Palettizing system

Abstract

To load so that articles are arranged properly in each section automatically, considering unlikeliness of collapse of articles, in the case where the articles are loaded in the plurality of sections set on a loading surface of one pallet.SOLUTION: In the case where the storage section number N determined by section number determination processing is larger than the empty section number M in loading processing of a second order article group Go, a control device executes pallet switching processing for controlling a pallet carrying-out device 3 and a pallet supply device 2 so as to carry-out a pallet P existing in a palletizing area A2 and supplying a new pallet P to the palletizing area A2.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] The present invention relates to a palletizing system. [Background technology]

[0002] For example, Japanese Patent No. 2947834 (Patent Document 1) discloses a technique for stacking articles on a pallet, so-called palletizing. In the following description of the background art, the reference numerals in parentheses refer to those in Patent Document 1.

[0003] Patent Document 1 discloses that a worker (M) loads items onto a loading surface of a pallet (40) divided into multiple sections, in accordance with the type and number of items displayed on a display (30). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 2947834 Summary of the Invention [Problem to be solved by the invention]

[0005] Recently, there is a need for automating palletizing. However, when palletizing is performed automatically using a robot or the like, it is difficult to respond flexibly compared to when an operator performs the palletizing. Therefore, when stacking items in multiple compartments set on the stacking surface of one pallet, it is not easy to stack items automatically so that they are appropriately arranged in each compartment while also taking into consideration the prevention of the load from shifting.

[0006] In view of the above situation, there is a need for a palletizing system that can automatically load items in multiple compartments set up on the loading surface of a single pallet so that the items are appropriately positioned in each compartment, while also taking into consideration the prevention of cargo shifting. [Means for solving the problem]

[0007] an article group supplying device that supplies a single article group consisting of a plurality of articles of a single type to a picking area; a pallet supply device that supplies pallets to a palletizing area; a pallet removal device that removes the pallet from the palletizing area; A transfer device that transfers the items between the picking area and the palletizing area; A palletizing system comprising: a control device that controls the article group supply device, the pallet supply device, the pallet carry-out device, and the transfer device, the control device is capable of receiving order information specifying the type and number of the items to be loaded onto the pallet in the palletizing area, and executing a loading process of loading the ordered item group onto the pallet, the ordered item group being the type and number of the items specified by the order information; A plurality of compartments are set on the loading surface of the pallet, and a limit height is set, which is an upper limit of the height of the items that can be loaded on the loading surface; The control device, in the stowage processing, an occupancy area determination process for determining an item group occupancy area, which is an area in a plan view when the ordered item group is stacked on the stowage surface so as to be equal to or less than the limit height; The number of storage compartments N (N is a natural number) that is the number of compartments that can accommodate the item group occupation area is determined. A process of determining the number of partitions to be a stowage section determination process for determining a stowage section, which is the section in which the group of ordered items is to be stowed, according to the number of storage sections N determined by the section number determination process; a transfer process for controlling the transfer device to pick up the items related to the ordered item group from the single item group in the picking area and load the ordered item group in the loading section; the control device, after completing the stowage process for the first ordered item group based on the first order information, when an empty section remains on the stowage surface, which is the section in which no item is stowed, executes the stowage process for the second ordered item group based on the second order information; When the number of storage compartments N determined by the compartment number determination process is greater than the number of empty compartments during the stowage process of the second group of ordered items, the control device executes a pallet replacement process that controls the pallet removal device and the pallet supply device to remove the pallet in the palletizing area and supply a new pallet to the palletizing area.

[0008] According to this configuration, it is possible to automatically and appropriately stack items in a plurality of compartments set on the stacking surface of a pallet according to the group of ordered items related to the order information and the state of the stacking surface of the pallet. In addition, in the stacking process, since the items are stacked within the range of the limit height at which the items can be stacked on the stacking surface, it is easy to prevent the load from collapsing on the pallet after stacking. Furthermore, according to this configuration, it is automatically determined whether or not the group of ordered items related to one order information can be stacked on the same pallet, and if it is possible, the stacking is performed. If it is not possible to stack the items, a pallet replacement process is performed to supply a new pallet to the palletizing area. In this way, it is possible to stack the group of ordered items related to one order information on the same pallet. As described above, according to this configuration, when items are stacked in a plurality of compartments set on the stacking surface of one pallet, it is possible to automatically stack the items so that the items are appropriately arranged in each compartment, taking into consideration the difficulty of causing the load to collapse.

[0009] Further features and advantages of the techniques disclosed herein will become more apparent from the following description of exemplary and non-limiting embodiments, which proceeds with reference to the drawings. [Brief description of the drawings]

[0010] [Figure 1] Schematic plan view of the palletizing system [Diagram 2] An explanatory diagram showing how to create a mixed load pallet [Diagram 3] Illustration of loading process [Figure 4] Diagram for creating master information [Diagram 5] FIG. 11 is an explanatory diagram showing a process when it is determined that a second group of ordered items can be loaded. [Figure 6] FIG. 11 is an explanatory diagram showing a process when it is determined that a second group of ordered items cannot be loaded. [Figure 7] Flowchart showing the procedure for loading processing [Figure 8] Flowchart showing the processing procedure depending on the presence or absence of vacant partitions [Figure 9] Flowchart showing the procedure of the second stowage process [Figure 10] FIG. 13 is an explanatory diagram showing the process of redetermining the number of partitions and the process thereafter. [Figure 11] FIG. 13 is an explanatory diagram showing the process of redetermining the number of partitions and the process thereafter. [Figure 12] FIG. 11 is an explanatory diagram showing a transshipment process in the second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] A palletizing system is a system for stacking goods on pallets, or what is called palletizing. In a palletizing system, palletizing is performed automatically. Below, we will take as an example a case where a palletizing system is applied to an article transport facility that transports goods using pallets. 1 shows an embodiment of a palletizing system.

[0012] [First embodiment] First, a first embodiment of a palletizing system will be described.

