ROBOT SYSTEM FOR TESTING A LOADING SPACE OF A LOADING AID IN A STORAGE AND PICKING SYSTEM AND OPERATING PROCEDURES FOR THIS

Description

[0001] The invention relates to a method for controlling a robot in a storage and order-picking system, which robot has a gripping unit movable relative to the robot base, in which the goods are picked up with the gripping unit from or from a first goods carrier and placed in or on a second goods carrier, wherein at least one of the goods carriers is designed as a loading aid. Furthermore, the invention relates to a robot system having a robot with a gripping unit movable relative to a robot base for gripping / picking up goods, wherein the robot is designed to pick up goods with the gripping unit from or from a first goods carrier and place them in or on a second goods carrier, and wherein at least one of the goods carriers is designed as a loading aid.Finally, the invention relates to a storage and order-picking system for order-picking goods, comprising a storage area for storing goods and a workstation for order-picking / repacking goods with a robot system of the above type.

[0002] A method, a robot system, and a storage and picking system of the aforementioned type are generally known. For example, DE 10 2015 007 863 A1 and US Pat. No. 9,868,207 B2 disclose a robot for gripping goods in a warehouse system. Information for gripping the aforementioned goods can be determined and used in conjunction with a database to determine a gripping strategy.

[0003] A disadvantage of the known methods is that goods that extend beyond the loading space of a loading aid are usually not detected, which can subsequently lead to disruptions in conveying and handling within the storage and picking system. As a result, loading aids are typically not fully utilized, meaning they are often not loaded all the way to the edge of a container, let alone beyond the container's edge. This has a correspondingly negative impact on the performance of the storage and picking system. As a result, they are usually built larger than necessary.

[0004] An object of the invention is therefore to provide an improved method for controlling a robot in a storage and picking system, an improved robot system, and an improved storage and picking system for picking goods. In particular, the above-mentioned disadvantages are to be overcome, i.e., disruptions during the conveying and handling of goods in a storage and picking system are to be avoided, and the performance of the storage and picking system is to be increased compared to the prior art.

[0005] This task is solved by a method of the type mentioned above, in which in the area of ​​at least one loading aid, a loading space is defined which is intended for accommodating the goods, the loading space and the goods located in the area of ​​the loading space are detected by means of a sensor system, after the gripping unit has picked up a product from or out of the first goods carrier, a check is carried out to determine whether a product protrudes beyond the said loading space, and a) the product protruding beyond the loading space is picked up by the gripping unit and placed in another position, or b) the part of the product protruding beyond the loading space is moved by the gripping unit into the loading space, if the outcome of said test is positive.

[0006] The said test is carried out in particular by a control of a robot system which comprises the robot and the sensor system.

[0007] Furthermore, the object of the invention is achieved by a robot system of the type mentioned at the outset, which has a control system which is designed to check, after the gripping unit has picked up a product from or out of the first product carrier, whether a product protrudes beyond the said loading space, and to instruct the robot if the result of the check is positive, a) to pick up the goods which extend beyond the loading space and place them in another position, or b) to move the part of the goods which extends beyond the loading space into the loading space.

[0008] Finally, the object of the invention is also achieved by a (largely automated) storage and order picking system of the type mentioned at the beginning, which comprises a (fully automated) robot system of the type mentioned above, which is connected in particular to the storage area by means of conveyor technology.

[0009] The proposed measures detect goods that extend beyond the loading space of a loading aid, thus preventing disruptions during conveying and handling in a storage and picking system. This allows loading aids to be fully utilized, and in particular, they can be loaded right up to the edge of a container or, in a defined manner, even beyond it. This significantly increases the performance of the storage and picking system compared to the state of the art. They also require less installation space than was previously the case.

[0010] In principle, it is advantageous if, for placing goods in or onto the second goods carrier, a position in the loading space is calculated at which the said goods are unlikely to protrude beyond the said loading space. If the goods cannot be placed down as expected, the problem is detected as described above and subsequently remedied automatically. The goods are either picked up and lifted again (case a), or the part of the goods protruding beyond the loading space is simply pushed, folded back, or pulled back into the loading space without lifting the goods completely (case b). When pulling back the part of the goods protruding beyond the loading space, the gripping function of the gripper is used. Pushing back or folding back the part of the goods protruding beyond the loading space, however, can take place with or without using the gripper's gripping function. Gripping the goods is therefore not absolutely necessary in case b).In general, case b) describes the movement of a part of the goods that protrudes above the loading space back into the loading space without lifting the goods completely.

[0011] For example, the loading aid can comprise a container base, side walls projecting from it, a loading opening defined by the side walls, and a loading space defined at the top by the loading opening. This means that in this case, the loading aid is loaded up to the container's edge.

[0012] It is also advantageous if the loading aid comprises a container base, side walls projecting from the base, and a loading opening defined by the side walls, with the loading space extending upwards beyond the aforementioned loading opening. This allows the loading aid to be loaded beyond the container edge. This means that the loading space is larger than the volume enclosed by the container base, the side walls, and the loading opening of the loading aid. This increases the loading capacity of a loading aid compared to the state of the art.

[0013] It is also advantageous if the loading space extends laterally beyond the side walls of the loading aid. This means that the loading space extends not only upwards beyond the container edge, but also laterally. This further increases the storage capacity of a loading aid compared to the state of the art.

[0014] Furthermore, it is advantageous if the loading space in the section protruding beyond the side walls extends below the level of the loading opening. This means that goods can also hang down over the container's edge. This further increases the storage capacity of a loading aid compared to the state of the art.

[0015] In the context of the invention, a "good" is understood to mean in particular an individually manageable object or an individually manageable group of objects.

[0016] A "goods carrier" can, for example, be a loading device (such as a carton, a tray, a container, or a pallet) or be formed by a conveyor (such as a belt conveyor, a roller conveyor, or a chain conveyor). A "goods carrier" can also be formed by a transport platform (such as on a storage and retrieval machine or an autonomous transport vehicle). The first goods carrier acts as the "source," the second goods carrier as the "destination." The second goods carrier can, for example, also be formed by a pivoting flap. In this case, the robot removes an item from or out of the source and places it on the flap. This item can then be transferred to another container, for example, by operating the flap, i.e., pivoting it upwards.

[0017] As stated above, a "loading aid" can be a container, such as a crate, a box, or a carton. It should be noted that a tray usually also has side walls and can therefore also be considered a flat container. In a pallet, for example, the loading space can extend upwards in a cuboid shape.

[0018] In a "storage and picking system," for example, goods can be delivered and received at a goods receiving area and then, if necessary, repackaged and stored in a warehouse. The goods can also be picked according to an order, meaning they are retrieved from the warehouse, assembled into an order, and prepared for transport at the goods dispatch area. The goods are not substantially altered between receiving and dispatch, in contrast to a manufacturing process. However, a slight change in shape is possible, particularly with non-rigid objects such as bags or sacks, or with other flexible packaging, such as cardboard or plastic.

[0019] The following scenarios are particularly conceivable for the occurrence of an error, i.e. the negative outcome of the check as to whether goods protrude beyond the loading space: i) The goods are properly picked up by the gripping unit from the first goods carrier (source) designed as a loading aid and are also properly placed in or on the second goods carrier (target). However, when the gripping unit is moved out of the loading aid, a product other than that picked up by the gripping unit is picked up or pulled along and as a result falls back into the loading aid so unluckily that it protrudes beyond its loading space. ii) The goods are picked up by the gripping unit from the first goods carrier (source) designed as a loading aid, but inadvertently fall back into the loading aid so unluckily that it protrudes beyond its loading space. iii) The goods are properly picked up by the gripping unit from or from the first goods carrier (source) and placed in the second goods carrier (target) designed as a loading aid. However, there it protrudes beyond the loading space.iv) The goods are properly picked up by the gripping unit from or from the first goods carrier (source), but unintentionally fall from it into the second goods carrier (destination), which is designed as a loading aid, in such an unfortunate way that they protrude beyond its loading space. v) The goods are properly picked up by the gripping unit from or from the first goods carrier (source), but unintentionally fall from it and do not remain on either the first goods carrier or the second goods carrier (destination).

