Shelving system

Abstract

A shelving system for sequencing goods from a high-bay warehouse (1) into sequencing racks (2), comprising a high-bay warehouse (1) with at least one sequencing level (E0), in particular on a floor level, and a plurality of storage levels (E1,..., E5), wherein, during normal operation of the shelving system, large load carriers (3) are stored at storage locations on the storage levels (E1,..., E5), each of which holds goods of a particular type, wherein at least one lift (4) for vertically transporting the large load carriers (3) is arranged in the high-bay warehouse (1), wherein the shelving system comprises at least one transverse transfer carriage (5) for horizontally transporting the large load carriers (3) on each storage level (E1,..., E5), wherein the shelving system comprises a control unit, wherein the control unit is configured to process sequencing orders in such a way that the required large load carriers (3) for a sequencing order are retrieved from the storage levels (E1,...,E5) are delivered to at least one second sequencing area (S2) in the sequencing level (E0), while goods from the required large load carriers (3) for another sequencing order in a first sequencing area (S1) in the sequencing level (E0) are arranged in a sequencing rack (2) of the first sequencing area (S1) and vice versa, so that the required large load carriers (3) for a sequencing order from the storage levels (E1,..., E5) are delivered to the first sequencing area (S1) in the sequencing level (E0), while goods from the required large load carriers (3) for another sequencing order in the second sequencing area (S2) in the sequencing level (E0) are arranged in a sequencing rack (3) of the second sequencing area (S2), wherein each sequencing area (S1, S2) has at least two storage spaces (P) for large load carriers (3) includes,wherein two sequencing areas (S1, S2) form a picking station (P1, P2) for a sequencer, i.e. a worker, wherein a variant number indicates how many storage locations (P) are required for a sequencing order in order to be able to carry out the order, wherein if the variant number is below the number of storage locations (P) of a sequencing area (S1, S2), all large load carriers (3) for the sequencing order are provided in one sequencing area (S1, S2), wherein if the variant number is above the number of storage locations (P) of a sequencing area (S1, S2) but below a variant limit, all large load carriers (3) for the sequencing order are provided in two sequencing areas (S1, S2) which form a picking station (P1, P2), wherein if the variant number is above the variant limit, large load carriers (3) for the sequencing order in two sequencing areas (S1, S2) which form a picking station form (P1,P2) are made available and remaining large load carriers (3) are noted in a surplus list.

Description

Field of the invention

[0001] The present invention relates to a shelving system for sequencing goods from a high-bay warehouse into sequencing racks. State of the art

[0002] It is known that goods can be stored on several levels in a fully automated high-bay warehouse, which is managed by a storage and retrieval machine, so that desired goods are transported from the high-bay warehouse to a workstation at ground level and new goods, or goods delivered to the workstation but not used at the workstation, can be placed back into the high-bay warehouse.

[0003] Furthermore, it is known that in a sequencing process, several single-type loading units, hereinafter referred to as large load carriers, in each of which goods of one type are accommodated and stored, are provided on a floor level and a person removes individual parts or small load carriers from the provided large load carriers and places them on a common load carrier, namely in a sequencing rack.

[0004] For this purpose, many large load carriers are usually made available on the ground level at the same time so that the goods can be removed from the large load carriers for several sequencing orders.

[0005] Such a sequencing process has several disadvantages: There are long walking distances for the people - sequencers - between several sequencing areas, long walking distances in a sequencing area during sequencing, a large space requirement for the provision of many required goods, for example, part variants, and a high risk of injuries since the work areas for forklifts and sequencers coincide.

[0006] EP 3 875 403 A1 discloses a method for storing and / or retrieving stored goods in or from a storage system, in particular a storage and retrieval system, comprising a rack warehouse with a plurality of spaced-apart storage racks, wherein the storage racks have one or more storage locations for a stored good in a plurality of stacked rack levels, and wherein a rack aisle is formed between adjacent storage racks, at least one bidirectional shuttle for transporting stored goods or containers for the stored goods from or to a storage location, wherein the shuttle(s) is / are designed to travel on aisle sections formed in the rack aisles, preferably by guide rails, in a rack level and to travel on one or more connecting sections of the rack warehouse connecting the aisle sections, preferably at the ends of the rack aisles, and at least one lifter arranged adjacent to an aisle section or connecting section,wherein the at least one lifter is designed to transfer and / or receive a stored item or a container for a stored item to and / or from a shuttle and to vertically transport a stored item or a container between shelf levels, wherein the lifter transports a stored item or one or more containers from the second shelf level or from a third shelf level adjacent to the second shelf level to the first shelf level or to a fourth shelf level directly following a vertical transport of a stored item or one or more containers from a first shelf level to a second shelf level.

[0007] DE 10 2014 118 896 A1 shows an order picking device with a plurality of provision locations at which the goods to be picked are provided, and with an automatic warehouse in which the goods to be picked are stored, wherein the warehouse has at least one storage and retrieval machine with which goods can be automatically brought from the warehouse to provision locations and vice versa, wherein the provision locations have provision locations of the first type in which a plurality of identical goods are provided in a storage and transport unit in a provision location, and wherein the warehouse has a first storage area in which the goods are stored in storage and transport units, wherein the order picking device has a plurality of provision locations of the second type in which one or more identical goods are provided individually in a provision location.

