LOAD CARRIER FOR PACKING UNITS, PACKING UNIT TRANSFER STATION AND PICKING SYSTEM FOR STORING AND PICKING PACKING UNITS

Description

[0001] The invention relates to a load carrier for transporting and storing various packaging units in a picking system, a packaging unit transfer station for loading the load carrier and / or unloading the load carrier, and a picking system for storing and picking packaging units, as described in the preambles of claims 1, 5 and 11.

[0002] EP 1 698 573 A1 discloses a load carrier for transporting and storing various packaging units in a picking system, a packaging unit transfer station for loading and / or unloading the load carrier, and a picking system according to the preamble of claims 1, 5 and 11.

[0003] Similarly, WO 2008 / 022767 A1 and WO 2011 / 006598 A1 disclose similar load carriers for the transport and storage of various packing units in a picking system, a similar packing unit transfer station for loading and / or unloading the load carrier, and a similar picking system.

[0004] In particular, EP 1 698 573 A1 discloses a picking system for storing and picking packaging units, in which the packaging units are depalletized from incoming containers and individually transferred onto load carriers (trays). A packaging unit is the smallest unit of a shipment. The trays are conveyed to a tray storage area and stored / retrieved there by conveyor vehicles. When a customer order is processed, the required packaging units are retrieved from the tray storage area, sorted into a loading sequence defined by a loading configuration in the stack, and transported to an automated picking device. Upon arrival, the packaging unit is lifted from the tray and transferred to a stationary loading platform, and then stacked onto an order load carrier according to the loading configuration. Each packaging unit is placed on its own tray.This entails a large space requirement for setting up the storage racks and high acquisition costs. A larger pallet warehouse requires an increasing number of material handling vehicles.

[0005] DE 41 43 282 C1 describes a load carrier for transporting and storing a packaging unit, comprising a base with a multitude of openings. A packaging unit transfer station for unloading the load carrier includes a transfer device for pushing the packaging unit from the load carrier onto a conveyor and a profile body that can be moved from a starting position to a pushing-off position. The profile body forms a number of transport ramps corresponding to the number of openings. For unloading the packaging unit, the load carrier is positioned on a receiving device in front of the conveyor. The profile body is then moved into the pushing-off position, in which the transport ramps project into the openings. The transport ramps bridge a step difference between the receiving device and the conveyor.The transfer device pushes the packaging unit from the load carrier via the transport ramps onto the conveyor device.

[0006] US Patent 2013 / 0062160 A1 discloses a load carrier for transporting and storing a packaging unit, comprising a base with longitudinal slots and side walls with openings. A packaging unit transfer station for loading or unloading the load carrier includes parallel conveyor belts spaced apart from each other, which engage in the openings and project into the longitudinal slots to transport a packaging unit between the load carrier and the conveyor belts.

[0007] EP 2 454 176 B1 also discloses a load carrier for the transport and storage of a packaging unit, comprising a base with longitudinal slots and side walls with openings.

[0008] EP 2 057 086 B1 discloses a load carrier for transporting and storing a packaging unit, which comprises a base perforated with a plurality of openings. WO 2010 / 012450 A2 discloses a picking system for storing and picking packaging units, in which packaging units are stored in a row one behind the other on a load carrier.

[0009] These familiar load carriers become problematic when smaller or flexible packaging units need to be handled. A packaging unit can be damaged at the

[0010] Longitudinal slots in the base and openings in the side walls can cause the packaging units to become stuck when being transported from the load carrier to a receiving station or vice versa at a packaging unit transfer station. Furthermore, if a packaging unit breaks, the liquid / solid material leaks out through these openings, contaminating the conveyor system and storage area. This necessitates a correspondingly high level of maintenance.

[0011] Various designs of load carriers for the transport and storage of a packaging unit are also known from US 4,533,585 A, EP 0 952 101 A2, WO 2013 / 178431 A1 and EP 2 955 121 A2.

[0012] EP 3 162 742 A1 discloses a sorting device with load carriers, each of which can be tilted about an axis in order to release packaging units from the load carriers.

[0013] The present invention is based on the objective of providing a load carrier and a packaging unit transfer station which enables the reliable operation of a (largely) automated order picking system. Furthermore, it is an objective of the invention to create a (largely) automated order picking system in which various packaging units can be reliably transported and stored.

[0014] The object of the invention is solved by the features of claim 1.

[0015] The load carrier according to the invention forms a first loading level on the ground at a first height level. The first loading level is a continuous, uninterrupted transport surface and is not provided with longitudinal slots or openings. Either a single packaging unit or a number of packaging units are placed on the transport surface. The single packaging unit or the number of packaging units are fully supported from below.

[0016] The load carrier can accommodate up to four packaging units on the first loading level. This allows for a significantly higher number of packaging units to be stored in the packaging unit storage area (higher storage density) compared to prior art picking systems with a single packaging unit per load carrier, within the same storage volume. The packaging units are preferably placed in a row, one behind the other. Alternatively, the packaging units can also be placed side by side in a row on the first loading level. This row contains packaging units of a single width class. The width dimension within this width class can vary slightly, for example, ± 20% of a standard width. This allows the load carriers to be loaded with different width classes.

[0017] The packaging units can also be placed side by side in several rows. A preferred option is to place the packaging units one behind the other in a single row. In this case, the packaging units in each row are either assigned to the same width class or to different width classes. For example, if the load carrier is loaded with two rows, each containing two packaging units, then both the first and second rows are assigned to the first width class, or the first row to the first width class and the second row to the second width class. Within each row, the packaging units are all of a single width class; for example, the first row contains the packaging units of the first width class, and the second row contains the packaging units of the second width class. The width dimension of the packaging units within each width class can vary.

[0018] Regardless of how the packaging units are stored on the load carrier, it can be advantageous to contain only one type of item per load carrier; therefore, so-called "product-single" load carriers are provided. If items are stored mixed on a load carrier, the packaging units are assigned to a width class.

[0019] The load carrier according to the invention additionally forms a second loading level on the ground at a second height level, wherein the first loading level is limited in a loading width by first stop edges that are parallel to each other and substantially vertical to the first loading level, and wherein the second loading level is limited in a loading width by second stop edges that run parallel to each other and substantially vertical to the second loading level, and wherein the second loading width is designed to be larger than the first loading width.

[0020] The range of packaging units is preferably divided into different width classes by an electronic computer system. The number of width classes can vary depending on the breadth of the product range. At least two width classes are defined.

[0021] It can now be arranged that a first load carrier is loaded with packaging units of a first width class and a second load carrier with packaging units of a second width class. The dimensions of the load carriers, however, do not vary and always remain the same. If the packaging units are assigned to a first width class (packing units with smaller dimensions), a correspondingly higher number of packaging units can be placed on one load carrier, for example, three packaging units with dimensions of 200 mm (length) x 150 mm (width) per load carrier. If the packaging units are assigned to a second width class (packing units with larger dimensions), a correspondingly lower number of packaging units can be placed on one load carrier, for example, a single packaging unit with dimensions of 600 mm (length) x 400 mm (width) per load carrier.

[0022] Since the load carriers are each equipped with different loading levels, a packaging unit from the first width class can be stored on a first load carrier on a first loading level between the first stop edges, and a packaging unit from the second width class can be stored on a second load carrier on a second loading level between the second stop edges.

[0023] In the first width class, the width of the packaging units is between 100 mm and 250 mm. The length can vary between 100 mm and 600 mm. In the second width class, the width of the packaging units is between 250 mm and 400 mm. The length can vary between 100 mm and 600 mm. Depending on the length, a corresponding number of packaging units can be placed on the first loading level or on the second loading level.

[0024] In the second width class, the width of the packaging units ranges between 250 mm and 400 mm. It is advantageous to define one width class per loading level. In the example shown, two loading levels and two width classes are defined.

[0025] If additional loading levels are provided, an additional width class is also defined. If three loading levels are provided, the width of the packaging units in the first width class can be between 100 mm and 160 mm, the width of the packaging units in the second width class between 200 mm and 260 mm, and the width of the packaging units in the third width class between 300 mm and 400 mm.

[0026] The staggered loading levels allow the individual packing units or the packing units to be guided laterally by the stop edges when the packing unit(s) are pushed from the load carrier to the transfer point or the packing unit(s) are pushed from the transfer point onto the load carrier.

