Automatic warehouse system

Abstract

To provide an automatic warehouse system capable of reducing manpower or space for picking.SOLUTION: An automatic warehouse system 100 comprises a storage shelf 22 having a plurality of storage parts 26 for storing a cargo 10, a picking device 18 for moving a first cargo stored in a first storage part 26p to a second storage part 26s in which a second cargo is stored, and a carrying-out device 28 for carrying the first cargo and the second cargo stored in the second storage part 26s together out of the storage shelf 22.SELECTED DRAWING: Figure 3

Description

[Technical field]

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

[0002] There is known a picking device for collecting products in a storage area or products temporarily placed thereto to a shipping area. For example, 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 the items 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 pallet. [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] The present inventors have studied automated warehouse systems and have come to the following realization. FIG. 17 is a diagram for explaining the flow from storage to retrieval in the automated warehouse system of the comparative example. FIG. 18 is a plan view showing the layout of the automated warehouse system of the comparative example. First, a single-loading pallet loaded with a plurality of loads of the same type is transported by a vehicle such as a truck, and the single-loading pallet is unloaded from the vehicle using a transport device such as a forklift (transported into the warehouse). In the automated warehouse system of the comparative example, a single-loading pallet loaded with a plurality of loads of the same type is stored (FIG. 17(a)), and a mixed pallet loaded with a plurality of loads and the single-loading pallet are retrievaled according to the request of the destination (FIG. 17(e)). For this purpose, in the automated warehouse system of the comparative example, the loads on the single-loading pallet are separated into a predetermined unit (hereinafter referred to as "case") (FIG. 17(b)), and the separated cases are stored in a case storage section (FIG. 17(c)). In addition, when retrieval is performed, different types of cases are stacked on the pallet according to the request of the destination to create a mixed pallet (FIG. 17(d)).

[0005] To realize this process, as shown in FIG. 18, it takes a lot of work to separate the single pallets that have been brought in into cases and to collect the separated and stored cases to create a mixed pallet (hereinafter referred to as "picking"). It is also difficult to secure workers to carry out the picking. In addition, the automated warehouse system of the comparative example requires a case storage section and space for picking in addition to the storage shelves for storing single pallets and mixed pallets, and therefore requires a large site area. In addition, when the site area is fixed, the storage shelves for storing single pallets must be made smaller by the amount of the case storage section and the space for picking, which reduces the number of loads that can be stored.

[0006] From these findings, the present inventors recognized that there is room for improvement in automated warehouse systems in terms of reducing the manpower and space required for picking.

[0007] The present invention has been made in consideration of such problems, and one of its objects is to provide an automated warehouse system that can reduce the manpower and space required for picking. [Means for solving the problem]

[0008] In order to solve the above problems, an automated warehouse system according to one embodiment of the present invention includes a storage shelf having a plurality of storage sections for storing items, a picking device that moves a first item stored in the first storage section to a second storage section in which a second item is stored, and an unloading device that unloads the first item and the second item stored in the second storage section together from the storage shelf.

[0009] 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

[0010] According to the present invention, it is possible to provide an automated warehouse system that can reduce the manpower and space required for picking. [Brief description of the drawings]

[0011] [Figure 1] 1 is a plan view illustrating an example of an automated warehouse system according to an embodiment of the present invention. [Diagram 2] 2 is an enlarged plan view showing the picking device of FIG. 1. [Diagram 3] FIG. 2 is a side view illustrating the automated warehouse system of FIG. 1. [Figure 4] 4 is an enlarged side view of the picking device of FIG. 3. [Diagram 5] 2 is a plan view illustrating an example of a first cart in the automated warehouse system of FIG. 1. [Figure 6] FIG. 6 is a front view of the first bogie in FIG. 5. [Figure 7] 2 is a plan view illustrating an example of a second cart in the automated warehouse system of FIG. 1. [Figure 8] FIG. 8 is a front view of the second bogie in FIG. [Figure 9] 2 is a bottom view showing the holding section of the picking device of FIG. 1. [Figure 10]FIG. 13 is a diagram illustrating the process of transferring a load from one pallet to another pallet. [Figure 11] FIG. 13 is a diagram illustrating the process of transferring a load from one pallet to another pallet. [Figure 12] FIG. 13 is a diagram illustrating the process of transferring a load from one pallet to another pallet. [Figure 13] FIG. 13 is a diagram illustrating the process of transferring a load from one pallet to another pallet. [Figure 14] FIG. 2 is an explanatory diagram illustrating an example of a picking operation of the automated warehouse system in FIG. [Figure 15] FIG. 11 is a plan view showing the periphery of the loading section and the unloading section of the first modified example. [Figure 16] FIG. 11 is a plan view showing the periphery of the loading section and the unloading section of the second modified example. [Figure 17] FIG. 1 is a diagram illustrating the flow from storage to shipping in an automated warehouse system of a comparative example. [Figure 18] FIG. 18 is a plan view showing the layout of the automated warehouse system of FIG. 17. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] The present invention will be described below based on preferred embodiments with reference to the drawings. In the embodiments and modifications, 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.

