SYSTEM AND METHOD FOR PROCESSING A NUMBER OF PICKING ORDERS WITH MULTIPLE ITEMS

Description

[0001] The invention relates to a system and a method for processing a large number of picking orders with multiple items according to claim 1.

[0002] EP 2 789 555 A1 discloses a device for order-oriented provision of individual goods for multiple orders from a warehouse, comprising at least one intermediate storage unit connected to a warehouse for temporarily storing individual goods of at least one order, a collection area connected to each intermediate storage unit for collecting the individual goods of the at least one completed order, and a separation area with several dispensing lines for order-oriented provision of the individual goods of the at least one completed order. Thus, items are permanently assigned to orders, and the device is then controlled based on these assignments.

[0003] DE 10 2011 104 511 B3 discloses a system and method for processing a large number of picking orders, each with several items, with a replenishment warehouse for items, with a buffer storage comprising a large number of parallel storage units for the overhead conveyors, and with a central control system configured to assign a large number of picking orders to each storage unit, to create a master list of all items and their quantity per storage unit from these orders, and to supply the items contained therein to the respective storage unit based on the master list, wherein the overhead conveyors are fed into the respective storage unit, wherein the control system is configured to regularly check each storage unit to see whether a) all items to fulfill an original order are contained and whether b) all items to fulfill a preferential other order are already contained in the storage unit.In contrast, the object of the present invention is to provide a more flexible alternative for processing picking orders.

[0004] This problem is solved by the system or method described in claim 1 and claim 8. Advantageous embodiments are described in the dependent claims and the description.

[0005] According to the invention, it has been recognized that with a system according to claim 1 or the method according to claim 8, a more flexible alternative for processing picking orders and therefore faster processing is possible, since it allows preferential treatment of orders of higher priority.

[0006] This is particularly the case because a central control system is in place to assign a large number of picking orders to each circulation storage unit, to create a complete list of all items and their quantities per circulation storage unit from these orders, and to supply the items contained therein to the respective circulation storage unit based on this complete list, with the hanging bags being fed into the respective circulation storage unit via a diverter valve. This central control system is also set up to regularly check each circulation storage unit to ensure that a) all items necessary to fulfill an original order are present, and then activates the diverter valve at the exit using the item identification device located there to divert the items of the order.and whether b) all items for fulfilling a different, preferable order are already contained in the circulation storage and the switch at the output is then controlled using the item identification device there to divert the items of this other order, and whether c) all items for fulfilling a different, preferable order are already distributed across two or more circulation storages and the switch at the output of the respective circulation storages is then controlled using the item identification devices there to divert the items of this other order.

[0007] Unlike current technology, the buffer storage is not filled solely according to fixed orders, but rather according to more flexible overall lists. The items already present in the buffer's circulation storage are variably reassigned to specific orders as needed and reallocated to more urgent, alternative orders. This flexible allocation allows for more flexible processing of picking orders.

[0008] Suitable hanging transport devices include, for example, hanging bags or clothes hangers and the like. Preferably, the items are transported individually in or on them.

[0009] The overall system includes at least one supply warehouse connected to at least one transshipment station for transshipment for suspended transport.

[0010] The connection is preferably made via a conveyor system adapted to the type of storage of the items in the replenishment warehouse. This could be, for example, a roller conveyor or belt conveyor. The replenishment warehouse will usually be a container storage system or a tray storage system.

[0011] The transfer station is in turn connected to the buffer storage. A continuous overhead conveyor is preferably used here, from which the parallel circulating storage units branch off or are connected via switches. The overhead conveyor is preferably a chain-driven conveyor that moves conveyor bags or clothes hangers directly via carriers / adapters, as described, for example, in EP 2 886 494 A1 and EP 3 480 142 A1.

[0012] Hanging bags (often also called transport bags) are preferably those described in EP 3 442 884 A1. Alternatively, those known, for example, from EP 2 130 968 B1 are also suitable.

[0013] Generally, hanging bags consist of two bag walls connected at one end by a bracket. This bracket has a hook for attaching the bag to a conveyor rail or to an adapter that runs in a rail. The bag walls can be permanently connected at the bottom, for example, by forming a loop. The sides of the bags can also be closed. Usually, only one item is transported per hanging bag.

