Storage rack for storing at least one storage carrier and method for recording the inventory of a storage rack

Abstract

Storage rack (10) with a plurality of superimposed support columns (12) for supporting storage carriers (20) which can be conveyed by means of an automatic transport device (14), with at least one loading and unloading opening (16) for feeding and unloading the storage carrier (20), wherein an image capture unit (40) is arranged on a top side (18) of the loading and unloading opening (16), characterized in that the storage rack (10) has a lighting device (50) for highlighting an area (21) of the storage carrier (20) which is detected by the image capture unit (40), and wherein the image capture unit (40) and the lighting device (50) are attached to a traversing device (30) which is traversable in a first horizontal direction (X) and in a second horizontal direction (Y).

Description

[0001] The invention relates to a storage rack with a plurality of support supports arranged one above the other for supporting storage goods carriers that can be conveyed by an automatic transport device, with at least one loading and unloading opening for feeding and unloading the storage goods carrier, wherein an image capture unit is arranged on an upper side of the loading and unloading opening. Furthermore, the invention relates to a method for detecting the inventory of a storage rack.

[0002] A storage rack of the type mentioned above is known from DE 10 2008 018 436 A1. In such storage racks, a storage goods carrier is automatically moved from one of the storage locations to the loading and unloading opening by means of a transport device for the purpose of loading and unloading stored goods. The warehouse worker can then place the stored goods to be stored on the storage goods carrier. The warehouse worker can then manually enter the storage location and further information about the stored goods in a system. Finally, the storage goods carrier with the stored goods is automatically moved to a storage location by means of the transport device and stored there until removal. An image capture unit for taking an image of the storage goods carrier is attached to the top side of the loading and unloading opening. Particularly in the case of large-area storage goods carriers, stored goods in the edge area of ​​the storage goods carrier can only be captured to a limited extent by an image capture unit attached in this way.Furthermore, the distance of the stored goods to the image capture unit depends on the storage location, so that a direct comparison of the geometric dimensions of the stored goods is only possible to a limited extent.

[0003] DE 10 2007 004 866 A1 discloses a storage rack with a display device on the top side of a loading and unloading opening, which displays stored goods on a storage surface of the storage goods carrier by means of light elements.

[0004] Particularly in high-bay warehouses, the problem often arises that an accurate, visual inventory recording is only possible with a significant amount of personnel. For example, to check the inventory or to create an inventory, each item carrier must be removed from storage individually and then returned to storage after the inventory has been recorded, such as the fill level of a small parts container. Furthermore, each item must be recorded separately during loading and / or removal. This reduces efficiency during loading and / or removal of stored items.

[0005] A warehouse inventory control system for monitoring the supply and removal of warehouse items is disclosed in WO 2008 / 029159 A1. The system comprises a camera system and a data processing device capable of receiving signals from the camera system. The data processing device further comprises an image recognition means for analyzing the signals received from the camera system to determine the presence and / or absence of the warehouse items. DE 10 2008 027 646 A1 discloses a system for automatically controlling storage and / or picking in automated small parts warehouses. A plurality of cameras and lighting devices are mounted in the storage area of ​​the small parts warehouse, which serve to detect the stored goods.

[0006] DE 10 2007 004 866 A1 discloses a storage rack having a display means for indicating the storage locations of stored goods on the upper side of the loading and unloading opening. However, the display means comprises a plurality of lighting devices, each of which directs a light beam onto a storage surface of the storage goods carrier.

[0007] The invention is based on the object of providing a storage rack in which inventory is recorded using precisely captured images from an image capture unit in a loading and unloading opening. Furthermore, a method for recording the inventory of such a storage rack is proposed, which enables automatic and precise image capture during the loading and / or unloading of stored goods.

[0008] To achieve this objective, a storage rack of the type mentioned above is proposed, which has a lighting device for highlighting an area of ​​the storage goods carrier that is captured by the image capture unit. Furthermore, the image capture unit and the lighting device are attached to a movement device that can be moved in a first horizontal direction and a second horizontal direction.

[0009] The storage rack according to the invention is particularly characterized by the fact that smaller items stored next to larger items are captured unobstructed from a bird's eye view, since the image capture unit is positioned centrally above a stored item by means of the traversing device. This creates an unobstructed image of the stored item. In particular, this allows for the capture of small items stored next to large items.