[0008] From DE 10 2014 117 235 A1 a method for operating a warehouse is known in which a shelving rack warehouse with a plurality of levels and storage locations is manually loaded and unloaded with goods by order pickers, wherein at least one central transfer point between the shelves of a level allows loading and unloading of goods, wherein the transfer points arranged on different levels are each connected to one another and to at least one common warehouse entrance and exit by means of conveyor technology. Summary of the invention

[0009] It is an object of the invention to provide a shelf system for sequencing goods that reduces at least some of the aforementioned problems. In particular, it enables shorter walking distances and thus faster, more efficient sequencing.

[0010] The problem is solved by a shelving system for sequencing goods from a high-bay warehouse into sequencing racks having the features according to claim 1.

[0011] The shelving system comprises a high-bay warehouse with at least one sequencing level, in particular on a floor level, and several storage levels, wherein, during normal operation of the shelving system, large load carriers are stored at storage locations on the storage levels, each of which contains goods of a specific type, wherein at least one lift is arranged in the high-bay warehouse for the vertical transport of the large load carriers, wherein the shelving system comprises at least one transverse transfer carriage on each storage level for the horizontal transport of the large load carriers, wherein the shelving system comprises a control unit, wherein the control unit is configured to process sequencing orders in such a way that the required large load carriers for a sequencing order are delivered from the storage levels to at least one second sequencing area on the sequencing level,while goods from the required large load carriers for another sequencing order in a first sequencing area in the sequencing level are arranged in a sequencing rack of the first sequencing area and vice versa, so that the required large load carriers for one sequencing order are delivered from the storage levels to the first sequencing area in the sequencing level, while goods from the required large load carriers for another sequencing order in the second sequencing area in the sequencing level are arranged in a sequencing rack of the second sequencing area.

[0012] According to the invention, an automated high-bay rack provides an employee or a robot, i.e., a "sequencer," who arranges the individual goods from large load carriers (LLCs) into a sequencing rack, with precisely the material or component required for the next sequencing process / order, i.e., the corresponding LLCs required for the sequencing order, in a sequencing area. Two or more sequencing areas can be managed alternately by one person. During sequencing in one sequencing area, a material change, i.e., the delivery of the required LLCs, takes place in at least one other sequencing area.The sequencer is not interrupted from their sequencing activities by the material delivery to the other sequencing area and can then switch to the other sequencing area that has been prepared in the meantime, which can preferably be located directly next to the previously processed sequencing area. The material changeover includes not only the delivery of the large load carriers required for the next sequencing order, but also the collection of the no longer required large load carriers from the previous sequencing order.

[0013] The sequencing areas for a sequencer, i.e. a worker, are collectively called a “picking station” or “SEQ bay” or picking station.

[0014] A variant count indicates how many slots are required for a sequencing job to be able to carry out the job.

[0015] According to the invention, if the number of variants is less than the number of storage spaces in a sequencing area, all large load carriers for the sequencing order are provided in one sequencing area, wherein if the number of variants is greater than the number of storage spaces in a sequencing area but less than a variant limit, all large load carriers for the sequencing order are provided in two sequencing areas that form a picking station, wherein if the number of variants is greater than the variant limit, large load carriers for the sequencing order are provided in two sequencing areas that form a picking station and remaining large load carriers are noted in a surplus list.

[0016] For the provision of goods, the vertical and horizontal movements are divided between several mechanical components, namely at least one lift and a transverse transfer carriage (QVW) for the horizontal movements on the floors, whereby the provision and return of several load carriers can be carried out simultaneously after different provision times in sequencing areas within the warehouse.

[0017] This makes the sequencing process as efficient as possible. The space required to store the many different part variants is reduced, and walking distances for the sequencer are minimized. A "goods-to-person" concept is applied, which, as a positive side effect, reduces the potential for danger between the forklift and the worker.

[0018] A "sequencing level" is a level that has at least one sequencing area. Sequencing can optionally be performed not only within a single level but also on different levels, so that multiple levels of a shelf can form sequencing levels.

[0019] The "floor level" and lowest level of the shelving system can preferably represent a sequencing level, but alternatively or additionally, other levels of the shelving can form a sequencing level. Sequencing can occur at a different level, for example, even if the high-bay warehouse is not located at the general floor level of the hall, but rather begins further down, deeper in the ground, and only a portion of the high-bay warehouse protrudes above the hall floor level. The sequencing level can also not be the lowest level, but rather somewhere vertically in the middle, for example, or even the top level of the shelving.

[0020] A "sequencing level," especially the floor level, may not be designed exclusively as a "sequencing level," but may also be designed as a "storage level." Thus, a level can simultaneously form a sequencing level and a storage level, for example, the floor level.

[0021] In this document, “large load carrier” is understood to mean a loading unit with goods or material, in contrast to, for example, the load carrier “sequencing rack”.

[0022] Further developments of the invention are specified in the dependent claims, the description and the accompanying drawings.

[0023] According to the invention, each sequencing area comprises at least two storage spaces for large load carriers, preferably three to ten storage spaces for large load carriers, in particular six storage spaces for large load carriers. This minimizes the distances for the sequencer.

[0024] Preferably, the lift or lifts are arranged along the longitudinal extent of the high-bay warehouse, inside the high-bay warehouse, preferably centrally, so that the first sequencing area is arranged on one side of the lift and the second sequencing area is arranged on the other side of the lift.

[0025] The shelving system comprises at least one, preferably two, transverse transfer carriages on each storage level for the horizontal transport of large load carriers, with one transverse transfer carriage being set up on one side of the lift for the transport of large load carriers on the storage level, and the other transverse transfer carriage being set up on the other side of the lift for the transport of large load carriers on the storage level. In a preferred embodiment, only one transverse transfer carriage is used on each storage level, and two transverse transfer carriages are used on a sequencing level or on a combined storage and sequencing level. In another variant, two transverse transfer carriages per level are provided on the pure storage levels to increase the throughput of large load carriers.