[0014] The transfer station for handling items for suspended transport is a manual and / or automated or fully automatic induction station in which the items from the replenishment warehouse are preferably transferred individually into hanging bags that are already hooked into the overhead conveyor, or in which the items from the replenishment warehouse are hooked in using clothes hangers. This is known, for example, from EP 3 442 884 A1 and Dürkopp EP 2 196 415 A1.

[0015] Preferably, each transfer station is connected to one aisle of the replenishment warehouse. However, it is also possible to connect two aisles to each transfer station if the throughput of the transfer stations is higher, for example through increased automation or dual operation by two order pickers.

[0016] The central control system is configured to assign a multitude of picking orders to each circulation storage unit and to generate a complete list of all items and their quantities for each unit from these orders. Based on this complete list, the items are then fed into the respective circulation storage unit, with hanging bags being routed into the appropriate unit via a diverter. Preferably, the central control system is a warehouse management system (WMS) that maps all necessary processes, such as warehouse structure, master data management, inventory management, transport management, internal warehouse processes (relocation, replenishment, stock transfer, control center), goods receipt (notification, acceptance, deconsolidation, quality inspection, putaway), goods issue (order management, picking, consolidation, packing, shipping), etc.

[0017] Preferably, the central control system is also set up to remove items from fulfilled or dispatched orders from the overall list of the respective circulation storage.

[0018] Preferably, the central control system is also set up to prioritize orders that have a higher or increased priority and / or where the other order to be prioritized is not included in the original overall list.

[0019] It is advisable, when central control is set up, to regularly check the circulation buffer when introducing items, i.e., to perform a check against the above criteria a, b and c with each introduction operation.

[0020] The replenishment warehouse is a "fast" system designed to retrieve or replace requested items within 5-15 minutes. This is typically achieved using automated small parts warehouses (AS / RS) for containers with stacker cranes. Specifically, these systems utilize single-level stacker cranes, such as shuttles, where a single-level stacker crane operates in virtually every aisle and level for storage and retrieval.

[0021] From EP 1 964 792 B1, for example, a storage system for providing transport units from a warehouse in a desired sequence on at least one collection line is known. In this system, storage and retrieval machines in each storage aisle, retrieval lift, and retrieval conveyor are coordinated and loaded with goods in such a way that they ultimately end up sorted on or are discharged from the collection line, which is suitable as a replenishment warehouse.

[0022] Preferably, the replenishment warehouse is such a warehouse with single-level storage and retrieval machines as storage and retrieval machines that run in the aisles between the racks, wherein the racks are double- or multi-deep racks that stand back-to-back, which shall be referred to overall as a shuttle warehouse.

[0023] It is particularly advantageous if the single-level storage and retrieval machines operate in every aisle and on every level. Furthermore, it is beneficial if the vertical transfer lifts for storing and retrieving items are decoupled from adjacent conveyors, as described in EP 2 794 430 A1.

[0024] If necessary, container exchange in the transverse direction (across the aisles) can take place using conventional conveying technology (transverse conveyor or conveyor loop) in the pre-zone and / or via a transverse transport, as described, for example, in EP 2 741 977 A1 or EP 3 606 846 A1.

[0025] By using the shuttle warehouse as a replenishment warehouse, the transfer stations can be fully utilized. This, combined with the elimination of sequencing, achieves the desired short retrieval times of a maximum of 15-20 minutes for all items of an order in the buffer or recirculating storage. Only in the buffer or recirculating storage are the items of an order then consolidated. This time is determined by the dynamics of the shuttle warehouse to which the transfer stations are connected. To continuously supply the transfer stations with storage containers, a certain "workload" of active orders is required. Experience has shown that this is 15-20 minutes for a shuttle warehouse.

[0026] The replenishment warehouse can be supplied with containers containing only one item as well as with mixed containers containing different items.

[0027] It is particularly advantageous if the replenishment warehouse itself is supplied with mixed containers from a (further) central warehouse. It is especially beneficial if mixed containers containing items from different orders are provided to supply the replenishment warehouse. These containers are supplied from the central warehouse, where a picker manually fills containers with mixed items from multiple orders, either single-item orders or orders that are scheduled for processing within approximately 15-minute slots. Several pickers move through the central warehouse in parallel, each filling mixed containers (mini-batches) in their respective zone. Each mini-batch is assigned to a slot or time period within a planned processing time (approximately one hour in the future).

