System and method for forming / dissolving a pallet layer

Abstract

System (10; 20) for forming or dissolving a complete charge carrier layer (16) from a plurality of individual, in particular heterogeneous, packing units (12), which has: a large number of FTF (22); and a control (24) that is set up: to assign each of the packing units (12) to the location (16) of one of the FTFs (22); to determine a packaging unit-specific position (36) for each of the packing units (12) of the layer (16) based on a layer pattern (34) predefined for the layer (16); and to specify the packing unit-specific position (36) to each of the AGVs (22) as an end / start position of an AGV-specific travel path, so that each of the packing units (12) of the layer (16) is moved to or from the packing unit-specific position (36) by the respective AGV (22) when the layer (16) is formed or dissolved.

Description

[0001] The present disclosure relates to an intralogistics, robot-based system and method for forming and / or dismantling a complete layer of load carriers, wherein the layer is formed from a plurality of individual, in particular heterogeneous, packing units. The present disclosure relates in particular to robot-based layer-by-layer palletizing and / or depalletizing of the packing units.

[0002] A palletizer is a robot used to automatically group packaging units onto load carriers (pallets of varying sizes). Four- or six-axis industrial robots are frequently used for this task. There are several different types of palletizers, such as articulated robots, layer palletizers, linear robots, and gantry robots. Layer palletizers pack complete layers of a pallet load onto a pallet. An example of a layer palletizer (LP) is shown in US 5,540,545 A, where (homogeneous) packaging units are fed via continuous conveyors (SF) (e.g., roller conveyors RF and belt conveyors BF), possibly rotated by rotary tables (DT), and pushed by pushers (S) from the continuous conveyor (SF) onto a pallet (P), where they are collected row by row to form a complete layer (see figure). Fig. 7. Another line or layer palletizer is shown in US 4 593 517 A.

[0003] Layer palletizers can be configured as gantry palletizers. Gantry palletizers are portal robots with three linear axes, allowing the robot, mounted on a frame, to move completely through a cubic (work) space. Full gantry palletizers stand on four legs, while half gantry palletizers stand on two. A gantry robot can define a palletizing cell. A palletizing cell is a particularly compact, modular, and standardized, and therefore cost-effective, robotic cell for the fully automated palletizing of packaging units. The cell includes the palletizing robot with its gripper (load handling device, LMD), a palletizing station, a feed conveyor system (ZF) for the products, and optionally a pallet conveyor system (PFT) for the fully automated transport of pallets (P). Further optional components include a pallet magazine (PM), an interlayer magazine (ZLM) for separating boxes, or camera technology.The gripper technology is adapted to the respective product. (Source: Wikipedia entry for "palletizer", as of March 19, 2024).

[0004] Furthermore, automated guided vehicles (AGVs) are known, which consist of automated guided vehicles (AGVs), also called autonomous mobile robots (AMRs). AGVs and AMRs are robots that can move and act independently within their environment.

[0005] The Fraunhofer Institute has developed a high-performance AGV (Automated Guided Vehicle) under the name "LoadRunner" (registered trademark), as described in the Fraunhofer Institute's press release of September 15, 2020, entitled "Formula 1 on the Factory Floor." This vehicle utilizes highly distributed artificial intelligence and 5G communication to operate as a high-speed swarm robot. The LoadRunner can dynamically organize itself within a swarm and, if necessary, even couple together for transport tasks. By coupling multiple vehicles together, they can move even large and bulky items. WO 2007 / 011 871 A2 (hereinafter referred to as WO' 871 A2) already demonstrates the concept of coupling multiple AGVs. In particular, WO' 871 A2 shows i.) the creation of a (shop-optimized) pallet load by logically delivering individual packaging units using a single AGV (see there). Fig. 4) and ii) several vehicles for the joint transport of an oversized packaging unit (see there). Fig. 11) or a full pallet load (see there) Fig. 12 and Fig. 19) to couple together.

[0006] EP 3 909 894 A1 relates to an establishment, a system and a method for storing and picking items.

[0007] DE 10 2018 105 614 A1 concerns a block storage facility, a driverless transport system and load carriers.