[0020] In general, the defects described in cases i) to v) can be remedied either by reloading the goods (case a) or by pushing, folding back or retracting the part of the goods projecting beyond the loading space into the loading space (case b).

[0021] In case i), two different scenarios for error correction are conceivable: In a first variant, the goods protruding beyond the loading space of the first goods carrier (source) are always transported completely back into the loading space of the first goods carrier (source). In a second variant, a check is carried out to determine whether the goods protruding beyond the loading space of the first goods carrier (source) contribute to the completion of a reloading order that involves reloading several goods from the first goods carrier to the second goods carrier. If this is the case, the goods protruding beyond the loading space of the first goods carrier (source) are transported into the loading space of the second goods carrier (destination). If this is not the case, the goods protruding beyond the loading space of the first goods carrier (source) are always transported completely back into the loading space of the first goods carrier (source).

[0022] In case v), it is also advantageous to additionally check whether goods that have fallen from the gripping unit are completely outside the loading space.

[0023] It is particularly advantageous to check whether the goods dropped from the gripper unit have actually fallen onto the floor. In both cases, it is conceivable that the error cannot be corrected by the robot system itself, and therefore an alarm message is issued. The problem can then be resolved by an operator if necessary.

[0024] In the above context, it is also advantageous if it is checked whether the goods which have fallen from the gripping unit are located on a depositing surface which is arranged adjacent to the first goods carrier and / or the second goods carrier, and the goods located on the depositing surface are picked up by the gripping unit and i) in or on the first goods carrier, or ii) in or on the second goods carrier, or iii) placed on a clearing station.

[0025] In this way, the problem that has occurred can be rectified by the robot system itself, making intervention by an operator unnecessary. The storage area can be formed by a horizontal or inclined plane, as well as by a pivoting flap, and can be arranged between the product carriers or around the product carriers. The flap can in particular be motor-driven or operated by the robot. With the help of a storage area, which is designed in the form of an inclined plane, an item that has fallen from the gripping unit can be automatically transported into or onto the first product carrier, into or onto the second product carrier, or to a clearing station. With the help of a flap, an item that has fallen from the gripping unit can be transported either into or onto the first product carrier, into or onto the second product carrier, or to a clearing station.

[0026] As explained above, it can be specified that an alarm message is issued in certain cases. It is therefore generally advantageous if the check for whether goods extend beyond the loading space and steps a) or b) are repeated recursively, and the recursive repetition of this process is aborted after a specified number of repetitions and an alarm message is issued. Accordingly, if problems occur that cannot be resolved by the robot system alone, an alarm message is issued to alert the operating personnel to the problem.

[0027] It is also advantageous if the check to determine whether goods protrude beyond the loading space, as well as steps a) or b), are repeated recursively until the outcome of the aforementioned check is negative. This variant of the proposed method assumes that all problems that could potentially arise during the reloading of goods can be solved by the robot system alone. This can be ensured in particular if the robot's workstation is designed in such a way that goods that have fallen from the gripping unit are always within the robot's range. For example, this can be achieved by ensuring that the gripping unit can also reach the floor and thus goods that have fallen onto the floor, or by providing appropriate storage areas around the first and second goods carriers.

[0028] It is particularly advantageous if the gripping / picking up of a product from or from the first product carrier and a detection of the second product carrier and the goods located in or on the second product carrier with the aid of the sensor system, and the placing of a product in or on the second product carrier and a detection of the first product carrier or the goods located in or on the first product carrier with the aid of the sensor system takes place alternately, with the processes overlapping in time.

[0029] In other words, this means that the picking up of goods and the inspection to determine whether they extend beyond the loading space take place alternately at two different locations, namely the first goods carrier and the second goods carrier. This prevents the gripping unit from covering the goods carrier being inspected, particularly during optical scanning of the first and second goods carriers, and thus thwarting the inspection. Furthermore, the process is accelerated overall by parallelizing the processes involved.

[0030] It is also advantageous if the check to see whether an item of goods protrudes beyond the loading space is carried out after another item of goods has been picked up from or out of the first goods carrier. This variant applies in particular to two cases, namely when an item of goods other than the picked up falls back into or onto the first goods carrier designed as a loading aid, or when the gripping unit has placed an item in or onto the second goods carrier designed as a loading aid, but prevents optical detection of the second goods carrier and the goods stored therein. In the first case, an item of goods other than the picked up is inadvertently pulled along and can consequently protrude beyond the loading space of the first goods carrier. In the second case, detection (in particular optical detection) of the second goods carrier and the goods stored therein can only take place when the gripping unit is moved out of the area of ​​the second goods carrier.

[0031] Generally, the check to determine whether goods extend beyond a loading space can be performed while the gripper unit is moving from the first goods carrier to the second goods carrier and vice versa, so that the check results in no noticeable waiting times. The loading aids can therefore also be removed by conveyor technology immediately after the repacking or picking process.

[0032] It is advantageous if the first goods carrier is designed as the first loading aid and the second goods carrier as the second loading aid, whereby a loading space is defined in the area of ​​the first loading aid, which is intended for accommodating goods, and a further loading space is defined in the area of ​​the second loading aid, which is intended for accommodating goods, the loading spaces and the goods located in the area of ​​the loading spaces of the first loading aid and the second loading aid are each detected using the sensor system, after the gripping unit has picked up a good from or out of the first loading aid and after the gripping unit has placed the good in or onto the second loading aid, a check is carried out to determine whether a good protrudes beyond one of the loading spaces, and a) the goods protruding beyond said loading space are picked up by the gripping unit and placed in another position, or b) the part of the goods protruding beyond said loading space is moved by the gripping unit into this loading space, if the outcome of said test is positive.

[0033] In this embodiment, both goods carriers are designed as loading aids. The first loading aid therefore has a first loading space, and the second loading aid has a second loading space.

[0034] It is advantageous if the check to determine whether goods protrude beyond the loading space is carried out after the gripping unit and / or the goods picked up by the gripping unit have been completely moved out of the loading space. If the check in question is carried out after the goods have been picked up, the gripping unit and the goods held by it should therefore have been completely moved out of the loading space before the check. If the check in question is carried out after the goods have been put down, only the gripping unit (which no longer holds any goods) needs to have been completely moved out of the loading space before the check. These measures ensure that a static state is established in the loading space that is not disturbed by the reloading of the goods. Accordingly, this also ensures that the check to determine whether goods protrude beyond the loading space is valid.

[0035] It is also advantageous if the check to determine whether goods protrude beyond the loading space is carried out after the gripping unit and / or the goods picked up by the gripping unit have been completely moved out of a detection range of the sensor system, in particular from a detection range which relates to the loading space of a goods carrier and the goods contained therein. It would be conceivable for the gripping unit and / or the goods picked up by the gripping unit to cover parts of the goods carrier and the (other) goods contained therein after being completely moved out of the loading space, so that a check to determine whether goods protrude beyond the loading space is only possible for part of the area detected by the sensor system. However, the proposed measures enable a complete check.

[0036] It is also particularly advantageous if the check to determine whether goods protrude beyond the loading space is carried out after the gripping unit and the goods picked up by the gripping unit have been completely moved sideways away from a goods carrier. As long as the gripping unit and the goods picked up by the gripping unit are positioned vertically above a goods carrier, it cannot be ruled out that the goods may inadvertently fall back into or onto the goods carrier. However, the proposed measures enable a valid check.

[0037] It is advantageous to check whether goods protrude beyond the specified loading space after each load is picked up. This allows goods protruding beyond the loading space to be detected promptly after the defect occurs, preventing the accumulation of the effects of several consecutive defects. In particular, the aforementioned measures apply to the first goods carrier (source).

[0038] Similarly, it is advantageous to check whether goods protrude beyond the specified loading space after each placement of goods in or onto the second goods carrier. This allows goods protruding beyond the loading space to be detected promptly after the defect occurs, again preventing the accumulation of the effects of several consecutive defects. These measures particularly affect the second goods carrier (target).

