System and procedure for picking flat-pack items

Abstract

System (10) for picking articles (12), in particular flat-pack articles (12), according to picking orders, each comprising different articles, wherein the system (10) comprises: a rack (24) extending substantially along a longitudinal and vertical direction (X, Y) of the system (10) and comprising a plurality of storage locations (30) configured to store source pallets (30); a gantry robot (36) with a handling unit (37) configured to transfer the articles (12); a packing position (62) configured to buffer a destination pallet (34); a plurality of conveyors (38); and a controller (74) preferably configured to determine an order-specific packing pattern for each of the orders in order to automatically pack several of the articles (12) from one or more of the source pallets (30) onto a destination pallet (34) in the packing position (62) by the gantry robot (36) according to the respective order;wherein each of the conveyors (38) has a receiving position (66) positioned within the rack (24) and configured to receive the source pallets (30), and a discharge position (58) positioned within an action space of the gantry robot (36) and configured to provide the source pallets (30), preferably dynamically; wherein the gantry robot (36) defines the action space within which the handling unit (37) is movable and which contains the packing position (62) and the discharge positions (58) of the conveyors (38); and wherein the control system (74) is further configured to cause those source pallets (30) to be transported from the storage locations (32) via the receiving positions (66) to the discharge positions (58) that contain the articles (12) required for packing according to the respective packing pattern.

Description

[0001] The present disclosure relates generally to an intralogistics system and method for the automated picking of items, in particular flat-pack items. Preferably, the picking process is fully automated. Sources and destinations of the picking process are represented by pallet-like load carriers.

[0002] There are many different automated order picking systems that are used for a wide variety of purposes and conditions.

[0003] EP 1 462 393 B1 describes a fully automated system in which items are separated from single-item incoming goods pallets onto individual trays, ensuring that each tray contains only one item. The incoming goods pallets are stored in a high-bay warehouse and depalletized to create a picking buffer (tray storage). Items required to fulfill a picking order are retrieved from the tray storage while still on the trays and, after sequencing, separated from the trays just before a packing machine. The packing machine then transfers the items onto a target pallet according to a predetermined packing pattern. The system described in EP 1 462 393 B1 is primarily used by food retailers. This means that the described system is used in distribution centers where target pallets are typically assembled for a specific branch of the food retailer.Direct picking of items from the storage pallets to the target pallets is not planned, especially because the storage machines in the high-bay warehouse cannot perform a sufficient number of exchanges.

[0004] Furthermore, order picking systems are known in the beverage wholesale sector, where gantry robots are used for the fully automated picking of beverage crates. Such a system is shown in the YouTube video "Construction Project Progress: Automated Beverage Warehouse" (www.youtube.com / watch?v=30vSIMfit3k). In this system, the items are also separated from source pallets and stacked into towers beforehand. A single-tray storage system is also used. The source pallets are depalletized layer by layer or row by layer using another gantry robot, so that they can be individually fed to the picking gantry robot on a roller conveyor, maintaining spacing between items. The picking gantry robot then restacks the individual items and places the stacks onto the target pallet. The throughput (items picked per unit of time) is low.Direct picking of the items (beverage crates) from the source pallets down to the target pallets is not possible.

[0005] Furthermore, the systems discussed above are fundamentally unsuitable for picking flat-pack items.

[0006] It is therefore a task to provide an improved system and procedure for picking items, especially flat-pack items.

[0007] This task is solved by a system for picking items according to picking orders, wherein the system comprises: a rack extending substantially along a longitudinal and vertical direction of the system and having a plurality of storage locations configured to store source pallets; a gantry robot with a handling unit configured to transfer the items; a packing position configured to buffer a destination pallet; a plurality of conveyors, preferably aligned parallel to a transverse direction of the system; and a controller preferably configured to determine an order-specific packing pattern for each order in order for the gantry robot to automatically stack several of the items according to the respective order from one or more of the source pallets onto a destination pallet in the packing position.to pack; wherein each of the conveyors has a receiving position, which is positioned within the rack and which is configured to receive the source pallets, and a discharge position, which is positioned within an action space of the gantry robot and which is configured to provide the source pallets, preferably dynamically; wherein the gantry robot defines the action space within which the handling unit is movable and which contains the packing position and the discharge positions of the conveyors; and wherein the control system is further configured to cause those of the source pallets to be transported from the storage locations via the receiving position to the discharge positions, which contain the items required for layering or packing according to the respective packing pattern.

[0008] The gantry robot is supplied directly from the shelf with the source pallets it needs for picking. Transport routes are short. Transport times are short. Picking performance is high. Required individual parts are picked directly from the source pallet. The system is fully automated, allowing even heavy and unwieldy items to be picked.

[0009] The source pallets are "tunneled" through the racking system by means of conveyors. The source pallets are then transported directly and via the shortest route to the picking zone.

[0010] The space requirement is minimal. A complex, branched conveyor network between a storage area and a picking area is unnecessary. Depalletizing and palletizing take place in the same location, meaning no conveyor network is required between the depalletizing and palletizing processes.

[0011] An additional picking warehouse, supplied with individual items from the pallet warehouse, is unnecessary. However, a piece- or case-picking concept can still be implemented, where pallets are the (sole) source of picking materials.

[0012] The system is particularly well-suited for picking flat-pack items. Flat-pack items are flat, large, and heavy, making them unsuitable for a picking concept that uses a picking buffer between the pallet warehouse and the picking zone. Picking flat-pack items is fully automated, eliminating the ergonomic challenges that can arise from manual picking.

[0013] The present picking concept is particularly well-suited for e-commerce applications in the furniture industry. Furniture pieces are stored in individual parts as "flat packs" on source pallets (separate by type, variety, or item) and picked according to concepts familiar from classic tote picking (goods-to-person). E-commerce is characterized by a large number of customers placing orders, each comprising only a few order lines. This means the system is confronted with a very large number of small orders (few different items, especially in small quantities; i.e., few order lines per order), which would normally argue against picking directly from a source pallet.