[0013] As shown in Fig. 1, the palletizing system 100 includes an article group supplying device 1 that supplies a single article group Gs consisting of a single type of multiple articles W to a picking area A1, a pallet supplying device 2 that supplies a pallet P to the palletizing area A2, a pallet unloading device 3 that unloads the pallet P from the palletizing area A2, a transfer device 4 that transfers the article W between the picking area A1 and the palletizing area A2, and a control device C that controls the article group supplying device 1, the pallet supplying device 2, the pallet unloading device 3, and the transfer device 4. In this specification, the single article group Gs refers not only to an article consisting of a single type of multiple articles W, but also to an article consisting of a single article W. In this embodiment, the article group supplying device 1 supplies a pallet P on which the single article group Gs is placed to the picking area A1. In the palletizing system 100, multiple or single items W are picked up (picked) from a single item group Gs in the picking area A1, and the picked multiple or single items W are loaded (palletized) onto a pallet P in the palletizing area A2. The palletizing system 100 according to this embodiment further includes a waiting area A3 in which the single item group Gs to be supplied to the picking area A1 is kept waiting.

[0014] In this embodiment, the palletizing system 100 includes a first storage section S1 for storing a plurality of items W by type, a second storage section S2 for storing a plurality of types of items W in a mixed state, and an empty pallet storage section S3 for storing an empty pallet P on which no item W is placed. In the first storage section S1, items α, β, γ, etc., which are different in type from each other in shape, size, etc., are stored by type. In the second storage section S2, items α, β, γ, etc. are stored in a mixed state. In the empty pallet storage section S3, a plurality of empty pallets P are stored in a stacked state. In the following, when the items W are distinguished by type, the items W may be referred to as items α, β, γ, etc. When there is no particular distinction by type, the items W may be simply referred to as items W.

[0015] In this embodiment, the item group supplying device 1 is configured using a conveyor. The item group supplying device 1 configures an item group supply path R1, which is a path along which a single item group Gs is supplied to the picking area A1. In this example, the item group supply path R1 configures at least a part of the path connecting the first storage section S1 to the picking area A1. In the illustrated example, the above-mentioned waiting area A3 is located in a part of the item group supply path R1.

[0016] In this embodiment, the pallet supplying device 2 is configured using a conveyor. The pallet supplying device 2 configures a pallet supply path R2 which is a path along which empty pallets P are supplied to the palletizing area A2. In this example, the pallet supplying device 2 configures at least a part of the path connecting the empty pallet storage unit S3 to the palletizing area A2.

[0017] In this embodiment, the pallet carry-out device 3 is configured using a conveyor. The pallet carry-out device 3 configures a pallet carry-out path R3, which is a path along which the pallet P after palletizing is carried out. The "pallet P after palletizing" is a pallet P on which multiple types of items W are placed by palletizing. In the palletizing system 100, a mixed pallet P on which multiple types of items W are placed on one pallet P is created by palletizing. In this example, the mixed pallet P after palletizing is transported to the second storage section S2 via the pallet carry-out path R3.

[0018] In this embodiment, the pallet discharge path R3 is a path through which the mixed pallet P after palletization is discharged. In addition to being a path, it also serves as a path for carrying out the pallet P after picking. In the illustrated example, the pallet carry-out path R3 is formed to extend from the palletizing area A2, and the picking area A1 is disposed in a part of the pallet carry-out path R3. The "pallet P after picking" is a pallet P on which a single type of item W (single item group Gs) whose number has been reduced by picking compared to before picking is placed, or a pallet P on which no item W is placed. In this example, the pallet P after picking on which the single item group Gs is placed is transported to the first storage section S1 via the pallet carry-out path R3. Although detailed illustration is omitted, the empty pallet P after picking on which no item W is placed may be transported to the empty pallet storage section S3 via the pallet carry-out path R3.

[0019] The transfer device 4 is configured to transfer an article W between the picking area A1 and the palletizing area A2. In this embodiment, the transfer device 4 transfers an article W between pallets P. Specifically, the transfer device 4 transfers an article W from a pallet P arranged in the picking area A1 to a pallet P arranged in the palletizing area A2. In this embodiment, the transfer device 4 includes an arm 40 that can freely rotate around a vertical axis, and a holding unit 41 attached to the arm 40.

[0020] In this embodiment, the arm 40 has a multi-joint structure and is configured to be able to move the holding part 41 three-dimensionally. The holding part 41 is configured to be able to hold an item W. In this example, the holding part 41 is configured to hold the item W by adsorbing to the upper surface of the item W. This makes it possible to appropriately hold one item W arbitrarily selected from a plurality of items W arranged closely on the pallet P. However, the holding part 41 may also be configured to hold the item W, for example, by clamping the item W.

[0021] In this embodiment, the transfer device 4 includes a recognition unit 42 for recognizing the state of the pallet P in the picking area A1 and the pallet P in the palletizing area A2. The transfer device 4 is configured to recognize the number and shape of the items W placed on the pallet P in the picking area A1, or the presence or absence of the items W, by the recognition unit 42. Similarly, the transfer device 4 is configured to recognize the number and shape of the items W placed on the pallet P in the palletizing area A2, or the presence or absence of the items W, by the recognition unit 42. In this example, the recognition unit 42 is configured using a camera, and the transfer device 4 recognizes the state of the pallet P in the picking area A1 and the pallet P in the palletizing area A2 based on an image captured by the camera, and transfers the items W between the picking area A1 and the palletizing area A2.

[0022] The control device C is configured to receive order information specifying the type and number of items W to be loaded onto a pallet P in the palletizing area A2, and to execute a loading process in which the type and number of items W specified by the order information are treated as an ordered item group Go and the ordered item group Go is loaded onto the pallet P.

[0023] The order information is information about a single type of item W and is indicated by "item type: quantity." The order information is transmitted to the control device C by a central control device (not shown) that centrally manages the entire system. For example, when it becomes necessary to replenish mixed pallets P in the second storage section S2, the central control device creates multiple pieces of order information and transmits the multiple pieces of order information one by one to the control device C.