[0008] DE 10 2018 109 559 A1 relates to a general cargo handling plant and a method for handling general cargo and / or packaging aids.

[0009] The objective of this disclosure is to provide an improved system and method for forming and dissolving a complete charge carrier layer from a multitude of individual, in particular (weakly) heterogeneous, packing units. In particular, the formation / dissolution of the layer should be fast, simple, and require minimal hardware.

[0010] This task is solved by a system for forming or dissolving a complete load carrier layer from a multitude of individual, especially heterogeneous, packaging units, comprising: a multitude of (freely and individually movable) AGVs; and a control system configured to: assign (at least) one AGV to each of the packaging units in the layer; determine a packaging unit-specific position for each of the packaging units in the layer based on a layer pattern predefined for the layer; and specify the packaging unit-specific position to each AGV as an end / start position of an AGV-specific travel path, so that each of the packaging units in the layer is moved to or from the packaging unit-specific position by the respective assigned AGV when the layer is formed or dissolved.

[0011] Instead of conventional continuous conveyors, discontinuous conveyors are used to create and dismantle load carrier layers. These conveyors can flexibly create and dismantle load carrier layers. The system offers high throughput because the AGVs can move and, in particular, rotate (align) in all directions, and because the AGVs can be quickly pre-grouped into subunits (e.g., a left and a right pallet half). The packaging units can be easily oriented by moving the AGVs accordingly. Turntables and tilting devices are not required for alignment.

[0012] The entire layer can be handled as a whole. Handling a complete layer is a standard task in intralogistics. Before a robot can grasp a complete layer to place it on a pallet, the layer must be arranged in a predefined layer pattern (packing pattern or layer pattern). Depending on the layer's structure (e.g., only in rows, staggered / nested, with or without gaps between, etc.), the effort required to assemble the packing units can vary. Complete layers are presented to the palletizing robot, eliminating the need to pick up individual packing units (saving time). This increases the palletizing robot's performance. The same applies to depalletizing robots.

[0013] Depalletizing a complete layer simplifies the subsequent singulation of the packaging units. The packaging units can be moved individually by the AGV, oriented as desired, and quickly transported to different destinations.

[0014] The system preferably includes a palletizing / depalletizing robot.

[0015] The palletizing and depalletizing processes are automated and do not require manual intervention. The entire layer can be moved as a whole. Individual repositioning of the packaging units within a layer is not necessary.

[0016] Preferably, a load handling device of the palletizing / depalletizing robot is set up to grip all packing units of the layer simultaneously (completely).

[0017] Individual handling of the packaging units is not required. This saves time. Palletizing and depalletizing can be carried out at a higher rate, especially because the upstream merging and downstream singulation take place elsewhere, namely on the AGV's travel path.

[0018] Preferably, the palletizing / depalletizing robot is a gantry robot.

[0019] A gantry robot has the advantage of a large workspace within which its load handling device can move freely. In contrast to articulated robots, the ratio between the robot's footprint and working area is significantly better. The gantry robot offers sufficient space to accommodate a group of AGVs (Automated Guided Vehicles) picking up or dropping off loads, simultaneously with the load carrier within the workspace from which the load is being lifted or onto which it is being placed.

[0020] Preferably, the system further comprises a discharge / feed conveyor for the load carrier, which runs through a working area of ​​the palletizing / depalletizing robot, wherein the working area further includes an area within which the plurality of AGVs can be positioned (simultaneously) to deliver or receive the load carrier.

[0021] Preferably, the system further comprises a warehouse and / or a production area where the packing units of the layer are picked up by the AGV or where the packing units of the layer are brought, wherein the warehouse and / or the production area is preferably located remotely from the palletizing / depalletizing robot.

[0022] The AGVs are capable of quickly covering large distances. During transport, the packing units can easily overtake each other, for example, by the AGVs accelerating and / or decelerating to achieve a desired sequencing at the destination.

[0023] Material flow control can be simplified; in the best-case scenario, a material flow computer can be completely eliminated because the material flow is regulated by the AGV itself, with only the start and end points of the routes being specified. The AGV determines the route itself.