[0013] 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.

[0014] [First embodiment] The configuration of the automated warehouse system 100 according to the first embodiment will be described with reference to the drawings. FIG. 1 is a plan view that shows a schematic example of the automated warehouse system 100 according to the first embodiment. FIG. 2 is a plan view that shows an enlarged view of the picking device 18 in FIG. 1. FIG. 3 is a side view that shows a schematic view of the automated warehouse system 100. FIG. 4 is a side view that shows an enlarged view of the picking device 18 in FIG. 3. In these drawings, the illustration of some pillars, beams, etc. is omitted.

[0015] For ease of explanation, as shown in the figure, an XYZ Cartesian coordinate system is defined in which a certain 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, i.e., the vertical direction, is the Z-axis direction. The positive directions of the X-axis, Y-axis, and Z-axis are defined as the directions of the arrows in each figure, and the negative directions are defined as the directions opposite to the arrows. 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.

[0016] In this specification, one or more items stored in a case such as a cardboard box is referred to as a load 10. An empty pallet is simply referred to as a "pallet". A single or multiple loads 10 of the same type are placed on a single pallet and a mixed pallet 12M is placed on a single pallet. For convenience, the mixed pallet 12M is also used when some of the loads to be placed are not loaded. The single pallet 12S and the mixed pallet 12M refer to a combination of a pallet and the load on the pallet. Hereinafter, the single pallet 12S and the mixed pallet 12M are collectively referred to as a "loaded pallet 12". The loaded pallet 12 may be composed of multiple stacked layers, and each layer may include multiple loads 10. The loaded pallet 12 may be the smallest unit to be stored, stored, and removed from the automated warehouse system 100. The load 10 may be the smallest unit to be handled when picking.

[0017] First, we will explain the overall configuration of the automated warehouse system 100. The automated warehouse system 100 is a system including a storage shelf 22 capable of storing a large number of articles 10. As shown in Fig. 1, the automated warehouse system 100 includes the storage shelf 22, an article sorting unit 20, a first cart 14, a second cart 16, a picking device 18, a carry-out device 28, a transfer mechanism 32, and a control unit 30.

[0018] The storage shelf 22 has a plurality of storage sections 26 for storing the loaded pallets 12. The goods sorting section 20 uses a picking device 18 to pick goods from the single pallets 12S before picking in the storage shelf 22, and creates a mixed pallet 12M (see FIG. 3). In order to create the mixed pallet 12M, the picking device 18 moves the goods 10 stored in one storage section 26 to another storage section 26. The first cart 14 is a cart that can carry the loaded pallet 12 and travel in the Y-axis direction on the storage shelf 22. The second cart 16 is a cart that can carry the loaded pallet 12 and the first cart 14 and travel in the X-axis direction on the storage shelf 22.

[0019] The discharge device 28 is a device for discharging the mixed pallet 12M created by picking from the storage shelf 22. The transfer mechanism 32 includes a lifting device 34 for raising and lowering the loaded pallet 12, and transfers the load 10 from one storage section 26 to another storage section 26. The control unit 30 controls the operations of the first cart 14, the second cart 16, the picking device 18, the discharge device 28, the transfer mechanism 32 and the lifting device 34. These elements will be described in detail below.

[0020] (Storage shelf) A plurality of storage shelves 22 are installed on the floor Lg, and are a so-called high-density storage type storage space capable of storing a large number of loads 10. As shown in FIG. 1, the storage shelf 22 of this embodiment includes three storage shelves 22a, 22b, and 22c. The storage shelves 22a, 22b, and 22c are divided by a second rail 44 and are arranged in this order from the negative direction to the positive direction in the Y-axis direction. The configuration of the storage shelves 22a, 22b, and 22c is not particularly limited as long as they can store and store a plurality of loads 10. The storage shelves 22a, 22b, and 22c have a plurality of storage stages 24 (for example, three stages) stacked in layers in the vertical direction. Each storage stage 24 includes a plurality of storage sections 26 arranged in the X-axis direction and the Y-axis direction. Each storage section 26 is configured to be able to store a loading pallet 12.