[0028] These mixed containers are then fed into the replenishment warehouse, especially the shuttle warehouse, for buffering / intermediate storage or consolidation and supply of the transfer station.

[0029] The replenishment warehouse is therefore supplied with mixed mini-batches. A mini-batch consists of one or more load carriers assigned to a common retrieval time slot from the replenishment warehouse. The items contained in one or more load carriers are for different orders. It is preferred that the number of items contained within each mini-batch is chosen to match the speed of an automated replenishment warehouse (e.g., a shuttle warehouse) and allow for even faster item provision. Unlike containers containing only one item, these mixed containers are always completely emptied or transferred at the transfer stations and then circulated either back to the central warehouse and / or to the receiving area for reuse.

[0030] Containers for the replenishment warehouse, containing only one item each, are provided in parallel from a receiving area. These containers are transported back to the replenishment warehouse at the transfer stations, if not emptied, after the required number of items have been transferred, and then restocked.

[0031] It is also conceivable that, depending on the size of the overall system, there could be several

[0032] Supply depots and several transfer station areas are provided, which are connected to each other via additional sorters, such as pocket sorters, in order to supply the appropriately designed buffer storage.

[0033] Preferably, but if possible, all items of an order should be sourced from the same supply warehouse.

[0034] The article identification device(s) preferably consist of sensors that read barcodes, RFID tags, etc., or image recognition using a camera to identify the articles or overhead conveyors and thus indirectly the articles themselves. Alternatively, the position of an article can be tracked via a designated window in the conveyor system during entry at the transfer station.

[0035] If the article identification device is also located at the entrance, articles can be identified and the switch can be easily controlled to feed the articles from the complete list into the respective circulation storage.

[0036] Preferably, a switch with an article identification device is provided at the entrance and at the exit of each circulating storage unit, which are connected to the central control system.

[0037] Depending on the overall system requirements, the buffer storage system is designed with multiple circulating storage tanks. The number of circulating storage tanks typically ranges from 4 to 20. The circulating storage tanks themselves preferably have a capacity of 50 to 400 suspended pockets.

[0038] The circulating storage units each have a separate drive and are controlled independently of each other and the supplying or discharge overhead conveyor lines.

[0039] Downstream of the discharge point, packing stations can be located to complete orders for shipment. These can be arranged on a central overhead conveyor discharge line or accessed via separate conveyor stages.

[0040] To fulfill the remaining (original) order, missing items are added back to the master list and delivered from the replenishment warehouse. Due to its design, this is possible within a short time (max. 15 minutes).

[0041] Further details of the invention will become apparent from the following description of exemplary embodiments with reference to the drawing, in which Fig. 1 shows a schematic view of the system for processing a large number of picking orders according to the invention; Fig. 2 shows a more detailed view of the storage area from a circulation storage system; and Fig. 3 shows a flow diagram of the material flow in the system according to the invention.

[0042] The figures show a system, labelled 1, for processing a large number of picking orders with multiple items.

[0043] The system generally comprises a storage area A with an automatic container replenishment warehouse 2 and a manual central warehouse 7, an adjoining transfer area B with a plurality of transfer stations 3 for transferring items from the containers for hanging transport into overhead conveyor pockets, a storage area C supplied by this system with a buffer storage 4 with circulating storage units 8 for the overhead conveyor pockets, and an adjoining packing area 5 with a plurality of packing stations and a shipping area 6.

[0044] Manual central storage 7 is used to supply replenishment warehouse 2 with mixed containers. It consists of shelving units separated by aisles through which several order pickers 20 walk, picking items from the shelves onto trolleys and placing them into containers on the trolleys. The order pickers are guided by systems such as pick-to-voice or pick-to-light, or manual order lists, etc.

[0045] In warehouse 7, 20 order pickers manually fill containers with a mix of different items from multiple orders by moving through their respective zones (I, II, III) and working through the assigned item lists. The assigned items come either from individual item orders or from orders that are scheduled for processing in circulation storage area 8 within approximately 15-minute slots. To do this, the 20 order pickers move in parallel through the central warehouse 7, filling containers within their zones (I, II, III) with items from different orders. Each container is assigned to a slot or time period within a planned processing time (approximately one hour in the future). The resulting mixed containers are grouped across all zones and order pickers according to the 15-minute time periods to complete orders to be delivered within that timeframe.

