Improved method for loading a target loading device and storage and picking system therefor

Description

[0001] The invention relates to a method for loading a target loading device with goods at a loading station with an automatic loading device. Furthermore, the invention relates to a storage and order-picking system for implementing the method. The storage and order-picking system comprises a storage area, a loading station with an automatic loading device, a source conveyor system, and an order computer.

[0002] Such a method and such a storage and picking system are generally known from the state of the art. The problem is that the type of loading of the target load carrier significantly influences the risk of damage to the goods contained therein during transport. For example, heavy goods are typically placed lower in a target load carrier, whereas lighter goods tend to be placed higher up. If a customer orders heavy cans of food and fragile wine glasses, the risk of the glasses breaking is reduced if they are placed at the top of the target load carrier, as indicated.

[0003] Due to the multitude of different types of goods handled in a modern warehouse and order-picking system, simple loading instructions do not necessarily result in a favorable type of packaging. In some cases, it may be advisable to reverse the loading sequence for certain types of goods, for example, if a customer orders a cushion and several jars of jam. The conventional procedure results in the jam, being heavier, being placed at the bottom of the target load carrier and the cushion at the top. The cushion would absorb the impact when the target load carrier is placed hard on a surface, significantly reducing the risk of jar breakage.

[0004] In addition, the performance requirements of modern warehouse and picking systems inevitably lead to ever-increasing speeds and accelerations when handling goods. Here, too, simple motion instructions do not always achieve optimal results. For example, the risk of a wine glass breaking at excessive acceleration is significantly higher than that of a jam jar.

[0005] Based on the current state of the art, the end result requires a differentiated approach when loading a target loading device.

[0006] SHIAU JY ET AL "A warehouse management system with sequential picking for multi-container deliveries", COMPUTERS & INDUSTRIAL ENGINEERING, PERGAMON, AMSTERDAM, Vol. 58, No. 3, 1 April 2010, pages 382-392, ISSN: 0360-8352 discloses a method for loading a target load carrier with goods at a manual loading device, comprising the steps: a) Recording an order and determining goods assigned to the order by an order computer, b) Providing goods properties in a database, c) Specifying loading parameters, comprising at least one parameter relating to the goods and / or at least one parameter relating to the target loading aid, d) Creating a loading pattern, e) Repeating steps b) to d) with changed loading parameters, f) Creating a loading instruction for the loading device, comprising the loading parameters which lead to the selected loading pattern, and g) Transporting the goods to the manual loading device and loading the target loading aid with the goods in accordance with the loading instruction by an operator.

[0007] One object of the invention is to provide an improved method for loading a target load carrier and an improved storage and picking system for implementing the method. In particular, a differentiated procedure for loading a target load carrier is to be provided.

[0008] The object of the invention is achieved by a method for loading a target loading aid with goods at a loading station according to claim 1.

[0009] In particular, the goods can be transported to the automatic loading device of the loading station, with or without source loading aids, on an automated source conveyor system.

[0010] In particular, loading the target loading device with the goods may include releasing a good from the loading device and transferring the good onto or into the target loading device, for example, a container, carton, etc. Loading a target loading device may include loading one or more goods.

[0011] In particular, goods can be moved from their delivery (at the loading device) to their pick-up (on a target loading device) solely by gravity, for example, by falling, sliding, and / or throwing. Only when appropriate can the goods be subjected to a force component during their movement (and "thrown"), for example, to increase their speed or change their orientation.

[0012] In particular, a distinction must be made between "distribution" of goods and "removal" of goods. "Distribution" of goods does not involve movement of goods against the force of gravity, hence lifting of goods, whereas "removal" does involve movement of goods against the force of gravity, hence lifting of goods. This applies in particular to goods being delivered by falling or sliding. If goods are thrown, the goods can be subjected to a force counter to the force of gravity in order to flatten a parabola of projection or to achieve a parabola with an upward-pointing first section.

[0013] Furthermore, the object of the invention is achieved by a storage and order picking system according to claim 14.

[0014] The storage and order picking system is designed in particular to carry out the method according to one of claims 1 to 13.

[0015] Using the presented method and the presented storage and picking system, optimized loading of a target load carrier can be achieved. For this purpose, a target specification is formulated and the loading process is simulated before the actual loading of the target load carrier, with at least the loading parameters being varied. If a suitable loading pattern is found, i.e., one that optimally meets the target specification, the loading of the target load carrier is carried out in real life using the determined loading parameters.

[0016] For example, to load the target load carrier, at least one of the goods can be dropped, slid, and / or thrown into the target load carrier. This enables particularly high loading speeds. However, this entails a certain degree of uncertainty regarding the outcome of the loading process, as it is not strictly deterministic due to the falling, slid, and / or throwing. The application of the measures presented here is particularly advantageous here, as this uncertainty can be reduced through pre-simulation. Therefore, the outcome of the loading process can be better predicted and assessed.

[0017] The "loading pattern" specifies, in particular, how the goods are positioned in the target loading device after the loading process, and in particular whether all the intended goods are in the target loading device or whether some of the goods are protruding from the target loading device or have even fallen out. In other words, the loading pattern corresponds to a packing order in the target loading device.

[0018] The target specification is preferably selected from a group comprising a fill level of the target loading aid, a state of the goods in the target loading aid and / or a pose of the goods in the target loading aid. The fill level can, for example, be specified as a percentage of the volume of the target loading aid occupied by the goods contained therein. In particular, the state of the goods in the target loading aid comprises an (elastic and / or plastic) permissible maximum change in shape of the goods, which they may exhibit after reaching a rest state, in particular after a simulated fall or throw, in the target loading aid. The pose of the goods is their position and orientation in the target loading aid. For example, it can be provided that goods are arranged in the target loading aid in a way that is appealing to the customer.For example, goods that have fallen out of the target load carrier as described above would also not have a position in the target load carrier and therefore would not meet a target specification regarding the pose of the goods. A target specification can also refer to a maximum tolerable risk of damage to the goods during the loading process and / or during the further transport route of the target load carrier. For example, a loading process with slightly modified loading characteristics can be simulated several times, and the proportion of simulation runs in which damage to the goods occurs can be determined.