[0010] Since the distance from the image capture unit to the storage goods carrier is always constant, the captured images can be compared relative to each other and, for example, geometric dimensions of the stored goods can be automatically classified and determined.

[0011] Advantageously, the image capture unit is aligned essentially perpendicular to a storage surface of the load carrier for capturing an image. This ensures a consistent angle for capturing a bird's-eye view image.

[0012] The displacement device according to the invention can move over the entire working area and can position the image capture unit over a stored item even in deep loading and unloading openings.

[0013] The traversing device is advantageously arranged on rails arranged orthogonally to one another, wherein the traversing device is preferably positionable along the rails by means of a motor. Furthermore, it is conceivable to position the traversing device using a pulling device that pulls the traversing device along the rails. In an advantageous embodiment, the position of the traversing device is detected by means of a motion sensor, in particular a cable pull sensor, a differential transformer, or a controlled motor. This enables a precise determination of the position of the traversing device.

[0014] The image capture unit advantageously has a lens with a fixed focal length. Due to the lens with a fixed focal length and the constant distance of the image capture unit from the work area, the geometric dimensions of the stored goods can be visually compared. For this purpose, the lens can also be equipped with a sensor that detects the settings of the image capture unit and the position of the traversing device. This allows the size of the stored goods to be calculated based on the detected settings, position of the traversing device, and distance from the work area. The unit of measurement of the image is thus known even with an adjustable focal length, allowing the stored goods to be compared to one another.

[0015] The lighting device according to the invention illuminates at least the part of the storage area that the image capture unit captures. This allows areas captured by the image capture unit to be illuminated, so that a detailed image can be taken. This is advantageous, for example, for deep containers that have a low fill level. The stored goods are concealed by the walls of the container compared to a centrally mounted light, which is not the case with the lighting arrangement according to the invention. This allows high-quality images to be created. The lighting elements can, in particular, be LEDs. A further advantage is that such a lighting device enables a reliable, unobstructed display of the stored goods.

[0016] In an advantageous embodiment, the image capture unit is arranged centrally on the moving device. The lighting elements of the lighting device are expediently mounted around the image capture unit. In a further advantageous embodiment, these can be arranged at a uniform distance from one another around the image capture unit. Due to the lighting elements arranged around the image capture unit, homogeneous illumination of the stored goods is possible, as the light elements illuminate the stored goods from different angles around the image capture unit. This results in minimal shadows.

[0017] Advantageously, the lighting device illuminates a first area of ​​the storage area, preferably by means of a red light to highlight the first area, or preferably by means of a white light to illuminate the first area. In this way, an area can be made known to the warehouse worker which, for example, contains a stored item that is to be stored. In addition to the first area, a second, third, fourth or fifth area can also be present, for example. The respective area is located on the storage area of ​​a storage item carrier. By illuminating an area, for example, the identification of a stored item can be made easier for the warehouse worker with a white light, or a storage location can be indicated to the warehouse manager with a red light.

[0018] Advantageously, the storage rack has an image evaluation device which combines images of several areas into an overall image, which comprise at least a first area and a second area which were recorded from different positions of the movement device by means of the image acquisition unit.

[0019] This offers the advantage of creating an overall image of a storage device, composed of multiple areas, each of which displays images of the stored goods from a bird's eye view. A precise, unobstructed representation of the entire storage device is thus possible. It is also conceivable that, in particular, larger stored goods can be created using multiple captured images that are combined via the image evaluation device. Furthermore, the image evaluation device can also link the captured data from the image acquisition unit and the traversing device with the captured image, so that detailed information on the position, size, and other information is stored.

[0020] For example, an overall image of the storage item carrier can be displayed on the warehouse rack via a display. This way, the warehouse worker can also see the area where the item is located that is to be retrieved. Furthermore, the images of the stored item can be updated as soon as a loading or unloading operation has been performed, without having to create a new overall image of the storage item carrier. This ensures that a current image of the storage item carrier is always stored.

[0021] Furthermore, to solve the problem, a method for recording the inventory of a storage rack, in particular a storage rack of the aforementioned type, is proposed. The method comprises the following steps: a. Positioning a storage goods carrier in a loading and / or removal opening of a storage rack; b. Moving an image capture unit over an area of ​​the storage goods carrier into which storage goods are inserted or from which they are removed; c. Taking a picture of the area; d. Saving, processing and evaluating the image.