[0014] Furthermore, existing systems can be easily converted or retrofitted. The conveyors can be integrated into existing racking systems with minimal effort, particularly on the lowest level. The gantry robot(s) can then be positioned directly alongside the racking. The picking cells, defined by the gantry robots, can be supplied with target pallets using discontinuous conveyors such as transfer carts, guided or autonomously moving automated guided vehicles (AGVs), and similar systems, which can then transport the completed target pallets to a shipping area.

[0015] A rack with at least two shelf levels is sufficient to integrate the conveyors. This means that existing systems with relatively low pallet storage can be retrofitted.

[0016] The material flow node of each rack, namely the front area or the aisle ends, is relieved because the material flow caused by order picking takes place through the long side of the rack, while the supply of the rack with replenishment and the disposal of empty load carriers continue to take place - as is traditionally the case - via the front of the rack or via the aisle ends.

[0017] Preferably, the portal robot is located essentially directly adjacent to one long side of the shelf.

[0018] The virtually flush arrangement of the gantry robot relative to the racking shortens transport routes and thus transport times. Picking performance is increased.

[0019] Furthermore, coupling to the long side is advantageous because a large number of conveyors can be arranged directly next to each other there.

[0020] Long transport routes from one end of the rack to the picking stations, i.e., to the gantry robots, are eliminated. The material flow bottleneck at the short ends of the rack is also eliminated. More source pallets can be retrieved per unit of time via the long side than via the end of the rack because there are more transfer points.

[0021] In particular, the conveyors are linear continuous conveyors that can be operated bidirectionally, are oriented perpendicularly, preferably horizontally perpendicular, to the longitudinal direction and have the receiving positions and the discharge positions at their respective end sections.

[0022] Linear continuous conveyors are easy to control. They do not require switches or branches. They offer high transport capacity (number of source pallets per unit of time).

[0023] The ability to operate the conveyors bidirectionally opens up the possibility of returning the source pallets via the same route.

[0024] The conveyors' perpendicular orientation to the system's longitudinal axis, along which the racking also extends, increases the density, or number, of source pallets / length segments that can be supplied to the gantry robot. This increases throughput because more target pallets can be picked per unit of time. The gantry robot does not have to wait for the next source pallet to arrive.

[0025] Furthermore, it is advantageous if the system also includes at least one storage and retrieval machine that is set up to automatically exchange the source pallets between storage locations and the receiving locations, with the storage and retrieval machine preferably being located on a long side of the rack that faces away from the portal robot.

[0026] The storage and retrieval machines are part of the fully automated system and enable the automatic transfer of source pallets within the racking area. The picking and storage locations, like the storage locations, are situated within the racking and are therefore easily accessible to the storage and retrieval machine.

[0027] The storage and retrieval machine is preferably positioned on the long side of the rack opposite the gantry robot, so that the conveyors extend across the rack to supply the gantry robots with the source pallets. The storage and retrieval machines and the gantry robots do not interfere with each other. While spatially separated, the storage and retrieval machines and the gantry robots are nevertheless directly connected in terms of material flow – via the shortest possible route.

[0028] Preferably, the system has additional delivery positions that are also positioned within the action space and are set up for the static provision of additional source palettes.

[0029] Static provisioning of source pallets eliminates the need to return them to storage. Static provisioning is particularly suitable for items with access frequency category A, as these items appear very frequently in picking orders. The corresponding source pallets are therefore emptied quickly, making return to storage uneconomical. Dynamically provided source pallets are more likely to fall into access frequency categories B and C. In these cases, returning the corresponding items to storage can be quite useful.

[0030] In particular, at least some, and preferably all, of the further delivery positions are coupled to a supply conveyor that differs from the conveyors and preferably includes a transfer carriage.

[0031] The supply conveyor is coupled to the rack in terms of material flow technology, preferably at the front of the rack, where the storage and retrieval machines can deliver source pallets.

[0032] The material flow connection between dynamically supplied and statically supplied source pallets is separate and uses different conveying technologies. Dynamic supply is preferably achieved using continuous conveyors, whereas static supply can be achieved particularly well using discontinuous conveyors.

[0033] Preferably, the system further comprises a discharge conveyor which preferably extends parallel to the longitudinal direction and centrally through the action space.

[0034] The removal conveyor can be used to remove waste, such as interleaving sheets, from the operating area of ​​the portal robot, so that the portal robot can access items located deeper within the source pallet that would otherwise be hidden.

[0035] In particular, the conveyors are arranged at the same floor level as the system.

[0036] This simplifies the setup. Stage-like structures are no longer needed. The conveyors are easily accessible for maintenance technicians.

[0037] Preferably, one level of the rack is exclusively equipped with the conveyors, wherein preferably several of the portal robots are arranged directly adjacent to each other in the longitudinal direction and wherein at least one separate packing station is provided for each of the portal robots.

[0038] The packing robots are not operated in overlapping mode. This simplifies the control of the gantry robots. The gantry robots can be operated independently of each other, particularly because each gantry robot delivers the items to its own packing station.

[0039] Furthermore, it is advantageous if the ratio between the number of conveyors and the number of storage locations along the longitudinal direction is 1:2 or 2:3.

[0040] Preferably, the portal robot is configured to depalletize the source palettes within the action space and to palletize the target palettes there.

[0041] In particular, each of the items is rectangular and plate-shaped; specifically, it has external dimensions in the range of 620 × 300 × 7 mm. 3 up to 2550 × 800 × 200 mm 3 ; preferably weighs a maximum of 62 kg; and / or preferably includes layered components of a ready-to-assemble piece of furniture.

[0042] The problem is further solved by a method for picking items according to picking orders, comprising the following steps: retrieving source pallets, which store the items required for packing according to a packing pattern onto a target pallet, from storage locations in a rack; delivering the retrieved source pallets to receiving positions of conveyors, wherein the receiving positions are arranged within the rack, the conveyors extending, in particular linearly, from the rack to a gantry robot arranged along one longitudinal side of the rack, preferably immediately adjacent to the side of the rack; transporting, with the conveyors, the delivered source pallets from the receiving positions to the corresponding delivery positions of the conveyors, which are positioned within an action area of ​​the gantry robot;and transferring the items required for packing according to the packing pattern on the target pallet using a handling unit of the portal robot.