[0019] Accordingly, it is also advantageous if the loading pattern is created the state of the goods is calculated by the simulation unit, which the goods have after reaching a rest state after a simulated loading of the target loading device with the goods, the fill level of the target loading device is calculated by the simulation unit, and / or the pose of the goods in the target loading device is calculated by the simulation unit, which the goods have after reaching the rest state after the simulated loading of the target loading device with the goods.

[0020] Accordingly, it is also advantageous to repeat step e) with modified loading characteristics. This allows for the fact that loading characteristics may not be precisely determinable under certain circumstances. Furthermore, the use of alternative loading devices or loading with alternative goods in step e) can lead to different properties of the loading device and the properties of the goods.

[0021] Generally, "loading properties" are fixed variables that are immutable or cannot be changed quickly and that influence the loading process. These include properties of the loading device and can, for example, affect the geometry of the loading device, the friction coefficient of a chute, etc. Product properties can, for example, affect the geometry of a product, the weight of a product, the friction coefficient of a product, etc.

[0022] "Loading parameters" are variables that can be changed (even temporarily) and that influence the loading process. A "parameter relating to the loading device" can be, for example, a loading speed, a dumping angle, a dumping height, a loading position, etc. A "parameter relating to the goods" can be, for example, a loading sequence, an orientation of the goods before loading, etc. A "parameter relating to the target loading device" can be, for example, a shape, a dimension, or a quality of the target loading device. The dumping angle of a source loading device can be, for example, the angle when dumping a hanging pocket intended as a source loading device. The dumping angle can be specified, in particular, as the angle between a base of the source loading device and a horizontal plane.

[0023] It is therefore also advantageous if the at least one parameter relating to the loading device is selected from a group comprising a design of the loading device, a loading speed, a tipping angle of a source loading aid, a drop height of the goods into the target loading aid and / or a loading position of the target loading aid, and / or the at least one parameter relating to the goods is selected from a group comprising a selection of goods of an order, a loading sequence and / or a pose of the goods when feeding the goods to the target loading aid, and / or the at least one parameter relating to the target loading aid is selected from a group comprising a target loading aid orientation, target loading aid position, target loading aid shape and / or target loading aid dimensioning.

[0024] The loading properties and / or loading parameters can be recorded using data technology and / or electronically using sensors. Loading parameters can also be formed by target or manipulated variables for actuators. Loading properties and / or loading parameters can be stored in a database, although not all loading properties and loading parameters used for the simulation necessarily have to be stored in the database. It is particularly advantageous if, on the one hand, some of the loading parameters, for example the parameters relating to the loading device, are stored in the database (such as possible dumping angles, possible dumping heights, and the like), and on the other hand, some of the loading parameters, in particular the loading sequence, are generated or recorded during the process and are preferably not already stored in the database.In particular, the database can be configured to provide loading parameters, which include at least one parameter relating to the loading device and / or at least one parameter relating to the goods and / or at least one parameter relating to the target loading device. The database is connected to the simulation unit via data technology, so that the simulation unit can access the electronically recorded loading properties and / or loading parameters.

[0025] In particular, product characteristics can originate from a supplier of the goods and also be stored in the database. Alternatively, product characteristics can also be recorded electronically using sensors in the warehouse and picking system and stored in the database. Since the database is connected to the simulation unit via data technology, the simulation unit can also access the electronically recorded product characteristics.

[0026] The warehouse and picking system generally includes one or more of the databases mentioned, which may be an integral part of the simulation unit.

[0027] At this point, it should be noted that the mention of a "loading property" and a "loading parameter" within the scope of this disclosure can refer to both a type or designation of this loading property / loading parameter and its value. For example, the loading property for the weight of a product consists of its type or designation "weight" and its value, e.g., "5 kg." If reference is made within the scope of this disclosure to a variation of loading properties or loading parameters, this can refer to a variation of the type and / or a variation of the value. For example, the loading property "width" can be incorporated into one simulation, and the loading property "weight" into another simulation. Likewise, the value for a weight of "5 kg" can be incorporated into one simulation, and the value "2 kg" into another simulation. Of course, a combined change of type and / or value is also possible.For example, one simulation might include the loading property "width" = "200 mm," while another might include the loading property "weight" = "2 kg." Finally, it is also conceivable to interpret a loading property and / or a loading parameter as a combination of type or designation and its value. For example, one loading property might be "weight 5 kg," and another might be "weight 2 kg."

[0028] It is also advantageous if in step b) additional tolerance ranges for the loading properties, in particular for the goods properties, are provided in the simulation unit and values for the loading properties are selected within the given tolerance ranges, in step d) the simulation is carried out for the selected values of the loading properties, and in step e) values for the loading properties are changed within the tolerance ranges, and the target specification in step f) comprises a robustness of the loading process against variations in the loading properties.

[0029] As mentioned, loading characteristics may not be precisely determinable under certain circumstances. It is advantageous to change loading characteristics by varying them within tolerance ranges, especially randomly. This allows the aforementioned uncertainty to be taken into account when determining loading characteristics. The "robustness of the loading process" indicates how strongly the result of the loading process, especially the resulting loading pattern, depends on scattered loading characteristics.

[0030] It is also advantageous if in step c) additional tolerance ranges for the loading parameters are provided in the simulation unit and values for the loading parameters are selected within the given tolerance ranges, in step d) the simulation is carried out for the selected values of the loading parameters, and in step e) values for the loading parameters are changed within the tolerance ranges, and the target specification in step f) includes a robustness of the loading process against variations in the loading parameters.

[0031] Loading parameters may also be impossible to determine precisely. For example, an actuator used to adjust a tipping angle may be subject to tolerances, which also introduces uncertainty into the loading process. Loading parameters can also advantageously be changed by varying them within tolerance ranges, especially randomly. This allows the aforementioned uncertainty to be taken into account when determining loading parameters. In this case, the "robustness of the loading process" indicates how strongly the result of the loading process depends on fluctuating loading parameters.