[0026] The high-bay warehouse is preferably designed as a double rack, so that it comprises a front high-bay rack and a parallel rear high-bay rack. The control unit is configured to deliver the required large load carriers for sequencing orders from the storage levels to at least a first and a second front sequencing area in the sequencing level, which are assigned to the front high-bay rack, and to deliver the required large load carriers for sequencing orders from the storage levels to at least a first and a second rear sequencing area in the sequencing level, which are assigned to the rear high-bay rack. The control system therefore also comprises two or at least two sequencing areas on both sides, front and rear, namely preferably a left and a right sequencing area.The lift or lifts can be arranged - along the length of the shelves - between the two sequencing areas on each side, i.e. at the front and rear of the double shelf.

[0027] The control unit is then preferably configured so that for each of the two shelves of the double rack, the two sequencing areas are alternately processed by the sequencer and refilled via a lift and transverse transfer carriage. While goods from the required large load carriers for one sequencing order are placed into a sequencing rack in one sequencing area on the sequencing level, the required large load carriers for another sequencing order are delivered to the other sequencing area on the sequencing level.

[0028] Preferably, the transverse transfer carriages are located between the front and rear high-bay racks of the high-bay warehouse. The lifts can be arranged laterally next to a central aisle for the transverse transfer carriages. The lifts can thus be located next to the storage spaces for large load carriers.

[0029] The shelving system preferably comprises at least two lifts, particularly preferably exactly two lifts. Preferably, one lift is configured for the vertical transport of the large load carriers of the front high-bay rack, and one lift is configured for the vertical transport of the large load carriers of the rear high-bay rack.

[0030] The shelving system preferably comprises four lifts or four transfer stations, with two lifts or transfer stations being arranged at least indirectly next to one another and configured for the vertical transport of the large load carriers of the front high-bay rack, and two lifts or transfer stations being arranged at least indirectly next to one another and configured for the vertical transport of the large load carriers of the rear high-bay rack. Vertical transport can be provided for transfer stations by a lift arranged between each of them. Thus, in particular, there can be four transfer stations and two lifts in the shelving system, with one lift preferably being arranged between each of the two transfer stations.

[0031] At the “transfer points”, large load carriers are preferably not transported outside the warehouse; instead, these points are used to move large load carriers only within the warehouse - in particular to / from the lift or to / from the transverse transfer carriage.

[0032] The lifts or transfer stations and the control unit are preferably configured such that the large load carriers can each be moved from one of the two lifts or transfer stations arranged next to one another to the other of the two lifts or transfer stations arranged next to one another, i.e. can change the respective location, wherein the change of location for transfer stations can take place indirectly via a lift and / or after a change of level.

[0033] Preferably, on each storage level, the front lifts or transfer stations are configured such that the large load carriers each change location in a first direction from one of the two lifts or transfer stations arranged next to one another to the other of the two lifts or transfer stations arranged next to one another, and the rear lifts or transfer stations are configured such that the large load carriers or transfer stations each change location in a second direction, which is opposite to the first direction, so that the respective front lifts or transfer stations are configured for transport in the opposite direction to the respective rear lifts or transfer stations. This allows all large load carriers to be transported to and from both sequencing areas (left and right) without interfering with one another.

[0034] The shelving system preferably comprises two lifts, one lift being configured for the vertical transport of the large load carriers of the front high rack and one lift being configured for the vertical transport of the large load carriers of the rear high rack.

[0035] Particularly preferably, the shelving system comprises two lifts and four transfer stations, with each of the two lifts being arranged between two transfer stations. In this embodiment, a high-bay warehouse system has two lifts—namely, one lift for the front high-bay rack and another lift for the rear high-bay rack—and four transfer stations. This allows for a one-way system as described above. The large load carriers can be transported from a transverse transfer carriage to the transfer station and from there into the lift—and, for example, on a different level, from the lift to another transfer station. Brief description of the drawings

[0036] The invention is described below by way of example with reference to the drawings. Fig. 1 shows a three-dimensional overview of the components and areas included in a possible embodiment of a shelving system according to the invention (also referred to as automatic grab warehouse “AGL”). Fig. 2 shows a schematic overview of the components and areas in a shelving system according to the invention. Fig. Figure 3 shows a schematic sequence of sequencing jobs. Fig. Figure 4 shows schematically how several AGLs can be used in combination. Fig. 5 shows a schematic overall view of the simulation model. Fig. Figure 6 shows a schematic representation of a subnetwork EOL and EOR. Fig. Figure 7 shows a schematic of a subnetwork E1 - E5. Fig. Figure 8 shows a schematic diagram of order creation and assignment. Fig. Figure 9 shows schematically transport routes between the levels. Fig. Figure 10 shows schematically transport routes between E0L and E0R. Fig. 11 shows schematically a provision of the GLTs. Fig. Figure 12 shows a schematic of a return transport of the GLTs. Detailed description of the invention

[0037] In Fig. 1 shows a shelving system according to the invention.

[0038] Lifts 4 are also called “lifters”.

[0039] Transverse transfer vehicles 5 are also called “shuttles” and abbreviated to “QVW”.

[0040] The sequencing areas for a sequencer, i.e. a worker - namely preferably the first sequencing area S1 and the second sequencing area S2 - are together also called a "picking station" or a "SEQ bay" or picking station.