[0043] Preferably, the transfer of the articles comprises: picking up the articles from the source pallets at the delivery positions; moving the picked-up articles to a position on the destination pallet specified by the packing pattern; and packing (by layering) the picked-up articles onto the destination pallet according to the respective packing pattern.

[0044] In particular, the procedure further includes: determining, by means of a controller or computer, the packing pattern for each order, including the source pallets that store the items required for packing according to the packing pattern onto the target pallet.

[0045] It is understood that the features mentioned above and those to be explained below can be used not only in the combinations specified, but also in other combinations or on their own, without leaving the scope of the present invention.

[0046] Exemplary embodiments of the invention are shown in the drawings and are explained in more detail in the following description. They show: Fig. Figure 1 shows a perspective view of a picking system according to a first embodiment; Fig. Figure 2 shows a perspective view ( Fig. 2A) of a portal robot and a block diagram ( Fig. 2B) of the portal robot; Fig. Figure 3 shows a detailed view of a goods receiving area of ​​the picking system of the Fig. 1; Fig. Figure 4 shows further detailed views of the order picking system of the Fig. 1; Fig. Figure 5 shows a schematic top view of a second embodiment of the order picking system; Fig. Figure 6 shows a user interface of a planning software ( Fig. 6A) and a fully packed destination pallet as planned ( Fig. 6B, left) and how actually packed ( Fig. 6B, right); and Fig. Figure 7 shows a flowchart of a picking procedure.

[0047] The proposed system 10 is generally used in an intralogistics warehouse and / or order picking environment, such as in a distribution center, shipping center or in a branch of a retailer, especially a furniture retailer.

[0048] Intralogistics encompasses the logistical flow of materials and goods within a company's premises, particularly within a company building. The term intralogistics was defined to distinguish it from the transport of goods outside the company, which is carried out, for example, by a freight forwarding company. The "Forum Intralogistics" within the "German Engineering Federation" defines "intralogistics" as the organization, control, execution, and optimization of the internal flow of goods and materials, information flows, and goods handling in industry, commerce, or public institutions.

[0049] The term "order picking" refers to the process of assembling a customer-specific quantity from an assortment of several product types. Order picking thus describes the assembly of a customer order (or simply "order"), i.e., the removal of partial quantities of larger units of individual items and their consolidation and preparation for shipment, or for handover within a branch, to the customer.

[0050] Fig. Figure 1 shows a perspective view of a first embodiment of a picking system 10 for (individual) articles 12 (not shown here), which are to be separated from an assortment and prepared for issue or shipment according to customer or picking orders. The articles 12 essentially have the shape of a rectangular parallelepiped.

[0051] The present development is particularly applicable to flatpack products, which represent a special variant of the aforementioned cuboid products 12. The term "flatpack" refers to a sheet-like package that typically contains a large number of (flat) pre-assembled components, which can later be assembled by the end customer into a complex object, such as a cabinet, after unpacking. Flatpack products are characterized by the fact that the length and width of the package are many times greater than its height. Flatpack products are used particularly in the furniture industry. Flatpack products are generally heavy and place particular ergonomic demands on their handling.

[0052] The following describes the current development in general terms using Article 12, which in intralogistics are referred to as SKU (stock keeping unit) or VPE (packaging units).

[0053] The picking system 10, which will hereinafter also be referred to simply as "System 10", comprises a storage zone 14 and a picking zone 16. Furthermore, System 10 can include a goods receiving zone 18 (in Fig. 1 is obscured because it is positioned behind storage zone 14, see also Fig. 3), a shipping zone 20 and one or more buffers 22 for empty destination pallets 34 (not shown).

[0054] The bearing zone 14 extends essentially parallel to a longitudinal direction X of the system 10. The bearing zone 14 of the Fig. 1 has at least one rack 24, here by way of example two racks 24-1 and 24-2, which are aligned parallel to the longitudinal direction X and which define a rack aisle 26 between them, where one or more (not shown here) storage and retrieval machines (SRMs) 28 are operated for the automated storage and retrieval of source pallets 30, preferably loaded with only one type of pallet. The storage zone 14 of the Fig. 1 is operated, for example, with two RBG 28 units, which are operated simultaneously within the same rack aisle 26. The storage zone 14 is preferably defined by the footprint of the racks 24 and the rack aisle 26. The term "source pallet 30" is understood below to mean the unit consisting of the stored articles 12 and the load carrier.

[0055] Generally, pallets are loading aids or load carriers that exist in various dimensions (Euro pallet, Düsseldorf pallet, etc.) and are used for bundling, storing, and transporting larger quantities of items. Pallets can be made from different materials (cardboard, wood, metal, etc.). In the furniture industry, extra-long pallets (2000 × 800 × 144 mm³) are often used.

[0056] The source pallets 30 can be stored – depending on their dimensions – single-deep or multi-deep (in the transverse direction Z) in storage locations 32 of the racks 24. Euro pallets are preferably used. Each storage location 32 represents a rack bay designed to hold one pallet. In a simple configuration, the rack bays are defined by the longitudinal beams, transverse beams, and / or uprights of the rack 24. The rack bays can be configured to hold different pallet types. This means that source pallets 30 with different load carriers can be stored simultaneously in the rack 24.

[0057] In Fig. 1 Each of the racks 24-1 and 24-2 comprises, by way of example, four storage levels arranged vertically, i.e., in the vertical direction Y. The storage locations 32 are arranged continuously side by side in the longitudinal direction X and continuously one above the other in the vertical direction Y. Each rack 24 has at least two levels, i.e., at least one level for storing the source pallets 30 (storage level) and at least one vertically spaced conveyor level for directly supplying the picking zone 16 with the source pallets 30 via the shortest route. The storage levels contain only storage locations 32. The conveyor level preferably contains only conveyor technology – and thus no storage locations 32 at least along or parallel to the picking zone 16.

[0058] It goes without saying that a single shelf 24 can be sufficient to implement storage zone 14. Into the Fig. This would be shelf 24-1, which is directly adjacent to picking zone 16. Storage zone 14 can also have more than two shelves 24.