[0032] The simulation unit may comprise a "simulation module" and a separate "analysis module." The analysis module may further comprise an output device for manual analysis or an analysis module for automatic analysis. If the simulation unit comprises a simulation module and an analysis module, the result is, in particular, a storage and order-picking system comprising a storage area for the provision of goods, a loading station with an automatic loading device for loading target loading aids with goods according to a loading instruction (if at least one loading pattern meets a target specification), a source conveyor system for transporting the goods, which connects the storage area and the loading station, an order computer for recording an order and for determining goods assigned to the order, at least one database in which loading properties, comprising properties of the loading device and goods properties of the goods, can be provided, and a simulation unit, which is data-technically connected to the at least one database and which has a simulation module and an analysis module, wherein the simulation unit is designed to

[0033] Processing of loading properties, in particular electronically recorded, including properties of the loading device and goods properties of the goods by the simulation module,

[0034] Processing a specification of loading parameters, comprising at least one parameter relating to the loading device and / or at least one parameter relating to the goods and / or at least one parameter relating to the target loading aid, by the simulation module,

[0035] Simulating a loading process of the target loading equipment with goods based on the loading properties and loading parameters by the simulation module, Creating a loading pattern by the simulation module, repeating the previously mentioned steps with changed loading parameters, analyzing created loading patterns on the basis of the target specification by the analysis module, selecting the loading pattern that best meets the target specification, and creating the loading instructions for the loading device, comprising the loading parameters that lead to the selected loading pattern, by the analysis module.

[0036] The goods can be provided in the storage area with or without loading aids and transported to the automatic loading device of the loading station using the source conveyor system, with or without loading aids. For example, the storage area can have a plurality of stationary storage racks and at least one automated storage and retrieval machine for storing goods in the storage racks and / or retrieving them from the storage racks. The storage racks can be designed for hanging and / or lying storage of goods.

[0037] Target loading aids can be loaded with goods at the automatic loading device.

[0038] If the goods are transported using loading aids, these correspond to "source loading aids." Loading a target loading aid can therefore also include unloading the source loading aid. Loading the target loading aid can be accomplished by transferring the goods from the source loading aid to the target loading aid. A source loading aid can be, for example, a container, a tray, a carton, or even a hanging bag. The goods can be provided on the warehouse shelves with the source loading aids.

[0039] In particular, a hanging pocket can be designed according to patent application WO 2019 / 195871 A1 or WO 2020 / 150762 A1 and used in the manner described therein for the method and the storage and picking system disclosed here. According to this embodiment, a target loading aid is loaded by unloading a hanging pocket (source loading aid). The hanging pocket can be unloaded using an unloading station described in WO 2019 / 195871 A1.

[0040] In particular, a container with a closable bottom opening can be designed according to patent application WO 2012 / 024714 A2 and used in the manner described therein for the method and the storage and picking system disclosed here. According to this embodiment, a target loading device is loaded by unloading a container (source loading device). Unloading the container can be performed using a transfer station described in WO 2012 / 024714 A2.

[0041] A "destination loading device" can be, for example, a container, a carton, a shipping package (shipping carton, shipping bag), etc.

[0042] An "automated source conveyor system" can comprise a stationary conveyor system and / or a mobile conveyor system. Similarly, an "automated destination conveyor system" can comprise a stationary conveyor system and / or a mobile conveyor system. An "automated source conveyor system" can also be designed for horizontal or suspended transport of goods. Similarly, an "automated destination conveyor system" can also be designed for horizontal or suspended transport of goods.

[0043] A stationary conveyor system for the horizontal transport of goods can, for example, be designed as a floor-based conveyor system, for example as a roller conveyor system or as a belt conveyor system.

[0044] A stationary conveyor system for the hanging transport of goods can preferably be designed as an overhead conveyor system, which can comprise hanging pockets for holding the goods. In this case, the goods can be transported on the overhead conveyor system by means of a transport carrier (e.g. with a coat hook) and in particular also in a hanging pocket. Preferably, exactly one item is transported with a transport carrier or in the hanging pocket. However, it is also possible for more than one item to be transported simultaneously with one transport carrier or with the hanging pocket. If several items are transported simultaneously with one transport carrier or a hanging pocket, these are predominantly goods of the same type.

[0045] A mobile conveyor system can, for example, include an automated conveyor vehicle, such as an "Automated Guided Vehicle" (AGV) or an "Autonomous Mobile Robot" (AMR). Mobile conveyor technology for the suspended transport of goods can also include overhead conveyor systems mounted on automated conveyor vehicles.

[0046] Loading the target load carrier can constitute the picking process or be part of a picking process. In this context, the loading station can also be understood and referred to as a "picking station." The target load carrier can also, in particular, assume the role of a shipping load carrier, which is subsequently transported from the storage and picking system and brought to a recipient.

[0047] Further advantageous embodiments and developments of the invention emerge from the subclaims and from the description in conjunction with the figures.

[0048] According to the invention, the presented method additionally comprises the step h2) transporting the goods to a further loading device of the loading station and loading the target loading aid with the goods by an operating element.

[0049] The additional loading device is a manual loading device, and the operating element is an operator. This allows for particularly flexible handling of goods for which no suitable loading pattern can be found during the loading simulation.

[0050] The assessment in step f) comprises checking whether at least one of the loading patterns meets the target specification, and steps g) and h1) are carried out if at least one of the loading patterns meets the target specification, or step h2) is carried out omitting step g) if none of the loading patterns meets the target specification.

[0051] This means that the warehouse and picking system can also handle goods for which no suitable loading pattern can be found during the loading process simulation.

[0052] The goods can be made available in the storage area with or without loading aids and transported to the further loading device of the loading station using the source conveyor technology with or without loading aids.

[0053] The target load carrier can be loaded with goods by the operator at the manual loading device. If the goods are transported in source load carriers, loading the target load carrier can involve removing the goods from the source load carriers and placing them in the target load carrier. In other words, the operator transfers the goods from the source load carriers to the target load carrier at the manual loading device.

[0054] The manual loading device can comprise an input and / or output device. The input and / or output device preferably has an output means for outputting loading instructions, for example, a screen, on which the operator receives loading instructions for loading the target loading device. Furthermore, the input and / or output device can have an input means for inputting an acknowledgment command, for example, a keyboard or a key, via which the operator can acknowledge (confirm) the successful loading of the target loading device. The input means and output means can be provided, for example, by a touch display.

[0055] It is also advantageous if step f) is carried out before step e), whereby the assessment in step f) comprises checking whether the loading pattern created meets the target specification, and after step f) step e) is carried out if the loading pattern determined does not meet the target specification, or after step f) step g) is carried out, omitting step e), if the loading pattern determined meets the target specification.