[0027] In its simplest form, the load carrier only forms the first transport ramp, first guide surface, and first edge on the first side wall. The second side wall, however, can be formed by an edge rib projecting from the first loading level. With this design, the load carrier can be loaded or unloaded from one (single) side.

[0028] The load carrier is either a single piece or made of multiple parts. For example, the base, the first side wall (including the transport ramp, guide surface, and edge), and the second side wall can be manufactured as a single piece using injection molding. Alternatively, the first transport ramp can also be manufactured separately as a single piece using injection molding and then joined to the base and / or the first side wall. In the latter case, the edge is formed on the first transport ramp.

[0029] It is also advantageous if the load carrier has a second transport ramp on the second side wall between the first longitudinal side and the second longitudinal side, which connects to the transport surface and forms an inclined surface that forms an angle (α) between 135° and 160° with the transport surface, and a second guide support, which connects to the second transport ramp and forms a guide surface running essentially parallel to the transport surface, and a second edge between the second transport ramp and the second guide support.

[0030] After this configuration, the load carrier can be unloaded from one side and loaded from the other. Alternatively, it can also be loaded or unloaded from a single side if more practical. The symmetrical arrangement of the transport ramp, guide surface, and edge allows for versatile use of the load carrier. The load carrier is either a single piece or a multi-piece construction. For example, the base, the first side wall (including the first transport ramp, first guide surface, and first edge), and the second side wall (including the second transport ramp, second guide surface, and second edge) can be manufactured as a single piece using injection molding. Alternatively, the first and second transport ramps can also be manufactured separately as single pieces using injection molding and then joined to the base and / or the first and second side walls.According to the latter design, the first edge is formed at the first transport ramp and the second edge at the second transport ramp. The transport area on the first loading level extends between the first and second transport ramps.

[0031] It is also advantageous if the first and / or second edge is rounded with a radius of at least 5 mm. This allows the package to tilt smoothly over the edge, facilitating gentler transport. Packages with delicate surfaces, such as those wrapped in plastic film, can now be easily moved without damaging the surface.

[0032] The object of the invention is also solved by the features of claim 5.

[0033] The load carrier according to the invention can be unloaded and / or loaded particularly easily in the packaging unit transfer station.

[0034] When the load carrier is loaded at the packaging unit transfer station, the single packaging unit or multiple packaging units are pushed (without lifting) from a transfer station onto the load carrier, which is provided at a loading station. The packaging unit(s) slide(s) onto the transport surface via the first guide surface and the first transport ramp, or the packaging unit(s) slide(s) onto the transport surface via the second guide surface and the second transport ramp. If the load carrier is located at the loading station in front of the transfer station, the first / second guide surface is at the same height as the conveyor level formed by the transfer station or slightly below it. The packaging unit(s) can be transported from the transfer station to the load carrier with particular care.

[0035] When the load carrier is unloaded at the packaging unit transfer station, the single packaging unit or number of packaging units is moved from the load carrier, which is positioned at a loading station, to a receiving station. The packaging unit(s) then slides on the transport surface over the first transport ramp and first guide surface, or the packaging unit(s) slides on the transport surface over the second transport ramp and second guide surface. If the load carrier is located at the loading station in front of the receiving station, the first / second guide surface is at the same height as the conveyor level formed by the receiving station, or slightly above it. This allows the packaging unit(s) to be transported from the load carrier to the receiving station with particular care.

[0036] Since the load carrier defines at least one additional loading level, during loading the packaging unit(s) slide over the first / second guide surface and the first / second transport ramp and, depending on the width class, either onto the transport surface on the first loading level or onto the transport surface on the second loading level, etc. Conversely, during unloading the packaging unit(s), depending on the width class, slide from the transport surface on the first loading level or from the transport surface on the second loading level, etc., over the first / second transport ramp onto the first / second guide surface.

[0037] It is also advantageous that the load carrier only needs to be positioned at a stationary loading station for loading and / or unloading. In other words, the load carrier is provided on a fixed horizontal work surface. The loading station can be located on an automated conveyor within the conveying system. In this case, the conveyor plane corresponds to the work surface in the area of ​​the loading station. Tilting the load carrier along one side and / or the other relative to the work surface (or conveyor plane) is not necessary for loading and / or unloading. The packaging transfer station is also designed to include a load carrier positioning system for positioning the load carrier relative to the transfer device.The load carrier is positioned at the loading station in a loading position in which, on the one hand, its longitudinal axis is aligned perpendicular to a sliding surface, and on the other hand, its longitudinal axis is centered on the loading station. This ensures that a single packaging unit, as well as a series of packaging units, can be transported without twisting in the unloading direction. If, according to the invention, several loading levels are provided, lateral guidance of the individual packaging unit or packaging units is also provided during the unloading movement.

[0038] In an advantageous design of the packaging unit transfer station for loading a load carrier, it is provided that this station includes a packaging unit positioning system for positioning at least one packaging unit relative to the load carrier, which is provided in a delivery position at the delivery station on the conveyor system. The load carrier is positioned in a delivery position at the delivery station as described above. Additionally, the individual packaging unit or a series of packaging units can also be positioned relative to the load carrier before being transferred from the transfer station to the load carrier. This ensures that a single packaging unit, as well as a series of packaging units, can be transported without rotation in the discharge direction.

[0039] According to one embodiment of the invention, the transfer device comprises a slide mounted on a base frame, which is movable relative to a load carrier positioned in the loading position at the loading station. The slide is coupled to a drive device and is moved from a rest position to an unloading position or from a rest position to a loading position in order to push at least one packaging unit from the load carrier to the receiving station or from a transfer station onto the load carrier. In the simplest case, the slide can perform a translational pushing motion, pushing the packaging units onto the load carrier or pushing them off the load carrier, with the pushing direction being parallel to the longitudinal axis of the load carrier.

[0040] It is also advantageous if the drive device has an electronically controlled actuator connected to a control unit that, in turn, controls the drive device so that the pusher pushes a calculated number of packaging units from the load carrier to the receiving station or a calculated number of packaging units from the transfer station onto the load carrier. The controlled drive allows the pushing motion to be monitored and the pushing distance to be evaluated (calculated). If the length dimensions of the packaging units are also electronically recorded in a computer system (with the database) connected to the control unit, the pushing distance can be calculated based on the length dimensions and / or number of packaging units.

[0041] According to another embodiment of the invention, the packaging unit transfer station may include a monitoring device, in particular a sensor, for detecting the transfer of a packaging unit from the transfer point to the load carrier or from the load carrier to the receiving point. A control device is connected to the monitoring device and controls the transfer device to push a packaging unit from the transfer point onto the load carrier or to push a packaging unit from the load carrier to the receiving point. This measure allows the transfer of a packaging unit from the transfer point to the load carrier or the transfer of a packaging unit from the load carrier to the receiving point to be evaluated.

[0042] The object of the invention is also solved by the features of claim 11.

[0043] In the picking system according to the invention, various packaging units can be reliably transported and stored via the load carrier and the packaging unit transfer station described above.

[0044] To better understand the invention, it is explained in more detail with reference to the following figures.

[0045] Each of them shows: Fig. 1 shows a block diagram of an exemplary implementation of a picking system; Figs. 2a, 2b show essential process steps for a picking system according to Fig. 1 Figs. 3a-3 show a first embodiment of a load carrier according to the invention in different views; Figs. 4a-4 show a second embodiment of a load carrier according to the invention in different views; Figs. 5a, 5 show a third embodiment of a load carrier according to the invention and different packing units in perspective views; Figs. 6a-6d show the load carrier according to Fig. 5a ,5b in different views; Fig. 7a, 7: the packaging unit transfer station for unloading a load carrier in perspective views; Fig. 8a-8d: the packaging unit transfer station for unloading a load carrier and a first conveyor device connected to it for transporting loaded load carriers and a second conveyor device connected to it for transporting fully or partially unloaded load carriers; Fig. 9a, 9b: the packaging unit transfer station for unloading a load carrier according to Fig. 7a , 7b ; Fig. 9c the packaging unit transfer station for unloading a load carrier during a transfer operation of packaging units from the load carrier to a transfer point on a conveyor device for transporting packaging units; Fig. 10 a packaging unit transfer station for loading a load carrier in perspective view.

[0046] It should be noted at the outset that in the differently described embodiments, identical parts are provided with the same reference numerals or component designations, and the disclosures contained in the entire description can be applied analogously to identical parts with the same reference numerals or component designations. Furthermore, the positional designations chosen in the description, such as top, bottom, side, etc., refer to the figure directly described and illustrated and must be applied analogously to any change in position.

