A shuttle picking device integrating storage and sorting

Abstract

This invention provides an integrated storage and sorting shuttle picking device, comprising: parallel storage shelves and picking shelves, both of which are multi-layered structures with the same number of layers; a fixed track fixedly connected between the same layers of the storage shelves and picking shelves; a picking shuttle that travels on the fixed track, with each picking shuttle corresponding to one of the fixed tracks; a power station with a conveyor roller structure, the discharge end of which corresponds to the fixed track; and a bin elevator, the discharge end of which corresponds to the inlet end of the lifting conveyor belt mechanism. This invention utilizes the power station and bin elevator in conjunction with the picking shuttle to pick up bins from the warehouse and move them to the picking position, achieving intelligent goods-to-person picking, which helps improve picking efficiency and accuracy while reducing labor intensity.

Description

Technical Field

[0001] This invention relates to the field of logistics technology, and in particular to an integrated storage and sorting shuttle picking device. Background Technology

[0002] In automotive logistics, material picking is typically used in the final stage before parts enter the production line – the supermarket buffer center. This stage requires accurately picking parts by vehicle within a specified timeframe and delivering them to the production line. Currently, material picking mostly employs the traditional "person-to-goods" picking method. Pickers need to repeatedly find, retrieve, and place parts based on the part information in the picking list, while also verifying information. This "person-to-goods" picking method requires a large number of pickers and suffers from pain points such as low picking efficiency, high risk of errors and omissions, and high labor intensity, which need to be addressed. Summary of the Invention

[0003] This invention provides an integrated storage and sorting shuttle picking device. Through the cooperation of a power station and a material box elevator, the picking shuttle clamps and picks up the material box from the warehouse to the picking position, realizing intelligent picking from goods to people. This helps to improve picking efficiency and accuracy, and reduce the labor intensity of personnel.

[0004] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows:

[0005] A storage and sorting integrated shuttle picking device includes:

[0006] The storage racks and picking racks are arranged side by side, both of which are multi-layer rack structures and have the same number of layers.

[0007] Fixed rails are fixedly connected between the same layers of the storage rack and the picking rack;

[0008] The picking shuttle car travels on the fixed track.

[0009] The power station is a conveyor roller structure, which has multiple layers, and the discharge end of the power station corresponds to the fixed track.

[0010] A bin elevator, wherein the discharge end of the lifting conveyor belt mechanism of the bin elevator corresponds to the inlet end of the power station;

[0011] The material inlet conveyor belt has its discharge end corresponding to the material inlet end of the lifting conveyor belt mechanism of the material box elevator.

[0012] Optionally, the power station, the material box elevator, and the warehouse conveyor are each provided in two sets, and the fixed track extends to the same-level station of the two sets of power stations to form a connecting platform.

[0013] Optionally, the first to third layers of the picking rack are picking positions, and the remaining upper layers of the picking rack are storage positions.

[0014] Optionally, both the picking rack and the storage rack have double-extension storage positions.

[0015] Optionally, the picking position includes:

[0016] The first picking station is located in the middle of the entire picking rack;

[0017] The second picking station is located on both sides of the first picking station;

[0018] An emergency picking station is located in the middle of the first picking station, and the structure of the emergency picking station is the same as that of the first picking station.

[0019] Optionally, the end of the first picking position away from the fixed track is formed with a first picking front end, and the end of the first picking front end away from the first picking position is inclined downward and provided with a baffle.

[0020] The end of the second picking position away from the fixed track is formed with a second picking front end, and the end of the second picking front end away from the second picking position is inclined downward and provided with a baffle.

[0021] Optionally, the integrated storage and sorting shuttle picking equipment further includes:

[0022] A flow bar mechanism that extends from the first picking position to the first picking front end;

[0023] A bidirectional conveyor belt mechanism that extends from the second picking position to the second picking front end.

[0024] Optionally, the storage spaces on the first to third layers of the storage rack store components with low usage, while the storage spaces on the remaining upper layers of the storage rack and the storage spaces on the upper layers of the picking rack store components with high usage.

[0025] Optionally, a picking shuttle is provided on each of the fixed tracks.