[0046] The containers are carried by the order pickers on a trolley, which is then unloaded after the run is completed, with the containers being fed into the replenishment warehouse 2 via a suitable station and conveyor technology.

[0047] Unlike containers containing only one item, these mixed containers are always completely emptied or transferred at the transfer stations and are then circulated either back to the central warehouse and / or to the goods receiving area for reuse.

[0048] The replenishment warehouse 2 is supplied with single-item containers from a receiving area 14 and with mixed containers from the central warehouse 7. It itself supplies a number of transfer stations 3 with containers for transferring the items from these containers into overhead conveyor pockets for suspended transport. For this purpose, each transfer station 3 is connected to an aisle of the replenishment warehouse via infeed and outfeed conveyors 15.

[0049] The replenishment warehouse 2 is a multi-aisle, multi-level rack storage system operated by single-level storage and retrieval machines, so-called shuttles 17, which supply and remove containers from the storage locations in the racks 18 via aisles 19. The containers can then be transported to and from the transfer stations 3 via lifts 21 and connected conveyors 15. Each aisle is connected to a transfer station 3.

[0050] The buffer storage 4, which is connected to the transfer stations 3 via an overhead conveyor loop 13, comprises a multitude of parallel circulating storage units 8 for the overhead transport devices.

[0051] The transfer stations 3 are manual or automatic stations where items are individually transferred from the containers into overhead conveyor bags. For this purpose, the suspended conveyor bags are provided open, allowing items to be placed inside manually or automatically.

[0052] The transfer stations 3 supply the buffer storage 4 with individually filled overhead conveyor bags via the overhead conveyor loop 13. There, the bags are stored in parallel circulation storage units 8 until all items for the respective order are complete. They are then transported via a collection line 24 to a packing area 5, where they are repacked into shipping containers according to the order. From there, the orders and shipping containers ultimately reach a shipping area 6. It is understood that there is an empty bag return from the shipping area, which is not shown. When the filled overhead conveyor bags are loaded into the overhead conveyor loop 13 at the transfer stations 3, they are tracked via assigned windows.

[0053] From the overhead conveyor loop 13 in the buffer storage 4, the overhead conveyor pockets are fed into the respective circulating storage units 8 via switches 11. Each circulating storage unit 8 consists of an infeed conveyor 25, which is connected to the incoming switch 11a and via which new overhead conveyor pockets are stored when the assigned window is reached. A stopper 28 is provided in the infeed conveyor 25 so that the overhead conveyor pockets can be buffered in a targeted manner onto an available space in the subsequent rotating circulating conveyor 26. Accordingly, another controlled switch 11b is provided at the interface between the infeed conveyor 25 and the circulating conveyor 26. Analogous to the infeed conveyor 25, an outfeed conveyor 27 is provided at the outlet of the circulating conveyor 26 to remove required overhead conveyor pockets from the circulating storage unit 8.Accordingly, an article identification device 12 and a further controlled diverter 11c are provided at the interface between the discharge conveyor 27 and the circulation conveyor 26 to selectively divert the desired hanging conveyor bag onto the discharge conveyor 27. The discharge conveyor 27 has two sections 29 and 30 separated by stoppers 28 before it flows into the collection section 24 via a further diverter 11d. The first section 29 is a reserve section to ensure continuous movement of the hanging conveyor bags. The second section 30 is a collection section for grouping hanging conveyor bags.

[0054] Preferably, the infeed conveyor 25 and the outfeed conveyor 27 are located on opposite sides of the recirculating conveyor 26. In a recirculating storage unit 8, there is selective access to each individual overhead conveyor pocket (no FIFO).

[0055] Individual orders 22, i.e., orders comprising only a single item, can be handled separately to avoid slowing down the overall system. This is indicated by dashed arrows. Such individual orders can be transported directly from warehouse 7 to transfer stations 3. Alternatively, they can be transported directly to packing area 5 or to a dedicated transfer station 3*, which supplies a bypass 23 leading directly into collection line 24, bypassing buffer 4. At transfer station 3*, or at its switch 11, individual orders originating from the regular transfer stations 3 in conveyor loop 13 can also be specifically diverted into bypass 23.

