Article storage device

Abstract

This invention provides an item storage device. The control system performs outbound processing, replenishment processing, movement processing, and return processing. The replenishment processing is as follows: when the quantity of a first type of item in the first storage warehouse (1A) falls below a quantity threshold, the first type of item in the second storage warehouse (1B) is transported from the second storage warehouse (1B) to the first storage warehouse (1A) so that it is stored in the first storage warehouse (1A) in a container. The movement processing is as follows: the second type of item, which is a picking item in the second storage warehouse (1B), is transported from the second storage warehouse (1B) to the first storage warehouse (1A) so that it is stored in the first storage warehouse (1A) in a container. The return processing is as follows: the container containing the second type of item, which has been returned to the first storage warehouse (1A) after the outbound processing is completed, is transported from the first storage warehouse (1A) to the second storage warehouse (1B).

Description

Technical Field

[0001] This invention relates to an article storage device for supplying articles to a picking area for picking operations and for storing articles that can be the objects of picking operations. Background Technology

[0002] An example of such an article storage device is disclosed in Japanese Patent Application Publication No. 2018-12586 (Patent Document 1). In the following description of the background art, reference numerals from Patent Document 1 are cited in parentheses.

[0003] Patent Document 1 describes an item storage device comprising: a storage warehouse (1) for storing goods that are objects of picking operations, supported on items (B) such as cardboard boxes or pallets; and conveyors (C10, C30) for supplying the items (B) stored in the storage warehouse (1) to the picking area. In the picking area, a picking robot (R) performs the picking operation of retrieving the required quantity of goods from the items (B) and placing the goods into a collection case (D). Summary of the Invention

[0004] Incidentally, in the aforementioned storage facilities, the storage capacity of the warehouse is typically designed to accommodate all types of items (goods in Patent Document 1) that can be used for picking operations. Therefore, the size of the warehouse can easily become large, and this large-scale operation may lead to larger storage facilities or a decrease in the efficiency of supplying items from the warehouse relative to the picking area.

[0005] Therefore, there is a desire for technologies that can mitigate the increase in the size of storage equipment and the decrease in the supply efficiency of goods relative to the picking area.

[0006] The item storage equipment disclosed herein supplies items to a picking area where a picking operation is performed, and stores items that can be the object of the picking operation, wherein the picking operation is an operation of retrieving items contained in a container; the item storage equipment comprises: a first storage warehouse for storing the containers that are to be supplied to the picking area; a second storage warehouse with a storage capacity larger than the first storage warehouse for storing the containers that are to be supplied to the first storage warehouse; a first conveying device for conveying the containers between the picking area and the first storage warehouse; and a second conveying device for conveying the containers between the first storage warehouse and the second storage warehouse. The system includes a system for transporting goods between the first and second storage warehouses, and a control system for controlling the first, second, first, and second storage warehouses, as well as the first and second conveying devices. Based on the type of the items, the frequency at which they become objects of the picking operation (i.e., the picking frequency) varies. Items that determine which type they are objects of the picking operation are designated as picking objects; items with a picking frequency of at least a predetermined first frequency threshold are designated as first-type items; and items with a picking frequency less than the first frequency threshold are designated as second-type items. The control system performs outbound processing, replenishment processing, movement processing, and return processing. The outbound processing is as follows: using the aforementioned first conveying device, the aforementioned container containing the aforementioned items to be picked is transported from the aforementioned first storage warehouse to the aforementioned picking operation area; using the aforementioned first conveying device, the aforementioned container after the aforementioned picking operation is completed is transported from the aforementioned picking operation area to the aforementioned first storage warehouse; the aforementioned supplementary processing is as follows: when the quantity of the aforementioned first type of item in the aforementioned first storage warehouse falls below a predetermined quantity threshold, using the aforementioned second conveying device, the aforementioned first type of item in the aforementioned second storage warehouse is transported from the aforementioned second storage warehouse to the aforementioned first storage warehouse, so that it is stored in the aforementioned container and placed in the warehouse. The first storage warehouse; the aforementioned movement process is as follows: when the aforementioned second type of item becomes the aforementioned picking target item, in order to carry out the aforementioned outbound process, the aforementioned second type of item, which is in the aforementioned second storage warehouse and has become the aforementioned picking target item, is transported from the aforementioned second storage warehouse to the aforementioned first storage warehouse using the aforementioned second conveying device, so that it is stored in the aforementioned first storage warehouse while being contained in the aforementioned container; the aforementioned return process is as follows: using the aforementioned second conveying device, the aforementioned container containing the aforementioned second type of item, which has been returned to the aforementioned first storage warehouse after the aforementioned outbound process is completed, is transported from the aforementioned first storage warehouse to the aforementioned second storage warehouse.

[0007] According to this structure, since containers containing items that can be picked can be stored in a second storage room with a larger storage capacity than the first storage room, in addition to the first storage room, it is easy to ensure a larger overall storage capacity for the storage rooms including the first and second storage rooms. Here, the first storage room needs to be configured so that containers can be transported between the first conveyor and the picking area. In contrast, the second storage room does not have such constraints; for example, it is easier to utilize the available space in the item storage equipment. Compared to the first storage room, the second storage room allows for greater flexibility in its configuration. Therefore, compared to the case where the required storage capacity is ensured solely by the first storage room without a second storage room, it is easier to prevent the item storage equipment from becoming too large.

[0008] Furthermore, according to this structure, since items with a picking frequency of 1 frequency threshold or higher are designated as Type 1 items and replenishment processing is performed on Type 1 items, there are always more Type 1 items than the quantity threshold in the first storage warehouse. Therefore, when Type 1 items become the items to be picked, the execution of outbound processing allows Type 1 items to be supplied from the first storage warehouse to the picking area relatively quickly. On the other hand, according to this structure, since items with a picking frequency lower than the 1 frequency threshold are designated as Type 2 items and return processing is performed on Type 2 items, Type 2 items are generally not stored in the first storage warehouse but in the second storage warehouse. Therefore, the large-scale operation of the first storage warehouse can be suppressed, and the decrease in the efficiency of supplying items from the first storage warehouse to the picking area can be suppressed. Furthermore, when the second item becomes a picking target, a movement process needs to be performed before the outbound processing in order to supply the second item from the second storage warehouse to the picking area. However, the picking frequency of the second item is lower than that of the first item. Therefore, even if the second item is stored in the second storage warehouse, the impact on the supply efficiency of picking target items to the picking area is limited.