[0056] In this version, no further simulation runs are performed once a loading pattern meets the target specification. This version therefore leads to a result particularly quickly.

[0057] It is also advantageous if an analysis set is defined which comprises any number of orders, wherein steps a) to g) are carried out for all orders of the analysis set, and wherein the method between steps f) and g) comprises the following steps: i) Creating a first order set comprising all orders for which at least one loading pattern has been created that meets the target specification, ii) Creating a second order set comprising all orders for which no loading pattern has been created that meets the target specification.

[0058] In this way, a large number of orders can be simulated in advance, with the orders subsequently being divided into automatically processable orders (first order set) and non-automatically processable orders (second order set) and processed accordingly. The second order set is handled by a control element, specifically an operator.

[0059] It is advantageous if the loading of the target loading device with the goods is recorded by a camera in step h1), and in the simulation unit, a model for simulating the loading is adaptively adapted to the actual loading process based on the recording of the loading by the camera. In particular, it is advantageous if the loading characteristics and / or loading parameters are adjusted according to the recording. This allows incorrect assumptions regarding the model for simulating the loading, and in particular incorrect assumptions regarding the loading characteristics and / or loading parameters, to be corrected and adapted to reality. Over time, the simulation thus becomes increasingly closer to the real-life conditions.

[0060] It is also advantageous to virtualize the loading of the target load carrier using virtual twins of the loading device, the target load carrier, and / or the goods, and to adjust the loading properties and / or loading parameters of the virtual loading device, the virtual target load carrier, and / or the virtual goods based on the camera's recording of the loading process. Virtual twins are particularly well-suited for implementing, observing, and evaluating simulations. A human or even artificial intelligence can help achieve an optimized result—i.e., optimal fulfillment of the target specification—in as few simulation runs as possible.

[0061] For a better understanding of the invention, it is explained in more detail using the following figures.

[0062] They show in a highly simplified, schematic representation: Fig. 1 shows a schematic representation of a first exemplary loading station in a storage and picking system; Fig. 2 shows a schematic representation of a second exemplary loading station in a storage and picking system; Fig. 3 shows a schematic representation of another exemplary loading station with an automatic loading device and a further loading device; Fig. 4 shows a flowchart relating to the central steps of the method presented; Fig. 5 shows a flowchart for an embodiment variant in which some of the goods are loaded automatically and another part of the goods is loaded manually into the target loading device; and Fig. 6 shows a flowchart for an embodiment variant of an abbreviated simulation method which is aborted when a target specification is met for the first time.

[0063] 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 analogously 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 analogously to the new position.

[0064] The Fig. 1 shows a first example of a loading station 1a for loading target loading aids 2 with goods 3 according to a loading instruction. The loading station 1a comprises an automatic loading device 4a, which in this example is designed as a chute, the inclination of which is adjustable, as in the Fig. 1 is symbolized by an arrow. A target loading device 2 can be, for example, a container, a carton, a shipping package (shipping box, shipping bag), etc.

[0065] In addition, the Fig. 1 an order computer 5, a database 6, and a simulation unit 7 are shown, which together form a computer system 8 or are part of such. The order computer 5 is configured to record an order OD and to determine goods 3 assigned to the order OD. Loading properties are provided in the database 6, and the simulation unit 7 serves to simulate a loading process of the target loading aid 2 with the goods 3. The simulation unit 7 can for this purpose comprise a simulation module and a separate analysis module. The analysis module can furthermore have an output device for manual analysis or an analysis module for automatic analysis. Furthermore, the simulation unit 7 can comprise the database 6.

[0066] In addition, the Fig. 1 also an optional camera 9 for recording the actual loading process of the target loading device 2 with the goods 3 is shown, which is connected to the computer system 8 and in particular to the simulation unit 7.

[0067] Furthermore, in the Fig. 1 a source conveyor system 10a and a destination conveyor system 11 are shown. The source conveyor system 10a is connected to an optional storage area 12. The source conveyor system 10a is intended for transporting the goods 3 from the storage area 12 to the loading station 1a, and the destination conveyor system 11 is designed to transport the destination loading aid 2 to the loading station 1a and to transport the destination loading aid 2 away from the loading station 1a.

[0068] The Fig. 1 The objects shown are part of or form part of a storage and order picking system 13a.

[0069] In the Fig. 1 In the example shown, the source conveyor system 10a and the target conveyor system 11 are designed as stationary conveyor systems. Specifically, the source conveyor system 10a comprises an exemplary conveyor belt, and the target conveyor system 11 comprises an exemplary roller conveyor. However, other embodiments are equally possible. It would also be conceivable for the source conveyor system 10a and / or the target conveyor system 11 to be designed as mobile conveyor systems. For example, such systems could include "automated guided vehicles" (AGVs) or "autonomous mobile robots" (AMRs).

[0070] Furthermore, the source conveyor system 10a and the destination conveyor system 11 are designed for the horizontal transport of the goods 3. Specifically, the goods 3 are transported on the source conveyor system 10a without a loading aid, whereas the goods 3 are transported on the destination conveyor system 11 with the aid of the destination loading aid 2. However, it would also be conceivable for the goods 3 to be transported on the source conveyor system 10a with a source loading aid (see also Fig. 2 ). A source loading aid can generally also be a container, a tray, or a carton. A source loading aid can also be designed with a closable bottom opening for dispensing goods 3 according to patent application WO 2012 / 024714 A2 and can be used in the manner described therein for the method and the storage and order-picking system 13a disclosed here.

[0071] The storage area 12 can comprise a plurality of stationary storage racks and at least one automated storage and retrieval machine for storing the goods 3 in the storage racks and / or retrieving the goods 3 from the storage racks. Such a storage rack and such a storage and retrieval machine are generally known from the prior art and are therefore not explained in detail here.

[0072] In this example, the source conveyor system 10a is height-adjustable and can also be adjustable in terms of conveying speed (see the arrows in the Fig. 1 ). In this respect, the loading process is also influenced by the source conveyor system 10a. Consequently, in this case, i.e., generally when it influences the loading process, the source conveyor system 10a can be considered part of the loading station 1a or part of the loading device 4a.

