Method and system for picking products in a picking station of an automated storage and retrieval system

Abstract

A method, system, and computer program for picking products from at least one storage container (106) in a picking station (410) of an automated storage and retrieval system (1). Picking is controlled by a picking system controller (401) that communicates with a warehouse management system (402), wherein the picking sequence is performed according to a sorted picking sequence, wherein the picking sequence is established by estimating the following: - the shortest travel distance for moving the picking device (405) to pick from one storage container (106) to pick from another storage container (106); - the fastest completion of picking products from the storage container (106) in the picking station (410) so that a new storage container (106) can enter the picking area of ​​the picking station (410); - the fastest completion of replacing the consolidation container with a new consolidation container; - sorting the picking sequences and selecting a picking sequence that provides a higher throughput of picking products according to the sorted product orders; performing the picking of products by having the picking system controller (401) control the picking device (405) to pick products from the storage container (106) and place them in the consolidation container within a time range according to the selected picking sequence; repeating the above method steps.

Description

Technical Field

[0001] The present invention relates to an automated storage and retrieval system for storage containers, and more particularly to a method, system, and computer program for picking items from a storage container and placing the items into a consolidation container at a picking station of the automated storage and retrieval system. Background Art

[0002] FIG1 discloses a typical prior art automated storage and retrieval system 1 having a frame structure 100 and a container handling vehicle 201 , also called a robot, operating on the system 1 .

[0003] The frame structure 100 comprises upright members 102, horizontal members 103 and a storage volume comprising storage columns 105 arranged in rows between the upright members 102 and the horizontal members 103. In these storage columns 105, storage containers 106, also called boxes, are stacked one on top of the other to form stacks 107. The members 102, 103 may typically be made of metal, such as extruded aluminum profiles.

[0004] The frame structure 100 also includes a rail system 108 arranged across the top of the frame structure 100, on which a plurality of container handling vehicles 201 are operated to lift storage containers 106 from the storage column 105 and lower storage containers 106 into the storage column 105, and also to transport storage containers 106 above the storage column 105.

[0005] The track system 108 includes a first set of parallel tracks 110 arranged to guide the container handling vehicle 201 to move along a first direction X across the top of the frame structure 100, and a second set of parallel tracks 111 arranged perpendicular to the first set of tracks 110 to guide the container handling vehicle 201 to move along a second direction Y, which is perpendicular to the first direction X.

[0006] 1 also shows a first track 110a in a first direction X, a second track 110b in a first direction X, a first track 111a in a second direction Y, and a second track 111b in a second direction Y. The container handling vehicle 201 moves laterally over the storage row 105, i.e., in a plane parallel to the horizontal XY plane.

[0007] The type of container handling vehicle 201 used may be any type known in the art, for example one of the automated container handling vehicles disclosed in WO 2014 / 090684 A1 or WO 2015 / 193278 A1 having a footprint covering one or two storage rows 105. The track system 108 may be arranged in a single track and / or dual track configuration.

[0008] Storage containers 106 are stored in rows 105 that define a third direction Z, which is orthogonal to the first direction X and the second direction Y. Container handling vehicles 201 access storage containers 106 via access points 112 in a rail system 108, i.e., the rail system 108 is arranged on a frame structure 100 that defines the perimeter of each access point 112 on top of each storage row 105. Upright members 102 of frame structure 100 can be used to guide storage containers as they are lowered into and out of rows 105. Stacks 107 of containers 106 are generally self-supporting.

[0009] The storage volume of the frame structure 100 is generally referred to as a storage grid 104, wherein the possible storage positions within the storage columns 105 in this storage grid 104 are referred to as storage cells. Each storage column 105 can be identified by a position in the X and Y directions, while each storage cell can be identified by a container number in the X, Y, and Z directions.

[0010] In the frame structure 100, most rows 105 are storage rows 105, i.e., rows 105 in which storage containers 106 are stored in stacks 107. However, some rows 105 may have other purposes, such as transferring storage containers 106 from the upper side to the lower side of the storage grid 104 or vice versa.

[0011] 1 , lanes 119 and 120 are specialized lanes used by container handling vehicles 201 to drop off and / or pick up storage containers 106 so that they can be transferred to an access station, such as a pick station (not shown), where the storage containers 106 can be accessed from outside of the frame structure 100 or transferred out of or into the frame structure 100. The access station is typically a pick station where product items are picked from the storage containers 106 and placed in a consolidation container.

[0012] In the art, the columns used to transfer storage containers into and out of the storage system are often referred to as port columns 119, 120 or transfer columns. Storage containers are transferred into and out of the port columns 119, 120 via ports 119', 120', which are typically located at openings at the ends of the port columns 119, 120, i.e., where storage containers are entering or leaving the port columns 119, 120. The ports can also be located at other locations, such as at the mid-plane or ground level of the port columns 119, 120.