[0047] In Fig. 1 A picking system for storing and picking packaging units is shown as a block diagram.

[0048] Such a picking system typically comprises an inbound warehouse 1, a warehouse 2 for packaging units 3 (packages), and a loading area 4. The inbound warehouse 1 can be configured as a manual warehouse, a semi-automated warehouse, or a fully automated warehouse. In the inbound warehouse 1, the packaging units 3 are delivered on storage containers, such as pallets, containers, and the like, and stored on racks. The packaging units 3 are stacked on the storage containers, preferably stacked according to type.

[0049] In a preferred embodiment, the receiving warehouse 1 is designed as an automated pallet warehouse. Such a pallet warehouse comprises storage racks and stacker cranes that move in a rack aisle between the storage racks for storing and retrieving containers from the storage racks. The storage racks comprise a multitude of storage locations side by side on stacked levels (SR), where the containers can be placed. The aforementioned stacker cranes are equipped with a load handling device that can store and retrieve one or more containers from the storage racks from both sides in a transverse direction (z-direction).

[0050] In a preferred embodiment, storage 2 for packaging units 3 is also designed as an automated storage system. The packaging units 3 are stored on load carriers 5, 5', 5" as described below. Fig. 3a-3d , 4a-4d, 6a-6d will be described in detail. The packaging units 3 are of different dimensions, as shown in the Fig. 5a , 5b depicted.

[0051] Such a warehouse 2 comprises storage racks and, in each aisle between storage racks, movable storage and retrieval machines for storing load carriers 5, 5', 5" into the storage racks and retrieving load carriers 5, 5', 5" from the storage racks. The storage racks comprise a multitude of storage locations side by side in stacked rack levels (SR), on which the load carriers 5, 5', 5" can be placed. Thus, each storage rack forms a multitude of storage locations side by side in stacked rack levels (SR).

[0052] Preferably, independently controllable storage and retrieval machines are arranged in each aisle on superimposed travel levels for storing load carriers (5, 5', 5") into the storage racks and retrieving load carriers (5, 5', 5") from the storage racks. For example, at least one storage and retrieval machine can be assigned to each rack level. Thus, one storage and retrieval machine serves one rack level. Such storage and retrieval machines are referred to as single-level storage and retrieval machines (shuttles).

[0053] However, it is also possible to use fewer storage and retrieval machines than there are rack levels. For example, a storage and retrieval machine can be moved between the travel levels using a lifting device.

[0054] However, it is also possible to have a design in which a single storage and retrieval machine is provided for each aisle for storing load carriers 5, 5', 5" into the storage racks and retrieving load carriers 5, 5', 5" from the storage racks.

[0055] The aforementioned storage and retrieval machines are equipped with a load handling device which can store one or more load carriers 5, 5', 5" in the storage racks and retrieve them from the storage racks on both sides in a transverse direction (z-direction).

[0056] Loading area 4 also includes at least one picking device 6 for the manual or automated loading of order load carriers (delivery containers). Fig. 1 For example, two picking devices 6 are listed. The order load carrier is, for example, a roll container or pallet on which the packing units 3 are stacked according to a picking order. A picking device 6 for manually loading order load carriers is described, for example, in WO 2009 / 109218 A1. A picking device 6 for automatically loading order load carriers is described, for example, in US 8,708,637 B2.

[0057] As in Fig. 1 As recorded, at least one first packaging unit transfer station 10 is provided between the receiving warehouse 1 and the packaging unit warehouse 2, as shown in Fig. 10 more precisely explained. Fig. 1 For example, two packaging unit transfer stations 10 are entered. At the first packaging unit transfer station 10, the load carriers 5, 5', 5" are loaded with packaging units 3. The packaging units 3 can be placed individually or in groups on the load carriers 5. The loading of the load carriers 5, 5', 5" can be done manually or automatically.

[0058] Following an initial setup (not shown), the packaging units 3 can be manually transferred by a worker onto the load carriers 5, 5', 5" . For this purpose, the storage containers are provided in the immediate vicinity of a first packaging unit transfer station, and the worker can take the packaging units 3 directly from a storage container and place them individually onto the load carriers 5, 5', 5" . On the other hand, the packaging units 3 can be depalletized from a storage container via a suitable depalletizing device 8, such as that described, for example, in US 8,668,429 B2, and separated via a suitable singulation device, such as that described, for example, in EP 2 297 005 B1, and conveyed via automated conveyor technology to a packaging unit delivery device in the vicinity of a first packaging unit transfer station, where the worker can remove the (separated) packaging units and manually transfer them onto the load carriers 5, 5', 5" . Fig. 1 For example, two depalletizing devices are listed under number 8.

[0059] According to a second embodiment, the packaging units 3 can be automatically transferred from a transfer device 9' to the load carriers 5, 5', 5"". Such automatic loading of the load carriers 5, 5', 5" is shown as a possible embodiment in Fig. 10 described. Of course, other designs of a transfer device are also possible.

[0060] The loaded load carriers 5, 5', 5" are transferred from the first packaging unit transfer station 10 onto an automated conveyor system (as in Fig. 1 (schematically indicated by the arrow), for example, roller conveyors, belt conveyors, and the like are conveyed to the packaging unit storage area 2. The storage of the loaded load carriers 5, 5', 5" into the packaging unit storage area 2 is carried out by the storage and retrieval machines described above.

[0061] Furthermore, at least one second packaging unit transfer station 11 is provided between the packaging unit storage 2 and the picking device 6 for manual or automated loading of order load carriers, as shown in the Fig. 7a , 7b , 9a and 9b A more detailed explanation.

[0062] The loaded load carriers 5, 5', 5" are transported from the packaging unit warehouse 2 on an automated conveyor system (as in Fig. 1 (schematically indicated by the arrow), for example, roller conveyors, belt conveyors, and the like are conveyed to the second packaging unit transfer station 11. The unloading of the loaded load carriers 5, 5', 5" from the packaging unit storage 2 is carried out by the storage and retrieval machines described above.

[0063] The packaging units 3 can be unloaded individually or in groups from the load carriers 5, 5', 5" . The unloading of the load carriers 5, 5', 5" can be done manually or automatically.

[0064] According to a first embodiment (not shown), the packaging units 3 can be manually unloaded from the load carrier 5, 5', 5" by a worker. For this purpose, the load carriers 5, 5', 5" are provided in the immediate vicinity of a second packaging unit transfer station, and the worker can remove the packaging units 3 directly from a load carrier 5, 5', 5" and preferably stack them directly onto a job load carrier.

[0065] According to a second embodiment, the packaging units 3 can be automatically unloaded from the load carrier 5, 5', 5" by a transfer device 9. Such automatic unloading of the load carriers 5, 5', 5" is described in the Fig. 8a-8d described.

[0066] The packaging units 3 are transferred from the second packaging unit transfer station 11 on an automated conveyor system (as in Fig. 1 (schematically indicated by the arrow), for example belt conveyors, and the like, conveyed to the picking device 6.

[0067] The following will be used as an example to illustrate the Fig. 2a and 2b The procedure for storing and picking packaging units 3 is described in the picking system described above.

[0068] In a first step (S1), the packaging units 3 are delivered to the delivery station on their storage containers, for example by truck, and then, in a second step (S2), stored in the manually or automatically operated receiving warehouse 1. As described, receiving warehouse 1 can include (computer-controlled) storage and retrieval machines, which are used to store the containers in the storage racks. Alternatively, the containers can also be stored in the storage racks using forklifts. This receiving warehouse 1 serves as a replenishment warehouse, in which the entire range of packaging units 3 is stored.

[0069] Receiving warehouse 1 supplies packing unit warehouse 2 with packing units 3 whenever a replenishment order is generated by a higher-level computer system (e.g., a warehouse management system). For example, a replenishment order is generated, and the transfer of packing units 3 from receiving warehouse 1 to packing unit warehouse 2 is initiated, if the required quantity of a packing unit 3, which is included in the picking orders recorded in the computer system within an analysis set, exceeds the current stock in packing unit warehouse 2. Packing unit warehouse 2 serves as a buffer warehouse where the packing units 3 required for picking orders within an analysis set are stored. In principle, a replenishment order can also be generated, and the transfer of packing units 3 from receiving warehouse 1 to packing unit warehouse 2 initiated, if the minimum stock level for a packing unit 3 in packing unit warehouse 2 is reached.