[0039] It is also advantageous, however, if the check to determine whether a product protrudes beyond the specified loading space is performed after a large number of products have been placed in or onto the second goods carrier (especially after all products assigned to an order have been placed). This can reduce the number of checks and thus the computing effort and time required to process them. This variant is therefore particularly suitable for robot systems with limited computing power.

[0040] It should be noted here that one inspection can be performed after the goods have been picked up (but before they have been put down) and another inspection after the goods have been put down. However, it is also conceivable that only one inspection could be performed after the goods have been put down, and thus after the goods have been picked up. This means that the time for the inspection scheduled after picking up is then postponed, specifically to a time after the goods have been put down.

[0041] It is advantageous if the occupancy status of the gripping unit is monitored after picking up an item, and if an unoccupied but activated gripping unit is detected and a check is carried out to determine whether an item protrudes beyond the loading space. This detects any unintentional dropping of an item from the gripping unit and subsequently initiates a check to determine whether an item protrudes beyond the loading space. Unintentional dropping is characterized by the gripping unit being unoccupied but activated. If the gripping unit is occupied and activated, then an item is being held by the gripping unit. If the gripping unit is unoccupied and deactivated, then an item has been intentionally or deliberately put down or dropped. The occupancy status of the gripping unit can be monitored, for example, using specially designed sensors on the gripping unit.The occupancy status of the gripping unit can also be monitored by the sensor system, which is designed to detect the loading space and the goods located in the loading space. For example, the sensor system can have a scale positioned beneath a goods carrier that can measure the weight of the goods carrier and the goods it contains. If an item is removed, the weight measured by the scale decreases. If the item falls from the gripping unit back onto the goods carrier from or from which the goods were removed, the weight measured by the scale increases. Accordingly, it can be concluded that the item has (accidentally) fallen from the gripping unit. In an equivalent way, it can be determined whether an item has accidentally fallen onto or into the second goods carrier (target).Further information on the use of a scale in this context can be found in the international patent application PCT / AT2018 / 060012.

[0042] It is also advantageous if the goods are delivered according to an order be transported to the robot with the help of the first goods carrier, be reloaded from or out of the first goods carrier into or onto the second goods carrier with the help of the robot, and be transported away from the robot with the help of the second goods carrier.

[0043] In this variant, the goods are transported to the robot, for example, directly on a belt conveyor, a roller conveyor, or a chain conveyor, or with a loading device on a belt conveyor, a roller conveyor, or a chain conveyor. The robot can therefore remain static in one location. However, it would also be conceivable for the robot to be designed as a mobile robot. For example, the robot could be mounted on an autonomous transport vehicle (Automated Guided Vehicle, or "AGV" for short).

[0044] It is advantageous if the sensor system includes a camera and / or a depth sensor and / or a laser scanner and / or an ultrasonic sensor. These sensors can be used to determine whether an item of goods protrudes beyond the loading space of the loading aid. In addition, the sensor system can also determine the location and position of an item in or on a goods carrier and use this information for gripping by the gripping unit. A camera (stereo camera), a depth sensor, a laser scanner or an ultrasonic sensor can be used to capture a three-dimensional image of the goods in or on the goods carrier. However, a three-dimensional image can also be generated from several two-dimensional images taken from different angles. These two-dimensional images can, for example, come from stereometrically arranged cameras or be recorded during a relative movement between the item and the camera.The (single) camera can move relative to the stationary goods, or vice versa. The three-dimensional detection of the goods lying in or on the goods carrier also allows the surface structure of the goods to be determined and their suitability for gripping by the gripping unit to be determined. For example, highly convex surfaces are less suitable for gripping with a suction gripper, whereas flat surfaces are particularly well-suited for gripping with a suction gripper. A camera is also particularly suitable for detecting the surface properties of the goods to be picked up, for example, a print on a packaging.

[0045] The gripping unit advantageously comprises at least one suction gripper. Suction grippers are suitable for quickly picking up goods of different qualities, for example, both for manipulating more or less rigid objects (e.g., boxes, cartons, and plastic containers) and for manipulating flexible and particularly flexible objects (e.g., sacks or bags filled with objects).

[0046] At this point, it should be noted that the presented method and robot are generally suitable (i.e., not only in connection with suction grippers) for picking up both rigid goods and deformable goods, such as sacks or bags. Both rigid goods and deformable goods can be formed by an individually handled object or by an individually handled group of objects. Specifically, a product can therefore be designed, for example, as a cardboard box or plastic box filled with multiple objects. Likewise, a product can also be designed as a sack or bag filled with multiple objects. The inventive method and robot system are particularly well suited for goods in the form of film bags, in particular in the form of so-called "polybags" or "polybags" made of polyethylene or polypropanol.Such film bags are primarily used in the textile industry, for example, for packaging T-shirts, shirts, and the like. Such film bags are also frequently used in the shoe and food industries.

[0047] It's also advantageous if the robot is designed as an articulated-arm robot or gantry robot. These designs represent tried-and-tested means for manipulating goods and are available in a wide variety of forms on the market.

[0048] Finally, it is advantageous if the workstation of the storage and order-picking system is designed for the fully automated order-picking of goods, and a first conveyor system for transporting goods in or on first goods carriers (warehouse loading aids, in particular containers) is arranged between the storage area and the robot at the workstation, and / or a second conveyor system for removing goods in or on second goods carriers (order loading aids, in particular boxes) is provided between the storage area and the robot at the workstation, wherein the robot is designed to pick up at least one item of goods from or out of the first goods carrier (warehouse loading aid, in particular containers) for an order and to place the at least one item in or on the second goods carrier (order loading aid, in particular boxes) for this order. In this way, an order-picking process can be carried out particularly efficiently and quickly.

[0049] At this point, it is noted that the embodiments disclosed for the method and the advantages resulting therefrom equally relate to the disclosed device and vice versa.

[0050] For a better understanding of the invention, it is explained in more detail using the following figures.

[0051] They show in a highly simplified, schematic representation: Fig. 1 a simplified first example of a robot system with a robot and a fixed camera system in an oblique view; Fig. 2 similar to Figure 1, but with a movable camera system with a camera that is attached to a robot arm segment of the robot; Fig. 3 a schematically illustrated example of a storage and order picking system in plan view; Fig. 4 a container with a loading space that is limited at the top by a loading opening of the container; Fig. 5 a container with a loading space that projects upwards beyond the loading opening; Fig. 6 a container with a loading space that projects laterally beyond the side walls of the container; Fig. 7 a container with a loading space that extends downwards below the level of the loading opening in the section projecting beyond the side walls; Fig. 8 a container with a loading space according to Fig. 5 and cuboid goods stored therein; Fig. 9 a container with a loading space according to Fig. 6 and cuboid goods stored therein; Fig. 10 a container with a loading space according to Fig. 4and cuboid goods stored therein; Fig. 11 a container with a loading space according to Fig. 4 with a flexible product hanging over the container edge; Fig. 12 a container with a loading space according to Fig. 4 and flexible goods stored therein; Fig. 13 an arrangement with two containers and a storage area in the area of ​​these containers on which a product lies; Fig. 14 the arrangement of Fig. 13 , but in a state in which the goods have been removed from the storage area; Fig. 15 an arrangement with four containers and a storage area in the area of ​​these containers on which a product lies; Fig. 16 the arrangement of Fig. 15 , but in a state in which the goods have been removed from the storage surface; Fig. 17 an example of a pivotable flap arranged between a first and second container.

[0052] By way of introduction, it should be noted that in the variously described embodiments, identical parts are provided with identical reference symbols or component designations. The disclosures contained throughout the description can be applied mutatis mutandis to identical parts with identical reference symbols or component designations. Furthermore, the positional information chosen in the description, such as top, bottom, side, etc., refers to the directly described and illustrated figure and, in the event of a change in position, is to be applied mutatis mutandis to the new position.