[0024] Alternatively, the control system is also configured to (fully) predetermine each of the FTF-specific routes.

[0025] In this case, the control system includes a route planning module for the AGVs. A collision avoidance module may also be included. The control system alone determines the AGVs' routes, ensuring that layer formation and resolution are given the highest priority. The computational load on the vehicles is therefore low.

[0026] Preferably, the control system is also configured to (pre-determine) the layer pattern for forming the layer from the packaging units.

[0027] In this case, the control system also includes a packing pattern generator and can therefore be operated independently of the storage and picking system.

[0028] Preferably, the footprint of each of the packing units in the location is larger than or equal to the footprint of the assigned AGV(S).

[0029] This prevents collisions between the AGVs, especially during layer formation. The packaging units can be arranged close together, i.e., without any gaps between them, according to the layer formation.

[0030] The task is further solved by a method for forming orDisassembling a complete load carrier layer from a plurality of individual, in particular heterogeneous, packaging units, wherein the method, which in particular comprises the system of the type described above, comprises the steps of: providing a plurality of AGVs, the plurality of packaging units of the layer, and a layer pattern predetermined for the layer, wherein a number of AGVs is in particular greater than or equal to a number of packaging units of the layer; assigning one of the AGVs to each of the packaging units of the layer, wherein in particular each of the packaging units of the layer is assigned another AGV; determining a packaging unit-specific position for each of the packaging units based on the layer pattern; and specifying the packaging unit-specific position as an end / start position of an AGV-specific travel path for each of the assigned AGVs, wherein each of the packaging units of the layer is moved to the respective end / start position by the respective assigned AGV.is moved from the packaging unit-specific position while the position is formed or dissolved.

[0031] It is understood that the aforementioned features 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 this disclosure.

[0032] Exemplary embodiments of the disclosure are shown in the drawings and are explained in more detail in the following description. They show: Fig. 1 a block diagram of an intralogistics system including a palletizer / depalletizer system; Fig. 2 a perspective view of a loaded pallet; Fig. 3 a schematic layer pattern; Fig. 4 a perspective view of a palletizer / depalletizer system; Fig. 5 a detailed view of the Fig. 4; Fig. 6. A flowchart of a procedure for forming / dissolving a complete charge carrier layer; and Fig. 7 a palletizing device in accordance with the state of the art.

[0033] In this disclosure, the term "intralogistics" generally 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 a company, 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.

[0034] In this disclosure, the term "order picking" is understood to mean the assembly of a customer-specific quantity from an assortment of several article or storage unit types. Order picking thus describes the assembly of orders according to a customer order (hereinafter referred to as "order"), i.e., the removal of partial quantities of larger storage units from a warehouse and their consolidation and preparation for shipment to the customer. A production facility can also serve as the source.

[0035] Fig. Figure 1 shows a block diagram of a fully automated intralogistics system 10, which can be configured for picking packages or packaging units 12 (e.g., beverage crates) that are to be separated or prepared for shipment from an assortment, e.g., from a warehouse 28 and / or a production facility 30, according to customer or picking orders. The system 10 of this disclosure can be used, for example, in shipping centers and distribution centers, particularly in the food and beverage industry, healthcare, retail and / or wholesale trade, the fashion industry, production logistics, the automotive industry, the cosmetics industry, or similar fields.

[0036] Preferably the packaging units 12 have the shape of rectangular parallelepipeds (e.g. beverage crates, cartons, six-packs, etc.), cf. Fig. 2. The packaging units 12 can be provided or packed on load carriers 13, such as Euro pallets, Düsseldorf pallets, or other pallets 14. It is understood that other load carriers 13 can also be used, such as trays, roll cages, or similar. Pallets 14 are considered below as an example. The packaging units 12 are packed and stacked, particularly in single-type packs, on the pallet 14, especially in layers 16. Single-type packs mean that only items of one (single) type (e.g., beer type A, lemonade B, water C, etc.) are loaded onto the pallet 14. It is understood that mixed pallets 14 (e.g., layer by layer) can also be produced. Fig. Figure 2 shows a fully loaded pallet 14 with a pallet load 18, which is formed by, for example, six layers 16-1 to 16-6 of, for example, homogeneous packing units 12, which are arranged in, for example, a nested packing pattern 19.

