Containment System

Abstract

To provide an automatic warehouse system capable of being flexibly constituted, as an objective according to the present disclosure.SOLUTION: An automatic warehouse system 100 according to one embodiment comprises: a first loading part 34 and a second loading part 36 that are capable of loading a loading pallet 12 where a cargo is loaded; a picking device 32 for preparing another loading pallet by taking out the cargo from the loading pallet 12 loaded on the first loading part 34 to move the cargo to a second loading part 36; and a carrying vehicle 18 for transferring the loading pallet 12 to the first loading part 34 by moving a lower portion of the picking device 32, that is movable while autonomously changing a moving direction.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an automated warehouse system. [Background technology]

[0002] Patent Document 1 describes a picking device that picks out items stacked on a pallet layer by layer. This picking device has a gripping device that grips items on a single-item pallet positioned at a load-removal position, layer by layer, and transfers them to each of a plurality of shipping pallets positioned at a loading position, and a load-transfer device that enables the gripping device to be raised and lowered relative to the shipping pallets. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2002-187618 A Summary of the Invention [Problem to be solved by the invention]

[0004] In an automated warehouse system, there is a process for creating a mixed pallet with multiple types of goods mixed together according to the destination's request from a single pallet that has multiple loads of the same type of goods. This process includes dividing the goods on the single pallet into predetermined units (hereinafter referred to as "cases"), storing the divided cases, and creating a mixed pallet by collecting the divided and stored cases according to the destination's request (hereinafter referred to as "picking").

[0005] The picking device described in Patent Document 1 requires large-scale equipment and it is difficult to implement a flexible configuration.

[0006] The present invention has been made in view of the above problems, and has as its object to provide an automated warehouse system that can be flexibly configured. [Means for solving the problem]

[0007] In order to solve the above problems, an automated warehouse system according to one embodiment of the present invention comprises a first loading section and a second loading section on which a loaded pallet can be placed, a picking device that removes cargo from the loaded pallet placed on the first loading section and moves it to the second loading section to create another loaded pallet, and a transport vehicle that is capable of autonomously changing its direction of movement and moves underneath the picking device to transport the loaded pallet to the first loading section.

[0008] Any combination of the above components, or mutual substitution of the components or expressions of the present invention between methods, systems, etc. are also valid aspects of the present invention. Effect of the Invention

[0009] According to the present invention, a flexibly configurable automated warehouse system can be provided. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a plan view illustrating an example of an automated warehouse according to an embodiment. [Diagram 2] FIG. 1 is a perspective view showing an example of an assembly in which a plurality of loads are stacked. [Diagram 3] FIG. 2 is a front view showing an example of the transport vehicle shown in FIG. [Figure 4] FIG. 4 is a side view showing the transport vehicle of FIG. 3. [Diagram 5] FIG. 2 is a plan view showing the picking device of FIG. [Figure 6] FIG. 6 is a side view showing the picking device of FIG. 5. [Figure 7] 6 is a bottom view showing the pick-up unit of the picking device of FIG. 5. FIG. [Figure 8] FIG. 2 is a front view showing a schematic example of the first carriage of FIG. 1. [Figure 9] FIG. 2 is a front view showing a schematic example of the second carriage of FIG. 1; [Figure 10]1. FIG. 4 is an explanatory diagram illustrating an example of a first operation of the automated warehouse in FIG. [Figure 11] 1. FIG. 4 is an explanatory diagram illustrating an example of a third operation of the automated warehouse in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] The present invention will be described below based on preferred embodiments with reference to the drawings. In the embodiments and modified examples, the same or equivalent components and members are given the same reference numerals, and duplicated descriptions are omitted as appropriate. The dimensions of the members in each drawing are enlarged or reduced as appropriate for ease of understanding. Some of the members that are not important for explaining the embodiments are omitted in each drawing.

[0012] In addition, terms including ordinal numbers such as first, second, etc. are used to describe various components, but these terms are used only for the purpose of distinguishing one component from another component, and the components are not limited by these terms.

[0013] [Embodiment] The overall configuration of the automated warehouse system 100 according to the embodiment will be described with reference to FIG. 1. FIG. 1 is a plan view showing an example of the automated warehouse system 100 according to the embodiment. For convenience of explanation, as shown in the figure, an XYZ orthogonal coordinate system is defined in which a horizontal direction is the X-axis direction, a horizontal direction perpendicular to the X-axis direction is the Y-axis direction, and a direction perpendicular to both directions, i.e., the vertical direction, is the Z-axis direction. The positive directions of the X-axis, Y-axis, and Z-axis are defined in the directions of the arrows in each figure, and the negative directions are defined in the directions opposite to the arrows. Note that the X-axis direction is sometimes called the "row direction", the Y-axis direction is sometimes called the "column direction", and the Z-axis direction is sometimes called the "up-down direction". Such directional notations do not limit the configuration of the automated warehouse system 100, and the automated warehouse system 100 can be used in any configuration depending on the application.

[0014] As shown in FIG. 1, the automated warehouse system 100 includes a storage shelf 22, a picking area 30, an outgoing area 38, and a control unit 50. A first cart 14 and a second cart 16 are arranged on the storage shelf 22. A transport vehicle 18, a picking device 32, a first placement unit 34, and a second placement unit 36 ​​are provided on the picking area 30. An outgoing unit 40 is provided on the outgoing area 38. In the example of FIG. 1, from the viewpoint of facilitating the travel of the transport vehicle 18, the outgoing unit 23, the first placement unit 34, the second placement unit 36, and the outgoing unit 40 of the storage shelf 22, which will be described later, are arranged on the same floor Fr.