[0053] The Figure 1shows a robot 1a in a robot system 2a. The robot 1a has a gripping unit 4 which is movable relative to a robot base 3 and which, in this example, has three spaced-apart suction grippers 5. The gripping unit 4 is connected to the robot base 3 via a robot arm which has two arm segments 6 and 7. Furthermore, the Figure 1 a sensor system 8a..8d, which serves to detect the goods carriers 9a and 9b and the goods stored therein and in this example comprises two cameras 8a, 8b and two further optional cameras 8c, 8d. The goods are in the Figure 1 However, they are not visible because they are stored in the goods carriers 9a and 9b, which in this example are designed as containers. Container 9a is a source container from which goods are picked up / removed by the gripping unit 4, and container 9b is a target container into which goods are placed / dropped by the gripping unit 4.

[0054] In this example, the cameras 8a, 8b are arranged above the containers 9a and 9b and are each designed as a stereo camera. Accordingly, the cameras 8a, 8b capture a three-dimensional image of the interior of at least the containers 9a and 9b and the goods stored therein. In principle, only the camera 8a (stereo camera) could be provided above the container 9a, or only the camera 8b (stereo camera) could be provided above the container 9b. It is also conceivable that only one common camera 8a (stereo camera) is provided for the containers 9a and 9b. Even if stereo cameras are used in a preferred embodiment, the cameras 8a, 8b could also be designed as cameras for capturing a two-dimensional image of the interior of at least the containers 9a and 9b and the goods stored therein.

[0055] With the two optional cameras 8c, 8d, the containers 9a and 9b, as well as the goods projecting beyond them, can also be captured from the side. The specific purpose of the optional cameras 8c, 8d is explained by the Figures 6 and 7 explained in detail. The Figure 1 The position and orientation of the two optional cameras 8c, 8d shown is purely illustrative, and other positions and orientations for the two optional cameras 8c, 8d are also conceivable.

[0056] The Figure 1 The arrangement shown further comprises a conveyor system for transporting the containers 9a, 9b to the robot system 2a and for transporting the containers 9a, 9b away from the robot system 2a. In particular, the conveyor system comprises a first conveyor line 10a for transporting the containers 9a, 9b to the robot system 2a and a second conveyor line 10b for transporting the containers 9a, 9b away from the robot system 2a.

[0057] Finally, the Figure 1The arrangement shown includes a controller 11, which is connected to the cameras 8a..8d and the robot 1a and serves in particular to check whether a product protrudes from a loading space of the containers 9a and 9b. Furthermore, the controller 11 serves to control the movement of the gripping unit 4 according to a predetermined reloading process.

[0058] The Figure 2 shows a robot system 2b, which is similar to the Figure 1is very similar to the robot system 2a shown. In contrast, however, no cameras 8a..8d are arranged above and to the side of the containers 9a and 9b, but rather a single camera 8e is arranged directly on the second arm segment 7 of the robot 1b. This camera 8e is also connected to a controller 11 (connection not shown). Furthermore, the camera 8e can again be designed as a stereo camera in order to capture a three-dimensional image of the containers 9a and 9b and the goods stored therein, for example by moving the camera 8e with the aid of the robot 1a over the container 9a or over the container 9b and capturing an image there.It would also be conceivable, however, for the camera 8e to be designed solely to capture a two-dimensional image, and for a three-dimensional image of the containers 9a and 9b, as well as the goods stored therein, to be generated by capturing multiple two-dimensional images during a movement of the camera 8e and subsequently calculating the three-dimensional image. Furthermore, the camera 8e can also be positioned so that the containers 9a, 9b, as well as the goods projecting beyond them, can also be captured from the side. It should also be noted at this point that the camera 8e can also be used with the cameras 8a..8d from the robot system 1a of the . Fig. 1 can be combined.

[0059] The Figure 3shows a storage and order picking system 12, which has a building 13, as well as a gate at a goods receipt 14 and a gate at a goods issue 15. In the area of ​​the goods receipt 14 there is a first conveyor line 16 and two second conveyor lines 17a and 17b. The first conveyor line 16 connects the goods receipt 14 to a robot system 2c. The two second conveyor lines 17a and 17b connect the robot system 2c to a storage area 18, which comprises several storage racks 19 and storage and retrieval machines 20a and 20b, which travel in rack aisles running between the storage racks 19. At the end of the rack aisles opposite the second conveyor lines 17a and 17b, a third conveyor line 21 is arranged, which in this example is ring-shaped and leads to another robot system 2d.A fourth conveyor line 22 is also arranged in the area of ​​operation of the robot system 2d, which connects the robot system 2d with the goods exit 15 in terms of conveyor technology.

[0060] The Figure 4 shows the container 9a in detail. The container 9a comprises a container base 24, side walls 25 projecting from the base, and a loading opening 26 defined by the side walls 25. Furthermore, the container 9a has a loading space 27a, which is defined at the top by the aforementioned loading opening 26.

[0061] The Figure 5 shows the container 9a now with a loading space 27b, which projects upwards beyond the aforementioned loading opening 26, specifically beyond the level 28 of the loading opening 26.

[0062] Figure 6 shows the container 9a further with a loading space 27c, which on the one hand projects upwards over the aforementioned loading opening 26, but on the other hand also laterally over the side walls 25.

[0063] Figure 7finally shows the container with a loading space 27d, which not only projects upwards beyond the said loading opening 26 and laterally beyond the side walls 25, but also extends downwards below the level 28 of the loading opening 26 in the section projecting beyond the side walls 25.

[0064] The Figures 4 to 7 The loading aid 9a shown is designed as a container, specifically, for example, as a carton, box, or crate. However, it is also conceivable that the loading aid used in the presented method is designed as a pallet or tray. Since a tray typically has (low) side walls, it can also be considered a container.

[0065] The Figure 8shows the container 9a loaded with cuboid goods 23f, which are not all located within the loading space 27a (shown in dashed lines), since the uppermost goods 23f protrude beyond the level 28 of the container opening 26. The Figure 8 The loading shown is therefore not permitted for the loading space 27a. However, the goods 23f are all located within the loading space 27b (shown in dotted lines), although the uppermost goods 23f protrude beyond the level 28 of the container opening 26. The Figure 8The loading shown is therefore permissible for the loading space 27b. It is clear from the illustration that the loading space 27b has a greater volume than the volume enclosed by the container base 24, the side walls 25, and the container opening 26, and that the container 9a is more heavily loaded than is the case in automatic storage and picking systems according to the prior art. According to the prior art, containers 9a are loaded up to a maximum of level 28 of the container opening 26. Consequently, the performance of a storage and picking system 12, in which containers 9a with relatively large loading spaces 27b, 27c, and 27b are used, is increased compared to conventional storage and picking systems.

[0066] The Figure 9shows the container 9a loaded with cuboid goods 23f, which are not all located within the loading space 27a (shown in dashed lines), since the uppermost goods 23f protrude beyond the level 28 of the container opening 26. The Figure 9 The loading shown is therefore not permitted for the loading space 27a. Furthermore, the uppermost item 23f extends beyond the loading space 27b (shown in dash-dotted lines). Figure 9 The loading shown is therefore not permitted for the loading space 27b. Figure 9 However, it shows a loading space 27c (shown in dotted lines) which extends laterally beyond the side walls 25. Although the uppermost item 23f protrudes laterally beyond the container wall 25, it is still located within the loading space 27c and therefore does not result in a negative outcome of the check as to whether all items 23f are located within the loading space 27c.

[0067] Furthermore, the Figure 10the container 9a loaded with goods 23f, but with a loading space 27a that extends only to the loading opening 26. Here, too, all goods 23f are arranged within the loading space 27a and therefore do not cause a negative outcome of the check as to whether all goods 23f are located within the loading space 27a.

[0068] The Figure 11 shows the container 9a loaded with goods 23g, which in turn has a loading space 27a that extends only to the loading opening 26. In this example, a pliable item of goods 23g hangs over the container edge, whereby the test as to whether all goods 23g are located within the loading space 27a fails. In the case of a loading space that extends downwards below the level 28 of the loading opening 26 in the section projecting beyond the side walls 25, as in the Figure 7For the loading space 27d, however, it would be conceivable that the above-mentioned test would be positive, provided that the loading space is large enough for the goods 23g.

