of the automated warehouses belonging to the respective driving areas change with time and are close to each other.

4. The automatic warehouse system according to claim 1, in, The controller determines the ratio of the number of the automatic warehouses to the number of work stations that transport goods to and from the unmanned transport vehicle and that belong to the travel area so that the ratio becomes larger in the larger travel area before and after the size of the travel area is changed.

5. The automatic warehouse system according to claim 1, in, The driving area includes a first driving area and a second driving area adjacent to each other. The controller determines the work station closest to the second driving area among the work stations belonging to the first driving area and the work station closest to the first driving area among the work stations belonging to the second driving area as the first work station and the second work station, respectively, so as to control the unmanned transport vehicle to transport goods between the first work station and the second work station and the automatic warehouse.

6. A control method for an automatic warehouse system, comprising a plurality of automatic warehouses, a plurality of workstations, a driving path capable of accessing the plurality of automatic warehouses and the plurality of workstations, and a plurality of unmanned transport vehicles traveling on the driving path, comprising the following steps: A step of determining an area including at least a portion of the driving route as a driving area for the automated guided vehicle; and The step of controlling the unmanned transport vehicle in such a manner that the goods are transported between the automatic warehouse and the work station belonging to the driving area, The size of the driving area is changed based on the operating conditions of the automated warehouse that change over time. Each automatic warehouse has a conveying device for conveying goods in the automatic warehouse. When the operation rate of the conveyor devices in the plurality of automated warehouses is high, the travel area is reduced, and when the operation rate of the conveyor devices in the plurality of automated warehouses is low, the travel area is increased.

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