[0024] In this embodiment, the multiple types of items W required to create the mixed pallet P for which a replenishment request has been made are supplied in random order for each of the multiple single item groups Gs by the item group supplying device 1. In other words, the order in which the single item groups Gs are supplied to the picking area A1 may be arbitrary, for example, The single item group Gs is supplied to the picking area A1 in the order of removal from the first storage section S1. In this embodiment, when the single item group Gs is in the waiting area A3, the control device C receives order information related to the single item group Gs in the waiting area A3. Only at this time does the control device C know the type and number of items W (order item group Go) to be transferred from the picking area A1 to the palletizing area A2. Thereafter, the single item group Gs in the waiting area A3 is supplied to the picking area A1. Then, from this single item group Gs, the transfer device 4 transfers the number of items W (order item group Go) based on the order information from the picking area A1 to the palletizing area A2. By performing such processing for each of the multiple types of items W supplied in random order, a mixed pallet P is created.

[0025] As shown in FIG. 2, for example, if the multiple types of items W required to create a mixed pallet P for which a replenishment request has been made are items α and β, a single item group Gs consisting of multiple items α and a single item group Gs consisting of multiple items β are supplied to the picking area A1 in no particular order by the item group supplying device 1. Then, the control device C receives order information regarding the items α and order information regarding the items β at different times. In the following, in order to distinguish between the multiple order information being different information from each other, they will be referred to as first order information, second order information, third order information, ..., but this does not indicate the order in which the processing is performed.

[0026] In the example shown in Fig. 2, the first order information is information indicated as "item α: 5 units" and specifies that five items α are to be loaded. The second order information is information indicated as "item β: 6 units" and specifies that six items β are to be loaded. In this example, the control device C executes a stowage process based on the first order information and a stowage process based on the second order information, thereby stacking five items α and six items β onto one pallet P to create a mixed pallet P.

[0027] In the palletizing system 100, as shown in Fig. 3, a plurality of sections X are set on the loading surface Pf of the pallet P, and a limit height H is set, which is an upper limit of the height of the items W that can be loaded on the loading surface Pf. In this embodiment, the plurality of sections X set on the loading surface Pf are of the same size. In this example, the plurality of sections X are arranged in a lattice pattern on the loading surface Pf. In the illustrated example, four sections X, A, B, C, and D, of the same size, are set on the loading surface Pf of the pallet P.

[0028] The control device C is configured to execute an occupied area determination process, a section number determination process, a stowage section determination process, and a transfer process in the stowage process.

[0029] In the occupied area determination process, the control device C determines the item group occupied area Ag, which is the area in a planar view when the ordered item group Go is stacked on the stowage surface Pf so as to be equal to or less than the limit height H. In the illustrated example, the control device C receives order information specifying "item α: 5 pieces" and determines the item group occupied area Ag when five items α are stacked on the stowage surface Pf so as to be equal to or less than the limit height H.

[0030] In the compartment number determination process, the control device C determines the number of storage compartments N (N is a natural number), which is the number of compartments X in which the item group occupation area Ag fits. In the illustrated example, the item group occupation area Ag determined based on the ordered item group Go of "item α: 5 pieces" fits into one of the compartments X, so the control device C determines the "number of storage compartments N=1" in the compartment number determination process.

[0031] In the loading section determination process, the control device C determines a loading section Xt, which is a section X in which the ordered item group Go is loaded, according to the number of storage sections N determined by the section number determination process. In the example, the number of storage sections N determined by the section number determination process is "1", and the control device C determines only "A" of the four sections X, A, B, C, and D, as the loading section Xt. In this embodiment, when a section X (hereinafter referred to as "already loaded section") in which another ordered item group Go has already been loaded is included among the multiple sections X set on the loading surface Pf of the pallet P, the loading section determination process determines the loading section Xt so as to include the section X adjacent to the already loaded section in the arrangement direction of the sections X (in this example, the vertical direction or the horizontal direction in the figure). For example, when the section X indicated by "A" is an already loaded section and the number of storage sections N determined by the section number determination process is "1", the section X indicated by "B" or the section X indicated by "D" is determined as the loading section Xt, not the section X indicated by "C". By determining the loading section Xt in this way, when performing the loading process for the next ordered item group Go, it becomes easy to determine multiple consecutive sections X as one loading section Xt, as described later.

[0032] In this embodiment, the control device C determines the stowage section Xt to be rectangular in plan view in the stowage section determination process. In the illustrated example, the number of storage sections N determined by the section number determination process is "1", and the control device C determines only one of the multiple sections X as the stowage section Xt, so the stowage section Xt is rectangular in plan view.

[0033] In this embodiment, when the number N of storage sections determined by the section number determination process is 2 or more, the control device C determines N consecutive sections X (N≧2) among the multiple sections X as one stowage section Xt. This makes it possible to determine the stowage section Xt to be rectangular in plan view.

[0034] For example, as shown in FIG. 2, if the order information indicates that six items β, whose dimensions in plan view are larger than item α, are to be loaded ("item β: 6 pieces"), the item group occupation area Ag will span two sections X, so the number of storage sections N will be "2". In this case, by determining two adjacent sections X as loading sections Xt among the multiple sections X set on the loading surface Pf, the shape of the loading section Xt in plan view will be rectangular. In the illustrated example, among the four sections X of A, B, C, and D, the adjacent sections "B, C" are determined as one loading section Xt. This makes it easier to simplify the loading section determination process and the control for executing the subsequent transfer process. Note that in order to make the loading section Xt rectangular in plan view, the control device C may determine each combination of "A, B", "C, D", and "A, D" as one loading section Xt in the illustrated example. However, in this embodiment, the control device C does not determine a combination of two diagonally arranged sections X, such as "A, C" or "B, D", as one stowage section Xt.

[0035] 3, in the transfer process, the control device C controls the transfer device 4 to take out an item W related to the ordered item group Go from the single item group Gs in the picking area A1 and load the ordered item group Go in the loading section Xt. In the illustrated example, five items α related to the ordered item group Go are taken out from the single item group Gs composed of multiple items α and loaded in the loading section Xt.