[0070] The replenishment order triggers the removal of packaging units 3 from the manually or automatically operated receiving warehouse 1. As described, receiving warehouse 1 can include (computer-controlled) storage and retrieval machines, which are used to remove the storage containers from the storage racks. Alternatively, the storage containers can also be removed from the storage racks using forklifts.

[0071] The storage containers retrieved from the receiving warehouse 1 are conveyed to the depalletizing device 8. In step S3, the packaging units 3 are separated from the storage containers by the depalletizing device 8. Subsequently, in step S4, the packaging units 3 are transferred individually or in groups to the load carriers 5, 5', 5" at the first packaging unit transfer station 10.

[0072] At the first packaging unit transfer station 10, the packaging units 3 are digitally linked to a corresponding load carrier 5, 5', 5" . The load carriers 5, 5', 5" are equipped for this purpose with a data carrier 14 ( Fig. 5a , 5b ), in particular a barcode or an RFID transponder (Radio Frequency Identification Device), and the like. Likewise, the packaging units 3 are equipped with a data carrier 15 ( Fig. 5a , 5b ), in particular a barcode or an RFID transponder (Radio Frequency Identification Device), and the like.

[0073] Regardless of the dimensions (especially the base area) of the packaging units 3, the same load carrier 5, 5', 5" is always used. To achieve better storage density in the packaging unit storage area 2, it is advantageous to accommodate several packaging units 3 per load carrier 5, 5', 5". A number of packaging units 3 are transferred from a complete layer of packaging units onto a load carrier 5, 5', 5" that is less than the number of packaging units 3 in the complete layer of packaging units. For example, if a complete layer of packaging units contains four packaging units with dimensions of 300 mm x 400 mm, a maximum of two of these packaging units 3 are transferred onto the load carrier 5, 5', 5". If a complete layer of packaging units contains four packaging units with dimensions of 600 mm x 400 mm, a maximum of one of these packaging units 3 is transferred onto the load carrier 5, 5', 5".

[0074] The load carrier 5, 5', 5" is only slightly larger in length and width than the length and width of the largest packaging unit 3.

[0075] After the packaging unit(s) have been transferred onto the load carrier 5, 5', 5" the load carrier 5, 5', 5" is conveyed from the first packaging unit transfer station 10 to the packaging unit storage 2 using automated conveyor technology.

[0076] In step S5, the load carriers 5, 5', 5" are stored in the packaging unit warehouse 2, specifically in the storage racks using the (computer-controlled) storage and retrieval machines. Packaging unit warehouse 2 contains those packaging units 3 required for picking orders. The picking orders are recorded by the (not shown) computer system, whereby a picking order can include one or more order load carriers.

[0077] As soon as a picking order is to be processed at a picking device 6, the packing units 3 required for this picking order are retrieved from the packing unit storage 2 on the load carriers 5, 5', 5" using at least one storage and retrieval machine and then conveyed from the packing unit storage 2 to the second packing unit transfer station 11 using the automated conveyor technology.

[0078] In step S6, at the second packaging unit transfer station 11, the individual packaging unit 3 or, if more than one packaging unit 3 can be accommodated on the load carrier 5, 5', 5", the required number of packaging units 3 is unloaded from the load carrier 5, 5', 5".

[0079] If a packaging unit 3 remains on the load carrier 5, 5', 5", this load carrier 5, 5', 5" is conveyed to the packaging unit storage area 2 using automated conveyor technology and then returned to a storage rack using at least one storage and retrieval machine, as shown in Fig. 1 indicated by the double arrow and in Fig. 2 The dashed lines indicate step S7.

[0080] In step S8, the packing units 3 required for the picking order are stacked onto the order load carrier in a loading configuration determined by the computer system. The packing units 3 are fed to the picking device 6 in a loading sequence determined from the loading configuration and stacked one after the other onto the order load carrier in this sequence. For this to happen, the load carriers 5, 5', 5" must either be sorted into the loading sequence before the second packing unit transfer station 11 or the packing units 3 must be sorted into the loading sequence after the second packing unit transfer station 11.It is also possible to combine a first sorting stage (sorting of the packaging units 3 on the load carriers 5, 5', 5") before the second packaging unit transfer station 11 and a second sorting stage after the second packaging unit transfer station 11 (sorting of the packaging units 3).

[0081] For each packaging unit 3, the computer system electronically records the unit properties, such as dimensions, weight, density, and / or shape, and stores this information as master data in a database. The packaging units 3 can be uniquely identified via the data carrier, in particular an identification code. Based on the packaging unit properties stored in the database, the computer system determines a spatially (three-dimensional) loading configuration within the stack on the order load carrier (shipping container), optimized with regard to stability, volume utilization, and / or height, etc. The loading sequence in which the stack is built up on the order load carrier (shipping container) is then determined from this loading configuration.The loading stack is stable and transportable when the heavier packaging units 3 are stored in the lower part of the stack and the lighter packaging units 3 in the upper part. Similarly, more fragile packaging units 3 are better placed in the upper part of the stack. The loading stack should also be packed as densely and as high as possible. The packaging units 3 must therefore be fed to the picking device 6 sequentially in a loading order determined by the loading configuration.

[0082] In step S9, the stack of items on the order carrier (shipping container) is wrapped with film. For example, it is possible for the stack to be wrapped with film during the stacking process (loading the order carrier). In this case, each picking device includes a (stationary) stacking chute and a wrapping device (ring wrapper) located below it. As soon as a layer of items emerges from the stacking chute during a lowering movement of the order carrier, the layer is wrapped with film. Such a design is described, for example, in WO 2009 / 109218 A1 and EP 2 358 617 B1.

[0083] In another embodiment, a wrapping device (ring wrapper) is assigned to several picking devices. A mobile stacking container is provided at the picking device, surrounding the forming stack of goods on at least three sides and thus serving as a support surface for a horizontal sliding movement of the packing units 3. As soon as an order load carrier is fully loaded with a stack of goods, the order load carrier, together with the stacking container, is transported to the central wrapping device by a conveyor system or a forklift. There, the loaded order load carrier is lifted out of the stacking container and simultaneously wrapped with a film to stabilize the stack of goods. Such an embodiment is described, for example, in EP 1 698 573 B1 and EP 1 386 864 B1.

[0084] The wrapped stack of goods is then loaded onto a truck in step S10 in the loading area. The truck transports the stack of goods on the order load carrier to the delivery location, for example, a retail store.

[0085] In the Fig. 3a bis 3d A first embodiment of a load carrier 5 for transporting and storing a packaging unit 3 (not shown) in a picking system, which is not in accordance with the invention, is shown in different views. Fig. 3a corresponds to the view according to section line X in Fig. 3b. Fig. 3c corresponds to the view according to section line XX in Fig. 3b. Fig. 3d is a cropped enlargement from Fig. 3a As shown, the load carrier 5 is made up of multiple parts. However, the load carrier 5 can also be manufactured as a single piece, for example, using injection molding. The load carrier 5 comprises a base 21, which forms a transport and storage surface 22 on the underside of the base, a first end face 23a, a second end face 23b, a first longitudinal side 24a, a second longitudinal side 24b, and a (single) loading level 25 on the top of the base. The transport and storage surface 22 is suitable for transport on automated conveyor systems and for placement in storage racks. The first longitudinal side 24a extends between the first end face 23a and the second end face 23b. The loading level 25 runs between the first end face 23a and the second end face 23b and is designed to accommodate a single packaging unit 3 or several packaging units 3.If several packaging units 3 can be accommodated on loading level 25, the packaging units 3 are placed in a row behind each other and between side walls. In principle, it is also possible for the packaging units 3 to be placed side by side in a row between side walls. It is also conceivable that the packaging units 3 are placed side by side in several rows on loading level 25.

[0086] Additionally, the load carrier 5 comprises a first side wall 26a projecting from the loading level 25 in the area of ​​the first end face 23a and a second side wall 26b projecting from the loading level 25 in the area of ​​the second end face 23b.

[0087] As can be seen in the figures, it is advantageous if, optionally, a third side wall 27a projecting onto the loading level 25 is arranged in the area of ​​the first longitudinal side 24a and a fourth side wall 27b projecting onto the loading level 25 is arranged in the area of ​​the second longitudinal side 24b.

[0088] The side walls 26a, 26b, 27a, 27b thus form a circumferential edge projecting from the loading level 25.