[0013] The transport and transfer of storage containers 106 to access stations can be in any direction, i.e., horizontal, inclined, and / or vertical. For example, storage containers 106 can be placed in a random or dedicated row 105 within the frame structure 100 and then picked up by any container handling vehicle 201 and transported to a port row 119, 120 for further transport to an access station. It should be noted that the term "inclined" refers to the transport of storage containers 106 with a general transport direction somewhere between horizontal and vertical.

[0014] In Figure 1, the first port row 119 can be, for example, a dedicated unloading port row where container handling vehicles 201 can drop off storage containers 106 for transport to a pick-up station, and the second port row 120 can be a dedicated pick-up port row where container handling vehicles 201 can pick up storage containers 106 for storage.

[0015] When operating the automated storage and retrieval system 1, each container handling vehicle 201 is assigned a task by receiving instructions. A task can be, for example, to retrieve a specific storage container 106 from the storage column 105 and deliver it to the port column 119 for further transport to a storage and retrieval station, or to move the storage container 106 from one storage unit to another. This means that each container handling vehicle 201 is instructed to follow a set route on the track 111 from its current location to a target location.

[0016] When a specific storage container 106 stored in one of the rows 105 disclosed in FIG1 is to be retrieved, a task is assigned to one of the container handling vehicles 201 and instructed to retrieve the storage container 106 from its location and transport it to a port 119′ of the port row 119. This operation includes moving the container handling vehicle 201 to a position above the storage row 105 where the storage container 106 is located, retrieving the storage container 106 from the storage row 105 using a lifting device (not shown) of the container handling vehicle 201, and transporting the storage container 106 to a port 119′ of the port row 119.

[0017] If the target storage container 106 is located deep within the stack 107, i.e., one or more other storage containers 106 are located above the target storage container 106, the operation also includes temporarily moving the above-located storage containers before lifting the target storage container 106 from the storage column 105. This step, sometimes referred to in the art as excavation, can be performed using the same container handling vehicle 201 that will later be used to transport the target storage container to the unloading port column 119, or using one or more other cooperating container handling vehicles 201. Alternatively or additionally, the automated storage and retrieval system 1 can include a container handling vehicle 201 specifically designed for the task of temporarily removing storage containers from the storage column 105. Once the target storage container 106 has been removed from the storage column 105, the temporarily removed storage container 106 can be relocated to the original storage column 105. However, the removed storage container 106 can alternatively be relocated to another storage column 105.

[0018] When a storage container 106 is to be stored in a row 105, a container handling vehicle 201 is instructed to pick up the storage container 106 from a port 120' of the port row 120, which transfers the storage container from the access station or transfer station and transports it to the location where the storage container is to be stored above the storage row 105. After removing any storage containers at or above the target location within the storage row stack 107, the container handling vehicle 201 positions the storage container 106 at the desired location. The removed storage container 106 can then be lowered back into the storage row 105 or relocated to another storage row.

[0019] The position of each storage container 106 within the frame structure 100 and the corresponding access station (e.g., a pick station), as well as the position and movement of each container handling vehicle 201 operating on the storage and retrieval system, are continuously monitored and controlled by the automated storage and retrieval system control system (i.e., the ASRS control system). The product stored in each storage container 106 is kept up to date by the warehouse management system. This ensures that the desired storage container 106 can be delivered to the designated access station at the desired time without the container handling vehicles 201 colliding with each other.

[0020] The automated storage and retrieval system 1 is typically operated by a plurality of container handling vehicles 201 that transfer storage containers from one location to another. Larger storage and retrieval systems may consist of several hundred container handling vehicles 201, each of which is assigned and given a task by receiving instructions transmitted via the communication module 500 of the ASRS control system. A task may, for example, be to retrieve a specific storage container 106 from the storage row 105 where the specific storage container is located, follow a route by driving a set distance in a set direction, and deliver the storage container 106 at a port 119' for further transport to a pickup station.

[0021] A conveyor system including conveyors and / or rail systems may be used to transport the storage containers 106 between the port 119 ′ and the picking station of the automated storage and retrieval system 1 .

[0022] The delivery vehicle may be arranged to receive the storage container from above when the storage container is placed under the transfer column and to transport the storage container to a picking station.

[0023] Picking up products from the storage container 106 in the picking station can be performed manually by one or more people and / or automatically by one or more robotic picking devices. The robotic picking device can be a robot or industrial robot mounted on a frame. The robotic picking device can be separated from the delivery vehicle carrying the storage container and operate independently. In this embodiment, the system can include a section of a track-based conveyor system having vertical guides in the X and Y directions for supporting a delivery vehicle carrying a container accessible from above. The delivery vehicle can move freely in the X and Y directions on the conveyor system within the picking station so that the products in the storage container can be approached for picking, as shown in NO 20191511.