[0059] The picking zone 16 is essentially defined by one or more gantry robots 36. The footprint of the picking zone 16 corresponds essentially to the footprint of the gantry robot(s) 36. The conveyor level is preferably at least as long as the picking zone 16. In other words, this means that further racks or rack sections (not shown) could be connected to the rack 24-1 in the longitudinal direction X, which do not require a conveyor level, particularly in the positive X direction.

[0060] Furthermore, it is understood that one or more additional picking zones 16 (not shown) can be provided. In particular, another picking zone 16 (not shown), e.g., mirrored, can be connected to rack 24-2. This additional picking zone could be reserved for orders picked up directly by customers, while picking zone 16 at rack 24-1 is reserved for shipping (or vice versa). The additional picking zone 16 at rack 24-2 would not be as long as the one at rack 24-1 because the lower shelf level of rack 24-2 is occupied by a supply conveyor that provides the second stacker crane 28 with source pallets (replenishment).

[0061] In picking zone 16, the source pallets 30 are (automatically) transported by means of conveyors 38 (see also Fig. 4 and Fig. 5) provided to depalletize those items 12 required to create a stack of items on a target pallet 34 (not shown here) according to a packing pattern (and thus according to the associated order). The target pallet 34 comprises a load carrier (pallet) and the order-specific items 12. No further distinction is made between the load carrier alone or the combination of load carrier and items 12, because the target pallet 34 is empty at the beginning of a picking operation, i.e., it is only comprised of the pallet, and contains the order-specific items 12 at the end.

[0062] The formation of the (article) stack on the target pallet 34 is determined and specified by a packing pattern generator (planning software) in the form of the packing pattern, in order to pack the articles 12 by means of one of the portal robots 36 in order-specific - as space-optimized, stable, mutually supporting - layers as a stack onto the associated target pallet 34. Fig. Figure 6A shows a section of a user interface (GUI, "graphical user interface") of the planning software, with the right column containing the Fig. Figure 6A visualizes a perspective view of the (planned) stack of articles on the target pallet 34, with the middle column of the Fig. 6A visualizes a semi-transparent top view of the stack, with the left column showing the Fig. 6A illustrates a list of the required article types (article ID) and quantities (order lines) as well as a photo of a currently processed article 12.

[0063] Links in the Fig. 6B is a fully packed target pallet as planned and shown on the right as actually packed.

[0064] The "portal robots 36" are (industrial) robots coupled to a portal-like frame (portal frame) to move their manipulation units 37 (end effectors) within a rectangular workspace defined by three translational (Cartesian) axes of motion (XYZ) of the respective robot. In general, the robots are universally applicable motion machines with multiple translational and / or rotational axes. The robots' movements are freely programmable with respect to motion sequences and paths and can be sensor-guided. The robots are equipped with the manipulation units 37 (preferably vacuum lifters, which use vacuum to adhere to the top side of the items and then lift, move, and set them down again) and can perform handling tasks (transferring an item from source pallet 30 to target pallet 34).

[0065] In Fig. Figure 2A schematically illustrates a single portal robot 36, which has a stationary (portal) frame with, for example, four stationary vertical supports, two stationary longitudinal beams, and two stationary crossbeams. A crossbeam movable in the X direction is mounted on these supports, and a vertically movable mast in the Y direction is coupled to the crossbeam. The mast is coupled to a carriage on the crossbeam. The three principal translational axes (A1-A3, not shown) are labeled X (longitudinal direction), Z (transverse direction), and Y (vertical direction). Furthermore, the Fig. 2A Three (optional) rotation axes A4-A6 for the gripping unit or the manipulation unit 37 are indicated. The carriages for the movable crossbeam and the mast are typically driven by electric motors, with power transmission occurring, for example, via toothed belts, racks, or spindles. Alternatively, linear motor direct drives, pneumatic drives, or other drives can be used.

[0066] The Fig. Figure 2A shows a full portal. However, half portals could also be used, which stand on only two vertical supports and could (optionally) be movably mounted on a base. The full portal of the Fig. 2A is also called a surface portal because it covers a large horizontal (ground) area.

[0067] Fig. Figure 2B shows a block diagram of the portal robot 36.

[0068] The portal robot 36 of the Fig. 2B generally comprises the portal frame, preferably arranged in a stationary position, and at least one manipulation unit 37. The manipulation unit 37, which is preferably implemented as a suction gripper, is movably coupled to the portal frame. The manipulation unit 37 is automatically movable along at least two axes. The portal frame projects vertically above the conveyors 38 (see Figure 2B). Fig. 4 and Fig. 5), so that the articles 12 can be picked up from above by the manipulation unit 37 from the source pallets 30, which comprise the (storage) articles 12 and the pallet-like load carrier, and delivered downwards to the target pallet(s) 34.

[0069] In picking zone 16, the portal robots 36 are used for depalletizing or singulating the source pallets 30 and for palletizing or layer-by-layer stacking on the target pallets 34, as will be explained in more detail below.

[0070] The source pallets 30 are preferably loaded with only one type of item, i.e., only one type of item - in any quantity of one or more - is stored on the source pallets 30.

[0071] In goods receiving area 18 of the Fig. 1, which is in Fig. As illustrated in detail in Figure 3, (goods receipt) items 12 are supplied to system 10, and in particular to storage zone 14, as replenishment from the outside and checked and prepared for storage in the shelves 24 (removing transport securing devices, identifying and counting the items 12, quality check, etc.). In the Fig. 3. Looking from behind, one sees the shelves 24 of storage zone 14. Fig. 1 (see arrow III in Fig. 1).

[0072] The goods receiving zone 18 can include one or more so-called teach-in stations 39, where, for example, (external) dimensions of incoming source pallets 30 and the associated individual articles 12, identification codes of the source pallets 30 and the articles 12 stored on them, a quantity of the articles 12 and the like are recorded, preferably automatically.

[0073] The goods receiving zone 18 is generally connected to the storage zone 14 via a conveyor system 40, preferably a continuous conveyor (such as chain conveyors, roller conveyors 42, belt conveyors, electric monorail, electric floor conveyor, etc.). In the Fig. 3. The conveyor technology 40 enters the rear shelf 24-2 from the rear in a central area of ​​the storage zone 14, in order to be equally accessible by both (not shown) RBG 28, which store the incoming goods source pallets in the shelves 24.