[0036] In this embodiment, the control device C executes the transfer process so that the height of the highest part T of the ordered item group Go is the lowest while satisfying the condition that the item group occupation area Ag is the same. In the illustrated example, the control device C executes the transfer process so that the ordered item group Go of "item α: 5 pieces" is divided and arranged in two and three tiers. As a result, the upper end of the items α in the third tier becomes the highest part T. For example, if the transfer process is executed so that the ordered item group Go of "item α: 5 pieces" is divided and arranged in one and four tiers, the upper end of the items α in the fourth tier becomes the highest part T, and the height of the highest part T is higher than in the above case. If the transfer process is executed so that the items are arranged in five tiers, the height of the highest part T will be even higher. In the palletizing system 100, by executing the transfer process in this manner, it is possible to widen the item group occupation area Ag. This makes it easier to prevent the load from collapsing on the pallet P after loading.

[0037] Here, the control device C stores master information in which the shape and dimensions of the article W are registered in advance for each type of article W. The control device C stores master information supplied from another device, such as the above-mentioned general control device, or stores master information generated by the control device C performing the measurement process described below. In this embodiment, the control device C is configured to execute the occupancy area determination process by referring to the master information. In this way, by executing the occupancy area determination process by referring to the master information, the processing speed can be increased.

[0038] As shown in FIG. 4, in this embodiment, the control device C performs a measurement process to measure the shape and dimensions of the article W constituting the single article group Gs, and creates master information on the shape and dimensions of the article W constituting the single article group Gs based on the result of the measurement process. In this example, the control device C performs the measurement process based on information recognized by the recognition unit 42 (see FIG. 1) provided in the transfer device 4. As described above, in this example, the recognition unit 42 is configured using a camera, and the control device C performs the measurement process based on image information captured by the camera. When performing the measurement process, one of the multiple articles W constituting the single article group Gs is set as the measurement target, and the transfer device 4 temporarily separates the measurement target article W from the single article group Gs (specifically, the other articles W constituting the single article group Gs). This makes it possible to clearly grasp the outer shape of the measurement target article W, and to accurately calculate the shape and dimensions of the measurement target article W based on the image information captured by the camera (recognition unit 42). The control device C creates master information on the article W by such measurement process, and performs an occupation area determination process and the like based on the master information.

[0039] In this embodiment, when a predetermined condition is met, the control device C measures the shape and dimensions of the item W constituting the single item group Gs through a measurement process and updates the master information. The "predetermined condition" refers to a case where the master information needs to be updated, such as when an error in the master information is discovered or when the master information needs to be confirmed or changed. In such a case, the control device C updates the master information by performing the measurement process again, thereby enabling each subsequent process to be performed appropriately.

[0040] 5 and 6 illustrate a case where the control device C executes a stowage process for the second order item group Go based on the second order information after the stowage process for the first order item group Go based on the first order information is completed. In the figure, one of the two order item groups Go already stowed on the pallet P in the palletizing area A2 is the first order item group Go related to the first order information. Then, the order information created based on the single item group Gs placed on the pallet P in the waiting area A3 is the second order information. As described above, the control device C receives order information (second order information) related to the single item group Gs in the waiting area A3 when the single item group Gs is in the waiting area A3. In the illustrated example, the second order information is "item γ: 2 pieces". That is, the second order information specifies that two items γ are to be stowed. In the illustrated example, the item γ has a size equivalent to two storage compartments X by itself. In other words, when a single item γ is loaded onto the loading surface Pf of the pallet P, at least two sections X are required.

[0041] After the loading process for the first ordered group of items Go is completed based on the first order information, if there is an empty section Xe, which is a section X where no items W have been loaded, remaining on the loading surface Pf, the control device C executes the loading process for the second ordered group of items Go based on the second order information.

[0042] As shown in FIG. 5, in the stowage process of the second order item group Go, if the number of storage sections N determined by the section number determination process is equal to or less than the number of empty sections M, which is the number of empty sections Xe, the control device C executes the stowage section determination process according to the number of empty sections M. In the example shown in FIG. 5, the second order information is "item γ: 2 pieces", and the number of storage sections N determined based on this is "2". And, two empty sections Xe remain on the stacking surface Pf of the pallet P in the palletizing area A2, and the number of empty sections M is "2". That is, in the example shown in FIG. 5, the number of storage sections N (N=2) is equal to or less than the number of empty sections M (M=2) (in detail, the number of storage sections N=the number of empty sections M). Therefore, the control device C determines that the second order item group Go can be stacked on the pallet P in the palletizing area A2, and executes the stowage section determination process and the transfer process. In this example, when the control device C determines that the second ordered item group Go can be loaded onto the pallet P in the palletizing area A2, it controls the item group supplying device 1 to move the single item group Gs containing the second ordered item group Go from the waiting area A3 to the picking area A1.

[0043] As shown in FIG. 6, in the stowage process of the second order group Go, when the number of storage sections N determined by the section number determination process is greater than the number of empty sections M, which is the number of empty sections Xe, the control device C executes a pallet replacement process that controls the pallet unloading device 3 and the pallet supplying device 2 to unload the pallet P in the palletizing area A2 and supply a new pallet P to the palletizing area A2. In the example shown in FIG. 6, the second order information is "item γ: 2 pieces", and the number of storage sections N determined based on this is "2". And, one empty section Xe remains on the stacking surface Pf of the pallet P in the palletizing area A2, and the number of empty sections M is "1". That is, in the example shown in FIG. 6, the number of storage sections N (N=2) is greater than the number of empty sections M (M=1). Therefore, the control device C determines that the second ordered item group Go cannot be loaded onto the pallet P in the palletizing area A2, and executes a pallet replacement process, removes the pallet P in the palletizing area A2, and supplies a new pallet P to the palletizing area A2. The control device C then executes a stowage process to load the second ordered item group Go onto the new pallet P.