[0021] The topmost storage tier of storage shelf 22a is referred to as top storage tier 24a1, and the tiers other than top storage tier 24a1 are referred to as storage tiers 24a2. The topmost storage tier of storage shelf 22b is referred to as top storage tier 24b1, and the tiers other than top storage tier 24b1 are referred to as storage tiers 24b2. The topmost storage tier of storage shelf 22c is referred to as top storage tier 24c1, and the tiers other than top storage tier 24c1 are referred to as storage tiers 24c2. Hereinafter, the top storage tiers 24a1, 24b1, and 24c1 will be collectively referred to as top storage tier 24p, and the tiers 24a2, 24b2, and 24c2 will be collectively referred to as storage tier 24s.

[0022] The sorting section 20 will be described. As described above, the sorting section 20 functions as a picking space for picking using the picking device 18 in the storage shelf 22. The sorting section 20 is provided with a first storage section 26p and a second storage section 26s for picking. The first storage section 26p is provided for placing the single-loading pallet 12S before picking, and the second storage section 26s is provided for placing the mixed-loading pallet 12M after picking. Note that the first storage section 26p and the second storage section 26s do not refer to a specific location in the picking space, but refer to a space for temporarily storing the loading pallet 12. Therefore, the positions and ranges of the first storage section 26p and the second storage section 26s in the sorting section 20 may change for each picking operation.

[0023] Although there is no limitation on the arrangement of the arranging section 20, the arranging section 20 in this embodiment is provided in the top storage tier 24b1 of the storage shelf 22b. The top storage tier 24b1 may be used entirely as the arranging section 20, but in this example, a part of the top storage tier 24b1 is used as the arranging section 20, and the remaining area is used for storing the loading pallets 12. In other words, based on the retrieval plan, when the retrieval frequency is high, the area used as the arranging section 20 may be expanded, and when the retrieval frequency is low, the area used as the arranging section 20 may be reduced. Since the retrieval can be flexibly expanded and contracted, the storage shelf 22b can be used effectively, and space efficiency is improved. The arranging section 20 is provided with a first storage section 26p and a second storage section 26s.

[0024] (rail) The storage shelf 22 is provided with a first rail 40 along which the first carriage 14 runs, and a second rail 44 along which the second carriage 16 runs. The first rail 40 extends in the Y-axis direction in the storage shelves 22a, 22b, and 22c. The first rail 40 is provided below each storage section 26 in each storage stage. The first carriage 14 can run below each storage section 26 in each storage stage. The second rail 44 extends in the X-axis direction in each storage stage between the storage shelves 22a and 22b and between the storage shelves 22b and 22c. In each storage stage, a power supply unit (not shown) for supplying power to the second carriage 16 is provided along the second rail 44.

[0025] An entrance section 50 and an exit section 52 are provided adjacent to one end of the second rail 44. In this embodiment, the entrance section 50 and the exit section 52 are provided in each storage tier 24. The entrance section 50 functions as an entrance to the storage shelf 22 that receives the loaded pallet 12 to be stored. The exit section 52 functions as an exit to the storage shelf 22 that receives the loaded pallet 12 to be shipped. A lifting device 34 is connected adjacent to one end of the second rail 44. The lifting device 34 can raise and lower the first cart 14 and the loaded pallet 12 from any storage tier 24 to another storage tier 24.

[0026] (First cart) Next, the first carriage 14 will be described with reference to Figs. 5 and 6. Fig. 5 is a plan view that shows a schematic example of the first carriage 14. Fig. 6 is a front view of the first carriage 14. As described above, the first carriage 14 carries the loading pallet 12 and travels on the first rails 40 of each storage stage of the storage shelves 22a, 22b, and 22c in the Y-axis direction. The first carriage 14 takes the loading pallet 12 in and out of the storage section 26. The first carriage 14 travels on the second carriage 16 in the Y-axis direction to get on and off the second carriage 16.