[0024] Instead of a transport vehicle operating on a conveyor rail system, the picking system may include a conveyor device for transferring the container to the picking station. The conveyor device may be arranged at different heights and presented to the robotic picking device in the form of a multi-layer conveyor device. In yet another alternative, instead of a transport vehicle and / or conveyor, the storage container may be transported to the picking station by a container handling vehicle of the prior art, which includes a lifting device for transporting the storage container, for example, raising the storage container from a storage column and lowering the storage container into a storage column, and transporting the storage container horizontally to the picking station. The picking station may include tracks in the X and Y directions that are flush with the tracks in the X and Y directions of the storage and retrieval system so that the container handling vehicle can enter the picking station on the same track system. In this alternative, the container handling vehicle can lower the storage container to a position within the picking station that is below the track system so that the robotic picking device can access the contents of the storage container.

[0025] The picking system may also include a conveyor for transferring the containers away from the picking station.

[0026] The products to be picked arrive at the picking station in storage containers 106 according to the order. An order typically includes a list of different products stored in different storage containers 106. How the picking is performed at the picking station, that is, from which storage containers 106 and in what order, will determine how quickly and efficiently the picking of the order can be performed.

[0027] US 2018 / 218469A1 describes a system for picking goods, and more specifically, a system and method for providing proxy picking of non-fungible goods within an automated storage and retrieval system, which repurposes one or more autonomous mobile robots operating within an automated inventory management system to perform multiple tasks across multiple different areas of the automated storage system. The proxy picking system and method are configured to pick individually identified non-fungible goods based on measured attributes and images of the goods, the attributes selected by the customer, according to the customer's selection on an ordering screen.

[0028] The present invention describes a method and picking system that provides optimal throughput of ordered products through a picking station operated by a robotic picking device. This is achieved by determining which products to pick from which storage containers and in what order, and in which consolidation containers the products are placed. Summary of the Invention

[0029] The present invention is set forth and characterized in the independent claim, while the dependent claims describe further characteristics of the invention.

[0030] The present invention addresses the control of a pickup device at a pickup station for picking up products stored in storage containers in an automated storage and retrieval system. The storage containers to be picked up are transported from the automated storage and retrieval system to the pickup station. The pickup station is controlled by a pickup system controller.

[0031] The picking station includes an area divided into sub-areas, which include a picking zone. The picking zone is the location for the storage container to pick up the product from and the location for the container to place the product in. The container for placing the picked product is often called a consolidation container.

[0032] More specifically, the present invention describes a method for increasing the throughput of ordered products picked from storage containers according to product orders by determining the fastest and most efficient way to pick the products.

[0033] The method is defined by picking products from at least one storage container in a picking zone of a picking station of an automated storage and retrieval system, wherein the picking is controlled by a picking system controller that communicates with a warehouse management system, and wherein the picking is performed by a picking device in the picking zone by placing the picked products in one or more consolidation containers according to an order. The picking system controller is adapted to control the picking device and the picking station to perform the method comprising the following steps:

[0034] a) Receive product orders and sort them in the warehouse management system,

[0035] b) moving the storage container with the ordered product toward the pickup area via the transport system according to the sequencing of the product order;

[0036] c) checking which storage containers are available and ready to be picked up from the picking station and which storage containers and consolidation containers will be available within a time frame, and determining a current position of the picking device relative to the position of the at least one storage container ready to be picked up and the consolidation container ready to receive the picked product;

[0037] d) establishing a different picking sequence for fulfilling each product order from the sequenced product orders, each picking sequence listing products to be picked from the storage container and in which consolidation containers the products are to be placed within a time frame, wherein each picking sequence is established by estimating:

[0038] - the shortest travel distance for moving the picking device to pick up from one storage container to pick up from another storage container;

[0039] - Complete the picking of products from storage containers in the picking station as quickly as possible so that new storage containers can enter the picking area of ​​the picking station;

[0040] -Complete the consolidation container as quickly as possible so that it can be replaced with a new consolidation container;

[0041] e) sorting the picking order and selecting a picking order that provides the highest throughput of picked products based on the sorted product orders;

[0042] f) performing picking of the product by causing the picking system controller to control the picking device to pick the product from the storage container and place it in the consolidation container within a time range according to the selected picking sequence;

[0043] g) Repeat steps a) to f) above.

[0044] According to the above steps, the picking sequence established will have different execution times because the picking device will have different movement patterns to and from the storage containers and the consolidation containers depending on their positions in the picking area of ​​the picking station and when the products listed in the product order are ready to be picked up in the picking station.