[0089] The loading level 25 forms a continuously uninterrupted (flat) transport surface 28, as shown in Fig. 3b As can be seen, the transport area 28 is formed between the first side wall 26a and the second side wall 26b, as well as between the third side wall 27a and the fourth side wall 27b. If the third side wall 27a and the fourth side wall 27b are not present, then the transport area 28 is formed between the first side wall 26a and the second side wall 26b, as well as between the first longitudinal side 24a and the second longitudinal side 24b. The transport and storage area 22 on the underside of the floor and the transport area 28 on the upper side of the floor run parallel to each other. The first side wall 26a includes, between the first longitudinal side 24a and the second longitudinal side 24b, a first transport ramp 29a, a first guide support 30a, and a first edge 31a between the first transport ramp 29a and the first guide support 30a.The transport ramp 29a connects to the transport surface 28 and forms an inclined surface 32a, which forms an angle between 135° and 160° with the transport surface 28. The first guide support 30a connects to the transport ramp 29a and forms a guide surface 33a that runs essentially parallel to the transport surface 28.

[0090] In an advantageous embodiment, the second side wall 26b between the first longitudinal side 24a and the second longitudinal side 24b also comprises a second transport ramp 29b, a second guide support 30b, and a second edge 31b between the second transport ramp 29b and the second guide support 30b. The transport ramp 29b adjoins the transport surface 28 and forms an inclined surface 32b that forms an angle between 135° and 160° with the transport surface 28. The second guide support 30b adjoins the transport ramp 29b and forms a guide surface 33b that runs substantially parallel to the transport surface 28.

[0091] It is also advantageous if the first edge 31a and, if applicable, the second edge 31b are each rounded with a radius. The radius is at least 5 mm.

[0092] In the Fig. 4a bis 4d An embodiment of a load carrier 5' according to the invention for transporting and storing a packaging unit 3 (not shown) in a picking system is shown in different views. Fig. 4a corresponds to the view according to section line X in Fig. 4b. Fig. 4c corresponds to the view according to section line XX in Fig. 4b. Fig. 4d is a cropped enlargement from Fig. 4a As shown, the load carrier 5' is made up of multiple parts. The load carrier 5' can also be manufactured as a single piece, for example, using injection molding. The load carrier 5' comprises a base 21. The base forms a transport and storage surface 22 on the underside, a first end face 23a, a second end face 23b, a first longitudinal side 24a, a second longitudinal side 24b, and loading levels 25, 25' on the top surface. The first loading level 25 is on a first height level and the second loading level 25' is formed on a second height level, wherein the first loading level 25 is limited in a loading width 34a by first stop edges 35a oriented parallel to each other and substantially perpendicular to the first loading level 25 and wherein the second loading level 25' is limited in a loading width 34b by second stop edges 35b oriented parallel to each other and substantially perpendicular to the second loading level 25'.The second loading width 34b is larger than the first loading width 34a. The first stop edges 35a are formed by support supports 36a, which run parallel to each other at a distance and extend between the first and second end faces 23a and 23b, and which are arranged on the floor 21 at the top of the floor. The support supports 36a project from the first loading level 25. The second stop edges 35b are formed by the side walls 27a and 27b, as shown.

[0093] Since the load carrier 5' comprises the first loading level 25 and the second loading level 25', packing units 3 of a first width class can be accommodated on the first loading level 25 and packing units 3 of a second width class can be accommodated on the second loading level 25', with the packing units 3 from the second width class being wider than the packing units 3 from the first width class.

[0094] In the first width class, the width dimension of the packaging units is between 100 mm and 250 mm. In the second width class, the width dimension of the packaging units is between 250 mm and 400 mm.

[0095] The number of loading levels can be selected depending on the dimensions of the packaging units in the existing product range.

[0096] Thus, a third loading level 25", as shown by the load carrier 5", can also be incorporated into the Fig. 5a , 5b , 6a bis 6d depicted. Fig. 6a corresponds to the view according to section line X in Fig. 6b. Fig. 6c corresponds to the view according to section line XX in Fig. 6b. Fig. 6d is a cropped enlargement from Fig. 6a As shown, the 5" load carrier is made up of multiple parts. However, the 5" load carrier can also be manufactured as a single piece, for example using injection molding.

[0097] The third loading level 25" is formed on a third height level, wherein the first loading level 25 is then limited in a loading width 34a by first stop edges 35a oriented parallel to each other and substantially perpendicular to the first loading level 25, and wherein the second loading level 25' is limited in a loading width 34b by second stop edges 35b oriented parallel to each other and substantially perpendicular to the second loading level 25', and wherein the third loading level 25" is limited in a loading width 34c by second stop edges 35c oriented parallel to each other and substantially perpendicular to the second loading level 25'.

[0098] If a third loading level 25" is also provided, the second stop edges 35b are formed on support supports 36b that run parallel to each other at a distance and extend between the first / second end faces 23a, 23b, and which are arranged on the floor 21 at the top of the floor. The support supports 36b project from the second loading level 25'. According to this embodiment, the second stop edges 35b are formed by the support supports 36b.

[0099] If the load carrier 5" also includes a third loading level 25", then the width dimension of the packaging units 3 in the first width class is between 100 mm and 150 mm, the width dimension of the packaging units 3 in the second width class is between 200 mm and 250 mm, and the width dimension of the packaging units 3 in the third loading level 25" is between 300 mm and 400 mm.

[0100] The transport and storage area 22 is suitable for transport on the automated conveyor system and for placement in the storage racks. The first longitudinal side 24a extends between the first end face 23a and the second end face 23b. The first loading level 25 and the second loading level 25' run between the first end face 23a and the second end face 23b.

[0101] The first loading level 25 is designed to accommodate a single packaging unit 3 or several packaging units 3. Likewise, the second loading level 25' is designed to accommodate a single packaging unit 3 or several packaging units 3. If the load carrier 5" also includes a third loading level 25", the third loading level 25" is designed to accommodate a single packaging unit 3 or several packaging units 3.

[0102] If several packing units 3 can be accommodated on the first loading level 25 and / or second loading level 25' and / or third loading level 25", the packing units 3 are placed in a row one behind the other between the stop edges 35a, 35b, 35c and the side walls 26a, 26b.

[0103] The load carrier 5', 5" is preferably loaded with the same packaging units 3. Multiple packaging units 3 are present either only on the first loading level 25, only on the second loading level 25', or only on the third loading level 25". This is referred to as a "single-item" load carrier 5', 5". However, different packaging units 3 could also be present on a single load carrier 5', 5". For example, a first packaging unit 3 could be present on the first loading level 25, a second packaging unit 3 on the second loading level 25', and a third packaging unit 3 on the third loading level 25". This is referred to as a "mixed" load carrier 5', 5".

[0104] Additionally, the load carrier 5', 5" comprises a first side wall 26a projecting from the loading level 25 in the area of ​​the first end face 23a and a second side wall 26b projecting from the loading level 25 in the area of ​​the second end face 23b.

[0105] As can be seen in the figures, in the area of ​​the first longitudinal side 24a a third side wall 27a projecting onto the loading level 25 and in the area of ​​the second longitudinal side 24b a fourth side wall 27b projecting onto the loading level 25 are arranged.

[0106] The side walls 26a, 26b, 27a, 27b thus form a circumferential edge projecting from the loading level 25.

[0107] The first loading level 25 forms, according to the explanations in the Fig. 4a bis 4d and the Fig. 6a bis 6d a continuously uninterrupted (level) transport surface 28, as in the Fig. 4b and 6bThis is evident. Specifically, the transport surface 28 is formed between the first side wall 23a and the second side wall 23b, as well as between the mutually facing stop edges 35a.

[0108] The second loading level 25' on the second height level is formed by a second transport surface 28' formed on the support supports 36a. Specifically, the second transport surface 28' is formed on the end faces of the support supports 36a that face away from the first loading level 25 and run parallel to each other.

[0109] If the load carrier 5" also includes the third loading level 25" at the third height level, the third loading level 25" is formed by a third transport surface 28" formed on the support supports 36b. Specifically, the third transport surface 28" is formed on the end faces of the support supports 36b that face away from the first loading level 25 and run parallel to each other.