[0044] As described above, in this embodiment, the pallet discharge path R3 not only serves as a path for discharging the pallet P after palletizing, but also as a path for discharging the pallet P after picking. The picking area A1 is located in a part of the pallet discharge path R3. That is, the pallet P discharged from the palletizing area A2 passes through the picking area A1. In this embodiment, the single item group Gs to be supplied to the picking area A1 waits in the waiting area A3 before being supplied to the picking area A1. This prevents the pallet P carrying the single item group Gs from interfering with the pallet P (mixed pallet P) passing through the picking area A1 on the way out of the palletizing area A2.

[0045] Next, the procedure of the process executed by the control device C will be described with reference to the flowcharts of FIGS.

[0046] As shown in FIG. 7, when the control device C executes a stowage process, it first executes an occupied area determination process (#1). In the occupied area determination process, it determines an item group occupied area Ag, which is an area in a plan view when the ordered item group Go is stowed on the stowage surface Pf so that it is equal to or less than the limit height H (see FIG. 3). After executing the occupied area determination process, the control device C executes a section number determination process (#2). In the section number determination process, it determines the number of storage sections N, which is the number of sections X that can accommodate the item group occupied area Ag (see FIG. 3). After executing the section number determination process, the control device C executes a stowage section determination process (#3). In the stowage section determination process, it determines a stowage section Xt, which is the section X where the ordered item group Go is stowed, according to the number of storage sections N determined by the section number determination process (see FIG. 3). After executing the stowage section determination process, the control device C does not execute a transfer process. In the transfer process, the group of ordered items Go is loaded into the loading section Xt determined by the loading section determination process. The control device C is configured to execute the loading process by sequentially executing each process described above.

[0047] Fig. 8 shows the processing procedure of the control device C when executing stowage processing based on each of multiple order information. For ease of explanation, the stowage processing for stowage of the first ordered item group Go related to the first order information will be referred to as the "first stowage processing", and the stowage processing for stowage of the second ordered item group Go related to the second order information will be referred to as the "second stowage processing".

[0048] As shown in FIG. 8, after the first stowage process for the pallet P in the palletizing area A2 is completed (#10), the control device C judges whether or not an empty section Xe exists on the stacking surface Pf of the pallet P in the palletizing area A2 (#20). This judgment may be made, for example, based on information recognized by the recognition unit 42 of the transfer device 4. In this example, the control device C judges whether or not an empty section Xe exists on the stacking surface Pf based on image information captured by a camera serving as the recognition unit 42. If the control device C judges that an empty section Xe exists on the stacking surface Pf (#20: Yes), it executes the second stowage process (#30). On the other hand, if the control device C judges that an empty section Xe does not exist on the stacking surface Pf (#20: No), it executes the pallet replacement process (#40).

[0049] FIG. 9 shows the detailed procedure of step #30 in FIG. 8, that is, the second stowage process.

[0050] As shown in Fig. 9, when the control device C executes the second stowage process, it first executes an occupied area determination process based on the second ordered item group Go related to the second order information (#31). After executing the occupied area determination process, the control device C executes a section number determination process (#32). This determines the number of storage sections N based on the second ordered item group Go.

[0051] Next, the control device C judges whether the number of storage sections N is greater than the number of empty sections M, which is the number of empty sections Xe present on the pallet P (#33). If the control device C judges that the number of storage sections N is equal to or less than the number of empty sections M on the pallet P (#33: No), it judges that the second order item group Go can be loaded onto the pallet P, and executes a loading section determination process according to the number of empty sections M (#34) and a transfer process (#35). On the other hand, if the control device C judges that the number of storage sections N is greater than the number of empty sections M on the pallet P (#33: Yes), it judges that the second order item group Go cannot be loaded onto the pallet P, and executes a pallet replacement process (#36) and supplies a new pallet P (empty pallet P) to the palletizing area A2. After that, the control device C executes a loading section determination process (#34) and a transfer process (#35) for loading the second order item group Go onto the new pallet P.

[0052] Here, as shown in Fig. 10, cases may occur where the group of ordered items Go related to one piece of order information cannot be loaded into the initially determined loading section Xt due to incomplete master information indicating the shape and dimensions of the item W, or the collapse of the load during the loading work of the item W, etc. In the example shown in Fig. 10, the order information is "item α: 5 pieces", and the load collapse occurs while loading the group of ordered items Go related to the order information, resulting in a situation where the fourth and subsequent items W cannot be loaded into the initially determined loading section Xt.

[0053] In this embodiment, when the ordered goods group Go cannot be loaded in the loading section Xt in the transfer process, the control device C selects one of the goods W constituting the ordered goods group Go. After executing an occupation area redetermination process to determine an item group occupation area Ag for the items W that could not be stowed in the stowage section Xt of the pallet P, the control device C executes a section number redetermination process to determine the number of storage sections N that can accommodate the item group occupation area Ag determined by the occupation area redetermination process. If the number of storage sections N determined by the section number redetermination process is equal to or less than the number of empty sections M, which is the number of empty sections Xe of the pallet P in the palletizing area A2, the control device C executes a stowage section determination process and a transfer process in accordance with the number of storage sections N determined by the section number redetermination process.

[0054] In the example shown in FIG. 10, the control device C executes an occupancy area re-determination process and a section number re-determination process for the (5-3) items α that could not be loaded. The number of storage sections N determined by this section number re-determination process is "1". In addition, the number of empty sections M, which is the number of empty sections Xe present on the pallet P, is "1", which is the number before loading, "2", minus the loaded empty sections Xe. In this case, the number of storage sections N (N=1) determined by the section number re-determination process is less than the current number of empty sections M (M=1) (in detail, the number of storage sections N = the number of empty sections M). Therefore, the control device C executes a loading section determination process and a transfer process to load the remaining two items α that could not be loaded among the items α that constitute the ordered item group Go into the current empty section Xe. As a result, even if a load collapse occurs during the loading operation of the ordered item group Go, the ordered item group Go can be loaded onto one pallet P.