[0037] System 10 of the Fig. System 1 can include a (palletizing / depalletizing) system 20 for the robot-based formation and / or dismantling of a complete (load carrier) layer 16 from a multitude of individual, in particular heterogeneous, packaging units 12. System 20 can be implemented and distributed independently of system 10.

[0038] System 20 comprises: a number of automated guided vehicles (AGVs) 22 and a control unit 24 for the AGVs 22. System 20 may also include a palletizing / depalletizing robot 26. It is understood that System 20 and the robot 26 can be configured: exclusively for palletizing; exclusively for depalletizing; or for palletizing and depalletizing.

[0039] Palletizing and depalletizing processes differ essentially only in the direction of material flow. During palletizing, the packaging units 12 are brought together to form the pallet load 18, which usually takes place in a goods issue area (not shown in Fig. 1) of system 10 takes place, whereas the packaging units 12 are moved apart, i.e. separated, during depalletizing, which is usually done in a goods receiving area (not shown in Fig. 1) of system 10 takes place.

[0040] Commercially available packing pattern generators 32 are used for the efficient palletizing of homogeneous and, in particular, (weakly) heterogeneous packaging units 12. Packing pattern generators 32 are algorithms or computer programs used for the automated and optimized determination of the packing pattern 19. The controller 24 can include the packing pattern generator 32. However, the packing pattern generator 32 can also be provided separately from the controller 24 in order to supply the controller 24 with an external packing pattern 19.

[0041] The packing pattern 19 refers to a specifically chosen arrangement and positioning of the packing units 12 within a (load carrier) load, such as within the pallet load 18 of the Fig. 2. The packing pattern 19 can in turn be formed from several vertically arranged (2D or 3D) layer patterns 34, cf. Fig. 2. The layer patterns 34 represent layers of the packing pattern 19 or the pallet load 18.

[0042] In the case of "weakly heterogeneous" packaging units 12, the pallet 14 is loaded in layers 16 of (preferably) nearly the same height. Each layer 16 should cover as much of the load carrier base area as possible. All packaging units 12 in the respective layer 16 should have a uniform height so that another layer 16 can be placed on top of them. When several layers 16 are stacked on top of each other, a layer stack is created, i.e., ultimately the complete pallet load 18, whereby the packaging space height is preferably utilized to the maximum extent. The layer patterns 34 of the individual layers 16 of such a stack can be identical, but they can also differ from each other, for example, because they are based on different packaging unit orientations or because they contain different packaging unit types.

[0043] The packaging units 12 can be heterogeneous by having different dimensions (in particular different base areas with preferably the same height) or by comprising different product types (possibly with identical dimensions).

[0044] When determining the packing pattern 19, criteria such as size, weight, stackability, compressive strength, and the picking and depalletizing sequence can be taken into account. What sounds so simple, however, requires a sophisticated software concept. The packing units 12 are arranged as densely as possible, depending on their geometry, to load or pack the pallet 14 as high as possible, thus minimizing the number of pallets required for each shipping order. The weight and stackability of the packing units 12 can be precisely calculated and considered to ensure that the goods are delivered undamaged to their respective destinations. Furthermore, the specific distribution of the packing units 12 or product groups within a particular branch can be included in the planning process to minimize sorting efforts there as well. Additional requirements may arise from the different packaging and product characteristics for various customers, industries, and markets.

[0045] The criteria mentioned above illustrate how difficult it can be to create a stable layer 16. One of the problems lies in the fact that different packaging units 12 from different staging locations must be brought together to assemble the layer 16 planned by the packaging pattern generator 32 in reality. The staging locations include, for example, the warehouse 28 and / or the production 30, cf. Fig. 1. Warehouse 30 can be divided into different areas or zones, e.g., according to an ABC classification. Warehouse 30 can include different storage types (e.g., pallet and / or container racking, floor storage, carousel storage, cube storage, etc.) that are located far apart from each other.