[0073] In the Fig. 1 In the example shown, the goods 3 are delivered into the target loading aid 2 by sliding and falling. This is not the only conceivable possibility. It would also be conceivable for the chute 4a to extend to the bottom of the target loading aid 2, and for the goods 3 therefore not to fall into the target loading aid 2, but rather to merely slide or slide. It would also be conceivable for the goods 3 to be thrown or placed into the target loading aid 2, for example, with the aid of an articulated-arm robot or gantry robot. It would also be possible to omit the chute 4a and deliver the goods 3 directly from the source conveyor system 10a into the target loading aid 2.

[0074] Fig. 2 shows an alternative exemplary embodiment of a loading station 1b or a storage and order picking system 13b, which corresponds to the Fig. 1 loading station 1a shown or the one shown in the Fig. 1 illustrated storage and order picking system 13a. In contrast, the source conveyor technology 10b in this example is designed as an overhead conveyor technology and is intended for the hanging transport of the goods 3 in source loading aids 14, which are designed as hanging pockets. The hanging pocket 14 is transported on a transport carrier of the source conveyor technology 10b from the storage area 12 to the loading station 1b and there, with the aid of the guide tracks 15, 15', is automatically opened and tilted, in particular to a tipping angle. The guide track 15 acts on the front part of the hanging pocket 14 and presses it downwards, whereas the guide track 15' acts on the rear part of the hanging pocket 14 and presses it upwards. Accordingly, the guide tracks 15, 15' in this example form the loading device 4b or are part of it.To better illustrate the process of opening and tilting the hanging pocket 14, the hanging pocket 14, the source conveyor system 10b, the loading device 4b, and the goods 3 in the area of the loading station 1b are shown in an oblique view. Here, the hanging pocket 14 is shown in a tipping position, in which the goods 3 can be automatically deposited into the target loading device 2, with the hanging pocket 14 tilted at the tipping angle.

[0075] Even with the Fig. 2 In the example shown, the goods 3 are delivered by sliding and falling into the target loading aid 2. However, it would also be conceivable, for example, that the goods 3 are transferred from the hanging pocket 14 onto a slide (compare Fig. 1 ) which leads to the bottom of the target loading aid 2. It would also be conceivable in general to deliver the goods 3 into the target loading aid 2 with the aid of a robot with a (suction) gripper, which removes the goods 3 from the source conveyor system 10b and places them in the target loading aid 2.

[0076] In particular, a hanging pocket 14 can be designed according to patent application WO 2019 / 195871 A1 or WO 2020 / 150762 A1 and used in the manner described therein for the method and the storage and order-picking system 13b disclosed here. Unloading of the hanging pocket 14 can be carried out using an unloading station described in WO 2019 / 195871 A1, which is constructed similarly to the schematically illustrated loading device 4b of Fig. 2 .

[0077] As in Fig. 3 As shown, a loading station 1 can have, in addition to the (automatic) loading device 4, a further loading device 4', which is designed for manual loading of the target loading aids 2 by an operator 16, i.e. as a manual loading device 4'.

[0078] At the further loading device 4', the target loading device 2 can thus be loaded with goods 3 by the operator 16. If the goods 3 are transported in source loading devices 14, the goods 3 can be reloaded from the source loading devices 14 to the target loading device 2 by the operator 16 at the further (manual) loading device 4', as shown in the Fig. 3 is shown.

[0079] The further loading device 4' can comprise an input and / or output device 17. The input and / or output device 17 preferably has an output means for outputting loading instructions, from which the operator 16 receives loading instructions for loading the target loading aid 14. Furthermore, the input and / or output device 17 can have an input means for inputting an acknowledgment command, for example, a keyboard or a key, via which the operator 16 can acknowledge (confirm) the successful loading of the target loading aid 14.

[0080] The source conveyor system 10 and the target conveyor system 11 can be used as described in connection with Fig. 1 and Fig. 2 described and be connected to both the loading device 4 and the further loading device 4' in terms of conveyor technology, as described in the Fig. 3 is shown.

[0081] The loading station 1, 1a, 1b can be used in particular for picking goods 3. Accordingly, the loading station 1, 1a, 1b can also be referred to as a "picking station" in this case.

[0082] The sequence of the presented method for loading a target loading device 2 in general is as follows, whereby the method is based on the Fig. 1 and 2 arrangements shown and the Fig. 4 The flow chart shown is explained as an example.

[0083] The presented procedure includes the following steps: a) Recording S1 of an order OD and determining goods 3 assigned to the order OD by the order computer 5, b) Providing S2 of, in particular electronically recorded, loading properties, comprising properties E1 of the loading device 4, 4a, 4b and goods properties E2 of the goods 3, in the database 6 for the simulation unit 7, c) Specifying S3 loading parameters, comprising at least one parameter P1 relating to the loading device 4, 4a, 4b and / or at least one parameter P2 relating to the goods 3 and / or at least one parameter P3 relating to the target loading aid 2, in the simulation unit 7, d) Simulating S4 a loading process of the target loading aid 2 with goods 3 with the aid of the simulation unit 7 based on the loading properties E1, E2 and the loading parameters P1..P3 and creating a loading pattern by the simulation unit 7, e) Repeating steps b) to d) with changed loading parameters P1..P3, f) analyzing S5 the created loading patterns on the basis of a target specification by means of the simulation unit 7, g) selecting S6 the loading pattern which best meets the target specification and creating a loading instruction for the loading device 4, 4a, 4b, comprising the loading parameters P1..P3 which lead to the selected loading pattern, by means of the simulation unit 7, h1) transporting S7 the goods 3, in particular by means of an automated source conveyor technology 10, 10a, 10b, to the automatic loading device 4, 4a, 4b of the loading station 1, 1a, 1b and loading the target loading aid 2 with the goods 3 by means of the automatic loading device 4, 4a, 4b according to the loading instruction, if at least one of the loading patterns meets the target specification.For example, the at least one parameter P1 relating to the loading device 4, 4a, 4b can be selected from a group comprising a design of the loading device 4, 4a, 4b, a loading speed, a tipping angle of a source loading aid 14, a drop height of the goods 3 into the target loading aid 2 and / or a loading position of the target loading aid 2, and / or the at least one parameter P2 relating to the goods 3 can be selected from a group comprising a selection of goods 3 of an order OD, a loading sequence and / or a pose of the goods 3 when feeding the goods 3 to the target loading aid 2, and / or the at least one parameter P3 relating to the target loading aid 2 can be selected from a group comprising a target loading aid orientation, target loading aid position, target loading aid shape and / or target loading aid dimensioning.