[0015] The storage shelf 22 can store a plurality of loads 10. The first placement section 34 and the second placement section 36 can each place a loading pallet carrying a plurality of loads 10. The picking device 32 removes the loads 10 from the loading pallet 12 placed on the first placement section 34 and moves it to the second placement section 36 to create another loading pallet 12. The transport vehicle 18 can move while autonomously changing its moving direction, and moves under the picking device 32 to transfer the loading pallet 12 to the first placement section 34. The loads 10 and the loading pallet 12 will be described later.

[0016] The control unit 50 includes an MPU (Micro Processing Unit) and the like. The control unit 50 controls the operation of the picking device 32 to pick the load 10. The control unit 50 also controls the operation of the first cart 14, the second cart 16, and the transport vehicle 18 to transport the load pallet 12 based on the result of an operation by the user.

[0017] FIG. 2 is a perspective view showing an assembly in which a plurality of loads are stacked. In this specification, one or more items housed in a case such as a cardboard box are referred to as loads 10. An empty pallet is simply referred to as a "pallet 12j". A single or multiple loads 10 placed on one pallet 12j are referred to as a "loaded pallet 12". The loaded pallet 12 refers to a combination of the pallet 12j and the loads 10 on the pallet 12j. The loaded pallet 12 may be composed of multiple stacked layers, and each layer may include multiple loads 10. In the example of FIG. 2, the loaded pallet 12 includes eight loads 10 in each of three layers. The loaded pallet 12 may be the smallest unit to be entered, stored, and removed from the automated warehouse system 100. The loads 10 may be the smallest unit to be handled when picking.

[0018] The transport vehicle 18 will be described with reference to Figs. 3 and 4. Fig. 3 is a front view showing an example of the transport vehicle 18 in a schematic manner. Fig. 4 is a side view of the transport vehicle 18. The transport vehicle 18 is a transport means for transporting a load based on a command from a control unit 50. The transport vehicle 18 functions as an automated guided vehicle (AGV) capable of autonomous travel to reach a destination position by controlling the rotation and steering angle of the wheels based on a destination position and the vehicle's own position. The travel route of the transport vehicle 18 may include a preset travel route and an autonomously determined travel route.

[0019] The transport vehicle 18 includes a platform 18c on which the loaded pallet 12 (hereinafter including an empty pallet 12j) is placed, and a lift mechanism 18d for raising and lowering the platform 18c. The transport vehicle 18 drives a plurality of wheels 18f by a motor (not shown) and travels with the loaded pallet 12 mounted. The transport vehicle 18 raises and lowers the loaded pallet 12 on the platform 18c by the lift mechanism 18d. In Figures 3 and 4, the platform 18c in the raised state is indicated by a dashed line, and the platform 18c in the lowered state is indicated by a solid line.

[0020] The transport vehicle 18 lifts and holds the loaded pallet 12 at the source. The transport vehicle 18 autonomously travels along a route from the source to the destination to transport the loaded pallet 12. The transport vehicle 18 unloads the loaded pallet 12 at the destination. The source and destination include, but are not limited to, the storage shelf 22, the first placement section 34, the second placement section 36, the outgoing section 40, etc.

[0021] Various known guidance methods can be used for the autonomous travel of the transport vehicle 18. The transport vehicle 18 of this embodiment is guided based on a weak induced current from an induction wire 18g embedded in the floor. The transport vehicle 18 is equipped with a safety device using sensors such as a proximity sensor and an ultrasonic distance meter to prevent collisions.

[0022] The picking device 32, the first placement section 34, and the second placement section 36 will be described with reference to Figs. 1, 5, and 6. Fig. 5 is a plan view showing the picking device 32. Fig. 6 is a side view showing the picking device 32. In these figures, the illustration of some pillars, beams, etc. is omitted. The picking device 32 is provided in a picking area 30 for picking. In this embodiment, the picking area 30 is provided in the vicinity of the storage shelf 22. The picking area 30 is arranged on the same floor as the discharge section 23 of the storage shelf 22, which will be described later.

[0023] The first placement section 34 and the second placement section 36 are provided in the picking area 30 and are arranged so as to overlap with the picking device 32 in a plan view. The first placement section 34 mainly places a loading pallet 12 (hereinafter referred to as a "single-loading pallet 12S") carrying a plurality of loads of the same type. The second placement section 36 mainly places a loading pallet 12 (hereinafter referred to as a "mixed-loading pallet 12M") carrying a plurality of loads. The picking device 32 takes out the loads 10 from the single-loading pallet 12S before picking and transfers them to the mixed-loading pallet 12M to create the mixed-loading pallet 12M after picking. There is no limitation on the arrangement of the first placement section 34 and the second placement section 36, but in the example of FIG. 1, they are arranged adjacent to each other along the traveling direction (hereinafter referred to as the "approaching direction") of the transport vehicle 18 in the first placement section 34 and the second placement section 36. The first placement portion 34 and the second placement portion 36 may be provided adjacent to each other.