[0009] As described above, this structure can suppress the increase in the size of the storage equipment and the decrease in the supply efficiency of items relative to the picking area.

[0010] Further features and advantages of the item storage equipment will become clear from the following description of the embodiments with reference to the accompanying drawings. Attached Figure Description

[0011] Figure 1 This is a conceptual diagram of a storage facility for goods.

[0012] Figure 2 It is a control block diagram.

[0013] Figure 3 It is a three-dimensional view of a part of the storage device.

[0014] Figure 4 This is an explanatory diagram of the outbound processing.

[0015] Figure 5 This is an explanatory diagram for supplementary processing.

[0016] Figure 6 This is an explanatory diagram of the moving and returning processes.

[0017] Figure 7 This is an illustration of the inbound processing.

[0018] Figure 8 This is a conceptual diagram of an article storage device with other implementation methods. Detailed Implementation

[0019] The implementation method of the item storage equipment is described with reference to the accompanying drawings.

[0020] The item storage equipment 100 is a device for supplying items W to the picking area 2 and storing items W that can be the object of picking operations. In the picking area 2, a picking operation is performed to retrieve items W contained in container 5. In this embodiment, during the picking operation, the items W retrieved from container 5 are stored in a sorting container 6 (see reference 100). Figure 4 (etc.). The entity performing the picking operation may be either the operator or the equipment, or both.

[0021] like Figure 1 As shown, the goods storage equipment 100 includes a first storage warehouse 1A for storing containers 5 that are to be supplied to the picking area 2, and a second storage warehouse 1B for storing containers 5 that are to be supplied to the first storage warehouse 1A. The first storage warehouse 1A and the second storage warehouse 1B are automated warehouses, receiving control from the control system 4 (see reference). Figure 2 The system controls the automatic outbound container 5 and the automatic inbound container 5 to return objects to the warehouse.

[0022] Storage vault 1A and storage vault 1B are equipped with storage devices 10. Figure 3 This is an example of a storage device 10. Figure 3 In the diagram, direction D1 and direction D2 are mutually orthogonal horizontal directions, and direction D3 is a vertical direction. Figure 3The storage device 10 shown includes a storage shelf 11 for storing containers 5 and a conveying device 12 for conveying the containers 5. The storage shelf 11 has storage sections 110 capable of arranging and storing multiple containers 5 in the first direction D1 (the transverse width direction of the shelf). Furthermore, the storage shelf 11 has storage sections 110 at multiple locations in the third direction D3, and the storage device 10 is configured to store containers 5 in each of multiple layers (shelf layers) of the storage shelf 11 (specifically, each of the storage sections 110 arranged in the third direction D3). Figure 3 In the example shown, a pair of storage shelves 11 are arranged opposite each other in the second direction D2 (shelf depth direction) so as to sandwich the travel path of the transport vehicle V described later.

[0023] Containers 5 entering the storage device 10 (in other words, containers 5 entering the storage facility 10) are transported from outside the storage device 10 to the receiving section 121, and containers 5 leaving the storage device 10 (in other words, containers 5 leaving the storage facility 10) are transported from the leaving section 123 back to the outside of the storage device 10. The conveying device 12 transports containers 5 entering the storage device 10 from the receiving section 121 to the storage section 110, and transports containers 5 leaving the storage device 10 from the storage section 110 to the leaving section 123. Figure 3 In the example shown, the conveying device 12 includes an inbound elevator 122 that transports the container 5 from the inbound section 121 to the relay conveyor 125, an outbound elevator 124 that transports the container 5 from the relay conveyor 125 to the outbound section 123, and a conveyor V that transports the container 5 between the relay conveyor 125 and the storage section 110.

[0024] Each relay conveyor 125 is installed at the height (position D3 in the third direction) where the storage section 110 is located. The inbound elevator 122 and the outbound elevator 124 are configured to be vertically movable (i.e., movable in the third direction D3). The inbound elevator 122 receives the container 5 from the storage section 121 when it is raised to a height corresponding to the storage section 121, and transfers the container 5 to the relay conveyor 125 when it is raised to a height corresponding to that relay conveyor 125, thus transporting the container 5 stored in the storage device 10 from the storage section 121 to the relay conveyor 125. The delivery elevator 124 receives the container 5 from the relay conveyor 125 when it is raised to a height corresponding to a relay conveyor 125, and transfers the container 5 to the delivery section 123 when it is raised to a height corresponding to the delivery section 123. The container 5 that is out of the storage device 10 is transported from the relay conveyor 125 to the delivery section 123.

[0025] The conveyor V travels in the first direction D1 on the front surface side of the storage shelf 11 (the side relative to the storage shelf 11 where containers 5 are picked up and placed), transporting containers 5 between the relay conveyor 125 and the storage section 110. The conveyor V is positioned at the same height as the storage section 110, transporting containers 5 between the relay conveyor 125 and the storage section 110 at the same level (in other words, between the relay conveyor 125 and the storage section 110 positioned at the same height). The conveyor V transports containers 5 entering the storage device 10 from the relay conveyor 125 to the storage section 110, and containers 5 leaving the storage device 10 from the storage section 110 to the relay conveyor 125. The conveyor V is equipped with a transfer device 120, which is used to transfer containers 5 between the conveyor V and the storage section 110. Figure 3 In the example shown, the transfer device 120 is also used to transfer the container 5 between the transport vehicle V and the relay conveyor 125.

[0026] Thus, in Figure 3 In the illustrated storage device 10, a transport vehicle V is provided at the height of the storage section 110. However, the structure of the storage device 10 is not limited to this. For example, the transport vehicle V may be a stacker crane that transports the container 5 between the storage section 121 and the outbound section 123 and the storage section 110.