[0110] The transport and storage area 22 on the underside of the floor and the transport surfaces 28, 28', 28" on the upper side of the floor run parallel to each other. The first side wall 26a comprises, between the first longitudinal side 24a and the second longitudinal side 24b, a first transport ramp 29a, a first guide support 30a, and a first edge 31a between the first transport ramp 29a and the first guide support 30a. The transport ramp 29a adjoins the transport surface 28, 28', 28" and forms an inclined surface 32a that forms an angle between 135° and 160° with the transport surface 28. The first guide support 30a adjoins the transport ramp 29a and forms a guide surface 33a that runs substantially parallel to the transport surface 28.

[0111] In an advantageous embodiment, the second side wall 26b between the first longitudinal side 24a and the second longitudinal side 24b also comprises a second transport ramp 29b, a second guide support 30b, and a second edge 31b between the second transport ramp 29b and the second guide support 30b. The transport ramp 29b adjoins the transport surface 28, 28', 28" and forms an inclined surface 32b that forms an angle between 135° and 160° with the transport surface 28. The second guide support 30b adjoins the transport ramp 29b and forms a guide surface 33b that runs substantially parallel to the transport surface 28.

[0112] It is also advantageous if the first edge 31a and, if applicable, the second edge 31b are each rounded with a radius. The radius is at least 5 mm.

[0113] In the Fig. 7a , 7b , 8a bis 8d , 9a bis 9c Figure 11 shows an embodiment of a packaging unit transfer station 11 for unloading a load carrier 5, 5', 5", for example, the load carrier 5". The packaging unit transfer station 11 comprises a transfer device 9 for pushing at least one packaging unit 3 from the load carrier 5, 5', 5" onto a receiving station 41 and a conveyor system for transporting the load carrier 5, 5', 5" and for positioning the load carrier 5, 5', 5" in front of the receiving station 41. The load carrier 5, 5', 5" is designed according to one of the embodiments described above. The conveying system comprises a delivery station 42 on an automated conveying device 43, to which the load carrier 5, 5', 5" is moved via the conveying device 43 and on which the load carrier 5, 5', 5" is positioned when at least one packaging unit 3 has to be transferred from the load carrier 5, 5', 5" to the receiving station 41.The receiving station 41 and the delivery station 42 are arranged within a working area of ​​the transfer device 9.

[0114] As can be seen, the transfer device 9 comprises a slide 45 that is movable relative to a (loaded) load carrier 5, 5', 5" provided at the delivery station 42 and is mounted on a base frame 44. The slide 45 forms a sliding surface 66 which faces the load carrier 5, 5', 5" . The transfer device 9 is mounted on a support frame 46 with the base frame 44 and is arranged above the conveying device 43.

[0115] The slide 45 is mounted on a carriage 47 which is movable along a guide arrangement 58 via a drive device. The transfer device 9 can optionally include a displacement measuring device (not shown) by means of which the adjustment movements of the slide 45 (or carriage 47) are recorded. The displacement measuring system is equipped with a (in the Fig. 7a , 7b The control device 65 (schematically represented) is connected to the electronic control device 65. The displacement measuring device is formed by a capacitive, inductive, magnetic, or optoelectronic displacement sensor of a type known per se. The measurement method of absolute and incremental displacement measurement is utilized. For example, the actuator 50 described below can be equipped with a resolver, incremental encoder, or absolute encoder. The control device 65 is connected to the computer system (with the database) described above.

[0116] The electronic control device 65 controls the drive device such that the slide 45 moves in the discharge direction 48 from a position in Fig. 8b depicted resting position in a Fig. 8c The unloading position shown is moved by computer control to push at least one packaging unit 3 or simultaneously several packaging units from the load carrier 5, 5', 5" onto the transfer station 41. The unloading position varies depending on the width of different packaging units 3 and / or the number of packaging units 3 to be pushed. The control device 65 calculates the adjustment path for the pusher 45, whereby the pusher 45 has reached the unloading position when the corresponding number of packaging units 3 have been (completely) pushed from the load carrier 5, 5', 5" onto the transfer station 41. The transfer station 41 is designed on an automated conveyor device 63 for transporting the packaging units 3 (without the load carrier), which connects to the packaging unit transfer station 11.

[0117] As shown, the drive device comprises a traction element 49 connected to the carriage 47. The traction element 49 comprises an endlessly rotating traction element which is guided around a deflection wheel and a drive wheel coupled to an electric actuator 50. By rotating the drive wheel clockwise or counterclockwise, the carriage 47 and the slide 45 mounted on it are moved relative to the load carrier 5, 5', 5" in a discharge direction 48 ( Fig. 9c ) moves.

[0118] The slide 45 is mounted on the carriage 47 and, according to a preferred embodiment, can be moved in a delivery direction 52 via a drive device 51 ( Fig. 9a ) between one in the Fig. 7a , 8a , 9a the depicted starting position into one in the Fig. 7b , 8b , 9bThe illustrated engagement position can be moved. In the engagement position, at least one packaging unit 3 can be pushed off. According to the illustrated embodiment, the drive device comprises a fluid-operated cylinder, for example, a pneumatic or hydraulic cylinder. According to another embodiment (not shown), the slide 45 can be rigidly connected to the carriage 47, and the drive device can be omitted.

[0119] As in Fig. 7b As can be seen, the packaging unit transfer station 11 also has a positioning system for positioning the load carrier 5, 5', 5" relative to the transfer device 9. The positioning system has a drive device 53 ( Fig. 9b ) between one in the Fig. 7a , 9a depicted starting position (lying below a support level) and one in the Fig. 7b , 9bThe positioning system 53 includes a movable first stop element 54 in the positioning position shown (lying above a conveyor level). The first stop element 54 is, for example, a stop plate. The load carrier 5, 5', 5" can be positioned against the movable stop element 54. Additionally, the positioning system 53 can include a second stop element 55 against which the load carrier 5, 5', 5" can be positioned, as shown in the Fig. 9a bis 9c The second stop element 55 is, for example, a stop plate.

[0120] The load carrier 5, 5', 5" is aligned on the loading station 42 with a longitudinal axis perpendicular to the sliding surface 66 on the one hand and the longitudinal axis is centered in the middle of the loading station 42 (or the sliding surface 66) on the other hand, so that a single packing unit 3, but also a series of packing units 3 can be transported without twisting in the pushing direction 48.

[0121] As in Fig. 9c As can be seen, a conveyor level 56 (or working level) is located at the delivery position and a conveyor level 57 is located at the transfer station 41, both at different heights. Specifically, a conveyor level 56 is located below a conveyor level 57, with the transport ramp 29a, 29b of the load carrier 5, 5', 5" bridging the step difference when the load carrier 5, 5', 5" is in a delivery position at the delivery station 42 in front of the transfer station 41. The guide surface 33a, 33b is at least at the same height as the conveyor level 57; preferably, the guide surface 33a, 33b is located above the conveyor level 57.

[0122] The packing units 3 pushed off the load carrier 5, 5', 5" are transported by the conveyor device 63 from the packing unit transfer station 11 and then, if necessary, sorted and conveyed to a manual / automatic picking device 6.

[0123] As shown in the figures, the packaging unit transfer station 11 can have a monitoring device 60 for detecting the release of at least one packaging unit 3 from the load carrier 5, 5', 5" . The monitoring device 60 includes a sensor, for example, a light barrier. The control device 65 is connected to the monitoring device 60 and controls the transfer device 9 to push at least one packaging unit 3 from the load carrier 5, 5', 5" to the receiving station 41. In particular, the control device 65 can count the number of packaging units 3 released from the load carrier 5, 5', 5" .

[0124] The in the Fig. 8a bis 8d The conveying system for transporting the load carriers 5, 5', 5" optionally also includes an automated conveying device 61 for transporting the load carriers 5, 5', 5" to the packaging unit transfer station 11, which are loaded with packaging units 3, and an automated conveying device 62 for transporting the load carriers 5, 5', 5" from the packaging unit transfer station 11, which after unloading still contain a residual quantity of packaging units 3 or no packaging units 3.

[0125] In Fig. 10 Figure 10 shows an embodiment of a packaging unit transfer station for loading a load carrier 5, 5', 5" . The packaging unit transfer station 10 comprises a transfer device 9' for sliding at least one packaging unit 3 from a transfer position 41' onto a load carrier 5, 5', 5" and a conveyor system for transporting the load carrier 5, 5', 5" and for positioning the load carrier 5, 5', 5" in front of the transfer position 41'. The transfer position 41' is designed on an automated conveyor device 63' for transporting the packaging units 3 (without the load carrier), which connects to the packaging unit transfer station 10. The load carrier 5, 5', 5" is designed according to one of the embodiments described above.The conveying system comprises a delivery station 42' on an automated conveying device 43', to which the load carrier 5, 5', 5" is moved via the conveying device 43' and on which the load carrier 5, 5', 5" is positioned when at least one packaging unit 3 has to be transferred from the transfer station 41' to the load carrier 5, 5', 5".