[0026] Optionally, at least two layers of the fixed rails share a single picking shuttle, and a shuttle lift is provided between adjacent fixed rails to drive the picking shuttle to move up and down to change layers.

[0027] The above-described solution of the present invention has at least the following beneficial effects:

[0028] The above-described solution of the present invention, by setting up parallel distributed storage shelves and picking shelves, both of which are multi-layered structures with the same number of layers; a fixed track, fixedly connected between the same layers of the storage shelves and picking shelves; a picking shuttle, which travels on the fixed track; a power station, which is a conveyor roller structure, with multiple layers, and the discharge end of the power station corresponding to the fixed track; a bin elevator, with the discharge end of the lifting conveyor belt mechanism of the bin elevator corresponding to the inlet end of the power station; and an inbound conveyor belt, with the discharge end of the inbound conveyor belt corresponding to the inlet end of the lifting conveyor belt mechanism of the bin elevator; and by using the power station and bin elevator in conjunction with the picking shuttle to pick up bins from the warehouse and transport them to the picking position, intelligent goods-to-person picking is achieved, which helps to improve picking efficiency and accuracy, and reduce the labor intensity of personnel. Attached Figure Description

[0029] Figure 1 This is a top view of the integrated storage and sorting shuttle picking equipment provided in an embodiment of the present invention;

[0030] Figure 2 This is a front view of the picking rack in the integrated storage and sorting shuttle picking equipment provided in an embodiment of the present invention;

[0031] Figure 3 This is a right view of the first picking position in the integrated storage and sorting shuttle picking device provided in an embodiment of the present invention;

[0032] Figure 4 This is a left view of the second picking position in the integrated storage and sorting shuttle picking device provided in an embodiment of the present invention;

[0033] Figure 5 This is a schematic diagram of the picking list clustering of the integrated storage and distribution shuttle picking equipment provided in the embodiments of the present invention;

[0034] Figure 6 This is a flowchart of the clustering algorithm for the picking list of the integrated storage and sorting shuttle picking equipment provided in the embodiments of the present invention.

[0035] The annotations in the attached figures are explained as follows:

[0036] 1. Picking rack; 2. Storage rack; 3. Picking shuttle; 4. Fixed track; 5. Connecting platform; 6. Power station; 7. Tobacco box elevator; 8. Inbound conveyor belt; 9. Storage location; 10. Second picking location; 11. First picking location; 12. Emergency picking location; 13. Second picking front end; 14. Flow rack mechanism; 15. Two-way conveyor belt mechanism; 16. First picking front end. Detailed Implementation

[0037] Exemplary embodiments of the invention will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the invention are shown in the drawings, it should be understood that the invention may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this invention will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

[0038] like Figures 1-4 As shown, an embodiment of the present invention proposes an integrated storage and sorting shuttle picking device, comprising:

[0039] Storage rack 2 and picking rack 1 are arranged side by side. Both storage rack 2 and picking rack 1 are multi-layer rack structures, and the number of layers of storage rack 2 and picking rack 1 is the same.

[0040] Fixed track 4 is fixedly connected between the storage rack 2 and the picking rack 1 on the same level;

[0041] The picking shuttle 3 travels on a fixed track 4;

[0042] The power station 6 is a conveyor roller structure. The power station 6 has multiple layers, and the discharge end of the power station 6 corresponds to the fixed track 4.

[0043] The discharge end of the lifting conveyor belt mechanism of the material box elevator 7 corresponds to the inlet end of the power station 6;

[0044] The discharge end of the inbound conveyor belt 8 corresponds to the feed end of the lifting conveyor belt mechanism of the material box elevator 7.

[0045] In this embodiment, such as Figure 1 The material boxes that need to be stored are transported to the lifting conveyor belt mechanism of the material box elevator 7 via the inbound conveyor belt 8. The material box elevator 7 works, causing the material boxes to rise and fall with the lifting conveyor belt mechanism. The lifting conveyor belt mechanism transports the material boxes to the power station 6 corresponding to the target layer. The picking shuttle 3 of the target layer grabs the material box on the power station 6, moves on the fixed track 4, and places the material box in the storage position 9 of the target storage shelf 2, thus completing the inbound storage of the material box.