[0024] Although there is no limitation on the configuration of the first placement section 34 and the second placement section 36, the placement sections in this embodiment have a plurality of placement tables arranged on either side of an entrance path for the transport vehicle 18 to enter. In the example of Fig. 1, the first placement section 34 has two placement tables 34p arranged at a distance in the vehicle width direction of the transport vehicle 18, and the second placement section 36 has two placement tables 36p arranged at a distance in the vehicle width direction of the transport vehicle 18.

[0025] In order to facilitate the entry and exit of the transport vehicle 18, the platforms 34p and 36p are configured as follows. The distance between the two platforms 34p and the distance between the two platforms 36p are set to a width equal to the width of the transport vehicle 18 plus a specified margin. The heights of the platforms 34p, 36p are set to be higher than the platform portion 18c in the lowered state and lower than the platform portion 18c in the raised state. The front-to-rear length (length in the entry direction) of the platforms 34p, 36p is set to be a length equal to the vehicle length of the transport vehicle 18 plus a specified margin.

[0026] The picking device of this embodiment picks up the article 10 from above the first placement section 34, and loads the article onto the second placement section 36 from above the second placement section 36. In the example of FIG. 1, the picking device 32 includes a so-called gantry-type crane mechanism. The picking device 32 includes a pair of vertical beams 32e, a cross beam 32k, a crane cart 32d, a hanging section 32j, and a take-out unit 32h. The pair of vertical beams 32e are provided at a distance on both sides in the Y-axis direction in the upper space of the picking area 30. Both ends of the vertical beam 32e are supported by the upper ends of the vertical columns 32g.

[0027] The cross beam 32k is a rail-like structure extending in the Y-axis direction and is spanned between a pair of vertical beams 32e. The cross beam 32k is configured to be self-moving on the vertical beams 32e in the X-axis direction. The cross beam 32k is sometimes called a crane girder. The crane dolly 32d is a dolly that is self-moving on the cross beam 32k in the Y-axis direction. The crane dolly 32d is sometimes called a trolley dolly. The suspending part 32j can suspend the take-out unit 32h from the crane dolly 32d and move it up and down in the Z-axis direction. The suspending part 32j can also rotate the take-out unit 32h horizontally. The take-out unit 32h is provided at the tip of the suspending part 32j and is configured to be able to lift the load 10.

[0028] The picking device 32 supports the take-out unit 32h so as to be freely movable in the horizontal direction (X-axis direction, Y-axis direction). Also, the picking device 32 supports the take-out unit 32h so as to be movable in the vertical direction (Z-axis direction).

[0029] The take-out unit 32h will be described. FIG. 7 is a bottom view showing the take-out unit 32h. The take-out unit 32h has a substantially rectangular shape in a bottom view. A plurality of suction parts 32s are arranged in a matrix in the X-axis direction and the Y-axis direction on the bottom surface of the take-out unit 32h. Each of the plurality of suction parts 32s generates a suction force by sucking in air. The magnitude of the suction force of the suction parts 32s is adjustable. Each of the suction parts 32s may be divided into a plurality of sections.

[0030] The suction unit 32s is configured to be switchable between an ON state in which it generates an attractive force capable of attracting the load 10, and an OFF state in which it does not substantially generate an attractive force. The OFF state includes not only a completely non-generating state, but also a state in which it generates an attractive force so small that it cannot attract the load 10. The take-out unit 32h adjusts the attractive forces of the multiple suction units 32s to attract and hold all the loads 10 on one layer. The take-out unit 32h also adjusts the area in which the attractive force is generated to selectively attract and hold one or more loads 10 on one layer.

[0031] The take-out unit 32h may have a clamping mechanism (not shown) that clamps the load 10 horizontally instead of or in addition to the suction portion 32s.

[0032] The storage shelf 22 will be described with reference to FIG. 1. The storage shelf 22 is a shelf section capable of storing a plurality of loads 10. The configuration of the storage shelf 22 is not particularly limited as long as it is capable of containing and storing a plurality of loads 10. The storage shelf 22 includes a plurality of storage sections 24 arranged along the X-axis direction and the Y-axis direction. Each storage section 24 is configured to be capable of storing a load 10. In particular, the storage shelf 22 can store a single-loading pallet 12S, a mixed-loading pallet 12M, and an empty pallet 12j in each storage section 24.

[0033] This embodiment includes N levels (N is an integer equal to or greater than 1, for example, 3) of storage shelves 22 arranged in layers one above the other. FIG. 1 shows the first level of storage shelves 22 closest to floor Fr. In the second level and above, the Nth level of storage shelves 22 is arranged above the N-1th level of storage shelves 22. The storage shelves 22 in each level may have a similar configuration to each other. In particular, each level of storage shelves 22 is provided with one or more sets of first carts 14 and second carts. Also, a lifting means (not shown) may be provided for lifting and lowering the first cart 14 with or without load 10 between the multiple levels of storage shelves 22.

[0034] The storage shelf 22 is provided with a first rail 26 as a running path for the first carriage 14 and a second rail 28 as a running path for the second carriage 16. The first rail 26 extends in the Y-axis direction in the storage shelf 22. The first carriage 14 is a transport means capable of running under each storage section 24. The second rail 28 extends in the X-axis direction adjacent to the storage shelf 22.