[0074] Alternatively or additionally, the conveyor technology 40 could extend to one or both ends of the racks 24 and / or parallel to the X-direction, at least partially within one or both racks 24, in order to supply the RBG 28 with new, loaded source pallets 30 and to dispose of old, empty pallets (see arrows indicating a conveying direction in Fig. 3 illustrate).

[0075] The teach-in station 39 may also optionally include a swivel arm 44 with a vacuum lifter 46, a roller table 48 for storing and manually inspecting individual items 12, a scale, a light curtain 50 and / or similar equipment to determine the necessary data for each incoming goods pallet in order to qualify and treat the incoming goods pallet as a source pallet 30.

[0076] In the Fig. In shipping zone 20, fully stacked or packed destination pallets 34 are prepared for shipment. These destination pallets contain all the items 12 specified in an order, arranged according to the packing pattern. Preparations include wrapping the flat-pack items 12 stacked on the destination pallet 34 with film (entirely) for transport protection, affixing shipping information, and similar tasks (not shown). Finished destination pallets 34 can also be buffered in shipping zone 20 until they finally leave system 10.

[0077] Alternatively or additionally, finished target pallets 34 can also be prepared for direct handover to an end customer, e.g. if the system 10 is directly connected to a sales outlet (branch), where end customers can view sales items in an assembled state in a separately provided showroom and then order and take them away as flat packs to assemble the objects themselves at home.

[0078] In the Fig. 1 The target pallet buffers 22 serve to replenish empty target pallets 34, which are preferably transported to or from the picking zone 16 by means of discontinuous conveyors (e.g. manned forklifts 52, driverless transport vehicles and the like), in order to be loaded there by the portal robot(s) 36 with the associated articles 12 according to the order-specific packing patterns.

[0079] Fig. Figure 4 shows perspective detail views ( Fig. 4A and Fig. 4B) of System 10 of the Fig. 1 along arrows IV-A and IV-B in the Fig. 1. The Fig. Figure 4 shows in particular a view into the picking zone 16, where the portal robots 36 are positioned one behind the other in the longitudinal direction X (directly) and parallel to an outer longitudinal side 54 of the first shelf 24-1 (see Figure 4). Fig. 1) are arranged. The gantry robots 36 and the picking zone 16 are directly adjacent to the storage zone 14 in the transverse direction Z. The gantry robots 36 are essentially directly adjacent to the rack 24-1 in the transverse direction Z and are directly connected to the storage zone 14, in particular to the first rack 24-1, with regard to a material flow (source pallets 30) via the conveyors 38.

[0080] In the Fig. Figure 4 shows a plurality of conveyors 38, which are implemented as chain conveyors by way of example. The conveyors 38 are preferably linear continuous conveyors, which are arranged in particular parallel and (minimally) spaced apart from each other and which extend essentially in the transverse direction Z. The conveyors 38 are configured to transport the source pallets 30 from the area of ​​the rack 24-1 to the picking zone 16, i.e., to the action areas of the gantry robots 36, (automatically) via the shortest path.

[0081] The conveyors 38 are preferably arranged on the lowest level of the rack 24-1. The lowest level of the rack 24-1 is preferably equipped exclusively with the conveyors 38, at least along the picking zone 16, i.e., along the gantry robots 36. This further means that no storage locations 32 are provided on the lowest level of the rack 24-1 along this rack section. This conveyor level represents a transfer level or zone between the storage zone 14 and the picking zone 16.

[0082] It is understood that this transfer zone can also be provided on a middle or top level of shelf 24. The embodiment of the Fig. Figure 4 illustrates a floor-based configuration where order picking and shipping take place on the (building) floor. It is understood that order picking and / or shipping can also take place on another floor of the (not illustrated) building in which system 10 is installed. The rack 24 extends over several floors and is horizontally connected to the picking zone 16 via the conveyors 38.

[0083] Furthermore, in the Fig. Figure 4 illustrates that, viewed in the longitudinal direction X, two conveyors 38 are provided for every three storage locations 32. In other words, instead of two directly adjacent conveyors 38, three directly adjacent storage locations 32 could be provided within the rack 24 (between two adjacent vertical rack uprights). Alternatively, a ratio of 2:1 for the number of storage locations 32 to conveyors 38 could be chosen.

[0084] Since the conveyors 38 supply the gantry robots 36 with source pallets 30, which are required for order-specific picking, it is preferable to provide as many conveyors 38 as possible per longitudinal section of the rack 24. The number of conveyors 38 is a measure of the throughput, i.e., the ability to quickly deliver different items 12 (according to the picking orders) to the gantry robots 36.

[0085] The source palettes 30, located in the left half of the action spaces of the portal robots 36 of the Fig. 4 are positioned, on end sections 56 of the conveyors 38, the so-called delivery positions 58 (see Fig. 4B) define Article 12 within the action spaces of the portal robots 36. The in the Fig. 4B, the source palette 30 shown below left, contains, for example, ten Flatpack items 12, which are stacked in two piles of five pieces each.

[0086] The source pallets 30 generally represent the picking points for order picking. The destination pallets 34 at the packing positions 62 generally represent the delivery destinations for order picking.

[0087] In the Fig. The delivery positions 58 shown in Figure 4B in the left half of the action areas of the portal robots 36 are preferably "dynamic" delivery positions. These dynamic delivery positions 58 are characterized by the fact that the source pallets 30 can be moved bidirectionally by the conveyors 38. This means that the source pallets 30 are moved to the delivery positions 58 for removal, i.e., depalletizing, by the portal robots 36, and subsequently—after the required items 12 have been removed—moved back to storage zone 14 or to the rack 24.

[0088] “Static” delivery positions 58 are characterized by the fact that all items 12 are consumed before the load carrier of the associated source pallet 30 is disposed of. In the Fig. 4B are, by way of example, all delivery positions 58 that are arranged in the longitudinal direction X adjacent to the packing positions 62 and that are located in the right half of the action areas of the portal robots 36, implemented as “stationary” delivery positions. The packing positions 62 are, for example, by end sections of, for example, roller conveyors 42 (see Figure 4B). Fig. 4A) formed, connecting picking zone 14 with shipping zone 20. It is understood that the packing positions 62, which are set up to provide the destination pallets 34, can also be supplied with the destination pallets 34 by discontinuous conveyors, such as forklifts 52. The destination pallets 34 could, for example, also be placed directly on the warehouse floor to define the packing positions 62.