[0046] The picking shuttle 3 receives the picking task from the control system, grabs the material box stored in the storage rack 2, moves it on the fixed track 4, and places the material box in the picking position of the picking rack 1, realizing the same-level movement of the material box between the storage rack 2 and the picking rack 1.

[0047] The picking shuttle 3 picks up the boxes stored on the storage rack and moves them on the fixed track 4, placing the boxes on the power station 6. The power station 6 is a conveyor roller structure that can transport the boxes to the lifting conveyor belt mechanism of the box elevator 7. The box elevator 7 works, causing the boxes to rise and fall with the lifting conveyor belt mechanism. The lifting conveyor belt mechanism transports the boxes to the power station 6 corresponding to the target layer. The picking shuttle 3 on the target layer picks up the boxes on the power station 6 and moves them on the fixed track 4, placing the boxes at the picking position of the target picking rack 1, thus realizing the movement of the boxes between different layers of the storage rack 2 and the picking rack 1.

[0048] Picking order clustering rules for picking equipment: The system collects picking orders in the order they are put into service, such as... Figure 5 a) Based on the similarity of the parts contained in the picking orders, apply algorithms such as genetic algorithms or K-Means to cluster similar picking orders into one class, such as... Figure 5 b. Enable similar picking orders to be picked together, reduce the number of times the picking shuttle needs to be moved, and improve picking efficiency;

[0049] like Figure 6 The process of the picking slip clustering algorithm is as follows: The algorithm starts by inputting picking slip information in the order of online input, and checks whether the data is parsed incorrectly. If the data is parsed incorrectly, the process stops and returns an error message. If the data is parsed correctly, the similarity between each pair of picking slips is calculated to obtain the picking slip clustering similarity matrix. The clustering algorithm is then used to cluster the picking slips, and the picking slip clustering results are output. The algorithm then ends.

[0050] Priority rules for picking equipment inbound / outbound / return: When there is an empty picking position, outbound > return > inbound; when there is no empty picking position, return > outbound > inbound; in case of abnormal situations, abnormal situation tasks take priority.

[0051] Replenishment and ordering rules for picking equipment: Empty box pull replenishment, the system automatically deducts the number of parts after picking is completed, and the system automatically orders goods from the front end when an empty box is picked.

[0052] First-in, first-out (FIFO) rule for picking equipment: When parts are received, they are divided into different batches according to their arrival date; when parts are shipped out, they are handled in the order of their batches.

[0053] By using the power station 6 and the bin elevator 7 in conjunction with the picking shuttle 3 to pick up the bins from the warehouse to the picking position, intelligent picking from goods to people is realized, which helps to improve picking efficiency and accuracy and reduce the labor intensity of personnel. At the same time, it maximizes the use of the upper space, improves the space utilization rate, reduces the area occupied by the picking area, and solves problems such as insufficient on-site logistics area and chaotic layout.

[0054] In an optional embodiment of the present invention, two sets of power station 6, material box elevator 7 and warehouse conveyor belt 8 are provided, and fixed track 4 extends to the same level of the two sets of power station 6 to form a connecting platform 5.

[0055] In this embodiment, such as Figure 1 By setting up two sets of power stations 6, a bin elevator 7, and an inbound conveyor belt 8, along with a connecting platform 5, the bin picking and bin storage can be carried out simultaneously, which helps to improve the overall operational reliability and efficiency of the equipment.

[0056] In an optional embodiment of the present invention, the first to third layers of the picking shelf 1 are picking positions, and the remaining upper layers of the picking shelf 1 are storage positions 9.

[0057] In this embodiment, such as Figure 2 The first to third shelves of the picking rack 1 are picking positions. The height of the first to third shelves of the picking rack 1 is within the comfortable height range for picking personnel to stand and work, which can ensure that picking personnel can pick comfortably and smoothly, and help reduce the workload of staff. The remaining upper shelves of the picking rack 1 are storage positions 9, which are used to store material boxes, thereby increasing the overall storage capacity of the equipment. Through the above structural settings, while ensuring smooth picking, the space can be fully utilized and the storage capacity of material boxes can be increased.