[0041] The core of a shelving system according to the invention is a high-bay warehouse 1 with automated horizontal and vertical transport components, namely lift 4 and transverse transfer carriage 5, to transport the required material, namely the required large load carriers 3, of the next sequencing order to the sequencing area S1, S2. On the lowest level E0, there are at least two sequencing areas S1, S2 to the left and right of lift 4. Several areas can be processed alternately by one or more sequencers. Several areas can also be combined into a common area for a short time. The areas can also come from more than one high-bay rack - see Fig. 4. While at least one sequencer in one area, for example, S1, sequences the actual sequencing order, in at least one other area, for example, S2, the material from the previous order is returned to the warehouse and the material is prepared for the next sequencing order. The sequencer is provided with only the material it needs for its sequencing task. After completing its sequencing order, the sequencer can switch to another sequencing area that has already been prepared for the next order. What is associated with sequencing in this text can also be used for picking.

[0042] Fig. 2 shows a schematic overview of the components and areas in a shelving system according to the invention, namely at the top at a) a side view, in the middle at b) a plan view of the storage levels E1-E5, at the bottom at c) a plan view of a level with sequencing areas, namely here the floor level, E0.

[0043] Full and empty container locations for large load carriers 3 can be replaced by a pre-zone. Any number of sequencing areas S1, S2 can be used, even by multiple high-bay warehouses 1 in a network. Fig. 2 shows two front sequencing areas S1V and S2V, which together can form a first picking station P1, and two rear sequencing areas S1H and S2H.

[0044] “Pre-zone” means storage locations for GLTs 3, e.g. storage and retrieval locations at the left edge of the shelf, in order to supply the shelf using a forklift and refilled GLTs 3 or to remove empty GLTs 3 from the shelf.

[0045] In the AGL shown, main storage locations for GLT are also shown on level E0. Therefore, sequencing level E0 is not only a sequencing level, but also a storage level. Level EO is thus a level in which sequencing areas are located, preferably in addition to other areas.

[0046] The illustrated design with two transverse transfer carriages 5 is the preferred variant for level E0 or generally for level(s) with sequencing areas. For storage levels such as E1-E5, the preferred, more cost-effective variant is only one transverse transfer carriage 5 per level. However, a variant with two transverse transfer carriages 5 per storage level E1-E5 would also be advantageous and enables faster pickup or delivery of goods.

[0047] Fig. Figure 3 shows a schematic flow of sequencing jobs that are processed one after the other. 1. A respective employee processes the active sequencing order at both picking stations - for example, at the front, right, in S2V and at the back, left, in S1H - i.e. diagonally offset on both sides of the shelf. 2. In the meantime, on the other side of the respective picking station, the old sequencing order can be stored back into the automatic storage system and all part variants for the next sequencing order can be made available from the automatic storage system. 3. If necessary, a loading unit can also be exchanged in the active sequencing order. 4. After completing the active sequencing job, the employee can change sides within the picking station, for example in P1 from S2V to S1V, and start sequencing the next job.

[0048] Fig. 4 shows schematically that several AGLs, i.e. automatic gripper warehouses, i.e. shelving systems, can be used in combination.

[0049] Here, the workstation Pickstation 2 can comprise the sequencing areas of two different high-bay racks, preferably a first and a second sequencing area S1, S2 of each of the two high-bay racks.

[0050] The system is highly flexible and easy to adapt. It can be customized to meet the required throughput, storage capacity, and available warehouse space. Storage levels E1 - E5 are connected by at least one Lift 4. No system-specific storage technology is required; conventional pallet racking can be used instead. Adapting or connecting the system technology to the racking system is not necessary. The length and height of the rack rows are freely scalable. Depending on the required throughput, a corresponding number of mechanical components (Lifts 4 and Transverse Transfer Carriages 5) must be used. The type of load handling device must be selected depending on the type of goods (SLC / GLC) to be moved. These can be designed as telescopic forks, chain conveyors, roller conveyors, belt conveyors, or similar. The use of system pallets is also possible.Depending on the design, the transverse transfer carriages 5 could also change levels together with the load carriers 3, for example, as a type of mobile undercarriage for large load carriers. In a preferred variant, however, the transverse transfer carriages are permanently assigned to the levels, and only the large load carriers are transported / moved by the transverse transfer carriage to the transfer points, and only the large load carriers change levels.

[0051] The sequencing of small load carriers and individual parts from the provided load units in sequencing containers, i.e., sequencing racks 2, can be performed manually or automatically, e.g., using a robot arm. This sequencing container 2 can be transported to the assembly line manually (e.g., lifting fork, rolling rack), semi-automatically (e.g., forklift), or fully automatically (e.g., AGV). A sequencing container or rack 2 can contain part variants of one or more part families for one or more production pieces.

[0052] The system does not have a pre-load area for staging load units. The lowest storage level (EO) can be used for this purpose. The system is primarily designed for picking small load carriers but also for sequencing parts. Several systems of this type can be arranged side by side in a network and further connected via conveyor technology to optimize the staging area and maintain flexibility. Furthermore, at least one automated high-bay warehouse, which serves as the main warehouse, can be installed upstream of this system in a series or in a row.

[0053] Fig. 5 shows schematically an overall view of a simulation model of a shelf according to the invention.

[0054] Fig. Figure 6 shows a schematic diagram of a subnetwork E0L and E0R, i.e. the level 0-left E0L and level 0-right E0R, i.e. the floor level, of a shelving system.