[0035] The first carriage 14 will be described with reference to FIG. 8. FIG. 8 is a front view showing an example of the first carriage 14. The first carriage 14 drives a plurality of wheels 14f by a motor (not shown) and travels on the first rail 26 in the Y-axis direction with the loaded pallet 12 mounted thereon. The first carriage 14 raises and lowers the loaded pallet 12 on the loading platform 14c by the lift mechanism 14d. In FIG. 8, the loading platform 14c in the raised state is shown by a broken line, and the loading platform 14c in the lowered state is shown by a solid line. The first carriage 14 can lower the loaded pallet 12 to the storage section 24. The first carriage 14 can lift and support the loaded pallet 12 from the storage section 24. The first carriage 14 can get on and off the second carriage 16.

[0036] The second carriage 16 will be described with reference to Fig. 9. Fig. 9 is a front view showing a schematic view of an example of the second carriage 16, showing a state in which the first carriage 14 is mounted. The second carriage 16 is a conveying means that drives a plurality of wheels 16f by a motor (not shown) and travels on the second rail 28 in the X-axis direction. The second carriage 16 can transport the first carriage 14 with a loading pallet 12 mounted thereon or when it is empty.

[0037] The storage shelf 22 transports the goods 10 brought into a carry-in section (not shown) to a prescribed storage section 24 by the first cart 14 and the second cart 16 for storage. The storage shelf 22 transports the goods 10 stored in the prescribed storage section 24 to an unloading section 23 by the first cart 14 and the second cart 16 for unloading.

[0038] As shown in FIG. 1, the storage shelf 22 has an unloading section 23 as an exit for unloading the loaded pallet 12. The unloading section 23 is configured to allow the first cart 14 and the transport vehicle 18 to enter. The unloading section 23 is provided with a first rail 26 for allowing the first cart 14 to enter. That is, the first cart 14 enters the unloading section 23, unloads the loaded pallet 12, and exits. Next, the transport vehicle 18 enters the unloading section 23, holds the loaded pallet 12, and exits. The reverse is also possible. That is, the unloading section 23 functions as a transfer section that transfers the loaded pallet 12 between the first cart 14 and the transport vehicle 18. From these, the unloading section 23 can be said to be an entrance and exit of the storage shelf 22.

[0039] Although there is no limitation on the configuration of the unloading section 23, the unloading section 23 in this embodiment has a plurality of tables arranged on either side of an entrance path through which the transport vehicle 18 enters. In the example of Fig. 1, the unloading section 23 has two tables 23p arranged at a distance from each other in the vehicle width direction of the transport vehicle 18.

[0040] From the viewpoint of smooth entry and exit of the transport vehicle 18, the distance between the two platforms 23p is set to a width equal to the width of the transport vehicle 18 plus a prescribed margin, and the height of the platform 23p is set to be higher than the platform portion 18c in the lowered state and lower than the platform portion 18c in the raised state. The front-to-rear length (length in the approach direction) of the platform 23p is set to be the length of the transport vehicle 18 plus a prescribed margin.

[0041] The outgoing section 40 will be described with reference to FIG. 1. The outgoing section 40 is a platform for outgoing the picked mixed pallet 12M to the destination. There is no limitation on the configuration of the outgoing section 40, but the outgoing section 40 of this embodiment has a plurality of platforms arranged on either side of an entrance road for the transport vehicle 18 to enter. In the example of FIG. 1, the outgoing section 40 has two platforms 40p arranged at a distance in the vehicle width direction of the transport vehicle 18. The two platforms 40p can be configured similarly to the two platforms 34p of the first placement section 34.

[0042] The operation of the automated warehouse system 100 configured as above will be described. In this operation, the transport vehicle 18 autonomously travels to the destination along the induction wire 18g while detecting the induced current of the induction wire 18g. Furthermore, when the transport vehicle 18 approaches the target platform, the transport vehicle 18 corrects its own position with respect to the platform using the detection result of a sensor that detects the platform, and travels while securing an appropriate gap with the platform. Examples of sensors that detect the platform include laser sensors and image sensors. Furthermore, when the transport vehicle 18 completes its operation, it moves to a predetermined standby position and waits.

[0043] (1st action) The first operation is a transfer operation. An example of the first operation will be described with reference to Fig. 10. Fig. 10 is an explanatory diagram for explaining the first operation. The first operation is a transfer operation in which the transport vehicle 18 transfers the single pallet 12S stored in the storage shelf 22 to the first placement section 34 based on a command from the control section 50 (hereinafter simply referred to as a "command").

[0044] (1) In the first operation, first, the first cart 14 and the second cart 16 transport the single pallet 12S stored in a predetermined storage section 24 of the storage shelf 22 to the carry-out section 23. During this process, the first cart 14 loads the single pallet 12S on the raised mounting platform 14c and enters the carry-out section 23 ( FIG. 10(a) ). After entering the carry-out section 23, the first cart 14 lowers the mounting platform 14c to lower the single pallet 12S onto the mounting platform 23p of the carry-out section 23. After unloading the single pallet 12S, the first cart 14 exits the carry-out section 23 and moves into the storage shelf 22.