[0027] The first cart 14 mainly includes a car body 14b, a platform section 14c, a lift mechanism 14d, and a plurality of (for example, four) wheels 14f. The car body 14b has a generally rectangular parallelepiped shape that is flat in the vertical direction. Inside the car body 14b, a motor (not shown) that drives the plurality of wheels 14f, a control circuit (not shown) that controls the motor, and a battery (not shown) are mounted. The first cart 14 is configured to drive the motor using the power of the battery. The battery is a secondary battery such as a repeatedly rechargeable lithium ion battery.

[0028] The loading platform 14c is a portion that lifts and holds the loading pallet 12. The lift mechanism 14d is a mechanism that raises and lowers the loading platform 14c. In FIG. 6, the loading platform 14c in the raised state is shown by a dashed line, and the loading platform 14c in the lowered state is shown by a solid line. The lift mechanism 14d can raise the loading platform 14c and lift the loading pallet 12 from the loading surface of the storage section 26. The lift mechanism 14d can lower the loading platform 14c and lower the loading pallet 12 onto the loading surface of the storage section 26. The multiple wheels 14f can roll on the first rail 40 and the second cart 16.

[0029] (Second bogie) Next, the second carriage 16 will be described with reference to Figs. 7 and 8. Fig. 7 is a plan view that shows a schematic example of the second carriage 16. Fig. 8 is a front view of the second carriage 16, showing the state in which the first carriage 14 is mounted. The second carriage 16 travels on the second rail 44 in the X-axis direction. The second carriage 16 transports the first carriage 14 in an empty state or in a state in which the loading pallet 12 is mounted.

[0030] The second bogie 16 mainly includes a bogie mounting portion 16c, a housing portion 16d, a cover portion 16e, a plurality of (for example, four) wheels 16f, and a current collecting unit 38. The bogie mounting portion 16c is provided in the center of the second bogie 16 in the X-axis direction. The bogie mounting portion 16c is a portion for mounting the first bogie 14, and has a pair of guide portions 16j that guide the first bogie 14. The cross section of each guide portion 16j has an angular sideways U-shape when viewed from the front. When viewed from the front, the second bogie 16 has a generally concave shape with the bogie mounting portion 16c recessed from the left and right.

[0031] The housing 16d and the cover 16e are provided on both sides of the cart mounting portion 16c in the X-axis direction, separated from each other. The housing 16d and the cover 16e each cover a part of the multiple wheels 16f from above. The housing 16d functions as a casing that houses a motor (not shown) for driving the wheels 16f and a control circuit (not shown) that controls the motor.

[0032] The second cart 16 receives power from the power supply unit via the power collection unit 38. The second cart 16 is configured to be able to rotate a motor (not shown) by the received power to drive the wheels 16f. The second cart 16 is configured to be able to charge the battery of the first cart 14 by the received power.

[0033] (Picking device) The picking device 18 will be described. As shown in FIG. 4, the picking device 18 moves the load 10 stored in the first storage section 26p to the second storage section 26s in which another load 10 is stored. Hereinafter, the load 10 stored in the first storage section 26p and moved by the picking device 18 will be referred to as the "first load 10a" or "load 10a", and the load 10 that was already stored in the second storage section 26s before the load 10a was moved will be referred to as the "second load 10b" or "load 10b". In other words, the load 10b refers to the load that was stored in the second storage section 26s before the load 10a, and the load 10a refers to the load that was stored in the second storage section 26s after the load 10b. It does not matter whether the load 10a and the load 10b are the same type of load 10 or different types of loads 10.

[0034] As shown in FIG. 1, the picking device 18 is provided at a position overlapping with the storage shelf 22 in a plan view. The picking device 18 can pick up the target load 10 from the loading pallet 12 in the top storage stage 24b1 of the storage shelf 22b and transfer it to another pallet. The picking device 18 may include a so-called gantry-type crane mechanism. As shown in FIG. 4, the picking device 18 of this embodiment includes a pair of cross beams 18e, a cross girder 18k, a crane cart 18d, a hanging part 18j, and a holding part 18h. The pair of cross beams 18e are provided at a distance on both sides in the Y-axis direction in the upper space of the top storage stage 24b1. Both ends of the cross beam 18e are supported by the upper ends of the vertical columns 18g.