[0055] The two subnetworks “Level 0-Left” (E0L) and “Level 0-Right” (EOR), shown in Fig. 6 as subnetworks E0L and E0R, are very similar. Both have at least one transfer carriage 5 and at least two transfer stations. The rack rows can be positioned on either side of the transfer carriage 5. In the middle between the rack rows is the QVW lane for at least one transfer carriage 5. At least one QVW can be used jointly for E0L and E0R, or, to increase GLT throughput, as in Fig. As shown in Figure 2, one QVW can be used for E0L and another QVW for E0R - preferably two QVWs for the sequencing level E0.

[0056] The storage locations closest to transfer points 6 are used as sequencing locations. Both sub-networks combine these sequencing locations into two sequencing areas S1, S2. The difference between the two networks is that, for example, in the front left of the E0L, additional storage locations are classified as storage and retrieval locations. However, several of these storage locations can also be arranged in different positions. These are ideally placed as close as possible to the sequencing area S1, S2, with a distance from a main storage location. The distance from a main storage location is preferable in order to separate the work areas of the workers and forklifts for safety reasons. These storage and retrieval locations can also be replaced by a fully automated pre-zone, whereby the goods, for example,is placed by a lifter 4 on the corresponding level at a transfer point 6 and from there is further stored by a QVW 5.

[0057] Fig. Figure 7 shows a schematic diagram of a subnetwork E1 - E5, i.e. levels 1 - 5.

[0058] The subnetwork "Levels 1 - 5" E1 - E5 consists of at least one transverse transfer carriage 5, for example, four transfer stations 6, and laterally arranged rack row(s). The QVW lane for at least one transverse transfer carriage 5 is located in the center. The storage spaces at the front left are ideally reserved for the storage and retrieval locations. They must be at least the same distance from lift 4 as the retrieval locations in E0L. Here, too, the pre-zone described above can replace the storage and retrieval locations.

[0059] In the following and in Fig. Chapter 8 describes processes and their strategies in high-bay warehouses. The following processes are typically performed in the same order for each order. However, since the system can have four sequencing areas (S1V, S1H, S2V, S2H), allowing four orders to be processed in parallel, all processes can be performed simultaneously, depending on the progress of the respective order.

[0060] Additional detailed explanation regarding software program: The starting point for the first process “Create and assign orders” is the input data from past working days or current data provided by the company.

[0061] Create and assign orders: The first step is to create sequencing orders from the sequence data. Each order subsequently represents a full sequencing rack 2. The process is Fig. 8 Order creation and assignment illustrated graphically. During this order creation, each order is given its own name, which can consist of the name of the respective sequencing scope and a consecutive serial number. The sequence of parts, the quantity of parts, and the total number of variants are noted under each order name. The number of variants indicates how many storage locations are required in the sequencing area to process the order. The number of variants refers to the vehicle variants present in the production line for which the sequencing rack is filled, for example, with different variants of steering wheels. A separate large load carrier must be provided in the sequencing area for each of these variants of steering wheels.

[0062] The "OrdersS" table in the illustration is required for subsequent sequencing and specifies the sequence and quantity of the part removal. The "OrdersB" table in the illustration is required for the subsequent provision of the large load carriers 3 (LLCs) and specifies which LLCs and how many parts from them are required for the order.

[0063] To sequence an order, the required variants must now be made available in a sequencing area. To do this, the required variants are searched for in the inventory of the automated grab warehouse (AGL), i.e., the shelving system, and reserved for this order. When making the reservation, care should be taken to ensure that the fill level of the GLT is sufficient for this one order. If this is not the case, the next oldest GLT of the same variant should also be made available. This special case is called double provisioning and increases the number of variants for this order by one, as an additional storage space is required. If all GLTs are reserved for an order, this order can be added to a transport pool.All the information necessary for the system to later locate the reserved GLTs is temporarily stored under the order name. The "Transport Pool Number" parameter can be freely selected and specifies how many such orders should be in the transport pool.

[0064] For example, the transport pool size is six. Thus, six orders with their reserved GLTs are in the transport pool, waiting to be assigned to a free sequencing area.

[0065] When assigned, the transport pool could pass its information about this order to the system and delete it to make room for a new order.

[0066] Normally, the oldest order in the transport pool is always assigned to a free sequencing area. However, if the number of variants exceeds the number of free slots in the sequencing area, this order can be skipped. After that, the number of variants of the next oldest order in the transport pool is always checked. The first order with a sufficiently small number of variants could be assigned. The next time an order is assigned, the check of the number of variants begins again with the oldest order. The task of the transport pool would be to ensure that a suitable order is always available for assignment to prevent sequencing areas from becoming unoccupied.

[0067] For optimal worker utilization, one sequencing area should be made available at a time while the neighboring sequencing area is sequenced by a worker, and vice versa. A free sequencing area with, for example, six locations would have six free locations. However, it is possible that there are many orders with a number of variants greater than six. Therefore, it is planned that an order for one sequencing area can be extended to the neighboring sequencing area. This means that not only six locations but twelve locations are available for one order. To maintain the aforementioned alternating operation of the neighboring sequencing areas, it should be ensured that there is always space for two orders in the twelve locations. This would be possible at any time with a correctly selected variant limit. The variant limit and the three ways of handling an order are explained in the following subsections.

[0068] Fig. Figure 8 shows a schematic diagram of order creation and assignment.

[0069] If the number of variants for an order exceeds the variant limit, the variants above this limit could still be reserved for that order, but instead of being listed with the other GLTs in the transport pool, they could be temporarily stored in a surplus list under the relevant order name. How this type of order could be further handled is explained in more detail in the following section using the third option.

[0070] The variant limit would have the effect that orders with any number of variants could be processed and there would still always be enough space for a second order on the total of, for example, twelve possible sequencing positions.