[0058] In an optional embodiment of the present invention, both the picking rack 1 and the storage rack 2 have double-extended storage positions 9.

[0059] In this embodiment, such as Figure 3 and Figure 4 Both the picking rack 1 and the storage rack 2 have double-extended storage positions 9, which can further increase the number of storage bins in the overall equipment and make full use of the site space.

[0060] In an optional embodiment of the present invention, the picking position includes:

[0061] The first picking station 11 is located in the middle of the entire picking rack 1;

[0062] The second picking station 10 is located on both sides of the first picking station 11;

[0063] An emergency picking station 12 is located in the middle of the first picking station 11, and the structure of the emergency picking station 12 is the same as that of the first picking station 11.

[0064] In this embodiment, such as Figure 2The central part of the picking rack 1 is designated as the first picking position 11, used for picking parts that are used in large quantities and frequently. The two sides of the first picking position 11 are designated as second picking positions 10, used for picking parts that are used in small quantities and less frequently. In case of emergencies where parts need to be retrieved immediately, the central part of the first picking position 11 is designated as an emergency picking position 12, and the structure of the emergency picking position 12 is the same as that of the first picking position 11, which can meet the needs of timely picking of parts in emergency situations. This layout reduces the movement of picking personnel, helps to improve picking efficiency, and reduces the workload of picking personnel.

[0065] In an optional embodiment of the present invention, a first picking front end 16 is formed at the end of the first picking position 11 away from the fixed track 4, and the end of the first picking front end 16 away from the first picking position 11 is inclined downward and provided with a baffle.

[0066] The end of the second picking position 10 away from the fixed track 4 is formed with a second picking front end 13. The end of the second picking front end 13 away from the second picking position 10 is inclined downward and is provided with a baffle.

[0067] In this embodiment, such as Figure 3 and Figure 4 By setting a first picking front end 16 and a second picking front end 13 with the ends tilted downwards, after the hopper moves to the first picking front end or the second picking front end 13, the opening of the hopper is tilted and fully presented in front of the picking personnel, which makes it easier for the picking personnel to pick parts, helps to improve picking efficiency and reduce the workload of picking personnel.

[0068] In an optional embodiment of the present invention, the picking device further includes:

[0069] The flow rack mechanism 14 extends from the first picking station 11 to the first picking front end 16;

[0070] A bidirectional conveyor belt mechanism 15 extends from the second picking position 10 to the second picking front end 13.

[0071] In this embodiment, such as Figure 3 The first picking position 11 and the first picking front end 16 are mainly used for picking parts that are used in large quantities and frequently. These parts need to be picked multiple times. In order to improve the overall efficiency of the equipment, after the hopper enters the first picking front end 16 through the flow bar mechanism 14, it stays in the first picking front end 16 for picking personnel to pick parts. The hopper does not need to return to the storage position 9 until the parts inside the hopper are picked. The picking personnel take off the empty hopper, and the picking equipment replenishes the hopper to the first picking front end 16.

[0072] like Figure 4The second picking position 10 and the second picking front end 13 are mainly used to pick parts that are used in small quantities and with low frequency. Since the number of these parts picked is small, in order to make full use of the second picking position 10 and the second picking front end 13, the bin needs to be returned to the storage position 9 after one picking is completed. Therefore, the bidirectional conveyor belt mechanism 15 can realize the bidirectional movement of the bin between the second picking position 10 and the second picking front end 13.

[0073] In an optional embodiment of the present invention, the storage positions 9 on the first to third layers of the storage shelf 2 store components with low usage, while the storage positions 9 on the remaining upper layers of the storage shelf 2 and the storage positions 9 on the upper layers of the picking shelf 1 store components with high usage.

[0074] In this embodiment, since the picking positions are set on the first to third layers of the picking rack 1, and the bins of parts with high usage quantity and frequency are always at the first picking front end 16, they do not need to return to the storage position 9. The bins of parts with low usage quantity and frequency need to return to the storage position 9 after one picking. By having the storage positions 9 on the first to third layers of the storage rack 2 store parts with low usage quantity, and the storage positions 9 on the other upper layers of the storage rack 2 and the storage positions 9 on the upper layers of the picking rack 1 store parts with high usage quantity, the movement distance of the picking shuttle 3 to transfer bins of parts with low usage quantity and frequency can be reduced, thereby improving the overall picking efficiency of the equipment.