[0045] (2) The transport vehicle 18 travels toward the discharge section 23 with the mounting platform 18c lowered (FIG. 10(b)). After entering the discharge section 23, the transport vehicle 18 raises the mounting platform 18c to lift up the single pallet 12S and exits the discharge section 23 (FIG. 10(c)).

[0046] (3) After leaving the unloading section 23, the transport vehicle 18 travels toward the first placement section 34 (FIG. 10(d)).

[0047] (4) After entering the first placement section 34, the transport vehicle 18 lowers the placement platform 18c to place the single pallet 12S on the placement platform 34p of the first placement section 34 (FIG. 10(e)). After placing the single pallet 12S, the transport vehicle 18 exits the first placement section 34.

[0048] (5) The transport vehicle 18 repeats this first operation in accordance with the shipping plan, and transports the single-loading pallets 12S of different types of loads 10 to other first placement sections 34. By operating in this manner, single-loading pallets 12S carrying different types of loads 10 are placed on the multiple first placement sections 34.

[0049] (2nd action) The second operation is a picking operation. An example of the second operation of the picking device 32 will be described with reference to FIG. 6. As described above, the second operation is an operation of removing the load 10 from the single-loading pallet 12S placed on the first loading section 34 based on a command corresponding to the shipping plan, and creating a mixed load pallet 12M on the second loading section 36 for shipping to a destination such as a retail store. In FIG. 6, the first type of load 10-A is shown with dashed hatching, the second type of load 10-B is shown with solid hatching, and the third type of load 10-C is shown in white without hatching.

[0050] (1) The transport vehicle 18 places an empty pallet 12j for creating a mixed pallet 12M on the second loading section 36 of the picking area 30. During this process, the transport vehicle 18 transports the pallet 12j from a pallet storage area (not shown) that stores the pallet 12j to a predetermined second loading section 36.

[0051] (2) The picking device 32 removes the required number of first type loads 10-A from the single-loading pallet 12S and places them on the pallet 12j of the second loading section 36. (3) The picking device 32 also picks up the required number of second type loads 10-B from another single-loading pallet 12S and places them on top of the first type loads 10-A on the pallet 12j. (4) The picking device 32 also picks out the required number of third type loads 10-C from another single-loading pallet 12S and places them on top of the second type loads 10-B on the pallet 12j. (5) In this manner, the picking device 32 stacks multiple types of cargo 10 corresponding to the shipping plan on the pallet 12j to create a mixed pallet 12M.

[0052] (3rd action) The third operation is a preparation operation for leaving the warehouse. An example of the third operation will be described with reference to FIG. 11. FIG. 11 is an explanatory diagram for explaining the third operation. The third operation is an operation of transferring the mixed pallet 12M of the second placement section 36 to the leaving section 40 by the transport vehicle 18 based on a command. The third operation may be performed by the transport vehicle 18 that performed the first operation, or may be performed by a transport vehicle 18 different from the transport vehicle 18 that performed the first operation. In this example, the third operation is performed by the transport vehicle 18 that performed the first operation. That is, one transport vehicle 18 performs the first operation and the third operation.

[0053] (1) The transport vehicle 18 travels toward the second placement section 36 with the placement platform section 18c lowered (FIG. 11(a)). (2) After entering the second placement section 36, the transport vehicle 18 raises the placement platform section 18c to lift up the mixed pallet 12M, exits the second placement section 36, and travels toward the outgoing section 40 (FIG. 11(b)).

[0054] (3) After entering the unloading section 40, the transport vehicle 18 lowers the loading platform 18c to place the mixed pallet 12M on the loading platform 40p of the unloading section 40 (FIG. 11(c)). After unloading the mixed pallet 12M, the transport vehicle 18 exits the unloading section 40 and repeats the third operation according to the shipping plan.

[0055] (4) The mixed pallet 12M unloaded at the outgoing section 40 is loaded onto a truck by a transport means such as a forklift, and shipped to the destination.

[0056] In this way, by transporting the mixed pallet 12M to the outgoing section 40 by the transport vehicle 18, even if the timing of the completion of picking varies, the pallets can be transported by the transport vehicle 18 in the order in which the picking was completed, which provides a higher degree of freedom in outgoing compared to using a conveyor, etc.

[0057] (4th action) The fourth operation is an operation of recovering the empty pallet. By the second operation, the empty pallet 12j after picking remains on the first placement section 34. The fourth operation is an operation of recovering the pallet 12j remaining on the first placement section 34 by the transport vehicle 18 based on a command.

[0058] In the fourth operation, the transport vehicle 18, with the loading platform 18c lowered, enters the first loading section 34, lifts up the pallet 12j, exits the first loading section 34, travels toward a designated pallet storage area, and lowers the pallet 12j into the pallet storage area.

[0059] A dedicated storage section may be provided as a pallet storage area, but in this embodiment, a part of the storage shelf 22 is used. In this case, the transport vehicle 18 transports the pallet 12j to the storage shelf 22. For example, the pallet 12j is transported to the discharge section 23, transferred to the first cart 14, and transported to a predetermined storage section 24 by the first cart 14 and the second cart 16.

[0060] Also, in the fourth operation, the transport vehicle 18 may transport the pallet 12j on the first placement section 34 to the second placement section 36 that has been emptied in the third operation.