[0071] The three ways in which sequencing orders could be handled, depending on their number of variants, are now briefly explained. It is assumed that, for example, an order with a variant count of three is already being sequenced in the left sequencing area and the right sequencing area has just become free and is waiting for an order assignment. First, the free sequencing slots and thus the maximum permitted number of variants that the new order may have must be determined. In this example, there are sequencing areas with six sequencing slots each. If you subtract three occupied slots from a total of twelve possible for this example, you get nine free slots. If the number of variants is greater than the number of available free slots, the order could be skipped in the transport pool, as already mentioned above, and would only be considered again the next time the order is assigned. 1. Option - Number of variants less than six

[0072] All GLTs can be deployed on the right sequencing area. 2nd possibility - number of variants over six but below the variant limit

[0073] The first six GLTs could be deployed on the right sequencing panel. The rest can be deployed on an adjacent sequencing panel.

[0074] 3rd Option - Number of variants exceeds the variant limit Assuming an example where an order has a number of variants of ten and a variant limit of eight, the first six GLTs could be deployed on the right-hand sequencing area. A further two GLTs can be deployed on the adjacent left-hand sequencing area. The remaining two GLTs can be noted in the backlog list and can wait. As soon as a GLT that has already been deployed is no longer needed, it can be removed from the sequencing area and the ninth GLT from the backlog list can be deployed. This process is repeated until all GLTs for this order have been deployed from the backlog list.

[0075] Before going into more detail about the individual transport routes, the overarching transport strategies should be briefly described. Since many transports are carried out simultaneously and in all directions, simple and basic traffic rules are useful to counteract possible traffic jams or even blockages and to carry out transports as efficiently as possible.

[0076] Fig. Figure 9 shows schematically the transport routes between the levels.

[0077] Fig. Figure 10 shows schematically the transport routes between EOL and EOR.

[0078] The most important measure is the introduction of a one-way system. On each level, there are at least two transfer points, one of which is for receiving and one for dropping off GLTs. Fig. The diagram shown in Figure 10 serves as an example. To transport GLTs to the sequencing area after EOR, they could be dropped off at the "Rear Left Transfer Point" (line). For transport to EOL, the GLT could be dropped off at the "Front Right Transfer Point" (other line). Similarly, the return transport from EOR could arrive at the "Front Left Transfer Point" and the return transport from EOL at the "Rear Right Transfer Point". For a transport from EOR to EOL or vice versa, as shown in the Fig. 10 transport routes between EOL and EOR are visible, connecting the lift platforms with the help of the "Right Transfer Points" and "Left Transfer Points." The one-way system helps prevent two GLTs from facing each other and trying to move in opposite directions.

[0079] This one-way system saves a lot of administrative work for individual transports, as no transport route would have to be blocked off in either direction. This also allows for short queues in each direction, which could have an optimal effect on the utilization of all devices. Each transfer carriage can deposit its load at a transfer point without the risk of an oncoming GLT. If, for example, there are too many transports to EOL, the first GLT could still be served by the transfer carriage in EOL. The following transports, however, could wait at the "front left transfer point" on Level 0, on the elevator at Level 0, and at the "front right transfer points" on Levels 1 - 5 until their predecessors become available. As shown in the Fig. 9 transport routes between the levels, the transport routes at the rear of the facility could run exactly the opposite way round. This would create a clockwise circular flow and maintain the principle of a one-way system for transport between E0L and E0R.

[0080] Each lift could have its own waiting list in which the GLTs can register for a transport. Each transfer carriage could have a storage waiting list and a retrieval waiting list. The GLTs in the storage waiting list want to go from a transfer location to a storage location, and the GLTs in the retrieval waiting list want to go from one storage location to another storage location or to a transfer location. With these three types of lists, the oldest transport could always be selected for a removal, although there could be a few exceptions. The transfer carriages could first process the storage waiting list and then deal with the retrievals. This could prevent the lift from blocking and thus heavy congestion on level 0. Furthermore, the lift could prioritize the transport of a GLT if the lift is already on the level of the GLT.This could reduce empty journeys and would be particularly helpful on Level 0 to minimize congestion on this level.

[0081] Fig. Figure 11 shows a schematic illustration of the provision of the GLTs, with the path of the GLT indicated as an arrow.

[0082] After an order has been assigned to a sequencing area, the provisioning of the GLTs could begin with the GLTs reserved for it in advance in the high-bay warehouse. The GLTs could receive their target sequencing area and set off with this information. They could enter their name on the retrieval queue of the transfer carriage 5 on their level and wait until it is in their position. The transfer carriage 5 picks up the GLT and takes it to a transfer station leading to the target sequencing area. After the GLT has been transferred at the transfer station, the transfer carriage could take the next transport from its queues and set off. In the meantime, the GLT could enter its name on the queue of the adjacent elevator. The GLT could be picked up by the elevator and transported towards Level 0.The lift delivers the GLT to one of the transfer locations on Level 0 and could move to its next position on its waiting list. The GLT could enter its name on the storage waiting list for the transfer car on Level 0 and wait until it's its turn. Once the transfer car is at the transfer location, it picks up the GLT and transports it, for example, to the nearest free location in the target sequencing area E0L.

[0083] As soon as at least one GLT of an order is provided, the parts could be removed from the provided GLTs and placed in the sequencing rack.

[0084] For orders whose number of variants exceeds the variant limit, the GLTs can be swapped during sequencing, as described above in "Three Options for Order Handling." At the end of a sequencing, the worker can move from the left side to the right side or vice versa to sequence the next order.