[0045] According to one embodiment of the method, product orders with high priority are ranked higher than other orders.

[0046] According to one embodiment of the method, the picking sequence is further established by estimating the arrival time of the next storage container entering the picking station and its position in the picking station. The next storage container entering the picking station may, for example, store the products required to complete the picking order.

[0047] According to another embodiment of the method, the picking sequence is further established by checking whether there are identical products listed in different product orders for consecutive picking of the identical products.

[0048] According to one embodiment of the method, the picking sequence is further established by checking whether the different products listed in the product order are stored in storage containers located close to each other in the picking area.

[0049] According to another embodiment of the method, the picking sequence is further established by prioritizing the completion of product orders having only a small amount of remaining product to be picked.

[0050] According to another embodiment of the method, the picking sequence is further established by estimating the arrival time of the next storage container into the picking zone and its position in the picking zone.

[0051] According to one embodiment of the method, picking from a storage container with less remaining product is prioritized over picking from a storage container with more product to allow new storage containers to enter the picking station. This will increase the throughput of the storage containers in the picking station.

[0052] According to one embodiment of the method, the buffer container is used to temporarily store product from a storage container when little product is left in order to change the storage container more quickly. The buffer container is placed so that it is accessible to a picking device.

[0053] According to one embodiment of the method, camera vision is used to determine the position of the product in the picking area. This is used to identify the location of a specific product in a specific storage container and accurately control the picking device to pick up the product in the storage container and place it in a specific consolidation container.

[0054] According to one embodiment of the method, the storage containers and / or consolidating containers in the picking station are rearranged to minimize the travel distance for the picking device. This is particularly advantageous when, for example, one or more storage containers contain several products that are listed in sequence. By placing the storage containers closer together, the time required to complete the picking of the products according to the order is reduced.

[0055] The present invention is further defined by a picking station of an automated storage and retrieval system, wherein the picking station is controlled by a picking system controller that communicates with a warehouse management system, and wherein picking is performed by a picking device that places the picked products in one or more consolidation containers according to an order, wherein the picking system controller is adapted to control the picking device and the picking station to perform the above-described method.

[0056] The invention is further defined by a computer program product which, when executed by a processor in a picking system controller, controls a picking station of an automated storage and retrieval system to perform picking of products from a storage container according to the method described above. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] The following drawings are provided to facilitate understanding of the present invention. The drawings illustrate embodiments of the present invention which will now be described by way of example only, in which:

[0058] FIG1 is a perspective view of a frame structure of an automatic storage and retrieval system of the prior art;

[0059] Figure 2 An example of a picking system arranged on a ground floor is shown, wherein the picking station comprises a double-layer conveyor for moving containers;

[0060] Figure 3 An exemplary picking system arranged on a mezzanine is shown, wherein the picking station includes a track system for moving containers;

[0061] Figure 4 Shown is a pickup system controller and connected systems for a pickup device;

[0062] Figure 5 is a flow chart showing the different steps of the picking method.

[0063] Reference Number List

[0064] 1-Automatic storage and retrieval system

[0065] 100-frame structure

[0066] 102-Upright members of frame structure

[0067] 103-Horizontal members of frame structures

[0068] 104-Storage Grid

[0069] 105-Storage Row

[0070] 106-Storage Container

[0071] 106' - Storage container location

[0072] 107-Stacking

[0073] 108-Top Rail System

[0074] 110-parallel tracks in the first direction (X)

[0075] 110a - first track in the first direction (X)

[0076] 110b - second track in the first direction (X)

[0077] 111-parallel tracks in the second direction (Y)

[0078] 111a-first track in the second direction (Y)

[0079] 111b-second track in the second direction (Y)

[0080] 112-Entrance and Exit

[0081] 119-First port column

[0082] 119'-First Port

[0083] 120 Second port column

[0084] 120'-Second Port

[0085] 201-Container handling vehicle

[0086] 400-Pickup System

[0087] 401-Pickup System Controller (PSC)

[0088] 402-Warehouse Management System (WMS)

[0089] 403-Automated Storage and Retrieval System (ASRS)

[0090] 405-Pickup device

[0091] 407-Vision System

[0092] 408-Container Contents Handling Location

[0093] 410-Pickup Station

[0094] 411-Upper Teleporter

[0095] 412-lower teleporter

[0096] 413-Gantry for robotic picking device

[0097] 414-Gate mount for camera

[0098] 415-Protective cover

[0099] 419-Pickup station protective cover

[0100] 425-Mezzanine

[0101] 500-Control System

[0102] X-first direction

[0103] Y-second direction

[0104] Z-third direction DETAILED DESCRIPTION

[0105] In the following description, the invention will be explained in more detail, by way of example only, and with reference to the accompanying drawings. It should be understood, however, that the drawings are not intended to limit the invention to the subject matter depicted in the drawings.