[0061] (5th action) The fifth operation is an operation for recovering the intermediate pallet. The second operation leaves a single-loading pallet 12S (hereinafter referred to as an "intermediate pallet") on the first loading section 34, from which some of the loads 10 have been removed and the remaining loads 10 have been stacked. For example, when the loads 10 on the intermediate pallet are not required in the immediate shipping plan and it is desired to place a single-loading pallet 12S for other types of loads 10 on the first loading section 34, the fifth operation can free up the first loading section 34. The fifth operation is an operation for recovering the intermediate pallet remaining on the first loading section 34 by the transport vehicle 18 based on a command.

[0062] In the fifth operation, the transport vehicle 18, with the loading platform 18c lowered, enters the first loading section 34, lifts the intermediate pallet, exits the first loading section 34, travels toward a designated intermediate pallet storage area, and deposits pallet 12j at the intermediate pallet storage area.

[0063] Although a dedicated storage section may be provided as the intermediate pallet storage area, in this embodiment, a part of the storage shelf 22 is used. In this case, the transport vehicle 18 transports the intermediate pallet j to the storage shelf 22. For example, the intermediate pallet j is transported to the discharge section 23, transferred to the first cart 14, and transported to a predetermined storage section 24 by the first cart 14 and the second cart 16.

[0064] In the fifth operation, the transport vehicle 18 may transport to the storage shelf 22 a single pallet 12S from which the article 10 has not yet been removed, instead of the intermediate pallet.

[0065] In addition, according to the fifth operation, for example, for a single-loading pallet 12S with low demand, only the required amount of load 10 can be removed, and the remainder can be temporarily evacuated from the first loading section 34, and then a single-loading pallet 12S with high demand can be brought into the first loading section 34.

[0066] (6th action) The sixth operation is an operation for recovering the mixed pallet 12M. There are cases where it is desired to temporarily recover the mixed pallet 12M from the second placement section 36 or the outgoing section 40. For example, when a shipping plan is changed, the sixth operation can vacate the second placement section 36 or the outgoing section 40. The sixth operation is an operation for recovering the mixed pallet 12M from the second placement section 36 or the outgoing section 40 by the transport vehicle 18 based on a command.

[0067] In the sixth operation, the transport vehicle 18, with the loading platform section 18c lowered, enters the second loading section 36 or the unloading section 40, lifts up the mixed pallet 12M, exits the second loading section 36 or the unloading section 40, travels toward the storage area for a specified mixed pallet 12M, and unloads pallet 12j into the storage area for the mixed pallet 12M.

[0068] (7th action) The seventh operation is an operation in which, based on a command, the transport vehicle 18 carries the loaded pallet 12 in the receiving section (not shown) into the storage shelf 22. For example, the loaded pallet 12 is unloaded from the truck to the receiving section by a transport means such as a forklift, the loaded pallet 12 in the receiving section is transported to the unloading section 23 by the transport vehicle 18, the loaded pallet 12 is transferred onto the first cart 14, and the loaded pallet 12 is transported to a predetermined storage section 24 by the first cart 14 and the second cart 16.

[0069] A dedicated storage section may be provided as a storage location for the mixed pallets 12M, but in this embodiment, a part of the storage shelf 22 is used. In this case, the transport vehicle 18 transports the mixed pallet 12M to the storage shelf 22. For example, the mixed pallet 12M is transported to the carry-out section 23, transferred to the first cart 14, and transported to a predetermined storage section 24 by the first cart 14 and the second cart 16. The mixed pallets 12M include unfinished pallets as well as completed pallets.

[0070] The above is a description of the first to seventh operations. This operational example is merely one example, and various modifications are possible.

[0071] A separate transport vehicle 18 may be provided for each operation. Also, the transport vehicle 18 may execute a plurality of operations in a time-sharing manner. Depending on the size of the warehouse and the volume of goods handled, one or a plurality of transport vehicles 18 may be provided.

[0072] As described above, this embodiment has a first path between the storage shelf 22 and the first placement section 34, a second path between the first placement section 34 and the second placement section 36, a third path between the second placement section 36 and the delivery area 38, and a fourth path between the delivery area 38 and the storage shelf. A single transport vehicle 18 may transport a loaded pallet along one of the first, second, third, and fourth paths, or a single transport vehicle 18 may transport a loaded pallet along at least two of these four paths, or a plurality of transport vehicles 18 may share the transport of a loaded pallet along these four paths. This can be flexibly configured according to the size and operation status of the warehouse.

[0073] The transport vehicle 18 may be configured to be capable of traveling on the storage shelf 22, and may function in the same manner as the first trolley 14. With this configuration, the same type of transport vehicle 18 can be used as long as the design of the route of the transport vehicle 18 (for example, the rail structure, its width, and the structure of the receiving portion) is common. In this case, when multiple transport vehicles 18 are used in the entire system including the storage shelf 22 and the picking area 30, the arrangement of the transport vehicles 18 can be flexibly operated.

[0074] For example, when four transport vehicles 18 are operated, at times, all of the transport vehicles 18 may be used in the storage shelf 22, or two of the four transport vehicles 18 may be used in the storage shelf 22 and the remaining two transport vehicles 18 may be used in the picking area 30.Furthermore, if there is a tendency for the transport vehicles 18 used in the picking area 30 to be insufficient, the transport vehicles 18 (for example, one vehicle) used in the storage shelf 22 may be used in the picking area 30 as support, or vice versa, allowing for flexible system operation.