[0046] The AGVs 22 are particularly well-suited for bringing together the various packing units 12, i.e., assembling them at the layer formation point, as required for the respective layer pattern 34. The AGVs 22 are autonomous. They are robots that can move and act independently and freely within their environment. Different levels of autonomy exist. Some AGVs 22 plan their routes independently, while others have them completely predetermined by a higher-level computer (e.g., fleet manager, MFR, etc.). The more autonomous the AGV 22, the more computing and storage capacity it must carry. Therefore, determining a route may only require specifying a start and end point to the AGV 22, while the AGV calculates the route in between itself. Collision avoidance can also be determined internally in real time or externally in advance (e.g., using a block-tracking algorithm).It is understood that the FTF 22 represent discontinuous conveyors whose travel paths can be individually and freely planned. Forced guidance (e.g., via grid-like waypoints (grid navigation) or inductive, capacitive, or optical guide lines) is unnecessary.

[0047] Fig. Figure 3 shows a top view of a schematically represented (2D) layer pattern 34 for a layer 16, which is formed, for example, from four vertical rows of packaging units 12 arranged horizontally next to each other from left to right. The first and third rows are each formed, for example, from four packaging units 12 of a first type. The second and fourth rows are each formed, for example, from six packaging units 12 of a second type. The layer pattern 34 defines the arrangement and number of packaging units 12 of the layer 16. Each of the packaging units 12 of the layer 16 has a (package unit-specific) position 36 within the layer pattern 34, which is described in Fig. 3 e.g. by a point within the respective packaging unit 12. The packaging unit-specific position 36 can be a (relative) 2D or 3D position that clarifies where the respective packaging unit 12 is positioned within its location 16. The position 36 can include not only a spatial coordinate, but also an orientation in space and / or a dimension of the respective packaging unit 12. The packaging unit-specific position 36 can be anchored in a center of gravity of the packaging unit 12, as shown in Fig. 3 is indicated by way of example.

[0048] In the Fig. 3. The position 16 is completely created by positioning the packaging units 12 at their respective assigned positions. Fig. Figure 3 illustrates a state where layer 16 is to be dismantled by moving the packing units 12 apart, i.e., singulating them, as indicated by arrows 38. The singulation can occur in any direction. Each of the packing units 12 of layer 16 of the Fig. 3 can be moved along an individually definable (travel) route to its individually definable destination (e.g., a desired storage location, a picking station, etc.), with at least one AGV 22 being used for the respective transport. The number of AGV 22s required for a transport can depend on the size (relative to the vehicle) and weight of the packaging unit 12. As a rule, the heavier and larger the packaging unit 12, the more AGV 22s are needed for (simultaneous) transport. In these cases, it is possible, for example, for the corresponding packaging unit 12 to be virtually subdivided within layer 16 or layer pattern 34 into a corresponding number of sub-packing units, with each sub-unit being assigned one of the AGV 22s and each sub-unit having its own position 36. However, a 1:1 assignment between the packaging unit 12 and the AGV 22 is preferred.

[0049] Fig. Figure 4 shows a perspective view of a palletizer / depalletizer system 20 according to the Fig. 1. The System 20 of the Fig. 4 features a multitude of AGVs 22 and a palletizing / depalletizing robot 26. The robot 26 is implemented as an example gantry robot 40 with a frame 42 that defines a cuboid workspace 42 within which a load handling device (LHD) 44 is movable, which can be configured to grip a complete layer 16.

[0050] A feed / discharge conveyor 46 for empty, full, or partially loaded load carriers 13 can run through the workspace 42. The workspace 42 is large enough that a group of AGVs 22, required to form or pick up a complete layer 16, can remain within the workspace 42 simultaneously while the LAM 44 removes the layer 16 from the AGVs 22 (palletizing) or places it onto them (depalletizing).