[0069] From the Figure 11 In particular, it can also be seen that the proposed method or the proposed robot system 2a..2d, as well as the proposed storage and order-picking system 12 are suitable not only for the manipulation of more or less rigid and cuboid-shaped bodies (goods 23f), but also for the manipulation of flexible and irregularly shaped goods 23g.

[0070] The Figure 12 Finally, it shows a container 9a loaded with the irregularly shaped goods 23g, in which all goods 23g are located within the loading space 27a extending to the loading opening 28. The check as to whether all goods 23g are located within the loading space 27a is therefore again positive.

[0071] The Figures 4 to 12were related to container 9a. Of course, the disclosed teaching can also be applied without restriction to containers 9b..9e.

[0072] Figure 13 shows an arrangement with two containers 9a, 9b and a storage surface 29a, which extends between these containers 9a, 9b and partially around the containers 9a, 9b. In this way, it can be prevented that a product 23j, which has accidentally fallen from the gripping unit 4, falls onto the floor. Instead, the product 23j falls onto the storage surface 29a, as shown in the Figure 13 is shown. From this storage area 29a, the goods 23j can be picked up and placed either in the first container 9a or in the second container 9b. Figure 14 shows the arrangement Figure 13 in a state in which the goods 23j were placed in the second container 9b.

[0073] The Figure 15shows an arrangement with four containers 9a..9d and a storage area 29b, which corresponds to the Figures 13 and 14 The arrangement is very similar to the one shown. However, instead of two containers 9a and 9b, there are four containers 9a..9d. The storage area 29b extends crosswise between the containers 9a and 9d. In this example, it is again assumed that a product 23m has inadvertently fallen from the gripping unit 4 onto the storage area 29b. From this storage area 29b, the product 23m can be picked up and placed in one of the containers 9a..9d. Figure 16 shows the arrangement Figure 15 in a state in which the goods were placed 23m into container 9c.

[0074] The Figures 13 to 16The storage areas 29a, 29b shown can be formed by horizontal surfaces (and possibly form a settling area), but they can also be inclined towards one of the containers 9a..9d. In this way, goods 23a..23n that have fallen from the gripping unit 4 automatically slide to one of the predetermined locations. Inclined storage areas 29a, 29b serve primarily to automatically transport goods 23a..23n that have inadvertently fallen from the gripping unit 4 to one of the predetermined locations. However, it would also be conceivable for the goods 23a..23n to be deliberately dropped onto an inclined storage area 29a, 29b or placed there in order to automatically transport the goods 23a..23n to one of the predetermined locations. This is advantageous in that the distance traveled by the gripping unit 4 when reloading goods 23a..23n can be reduced.

[0075] Fig. 17shows an example of a flap 31 arranged between a first container 9a and a second container 9b and pivotable about a rotation axis 30. In this way, a product 23n that has inadvertently fallen from the gripping unit 4 can be specifically conveyed into the second container 9b by pivoting the flap 31 upwards. For this purpose, the flap 31 can have its own pivot drive, or the flap 31 can be pivoted upwards by the robot 1a, 1b itself. Advantageously, the product 23n (which may be difficult to pick up / grasp) does not need to be grasped by the gripping unit 4 for this purpose.

[0076] It is also conceivable that the flap 31 can be tilted toward the first container 9a, alternatively or additionally. It is also conceivable that the flap 31 can be tilted toward a storage position / treatment area or a container placed there, alternatively or additionally. It is also conceivable that the horizontally oriented flap 31 itself forms the treatment area.

[0077] At this point it is noted that the Figures 13 and 14 shown storage area 29a, which is in the Figures 15 and 16 shown storage area 29b and the one in the Figure 17 shown flap 31 also in a robot system 2a, 2b according to the Figures 1 and 2 , as well as in a storage and picking system 12 according to the Figure 3 can be used. Furthermore, it is of course possible for the storage area 29a, 29b to extend around and enclose the containers 9a..9d, so that the risk of goods 23a..23n falling onto the floor is even lower.

[0078] The function of the arrangements shown in the figures is now explained in detail below: In the Figures 1 and 2The process for reloading goods 23a..23n using the gripping unit 4 from a first goods carrier 9a (source container) to a second goods carrier 9b (destination container) is shown. The goods carriers 9a and 9b, designed as box-shaped containers, are transported to the robot 1a, 1b for the reloading process using the conveyor system 10a and 10b and transported away from the robot 1a, 1b after the reloading process. However, the transport of the goods 23a..23n using loading aids 9a and 9b is not a necessary condition; rather, the goods 23a..23n can also be transported directly on the conveyor system if, for example, this comprises a belt conveyor, a link belt conveyor, or the like as the first conveyor line 10a and a belt conveyor, a link belt conveyor, or the like as the second conveyor line 10b. Of course, roller conveyors 10a and 10b could also be provided.Likewise, other loading aids could be provided instead of the containers 9a and 9b, for example trays or boxes.

[0079] If (source) load supports (containers, trays, cartons) are used as the first goods carriers in the area of ​​the robot system 2a..2d, from which or from which goods 23a..23n are removed with the suction grippers 5, the (source) load supports can advantageously be loaded with goods 23a..23n by type or divided into compartments by type. For example, a first load support contains goods "A," a second load support contains goods "B," etc. On the other hand, it is also possible for a load support to be divided into several receiving compartments by partition walls and to accommodate different goods "A" and "B," whereby the first receiving compartment can accommodate goods "A" and the second compartment can accommodate goods "B."

[0080] In the Figure 3A somewhat more complex arrangement is shown, specifically a storage and picking system 12. Goods 23a..23e are delivered to the goods receipt 14, loaded onto the first conveyor line 16, transferred by the robot system 2c from the first conveyor line 16 to the second conveyor lines 17a and 17b, and stored in the storage racks 19 using the storage and retrieval machines 20a and 20b. The first conveyor line 16 acts as the first goods carrier or source in this process, whereas the second conveyor lines 17a and 17b act as the second goods carrier or destination in this process.

[0081] If a picking order is to be processed, the goods 23a..23e assigned to the order are retrieved from at least one storage rack 19 using at least one storage and retrieval machine 20a and 20b and transferred to the third conveyor line 21. The goods 23a..23e are then transported to the robot system 2d using the third conveyor line 21, and from there they are reloaded from the third conveyor line 21 to the fourth conveyor line 22, and finally transported to the goods exit 15 using the fourth conveyor line 22. The third conveyor line 21 functions as the first goods carrier or source in this process, whereas the fourth conveyor line 22 functions as the second goods carrier or destination in this process.

[0082] As from the Figure 3As can be seen, the goods 23a, 23b and 23e are transported directly on the conveyor lines 16, 17a, 17b, 21 and 22, which act as goods carriers, whereas the goods 23c and 23d are transported by means of loading aids 9c..9e, which accordingly also act as goods carriers. Figure 3 This constitutes a mixed mode of transport. It would also be conceivable, of course, for the goods 23a..23e to be transported exclusively on conveyor lines 16, 17a, 17b, 21, and 22, which act as goods carriers, or exclusively using loading equipment 9c..9e.

[0083] The design and arrangement of the conveyor lines 16, 17a, 17b, 21 and 22 in the Figure 3is of course only illustrative, and other shapes and arrangements of the mentioned conveyor lines 16, 17a, 17b, 21 and 22 are also conceivable. In particular, a ring-shaped conveyor line could be arranged at the goods inlet 14, or linear conveyor lines could be provided at the goods outlet 15. The conveyor connection of the robot system 2c and 2d to the goods inlet 14, to the storage area 18 and to the goods outlet 15 is also not necessarily carried out via stationary conveyor means, as is the case in the Figure 3 shown, but could also be carried out entirely or partly by autonomous transport vehicles (in particular autonomous industrial trucks), whose loading platforms then also serve as goods carriers.