[0075] The features of the automated warehouse system 100 of this embodiment configured as above will be described. Since this embodiment is equipped with the storage shelves 22, the first placement section 34, the second placement section 36, the transport vehicle 18, and the picking device 32, picking for removing the articles 10 from the single pallet 12S and creating the mixed pallet 12M can be achieved with few steps.

[0076] Furthermore, according to this embodiment, the scales of the first placement section 34, the second placement section 36, and the picking device 32 can be selected according to the scale of the warehouse and the amount of cargo handled, so that the automated warehouse system can be flexibly configured. Furthermore, when the scale of the warehouse and the amount of cargo handled change, the number and operation form of the transport vehicles 18 can be changed to flexibly accommodate the change. Furthermore, according to the scale of the warehouse and the amount of cargo handled, the change can be flexibly accommodated by extending the vertical beams 32e and the horizontal beams 32k of the crane mechanism, adding movable bodies of the crane mechanism, adding the discharge section 23, adding the first placement section 34, adding the second placement section, and the like.

[0077] Also, according to this embodiment, the loads 10 taken out from the single-loading pallet 12S are loaded directly onto the mixed-loading pallet 12M. Therefore, compared to a method in which the loads 10 taken out from the single-loading pallet 12S are divided into a plurality of cases and stored in a separate space, and the cases stored in the separate space are loaded onto the mixed-loading pallet, space efficiency is improved because a separate space for storing the cases is not used. Also, since the removal of the loads 10 and the loading onto the mixed-loading pallet 12M are performed integrally, productivity is improved and equipment costs can be reduced compared to a method in which separation and loading are performed separately.

[0078] Furthermore, according to this embodiment, the travel route of the transport vehicle 18 can be easily changed by replacing the guide wire 18g.

[0079] This embodiment may also include another transport vehicle that moves the mixed pallet 12M from the second placement section 36 to the outgoing area 38. In this case, the throughput of the warehouse can be improved.

[0080] Furthermore, in this embodiment, the mixed pallet 12M can be moved from the second placement section 36 to the outgoing area 38 by the transport vehicle 18 used in the first operation. In this case, capital investment can be reduced.

[0081] Furthermore, in this embodiment, the empty pallet 12j can be carried out from the first placement section 34 by the transport vehicle 18. In this case, a mechanism for carrying out the empty pallet 12j can be omitted.

[0082] Furthermore, in this embodiment, an empty pallet 12j can be carried into the second placement section 36 by the transport vehicle 18. In this case, a mechanism for carrying in the empty pallet 12j can be omitted.

[0083] Furthermore, in this embodiment, the single pallet 12S or the single pallet 12S with some of the loads 10 removed from the first placement section 34 can be moved by the transport vehicle 18 to the storage shelf 22. In this case, the first placement section 34 can be used effectively.

[0084] In this embodiment, the unloading section 23, the first placement section 34, the second placement section 36, and the delivery section 40 each have a plurality of tables arranged on either side of an entrance path through which the transport vehicle 18 enters. In this case, the unloading section 23, the first placement section 34, the second placement section 36, and the delivery section 40 can be simply configured.

[0085] In this embodiment, the unloading section 23, the first placement section 34, the second placement section 36, and the delivery section 40 of the storage shelf 22 are arranged on the same floor Fr. In this case, the step on the travel path of the transport vehicle 18 is small, so that the transport vehicle 18 can travel easily.

[0086] Above, examples of the embodiments of the present invention have been described in detail. The above-mentioned embodiments are merely examples of implementing the present invention. The contents of the embodiments do not limit the technical scope of the present invention, and many design changes such as changes, additions, and deletions of components are possible within the scope of the invention as defined in the claims. In the above-mentioned embodiments, the contents for which such design changes are possible are described with notations such as "of the embodiment" and "in the embodiment", but this does not mean that design changes are not permitted for contents without such notations. In addition, hatching in the drawings does not limit the material of the hatched object.

[0087] (Modification) The following describes the modified examples. In the drawings and description of the modified examples, the same or equivalent components and members as those in the embodiment are denoted by the same reference numerals. Descriptions that overlap with the embodiment will be omitted as appropriate, and the description will focus on configurations that differ from the embodiment.

[0088] In the description of the embodiment, an example in which the automated warehouse system 100 executes the first to seventh operations has been shown, but the present invention is not limited to this. It is not essential to execute all of the first to seventh operations, and the automated warehouse system 100 only needs to execute the first and second operations.

[0089] In the description of the embodiment, an example in which the storage shelf 22 has the first cart 14 and the second cart 16 has been shown, but the present invention is not limited to this. For example, the storage shelf 22 may not have one or both of the first cart 14 and the second cart 16.

[0090] In the description of the embodiment, an example was shown in which the picking device 32 is supported from the ceiling side by a gantry-type crane mechanism, but the present invention is not limited to this. For example, the picking device may be supported by an articulated robot or a support means of a different configuration. In addition, the picking device may be attached to a side wall on the side and supported from the side.

[0091] In the description of the embodiment, an example was shown in which the picking operation removes the loads 10 from a collection of the same type of loads 10 (single-loading pallet 12S) to create a collection of multiple types of loads 10 (mixed pallet 12M), but the present invention is not limited to this. The picking operation may include an operation of removing the loads 10 from a collection of multiple types of loads 10, or may create a collection of the same type of loads 10 using the removed loads 10. In addition, the collection of the same type of loads 10 created by picking may be shipped out.