[0027] The storage capacity of the second storage facility 1B is larger than that of the first storage facility 1A. Here, the storage capacity used for comparison can be defined, for example, as the volume of the storage space capable of holding the stored items (containers 5, etc.) in each storage facility, or as the maximum number of stored items that each storage facility can hold. For example, the first storage facility 1A and the second storage facility 1B have... Figure 3 In the case of the storage device 10 shown, the storage capacity of one storage device 10 is determined by the length of the storage shelf 11 in the first direction D1 and the number of layers of the storage shelf 11 (in other words, the number of storage sections 110 arranged in the third direction D3). Specifically, the storage capacity of one storage device 10 increases as the length of the storage shelf 11 in the first direction D1 increases, and also increases as the number of layers of the storage shelf 11 increases. Furthermore, the storage capacity of the first storage vault 1A and the second storage vault 1B is determined by the number of storage devices 10 provided in each storage vault. Specifically, the storage capacity of one storage vault increases as the number of storage devices 10 provided in that storage vault increases.

[0028] As in Figure 1As illustrated in the diagram, for example, by configuring the first vault 1A and the second vault 1B such that the number of storage devices 10 in the second vault 1B is greater than the number of storage devices 10 in the first vault 1A, and the length of the first direction D1 of the storage shelf 11 of each storage device 10 in the second vault 1B is greater than the length of the first direction D1 of the storage shelf 11 of each storage device 10 in the first vault 1A, the storage capacity of the second vault 1B is greater than the storage capacity of the first vault 1A.

[0029] like Figure 3 As shown, in this embodiment, the container 5 is formed as a box (barrel) with an open top surface. For example, a foldable container can be used as the container 5. Other items besides the container 5 can also be stored in one or both of the first storage room 1A and the second storage room 1B. In this embodiment, in addition to the container 5, the second storage room 1B also stores corrugated cardboard boxes and other cardboard cases 7 (see reference). Figure 5 In addition, in this embodiment, the second storage warehouse 1B stores not only container 5 but also sorting containers 6 after the picking operation is completed (see reference). Figure 6 That is, the second storage warehouse 1B stores at least container 5, and in this embodiment also stores cardboard box 7 and sorting container 6. The sorting container 6 is formed as a box (barrel) with an open top surface. As the sorting container 6, for example, a foldable container can be used. Alternatively, the sorting container 6 can be a container of the same specifications as container 5.

[0030] like Figure 1 As shown, the goods storage equipment 100 includes a first conveying device 3A for transporting containers 5 between the picking area 2 and the first storage warehouse 1A, and a second conveying device 3B for transporting containers 5 between the first storage warehouse 1A and the second storage warehouse 1B. The first storage warehouse 1A is equipped with... Figure 3 In the case of the illustrated inbound section 121 and outbound section 123, the first conveying device 3A conveys the container 5 from the outbound section 123 of the first storage warehouse 1A to the picking area 2, and conveys the container 5 from the picking area 2 to the inbound section 121 of the first storage warehouse 1A. Furthermore, the first storage warehouse 1A and the second storage warehouse 1B are equipped with... Figure 3 In the case of the illustrated inbound section 121 and outbound section 123, the second conveying device 3B conveys the container 5 from the outbound section 123 of the second storage warehouse 1B to the inbound section 121 of the first storage warehouse 1A, and conveys the container 5 from the outbound section 123 of the first storage warehouse 1A to the inbound section 121 of the second storage warehouse 1B.

[0031] exist Figure 1In the example shown, the first conveyor 3A and the second conveyor 3B transport the transported items in one direction. Therefore, the first conveyor 3A includes a conveying section for transporting the transported items from the first storage area 1A to the picking area 2, and a conveying section for transporting the transported items from the picking area 2 to the first storage area 1A. The second conveyor 3B includes a conveying section for transporting the transported items from the second storage area 1B to the first storage area 1A, and a conveying section for transporting the transported items from the first storage area 1A to the second storage area 1B.

[0032] In this embodiment, the item storage equipment 100 further includes a third conveying device 3C for conveying the sorting container 6 between the picking area 2 and the second storage warehouse 1B, a fourth conveying device 3D for conveying the sorting container 6 into the picking area 2, a fifth conveying device 3E for conveying the sorting container 6 out of the second storage warehouse 1B, and a sixth conveying device 3F for conveying the container 5 into the first storage warehouse 1A.

[0033] The third conveyor 3C transports the sorting container 6 from the picking area 2 to the second storage warehouse 1B. The second storage warehouse 1B is equipped with... Figure 3 In the case of the illustrated receiving section 121, the third conveyor 3C conveys the sorting container 6 from the picking area 2 to the receiving section 121 of the second storage warehouse 1B. The fourth conveyor 3D conveys the sorting container 6 from its storage location (an example of a conveying source, not shown) to the picking area 2. The fifth conveyor 3E conveys the sorting container 6 from the second storage warehouse 1B to the shipping area (an example of a conveying target, not shown) where shipping operations are performed. For example, the fifth conveyor 3E conveys the sorting container 6 from the second storage warehouse 1B to the shipping area in shipping sequence. The second storage warehouse 1B is equipped with... Figure 3 In the case of the illustrated outbound section 123, the fifth conveying device 3E will separate containers 6 and transport them from the outbound section 123 of the second storage warehouse 1B to the shipping area. The sixth conveying device 3F will transport containers 5 from the flat area where containers 5 are placed (an example of a conveying source, not shown) to the first storage warehouse 1A. The first storage warehouse 1A is equipped with Figure 3 In the case of the accumulator section 121 shown, the sixth conveying device 3F conveys the container 5 from the flat area to the accumulator section 121 of the first storage warehouse 1A.

[0034] The six conveying devices (specifically, the first conveyor 3A, the second conveyor 3B, the third conveyor 3C, the fourth conveyor 3D, the fifth conveyor 3E, and the sixth conveyor 3F) of the goods storage equipment 100 are controlled by the control system 4 (see reference). Figure 2The system controls the transport of objects (container 5, sorting container 6, etc.). Each of these six transport devices can be, for example, a belt conveyor, a roller conveyor, or a transport vehicle such as an unmanned transport vehicle. Furthermore, these six transport devices are at least conceptually distinct, although two or more transport devices may share a common transport section.