[0035] The cross beam 18k is a rail-like structure extending in the Y-axis direction, and is spanned between a pair of cross beams 18e. The cross beam 18k is configured to be self-moving on the cross beam 18e in the X-axis direction. The cross beam 18k is sometimes called a crane girder. The crane dolly 18d is a dolly that is self-moving on the cross beam 18k in the Y-axis direction. The crane dolly 18d is sometimes called a trolley dolly. The hanging part 18j can hang the holding part 18h from the crane dolly 18d and move it up and down in the Z-axis direction. The hanging part 18j can also rotate the holding part 18h horizontally. The holding part 18h is provided at the tip of the hanging part 18j, and is configured to be able to lift the load 10.

[0036] The picking device 18 can freely move the holder 18h in the X-axis direction, the Y-axis direction, and the Z-axis direction in the space above the top storage tier 24b1. By moving the holder 18h, the picking device 18 can pick up the target load 10 from above one storage section of the top storage tier 24b1, move it horizontally, and unload the target load 10 from above onto a pallet in another storage section 26 of the top storage tier 24b1.

[0037] The holder 18h will be described. FIG. 9 is a bottom view showing the holder 18h of the picking device 18. The holder 18h has a substantially rectangular shape when viewed from the bottom. A plurality of suction parts 18s are arranged in a matrix in the X-axis direction and the Y-axis direction on the bottom surface of the holder 18h. Each suction part 18s can generate an adhesive force independently. That is, the holder 18h can select an adhesive part 18s that generates an adhesive force, and thereby adsorb and hold the load 10 in the area corresponding to the adhesive part 18s. The adhesive part 18s may be configured to generate an adhesive force by sucking in air.

[0038] 10 to 13 are top views illustrating the process of transferring a load 10 from a source pallet to a destination pallet. For example, the source pallet may be a single-loading pallet 12S stored in the first storage section 26p. In this example, the source pallet has eight loads 10 stacked on each layer. For example, the destination pallet may be an empty pallet stored in the second storage section 26s. In explaining these figures, the loads 10 are distinguished by adding "(1)", "(2)", and "(3)" to the end of the reference numerals.

[0039] 10, the holding unit 18h generates an adsorption force in the adsorption unit 18s among the multiple adsorption units 18s that corresponds to the single load 10(1) so as to adsorb only the load 10(1). In this example, the picking device 18 takes out only the load 10(1) from the source pallet, moves it horizontally, and drops it onto the destination pallet.

[0040] 11, the holding unit 18h generates an adsorption force in the adsorption units 18s corresponding to the multiple loads 10(2) among the multiple adsorption units 18s so as to adsorb only the multiple loads 10(2) (e.g., five loads 10(2). In this example, the picking device 18 takes out only the multiple loads 10(2) from the source pallet, moves them horizontally, and drops them onto the destination pallet.

[0041] 12, the holding unit 18h generates an adhesive force in the adhesive unit 18s corresponding to the load 10(3) of one layer among the plurality of adhesive units 18s so as to adsorb all the loads 10(3) of one layer. In this case, the holding unit 18h may generate an adhesive force in all the adhesive units 18s.

[0042] 13, the holding unit 18h generates an adsorption force on the adsorption unit 18s among the multiple adsorption units 18s that corresponds to the single load 10(1) so as to adsorb only this load 10(1). In this example, the picking device 18 takes out only the load 10(1) from the source pallet, moves it horizontally and rotates it horizontally, and lowers the load 10(1) onto the destination pallet in a changed position.

[0043] In this manner, the picking device 18 of this embodiment can transfer a desired number of loads 10 from among a plurality of loads 10 on one layer in one picking operation.

[0044] (Unloading device) The carry-out device 28 will be described with reference to Figs. 1 to 4 and 14. The carry-out device 28 is a device for carrying out the mixed pallet 12M in the second storage section 26s from the storage shelf 22. There are no limitations on the configuration of the carry-out device 28, but in this embodiment, the carry-out device 28 is realized by the first cart 14 and the second cart 16. The carry-out device 28 may include a lifting device 34.

[0045] An example of the operation of the discharge device 28 will now be described. (1) In this example, the first cart 14 moves to the bottom of the second storage section 26s, loads the mixed pallet 12M, and then travels in the Y-axis direction on the first rail 40 of the storage shelf 22b1 to move onto the second cart 16. (2) The second cart 16 travels on the second rail 44 to transport the first cart 14 carrying the mixed pallet 12M to the outgoing section 52. This transport ends the operation of the carry-out device 28. The mixed pallet 12M transported to the outgoing section 52 is carried out, for example, by a forklift 54 ​​and loaded onto external transport means 56 such as a truck. In this case, the forklift 54 ​​loads the mixed pallet 12M from the outgoing section 52 of the desired level onto the external transport means 56.