[0075] In an optional embodiment of the present invention, a picking shuttle 3 is provided on each layer of fixed track 4.

[0076] In this embodiment, based on the actual picking needs of the parts, when the picking pace is fast and the workload is large, picking shuttle cars 3 are arranged on each fixed track 4 to improve picking efficiency.

[0077] In an optional embodiment of the present invention, at least two layers of fixed tracks 4 share a single picking shuttle 3, and a shuttle lift for driving the picking shuttle 3 to move up and down between adjacent layers of fixed tracks 4 is provided.

[0078] In this embodiment, based on the actual picking requirements of the parts and the picking rhythm of the parts, at least two layers of fixed tracks 4 share one picking shuttle 3. The picking shuttle 3 is lifted and lowered between the two layers of fixed tracks 4 by the shuttle lift. Through the above structural arrangement, fewer picking shuttles 3 are used, which can reduce equipment costs while ensuring the picking rhythm.

[0079] Specific examples:

[0080] Warehouse M is a production distribution warehouse for an automotive logistics company. Picking area X is located on a steel platform on the second floor of warehouse M, where the usable height is only 3.5 meters. The original model used three-tiered flow racks to store boxes. Due to the limited logistics space, this often resulted in boxes being piled up haphazardly and creating a chaotic layout. Picking area X uses a "person-to-goods" picking model, requiring parts to be picked individually by vehicle. As the final step before parts are put into service, this step has extremely strict requirements for picking accuracy and time, demanding 6 picking orders to be completed within 5 minutes with 100% accuracy. However, "person-to-goods" order picking requires back-and-forth movement and manual judgment, leading to low picking efficiency, high risk of errors and omissions, high labor intensity, and high labor costs.

[0081] Picking area X contains 87 types of parts, including 35 high-frequency parts and 52 low-frequency parts. All equipment packaging dimensions are below 600mm x 400mm. The hourly usage of parts is 1301.28. The hourly flow rate is 68.31 boxes / hour, and the 4-hour inventory is 275 boxes. Therefore, the required storage locations are 275.

[0082] Based on the usable height of 3.5m in the picking area on the second floor of warehouse M, the automated storage and retrieval system (AS / RS) is designed with 5 layers. Since the dimensions of the equipment in the picking area X are all below 600mm*400mm, the length and width of the shuttle-type picking AS / RS racks are designed to be 600mm and 400mm respectively, with each layer consisting of 5 racks as a group.

[0083] To meet the 4-hour inventory requirements of parts in the X picking area, 8 sets of shelves are designed: 4 sets on the storage side and 4 sets on the picking side, totaling 280 storage locations and 75 picking locations. Since high-frequency parts picking locations are fixed-position, the first picking location has 35 locations. Low-frequency parts are handled based on demand for outbound and return operations; therefore, the number of low-frequency picking locations depends on the maximum number of SKUs that need to be picked out in a single wave. Statistics show that the maximum number of SKUs that need to be picked out in a single wave is 25, hence the second picking location has 25 locations. The remaining shelves are used as emergency picking shelves, with 15 emergency picking locations.

[0084] The original picking area occupied approximately 78.94 m2, while the current picking area occupies 50.4 m2, representing a 36% reduction in area. This maximizes the use of space, increasing the space utilization rate to 93.5%, and resolving issues such as chaotic warehouse layout and difficulties in on-site 5S management.

[0085] Picking orders were clustered in 5-minute intervals, dividing one hour into 12 intervals. The hourly throughput of the picking shuttle depended on the frequency of parts inbound, outbound, and return operations. The parts inbound flow was 68.31 boxes / hour, the high-frequency parts outbound flow was 38.9 boxes / hour, and the sum of the low-frequency parts outbound and return frequencies in a single interval was 100 times / hour.