[0035] like Figure 2 As shown, the goods storage equipment 100 includes a control system 4. The control system 4 includes a processing unit such as a CPU and peripheral circuits such as a memory. Through the cooperation of these hardware components and the program executed on the processing unit, the various functions of the control system 4 are realized. Alternatively, the control system 4 may not be a single piece of hardware, but rather a collection of multiple pieces of hardware (multiple separate pieces of hardware) capable of communicating with each other. Furthermore, at least a portion of the control system 4 may be integrated with the object controlled by the control system 4. The technical features of the control system 4 disclosed in this specification can also be applied to the control method of the goods storage equipment 100, and the control method of the goods storage equipment 100 is also disclosed in this specification. This control method includes the control system 4 executing the processes described later (specifically, outbound processing P1, replenishment processing P2, movement processing P3, return processing P4, pre-information acquisition processing, inbound processing P5, and post-operation processing P6).

[0036] Control system 4 controls the first storage vault 1A and the second storage vault 1B. Control system 4 controls the entry and exit actions of stored items in the first storage vault 1A and the second storage vault 1B. Specifically, the entry and exit actions of stored items in the first storage vault 1A are controlled by an equipment controller (e.g., an equipment controller installed in the conveyor 12) based on instructions from control system 4, which controls the drive of a power source (e.g., an electric motor installed in the conveyor 12) installed in the first storage vault 1A. The entry and exit actions of stored items in the second storage vault 1B are also controlled in the same way.

[0037] Furthermore, the control system 4 controls the first conveying device 3A and the second conveying device 3B. In this embodiment, the control system 4 also controls the third conveying device 3C, the fourth conveying device 3D, the fifth conveying device 3E, and the sixth conveying device 3F. The control system 4 controls the conveying action of the objects conveyed by these conveying devices. Specifically, the device controller installed in the first conveying device 3A controls the drive of the drive power source (e.g., an electric motor) installed in the first conveying device 3A according to the instructions from the control system 4, thereby controlling the conveying action of the objects conveyed by the first conveying device 3A. The conveying action of the objects conveyed by the conveying devices other than the first conveying device 3A is also controlled in the same way.

[0038] Here, the item W that determines the type of item to be picked is designated as the picking item WP. The type of item W to be picked is determined based on the order. In this embodiment, the management device 8 (refer to...) Figure 2 Based on the order from the shipment target of item W, an order is generated, and the information of the generated order is matched with the shipment target for management. The order contains information about the type of item W and the quantity of item W for each type. That is, the order specifies the type of item W and the quantity of item W for each type. The control system 4 obtains the order information from the management device 8 and determines the type of item W included in the order as the type of item W to be picked. Then, through the picking operation, the type and quantity of item W determined by the order are collected into the sorting container 6.

[0039] The frequency with which an item becomes the object of a picking operation, i.e., the picking frequency, typically varies depending on the type of item W. For example, best-selling items W tend to be picked more frequently than other items W. Furthermore, even for the same item W, if it is a seasonal item, the picking frequency during busy periods is likely to be higher than during off-peak periods. Thus, the frequency with which an item becomes the object of a picking operation, i.e., the picking frequency, varies depending on the type of item W. In this embodiment, items W are classified into three categories based on their picking frequency: Item 1 W1, Item 2 W2, and Item 3 W3. The picking frequency for each item W can be set, for example, based on actual performance, based on predicted performance, or based on both actual performance and predicted performance.

[0040] Here, the first type of item W1 is an item W of a type with a picking frequency of at least a predetermined first frequency threshold. The second type of item W2 is an item W of a type with a picking frequency less than the first frequency threshold. In this embodiment, it is an item W of a type with a picking frequency less than the first frequency threshold and at least a predetermined second frequency threshold, where the second frequency threshold is lower than the first frequency threshold. The third type of item W3 is an item W of a type with a picking frequency less than the second frequency threshold. In this embodiment, items W whose shapes are not suitable for storage in the second storage warehouse 1B are also designated as the third type of item W3. For example, items W with special shapes (package shape) such as long items are considered items W whose shapes are not suitable for storage in the second storage warehouse 1B. Thus, in this embodiment, items W whose shape is not suitable for storage in the second storage warehouse 1B are classified as third type items W3 regardless of the picking frequency, while other items W are classified as first type items W1, second type items W2, or third type items W3 according to the picking frequency.

[0041] Items W of the same kind are stored in a container 5. That is, items W are stored in the container 5 according to their type. In this embodiment, an item W of one type is stored in a container 5. Alternatively, it is also possible to make a structure in which multiple types of items W that are classified into the same item category (for example, two types of items W classified as item W1) are stored in a container 5 in a state separated by a partition or the like.

[0042] The control system 4 executes outbound processing P1, replenishment processing P2, movement processing P3, and return processing P4. In this embodiment, the control system 4 also executes inbound processing P5 and post-operation processing P6. For each of the stored items stored in the first storage warehouse 1A and the second storage warehouse 1B, the control system 4 generates and manages data that associates information about the storage location of the stored item with information about the type of item W contained in that stored item. Based on the order information obtained from the management device 8, the control system 4 executes the above-described processes to supply the type of item W specified by the order to the picking area 2.

[0043] Outbound processing P1 is the following process: Using the first conveyor 3A, the container 5 containing the item WP to be picked is conveyed from the first storage area 1A to the picking area 2; using the first conveyor 3A, the container 5 after the picking operation is completed is conveyed from the picking area 2 to the first storage area 1A (see reference). Figure 4 , Figure 6 , Figure 7 In picking area 2, a picking operation (sorting operation) is performed whereby the quantity of picking objects WP specified by the order is removed from container 5 that has been brought into picking area 2 and placed into sorting container 6.

[0044] Figure 4 The outbound process P1 shown is the outbound process when the first item W1 becomes the picking item WP. After the outbound process P1 is completed, the container 5 containing the first item W1 will be returned to the first storage warehouse 1A for storage. Figure 6 The outbound process P1 shown is the outbound process when the second item W2 becomes the picking item WP. The container 5 containing the second item W2, which was sent back to the first storage warehouse 1A after the completion of the outbound process P1, is sent back to the second storage warehouse 1B through the execution of the return process P4 described later, and stored in the second storage warehouse 1B.

[0045] Figure 7 The outbound processing P1 shown is the outbound processing P1 when item W3 (the third type of item) becomes the picking target item WP. Figure 7In this case, we envision a scenario where all items W are removed from container 5 through a picking operation (i.e., container 5 becomes empty due to the picking operation). In such a case, the following structure can also be implemented: In the outbound process P1, the control system 4 does not perform the process of using the first conveyor 3A to transport the container 5, which has completed the picking operation, from the picking area 2 to the first storage warehouse 1A, but instead performs the process of transporting the container 5 to another location other than the first storage warehouse 1A (e.g., the location where the empty container 5 will be collected).