[0085] Fig. Figure 12 shows a schematic of a return transport of the GLTs.

[0086] The return transport for a GLT can be released as soon as no further parts are needed from that GLT or it is empty. These released GLTs could be removed from the sequencing areas even if the worker has not yet completed the sequencing process for the order. A free main storage location could be found for them and returned there, or they could be removed from storage as empties.

[0087] For all the cases just mentioned, the return transport process could be the same. The GLT could again enter its name on the retrieval waiting list of the transfer car on Level 0 and wait for the customer. This could then take the customer to a retrieval, main storage, or transfer location on Level 0, depending on the case. If the customer arrives at a transfer location, the GLT could enter its name on the waiting list for the elevator, which could transport the customer to the level where, for example, its assigned main storage location or retrieval location is located. After the transfer from the elevator to the transfer location, the GLT could enter its name on the storage waiting list of the transfer car on this level. The GLT can wait until it is its turn and then go to its location or main storage location (in Fig. 12 for example, third place on the left in one of the levels E1 - E5) where it waits for its next call.

[0088] Overall, the most important process steps that can be supported by a shelving system according to the invention are: A worker / sequencer removes the desired material from the single-type loading units / boxes / component boxes / pallet boxes - referred to here in the text as large load carriers (=GLT) 3, which are made available to the worker by the AGL in the sequencing level, here the lowest level EO of the high bay 1 of the AGL depending on the specific sequencing order (see e.g. Fig. 2) and places them in a sequencing rack 2, which is then brought to the production line to assemble the parts according to the sequence (variants) of the vehicle bodies arranged on the production line (not shown). The term "large load carrier" used in this text does not imply any restriction on the size of the components / materials held in the load carrier and required for the respective sequencing. All components that are suitable for sequencing in vehicle production fall under this definition.

[0089] The worker / sequencer is supported by the AGL in that the AGL, as in Fig. 2, on the lowest level on each side of the AGL there are two sequencing areas S1V, S2V, S1H, S2H - to the left of the lift, for example, S2H, and to the right of the lift, for example, S1H on one side. Two sequencing areas, such as S1H and S2H, form a picking station, e.g. P2 here. The same applies to the opposite side of the AGL. For this purpose, the AGL preferably provides six storage spaces P for GLTs in each sequencing area S1V, S2V, S1H, S2H, which are automatically stocked by the AGL with the required component boxes or GLTs 3 according to the respective order to be sequenced. Six storage locations P or the possibility of providing a maximum of six component boxes / GLTs 3 per sequencing area is the preferred, most optimal variant, due to the time required by the worker who has to go from box to box, space consumption, etc. In the sequencing area S1H, only three GLT 3 are provided for the current sequencing order, three locations P remain free.The sequencing area S2H is still under construction; four P locations are currently still free, and two P locations already have a GLT 3; the material changeover is still in progress. The GLT 3s are moved on the AGL using Lift 4 – for up and down transport – and QVW 5 in the rack to the left and right. The QVW 5 transports the GLT 3 in EO to the correct position in the respective sequencing area. To do this, the QVW simply positions / pushes the GLT 3 from the inside to the outside, or the GLT 3 transported in the middle between the two rows of shelves to the appropriate position in the respective sequencing area to the outside or under the rows of shelves – to the correct sequencing area S1V, S2V, S1H, S2H. In this way, the worker / sequencer (shown between sequencing station 2 and AGL) is not hindered in his sequencing during the exchange of GLTs 3 (because a new sequencing job with other components is pending or a GLT becomes empty).It can, for example, as in . Fig. 2, complete the job in sequencing area S1H while sequencing area S2H is prepared for the next sequencing job. Forklifts or other people approaching the sequencing area are also not hindered. On the other side of the AGL, another worker / sequencer is shown who is currently processing his job in sequencing area S1V and is taking the parts / material available for his sequencing job from the four GLTs 3 provided to him by the AGL and placing them in his sequencing station 2. While the sequencing area S2V is automatically prepared for the next sequencing job for this worker / sequencer by the AGL.

[0090] The picking of parts / small load carriers from the GLTs 3 to fill the sequencing rack / container 2 can be done not only manually, by workers, but also automatically, by robots.

[0091] A “one-way transport strategy” can preferably be used for the GLTs 3, as described above. List of reference symbols 1 high-bay warehouse 2 sequencing racks 3 large load carriers 4 elevators 5 transverse transfer carriages 6 Transfer point E0 sequencing level E0L sequencing level left E0R sequencing level right E1, E2, E3, E4, E5 storage levels P parking space P1 Picking Station 1 P2 Picking Station 2 S1 first sequencing area S2 second sequencing area S1V first anterior sequencing area S2V second anterior sequencing area S1H first posterior sequencing region S2H second rear sequencing area