[0056] The entire system 1 and its areas, as well as all the systems and facilities located therein, are controlled by a central control unit 16.

[0057] The control system 16 is set up to assign a large number of picking orders to each circulation storage unit 8 and to create a complete list of all items and their quantity per circulation storage unit 8 from these orders and to supply the items contained therein to the respective circulation storage unit 8 based on the complete list, whereby the overhead conveyor bags are fed into the respective circulation storage unit 8 via the respective switch 11.

[0058] Based on incoming orders, the control unit 16 distributes the orders, and thus the items, to specific circulation storage units 8. From this distribution, master lists are generated, which control the provision of items from the replenishment warehouse 2 to the transfer stations 3 and finally the feeding of the items into the circulation storage units 8 according to the master list. This also involves supplying the replenishment warehouse 2 with mixed containers from the central warehouse 7 and single-item containers via the goods receiving area 14.

[0059] The control system 16 is set up to regularly check each circulation storage unit 8 after the introduction of a new item using the item identification device 12 at the outlet of the circulation conveyor 26 to see if all items required to fulfill an original order are included in the complete list and then to control the switch 11c using the item identification device 12 located there to remove the items of the order, which then then goes onto the discharge conveyor 27 and later onto the collection line 24 for feeding to the packing area 5.

[0060] The control system 16 is also set up to regularly check each circulation storage unit 8 after the introduction of a new item using the item identification device 12 at the outlet of the circulation conveyor 26 to see if all items required to fulfill a different, preferred order are already contained in the respective circulation storage unit 8, and then to control the switch 11c using the item identification device 12 located there to remove the items of this other order, which then then goes onto the discharge conveyor 27 and later onto the collection line 24 for feeding to the packing area 5.

[0061] The system also checks whether all items required to fulfill a higher-priority order are already distributed across two or more circulation storage units 8. If so, the switches 11c of the respective circulation storage units 8 are controlled using the item identification devices 12 located therein to divert the items of this other order onto the collection line 24 for feeding into the packing area 5. The items then originate from more than one circulation storage unit 8.

[0062] This approach allows new, urgent express orders with higher priority to be prioritized and processed sooner. Missing items for the original order are then added back to the overall list and delivered within 15 minutes. (Based on the flowchart of the...) Figure 3 This procedure will be explained again in general terms.

[0063] First, a large number of orders are entered into the system, which originate, for example, from an e-commerce ordering system (Step I).

[0064] These orders are distributed to the circulation storage units 8 (step II) and from this a complete list of the items for each circulation storage unit 8 is generated based on the large number of items contained in the orders (step III).

[0065] This list is used to control the rest of the system in order to supply the articles to the respective circulation storage unit 8 in a timely manner (step IV).

[0066] Each circulation storage unit 8 requests, as it were, the items from the complete list, which are provided by the control unit 16, starting with the supply of the replenishment warehouse 2 from the goods receiving area 14 or central warehouse 7, the removal of the corresponding containers and transfer in the transfer stations 3 and conveyance to the entrance 9 of the respective circulation storage units 8 (step V).

[0067] After the insertion of a hanging conveyor bag via the switch 11a at the entrance and the insertion conveyor 25 and the switch 11b, the control 16 regularly checks in the respective circulating conveyor 26 of the circulating storage 8 with the help of the article identification device 12 at the switch 11c whether all articles are available to fulfill an order (step VI or VIC).

[0068] If this is not the case, further articles will be awaited.

[0069] However, once all items or hanging conveyor bags are available to fulfill an order, they are diverted via switch 11c onto the discharge conveyor and via switch 11d onto the collection section 24 (step VII) to be conveyed to packing area 5 (step VIII). If necessary, stoppers 28 are used at sections 29 and 30.