[0084] To create the loading pattern, the simulation unit 7 can, for example, calculate: the state of the goods 3 which the goods 3 have after reaching a rest state after a simulated loading of the target loading aid 2 with the goods 3, the degree of filling of the target loading aid 2, and / or the pose of the goods 3 in the target loading aid 2 which the goods 3 have after reaching the rest state after the simulated loading of the target loading aid 2 with the goods 3.

[0085] In particular, the state of the goods 3 in the target loading aid 2 includes an (elastic and / or plastic) change in the shape of the goods 3, which they exhibit after reaching a resting state (in particular after a simulated fall or throw) in the target loading aid 2. The loading pattern also indicates, in particular, how the goods 3 are positioned in the target loading aid 2 after the loading process and, in particular, whether all of the intended goods 3 are positioned in the target loading aid 2 or whether some of the goods 3 protrude from the target loading aid 2 or have even fallen out of it. In other words, the loading pattern corresponds to a packing order in the target loading aid 2.

[0086] From the multitude of loading patterns obtained in multiple simulation runs, the one that best meets a target specification is selected. A corresponding loading specification is then created, which serves as the basis for the actual loading process of the target loading device 2.

[0087] The target specification is preferably selected from a group comprising a fill level of the target loading aid 2, a state of the goods 3 in the target loading aid 2 and / or a pose of the goods 3 in the target loading aid 2. In particular, the target specification can also relate to a permissible (elastic and / or plastic) change in shape of the goods 3, which it may exhibit at most after reaching a rest state (in particular after a simulated fall or throw) in the target loading aid 2. The fill level can, for example, be specified as a percentage of the volume of the target loading aid 2 occupied by the goods 3 located therein. The pose of the goods 3 is their position and orientation in the target loading aid 2. For example, it can be provided that goods 3 are arranged in the target loading aid 2 in a way that is appealing to the customer.A target specification can also relate to a maximum tolerable risk of damage to goods 3 during the loading process and / or during the further transport of the target loading device 2. For example, a loading process with slightly modified loading properties E1, E2 can be simulated several times, and the proportion of simulation runs in which damage to goods 3 occurs can be determined.

[0088] The loading properties E1, E2 and / or loading parameters P1..P3 can be stored in the database 6 and read out there by the simulation unit 7. However, the loading properties E1, E2 and / or loading parameters P1..P3 can also be recorded data-wise and / or electronically using sensors. For example, the dimensions of the target loading aid 2 could be recorded using a sensor. These dimensions then do not need to be stored in the database 6. It is also conceivable that the loading properties E1, E2 and / or loading parameters P1..P3 are determined by reading an identification mark, such as an RFID tag, a barcode, a two-dimensional code, such as a quick response code, or the like, which is arranged on the goods 3, the target loading aid 2, or the source loading aid 14.Loading parameters P1, P3 can also be formed by manipulated or setpoint variables for actuators, for example by a manipulated or setpoint variable for the actuator of the chute 4a or by a manipulated or setpoint variable for a drive roller of the target conveyor 11. It is also conceivable that some of the loading parameters P1..P3 are generated for the simulation, for example a loading sequence for the target loading aid 2.

[0089] The optional camera 9 is used to record the loading of the target loading device 2 with the goods 3 in step h1). Subsequently, a model for simulating the loading process can be adaptively adapted to a real loading process based on the recording of the loading by the camera 9. In particular, the loading properties E1, E2 and / or the loading parameters P1..P3 are adjusted according to the recording. This allows incorrect assumptions regarding the model for simulating the loading process, and in particular incorrect assumptions regarding the loading properties E1, E2 and / or the loading parameters P1..P3, to be corrected and adapted to reality. Over time, the simulation thus becomes increasingly closer to the real-life conditions.

[0090] It is generally also advantageous if the loading of the target loading device 2 is virtualized using virtual twins of the loading device 4, 4a, 4b, the target loading device 2 and / or the goods 3, and the loading properties E1, E2 and / or the loading parameters P1..P3 of the virtual loading device 4, 4a, 4b, the virtual target loading device 2 and / or the virtual goods 3 are adjusted according to the recording of the loading by the camera 9. Virtual twins are particularly well suited for implementing simulations, as well as for observing and evaluating them. A human or even artificial intelligence can help achieve an optimized result, i.e., optimized fulfillment of the target specification, in as few simulation runs as possible.

[0091] It is generally also advantageous if step e) is repeated with modified loading properties E1, E2. This allows for the fact that loading properties E1, E2 may not be precisely determinable under certain circumstances. Furthermore, the use of alternative loading devices 4, 4a, 4b or loading the target loading device 2 with different goods 3 in step e) can lead to different properties E1 of the loading device 4, 4a, 4b and different goods properties E2 of the goods 3.

[0092] It is generally also advantageous if in step b) additional tolerance ranges for the loading properties E1, E2, in particular for the goods properties, are provided in the simulation unit 7 and values for the loading properties E1, E2 are selected within the given tolerance ranges, in step d) the simulation is carried out for the selected values of the loading properties E1, E2, and in step e) values for the loading properties E1, E2 are changed within the tolerance ranges, and the target specification in step f) comprises a robustness of the loading process against variations in the loading properties E1, E2.

[0093] As mentioned above, loading characteristics E1 and E2 may not be precisely determinable under certain circumstances. It is advantageous to change loading characteristics E1 and E2 by varying them within tolerance ranges, especially randomly. This allows the aforementioned uncertainty to be taken into account when determining loading characteristics E1 and E2.

[0094] It is also generally advantageous if in step c) additional tolerance ranges for the loading parameters P1..P3 are provided in the simulation unit 7 and values for the loading parameters P1..P3 are selected within the given tolerance ranges, in step d) the simulation is carried out for the selected values of the loading parameters P1..P3, and in step e) values for the loading parameters P1..P3 are changed within the tolerance ranges, and the target specification in step f) includes a robustness of the loading process against variations in the loading parameters P1..P3.