[0126] As can be seen, the transfer device 9' comprises a slide 45' that is movable relative to a (empty or partially loaded) load carrier 5, 5', 5" provided at the delivery point 42' and is mounted on a base frame 44'. The slide 45' forms a sliding surface 66' (not shown) which faces the load carrier 5, 5', 5". The transfer device 9' is mounted on a support frame 46' with the base frame 44' and is arranged above the conveying device 43'.

[0127] The slide 45' is mounted on a carriage 47' (not shown) which is movable along a guide arrangement 58' (not shown) via a drive device. The transfer device 9' can optionally include a displacement measuring device (not shown) by means of which the adjustment movements of the slide 45' (or carriage 47') are recorded, as described in detail above.

[0128] The electronic control device 65 controls the drive device such that the slide 45' is moved in the discharge direction 48' from a rest position (shown in dashed lines) to a loading position (shown in solid lines) in a computer-controlled manner, in order to discharge at least one packaging unit 3 or simultaneously several packaging units from the transfer point 41' onto the load carrier 5, 5', 5". The loading position varies depending on the width of different packaging units 3 and / or the number of packaging units 3 to be discharged. The control device 65 calculates the travel distance for the slide 45', whereby the slide 45' has reached the loading position when the corresponding number of packaging units 3 have been (completely) discharged from the transfer point 41' onto the load carrier 5, 5', 5". The control device 65 is connected to the computer system (with the database) described above.

[0129] As shown, the drive device comprises a traction drive 49' connected to the carriage 47', as described above. By rotating the drive wheel clockwise or counterclockwise, the carriage 47' and a slide 45' mounted on it are moved relative to the load carrier 5, 5', 5" in a discharge direction 48'.

[0130] The slide 45' is mounted on the carriage 47' and, according to a preferred embodiment, can be moved by a drive device 51' in a feed direction 52' (not shown) between a starting position and an engagement position, as described above. In the starting position, the slide 45' is moved sufficiently out of the path of movement of the packaging units 3 that the packaging units 3 can be conveyed unhindered. In the engagement position, at least one packaging unit 3 can be pushed onto the conveyor.

[0131] As in Fig. 10 As can be seen, the packaging unit transfer station 10 also has a load carrier positioning system for positioning the load carrier 5, 5', 5" relative to the transfer device 9'. The positioning system comprises a first stop element 54', as described above, which is movable between a starting position (below a conveyor level) and a positioning position (above a conveyor level) via a drive device 53' (not shown). The first stop element 54' is, for example, a stop plate. The load carrier 5, 5', 5" can be positioned against the first stop element 54', which is moved into the positioning position, in a first direction (conveyor direction). Additionally, the positioning system can include a second stop element 55', against which the load carrier 5, 5', 5" can be positioned in a second direction (perpendicular to the conveyor direction).The second stop element 55' is movable between a starting position (below a conveying level) and a positioning position (above a conveying level) via a (not shown) drive device. The second stop element 55' includes, for example, stop bolts.

[0132] The load carrier 5, 5', 5" is aligned on the delivery point 42' on the one hand with a longitudinal axis perpendicular to a sliding surface 66' (not shown) and on the other hand the longitudinal axis is centered in the middle to the transfer point 41' (or the sliding surface 66'), so that a single packing unit 3, but also a series of packing units 3 can be transported without twisting in the discharge direction 48'.

[0133] It is also advantageous if the packaging unit transfer station 10 for loading a load carrier 5, 5', 5" has a packaging unit positioning system for positioning the packaging unit 3 or several packaging units 3 relative to the load carrier 5, 5', 5" provided at the conveyor system 43' on the delivery station 42'. The transfer station 41' and delivery station 42' are arranged within a working area of ​​the transfer device 9'.

[0134] The positioning system comprises positioning elements 64' that are movable between a starting position and a positioning position via drive devices (schematically indicated by double arrows). This design has the advantage that a packaging unit 3 is positioned centrally to the load carrier 5, 5', 5" regardless of its dimensions, and that precise transfer of at least one packaging unit 3 from the transfer station 41' to the load carrier 5, 5', 5" is possible. The positioning system is arranged along the automated conveyor 63', preferably in the area of ​​the transfer station 41'. The positioning system can include a displacement measuring device (not shown) by means of which the adjustment movements of the positioning elements 64' are detected. The displacement measuring device / drive device is connected to the electronic control device 65.The displacement measuring device is formed by a known capacitive, inductive, magnetic, or optoelectronic displacement sensor. The measurement method of absolute and incremental displacement measurement is utilized. For example, an actuator of the drive device can be equipped with a resolver, incremental encoder, or absolute encoder. Although, according to the illustrated embodiments, the positioning elements 64' are each coupled to a drive device, it is alternatively possible to use a single drive device and to couple the positioning elements 64' by means of a traction drive.

[0135] As described above, in this embodiment of the packaging unit transfer device 10, a conveyor level 56' (not shown) is located at the delivery station 42' and a conveyor level 57' is located at the transfer station 41' at different height levels. Specifically, a conveyor level 56' is located below the conveyor level 57', with the transport ramp 29a, 29b of the load carrier 5, 5', 5" bridging the step difference when the load carrier 5, 5', 5" is in a delivery position at the delivery station 42' in front of the transfer station 41'. The guide surface 33a, 33b is at the same height level as the conveyor level 57'; preferably, the guide surface 33a, 33b is located below the conveyor level 57'.

[0136] As can be seen, the packaging unit transfer station 10 can have a monitoring device 60' for detecting the transfer of at least one packaging unit 3 onto the load carrier 5, 5', 5". The monitoring device 60' includes a sensor, for example, a light barrier. The control device 65 is connected to the monitoring device 60' and controls the transfer device 9' to push at least one packaging unit 3 from the transfer point 41' onto the load carrier 5, 5', 5". In particular, the control device 65 can count the number of packaging units 3 transferred onto the load carrier 5, 5', 5".

[0137] The conveying system for transporting the load carriers 5, 5', 5" optionally also includes an automated conveying device 61' for transporting at least those load carriers 5, 5', 5" to the packaging unit transfer station 10 which do not yet contain any packaging units 3, and an automated conveying device 62' for transporting those load carriers 5, 5', 5" from the packaging unit transfer station 10 which have been loaded with one or more packaging units 3.

[0138] As not shown in detail, the load carrier 5, 5', 5" described above can only include the (first) transport ramp 29a, (first) guide support 30a, and (first) edge 31a on the first side wall 26a. This means that the (second) transport ramp 29b, (second) guide support 30b, and (second) edge 31b are not present on the second side wall 26b. In this case, the second side wall 26b merely forms a perpendicular edge web projecting from the first loading level 25, 25', 25" above. With this configuration, the load carrier 5, 5', 5" can be loaded and / or unloaded from one (single) side.

[0139] To enable the unloading or loading of such a load carrier 5, 5', 5" using the above-described packing unit transfer station 10, 11, it is only necessary to ensure that the load carrier 5, 5', 5" is provided in the correct orientation at the delivery point 42, 42'. The load carrier 5, 5', 5" is provided at the delivery point 42, 42' in such a way that the first side wall 26a with the (first) transport ramp 29a, (first) guide support 30a and (first) edge 31a is adjacent to the receiving point 41, if it is the packaging unit transfer station 11 for unloading a load carrier 5, 5', 5" or transfer point 41', if it is the packaging unit transfer station 10 for loading the load carrier 5, 5', 5", when the load carrier 5, 5', 5" is provided at the delivery point 42, 42' and there in particular in a delivery position.

[0140] Preferably, the load carrier 5, 5', 5" is transported by the conveyor system to the delivery point 42, 42' already in the appropriate orientation. If necessary, the conveyor system can, for example, include a (not shown) conveying device designed to rotate the load carrier 5, 5', 5" about a vertical axis as required.