[0092] In the description of the embodiment, an example has been given in which the transport vehicle 18 is guided based on the induced current of an electric wire installed on the floor, but a different guidance method may be adopted for the transport vehicle 18. Examples of the method for guiding the transport vehicle 18 include a method using lines drawn on the floor, a method using facility shapes such as walls and shelves using a laser scanner, a method using light and a reflector, a method using radio waves and an RFID (Radio Frequency Identifier), a method using a magnetic signal from a magnetic tape installed on the floor, a method using radio waves from a beacon, and a combination of these methods.

[0093] The transport vehicle 18 may be configured to recognize its own vehicle position and autonomously travel to a destination position based on the recognition result and the stored map information. The transport vehicle 18 may be equipped with various methods for recognizing its own vehicle position. For example, the transport vehicle 18 may recognize its own vehicle position using a plurality of reflectors installed in a warehouse and a laser scanner mounted on the transport vehicle. For example, the positions of the plurality of reflectors may be stored on the map of the transport vehicle. In this case, the transport vehicle 18 can recognize at least three reflectors using a laser scanner and identify its own vehicle position based on the principle of triangulation by referring to the position information of the reflectors stored on the map.

[0094] The transport vehicle 18 may also be configured to correct its own vehicle position information in order to improve its travel accuracy. For example, the transport vehicle 18 may recognize images of floors, walls, equipment, and the like using an image sensor, and correct its own vehicle position based on the recognition results. The transport vehicle 18 may also correct its own vehicle position based on the amount of wheel rotation identified from the detection results of an encoder that detects the rotation of the wheels. The transport vehicle 18 may also correct its own vehicle position based on the detection results of an acceleration sensor such as a gyro.

[0095] In the description of the embodiment, an example in which the transport vehicle 18 is provided separately from the first cart 14 has been shown, but the present invention is not limited to this. As an example, the first cart 14 traveling on the storage shelf 22 may function as the transport vehicle 18 as it is. For example, the first rail 26 of the lowest level of the storage shelf 22 may be connected to the rail of the placement section of the picking area 30, and the first cart 14 may directly move the single-loading pallet 12S to the picking area 30. The connection relationship of this rail may be provided in accordance with the number of placement sections arranged in the X-axis direction of the picking area 30. In this case, a linked system in which each storage shelf 22 can directly access the placement section of the picking area 30 can be constructed.

[0096] Also, the picking area 30 may be provided with another transport means having the same function as the second cart 16 and capable of transporting the first cart 14. In this case, the above-mentioned linkage system can be constructed by providing at least one rail between the storage shelf 22 and the picking area 30 without providing rails corresponding to all of the multiple placement sections. In addition, by using this other transport means and the first cart 14, it is possible to selectively control where in the multiple placement sections the single pallet is carried in. In addition, from the viewpoint of constructing the above-mentioned linkage system in a compact manner, it is preferable that the picking area 30 and the storage shelf 22 are adjacent to each other, and it is more preferable that they are structurally integrated. In this case, the transport path between the picking area 30 and the storage shelf 22 can be shortened.

[0097] In the description of the embodiment, an example has been shown in which the transport vehicle 18 moves under the picking device 32 to transport the loaded pallet 12, but the present invention is not limited to this. The transport vehicle 18 may be configured to move beside the picking device 32. In this case, the travel route of the transport vehicle 18 can be flexibly set.

[0098] In the description of the embodiment, an example in which the placement table 34p of the first placement portion 34 and the placement table 36p of the second placement portion 36 are separated from each other has been shown, but the present invention is not limited to this. The placement table 34p and the placement table 36p may be connected to each other or may be formed integrally.

[0099] Each of these modified examples provides the same effects as the embodiment.

[0100] Any combination of the above-described embodiments and modifications is also useful as an embodiment of the present invention. A new embodiment resulting from the combination has the combined effects of the respective embodiments and modifications. [Explanation of symbols]

[0101] 10 load, 12 loaded pallet, 12M mixed pallet, 12S single pallet, 18 transport vehicle, 18g induction wire, 22 storage shelf, 23 discharge section, 32 picking device, 34 first loading section, 36 second loading section, 40 outgoing section, 50 control section, 100 automated warehouse system.

Claims

1. a storage section capable of storing a plurality of loaded pallets; A first placement section and a second placement section on which a load-carrying pallet can be placed on a floor that does not have a storage shelf capable of storing a plurality of loads therebelow; a transport vehicle capable of moving while autonomously changing a moving direction and capable of transporting a plurality of single-loading pallets each including different types of loads from the storage unit to the first loading unit; a picking device including a gantry-type crane mechanism provided so as to cover the first placement section and the second placement section from above, which picks up an article from a single pallet placed on the first placement section and moves the article to the second placement section to create a mixed pallet; A containment system comprising:

2. A storage system as described in claim 1, wherein the transport vehicle transports cargo stored on the same floor of the storage section as the first loading section and the second loading section to the first loading section.

3. A storage system as described in claim 1 or 2, wherein the first loading section and the second loading section are selectable from a plurality of loading sections provided below the gantry-type crane.

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