[0051] In the Fig. Figure 4 shows an exemplary depalletizing process in which the AGVs 22 (individually) enter the work area 42 from, for example, the left and below, group together to pick up a pallet layer, which consists of, for example, four packaging units 12, and then leave the work area 42 to the right (e.g., individually). The travel areas of the AGVs are shown in the Fig. 4 indicated by dashed lines and arrows. It is understood that the direction of travel of the AGV 22 could be exactly reversed in the case of palletizing. However, a palletizing process is usually somewhat more complex than a depalletizing process because the packing units 12 in the middle of layer 16 – compared to packing units 12 at the outer edge – must first be positioned within a layer formation of the AGV 22, as will be explained in more detail below. This requires a certain amount of synchronization. In addition, the travel paths of the AGV 22 must be coordinated so that the packing units 12 do not touch each other during navigation to the desired final position, i.e., to the packing unit-specific position 36, but are positioned as close as possible at the end of the travel path, in particular in (surface) contact with each other, in order to form a formation without gaps.It is understood that layer 16 can also be formed with intervals between the packing units 12.

[0052] Fig. Figure 5 illustrates, by way of example, a group of depalletizing FTF 22s shortly after they have left workspace 42 of the Fig. 4 have left. Each of the FTF 22 carries one of the Pack Units 12. In the Fig. 5 carries, for example, each of the FTF 22 exactly one of the pack units 12. Furthermore, in Fig. Figure 5 shows that the footprint of each of the FTF 22 is smaller than the footprint of the associated packaging unit 22. The footprint corresponds to an outline (i.e., a projected area) when viewed perpendicularly from above. This is preferably generally the case so that the FTF 22 do not touch each other and thus do not collide when picking up and delivering a complete layer 16. In other words, this means that the FTF 22 do not extend laterally beyond the packaging units 12 loaded onto them. Preferably, each of the FTF 22 is provided with means (not shown) to fix the packaging units 12 during transport, i.e., during movement into or out of a layer formation. The means can be (transport) surfaces with friction-enhancing properties, clamps, retaining pins acting from below, or the like.

[0053] Fig.Figure 6 illustrates a method 100 for forming or dissolving a complete charge carrier layer 16, which consists of a plurality of individual, in particular heterogeneous, packing units 12, as already explained above. The method 100, which can be carried out in particular with a system 10 and / or 20 of the type described above, comprises several steps.

[0054] In step S102, the following are provided: a multitude of AGVs 22, a multitude of packing units 12, and a layer pattern 34 for the layer 16 to be handled. The layer pattern 34 can be generated by the controller 24 or received by the controller 24 from the packing pattern generator 32 if the generator 32 is not integrated into the controller 24. Layer 16 specifies the number or multitude of packing units 12 from which it is formed. The packing units 12, in turn, determine how many AGVs 22 are required for their transport, with typically one packing unit 12 being transported by one AGV 12. It is generally assumed that all AGVs 12 are of the same type. However, different AGV types can also be used, particularly to maintain a 1:1 ratio between the AGVs 12 and the packing units 22 of the respective layer 16. For heavier and / or larger packing units 12, larger FTF 12 vehicles could be used.The 1:1 ratio can simplify the planning of AGV-specific routes because fewer individual routes need to be planned in this case. Therefore, the number of AGVs (22) is preferably greater than or equal to the number of packing units (12) in layer 16.

[0055] The layer pattern 34 can be pre-planned in a separate step to determine the number of FTF 22 required. Determining and pre-planning the number of FTF 22 required can be based on an additional analysis of the packaging units 12 contained in the layer pattern 34 with regard to their respective weight and dimensions. This information is preferably also included in the layer pattern 34, as are optional storage and / or destination or usage locations of the packaging units 12. Each packaging unit 12 can be assigned a sequence number so that inner packaging units 12 are formed first during palletizing.

[0056] In step S104, the controller 24 assigns (at least) one AGV 22 to each of the packaging units 12 in layer 16. This assignment can be stored, for example, in a table (not shown) in a memory unit (not shown) of the controller 24. The layer pattern 34 can also be stored, for example, in a table, particularly in the same table. Preferably, each of the packaging units 12 in layer 16 is assigned a different AGV 22.