[0084] It would also be conceivable for the goods 23a..23e to be loaded directly onto the storage and retrieval machines 20a and 20b by the robot system 2c or picked up directly from the storage and retrieval machines 20a and 20b by the robot system 2d. In this case, the loading platforms of the storage and retrieval machines 20a and 20b also serve as goods carriers.

[0085] At this point, it is also noted that the robots 1a and 1b do not necessarily have to be designed as articulated arm robots, but can also be designed as gantry robots, for example.

[0086] It should also be mentioned that the goods 23a..23n in or on the first goods carrier 9a, 9c, 9e, 10a, 16, 21 can be arranged next to each other, one above the other, standing or lying down, and therefore in a disordered (chaotic) or jumbled manner.

[0087] It is further noted that the sensor system may comprise not only cameras 8a..8e, but alternatively or additionally may also include a spatial depth sensor, a laser scanner, and / or an ultrasonic sensor. These sensors can be used, in particular, to capture a three-dimensional image of the goods 23a..23n located in or on a goods carrier (for example, in the containers 9a..9e or on the conveyor lines 10a and 10b).

[0088] In general, a three-dimensional detection can be used to determine the surface structure of the goods 23a..23n and to determine their suitability for gripping by the suction grippers 5. For example, strongly convex surfaces are less suitable for gripping, whereas flat surfaces are particularly easy to grip.

[0089] Generally, in the processes described above in a robot system 2a, 2b or in the storage and order picking system 12, after picking up a product 23a..23n by the gripping unit 4 from or out of the first product carrier 9a, a check is carried out to determine whether a product 23a..23n protrudes beyond the said loading space 27a..27d (compare the Figures 4 to 12). If the outcome of said test is positive, the goods 23a..23n projecting beyond the loading space 27a..27d can be picked up by the gripping unit 4 in a further step and deposited at a different position (case a). This different position can be located, in particular, in the loading space 27a..27d of the loading aid 9a, from which the goods 23a..23n in question were picked up. However, the different position can also be located in the loading space 27a..27d of another loading aid 9b. Finally, it is also possible to deposit the goods 23a..23n at a different position outside a loading space 27a..27d of a loading aid 9a, 9b, for example at a sewage treatment plant. Alternatively, it is also possible to move the part of the goods 23a..23n projecting beyond the loading space 27a..27d back into the loading space 27a..27d using the gripping unit 4 (case b).

[0090] The outcome of said test may be positive in particular if a product 23a..23n falls unintentionally from the gripping unit 4 or if a position calculated for the product 23a..23n to be placed or dropped onto the second product carrier 9b turns out not to have been reached.

[0091] In particular, in the above processes, it is conceivable that the check to determine whether a product 23a..23n protrudes beyond a loading space 27a..27d, as well as steps a) or b), are repeated recursively until the outcome of the aforementioned check is negative. It is assumed that the robot system 2a..2d is fundamentally capable of correcting any errors that occur.

[0092] In particular, it would also be conceivable for the check to determine whether a product 23a..23n protrudes beyond a loading space 27a..27d, as well as steps a) or b), to be repeated recursively, and for the recursive repetition of this process to be aborted after a specified number of repetitions and an alarm to be issued. In this variant, an operator may be called in to resolve the problem that has occurred.

[0093] In general, the unintentional dropping of an item 23a..23n can be detected by monitoring the occupied status of the gripping unit 4 after picking up an item 23a..23n. The unintentional dropping of an item 23a..23n is characterized by the gripping unit 4 being unoccupied but activated. Subsequently, a check is initiated to determine whether an item 23a..23n protrudes beyond a loading space 27a..27d. If, however, the gripping unit 4 is occupied and activated, then an item 23a..23n is held by the gripping unit 4. If the gripping unit 4 is unoccupied and deactivated, then an item 23a..23n was intentionally or deliberately placed or dropped. The occupancy status of the gripping unit 4 can be monitored, for example, by a specially designed sensor system on the gripping unit 4 (not shown). The occupancy status of the gripping unit 4 can also be monitored by the sensor system 8a..8e, which is used to detect the loading space 27a..27d and the goods 23a..23n located in the cargo hold 27a..27d (i.e. in the area specified in the . Figures 1 and 2 shown example with cameras 8a..8e).

[0094] Furthermore, it is advantageous if the check to determine whether a product 23a..23n protrudes beyond a loading space 27a..27d is performed after the gripping unit 4 and / or the product 23a..23n picked up by the gripping unit 4 have been completely moved out of the loading space 27a..27d. If the said check is performed after the product 23a..23n has been picked up, the gripping unit 4, together with the product 23a..23n held by it, should have been completely moved out of the loading space 27a..27d before the check. If the said check is performed after the product 23a..23n has been deposited, only the gripping unit 4 (which no longer holds any product 23a..23n) needs to have been completely moved out of the loading space 27a..27d before the check. It is furthermore advantageous if the check as to whether a product 23a..23n protrudes beyond the loading space 27a..27d is carried out after the gripping unit 4 and / or the product 23a..23n picked up by the gripping unit 4 have been completely moved out of a detection range of the sensor system 8a..8e.Furthermore, it is advantageous if the check as to whether a product 23a..23n protrudes beyond the loading space 27a..27d is performed after the gripping unit 4 and the product 23a..23n picked up by the gripping unit 4 have been completely moved laterally away from a product carrier 9a..9d, 10a, 10b, 16, 17a, 17b, 21, 22. These measures ensure that a static state is established in the loading space 27a..27d that is not disturbed by the reloading process of the goods 23a..23n. Accordingly, this also ensures that the check as to whether a product 23a..23n protrudes beyond the loading space 27a..27d is valid.

[0095] It is also advantageous if the check to determine whether a product 23a..23n protrudes beyond the aforementioned loading space 27a..27d is performed after each pick-up of a product 23a..23n. This allows a product 23a..23n protruding beyond the loading space 27a..27d to be detected promptly after the defect occurs, and prevents the accumulation of the effects of several consecutive defects. In particular, the aforementioned measures apply to the first product carrier 9a (source).

[0096] Similarly, it is advantageous if the check to determine whether a product 23a..23n protrudes beyond the aforementioned loading space 27a..27d is performed after each placement of a product 23a..23n in or onto the second product carrier 9b. This allows a product 23a..23n protruding beyond the loading space 27a..27d to be detected promptly after the occurrence of the error, thus preventing the accumulation of the effects of several consecutive errors. These measures particularly affect the second product carrier 9b (target).

[0097] Finally, it is also advantageous if the check to determine whether a product 23a..23n protrudes beyond a loading space 27a..27d is performed after a plurality of products 23a..23n (in particular after all products 23a..23n assigned to an order) have been deposited in or onto the second product carrier 9b. This allows the number of checks and thus the computing effort and time required to process them to be reduced. This variant is therefore particularly suitable for robot systems 2a..2d with limited computing power.

[0098] In general, one inspection can be performed after picking up the goods 23a..23n (but before putting them down) and another inspection after putting down the goods 23a..23n. However, it is also conceivable that only one inspection can be performed after putting down the goods 23a..23n (and thus after picking up the goods 23a..23n).

[0099] It is also advantageous if the check to determine whether a product 23a..23n protrudes beyond the loading space 7a..7d is carried out after gripping / picking up another product 23a..23n from or out of the first product carrier 9a. This variant applies in particular to two cases, namely when a product 23a..23n other than the picked up one falls back into or onto the first product carrier 9a, or when the gripping unit 4 has placed a product 23a..23n in or onto the second product carrier 9b, but prevents optical detection of the second product carrier 9b and the goods 23a..23n stored therein. In the first case, a product 23a..23n other than the picked up one is inadvertently pulled along and can subsequently protrude beyond the loading space 17a..17d of the first product carrier 9a. In the second case, detection (in particular optical detection) of the second goods carrier 9b and the goods 23a..23n stored therein can only take place when the gripping unit 4 is moved out of the area of ​​the second goods carrier 9b.

[0100] In general, the check to determine whether a product 23a..23n protrudes beyond the loading space 7a..7d can be performed during the movement of the gripping unit 4 from the first goods carrier 9a to the second goods carrier 9b and vice versa, so that the check does not result in any noticeable waiting times. Loading aids can thus be transported away by a conveyor system 10a, 10b immediately after the repacking or picking process.