[0046] Supplementary processing P2 is the following process: When the quantity of the first type of item W1 in the first storage warehouse 1A falls below a predetermined quantity threshold, the second conveying device 3B is used to convey the first type of item W1 in the second storage warehouse 1B from the second storage warehouse 1B to the first storage warehouse 1A, so that it is stored in the first storage warehouse 1A while being housed in the container 5 (see reference). Figure 5 The control system 4 performs supplementary processing P2 for each of the first type of item W1. For example, when the first object item and the second object item are of two different types of items W, and the first object item is W1, supplementary processing P2 is performed for each of the first object item and the second object item as follows: That is, when the quantity of the first object item (the quantity in the first storage vault 1A) is below a quantity threshold, supplementary processing P2 is performed for the first object item, and the first object item is stored in the first storage vault 1A while being housed in the container 5. Furthermore, when the quantity of the second object item (the quantity in the first storage vault 1A) is below a quantity threshold, supplementary processing P2 is performed for the second object item, and the second object item is stored in the first storage vault 1A while being housed in the container 5.

[0047] In this embodiment, the first type of article W1 is housed in a cardboard box 7 (see reference). Figure 5 The item W1 is stored in the second storage warehouse 1B in the state of being contained in the cardboard box 7. Therefore, in the supplementary processing P2, the first item W1 is taken out of the second storage warehouse 1B while still contained in the cardboard box 7. Moreover, during the period until the first item W1 is transported to the first storage warehouse 1A by the second conveyor 3B, the operation of removing the first item W1 from the cardboard box 7 and storing it in the container 5 is performed (see reference). Figure 5 Thus, the first item W1, which will be taken out of the second storage warehouse 1B, will be stored in the first storage warehouse 1A while still contained in the container 5. The second conveying device 3B (specifically, the conveying section that transports the item from the second storage warehouse 1B to the first storage warehouse 1A) is configured to perform the operation of transferring the item W from the cardboard box 7 to the container 5 as described above. This operation can be performed by an operator or by the operating device.

[0048] Alternatively, the structure can be configured such that the first item W1 is stored in the container 5 in the second storage vault 1B. In this case, during supplementary processing P2, after the first item W1 is taken out of the second storage vault 1B in the container 5, it is stored in the first storage vault 1A in its original state as it was stored in the container 5.

[0049] The movement process P3 is as follows: When the second type of item W2 becomes the picking target item WP, in order to perform the outbound process P1, the second conveyor 3B is used to transport the second type of item W2, which is the picking target item WP, from the second storage warehouse 1B to the first storage warehouse 1A, so that it is stored in the first storage warehouse 1A while being contained in the container 5 (see reference). Figure 6 The second item W2, which is stored in container 5 and moved into storage room 1A via moving process P3, is then transported to picking area 2 via outbound process P1.

[0050] There is a case where, in order for control system 4 to execute the return process P4 (described later), the second type of item W2, which will become the picking target item WP, is stored in container 5 in the second storage warehouse 1B. Figure 6 The paper envisions a scenario where, during the movement process P3, the second item W2, which will become the item to be picked, is taken out of the second storage vault 1B while still contained in container 5, and then returned to the first storage vault 1A in its original state as contained in container 5.

[0051] If both a container 5 containing a second item W2 (which is the item to be picked) and a cardboard box 7 containing the second item W2 (which is the item to be picked) are present in the second storage warehouse 1B, the container 5 containing the second item W2 is transported from the second storage warehouse 1B to the first storage warehouse 1A during the transfer process P3. Conversely, if the container 5 containing the second item W2 (which is the item to be picked) is not present in the second storage warehouse 1B, the cardboard box 7 containing the second item W2 (which is the item to be picked) is removed from the second storage warehouse 1B during the transfer process P3. Then, during the period until the second item W2 is transported to the first storage warehouse 1A by the second conveyor 3B, the operation of removing the second item W2 from the cardboard box 7 and placing it into the container 5 is performed. Thus, the second item W2, removed from the second storage warehouse 1B, is stored in the first storage warehouse 1A while contained in the container 5.

[0052] In this embodiment, the control system 4 is configured to perform a pre-processing information acquisition process to obtain information about the type of item W to be picked before the container 5 containing the item WP to be picked is transported from the first storage warehouse 1A to the picking area 2 in the outbound process P1. Then, the control system 4 is configured to perform a movement process P3 based on the information obtained through the pre-processing information acquisition process. As a result, if the item W to be picked includes a second item W2, the movement process P3 can be started before the outbound process P1, so that the second item W2 can be moved from the second storage warehouse 1B to the first storage warehouse 1A.

[0053] Specifically, the control system 4 obtains information on the types of items W destined for picking operations by collecting order information from the management device 8 for a certain period (e.g., 1 day's worth) before the aforementioned transport in the outbound processing P1 begins. Then, the control system 4 performs movement processing P3 for each of the second type of item W2 included among the items W destined for picking operations.

[0054] Return processing P4 is the following process: using the second conveyor 3B, the container 5 containing the second item W2, which was returned to the first storage warehouse 1A after the completion of the outbound processing P1, is transported from the first storage warehouse 1A to the second storage warehouse 1B (see reference). Figure 6 ). Container 5, which was returned to the second vault 1B via return processing P4, was stored in the second vault 1B.

[0055] In this embodiment, the control system 4 is configured such that even if the outbound processing P1 for the container 5 containing the second item W2 is completed, if, based on information obtained through the pre-information acquisition process, the same second item W2 is scheduled to become a picking item WP within a predetermined time, the return processing P4 is not performed until the next outbound processing P1 (the outbound processing P1 for the container 5 containing the second item W2) is completed. Therefore, when the second item W2 then becomes a picking item WP, the container 5 containing the second item W2 can be supplied to the picking area 2 without performing the movement processing P3. Furthermore, the predetermined time is set, for example, to 30 minutes or 1 hour.