[0106] A typical prior art automated storage and retrieval system 1 having a frame structure 100 is described with reference to FIG. 1 in the background section above.

[0107] The frame structure 100 can be of any size, and it should be understood that it can be much wider and / or longer and / or deeper than the frame structure disclosed in Figure 1, for example, the frame structure 100 can have a horizontal range of storage columns 105 exceeding 700×700 and a storage depth for storing more than eight stacked storage containers 106, and wherein the storage containers 106 are handled by hundreds of container handling vehicles 201 operating on a rail system 108.

[0108] Furthermore, the storage grid 104 may be much deeper than disclosed in Figure 1. For example, the storage grid 104 may be deeper than eight grid cells 122, ie, in the Z direction indicated in Figure 1 .

[0109] Figure 2 An example of a picking system 400 is shown, which comprises a picking station 410 arranged on the ground floor, i.e. at the lower part of the connected automated storage and retrieval system 1, and wherein the picking station 410 comprises a double-layer conveyor 411, 412 for bringing storage containers 106 into and out of the picking station 410. The picking station 410 comprises a picking area at which storage containers and consolidating containers are within reach of one or more picking devices 405.

[0110] In this example, there are a total of eight container content transfer locations 408 on the conveyors 411, 412 of the pick station 410. Storage containers 106 are shown occupying three of the container content transfer locations 408, while the remaining five container content transfer locations 408 on the conveyors 411, 412 are unoccupied.

[0111] In the disclosed embodiment, the picking station 410 includes dual-layer conveyors 411, 412 for conveying storage containers 106 between a location within the automated storage and retrieval system 1 and a container handling location 408. The dual-layer conveyors 411, 412 are illustrated as an upper conveyor 411 and a lower conveyor 412. The lower conveyor 412 extends relative to the upper conveyor 411 at the picking end by a distance at least equal to the size of one storage container 106. Similarly, although not shown in the figures, in order to enable storage containers 106 to be placed on and retrieved from the conveyors 411, 412, the lower conveyor 412 extends relative to the upper conveyor 411 on the opposite end of the conveyors 411, 412 at the loading end by a distance at least equal to the size of one storage container 106. In the disclosed example, the robotic picking device 405 is disposed on a gantry apparatus 413, and the camera 407 is movably disposed on a separate gantry 414 above the gantry apparatus 413 for the robotic picking device 405. Although a gantry apparatus 413 is described herein, other mechanisms for moving the camera around over a storage container being picked are also contemplated.

[0112] In operation, the container content transfer locations 408 on the upper conveyor 411 can be used for picking, while the container content transfer locations 408 on the lower conveyor 412 can be used to consolidate picking orders. However, the arrangement of the container content transfer locations 408 for picking and consolidation can be varied to suit different needs. For example, if more container content transfer locations 408 are required for picking or consolidation, this can be easily arranged. While the exemplary embodiment includes eight conveyors 411, 412, other devices for transporting storage containers 106 to and from the picking device 405 are contemplated.

[0113] The protective panel 415 may be used to provide a physical barrier to the storage and retrieval system 1 so that an operator may safely perform manual repairs or maintenance in the picking station 410 .

[0114] Figure 3Another example of a picking system disposed on mezzanine 425 is shown. Picking station 410 includes a rail system for moving storage containers 106. The rail system in picking station 410 is flush with the top rail system 108 of the automated storage and retrieval system 1 operated by container handling vehicles 201, enabling the container handling vehicles to transport storage containers 106 directly from the automated storage and retrieval system 1 to a stationary container contents transfer location disposed horizontally below the rail system of the picking station. In this example, container handling vehicles 201 are disclosed as delivering and / or picking up storage containers 108 from the container contents transfer location below the rail system 108 within picking station 410, enabling robotic picking devices 405 to access the contents of storage containers 106. Cameras 407 and robotic picking devices 405 are disclosed as being mounted on gantries 414 and 413, respectively. Camera 407 is movable and can generate images of the contents of storage containers 106 placed at any container contents transfer location 408 in picking station 410.

[0115] To increase the safety of any operator, a pick station protective cover 419 may be disposed around the exterior of the pick station 410 and the protective panel 415 .

[0116] Figure 4 The figure shows a picking system controller 401 and connected systems of a picking device 405. A picking station 410 is controlled by the picking system controller 401, which is connected to the picking device 405 for controlling the picking device 405. The picking system controller 401 is further connected to an automated storage and retrieval system (ASRS) control system 403 and a warehouse management system (WMS) 402 for exchanging information about storage containers entering the picking station and products to be picked.