[0101] In a particularly advantageous variant, the gripping / picking up of a product 23a..23n from or out of the first product carrier 9a and a detection of the second product carrier 9b and the goods 23a..23n located in or on the second product carrier 9b with the aid of the sensor system 8a..8e, and the placing of a product 23a..23n in or onto the second product carrier 9b and a detection of the first product carrier 9a or the goods 23a..23n located in or on the first product carrier 9a with the aid of the sensor system 8a..8e in alternation.

[0102] This variant can be particularly well illustrated using the robot system 1a from Fig. 1 explained: In a first time period, an item of goods 23a..23n is picked up from the first goods carrier 9a. In a second time period, the item of goods 23a..23n is placed in the second goods carrier 9b. If necessary, a correction is also made regarding goods 23a..23n that protrude beyond the loading space 7a..7d of the second goods carrier 9b, according to cases a) or b). In the second time period, the camera 8a also captures the first goods carrier 9a and the goods 23a..23n stored therein. In a third time period, the gripping unit 4 returns to the first goods carrier 9a and picks up another item of goods 23a..23n from the first goods carrier 9a. If necessary, a correction is made regarding goods 23a..23n that protrude beyond the loading space 7a..7d of the first goods carrier 9a, according to cases a) or b). In the third time period, the camera 8b also captures the second goods carrier 9b along with the goods 23a..23n stored therein. In a fourth time period, the goods 23a..23n is placed in the second goods carrier 9b. If necessary, a correction is again made regarding goods 23a..23n that protrude beyond the loading space 7a..7d of the second goods carrier 9b, according to cases a) or b). In the fourth time period, the first goods carrier 9a, along with the goods 23a..23n stored therein, is also captured by the camera 8a. Subsequently, the processes described for the odd and even time periods are repeated as often as desired.

[0103] The picking of a product 23a..23n and the correction regarding a product 23a..23n protruding beyond the loading space 7a..7d of the first product carrier 9a in the third time period are based on the camera image of the first product carrier 9a, including the goods 23a..23n stored therein, captured in the second time period. The setting down of a product 23a..23n and the correction regarding a product 23a..23n protruding beyond the loading space 7a..7d of the second product carrier 9b, in the fourth time period are based on the camera image of the second product carrier 9b, including the goods 23a..23n stored therein, captured in the third time period, and so on. The processes occurring in the odd-numbered and even-numbered time periods are thus repeated "alternately." It should be noted that the time periods can be completely separate from each other, but they can also overlap in time.

[0104] The above variant was explained using robot system 2a. Of course, it also applies without restriction to robot system 2b from Fig. 2 or on the storage and picking system 12 Fig. 3 .

[0105] The proposed measures detect goods 23a..23n that extend beyond the loading space 27a..27d of a loading aid 9a..9e, thereby avoiding disruptions during conveying and handling in a storage and picking system 12, for example when the loading aids 9a..9e pass through areas with low clearance height during transport or when the loading aids 9a..9e are subjected to strong accelerations and / or vibrations and goods 23a..23n that extend beyond a loading space 27a..27d could fall out of or from the loading aid 9a..9e. The proposed measures thus increase the availability of a storage and picking system 12. Furthermore, the performance of the storage and picking system 12 can be significantly increased compared to the prior art because the loading aids 9a..9e can be loaded right up to the edge of a container or even beyond. These therefore require less installation space than was previously the case.

[0106] Finally, it should be noted that the scope of protection is determined by the patent claims. However, the description and drawings must be used to interpret the claims. Individual features or combinations of features from the various embodiments shown and described may represent independent inventive solutions. The problem underlying these independent inventive solutions can be derived from the description.

[0107] In particular, it is also noted that the devices depicted may in reality comprise more or fewer components than shown. In some cases, the depicted devices or their components may also be shown not to scale and / or enlarged and / or reduced in size. Reference symbol list

[0108] 1a, 1bRobot 2a..2dRobot system 3Robot base 4Gripping unit 5Suction gripper 6First robot arm segment 7Second robot arm segment 8a..8eCamera (sensor system) 9a..9eContainer (goods carrier) 10a, 10bConveyor system (goods carrier) 11Control 12Storage and picking system 13Building wall 14Goods receipt 15Goods issue 16First conveyor line (goods carrier) 17a, 17bSecond conveyor line (goods carrier) 18Storage area 19Storage rack 20a, 20bStorage and retrieval machine 21Third conveyor line (goods carrier) 22Fourth conveyor line (goods carrier) 23a..23nGoods 24Container base 25Side wall 26Loading opening 27a..27dLoading space 28Level of the loading opening 29a, 29bStorage area 30Rotation axis 31Flap

Claims

1. A method for controlling a robot (1a, 1b) in a storage and order-picking system (12), the robot comprising a gripping unit (4) movable in relation to a robot base (3), in which the articles (23a..23n) are gripped from or out of a first article carrier (9a, 9c, 9e, 10a, 16, 21) and placed in or on a second article carrier (9b, 9d, 10b, 17a, 17b, 22) by the gripping unit (4), wherein - at least one of the article carriers is configured as a loading aid (9a..9e) suitable for transporting the articles (23a..23n), - a loading space (27a..27d) is defined in the region of the at least one loading aid (9a..9e), the loading space is intended for accommodating the articles (23a..23n), - the loading space (27a..27d) and the articles (23a..23n) located in the area of the loading space (27a..27d) are detected by a sensor system (8a..8e), - after an article (23a..23n) has been picked up by the gripping unit (4) from or out of the first article carrier (9a, 9c, 9e, 10a, 16, 21), a check is carried out to determine whether an article (23a..23n) protrudes beyond said loading space (27a..27d), and - the article (23a..23n) protruding beyond the loading space (27a..27d) is picked up by the gripping unit (4) and placed in another position if the outcome of said check is positive.

2. The method according to claim 1, characterized in that for placing an article (23a..23n) in or on the second loading aid (9b, 9d, 10b, 17a, 17b, 22), a position within the loading space (27a..27d) is calculated, at which the article (23a..23n) likely does not protrude beyond the loading space (27a..27d).

3. The method according to claim 1 or 2, characterized in that the loading aid (9a..9e) used comprises a container bottom (24), side walls (25) projecting therefrom and a loading opening (26) delimited by the side walls (25), and the loading space (27a) is delimited at the top by the loading opening (26).

4. The method according to claim 1 or 2, characterized in that the loading aid (9a..9e) used comprises a container bottom (24), side walls (25) projecting therefrom and a loading opening (26) delimited by the side walls (25), and the loading space (27b) projects upwards beyond the mentioned loading opening (26).

5. The method according to claim 4, characterized in that the loading space (27c) projects laterally beyond the side walls (25) of the loading aid (9a..9e) used.

6. The method according to claim 5, characterized in that the loading space (27d) extends downwards below the plane (28) of the loading opening (26) in the section projecting beyond the side walls (25).

7. The method according to one of claims 1 to 6, characterized in that it is checked whether an article (23a..23n) dropped from the gripping unit is completely outside the loading space (27a..27d).

8. The method according to claim 7, characterized in that - it is checked whether the article (23a..23n) dropped from the gripping unit (4) is located on a rest surface (29a, 29b) which is arranged to be adjacent to the first article carrier (9a, 9c, 9e, 10a, 16, 21) and / or the second article carrier (9b, 9d, 10b, 17a, 17b, 22), and - the article (23a..23n) located on the rest surface (29a, 29b) is picked up by the gripping unit (4) and is placed i) in or on the first article carrier (9a, 9c, 9e, 10a, 16, 21), or ii) in or on the second article carrier (9b, 9d, 10b, 17a, 17b, 22), or iii) at a clearing place.

9. The method according to claim 7 or 8, characterized in that it is checked whether the article (23a..23n) dropped from the gripping unit (4) has dropped on the floor.