[0056] Warehouse entry processing P5 is the process of entering container 5, which contains item W3 (the third type of item), which is to be selected item WP, into warehouse 1A (see reference). Figure 7When the third type of item W3 becomes the picking target item WP, the control system 4 performs an inbound process P5 for outbound process P1. In this embodiment, during inbound process P5, the container 5 containing the third type of item W3, which has become the picking target item WP, is conveyed to the first storage warehouse 1A using the sixth conveyor 3F. The third type of item W3, which has been stored in the first storage warehouse 1A through inbound process P5, is then conveyed to the picking work area 2 through the subsequently executed outbound process P1.

[0057] In this embodiment, during the receiving process P5, a container 5 containing the same quantity of the third type of item W3 as specified in the order is placed in the warehouse. Figure 7 In the example shown, container 5, which contains two third items W3, is put into storage 1A. Therefore, through the picking operation, container 5 becomes empty.

[0058] Post-processing P6 is the process of using the third conveyor 3C to transport the sorting container 6, which has been sorted after the picking operation, from the picking area 2 to the second storage warehouse 1B (see reference). Figure 4 , Figure 6 , Figure 7 After the picking operation is completed, the sorting container 6 contains the type and quantity of items W determined according to the order. The sorting container 6, which is transported to the second storage warehouse 1B, is stored in the second storage warehouse 1B until it is transported to the shipping area.

[0059] [Other Implementation Methods]

[0060] Next, other embodiments of the item storage equipment will be described.

[0061] (1) In the above embodiment, the structure in which the third conveying device 3C conveys the sorting container 6 between the picking area 2 and the second storage warehouse 1B has been described as an example. However, this disclosure is not limited to such a structure; for example, as Figure 8 As shown, the following structure can also be implemented: In addition to the first storage warehouse 1A and the second storage warehouse 1B, the goods storage equipment 100 also includes a third storage warehouse 1C, and the third conveyor 3C transports the sorting container 6 between the picking area 2 and the third storage warehouse 1C. In this case, the control system 4 replaces the post-processing P6 in the above embodiment and performs the process of using the third conveyor 3C to transport the sorting container 6, after the picking operation is completed, from the picking area 2 to the third storage warehouse 1C. Thus, the sorting container 6, after the picking operation is completed, is stored in the third storage warehouse 1C until it is transported from the third storage warehouse 1C to the shipping area using the fifth conveyor 3E.

[0062] (2) In the above embodiment, the structure of the second type of item W2 being defined as an item W of a type whose picking frequency is less than the first frequency threshold and is a type of item W of a predetermined second frequency threshold lower than the first frequency threshold has been described as an example. However, this disclosure is not limited to such a structure, and the second type of item W2 may also be defined as an item W of a type whose picking frequency is less than the first frequency threshold. That is, instead of classifying the item W into three item categories according to the picking frequency: the first type of item W1, the second type of item W2, and the third type of item W3, the item W may be classified into two item categories according to the picking frequency: the first type of item W1 and the second type of item W2. In this case, although the item W whose shape is not suitable for storage in the second storage warehouse 1B is classified as the third type of item W3 in the same way as in the above embodiment, the other items W are basically classified into the first type of item W1 or the second type of item W2 according to the picking frequency.

[0063] (3) In the above embodiment, the example described is that even if the outbound processing P1 of the container 5 containing the second item W2 is completed, and the control system 4, based on information obtained through the prior information acquisition process, determines that the same second item W2 is scheduled to become a picking item WP within a specified time, the return processing P4 is not executed until the next outbound processing P1 is completed. However, this disclosure is not limited to such a structure, and it is also possible to execute the return processing P4 of the container 5 containing the second item W2 even if the same second item W2 is scheduled to become a picking item WP within a specified time.

[0064] (4) In the above embodiment, the structure of the control system 4 performing pre-information acquisition processing before the container 5 in the outbound processing P1 is transported from the first storage warehouse 1A to the picking area 2, and performing movement processing P3 based on the information obtained through the pre-information acquisition processing, has been described as an example. However, this disclosure is not limited to such a structure, and it is also possible to make the control system 4 not perform movement processing P3 based on the information obtained through the pre-information acquisition processing, or to make the control system 4 not perform pre-information acquisition processing.

[0065] (5) In the above embodiment, the structure of the control system 4 performing the warehousing process P5 has been described as an example. However, this disclosure is not limited to such a structure. For example, it can also be made into a structure in which the third item W3, which will become the item to be picked, is directly transported to the picking area 2.

[0066] (6) Furthermore, the structures disclosed in the above embodiments can be combined with structures disclosed in other embodiments (including combinations of embodiments described as other embodiments) as long as there is no contradiction. Regarding other structures, the embodiments disclosed in this specification are merely illustrative in all respects. Therefore, various changes can be appropriately made without departing from the spirit of this disclosure.

[0067] [Summary of the above embodiments]

[0068] The following is a summary of the item storage equipment described above.

[0069] An item storage device is provided for supplying items to a picking area where a picking operation is performed, and for storing items that can be the object of the picking operation, wherein the picking operation is the process of retrieving items contained in a container. The item storage device comprises: a first storage warehouse for storing the containers that are to be supplied to the picking area; a second storage warehouse with a larger storage capacity than the first storage warehouse for storing the containers that are to be supplied to the first storage warehouse; a first conveying device for conveying the containers between the picking area and the first storage warehouse; and a second conveying device for conveying the containers between the first storage warehouse and the first storage warehouse. The aforementioned second storage warehouse is used for inter-warehouse transport; and a control system controls the aforementioned first storage warehouse, the aforementioned second storage warehouse, the aforementioned first conveying device, and the aforementioned second conveying device; based on the type of the aforementioned items, the frequency at which they become objects of the aforementioned picking operation (i.e., different picking frequencies) is determined; the aforementioned items that determine the type of items that become objects of the aforementioned picking operation are set as picking object items, the aforementioned items of the aforementioned type with a picking frequency of more than a predetermined first frequency threshold are set as first type items, and the aforementioned items of the aforementioned type with a picking frequency less than the aforementioned first frequency threshold are set as second type items; the aforementioned control system performs outbound processing, replenishment processing, movement processing, and return processing; the aforementioned outbound... The warehouse processing is as follows: using the aforementioned first conveying device, the aforementioned container containing the aforementioned items to be picked is conveyed from the aforementioned first storage warehouse to the aforementioned picking operation area; using the aforementioned first conveying device, the aforementioned container after the aforementioned picking operation is completed is conveyed from the aforementioned picking operation area to the aforementioned first storage warehouse; the aforementioned replenishment processing is as follows: when the quantity of the aforementioned first type of item in the aforementioned first storage warehouse falls below a predetermined quantity threshold, using the aforementioned second conveying device, the aforementioned first type of item in the aforementioned second storage warehouse is conveyed from the aforementioned second storage warehouse to the aforementioned first storage warehouse, so that it is stored in the aforementioned container and placed in the warehouse. The first storage warehouse; the aforementioned moving process is as follows: when the aforementioned second type of item becomes the aforementioned picking target item, in order to carry out the aforementioned outbound process, the aforementioned second type of item, which is the aforementioned picking target item and is located in the aforementioned second storage warehouse, is transported from the aforementioned second storage warehouse to the aforementioned first storage warehouse using the aforementioned second conveying device, so that it is stored in the aforementioned first storage warehouse while being contained in the aforementioned container; the aforementioned return process is as follows: using the aforementioned second conveying device, the aforementioned container containing the aforementioned second type of item, which has been returned to the aforementioned first storage warehouse after the aforementioned outbound process is completed, is transported from the aforementioned first storage warehouse to the aforementioned second storage warehouse.