[0141] Finally, for the sake of clarity, it should be noted that, for a better understanding of the structure of the load carrier 5, 5', 5" and the packing unit transfer station 10, 11, these have been shown partly not to scale and / or enlarged and / or reduced in size. Bezugszeichenaufstellung

[0142] 1 Incoming warehouse 2 Packing unit warehouse 3 Packing unit 4 Loading area 5, 5', 5" Load carriers 6 Picking device 8 Depalletizing device 9, 9' Transfer device 10 Packing unit transfer station (loading) 11 Packing unit transfer station (unloading) 14 Data carrier Load carrier 15 Data carrier Packing unit 21 Floor 22 Transport and storage area 23a, 23b Front 24a, 24b Long side 25, 25', 25" Loading level 26a, 26b Side wall 27a, 27b Side wall 28, 28', 28" Transport area 29a, 29b Transport ramp 30a, 30b Guide support 31a, 31b Edge 32a, 32b Inclined surface 33a, 33b Guide surface 34a, 34b, 34c Loading width 35a, 35b, 35c Stop edge 36a, 36b Support support 41, 41' Receiving / transfer point 42, 42' Delivery point 43, 43'Conveyor device 44, 44'Base frame 45, 45'Slide 46, 46'Support frame 47, 47'Carrier 48, 48'Displacement direction 49, 49'Traction drive 50, 50'Actuating motor 51, 51'Drive device 52, 52'Adjustment direction 53, 53'Drive device (stop plate) 54, 54'Stop element 55, 55'Stop element 56, 56' Conveyor level 57, 57' Conveyor level 58, 58' Guide arrangement 60, 60' Monitoring device 61, 61' Conveyor device 62, 62' Conveyor device 63, 63' Conveyor device 64' Positioning element 65 Control device 66, 66' Sliding surface

Claims

1. A load carrier (5', 5") for transporting and storing different packing units (3) in a picking system, which load carrier (5', 5") comprises - a bottom (21) comprising a transport and storage surface (22) at a bottom lower side, a first front end (23a), a second front end (23b), a first longitudinal side (24a), which extends between the first front end (23a) and second front end (23b), a second longitudinal side (24b), which extends between the first front end (23a) and second front end (23b), a first loading plane (25) at a bottom upper side, which runs between the first front end (23a) and second front end (23b) and is configured for receiving the packing unit (3), - a first side wall (26a) protruding beyond the first loading plane (25) in the region of the first front end (23a), - a second side wall (26b) protruding beyond the first loading plane (25) in the region of the second front end (23b), - a third side wall (27a) protruding beyond the first loading plane (25) in the region of the first longitudinal side (24a), and - a fourth side wall (27b) protruding beyond the first loading plane (25) in the region of the second longitudinal side (24b), wherein the bottom (21) forms the first loading plane (25) at a first height level, characterized in that the bottom (21) forms a second loading plane (25') at a second height level, wherein the first loading plane (25) is limited in a first loading width (34a) by first stop edges (35a) running parallel to each other and aligned substantially vertically to the first loading plane (25) and wherein the second loading plane (25') is limited in a second loading width (34b) by second stop edges (35b) running parallel to each other and aligned substantially vertically to the second loading plane (25') and wherein the second loading width (34b) is configured larger than the first loading width (34a), and wherein the first stop edges (35a) are formed by support rests (36a) running in parallel at a mutual distance and extending between the first front end (23a) and the second front end (23b), which support rests (36a) are arranged at the bottom (21) on the bottom upper side and protrude at the first loading plane (25), and wherein the second stop edges (35b) are formed by the third and fourth side walls (27a, 27b), and wherein the first loading plane (25) forms a continuously uninterrupted planar transport surface (28), and wherein between the first longitudinal side (24a) and second longitudinal side (24b) the first side wall (26a) forms a first transport ramp (29a) that adjoins the transport surface (28) and forms a diagonal surface (32a) which encloses an angle (α) between 135° and 160° with the transport surface (28), a first guide rest (30a) that adjoins the first transport ramp (29a) and forms a guide surface (33a) running substantially parallel to the transport surface (28), and a first edge (31a) between the first transport ramp (29a) and the first guide rest (30a), and wherein the second loading plane (25') at the second height level is formed by a second transport surface (28') configured at the support rests (36a), which second transport surface (28') is configured at front edges of the support rests (36a) facing away from the first loading plane (25) and running parallel to each other, and wherein the transport and storage surface (22) on the bottom lower side and the transport surfaces (28, 28') on the bottom upper side run parallel to each other.

2. The load carrier according to claim 1, characterized in that between the first longitudinal side (24a) and second longitudinal side (24b), the second side wall (26b) forms a second transport ramp (29b) that adjoins the transport surface (28) and forms a diagonal surface (32b) which encloses an angle (α) between 135° and 160° with the transport surface (28), a second guide rest (30b) that adjoins the second transport ramp (29b) and forms a guide surface (33b) running substantially parallel to the transport surface (28), and a second edge (31b) between the second transport ramp (29b) and the second guide rest (30b).

3. The load carrier according to claim 2, characterized in that the first edge (31a) and second edge (31b) are each rounded with a radius.

4. The load carrier according to claim 3, characterized in that the radius is at least 5 mm.

5. A packing unit transfer station (10, 11) for loading a load carrier (5', 5") and / or unloading a load carrier (5', 5"), comprising - a load carrier (5', 5"), - a transfer device (9', 9) for pushing at least one packing unit (3) from a handover location (41') onto the load carrier (5', 5") and / or for pushing at least one packing unit (3) from the load carrier (5', 5") onto a takeover location (41), - a conveying system (43, 43') for transporting the load carrier (5', 5") to a provisioning location (42, 42') and for transporting the load carrier (5', 5") away from this provisioning location (42, 42'), and - a load carrier positioning system (54, 54', 55, 55') for positioning the load carrier (5', 5") in a provisioning position at the provisioning location (42, 42') in front of the takeover location (41) or in front of the handover location (41'), characterized in that the load carrier (5', 5") is configured according to any one of the claims 1 to 4.

6. The packing unit transfer station according to claim 5, characterized in that the packing unit transfer station (10) for loading a load carrier (5', 5 ")comprises a packing unit positioning system (64') for positioning the at least one packing unit (3) relative to the load carrier (5', 5") provisioned in a provisioning position at the provisioning location (42') at the conveying system (43').

7. The packing unit transfer station according to claim 5, characterized in that the transfer device (9, 9') comprises a pusher (45, 45') that is movable relative to a load carrier (5', 5") provisioned in the provisioning position at the provisioning location (42, 42') and mounted on a base frame (44, 44').

8. The packing unit transfer station according to claim 7, characterized in that the pusher (45, 45') is coupled to a drive device and is movable from an inoperative position to an unloading position or from an inoperative position to a loading position in order to push at least one packing unit (3) from the load carrier (5', 5") onto the takeover location (41) or from a handover location (41') onto the load carrier (5', 5").

9. The packing unit transfer station according to claim 8, characterized in that the drive device comprises an electronically controlled actuating motor (50, 50') and which packing unit transfer station (10, 11) is connected to a control device (65), wherein the control device (65) controls the drive device such that the pusher (45, 45') pushes a calculated number of packing units (3) from the load carrier (5', 5") onto the takeover location (41) or pushes a calculated number of packing units (3) from the handover location (41') onto the load carrier (5', 5").

10. The packing unit transfer station according to claim 5 or 9, characterized in that the packing unit transfer station (10, 11) comprises a monitoring device (60, 60'), in particular a sensor system, for detecting a transfer of a packing unit (3) from the handover location (41') onto the load carrier (5', 5") or for detecting a transfer of a packing unit (3) from the load carrier (5', 5") onto the takeover location (41), wherein a control device is connected to the monitoring device (60, 60') and controls the transfer device (9, 9') in order to push a packing unit (3) from the handover location (41') onto the load carrier (5', 5") or push a packing unit (3) from the load carrier (5', 5") onto the takeover location (41).

11. A picking system for storing and picking packing units (3), comprising - a first packing unit transfer station (10) for loading a load carrier (5', 5") having one or multiple packing units (3), - an automated packing unit storage (2) for storing the packing units (3) on the load carriers (5', 5"), - a first conveying device between the first packing unit transfer station (10) and the packing unit storage (2), - a second packing unit transfer station (11) for unloading a load carrier (5', 5") having one or multiple packing units (3), - a second conveying device between the packing unit storage (2) and the second packing unit transfer station (11), and - a picking station for loading an order load carrier with packing units (3) in a defined loading sequence and according to a picking order, characterized in that the first packing unit transfer station (10) and / or second packing unit transfer station (11) is configured according to any one of the claims 5 to 10.