[0086] Based on the 33-second time taken for the picking shuttle to complete a single box's out / in / return, the total time for the shuttle to complete one hour's worth of work is calculated to be approximately 49.5 minutes. This indicates that, under the worst-case scenario (assuming that the maximum number of SKUs is switched for each wave of low-frequency parts), the total work time for one hour (12 waves) is 2968.75 seconds / 49.5 minutes, which meets the picking efficiency requirement of completing 6 picking orders within 5 minutes.

[0087] In summary, by establishing an integrated storage and sorting shuttle picking system, the upper space is maximized, space utilization is improved, the picking area is reduced, and problems such as insufficient on-site logistics area and chaotic layout are solved. At the same time, "goods-to-person" picking improves picking efficiency, reduces the risk of errors and omissions, and lowers labor intensity and labor costs.

[0088] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A storage and sorting integrated shuttle picking device, characterized in that, include: The storage racks (2) and picking racks (1) are arranged side by side. Both the storage racks (2) and picking racks (1) are multi-layer rack structures, and the storage racks (2) and picking racks (1) have the same number of layers. Fixed track (4) is fixedly connected between the same layer of the storage shelf (2) and the picking shelf (1); The picking shuttle (3) travels on the fixed track (4); The power station (6) is a conveyor roller structure. The power station (6) has multiple layers, and the discharge end of the power station (6) corresponds to the fixed track (4). The discharge end of the lifting conveyor belt mechanism of the material box elevator (7) corresponds to the feed end of the power station (6); The discharge end of the inbound conveyor belt (8) corresponds to the feed end of the lifting conveyor belt mechanism of the material box elevator (7); Among them, the first to third layers of the picking shelf (1) are picking positions, and the remaining upper layers of the picking shelf (1) are storage positions (9). The picking station includes: The first picking station (11) is located in the middle of the entire picking rack (1) and is used to pick parts that are used in large quantities and frequently. The second picking station (10) is set on both sides of the first picking station (11) and is used to pick parts that are used in small quantities and with low frequency of use. An emergency picking station (12) is located in the middle of the first picking station (11), and the structure of the emergency picking station (12) is the same as that of the first picking station (11). Wherein, the end of the first picking position (11) away from the fixed track (4) is formed with a first picking front end (16), and the end of the first picking front end (16) away from the first picking position (11) is inclined downward and provided with a baffle. The end of the second picking position (10) away from the fixed track (4) is formed with a second picking front end (13), and the end of the second picking front end (13) away from the second picking position (10) is inclined downward and provided with a baffle. The flow bar mechanism (14) extends from the first picking position (11) to the first picking front end (16); after the hopper enters the first picking front end (16) through the flow bar mechanism (14), it remains in the first picking front end (16) until the parts inside the hopper are picked. A bidirectional conveyor belt mechanism (15) extends from the second picking position (10) to the second picking front end (13) to enable bidirectional movement of the hopper between the second picking position (10) and the second picking front end (13).

2. The integrated storage and sorting shuttle picking equipment according to claim 1, characterized in that, The power station (6), the material box elevator (7) and the warehouse conveyor belt (8) are each provided in two sets, and the fixed track (4) extends to the same level of the two sets of power stations (6) to form a connecting platform (5).

3. The integrated storage and sorting shuttle picking equipment according to claim 1, characterized in that, The storage positions (9) of both the picking rack (1) and the storage rack (2) are double-extended storage positions.

4. The integrated storage and sorting shuttle picking equipment according to claim 1, characterized in that, The storage positions (9) on the first to third layers of the storage rack (2) store components with low usage, while the storage positions (9) on the remaining upper layers of the storage rack (2) and the storage positions (9) on the upper layer of the picking rack (1) store components with high usage.

5. The integrated storage and sorting shuttle picking equipment according to claim 1, characterized in that, Each layer of the fixed track (4) is equipped with a picking shuttle (3).

6. The integrated storage and sorting shuttle picking equipment according to claim 1, characterized in that, At least two layers of the fixed track (4) share a picking shuttle (3), and a shuttle lift is provided between two adjacent fixed tracks (4) to drive the picking shuttle (3) to lift and change layers.

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