[0070] According to this structure, since containers containing items that can be picked can be stored in a second storage room with a larger storage capacity than the first storage room, in addition to the first storage room, it is easy to ensure a larger overall storage capacity for the storage rooms including the first and second storage rooms. Here, the first storage room needs to be configured so that containers can be transported between the first conveyor and the picking area. In contrast, the second storage room does not have such constraints; for example, it is easier to utilize the available space in the item storage equipment. Compared to the first storage room, the second storage room allows for greater flexibility in its configuration. Therefore, compared to the case where the required storage capacity is ensured solely by the first storage room without a second storage room, it is easier to prevent the item storage equipment from becoming too large.

[0071] Furthermore, according to this structure, since items with a picking frequency of 1 frequency threshold or higher are designated as Type 1 items and replenishment processing is performed on Type 1 items, there are always more Type 1 items than the quantity threshold in the first storage warehouse. Therefore, when Type 1 items become the items to be picked, the execution of outbound processing allows Type 1 items to be supplied from the first storage warehouse to the picking area relatively quickly. On the other hand, according to this structure, since items with a picking frequency lower than the 1 frequency threshold are designated as Type 2 items and return processing is performed on Type 2 items, Type 2 items are generally not stored in the first storage warehouse but in the second storage warehouse. Therefore, the large-scale operation of the first storage warehouse can be suppressed, and the decrease in the efficiency of supplying items from the first storage warehouse to the picking area can be suppressed. Furthermore, when the second item becomes a picking target, a movement process needs to be performed before the outbound processing in order to supply the second item from the second storage warehouse to the picking area. However, the picking frequency of the second item is lower than that of the first item. Therefore, even if the second item is stored in the second storage warehouse, the impact on the supply efficiency of picking target items to the picking area is limited.

[0072] As described above, this structure can suppress the increase in the size of the storage equipment and the decrease in the supply efficiency of items relative to the picking area.

[0073] Here, preferably, the aforementioned control system also performs a prior information acquisition process, which acquires information about the type of the aforementioned items that are intended to be the objects of the aforementioned picking operation before the aforementioned container containing the aforementioned items to be picked is transported from the aforementioned first storage warehouse to the aforementioned picking operation area in the aforementioned outbound process; the aforementioned control system performs the aforementioned movement process based on the information acquired through the aforementioned prior information acquisition process.

[0074] According to this structure, when a second type of item is included among the items designated for picking, the movement process can begin before the start of the outbound process, moving the second type of item from the second storage warehouse to the first storage warehouse. Therefore, when the second type of item subsequently becomes a picking item, it can be quickly supplied to the picking area, thereby improving the supply efficiency of items relative to the picking area.

[0075] In the structure where the aforementioned control system performs the aforementioned movement process based on the information obtained through the aforementioned prior information acquisition process, as described above, it is preferable that even if the aforementioned outbound process for the aforementioned container containing the aforementioned second type of item is completed, the aforementioned control system will not perform the aforementioned return process until the next aforementioned outbound process is completed, provided that the same aforementioned second type of item is scheduled to become the aforementioned picking item within a predetermined time, based on the information obtained through the aforementioned prior information acquisition process.

[0076] According to this structure, if a second item, which has been returned to the first storage warehouse via outbound processing, is scheduled to become a picking item within a specified time, the second item can be stored in the first storage warehouse in advance without being returned to the second storage warehouse. This allows for fewer return and relocation processes, more efficient transport of containers between the first and second storage warehouses, and enables the second item to be quickly supplied to the picking area when it becomes a picking item.

[0077] In the above-described item storage equipment, preferably, the second type of item is the item of the type whose picking frequency is less than the first frequency threshold and is above a predetermined second frequency threshold, wherein the second frequency threshold is lower than the first frequency threshold; the third type of item is defined as the item of the type whose picking frequency is less than the second frequency threshold and the item whose shape is not suitable for storage in the second storage warehouse; when the third type of item becomes the item to be picked, the control system performs an inbound process to put the container containing the third type of item that has become the item to be picked into the first storage warehouse for the purpose of the outbound process.

[0078] According to this structure, when a third type of item becomes a picking target, by performing inbound and outbound processing, the third type of item can be appropriately supplied to the picking area. Furthermore, by preventing items with a picking frequency lower than the second frequency threshold from being stored in the second storage warehouse, this structure can prevent the second storage warehouse from becoming too large for items with low picking frequency, thus suppressing the need for large-scale item storage equipment. Additionally, by preventing items with shapes unsuitable for storage in the second storage warehouse from being stored there, the container transport in the second storage warehouse can be appropriately performed.

[0079] Furthermore, preferably, in the aforementioned picking operation, the aforementioned items taken from the aforementioned container are housed in a sorting container; and a third conveying device is provided to transport the aforementioned sorting container between the aforementioned picking operation area and the aforementioned second storage warehouse; the aforementioned control system performs post-operation processing by using the aforementioned third conveying device to transport the aforementioned sorting container, after the aforementioned picking operation is completed, from the aforementioned picking operation area to the aforementioned second storage warehouse.