[0117] For larger storage and retrieval systems 1, high order activity is expected and the delivery of storage containers 106 to be picked from the picking stations 410 will be performed at a high rate. To avoid queues at the picking stations, it is important that the picking is performed in an optimal manner to achieve a high throughput of containers, i.e., storage containers 106 and consolidation containers.

[0118] Figure 51 is a flow chart illustrating the different steps of a picking method 500 for picking products from at least one storage container 106 in a picking station 410, which comprises a picking zone of an automated storage and retrieval system 1, according to an embodiment of the present invention. Picking is controlled by a picking system controller 401, which communicates with a warehouse management system (WMS) 402, and is performed by a picking device 405 in the picking zone by placing the picked products in one or more consolidation containers according to an order. The picking system controller 401 is adapted to control the picking device 405 and the picking station 410 according to the method of the present invention.

[0119] The completed consolidated container will be moved from the picking station to another area where its contents are further processed, such as being sorted and prepared for shipping.

[0120] The first step 510 of the method is to receive and sequence a product order in the warehouse management system 402. An order typically includes a list of several different products to be shipped to a recipient after being picked and placed together in one or more consolidation containers.

[0121] Orders are typically sorted based on the time they were received and / or based on their priority. The purpose of sorting is to determine which storage containers 106 are first transferred to the picking station 410. Typically, orders are processed, sorted, and fulfilled sequentially as they are received. However, if an order is marked as high priority, it may be sorted and fulfilled first.

[0122] The next step 520 is to move the storage container 106 with the ordered products to the picking station 410 and into the picking area according to the order. This is performed by a transport system that brings the storage container to the picking device 405. As described above, the movement of the storage container 106 between the automated storage and retrieval system 1 and the picking station 210 can be performed by Figure 2 and Figure 3 This is performed by the conveyor and / or container handling vehicle 201 shown by way of example.

[0123] Other means for moving the storage containers 106 between the automated storage and retrieval system 1 and the picking station 210 are contemplated, such as a rotating conveyor belt arrangement or a dedicated transport vehicle. The transport vehicle can move freely on a rail system arranged below the automated storage and retrieval system 1. In this embodiment, the same rail system will be run from the automated storage and retrieval system 1, for example from a position below the transport column of the automated storage and retrieval system 1, into the picking station 410, thereby becoming part of the picking station 410. By having a rail system in the picking station that is constructed similarly to the rail system described previously, i.e., the rail system 108 is arranged across the top of the frame structure 100, the position of the transport vehicle, and therefore the position of the storage container, can be easily rearranged on the rail system within the picking station 410.

[0124] A conveying system is envisioned in combination with the above-mentioned transfer device for moving the storage container 106 to the picking station 410, for example, transporting the storage container 106 from the storage and retrieval system 1 to a conveyor that moves the storage container 106 to a rotating conveyor before transferring from the conveyor belt to the picking station 410.

[0125] The picking station 410 may have its own transport system, or the transport system within the picking station 410 may be part of a transport system that transports the storage container 106 from the storage and retrieval system 1 to the picking station 410, e.g. Figure 2 and Figure 3 A conveyor and container handling vehicle 201 are shown.

[0126] The next step 530 is to check which storage containers 106 are currently available and ready to be picked up in the picking station 410 and which storage containers 106 and consolidation containers will be available within a time frame (e.g., the next 10 seconds), and to determine 540 the current position of the picking device 405 relative to the position of the at least one storage container 106 ready to be picked up and the consolidation container ready to receive the picked product. The size of the time frame can be adjusted and set according to the size of the storage and retrieval system, the number of containers that can be fitted in the picking area, the number of operating picking devices 405, etc.

[0127] Detect and determine which storage container 106 has arrived at the picking station and its position can be completed in several ways.When storage container 106 is transported to the picking station 210 by above-mentioned delivery vehicle, the position of each delivery vehicle on the track system in the picking station is known by the control system of control delivery vehicle.

[0128] When a storage container 106 is transported to a pickup station 210, its relative position can be determined using a visual device, such as a camera, that captures an image of the storage container and its stored products within the pickup station. The captured image can be used to optimize the container's position and help optimize product pickup. An RFID tag unique to each storage container 106 can also be read to confirm the identity of the container at the pickup station 410.

[0129] The next step 550 is to establish a different picking sequence for fulfilling each product order from the sequenced product orders, where each picking sequence lists the products to be picked from the storage container 106 and in which consolidation containers the products are to be placed within a time frame.

[0130] Each picking sequence is established by estimating parameters that facilitate efficient picking, such as by keeping the picking device 405 in constant operation with a minimum travel distance from one picking operation to another.