[0055] On the other hand, as shown in FIG. 11, the number of storage sections N determined by the section number re-determination process may be greater than the number of empty sections Xe of the pallet P in the palletizing area A2. In the example shown in FIG. 11, the number of empty sections M, which is the number of empty sections Xe present on the pallet P, is "0", which is the number before stacking, "1", minus the number of stacked empty sections Xe. In this case, since there is no empty section Xe on the pallet P for stacking the remaining two items α that could not be stacked among the items α constituting the order item group Go, stacking of further items α on this pallet P is impossible. In this embodiment, the control device C issues error information when the number of storage sections N (N=1 in the illustrated example) determined by the section number re-determination process is greater than the number of empty sections M (M=0 in the illustrated example), which is the number of empty sections Xe of the pallet P in the palletizing area A2. In this way, by issuing error information when stacking is impossible, the situation can be notified to an operator, etc., and the operator can perform the subsequent work. The control device C can notify the worker of the error information by a means that appeals to the worker's visual or auditory senses. For example, the control device C may display an error message on a terminal screen operated by the worker, or may blink or light a light. The control device C may also emit an alarm sound, or output an error message by voice.

[0056] According to the palletizing system 100 described above, when items W are loaded into multiple sections X set on the loading surface Pf of a single pallet P, it is possible to automatically load the items W so that they are appropriately positioned in each section X, taking into consideration the likelihood of the items falling apart.

[0057] Second Embodiment Next, a second embodiment of the palletizing system will be described. The following mainly describes the differences from the first embodiment. Points that are not particularly described are the same as those in the first embodiment.

[0058] As shown in the left diagram of FIG. 12, there are cases where the number of storage sections N determined by the section number re-determination process (N=1 in the illustrated example) is greater than the number of empty sections M (M=0 in the illustrated example), which is the number of empty sections Xe of the pallet P in the palletizing area A2. In this case, in the first embodiment, In the conventional example, the control device C is configured to notify error information. However, in this embodiment, the control device C executes a process other than error notification.

[0059] As shown in FIG. 12, in this embodiment, when the number of storage sections N determined by the section number re-determination process is greater than the number of empty sections M, which is the number of empty sections Xe on the pallet P in the palletizing area A2, the control device C removes from the stowage section Xt those items W that constitute the ordered item group Go that have already been loaded in the stowage section Xt, and then performs a pallet replacement process and a reloading process in which all items W that constitute the ordered item group Go, including the items W removed from the stowage section Xt, are loaded onto a new pallet P supplied to the palletizing area A2 by the pallet replacement process.

[0060] In the example shown in Fig. 12, the control device C executes an occupied area redetermining process and a section number redetermining process for the (5-3) items α that could not be loaded. The number of storage sections N determined by the section number redetermining process is "1" (N=1). The number of empty sections M of the pallet P in the palletizing area A2 is "0" (M=1-1=0). In this case, there is no empty section Xe on the pallet P to load the remaining two items α that could not be loaded among the items α that make up the ordered item group Go, so loading further items α onto the pallet P is not possible.

[0061] Therefore, the control device C controls the transfer device 4 to take out the three items α already stacked in the stacking section Xt from the pallet P (see the center diagram of FIG. 12). At this time, the control device C may control the transfer device 4 to temporarily return the three removed items α to the pallet P in the picking area A1, or may temporarily move them to a separate temporary placement table. Then, the control device C executes a pallet replacement process to replace the pallet P and supply a new pallet P to the palletizing area A2. After that, the control device C stacks all the items α constituting the order item group Go, including the three removed items α, that is, five items α in this case, onto the new pallet P. This series of processes is the reloading process. With this configuration, even if the order item group Go cannot be stacked within the initially determined stacking section Xt, it is possible to avoid the order item group Go related to one order information being stacked on two pallets P.

[0062] Other embodiments Next, other embodiments of the palletizing system will be described.

[0063] (1) In the above second embodiment, an example has been described in which the control device C replaces the pallet P by executing a pallet replacement process in the transshipment process, supplies a new pallet P to the palletizing area A2, and then stacks all of the items W that make up the group of ordered items Go, including the removed item W, onto the new pallet P. However, the present invention is not limited to this example, and the control device C does not need to execute a pallet replacement process in the transshipment process. In this case, after removing the item W that was loaded in the stowage section Xt from the stowage section Xt, the control device C may again load all of the items W that make up the group of ordered items Go, including the removed item W, into the stowage section Xt.

[0064] (2) In the above embodiment, an example was described in which the control device C executes the transfer process so that the height of the highest part T of the ordered item group Go is the lowest while satisfying the condition that the item group occupancy area Ag is the same. However, the present invention is not limited to such an example, and it is sufficient that the height of the highest part T is equal to or less than the limit height H (see FIG. 3).

[0065] (3) In the above embodiment, the control device C detects the shape and dimensions of the article W by using a pre-registered machine. In the above example, the control device C is configured to execute the occupancy area determination process by referring to the master information. However, the present invention is not limited to this example, and the control device C may execute the occupancy area determination process without referring to the master information. In this case, the control device C may recognize the shape and dimensions of the item W placed on the pallet P in the picking area A1 by the recognition unit 42 every time the control device C executes the stowage process.

[0066] (4) In the above embodiment, an example has been described in which four sections X, A, B, C, and D, are set on the loading surface Pf of the pallet P. However, the present invention is not limited to this example, and any number of sections X may be set on the loading surface Pf of the pallet P.

[0067] (5) In the above embodiment, an example has been described in which the control device C determines N consecutive (N≧2) sections X among the multiple sections X as one stowage section Xt when the number of storage sections N determined by the section number determination process is 2 or more. However, without being limited to such an example, the control device C may determine N non-consecutive (N≧2) sections X among the multiple sections X as one stowage section Xt. When N non-consecutive (N≧2) sections X are determined as one stowage section Xt, the stowage section Xt does not have a rectangular shape in a plan view.

[0068] (6) In the above embodiment, an example has been described in which the pallet discharge path R3 serves not only as a path for discharging the mixed pallet P after palletizing, but also as a path for discharging the pallet P after picking. However, the present invention is not limited to this example, and the path for discharging the mixed pallet P after palletizing and the path for discharging the pallet P after picking may be provided separately.

[0069] (7) The configurations disclosed in the above-described embodiments can be applied in combination with configurations disclosed in other embodiments, as long as no contradiction occurs. As for other configurations, the embodiments disclosed in this specification are merely examples in all respects. Therefore, various modifications can be made as appropriate within the scope of the present disclosure.