[0080] According to this structure, since there is no need to set up a separate storage warehouse for storing the sorted containers after the picking operation is completed, it is easy to miniaturize the item storage equipment.

[0081] The article storage device disclosed herein is sufficient to achieve at least one of the aforementioned effects.

[0082] Explanation of reference numerals in the attached figures

[0083] 1A: First Vault

[0084] 1B: Second Vault

[0085] 2: Picking area

[0086] 3A: First Conveying Device

[0087] 3B: Second Conveying Device

[0088] 3C: Third Conveying Device

[0089] 4: Control System

[0090] 5: Container

[0091] 6: Differentiate containers

[0092] 100: Goods storage equipment

[0093] P1: Outbound Processing

[0094] P2: Supplementary processing

[0095] P3: Movement Processing

[0096] P4: Return Processing

[0097] P5: Inbound Processing

[0098] P6: Post-job processing

[0099] W: Items

[0100] WP: Select Items

[0101] W1: Type 1 item

[0102] W2: Second type of item

[0103] W3: The third type of item.

Claims

1. An item storage device for supplying items to a picking area where a picking operation is performed and for storing items that can be the object of the picking operation, wherein the picking operation is an operation of retrieving the items contained in a container, the item storage device being characterized in that... have: The first storage warehouse stores the aforementioned containers that become the objects supplied to the aforementioned picking operation area; The second storage facility has a larger storage capacity than the first storage facility, and stores the aforementioned containers that are supplied to the first storage facility. The first conveying device transports the aforementioned containers between the aforementioned picking area and the aforementioned first storage warehouse; The second conveying device conveys the aforementioned container between the aforementioned first storage facility and the aforementioned second storage facility; and The control system controls the aforementioned first storage warehouse, the aforementioned second storage warehouse, the aforementioned first conveying device, and the aforementioned second conveying device; The frequency of the items being picked varies depending on the type of the items. The aforementioned items that are determined to be the objects of the aforementioned picking operation are designated as picking object items, the aforementioned items of the aforementioned types with a picking frequency of more than or equal to the specified first frequency threshold are designated as first type items, and the aforementioned items of the aforementioned types with a picking frequency less than the aforementioned first frequency threshold are designated as second type items. The aforementioned control system performs outbound processing, replenishment processing, movement processing, and return processing; The aforementioned outbound processing is as follows: using the aforementioned first conveying device, the aforementioned container containing the aforementioned items to be picked is conveyed from the aforementioned first storage warehouse to the aforementioned picking operation area; using the aforementioned first conveying device, the aforementioned container after the aforementioned picking operation is completed is conveyed from the aforementioned picking operation area to the aforementioned first storage warehouse. The aforementioned supplementary processing is as follows: when the quantity of the aforementioned first type of item in the aforementioned first storage warehouse is below a predetermined quantity threshold, the aforementioned second conveying device is used to convey the aforementioned first type of item in the aforementioned second storage warehouse from the aforementioned second storage warehouse to the aforementioned first storage warehouse, so that it is stored in the aforementioned first storage warehouse while being contained in the aforementioned container. The aforementioned moving process is as follows: when the aforementioned second type of item becomes the aforementioned picking target item, in order to carry out the aforementioned outbound process, the aforementioned second conveying device is used to transport the aforementioned second type of item, which is the aforementioned picking target item and is located in the aforementioned second storage warehouse, from the aforementioned second storage warehouse to the aforementioned first storage warehouse, so that it is stored in the aforementioned first storage warehouse while being contained in the aforementioned container. The aforementioned return process is as follows: using the aforementioned second conveying device, the aforementioned container containing the aforementioned second type of item, which has been returned to the aforementioned first storage warehouse after the aforementioned outbound process is completed, is conveyed from the aforementioned first storage warehouse to the aforementioned second storage warehouse.

2. The article storage device as described in claim 1, characterized in that, The aforementioned control system also performs a pre-processing information acquisition process, which acquires information about the type of the aforementioned items that are intended to be the objects of the aforementioned picking operation before the aforementioned container containing the aforementioned items to be picked is transported from the aforementioned first storage warehouse to the aforementioned picking operation area in the aforementioned outbound process. The aforementioned control system performs the aforementioned movement processing based on the information obtained through the aforementioned prior information acquisition and processing.

3. The article storage device as described in claim 2, characterized in that, Even if the outbound process for the container containing the aforementioned second type of item is completed, the aforementioned control system will not perform the aforementioned return process until the next outbound process is completed, provided that the same aforementioned second type of item is scheduled to become the aforementioned picking item within a specified time, based on the information obtained through the aforementioned prior information acquisition process.

4. The article storage device as described in any one of claims 1 to 3, characterized in that, The second type of item mentioned above refers to the aforementioned items whose picking frequency is less than the aforementioned first frequency threshold and is above the specified second frequency threshold, wherein the second frequency threshold is lower than the aforementioned first frequency threshold; The aforementioned items of the type whose picking frequency is less than the aforementioned second frequency threshold, and the aforementioned items whose shape is not suitable for storage in the aforementioned second storage warehouse, are designated as the third type of item. When the aforementioned third type of item becomes the aforementioned picking target item, the aforementioned control system performs an inbound process to put the aforementioned container containing the aforementioned third type of item, which has become the aforementioned picking target item, into the aforementioned first storage warehouse in order to perform the aforementioned outbound process.

5. The article storage device as described in any one of claims 1 to 3, characterized in that, In the aforementioned picking operation, the aforementioned items taken from the aforementioned container are housed in the sorting container; It also includes a third conveying device for transporting the aforementioned sorting containers between the aforementioned picking area and the aforementioned second storage warehouse; The aforementioned control system performs post-operation processing by using the aforementioned third conveying device to transport the aforementioned sorting containers, after the aforementioned picking operation is completed, from the aforementioned picking operation area to the aforementioned second storage warehouse.

6. The article storage device as described in claim 4, characterized in that, In the aforementioned picking operation, the aforementioned items taken from the aforementioned container are housed in the sorting container; It also includes a third conveying device for transporting the aforementioned sorting containers between the aforementioned picking area and the aforementioned second storage warehouse; The aforementioned control system performs post-operation processing by using the aforementioned third conveying device to transport the aforementioned sorting containers, after the aforementioned picking operation is completed, from the aforementioned picking operation area to the aforementioned second storage warehouse.

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