10. The method according to one of claims 1 to 9, characterized in that the check whether an article (23a..23n) protrudes beyond the loading space (27a..27d) and the step of picking up the article (23a..23n) protruding beyond the loading space (27a..27d) by the gripping unit (4) and placing it at another position, if the outcome of said check is positive, is repeated recursively until the outcome of the check is negative.

11. The method according to one of claims 1 to 9, characterized in that the check whether an article (23a..23n) protrudes beyond the loading space (27a..27d) and the step of picking up the article (23a..23n) protruding beyond the loading space (27a..27d) by the gripping unit (4) and placing it at another position, if the outcome of said check is positive, is repeated recursively and the recursive repetition of this procedure is canceled after a predefined number of repetitions, and an alarm message is issued.

12. The method according to one of claims 1 to 11, characterized in that - picking up an article (23a..23n) from or out of the first article carrier (9a, 9c, 9e, 10a, 16, 21) and detecting the second article carrier (9b, 9d, 10b, 17a, 17b, 22) and the articles (23a..23n) located in or on the second article carrier (9b, 9d, 10b, 17a, 17b, 22) by the sensor system (8a..8e), and - placing an article (23a..23n) in or on the second article carrier (9b, 9d, 10b, 17a, 17b, 22) and detecting the first article carrier (9a, 9c, 9e, 10a, 16, 21) and the articles (23a..23n) located in or on the first article carrier (9a, 9c, 9e, 10a, 16, 21) by the sensor system (8a..8e) take place alternately.

13. The method according to one of claims 1 to 12, characterized in that the check whether an article (23a..23n) protrudes beyond the loading space (27a..27d) takes place after another article (23a..23n) has been picked up from or out of the first article carrier (9a, 9c, 9e, 10a, 16, 21).

14. The method according to one of claims 1 to 13, characterized in that the first article carrier is configured as a first loading aid (9a, 9c, 9e) and the second article carrier is configured as a second loading aid (9b, 9d), wherein - a loading space (27a..27d), which is intended for accommodating articles (23a..23n), is defined in the region of the first loading aid (9a, 9c, 9e), and a further loading space (27a..27d), which is intended for accommodating articles (23a..23n), is defined in the region of the second loading aid (9b, 9d), - the loading spaces (27a..27d) and the articles (23a..23n) of the first loading aid (9a, 9c, 9e) and of the second loading aid (9b, 9d) located in the area of the loading spaces (27a..27d) are each detected by the sensor system (8a..8e), - after an article (23a..23n) has been picked up by the gripping unit (4) from or out of the first loading aid (9a, 9c, 9e) and after the article (23a..23n) has been placed by the gripping unit (4) into or onto the second loading aid (9b, 9d), a check is carried out in each case to determine whether an article (23a..23n) protrudes beyond one of the loading spaces (27a..27d), and - the article (23a..23n) protruding beyond the loading space (27a..27d) is picked up by the gripping unit (4) and placed in another position if the result of said check is positive.

15. The method according to one of claims 1 to 14, characterized in that the check whether an article (23a..23n) protrudes beyond the loading space (27a..27d) takes place after the gripping unit (4) and / or the article (23a..23n) picked up by the gripping unit (4) has been completely moved out of the loading space (27a..27d).

16. The method according to one of claims 1 to 15, characterized in that the check whether an article (23a..23n) protrudes beyond the loading space (27a..27d) is carried out after the gripping unit (4) and / or the article (23a..23n) picked up by the gripping unit (4) has been moved completely out of a detecting range of the sensor system (8a..8e).

17. The method according to one of claims 1 to 16, characterized in that the check whether an article (23a..23n) protrudes beyond the loading space (27a..27d) is carried out after the gripping unit (4) and the article (23a..23n) picked up by the gripping unit (4) have been moved completely sideways away from an article carrier (9a..9d, 10a, 10b, 16, 17a, 17b, 21, 22).

18. The method according to one of claims 1 to 17, characterized in that the check whether an article (23a..23n) protrudes beyond the mentioned loading space (27a..27d) is carried out after each picking up of an article (23a..23n).

19. The method according to one of claims 1 to 18, characterized in that the check whether an article (23a..23n) protrudes beyond the loading space (27a..27d) is carried out after each placing of an article (23a..23n) into or onto the second article carrier (9b, 9d, 10b, 17a, 17b, 22).

20. The method according to one of claims 1 to 18, characterized in that the check whether an article (23a..23n) protrudes beyond said loading space (27a..27d) is carried out after placing a plurality of articles (23a..23n) into or onto the second article carrier (9b, 9d, 10b, 17a, 17b, 22).

21. The method according to one of claims 1 to 20, characterized in that an occupied status of the gripping unit (4) is monitored after picking up an article (23a..23n) and the check whether an article (23a..23n) protrudes beyond the loading space (27a..27d) is carried out upon recognition of an unoccupied but activated gripping unit (4).

22. The method according to one of claims 1 to 21, characterized in that, according to an order, the articles (23a..23n) - are transported to the robot (1a, 1b) by the first article carrier (9a, 9c, 9e, 10a, 16, 21), - are transferred from or out of the first article carrier (9a, 9c, 9e, 10a, 16, 21) into or onto the second article carrier (9b, 9d, 10b, 17a, 17b, 22) by the robot (1a, 1b), and - are transported away from the robot (1a, 1b) by the second article carrier (9b, 9d, 10b, 17a, 17b, 22).

23. A robot system (2a..2d), comprising - a robot (1a, 1b) with a gripping unit (4) movable relative to a robot base (3) for picking up articles (23a..23n), wherein the robot (1a, 1b) is configured to pick up articles (23a.. 23n) with the gripping unit (4) from or out of a first article carrier (9a, 9c, 9e, 10a, 16, 21) and placing them into or onto a second article carrier (9b, 9d, 10b, 17a, 17b, 22), and wherein at least one of the article carriers is configured as a loading aid (9a..9e) suitable for transporting the articles (23a..23n), - a sensor system (8a..8e) for detecting a loading space (27a..27d) of the at least one loading aid (9a..9e) which is intended for accommodating the articles (23a..23n) and which is located within the range of action of said robot (1a, 1b), and - a controller (11) which is configured to check, after an article (23a..23n) has been picked up by the gripping unit (4) from or out of the first article carrier (9a, 9c, 9e, 10a, 16, 21), whether an article (23a..23n) protrudes beyond the loading space (27a..27d), and to instruct the robot (1a, 1b), if the result of the check is positive, to pick up the article (23a..23n) protruding beyond the loading space (27a..27d) and place it at another position.

24. The robot system (2a..2d) according to claim 23, characterized in that the sensor system (8a..8e) comprises a camera and / or a room depth sensor and / or a laser scanner and / or an ultrasonic sensor.

25. The robot system (2a..2d) according claim 23 or 24, characterized in that the gripping unit (4) is formed by at least one suction gripper (5).

26. The robot system (2a..2d) according to one of claims 23 to 25, characterized in that the robot (1a, 1b) is formed as a jointed-arm robot or a gantry robot.

27. A storage and order-picking system (12) for order-picking of articles (23a..23n) comprising a storage area (18) for storing articles (23a..23n) and a working area for picking / repacking articles (23a..23n) using a robot system (2a..2d), characterized in that said robot system (2a..2d) is designed according to one of claims 23 to 26.

28. The storage and order-picking system (12) according to claim 27, characterized in that the working area is designed for the automated order-picking of articles (23a..23n), and a first conveying system for transporting articles (23a..23n) in or on first article carriers (9a, 9c, 9e, 10a, 16, 21) is arranged between the storage area (18) and the robot (1a, 1b) in the working area, and / or a second conveying system for transporting articles (23a..23n) in or on second article carriers (9b, 9d, 10b, 17a, 17b, 22) is provided between the storage area (18) and the robot (1a, 1b) in the working area, wherein the robot (1a, 1b) is designed for picking up at least one article (23a..23n) from or out of the first article carrier (9a, 9c, 9e, 10a, 16, 21) for an order and for placing the at least one article (23a..23n) in or on the second article carrier (9b, 9d, 10b, 17a, 17b, 22) for this order.