[0095] Loading parameters P1..P3 may also not be precisely determinable under certain circumstances. For example, an actuator for adjusting chute 4a may be subject to tolerances, which also introduces uncertainty into the loading process. Loading parameters P1..P3 can also advantageously be changed by varying them within tolerance ranges, particularly randomly. This allows the aforementioned uncertainty to be taken into account when determining loading parameters P1..P3.

[0096] Fig. 5 shows the embodiment variant according to the invention, in which the presented method additionally comprises the step h2) transporting the goods 3 to the further loading device 4' of the loading station 1, 1a, 1b and loading the target loading aid 2 with the goods 3 by the operating element, wherein the assessment in step f) comprises checking whether at least one of the loading patterns meets the target specification, and steps g) and h1) are carried out if at least one of the loading patterns meets the target specification (see step S7a), or

[0097] Step h2) is carried out omitting step g) if none of the loading patterns meets the target specification (see step S7b).

[0098] This means that goods 3 for which no suitable loading pattern can be found during the simulation of the loading process can also be handled in the storage and order picking system 13a, 13b.

[0099] The operating element is an operator 16. However, an operating element can also be a humanoid robot or a robot with a gripper arm capable of independently selecting a storage position in the target loading device 2, for example, using an artificial intelligence algorithm. The additional loading device 4' is a manual loading device 4'.

[0100] In a further advantageous variant, an analysis set is defined which comprises any number of orders OD, wherein steps a) to g) are carried out for all orders OD of the analysis set, wherein the method between steps f) and g) comprises the following steps: i) Creating a first order set comprising all orders OD for which at least one loading pattern has been created that meets the target specification, ii) Creating a second order set comprising all orders OD for which no loading pattern has been created that meets the target specification.

[0101] In this way, a large number of orders OD can be simulated in advance, with the orders OD subsequently being divided into automatically processable orders OD (first order quantity) and non-automatically processable orders OD (second order quantity) and processed accordingly. The second order quantity is processed in particular by an operator (see also Fig. 5 ).

[0102] Fig. 6 shows a further embodiment in which step f) is carried out before step e), where the assessment in step f) comprises checking whether the loading pattern created meets the target specification, and after step f) step e) is carried out if the loading pattern determined does not meet the target specification, or after step f) step g) is carried out, omitting step e), if the loading pattern determined meets the target specification.

[0103] In this version, no further simulation runs are performed once a loading pattern meets the target specification. This version therefore leads to a result particularly quickly.

[0104] 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.

[0105] 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

[0106] 1, 1a, 1bLoading station 2Target loading aid 3Goods 4, 4a, 4b(automatic) loading device 4'(manual) loading device 5Order computer 6Database 7Simulation unit 8Computer system 9Camera 10, 10a, 10bSource extraction technology 11Target conveyor system 12Storage area 13a, 13bStorage and picking system 14Source loading aid (hanging pocket) 15, 15'Guide track 16Operator 17Input and / or output device ODOrder E1, E2Loading property P1..P3Loading parameters S1..S7Process step

Claims

1. A method for loading a target loading aid (2) with articles (3) at a loading station (1, 1a, 1b) with an automatic loading device (4, 4a, 4b) comprising the steps: a) acquiring (S1) an order (OD) and determining the articles (3) associated with the order (OD) using an order-processing computer (5), b) providing (S2) loading properties comprising properties (E1) of the loading device (4, 4a, 4b) and articles properties (E2) of the articles (3) in a database (6) for a simulation unit (7), c) specifying (S3) loading parameters comprising at least one parameter (P1) relating to the loading device (4, 4a, 4b) and / or at least one parameter (P2) relating to the articles (3) and / or at least one parameter (P3) relating to the target loading aid (2) in the simulation unit (7), d) simulating (S4) a loading operation of the target loading aid (2) with articles (3) using the simulation unit (7) based on the loading properties (E1, E2) and the loading parameters (P1..P3) and generating a loading pattern with the simulation unit (7), e) repeating steps b) to d) with modified loading parameters (P1..P3), f) analysing (S5) the loading patterns generated on the basis of a target specification using the simulation unit (7) including checking whether at least one of the loading patterns fulfils the target specification and executing the following steps g) and h1) if at least one of the loading patterns fulfils the target specification or executing the following step h2), omitting step g), if none of the loading patterns fulfils the target specification, g) selecting (S6) that loading pattern which best fulfils the target specification and generating the loading regulation for the loading device (4, 4a, 4b) comprising the loading parameters (P1..P3) which lead to the selected loading pattern using the simulation unit (7), and h1) transporting (S7) the articles (3) to the automatic loading device (4, 4a, 4b) of the loading station (1, 1a, 1b) and loading the target loading aid (2) with the articles (3) using the automatic loading device (4, 4a, 4b) according to the loading regulation, or h2) transporting the articles (3) to a manual loading device (4') of the loading station (1, 1a, 1b) and loading the target loading aid (2) with the articles (3) by an operator (16).

2. The method according to claim 1, characterized in that for loading the target loading aid (2), at least one article (3) of the articles (3) is transferred to the target loading aid (2) by falling, sliding and / or throwing.

3. The method according to claim 1 or 2, characterized in that the step f) is executed before the step e), wherein evaluating in step f) comprises checking whether the generated loading pattern fulfils the target specification, and after step f), step e) is executed if the determined loading pattern does not fulfil the target specification, or after step f), step g) is executed, omitting step e), if the determined loading pattern fulfils the target specification.

4. The method according to one of the preceding claims, characterized in that an analysis quantity is defined that comprises any number of orders (OD), wherein steps a) to g) are executed for all orders (OD) of the analysis quantity, wherein the method comprises the following steps between steps f) and g): i) generating a first order quantity, which comprises all orders (OD) for which at least one loading pattern has been generated that fulfils the target specification, and ii) generating a second order quantity, which comprises all orders (OD) for which at least one loading pattern has been generated that fulfils the target specification.