[0070] [Summary of the above embodiment] The above-described palletizing system will now be described.

[0071] an article group supplying device that supplies a single article group consisting of a plurality of articles of a single type to a picking area; a pallet supply device that supplies pallets to a palletizing area; a pallet removal device that removes the pallet from the palletizing area; A transfer device that transfers the items between the picking area and the palletizing area; A palletizing system comprising: a control device that controls the article group supply device, the pallet supply device, the pallet carry-out device, and the transfer device, the control device is capable of receiving order information specifying the type and number of the items to be loaded onto the pallet in the palletizing area, and executing a loading process of loading the ordered item group onto the pallet, the ordered item group being the type and number of the items specified by the order information; A plurality of compartments are set on the loading surface of the pallet, and a limit height is set, which is an upper limit of the height of the items that can be loaded on the loading surface; The control device, in the stowage processing, an occupancy area determination process for determining an item group occupancy area, which is an area in a plan view when the ordered item group is stacked on the stowage surface so as to be equal to or less than the limit height; a compartment number determination process for determining a number N of storage compartments (N is a natural number) that is the number of compartments that can accommodate the item group occupation area; a stowage section determination process for determining a stowage section, which is the section in which the group of ordered items is to be stowed, according to the number of storage sections N determined by the section number determination process; a transfer process for controlling the transfer device to pick up the items related to the ordered item group from the single item group in the picking area and load the ordered item group in the loading section; the control device, after completing the stowage process for the first ordered item group based on the first order information, when an empty section remains on the stowage surface, which is the section in which no item is stowed, executes the stowage process for the second ordered item group based on the second order information; When the number of storage compartments N determined by the compartment number determination process is greater than the number of empty compartments during the stowage process of the second group of ordered items, the control device executes a pallet replacement process that controls the pallet removal device and the pallet supply device to remove the pallet in the palletizing area and supply a new pallet to the palletizing area.

[0072] According to this configuration, it is possible to automatically and appropriately stack items in a plurality of compartments set on the stacking surface of a pallet according to the group of ordered items related to the order information and the state of the stacking surface of the pallet. In addition, in the stacking process, since the items are stacked within the range of the limit height at which the items can be stacked on the stacking surface, it is easy to prevent the load from collapsing on the pallet after stacking. Furthermore, according to this configuration, it is automatically determined whether or not the group of ordered items related to one order information can be stacked on the same pallet, and if it is possible, the stacking is performed. If it is not possible to stack the items, a pallet replacement process is performed to supply a new pallet to the palletizing area. In this way, it is possible to stack the group of ordered items related to one order information on the same pallet. As described above, according to this configuration, when items are stacked in a plurality of compartments set on the stacking surface of one pallet, it is possible to automatically stack the items so that the items are appropriately arranged in each compartment, taking into consideration the difficulty of causing the load to collapse.

[0073] When the ordered item group cannot be loaded into the loading section in the transfer process, the control device executes an occupation area redetermination process to determine the item group occupation area for the items that cannot be loaded into the loading section among the items constituting the ordered item group, and then executes a section number redetermination process to determine the number of storage sections N that can accommodate the item group occupation area determined by the occupation area redetermination process, The control device includes: If the number of storage sections N determined by the section number re-determination process is equal to or less than the number of empty sections of the pallet in the palletizing area, execute the stowage section determination process and the transfer process according to the number of storage sections N determined by the section number re-determination process; It is preferable that, when the number N of storage sections determined by the section number re-determination process is greater than the number of empty sections of the pallet in the palletizing area, error information is notified.

[0074] There may be cases where a group of ordered items related to one order information cannot be stowed within the initially determined stowage section due to incomplete master information indicating the shape and dimensions of the items, or the collapse of the cargo during the stowage work of the items, etc. With this configuration, even in such a case, the situation is taken into consideration and it is automatically determined whether or not the group of ordered items related to the order information can be stowed on the same pallet. If stowage is possible, stowage is carried out. If stowage is not possible, an error message is issued to inform a worker or the like of the situation, so that the worker can carry out the subsequent work. As described above, with this configuration, it is possible to stow a group of ordered items within the initially determined stowage section. Even if this is not possible, it is possible to avoid a situation where a group of ordered items related to one piece of order information is packed onto two pallets.

[0075] When the ordered item group cannot be loaded into the loading section in the transfer process, the control device executes an occupation area redetermination process to determine the item group occupation area for the items that cannot be loaded into the loading section among the items constituting the ordered item group, and then executes a section number redetermination process to determine the number of storage sections N that can accommodate the item group occupation area determined by the occupation area redetermination process, The control device includes: If the number of storage sections N determined by the section number re-determination process is equal to or less than the number of empty sections of the pallet in the palletizing area, execute the stowage section determination process and the transfer process according to the number of storage sections N determined by the section number re-determination process; If the number of storage sections N determined by the section number re-determination process is greater than the number of empty sections on the pallet in the pallet in the palletizing area, it is preferable to remove from the stowage section those items that make up the group of ordered items that have already been loaded in the stowage section, and then execute the pallet replacement process, while simultaneously executing a reloading process in which all of the items that make up the group of ordered items, including the items removed from the stowage section, are loaded onto a new pallet supplied to the palletizing area by the pallet replacement process.

[0076] There may be cases where a group of ordered items related to one order information cannot be loaded in the initially determined loading section due to insufficient master information indicating the shape and dimensions of the items, or due to a collapse of the cargo during loading work of the items. According to the present configuration, even in such a case, it is automatically determined whether the group of ordered items related to the above order information can be loaded on the same pallet while taking into consideration the situation. If loading is possible, loading is performed. If loading is impossible, the items already loaded in the loading section are removed from the loading section, and then all items constituting the group of ordered items including the items removed from the loading section are loaded onto a pallet newly supplied to the palletizing area. In this way, according to the present configuration, even if the group of ordered items cannot be loaded into the initially determined loading section, it is possible to avoid the group of ordered items related to one order information being loaded onto two pallets. Note that after the items loaded in the loading section are removed from the loading section, all items constituting the group of ordered items including the removed items may be loaded again into the loading section.