[0046] The discharge device 28 may be used to transfer the mixed pallet 12M stored in the second storage section 26s to another storage shelf. For example, the discharge device 28 may be controlled to transfer the mixed pallet 12M stored in the second storage section 26s of the storage shelf 22b to the storage shelves 22c and 22a.

[0047] (transfer mechanism) The transfer mechanism 32 will be described. The transfer mechanism 32 is a mechanism for transferring the load 10 from the storage section 26 of one storage stage to the storage section 26 of another storage stage. The transfer mechanism 32 of this embodiment transfers the load 10 from the storage section 26 (transfer source) of the storage stage 24s other than the top storage stage 24p to the first storage section 26p (transfer destination) of the load sorting section 20. Here, the load 10 transferred to the first storage section 26p by the transfer mechanism 32 is referred to as the "third load 10c" or "load 10c". The load 10c may be the same type of load 10 as the load 10a or the load 10b, or may be a different type of load 10. The storage section 26 of the transfer source may be any of the storage sections of the storage shelves 22a, 22b, and 22c. There is no limitation on the configuration of the transfer mechanism 32, but in this embodiment, the transfer mechanism 32 is realized by the first cart 14, the second cart 16, and the lifting device 34.

[0048] A description will now be given of an example of the operation of the transfer mechanism 32. In this example, a single-loading pallet 12S including a third load 10c is transferred from the storage section 26 (origin) of the second storage level 24a2 of the storage shelf 22a to the destination. (1) The first cart 14 moves to the lower part of the source storage section 26, loads the single pallet 12S, and travels in the Y-axis direction on the first rail 40 of the storage shelf 22a1 to move onto the second cart 16. (2) The second carriage 16 travels on the second rail 44 and transports the first carriage 14 carrying the single pallet 12S to the lifting device 34.

[0049] (3) The lifting device 34 transports the first cart 14 carrying the single pallet 12S to the top storage tier 24b1. The first cart 14 transported to the top storage tier 24b1 moves, together with the single pallet 12S, onto the second cart 16 on the top storage tier 24b1. (4) The second carriage 16 travels on the second rail 44 and transports the first carriage 14 carrying the single pallet 12S to the entrance of the storage row to which the first storage section 26p belongs. (5) The transported first carriage 14 travels along the first rail 40 with the single pallet 12S, and transports the single pallet 12S to the destination first storage section 26p. (6) The first carriage 14 lowers the single pallet 12S into the first storage section 26p, whereby the operation of the transfer mechanism 32 is terminated.

[0050] (Control unit) The control unit 30 will be described. The control unit 30 is configured to include an MPU (Micro Processing Unit) and controls the movement of the loaded pallet 12 for storing, retrieving, carrying out, transporting, etc., based on the result of an operation from a user. As an example, the control unit 30 controls the first cart 14 and the second cart 16 to transport the loaded pallet 12 between a predetermined storage unit and the storing unit 50 or the discharging unit 52, or between multiple storage units. The control unit 30 also controls the operation of the picking device 18 to pick the load 10. The control unit 30 also controls the lifting device 34 to lift and lower the first cart 14 and the loaded pallet 12 from an arbitrary storage level 24 to another storage level 24.

[0051] (warehousing operation) 1 to 4, an example of a warehousing operation of the automated warehouse system 100 will be described. In this example, a process will be described in which a single pallet 12S, which has been transported and received by external transport means 56 such as a truck, is stored in the storage section 26 of the storage shelf 22a. (1) A single pallet 12S produced in a manufacturing plant is loaded onto an external transport means 56, and transported to the automated warehouse system 100 for arrival. (2) The single pallet 12S received by the external transport means 56 is carried into the receiving section 50 by the forklift 54 ​​or the like. In this case, the forklift 54 ​​carries the single pallet 12S from the external transport means 56 into the receiving section 50 at the desired level. (3) The single pallet 12S carried into the receiving section 50 is transported by the first cart 14 and the second cart 16 to a predetermined storage section 26 of the storage shelf 22a and stored therein.

[0052] Through these operations, the warehousing operation is completed. During the warehousing operation, the first cart 14 and the second cart 16 are controlled by the control unit 30.