[0089] The supply of the stationary delivery positions 58 with the source pallets 30 (of access frequency type A) can be carried out, for example, via a transfer carriage 60, which is guided by rails in the longitudinal direction X in order to then deliver the source pallets 30 in the transverse direction Z. The transfer carriage 60 is also a discontinuous conveyor, which is connected via a further conveyor system 40' to the (goods receiving) conveyor system 40 (see figure). Fig. 3) and / or can be coupled to the RBG 28 in the area of ​​the front of the racks 24 in order to transport the source pallets 30 from storage zone 14 to the static delivery positions 58. Completely emptied source pallets 30, i.e. their load carriers, can be disposed of with the transfer trolley 60 and replaced by new source pallets 30.

[0090] The material flow connection of the stationary dispensing positions 58, or of those positions 58 that are not realized by the conveyors 38, is preferably achieved by – or incorporating – existing conveyor systems, such as the conveyor technology 40 from the goods receiving zone 18 or the forklift trucks 52. It is understood that other (not shown) conveyor technologies (e.g., automated guided vehicles, overhead conveyors, etc.) could be used.

[0091] The transfer carriage 60 can also be used to transport empty destination pallets 34 – via, for example, the roller conveyors 42 – into the operating areas of the gantry robots 36. In this case, the empty destination pallets 34 are positioned in a packing position 62 within the operating areas of the gantry robots 36. Fig. 4B shows the packing positions 62 in the right half of the action space.

[0092] The (dynamic) delivery positions 58 are supplied with source pallets 30 directly and via the shortest route from storage zone 14. The supply is preferably fully automated, integrating the stacker crane(s) 28, which operate along a long side of the rack 24-1 facing away from picking zone 16. This long side (68 in Fig. 5) is located in Fig. 4 shown longitudinal side 54 opposite in the Z-direction.

[0093] The transfer carriage 60 represents an exemplary implementation of the conveyor connection of the right half of the action areas, which could also be achieved by other conveyor types (continuous conveyor or discontinuous conveyor), as mentioned above.

[0094] Fig. Figure 5 shows a top view of a schematically represented second embodiment of the system 10, which differs only slightly from the system 10 of the Fig. 1-4 differs.

[0095] System 10 of the Fig. 5 includes, for example, a (single) shelf 24 for buffering the source pallets 30 on several levels and, for example, a (single) portal robot 36 as well as, for example, four conveyors 38 that connect the shelf 24 to the action area of ​​the portal robot 36 in terms of material flow, the base area of ​​which is in the Fig. 5 is bordered by a dashed line 64. More or fewer conveyors 38 could also be provided.

[0096] The conveyors 38 begin again in shelf 24 and end again in the operating area of ​​the portal robot 36. The first end sections 55 of the conveyors 38, which lie within shelf 24, define the receiving positions 66, and the second, opposite end sections 56 of the conveyors define the delivery positions 58. The conveyors 38 are again preferably operated bidirectionally. Thus, four receiving positions 66-1 to 66-4 and four delivery positions 58-1 to 58-4 are shown, which are assigned to the four conveyors 38-1 to 38-4.

[0097] At the receiving positions 66, the source pallets 30 are picked up, originating from the storage locations 32 (not shown) of the rack 24. The source pallets 30 are retrieved from the long side 68 of the rack 24 facing away from the portal robot 24 and moved into the receiving positions 66. The retrieval from the storage locations 32 and the delivery to or storage in the receiving positions 66 are preferably automated by the RGB 28.

[0098] The sponsors 38 of the Fig. 5 are preferably linear continuous conveyors, but could also generally be implemented by discontinuous conveyors (e.g. driverless transport vehicles, AGVs).

[0099] The length of the conveyors 38 (in the transverse direction Z) is chosen to be as short as possible in order to minimize the time required to transport the source pallets 30 between the respective receiving position 66 and the corresponding delivery position 58, thus enabling the portal robot 36 to be supplied with more source pallets 30 per unit of time (throughput / performance). The conveyors 38 automatically move the source pallets 30 from the receiving positions 66 to the corresponding delivery positions 58, where the articles 12 (not shown) are delivered to the portal robot 36 for order picking.The portal robot 36 moves its crossbeam in the longitudinal direction X to the corresponding delivery position 58, moves the manipulation unit 37 by means of the carriage in the transverse direction Z directly over the desired article 12, lowers the manipulation unit 37, grasps the (single) article 12, lifts it vertically and moves the manipulation unit 37 in the longitudinal and transverse directions to the packing position 62, where the associated target pallet 34 is buffered, in order to place the article 12 there at the position specified by the packing pattern and in the corresponding orientation vertically.

[0100] The transport time of the source pallets 30 is therefore essentially determined by the distance between the rack 24 and the gantry robot 36. Preferably, the gantry robot 36 is arranged directly adjacent to the rack 24 in the Z-direction. The gantry robot 36 is directly adjacent to the long side 54 of the rack 24 that faces the gantry robot 36.

[0101] The portal robot 36 can also brace itself against shelf 24. Parts of the portal frame can be implemented, for example, through the shelf construction. In the Fig. However, the portal frame is provided separately from the shelf construction (see section 5).

[0102] The vertical orientation and even distribution of the conveyors 38 along the long side 54 of the rack increases the number of delivery positions 58 within the operating area of ​​the gantry robot 36. This means that more differently loaded source pallets 39 can be made available to the gantry robot 36 for picking simultaneously. In this way, the picking time can also be reduced. The gantry robot 36 does not have to wait for the provision of further source pallets 30 required to process an order.

[0103] Furthermore, a large number of delivery positions 58 increases the possibility of sequenced provision of the source pallets 30. The order-specific packing patterns require the provision of the items 12 in a predetermined order. Heavy and / or large items 12 are preferably arranged in a lower part of the packing pattern, while light and / or small items 12 are preferably positioned in an upper part of the stack of items to be formed on the target pallet 34. The order in which the corresponding source pallets 30 are provided at the delivery positions 58 is therefore relevant.