Claims

[1] Shelving system for sequencing goods from a high-bay warehouse (1) into sequencing racks (2), comprising a high-bay warehouse (1) with at least one sequencing level (E0), in particular on a floor level, and a plurality of storage levels (E1,..., E5), wherein, during normal operation of the shelving system, large load carriers (3) are stored at storage locations on the storage levels (E1,..., E5), each of which holds goods of a particular type, wherein at least one lift (4) for vertically transporting the large load carriers (3) is arranged in the high-bay warehouse (1), wherein the shelving system comprises at least one transverse transfer carriage (5) for horizontally transporting the large load carriers (3) on each storage level (E1,..., E5), wherein the shelving system comprises a control unit, wherein the control unit is configured to process sequencing orders in such a way that the required large load carriers (3) for a sequencing order are retrieved from the storage levels (E1,...,E5) are delivered to at least one second sequencing area (S2) in the sequencing level (E0), while goods from the required large load carriers (3) for another sequencing order in a first sequencing area (S1) in the sequencing level (E0) are arranged in a sequencing rack (2) of the first sequencing area (S1) and vice versa, so that the required large load carriers (3) for a sequencing order from the storage levels (E1,..., E5) are delivered to the first sequencing area (S1) in the sequencing level (E0), while goods from the required large load carriers (3) for another sequencing order in the second sequencing area (S2) in the sequencing level (E0) are arranged in a sequencing rack (3) of the second sequencing area (S2), wherein each sequencing area (S1, S2) has at least two storage spaces (P) for large load carriers (3) includes,wherein two sequencing areas (S1, S2) form a picking station (P1, P2) for a sequencer, i.e. a worker, wherein a variant number indicates how many storage locations (P) are required for a sequencing order in order to be able to carry out the order, wherein if the variant number is below the number of storage locations (P) of a sequencing area (S1, S2), all large load carriers (3) for the sequencing order are provided in one sequencing area (S1, S2), wherein if the variant number is above the number of storage locations (P) of a sequencing area (S1, S2) but below a variant limit, all large load carriers (3) for the sequencing order are provided in two sequencing areas (S1, S2) which form a picking station (P1, P2), wherein if the variant number is above the variant limit, large load carriers (3) for the sequencing order in two sequencing areas (S1, S2) which form a picking station form (P1,P2) are made available and remaining large load carriers (3) are noted in a surplus list. [2] Shelving system according to claim 1, characterized by that each sequencing area (S1, S2) comprises three to ten storage spaces (P) for large load carriers (3), particularly preferably about six storage spaces (P). [3] Shelving system according to claim 1 or 2, characterized by that the lift (4) is arranged along the longitudinal extent of the high-bay warehouse (1) in the interior of the high-bay warehouse (1), preferably approximately centrally, so that the first sequencing area (S1) is arranged on one side of the lift (4) and the second sequencing area (S2) is arranged on the other side of the lift (4). [4] Shelving system according to claim 3, characterized bythat the shelving system comprises two transverse transfer carriages (5) for the horizontal transport of the large load carriers (3) in each sequencing level (E0) and / or in each storage level (E1,.., E5), wherein one transverse transfer carriage (5) is set up for the transport of the large load carriers (3) in the storage level (E1,.., E5) on one side of the lift (4) and the other transverse transfer carriage (5) is set up for the transport of the large load carriers (3) in the storage level (E1,.., E5) on the other side of the lift (4). [5] Shelving system according to at least one of the preceding claims, characterized byin that the high-bay warehouse (1) is designed as a double rack, so that it comprises a front high-bay rack and a rear high-bay rack parallel thereto, wherein the control unit is set up to deliver the respectively required large load carriers (3) for sequencing orders from the storage levels (E1,.., E5) to at least a first and a second front sequencing area (S1V, S2V) in the sequencing level (E0), which are assigned to the front high-bay rack, and to deliver the respectively required large load carriers (3) for sequencing orders from the storage levels (E1,.., E5) to at least a first and a second rear sequencing area (S1H, S2H) in the sequencing level (E0), which are assigned to the rear high-bay rack. [6] Shelving system according to claim 5, characterized by that the transverse transfer carriages (5) are arranged between the front and rear high racks of the high rack warehouse (1). [7] Shelving system according to at least one of claims 3 to 4 and at least one of claims 5 to 6, characterized by that the shelving system comprises four lifts (4) or four transfer stations (6), wherein two lifts (4) or transfer stations (6) are arranged at least indirectly next to one another and are set up for the vertical transport of the large load carriers (3) of the front high rack and two lifts (4) or transfer stations (6) are arranged at least indirectly next to one another and are set up for the vertical transport of the large load carriers (3) of the rear high rack. [8] Shelving system according to claim 7, characterized bythat the lifts (4) or transfer points (6) are set up in such a way that the large load carriers (3) can each be moved from one of the two lifts (4) or transfer points (6) that are arranged next to one another to the other of the two lifts (4) or transfer points (6) that are arranged next to one another, i.e. can change the respective place, wherein the change of place for transfer points (6) can preferably take place indirectly via a lift (4), and / or wherein the change of place can take place after a change of level (E0,..,E5) by a lift (4). [9] Shelving system according to claim 8, characterized bythat in each storage level (E1,.., E5) the front lifts (4) or transfer stations (6) are arranged in such a way that the large load carriers (3) each change position in a first direction from one of the two lifts (4) or transfer stations (6) arranged next to one another to the other of the two lifts (4) or transfer stations (6) arranged next to one another, and the rear lifts (4) or transfer stations (6) are arranged in such a way that the large load carriers (3) or transfer stations (6) each change position in the second direction, which is opposite to the first direction, so that the respective front lifts (4) or transfer stations (6) are arranged for transport in the other direction than the respective rear lifts (4) or transfer stations (6). [10] Shelving system according to at least one of claims 3 to 4 and at least one of claims 5 to 6, characterized bythat the shelving system comprises two lifts (4), one lift (4) being arranged for the vertical transport of the large load carriers (3) of the front high rack and one lift (4) being arranged for the vertical transport of the large load carriers (3) of the rear high rack. [11] Shelving system according to at least one of claims 7 to 9 and according to claim 10, characterized by that the shelving system comprises two lifts (4) and four transfer stations (6), each of the two lifts (4) being arranged between two transfer stations (6).

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