[0022] This process makes it possible to capture stored goods on a storage carrier from a bird's eye view. A current image of the stored goods is also always saved. A particularly advantageous feature is that this information can be retrieved via a central image evaluation device in conjunction with intelligent warehouse management software with an integrated database, where the captured data is stored.

[0023] The image capture unit advantageously captures images using a consistent focal length and / or consistent orientation. This allows images to be captured that are comparable in size to previously captured images. This allows stored items to be compared in size using the images.

[0024] In a further advantageous embodiment, the size of the captured stored item is calculated. Thus, the image capture unit can also include a lens with a variable focal length. For the calculation, a sensor can be present on the lens, or a reference point can be imaged on the storage surface, so that the number of pixels, or image points, of a digital image is defined along a dimension determined by the defined size of the reference point.

[0025] Advantageously, the image evaluation device crops the captured image of the area in such a way that at least one storage area is depicted. Thus, images of the storage areas can be arranged side by side without overlapping parts of the captured areas.

[0026] Advantageously, the image evaluation device preferably creates an overall image of the storage item carrier by capturing a plurality of images of the storage areas. Using the described method, it is possible to create a current overall image of the storage item carrier, so that a current image of the inventory is always stored on the storage unit included in the image evaluation device. To simplify storage location identification and display during storage, the individual images of the recorded stored goods are always enclosed in a "rectangle." This allows the warehouse manager to view the current inventory on the storage item carrier in advance via a screen linked to warehouse management software.

[0027] It is advantageous to visually mark a free storage area on the storage carrier in the overall image of the storage carrier. This has the advantage that the warehouse worker is shown in a clear and understandable way which area the stored goods must be transported to in order to deposit them. The warehouse worker is also clearly shown which areas are already occupied and which areas are unoccupied. This type of marking can be implemented using a hatched area or a colored, transparent surface that is placed over the image. It would also be conceivable to implement this marking by changing the brightness of the area, or by providing the edge of the area with a frame that allows for marking or highlighting.

[0028] Advantageously, a stored item in the storage area is identified using image recognition, and information about the stored item is displayed on a display unit. Image recognition enables automatic detection of the stored item, thus allowing information and descriptions to be automatically linked to the created image and stored in a system. The information can include, for example, the quantity of stored items in this storage area, the fill level of a small parts container, especially a box containing screws, but also information about an engine block, such as its size, circumference, or other features, such as a type number or serial number.

[0029] It is advantageous to create an inventory list automatically or, preferably, to update it after goods have been loaded into or removed from storage. This has the advantage that the inventory list always shows the current stock. This process can also be automated, allowing stocks to be checked regularly. Image recognition can also be used to identify incorrectly placed or unrecorded goods. Each goods carrier is moved manually or automatically into the removal opening to create an overall image of the goods carrier. This image is compared with the information already stored. If there are any discrepancies, an inventory order (counting suggestion) can be created for the corresponding goods carrier. It is advisable to carry out an inventory during a period in which no loading and / or removal is taking place or is expected, particularly during the end of operations.

[0030] The following describes a storage rack in more detail, which is shown schematically in the attached drawings. Here: Fig. 1 shows a storage rack according to the invention; Fig. 2 a moving device arranged on an upper side of the loading and unloading opening of the storage rack; Fig. 3 Top view of a storage goods carrier; Fig. 4 Flowchart of a method according to the invention for recording the inventory of a storage rack.

[0031] The Fig. The storage rack 10 shown in Figure 1 for storing a plurality of storage goods carriers 20 comprises two modules 11a, 11b arranged at a distance from one another. The modules 11a, 11b comprise a plurality of spaced-apart, paired support supports 12a, 12b arranged on opposite side walls 13a, 13b. The support supports 12a, 12b serve to support trough-shaped storage goods carriers 20, in which the stored goods 28 are received. Thus, the support supports 12a, 12b form a plurality of storage locations for supporting the storage goods carriers 20.

[0032] The stored goods 28 are located on a storage area 26 of a storage surface 25 of the storage goods carrier 20. The stored goods 28 can include small parts containers, such as a large number of screws, but also individual parts, such as engine parts. A large stored item 28a protrudes higher from the storage goods carrier 20 than a small stored item 28b.