[0104] While the conveyors 38 could also exit from the end walls 70 of the rack 24, in this case only a single receiving position 66 would be available within the rack 24, reducing throughput. This single receiving position 66 would represent a bottleneck for the RBG 28 because source pallets 30 cannot be temporarily parked there, as is shown in the arrangement of the Fig. 5 but that is the case. Furthermore, the route of the conveyors 38 from shelf 24 to the portal robot 36 would be more complex, as switches and crossings would have to be used to terminate in the corresponding number of delivery positions 58, as is the case in Fig. 5 is shown.

[0105] In the Fig. Figure 5 shows two exemplary packing positions 62-1 and 62-2, which may have a table-like frame and optionally also conveying means to provide the empty target pallets 34 at predetermined locations that correspond to packing position 62.

[0106] While the portal robot 36 moves the article 12 to the target pallet 34, the source pallet 30 can already be moved back to the shelf 24 by moving the source pallet 30 to the pickup position 66, where it is picked up by the RBG 28 and transferred to the old (or alternatively to a new) storage location 32.

[0107] In the Fig. The corresponding movements are indicated by arrows in 5.

[0108] Dispensing positions 58-1 to 58-4 are operated dynamically, preferably dispensing items 12 with access frequencies B and C. Dispensing positions 58-5 and 58-6, which are located adjacent to packing positions 62-1 and 62-2 along the outer edge X, are operated statically. This means that the source pallets 30 remain there until all items 12 have been removed and these source pallets 30 are "empty." These source pallets 30 are not returned to the rack 12. The source pallets 30 at static dispensing positions preferably contain items 12 with access frequency A.

[0109] For the reasons stated above, packing positions 62 are preferably not arranged on the side of the (dynamic) dispensing positions 58-1 to 58-4. The packing position(s) 62 are preferably arranged opposite (in the transverse direction Z) to the dispensing positions 58-1 to 58-4.

[0110] In the Fig. The discharge positions 58-1 to 58-4 are arranged in the transverse direction Z at intervals from the packing positions 62 to accommodate an (optionally provided) discharge conveyor 72, which can be used to remove intermediate layers (e.g., cartons) used between layers of items on the source pallets 30 from the operating area. The discharge conveyor 70 can also be used to remove empty pallets, e.g., with the handling unit 37, which have been emptied at the static discharge positions 58-5 and 58-6, to make room for new source pallets 30.

[0111] It is understood that positions 58-1 to 58-4 can also be arranged without any distance in the Z-direction to positions 58-5, 58-6, 62-1 and 62-2 in order to keep the picking zone 16 small (reduced space requirement).

[0112] The dynamic delivery positions 58-1 to 58-4 are arranged as follows: Fig. 5 is preferably positioned “above” the conveyor 72, and the static discharge positions 58-5 and 58-6, as well as the packing positions 62-1 and 62-2, are preferably positioned “below” the conveyor 72. This has the advantage that the material flows of the discharge positions 58 and the packing positions 62 mix little or not at all, resulting in increased throughput.

[0113] It goes without saying that in the Fig. Five more or fewer packing positions 62 than shown can be used. Furthermore, it is understood that the dispensing positions 58-1 to 58-4 can also be operated statically and / or the dispensing positions 58-5 and 58-6 can also be operated dynamically. Dispensing positions 58-5 and 58-6 can also be omitted or replaced by additional packing positions 62. The base area of ​​the action space, in particular its length in the X direction, can be increased or decreased to define more or fewer positions 58 and / or 62.

[0114] In general, each system 10 also has a control unit 74 that controls the material flow and is preferably configured to determine the packing pattern. To this end, the control unit evaluates the orders and / or the packing pattern and generates corresponding transport orders to initiate the necessary movements of the source pallets 30 and destination pallets 34 using the conveying technology (e.g., stacker crane 28, conveyor 38, roller conveyor 42, forklift 52, transfer car 60, etc.).

[0115] It is understood that the planning software for the packing pattern can also be run on a computer that is separate from the controller 74. In this case, the controller 74 determines the source pallets 30 required for the batch from the data received by the planning software, preferably via an article identifier.

[0116] The Fig. Figure 5 illustrates a “picking cell” formed by a section of shelf 24 and the associated portal robot 36 or its action space, which is located directly opposite the shelf section and is directly connected to shelf 24 via several of the conveyors 38 that tunnel through shelf 24 or the corresponding section of shelf 24.

[0117] It is understood that several of these picking cells can be arranged directly adjacent to each other, or spaced apart, along one or both long sides of the shelf 24.

[0118] Furthermore, it is understood that, in general, each of the portal robots 36 defines its own action space, which is usually bounded by the portal frame. If several portal robots 36 are arranged directly adjacent to one another, they can share a (single) portal frame. In this case, each of the portal robots 36 is essentially defined by its manipulation unit 37 and the associated crossbeam, which is movable in the X-direction on the portal frame. The movements can overlap, meaning that certain areas of the (shared) portal frame can be reached by several crossbeams (at different times). This means that the action spaces can overlap. In this case, the boundaries of the action spaces are not rigid, as is usually the case, but dynamic.

[0119] Fig. Figure 7 shows a flowchart of a procedure 100 for picking the articles 12 according to picking orders.

[0120] In a first optional step S10, the order is evaluated using the control 74 and / or the separate computer to determine the packing pattern and the required source pallets 30.

[0121] In step S12, the corresponding source palettes 30 are outsourced, as described above.

[0122] In step S14, the outsourced source palettes 30 are transferred to the receiving positions 66, as described above.

[0123] In step S16, the delivered source pallets 30 are conveyed to the corresponding receiving positions 58 by means of the conveyors 38.

[0124] In step S18, the articles 12 are transferred from the source pallets 30 to the target pallet 34 using the portal robot 36. The transfer step S18 includes picking up the articles 12 from the source pallets 30 at the picking positions 58, moving the picked-up articles 12 to a position on the target pallet 34 specified by the packing pattern, and, if necessary, aligning the article 12 accordingly beforehand, and packing the picked-up article 12 onto the target pallet according to the packing pattern.