[0057] In step S106, the controller 24 determines the packaging unit-specific position 36 for each of the packaging units 12 based on the layer pattern 34. In step S108, the controller 24 specifies the corresponding packaging unit-specific position 36 as an end / start position of an FTF-specific travel path to each of the assigned AGVs 12, so that each of the packaging units 12 of layer 16 is moved to or away from the packaging unit-specific position 36 by the respective assigned AGV 22, while layer 16 is formed or dissolved.

[0058] The determination of the AGV-specific route, which includes the packing unit-specific position 36 as an end or start position, can also be performed by the controller 24, which in this case is preferably equipped with a corresponding route generation module—and optionally also with a collision avoidance module—so that the entire computational load lies with the controller 24. However, it is preferred that either the AGV 22 itself or an AGV fleet manager determines the AGV-specific routes. In this case, it is sufficient for the controller 24 to communicate the packing unit-specific position 36 as the end / start position to the corresponding entity, which can then plan the routes in an AGV-specific manner. It is understood that the system 20—and in particular the controller 24—is equipped with appropriate interfaces and communication means.

[0059] A special feature of forming a layer 16 is that the transport routes must be planned so that packing units 12, located inside layer 16, arrive at their position 36 first. A specific sequence must therefore be observed.

[0060] Furthermore, the routes are to be planned in such a way that the packing units 12 come to a stop at their positions 36 in a desired orientation.

[0061] The transport routes must be planned so that the packing units 12 are positioned as close together as possible, preferably without gaps between them, in the desired layer formation. Some orchestration may be necessary.

[0062] When planning transport routes, storage locations can be relevant as starting points for the routes when creating a layer and as destination points when dismantling the layer. This information may already be stored in layer pattern 34 or retrieved from a warehouse management system (WMS) or a material flow computer (MFC).

[0063] Control unit 24 is configured to extract relevant information from the layer pattern 34, retrieve it from the warehouse management computer or material flow computer, and / or take it into account when planning the routes or transmit it to the planning entity.

[0064] Next, hardware configurations of the controller 24, the palletizing / depalletizing robot 26, and / or the AGV 22 according to the embodiments described above are explained. The controller 24 can be implemented as hardware that implements each function of the controller 24 according to the embodiments and that, in particular, analyzes the layer pattern 34, extracts the number of AGVs 22 and the positions 36, and, if necessary, generates the travel paths.

[0065] Each of the functions of the controller 24, the palletizing / depalletizing robot 26, and / or the FTF 22 could be implemented using a processing circuit. Where dedicated hardware is used, a dedicated processing circuit could be a single circuit, a composite circuit, an application-specific integrated circuit (ASIC), a custom programmable gate array (FPGA), or a combination thereof. The functions of the controller 24 could each be implemented by a processing circuit, or they could be implemented collectively by a processing circuit.

[0066] Furthermore, the control 24 can be implemented by a processor and a memory device. The processor could be an arithmetic means, such as an arithmetic unit, a microprocessor, a microcomputer, a central processing unit (CPU), or a digital signal processor (DSP). Examples of the memory device include non-volatile or volatile semiconductor memories, such as random-access memory (RAM), read-only memory (ROM), flash memory, erasable programmable ROM (EPROM), and electrical EPROM (EEPROM (registered trademark)).

[0067] In a case where the processor and the memory device are used, each of the functions of the controller 24 can be implemented by software, firmware, or a combination thereof. The software or firmware can be written as a program and stored in the memory device. The processor can read such programs stored in the memory device and execute them. These programs can cause a computer to execute procedures and processes for the respective functions of the controller 24, the palletizing / depalletizing robot 26, and / or the AGV 22.

[0068] Some of the functions of the controller 24, the palletizing / depalletizing robot 26, and / or the FTF 22 could be implemented by hardware, and other functions could be implemented by software or firmware. For example, the functions of the controller 24 could be implemented using dedicated hardware, and the functions of the FTF 22 could be implemented using a processor or a storage device.