[0033] A transport device 14 is arranged between the modules 11a, 11b, which automatically moves the storage goods carrier 20 between the loading and unloading opening 16 and a storage location in the modules 11a, 11b. The storage rack 10 can also, for example, have a second loading and / or unloading opening 16, which Fig. 1 is not shown.

[0034] An image evaluation device 80 and a display 85 are assigned to the storage rack 10.

[0035] A storage goods carrier 20 can be positioned in the loading and / or removal opening 16. Storage goods 28 can be placed on or removed from the storage goods carrier 20. An image capture unit 40 for capturing the storage goods 28 placed on the storage goods carrier 20 is arranged on an upper side 18 of the loading and removal opening 16. The image capture unit 40 is attached to a traversing device 30.

[0036] The displacement device 30 is mounted on two orthogonally arranged rails 31, 32, as shown in Fig. 2. The rails 31, 32 are arranged on the upper side 18 of the loading and / or removal opening 16. The movement unit 30 can be moved along the first horizontal direction X via rails 31 and the second horizontal direction Y via rails 32 of the loading and / or removal opening 16, so that the entire storage goods carrier 20 can be captured by the image capture unit 40. For this purpose, the movement device 30 is positioned, for example, by means of a motor 34.

[0037] The image capture unit 40 with a lens 45 is fixed centrally to the traversing device 30. The image capture unit 40 is aligned essentially perpendicular to the storage item carrier 20. Thus, the storage item 28 is captured from a bird's eye view. In particular, this prevents larger storage items 28b, for example, from obscuring smaller storage items 28a.

[0038] In the illustrated embodiment, the image capture unit 40 is not adjustable, so its alignment remains constant. In combination with a consistent focal length setting of the lens 45 and a constant alignment, comparable images can be created.

[0039] Lighting elements 55 of a lighting device 50 are arranged around the image capture unit 40. In an advantageous embodiment, these lighting elements 55 are arranged uniformly around the lens 45 of the image capture unit 40. The lighting elements 55 are directed toward the same area that is captured by the image capture unit 40.

[0040] The image evaluation device 80 processes all data acquired during loading and / or removal. The image evaluation device 80 also includes a storage unit that stores the acquired data.

[0041] Furthermore, the image evaluation device 80 can be coupled to the image acquisition unit 40 by means of a wireless connection.

[0042] Display 85 describes a display unit that can be used to display information about a loading and / or retrieval order to a warehouse operator. In particular, this information includes an overall image of the storage item carrier 20, booking information, material number, moved quantity, user, time and date, etc., in tabular form.

[0043] In Fig. Figure 3 shows an example of a captured overall image of a storage goods carrier 20. For this purpose, the image capture unit 40 records at least a first area 21 and / or a second area 22. A plurality of areas 21, 22 of the storage goods carrier 20 can also be captured. Each area 21, 22 includes at least one storage area 26. To capture the areas 21, 22, the image capture unit 40 is arranged centrally above the storage area 26.

[0044] In one possible embodiment, a storage area 26 can also be represented by two captured areas 21, 22 combined by the image evaluation device 80. The captured first area 21 can be cropped by the image evaluation device 80 such that only the storage area 26 is visible on the stored image, which is Fig. 3 is occupied by a storage item 28, for example.

[0045] The overall appearance of the storage carrier 20 is thus represented by a plurality of storage areas 26, which can be individually renewed after a loading and / or removal activity. Likewise, unoccupied storage areas 25 of the storage carrier 20 can be marked. In particular, as shown in the Fig. 3, by means of a hatched area.

[0046] Fig.4 uses a flow chart to show, by way of example, the individual process steps involved in removing a stored item from the storage rack 10 described above.

[0047] In a first step, a storage goods carrier 20 with a storage item 28 to be removed is positioned in a loading and removal opening 16 after the warehouse manager has initiated a corresponding booking for a removal of a storage item 28.

[0048] In a next step, the image capture unit 40 is positioned centrally over the storage area 26 of the storage goods carrier 20, which comprises a storage item 28 to be removed.

[0049] Subsequently, the first area 21, which has the storage area 26 with the stored goods 28, is marked by means of a lighting element 55, so that the storage location of the stored goods 28 in the loading and removal opening 16 is indicated to the storage rack.

[0050] For example, the storage rack removes only a part of the stored goods 28, e.g., a screw, from a container that stands on a storage area 26 on the storage goods carrier 20.

[0051] The image capture unit 40 then takes a new image of the first area 21, which includes the storage area 26 with the stored goods 28.