[0125] In an optional step S20, the source pallets 30 that were not emptied during the previous picking process are returned to storage. These source pallets 30 are located on the dynamic picking positions 58 mentioned above.

[0126] Finished destination pallets 34 can then be transported to shipping zone 20 (not shown).

[0127] The procedure ends at 100. Reference symbol list 10 order picking systems 12 (flat pack) items 14 Storage area 16 Picking zone 18 Goods Receiving Zone 20 Shipping Zone 22 target pallet buffers 24 shelf 26 Shelf Lane 28 Storage and retrieval machine 30 Source palette 32 storage spaces 34 Target range 36 portal robots 38 sponsors 39 Track-in Station 40, 40` Conveyor technology 42 roller conveyors 44 Swivel arm 46 vacuum lifters 48 Rolling table 50 light curtain 52 forklifts 54 Long side 55, 56 End sections of 38 58 Delivery item 60 shunting wagons 62 Packing position 64 Action area 66 Recording position 68 long side of 24 70 Front side of 24 72 discharge conveyors QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] EP 1462393 B1

[0003]

Claims

[1] System (10) for picking articles (12), in particular flatpack articles (12), according to picking orders, wherein the system (10) comprises: a rack (24) which extends substantially along a longitudinal and vertical direction (X, Y) of the system (10) and which has a plurality of storage locations (30) which are set up to store source pallets (30); a portal robot (36) with a manipulation unit (37) which is set up to implement the articles (12); a packing position (62) which is set up to buffer a target pallet (34); a large number of sponsors (38); and a control system (74) which is preferably configured to determine an order-specific packing pattern for each of the orders in order to automatically pack several of the articles (12) from one or more of the source pallets (30) onto a target pallet (34) in the packing position (62) by the portal robot (36) according to the respective order; wherein each of the conveyors (38) has a receiving position (66) which is positioned within the rack (24) and which is set up to receive the source pallets (30), and a delivery position (58) which is positioned within an action space of the portal robot (36) and which is set up to provide the source pallets (30), preferably dynamically; wherein the portal robot (36) defines the action space within which the manipulation unit (37) is movable and which contains the packing position (62) and the delivery positions (58) of the conveyors (38); and wherein the control (74) is further configured to cause such source pallets (30) to be transported from the storage locations (32) via the receiving positions (66) to the delivery positions (58) which contain the articles (12) required for packing according to the respective packing pattern. [2] System (10) according to claim 1, wherein the portal robot (36) is substantially directly adjacent to a longitudinal side (54) of the shelf (24). [3] System (10) according to one of claims 1 or 2, wherein the conveyors (38) are linear continuous conveyors which are bidirectionally operable, are oriented perpendicularly, preferably horizontally perpendicular, to the longitudinal direction (X), and the receiving positions (66) and the delivery positions (58) have at their ends. [4] System (10) according to one of claims 1 to 3, which further comprises at least one storage and retrieval machine (28) which is configured to automatically exchange the source pallets (30) between the storage locations (32) and the receiving locations (66), and which preferably adjoins a longitudinal side (68) of the rack (24) which is facing away from the portal robot (36). [5] System (10) according to one of claims 1 to 4, which further comprises dispensing positions (58-5, 58-6) which are also positioned within the action space and which are set up for the static provision of the source palettes (30). [6] System (10) according to claim 5, wherein at least some, and preferably all, of the further delivery positions (58-5, 58-6) are coupled to a supply conveyor which is different from the conveyors (38) and which preferably comprises a transfer carriage (62). [7] System (10) according to one of claims 1 to 6, further comprising a discharge conveyor (72) which preferably extends parallel to the longitudinal direction (X) and centrally through the action space. [8] System according to any one of claims 1 to 7, wherein the conveyors (38) are arranged at a floor level of the system (10). [9] System according to one of claims 1 to 8, wherein one level of the rack (24) is exclusively provided with the conveyors (38) and wherein preferably several of the portal robots (36) are arranged directly adjacent to each other in the longitudinal direction (X), wherein at least one packing position (62) is provided for each of the portal robots (36). [10] System (10) according to any one of claims 1 to 9, wherein the ratio between the number of conveyors (38) and the number of storage locations along the longitudinal direction (X) is 1:2 or 2:

3. [11] System (10) according to any one of claims 1 to 10, wherein the portal robot (36) is configured to depalletize the source palettes (30) and palletize the target palettes (34) within the action space. [12] System (10) according to any one of claims 1 to 11, wherein each of the flatpack articles (12): rectangular plate-shaped; especially external dimensions in the range of 620x300x7 mm3 to 2550x800x200 mm3; preferably weighs a maximum of 62 kg; and / or preferably includes layered individual parts of a ready-to-assemble piece of furniture. [13] Procedure for picking articles (12) according to picking orders, comprising the steps: Retrieval of source pallets (30) containing the items (12) required for packing according to a packing pattern on a destination pallet (34) from storage locations (32) of a rack (24); Delivery of the outsourced source pallets (30) to receiving positions (66) of conveyors (38), wherein the receiving positions (66) are arranged within the rack (12), wherein the conveyors (38) extend, in particular linearly, from the rack (12) to a portal robot (36) which is arranged along a longitudinal side (54) of the rack (12), preferably directly, laterally adjacent to the rack (12); Transporting, with the conveyors (38), the discharged source pallets (30) from the receiving positions (66) to corresponding discharge positions (58) of the conveyors (38), which are positioned within an action area of ​​the portal robot (36); and Transferring the articles (12) required for packing according to the packing pattern onto the target pallet (34) using a handling unit (37) of the portal robot (36), wherein the target pallet (34) is provided at a packing position (62) within the action space of the portal robot (36). [14] Method according to claim 13, wherein the conversion of the articles (12) comprises: Picking up the items (12) from the source pallets (30) at the delivery positions (58); Moving the picked-up items (12) to a position on the target pallet (34) specified by the packing pattern; and Packing the received items (12) onto the target pallet (34) according to the respective packing pattern. [15] The method of claim 13 or 14, further comprising: Determine, by means of a controller (74) or a computer, the packing pattern for each order including the source pallets (30) which store those of the items (12) required for packing according to the packing pattern onto the destination pallet (34).

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