[0053] (Picking operation) Next, an example of the picking operation of the automated warehouse system 100 will be described with reference to FIG. 14. FIG. 14 is an explanatory diagram for explaining an example of the picking operation. The picking operation in this example is an operation of taking out the load 10 from the single-loading pallet 12S based on a shipping plan and creating a mixed-loading pallet 12M for shipping to a destination such as a retail store. In this example, the single-loading pallet 12S is stored on the storage shelf 22a, picking is performed in the load sorting section 20 set on the top storage stage 24b1 of the storage shelf 22b, and the mixed-loading pallet 12M is stored on the storage shelf 22c. In this description, in order to distinguish the load, the pallet, and the first storage section, the symbols are suffixed with "-A", "-B", and "-C". In FIG. 14, the load 10-A is shown in white, the load 10-B is shown in straight hatching, and the load 10-C is shown in dashed hatching.

[0054] (1) The first cart 14 and the second cart 16 transport the single pallet 12S from the storage section 26 of the storage shelf 22a to the first storage section 26p of the item sorting section 20. In this example, the single pallets 12S-A, 12S-B, and 12S-C loaded with different types of items 10-A, 10-B, and 10-C are transported to the first storage sections 26p-A, 26p-B, and 26p-C. (2) An empty pallet for creating a mixed pallet 12M is placed in the second storage section 26s of the product sorting section 20.

[0055] (3) The picking device 18 removes the required number of loads 10-A from the single-loading pallet 12S-A and places them on an empty pallet to create a mixed-loading pallet 12M. At this time, the picking device 18 may change the position of the loads 10-A, for example by rotating them horizontally. (4) The picking device 18 picks out the required number of loads 10-B from the single-loading pallet 12S-B and places them on the mixed-loading pallet 12M on which the loads 10-A are placed. At this time, the picking device 18 may change the position of the loads 10-B.

[0056] (5) The picking device 18 picks out the required number of loads 10-C from the single-loading pallet 12S-C and places them on the mixed-loading pallet 12M on which the loads 10-A and 10-B are placed. At this time, the picking device 18 may change the position of the loads 10-C. (6) The mixed pallet 12M loaded with the loads 10-A, 10-B, and 10-C is transported from the second storage section 26s to the storage section 26 of the storage shelf 22c by the first cart 14 and the second cart 16. At this time, the lifting device 34 may also be used to transport the mixed pallet 12M to another level of the storage shelf 22c.

[0057] The picking operation is completed by these operations. In the picking operation, the first cart 14, the second cart 16 and the picking device 18 are controlled by the control unit 30.

[0058] (Removal operation) 1 to 4, a description will be given of an example of a retrieval operation of the automated warehouse system 100. In this example, a process of loading a mixed pallet 12M stored in the storage section 26 of the storage shelf 22c onto an external transport means 56 will be described. (1) The mixed pallet 12M stored in the storage section 26 of the storage shelf 22c is transferred to the out-of-warehouse section 52 by the first cart 14 and the second cart 16. At this time, the first cart 14 and the second cart 16 are controlled by the control section 30. (2) The mixed pallet 12M transferred to the delivery section 52 is loaded onto the external transport means 56 by a forklift 54 ​​or the like. In this case, the forklift 54 ​​loads the mixed pallet 12M onto the external transport means 56 from the delivery section 52 of the desired level. (3) The mixed pallet 12M loaded onto the external transportation means 56 is transported to and shipped to its destination.

[0059] Through these operations, the leaving operation is completed. During the leaving operation, the first cart 14 and the second cart 16 are controlled by the control unit 30.

[0060] The features of the automated warehouse system 100 configured as above will be described. The automated warehouse system 100 includes a storage shelf 22 having a plurality of storage sections 26 for storing the load 10, a picking device 18 for moving the first load 10a stored in the first storage section 26p to the second storage section 26s in which the second load 10b is stored, and a carrying-out device 28 for carrying out the first load 10a and the second load 10b stored in the second storage section 26s together from the storage shelf 22. This configuration can reduce the space for case storage sections and picking compared to the automated warehouse system of the comparative example, so that the ratio of storage shelves to the site area can be increased and storage efficiency can be improved. In addition, the manpower required for picking can be reduced.