[0052] The recorded image is then transmitted to an image evaluation device 80.

[0053] The image evaluation device 80 saves the image and crops the captured image to the storage area 26 such that only the stored goods 28 are visible. The new fill level of the container is recorded and also saved.

[0054] Finally, the new information recorded is entered into an inventory list and the part of the overall image of the storage item carrier 20 or storage area 25 comprising the storage area 26 is updated.

[0055] The invention is particularly characterized by the fact that it allows for a simple and precise, unobstructed recording of the stored goods 28. Furthermore, only one image capture device 40 is required.

[0056] By means of such a device and / or method, efficient storage of stored goods 28 can be achieved. It is also possible to create an inventory list fully automatically, ensuring an exact and up-to-date recording of the inventory. List of reference symbols 10 storage shelves 11a Module 11b Module 12a,b support columns 13a,b side wall 14 Transport device 16 Loading and / or unloading opening 18 Top 20 storage goods carriers 21 first area 22 second area 25 storage space 26 Storage area 28 stored goods 28a large storage goods 28b small storage goods 30 Traversing device 31 rail 32 rail 34 Engine 40 image acquisition unit 45 lens 50 lighting devices 55 lighting elements 80 Image evaluation device 85 Display X first horizontal direction Y second horizontal direction

Claims

[1] Storage rack (10) with a plurality of support supports (12) arranged one above the other for supporting storage goods carriers (20) which can be conveyed by means of an automatic transport device (14), with at least one loading and unloading opening (16) for feeding and unloading the storage goods carrier (20), wherein an image capture unit (40) is arranged on an upper side (18) of the loading and unloading opening (16), characterized by in that the storage rack (10) has a lighting device (50) for highlighting an area (21) of the storage goods carrier (20) which is detected by the image capture unit (40), and wherein the image capture unit (40) and the lighting device (50) are fastened to a displacement device (30) which is movable in a first horizontal direction (X) and in a second horizontal direction (Y). [2] Storage rack (10) according to claim 1, characterized bythat the image capture unit (40) is aligned to capture an image substantially perpendicular to a storage surface (25) of the storage goods carrier (20). [3] Storage rack (10) according to claim 1 or 2, characterized by that the displacement device (30) is arranged on rails (31, 32) arranged orthogonally to one another, wherein the displacement device (30) can preferably be positioned along the rails (31, 32) by means of a motor (34). [4] Storage rack (10) according to one of claims 1 to 3, characterized by that the image capture unit (40) has a lens (45) with a fixed focal length. [5] Storage rack (10) according to claim 4, characterized by that the lighting device (50) illuminates the first area (21) of the storage surface (25) by means of a red light to highlight the first area (21) or by means of a white light to illuminate the first area (21). [6] Storage rack (10) according to one of claims 1 to 5, characterized byan image evaluation device (80) which records images of a plurality of regions, which comprise at least the first region (21) and a second region (22), from different positions of the displacement device (30) by means of the image acquisition unit (40) and combines them into an overall image. [7] Method for detecting a stock level of a storage rack (10) according to one of claims 1 to 6, comprising the following steps: a. Positioning a storage goods carrier (20) in a loading and / or removal opening (16) of the storage rack (10); b. Moving an image capture unit (40) over an area of ​​the storage goods carrier (20) into which storage goods (28) are inserted or from which they are removed; c. taking an image of the area (21, 22); d. Saving, processing and evaluating the image. [8] Method according to claim 7, characterized bythat the image capture unit (40) captures images using a constant focal length and / or has a constant orientation for capturing the image. [9] Method according to claim 7 or 8, characterized by that the image evaluation device (80) crops the captured image of the area (21, 22) in such a way that at least one storage area (26) is imaged. [10] Method according to claim 9, characterized by that the image evaluation device (80) preferably creates an overall image of the storage goods carrier (20) by means of a plurality of images of the storage areas (26). [11] Method according to claim 10, characterized by that an unoccupied storage area (26) on the storage goods carrier (20) is visually marked in the overall image of the storage goods carrier (20). [12] Method according to one of claims 7 to 11, characterized bythat a stored item (28) in the storage area (26) is identified by means of image recognition and information about the stored item (28) is displayed on a display unit (85). [13] Method according to claim 12, characterized by that an inventory list is created automatically or updated after loading and / or removing stored goods (28).

Images