[0131] The first estimated parameter is the shortest travel distance for moving the picking device 405 from one storage container 106 to another. As an example, assume that within the same timeframe, several storage containers 106 are currently available from which products are to be picked based on product lists in different orders. Two orders list several identical products to be picked and placed in corresponding consolidation containers positioned adjacent to one another. By estimating a picking sequence that sequentially picks these identical products, it is expected that the travel distance of the picking device 407 will be minimized, thereby providing efficient picking. The same applies if different products listed in different product orders are stored in storage containers 106 positioned close to one another in the picking zone. These can then be listed consecutively in the picking sequence.

[0132] The second estimated parameter is the fastest completion of picking products from storage containers 106 in the pick stations 410, which are listed in the order that allows new storage containers 106 to enter the pick zone. If, for example, one or two products are being picked to complete an order, these products will be processed first. In addition to freeing up space in the pick station, a new consolidation container can replace a completed consolidation container containing all products according to the order.

[0133] The third estimation parameter is the fastest completion of placing an order in a consolidation container so that it can be replaced with a new consolidation container. For example, if a consolidation container only needs one or two or more products to complete an order, then completing placing the products in this consolidation container will allow the consolidation container to be replaced by another consolidation container.

[0134] The next step 560 of the method is to sort the established picking sequences and prioritize the picking sequences based on the ordered product orders, thereby providing a higher throughput of picked products. Different picking sequences established from the above steps will have different execution times for completing the picking of different orders and for completing the picking from the storage container 106 and placing the products in the consolidation container. These are all factors that contribute to the throughput of storage containers and products at the picking station. The first-ranked picking sequence will generally be the picking sequence that provides the highest throughput.

[0135] The last step 570 is to perform the picking of the products by causing the picking system controller 401 to control the picking device 405 to pick the products from the storage container 106 and place them in the consolidation container according to the selected picking sequence within a time range.

[0136] The above steps are repeated for consecutive time ranges. The effect of the described method is that the picking device 405 will be occupied with picking and have a minimum waiting time or elapsed time to move between different storage containers to complete picking from the storage container 106 and placing the product in the consolidation container.

[0137] According to one embodiment of the present invention, the picking sequence is further established by estimating the arrival time of the next storage container 106 entering the picking zone and its position in the picking zone. Like this, a new picking sequence can be established by including the next storage container before the next storage container 106 arrives in the picking zone.

[0138] According to one embodiment of the present invention, completing a pick from a storage container 106 with fewer remaining products takes precedence over picking from a storage container 106 with more products to allow a new storage container 106 to enter the picking station 410. If, for example, a storage container only has two or three products left, completing a pick from that storage container will allow another storage container to replace it.

[0139] According to one embodiment of the invention, the buffer container is used to temporarily store products from the storage container 106 while only a small amount of product is left in order to more quickly replace the storage container 106. The buffer container will then typically hold different products that are not included in the orders in the current time frame.

[0140] According to one embodiment of the present invention, an image processing system is used to determine where the product to be picked is placed in a particular storage container 106. A vision system 407 including camera vision can be used to determine the location of the storage containers and consolidation containers in the picking station and the location of the products within the storage container 106. The image information is then used as input to the picking system controller 401 that controls the picking device 405.

[0141] According to one embodiment of the present invention, the positions of the storage containers 106 and / or consolidating containers in the picking station 410 are rearranged to provide a minimum travel distance for the picking device 405. As described above, a transport vehicle that transports the storage containers 106 can be used to rearrange the positions of the storage containers 106 in the picking station, wherein the storage containers can be freely moved in the X and Y directions on the conveyor system in the picking station. Conveyor equipment for rearranging the storage containers 106 in the picking station is also feasible.

[0142] The invention is further defined by a computer program product which, when executed by a processor in a picking system controller 401 controlling a picking station 410 of an automated storage and retrieval system 1 , performs the above-described method.

[0143] The present invention is further defined by a picking station 410 of the automated storage and retrieval system 1, wherein the picking station 410 is controlled by a picking system controller 401 in communication with a warehouse management system 402, and wherein picking is performed by a picking device 405 that places the picked products in one or more consolidation containers according to an order, wherein the picking system controller 401 is adapted to control the picking device 405 and the picking station 410 to perform the method according to the above method. Figure 2 and Figure 3 An example of a picking station is described.The operation of the picking device 405 is controlled by the picking system controller 401 when implementing a computer program comprising instructions for performing the above-described method.

[0144] The position of the storage container in the picking station can be rearranged. This is advantageous because each position for a storage container in the picking station may require a different number of picks.

[0145] The picking system controller 401 will optimize the operation of the picking device 405 by selecting the optimal order of picking tasks, which corresponds to the order that gives the minimum total physical distance the picker needs to move or the minimum calculated weighted transportation cost based on the current configuration of the picking station, which minimum calculated weighted transportation cost is, for example, the number of storage containers in the picking station and the number of consolidation containers into which the products are placed.