5. The method according to one of the preceding claims, characterized in that the at least one parameter (P1) relating to the loading device (4, 4a, 4b) is selected from a group comprising a construction of the loading device (4, 4a, 4b), a loading speed, a dumping angle of a source loading aid (14), a drop height of the article (3) into the target loading aid (2) and / or a loading position of the target loading aid (2), and / or the at least one parameter (P2) relating to the articles (3) is selected from a group comprising a selection of articles (3) of an order (OD), a loading sequence and / or a pose of the article (3) when the articles (3) are fed to the target loading aid (2), and / or the at least one parameter (P3) relating to the target loading aid (2) is selected from a group comprising a target loading aid orientation, target loading aid position, target loading aid shape and / or target loading aid dimensioning.

6. The method according to one of the preceding claims, characterized in that the target specification is selected from a group comprising a fill level of the target loading aid (2), a state of the articles (3) in the target loading aid (2) and / or a pose of the articles (3) in the target loading aid (2).

7. The method according to claim 6, characterized in that, to generate the loading pattern, the state of the articles (3) is calculated by the simulation unit (7), the article (3) having said state after reaching the resting state after simulated loading of the target loading aid (2) with the articles (3), the fill level of the target loading aid (2) is calculated by the simulation unit (7), and / or the pose of the articles (3) in the target loading aid (2) is calculated by the simulation unit (7), the articles (3) having said pose after reaching the resting state after the simulated loading of the target loading aid (2) with the articles (3).

8. The method according to one of the preceding claims, characterized in that the step e) is repeated with modified loading properties (E1, E2).

9. The method according to one of the preceding claims, characterized in that in step b), tolerance ranges for the loading properties (E1, E2) are additionally provided in the simulation unit (7) and values for the loading properties (E1, E2) are selected within the given tolerance ranges, in step d), the simulation is executed for the selected values of the loading properties (E1, E2), in step e), values for the loading properties (E1, E2) are modified within the tolerance ranges, and the target specification in step f) comprises a robustness of the loading process in relation to variations of the loading properties (E1, E2).

10. The method according to one of the preceding claims, characterized in that in step c), tolerance ranges for the loading parameters (P1..P3) are additionally provided in the simulation unit (7) and values for the loading parameters (P1..P3) are selected within the given tolerance ranges, in step d), the simulation is executed for the selected values of the loading parameters (P1..P3), in step e), values for the loading parameters (P1..P3) are modified within the tolerance ranges, and the target specification in step f) comprises a robustness of the loading process in relation to variations of the loading parameters (P1..P3).

11. The method according to one of the preceding claims, characterized in that loading the target loading aid (2) with the articles (3) in step h1) is detected by a camera (9) and a model for simulating loading in the simulation unit (7) is adaptively adjusted in accordance with the detection of the camera (9) to real loading.

12. The method according to claim 11, characterized in that the loading properties (E1, E2) and / or the loading parameters (P1..P3) are adjusted according to the detection.

13. The method according to claim 11 or 12, characterized in that loading the target loading aid (2) is virtualised using virtual twins of the loading device (4, 4a, 4b), the target loading aid (2) and / or the articles (3), and the loading properties (E1, E2) and / or the loading parameters (P1..P3) of the virtual loading device (4, 4a, 4b), the virtual target loading aid (2) and / or the virtual articles (3) are adjusted in accordance with the detection of loading by the camera (9).

14. A storage and picking system (13a..13b) comprising - a storage zone (12) for providing articles (3), - a loading station (1, 1a, 1b) with an automatic loading device (4, 4a, 4b) and a manual loading device (4'), - a source conveying system (10, 10a, 10b) for transporting the articles (3) that connects the storage zone (12) and the loading station (1, 1a, 1b), - an order-processing computer (5) for acquiring (S1) an order (OD) and determining the articles (3) associated with the order (OD), - at least one database (6), in which loading properties comprising properties (E1) of the loading device (4, 4a, 4b) and articles properties (E2) of the articles (3), can be provided, and - a simulation unit (7), which is data-technically connected to the at least one database (6) and which is configured for processing (S2) loading properties, comprising properties (E1) of the loading device (4, 4a, 4b) and articles properties (E2) of the articles (3), processing a loading parameter specification (S3) comprising at least one parameter (P1) relating to the loading device (4, 4a, 4b) and / or at least one parameter (P2) relating to the articles (3) and / or at least one parameter (P3) relating to the target loading aid (2), simulating (S4) a loading operation of the target loading aid (2) with articles (3) based on the loading properties (E1, E2) and the loading parameters (P1..P3), generating a loading pattern, repeating the aforementioned steps with modified loading parameters (P1..P3), analysing (S5) the loading patterns generated on the basis of the target specification including checking whether at least one of the loading patterns fulfils the target specification, and selecting (S6) that loading pattern which best fulfils the target specification and generating the loading regulation for the loading device (4, 4a, 4b) comprising the loading parameters (P1..P3) that lead to the selected loading pattern if at least one of the loading patterns fulfils the target specification, wherein the source conveying system (10, 10a, 10b) is configured to transport (S7) the articles (3) to the automatic loading device (4, 4a, 4b) if at least one of the loading patterns fulfils the target specification and to transport (S7) the articles (3) to the manual loading device (4') if none of the loading patterns fulfils the target specification, and wherein the loading station (1, 1a, 1b) is configured to load the target loading aid (2) with the articles (3) by the automatic loading device (4, 4a, 4b) according to the loading regulation if at least one of the loading patterns fulfils the target specification and to load the target loading aid (2) with the articles (3) by the operator (16) at the manual loading device (4') if none of the loading patterns fulfils the target specification.

15. The storage and picking system (13a, 13b) according to claim 14, characterized in that the storage zone (12) has a plurality of stationary storage racks and at least one automatically operated storage and retrieval device for storing the articles (3) in the storage racks and / or retrieving the articles (3) from the storage racks.

16. The storage and picking system (13a, 13b) according to claim 14 or 15, characterized in that the source conveying system (10, 10a, 10b) and / or a target conveying system (11) is configured as a stationary or mobile conveying system.

17. The storage and picking system (13a, 13b) according to one of claims 14 to 16, characterised in that the source conveying system (10, 10a, 10b) is configured for horizontal (lying) or suspended transport of articles (3) or source loading aids (14) with articles (3), and / or the target conveying system (11) is configured for horizontal (lying) or suspended transport of the articles (3) or target loading aids (2) with articles (3).