[0077] It is preferable that, in the stowage section determination process, the control device determines the stowage section to have a rectangular shape in a plan view.

[0078] According to this configuration, it is easy to simplify the control for executing the stowage section determination process and the subsequent transfer process.

[0079] It is preferable that the control device executes the transfer process so that the height of the highest part of the ordered item group is the lowest while satisfying the condition that the item group occupation area is the same.

[0080] According to this configuration, it is possible to easily prevent the load from collapsing on the pallet after loading, without expanding the area occupied by the group of items.

[0081] The control device is configured to execute the occupancy area determination process by referring to master information in which the shape and dimensions of the article are registered in advance, It is preferable that, when a predetermined condition is met, the control device performs a measurement process to measure the shape and dimensions of the articles that constitute the single article group, and updates the master information.

[0082] According to this configuration, the occupancy area determination process is performed by referring to the master information, so that the processing speed can be increased. Also, when it becomes necessary to update the master information, such as when an error in the master information is found or when it becomes necessary to confirm or change the master information, the shape and dimensions of the item can be measured on the item conveying line, and the master information can be updated. [Industrial Applicability]

[0083] The technology disclosed herein can be used in palletizing systems. [Explanation of symbols]

[0084] 100: Palletizing system 1: Goods group supply device 2: Pallet supply device 3: Pallet removal device 4:Transfer device C: Control device A1: Picking area A2: Palletizing area P: Palette Pf: Loading surface X : Partition Xe: Empty parcel Xt: Loading section Ag: Goods group occupied area H: Height limit N: Number of storage compartments Gs: Single item group Go: Order items W:Goods T:Top part α :Goods β :Goods γ :Goods

Claims

1. an article group supplying device that supplies a single article group consisting of a plurality of articles of a single type to a picking area; a pallet supply device that supplies pallets to a palletizing area; a pallet removal device that removes the pallet from the palletizing area; A transfer device that transfers the items between the picking area and the palletizing area; A palletizing system comprising: a control device that controls the article group supply device, the pallet supply device, the pallet carry-out device, and the transfer device, the control device is capable of receiving order information specifying the type and number of the items to be loaded onto the pallet in the palletizing area, and executing a loading process of loading the ordered item group onto the pallet, the ordered item group being the type and number of the items specified by the order information; A plurality of compartments are set on the loading surface of the pallet, and a limit height is set, which is an upper limit of the height of the items that can be loaded on the loading surface; The control device, in the stowage processing, an occupancy area determination process for determining an item group occupancy area, which is an area in a plan view when the ordered item group is stacked on the stowage surface so as to be equal to or less than the limit height; a compartment number determination process for determining a number N of storage compartments (N is a natural number) that is the number of compartments that can accommodate the item group occupation area; a stowage section determination process for determining a stowage section, which is the section in which the group of ordered items is to be stowed, according to the number of storage sections N determined by the section number determination process; a transfer process for controlling the transfer device to pick up the items related to the ordered item group from the single item group in the picking area and load the ordered item group in the loading section; the control device, after completing the stowage process for the first ordered item group based on the first order information, when an empty section remains on the stowage surface, which is the section in which no item is stowed, executes the stowage process for the second ordered item group based on the second order information; A palletizing system in which, when the number of storage compartments N determined by the compartment number determination process during the stowage process of the second group of ordered items is greater than the number of empty compartments, the control device executes a pallet replacement process that controls the pallet unloading device and the pallet supplying device to unload the pallet in the palletizing area and supply a new pallet to the palletizing area.

2. When the ordered item group cannot be loaded into the loading section in the transfer process, the control device executes an occupation area redetermination process to determine the item group occupation area for the items that cannot be loaded into the loading section among the items constituting the ordered item group, and then executes a section number redetermination process to determine the number of storage sections N that can accommodate the item group occupation area determined by the occupation area redetermination process, The control device includes: If the number of storage sections N determined by the section number re-determination process is equal to or less than the number of empty sections of the pallet in the palletizing area, execute the stowage section determination process and the transfer process according to the number of storage sections N determined by the section number re-determination process; The palletizing system according to claim 1 , wherein if the number of storage sections N determined by the section number re-determination process is greater than the number of empty sections of the pallet in the palletizing area, error information is notified.

3. When the ordered item group cannot be loaded into the loading section in the transfer process, the control device executes an occupation area redetermination process to determine the item group occupation area for the items that cannot be loaded into the loading section among the items constituting the ordered item group, and then executes a section number redetermination process to determine the number of storage sections N that can accommodate the item group occupation area determined by the occupation area redetermination process, The control device includes: If the number of storage sections N determined by the section number re-determination process is equal to or less than the number of empty sections of the pallet in the palletizing area, execute the stowage section determination process and the transfer process according to the number of storage sections N determined by the section number re-determination process; 2. The palletizing system of claim 1, further comprising: if the number of storage sections N determined by the section number re-determination process is greater than the number of empty sections on the pallet in the pallet in the palletizing area, then the items that make up the group of ordered items and that have already been loaded in the stowage section are removed from the stowage section, and then the pallet replacement process is performed, and a reloading process is performed to load all of the items that make up the group of ordered items, including the items removed from the stowage section, onto a new pallet supplied to the palletizing area by the pallet replacement process.

4. The palletizing system according to claim 1 , wherein the control device, in the stowage section determination process, determines the stowage sections to have a rectangular shape in a plan view.

5. The palletizing system according to any one of claims 1 to 4, wherein the control device executes the transfer process so as to minimize the height of the highest part of the ordered item group while satisfying the condition that the item group occupation area is the same.

6. The control device is configured to execute the occupancy area determination process by referring to master information in which the shape and dimensions of the article are registered in advance, The palletizing system according to any one of claims 1 to 5, wherein the control device performs a measurement process to measure the shape and dimensions of the items that constitute the single item group when predetermined conditions are met, and updates the master information.

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