[0146] The present invention described above provides an overall throughput of a picking system that is optimized by dynamically weighting different strategies based on which factors will limit the picking operation.

[0147] In the foregoing description, various aspects of the operation of the pickup station and examples of the pickup station have been described with reference to illustrative embodiments. For the purpose of explanation, specific numbers, systems, and configurations have been set forth to provide a full understanding of the system and its work. However, this specification is not intended to be interpreted in a restrictive sense. Various modifications and variations of the illustrative embodiments that are obvious to those skilled in the art of the disclosed subject matter and other embodiments of the method and system are considered to fall within the scope of the present invention.

Claims

1. A method of picking a product from at least one storage container (106) in a picking zone of a picking station (410) of an automated storage and retrieval system (1), wherein: Picking is controlled by a picking system controller (401) in communication with a warehouse management system (WMS) (402), and wherein picking is performed by a picking device (405) in the picking zone by placing the picked products in one or more consolidation containers according to the order, wherein the picking system controller (401) is adapted to control the picking device (405) and the picking station (410) to perform the method, the method comprising: a) receiving product orders and sorting the product orders in the warehouse management system (402), b) moving the storage container (106) with the ordered products toward the pickup area by a transport system according to the sequencing of the product orders, c) checking which storage containers (106) are available and ready to be picked up from the picking station (410) within a timeframe, and which storage containers (106) and consolidation containers will be available, and determining a current position of the picking device (405) relative to the position of at least one storage container (106) ready to be picked up and the position of the consolidation container ready to receive the picked product; d) establishing a different picking sequence for fulfilling each product order from the sequenced product orders, each picking sequence listing products to be picked from the storage container (106) and in which consolidation containers the products are to be placed within the time frame, wherein each picking sequence is established by estimating: - a shortest travel distance for moving the picking device (405) to pick up from one storage container (106) to pick up from another storage container (106); - completing the picking up of the storage container (106) from the picking station (410) as quickly as possible so that a new storage container (106) can enter the picking area of ​​the picking station (410); - completing the replacement of the consolidation container with a new consolidation container as quickly as possible; e) sorting the picking sequences and selecting a picking sequence that provides a higher throughput of picked products based on the sorted product orders; f) performing product picking by causing the picking system controller (401) to control the picking device (405) to pick products from the storage container (106) according to the selected picking sequence within the time range and place the products in the consolidation container; and g) Repeat steps a) to f) above.

2. The method according to claim 1, wherein Product orders with high priority are ranked higher than other orders.

3. The method according to claim 1 or 2, wherein The picking sequence is further established by estimating the arrival time of the next storage container (106) entering the picking station (410) and the position of the next storage container in the picking station (410).

4. The method according to claim 1 or 2, wherein: The picking sequence is further established by checking whether there is the same product listed in different product orders for consecutive picking of the same product.

5. The method according to claim 1 or 2, wherein: The picking sequence is further established by checking whether the different products listed in the product order are stored in storage containers located close to each other in the picking area.

6. The method according to claim 1 or 2, wherein: The picking order is further established by prioritizing the completion of product orders that have only a small amount of product remaining to be picked.

7. The method according to claim 1 or 2, wherein: The picking sequence is further established by estimating the arrival time of the next storage container (106) into the picking zone and the position of the next storage container in the picking zone.

8. The method according to claim 1 or 2, wherein: Picking from storage containers (106) with less remaining product is completed in priority over picking from storage containers (106) with more product to allow new storage containers (106) to enter the picking station (410).

9. The method according to claim 1 or 2, wherein: The buffer container is used to temporarily store product from a storage container (106) with little product left, in order to allow for faster replacement of said storage container (106).

10. The method according to claim 1 or 2, wherein: Camera vision is used to determine where an identified product to be picked is located in a given one of the storage containers (106).

11. The method according to claim 10, wherein: The picking device (405) is controlled to target the identified product.

12. The method according to claim 1 or 2, wherein: The storage container (106) and / or the consolidation container in the picking station (410) are rearranged to provide a minimum travel distance for the picking device (405).

13. A picking station (410) of an automated storage and retrieval system (1), wherein: The picking station (410) is controlled by a picking system controller (401) that communicates with a warehouse management system (402), and wherein picking is performed by a picking device (405) that places the picked products in one or more consolidation containers according to an order, wherein the picking system controller (401) is suitable for controlling the picking device (405) and the picking station (410) to perform the method according to any one of claims 1 to 12.

14. A computer program product which, when executed by a processor in a picking system controller (401) controlling a picking station (410) of an automated storage and retrieval system (1), causes the picking station (410) to perform the method according to any one of claims 1 to 12.

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