[0070] It is understood that, within the scope of the invention, a "completed" order in this sense can also be a new order with a higher priority, which is therefore preferable. This is also checked in step VI or substep VIA. Likewise, it is checked whether a new order with a higher priority can be fulfilled if other circulating memory contents are taken into account (step VIB). Reference symbol list

[0071] 1 System 2 Replenishment warehouse 3 Transfer station 4 Buffer storage 5 Packing area 6 Shipping area 7 Central warehouse 8 Circulating storage 9 Input 10 Output 11 Diverter 12 Item identification device 13 Overhead conveyor loop 14 Goods receiving area 15 Inbound and outbound conveyor 16 Control 17 Shuttle 18 Rack 19 Aisle 20 Order picker 21 Lift 22 Single item / Single order 23 Bypass 24 Collection line 25 Infeed conveyor 26 Circulating conveyor 27 Outfeed conveyor 28 Stopper 29 First area 30 Second area A Storage area B Loading area C Storage area I, II, III Zone

Claims

1. System (1) for processing a multiplicity of picking orders each with a plurality of articles having a replenishing storage (2) for articles, having at least one reloading station (3) connected to the replenishing storage for reloading of articles for hanging transportation, having a buffer storage (4) connected to the at least one reloading station (3) and comprising a multiplicity of parallel circulating storages (8) for the hanging transport means, wherein at the intake (9) and at the output (10) of each circulating storage (8) a respective switch (11) is disposed and at the output a respective article identification device (12) is disposed, and having a central controller (16) arranged to allocate a multiplicity of orders to be picked to each circulating storage (8) and to draw up from these orders an overall list of all articles and the quantity thereof per circulating storage (8) and to supply the articles present therein to the respective circulating storage (8) with the aid of the overall list, wherein the hanging transport means are introduced via a switch (11) into the respective circulating storage (8), wherein the controller (16) is arranged to regularly check each circulating storage (8) to determine whether a) all articles for the fulfilment of an original order are present, and thereupon actuates the switch (11) at the output (10) with the aid of the article identification device (12) located there in order to discharge the articles of the order, and b) all articles for the fulfilment of another order to be treated preferentially are already present in the circulating storage, and thereupon actuates the switch (11) at the output (10) with the aid of the article identification device (12) located there to discharge the articles of this other order and c) all articles for the fulfilment of another order to be treated preferentially are already present, distributed into two or more circulating storages (8), and thereupon actuates the switches (11) at the output (10) of the respective circulating storage (8) with the aid of the article identification devices (12) located there to discharge the articles of this other order.

2. System as claimed in claim 1, characterised in that the central controller (16) is arranged to delete articles of fulfilled or discharged orders from the overall list of the respective circulating storage (8).

3. System as claimed in claim 1 or 2, characterised in that the central controller (16) is arranged to preferentially treat orders during processing which have a higher or raised priority.

4. System as claimed in any one of the preceding claims, characterised in that the other order to be treated preferentially is not present on the original overall list.

5. System as claimed in any one of the preceding claims, characterised in that the central controller (16) is arranged to regularly check the circulating storage (8) during the introduction of articles.

6. System as claimed in any one of the preceding claims, characterised in that the replenishing storage (2) is a shuttle storage.

7. System as claimed in any one of the preceding claims, characterised in that the replenishing storage (2) is supplied with mini-batches.

8. Method for processing a multiplicity of picking orders with a plurality of articles, wherein, from a replenishing storage (2) for articles, at least one reloading station (3) connected to the replenishing storage (2) is supplied for the reloading of articles for hanging transportation and the hanging transport means are intermediately stored with a buffer storage (4) connected to the at least one reloading station (3) and having a multiplicity of parallel circulating storages (8), wherein a central controller is connected by means of a respective switch (11) at the intake and at the output of each circulating storage (8), which central controller (16) allocates to each circulating storage (8) a multiplicity of orders to be picked and draws up an overall list of all articles and the quantity thereof per circulating storage (8) from these orders and which actuates the switch (11) at the intake (9) for introduction of the allocated articles of the overall list into the respective circulating storage (8), and the controller (16) regularly checks each circulating storage to determine whether a) all articles for the fulfilment of an original order are present, and thereupon actuates the switch (11) at the output (10) with the aid of the article identification device (12) located there in order to discharge the articles of the order, and b) all articles for the fulfilment of another order to be treated preferentially are already present in the circulating storage (8), and thereupon actuates the switch (11) at the output (10) with the aid of the article identification device (12) located there to discharge the articles of this other order and c) all articles for the fulfilment of another order to be treated preferentially are already present, distributed into two or more circulating storages (8), and thereupon actuates the switches (11) at the output of the respective circulating storage (8) with the aid of the article identification devices (12) located there to discharge the articles of this other order.