[0069] The configurations shown in the above embodiments are examples, and it is possible to combine the configurations with another known method or to combine the embodiments with each other, and it is also possible to partially omit or modify the configurations without deviating from the scope of the present disclosure.

[0070] Furthermore, it is understood that the system 20 can include a vision system (camera system), in particular to verify the positions of the FTF 22 during the recording or delivery of the position 16. Image processing can thus be used to generate correction commands for fine-tuning the positioning of the FTF 22. 10 (Intralogistics) systems 12 pack units 13 load carriers 14 pallets 16 Location 18 pallet loads 19 Pack samples 20 Systems for forming / dissolving layers 22 FTF (driverless transport vehicle) 24 (FTF) control 26 palletizing / depalletizing robots 28 warehouses 30 Production 32 Pack Pattern Generator 34 layer patterns 36 positions, pack unit specific 38 Arrow (route) 40 portal robots 42 workroom 44 Load-handling attachments (LHA) 46 Feed / Discharge Conveyors

Claims

System (10; 20) for forming or dissolving a complete load carrier layer (16) from a plurality of individual, in particular heterogeneous, packaging units (12), comprising: a plurality of AGVs (22); and a control system (24) configured to: assign each of the packaging units (12) of the layer (16) to one of the AGVs (22); determine a packaging unit-specific position (36) for each of the packaging units (12) of the layer (16) based on a layer pattern (34) predefined for the layer (16); and specify the packaging unit-specific position (36) to each AGV (22) as an end / start position of an AGV-specific travel path, so that each of the packaging units (12) of the layer (16) is moved to or from the packaging unit-specific position (36) by the respective assigned AGV (22) when the layer (16) is formed or dissolved. System (10; 20) according to claim 1, further comprising a palletizing / depalletizing robot (26). System (10; 20) according to claim 2, wherein a load handling means of the palletizer / depalletizer robot (26) is configured to grasp all packing units (12) of the layer (16) simultaneously. System (10; 20) according to claim 2 or 3, wherein the palletizing / depalletizing robot (26) is a portal robot. System (20) according to one of claims 2 to 4, which further comprises a discharge / feed conveyor (46) for the load carrier (13) which passes through a working space of the palletizer / depalletizer robot (26), wherein the working space further includes an area within which the plurality of AGVs can be positioned to deliver or receive the load carrier (16). System (10) according to one of claims 1 to 5, which further comprises a warehouse (28) and / or a production facility (30) from where the packing units (12) of the layer are picked up by the AGV (22) or to where the packing units (12) of the layer (12) are brought, wherein preferably the warehouse and / or the production facility are arranged remotely from the palletizing / depalletizing robot (26). System (10; 20) according to one of claims 1 to 6, wherein the control (24) is further configured to determine each of the FTF-specific travel paths in advance. System (10; 20) according to one of claims 1 to 7, wherein the control (24) is further configured to determine the layer pattern (34) for forming the layer (16) from the packing units (12). System (10; 20) according to one of claims 1 to 8, wherein a footprint of each of the packing units (12) of the layer (16) is greater than or equal to a footprint of the associated FTF or FTFs (22). Method (100) for forming or dissolving a complete load carrier layer (16) from a plurality of individual, in particular heterogeneous, packing units (12), wherein the method, which is in particular carried out with a system (20) according to one of the preceding claims, comprises the steps: providing (S102) a plurality of FTFs (22), the plurality of packing units (12) of the layer (16) and a layer pattern (34) predetermined for the layer (16), wherein a number of FTFs (22) is in particular greater than or equal to a number of packing units (12) of the layer (16); assigning (S104) one of the FTFs (22) to each of the packing units (12) of the layer (16), wherein each of the packing units (12) of the layer (16) is assigned another of the FTFs (22); determining (S106) a packing unit-specific position (36) for each of the packing units (12) based on the layer pattern (34);and specifying (S108) the packing unit-specific position (36) as an end / start position of an AGV-specific travel path for each of the assigned AGVs (22), wherein each of the packing units (12) of the layer (16) is moved to or from the packing unit-specific position (36) by the respective assigned AGV (22), while the layer (16) is formed or dissolved.;

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