[0061] The storage shelf 22 has a plurality of storage sections 26 arranged in a horizontal direction on a storage tier 24, and the storage tiers 24 are arranged in a vertical direction on a storage tier basis, with the first storage section 26p and the second storage section 26s being provided on the topmost storage tier 24p, which is the uppermost of the plurality of storage tiers 24. In this case, the space above the topmost storage tier 24p, which is relatively spacious, can be effectively utilized, thereby improving the space efficiency of the automated warehouse system 100.

[0062] The picking device 18 takes out the first load 10a from above the first storage section 26p, and loads the first load 10a into the second storage section 26s from above the second storage section 26s. In this case, the work space in a plan view can be reduced compared to when taking out or loading from the side, and therefore the space efficiency of the site can be improved.

[0063] The picking device 18 has a transfer mechanism 32 that transfers the third load 10c in a storage stage 24s other than the top storage stage 24p among the multiple storage stages 24 to the first storage section 26p, and the picking device 18 moves the third load to the second storage section 26s. In this case, the load 10 in the storage stage 24s other than the top storage stage 24p can be picked.

[0064] The picking device 18 is provided at a position overlapping with the storage shelf 22 in a plan view. In this case, the picking space in a plan view can be reduced, and therefore the space efficiency of the site can be improved.

[0065] The second and third embodiments of the present invention will be described below. In the drawings and description of the second and third embodiments, the same or equivalent components and members as those of the first embodiment are denoted by the same reference numerals. Explanations that overlap with the first embodiment will be omitted as appropriate, and the description will focus on the configurations that differ from the first embodiment.

[0066] [Second embodiment] The second embodiment of the present invention is an operation method S80 of the automated warehouse system 100. This operation method S80 is an operation method of the automated warehouse system equipped with a storage shelf 22 having a plurality of storage sections 26 for storing the load 10, and includes moving a first load 10a stored in a first storage section 26p to a second storage section 26s in which a second load 10b is stored to perform picking, and carrying out the first load 10a and the second load 10b stored in the second storage section 26s together from the storage shelf 22. According to the operation method S80, picking is performed within the storage shelf 22, so that the space for picking can be reduced.

[0067] In the operating method S80, the storage shelf 22 has a plurality of storage tiers 24 in which storage sections 26 are arranged horizontally, and the plurality of storage tiers 24 are arranged vertically, and the above-mentioned picking may be performed in the uppermost storage tier 24p, which is the uppermost of the plurality of storage tiers 24. In this case, the space above the relatively spacious uppermost storage tier 24p can be effectively utilized, thereby improving the space efficiency of the automated warehouse system 100.

[0068] The operation method S80 further includes transferring the third load 10c in a storage stage 24s other than the top storage stage 24p among the multiple storage stages 24 to the top storage stage 24p, and performing the above-mentioned picking may include moving the third load 10c transferred to the top storage stage 24p to the second storage section 26s. In this case, the load 10 in the storage stage 24s other than the top storage stage 24p can be picked.

[0069] In the operating method S80, while the above-mentioned picking is being performed within the storage shelf 22, an item 10 other than the first item 10a and the second item 10b may be carried in or out of the storage shelf 22. In this case, since storage and retrieval can be performed even while picking is being performed, the operating efficiency of the automated warehouse system 100 can be improved.

[0070] [Third embodiment] A third embodiment of the present invention is a method S90 for receiving and shipping goods using the automated warehouse system 100. This method S90 receives a single pallet 12S on which a plurality of goods of the same type are loaded, receives the received single pallet 12S into the automated warehouse system 100 for storage, removes goods to be shipped from the single pallet 12S within the automated warehouse system 100 and places them on one pallet, creates a mixed pallet 12M on which a plurality of goods are loaded on the one pallet, and takes the mixed pallet 12M out of the automated warehouse system 100 for shipping.

[0071] The receiving / shipping method S90 can be realized by combining the receiving operation, the picking operation, and the shipping operation described in the first embodiment.

[0072] According to the receiving / shipping method S90, it is possible to reduce the manpower and space required from the time when the single-loading pallet 12S arrives until the time when the mixed-loading pallet 12M is shipped.

[0073] 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.

[0074] (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.

[0075] [First Modification] In the description of the first embodiment, an example in which the storage section 50 and the delivery section 52 are provided for each tier has been shown, but the present invention is not limited thereto. For example, a single storage section 50 and delivery section 52 may be provided for all tiers, and the lifting device 34 may be connected to each storage section 50 and delivery section 52. FIG. 15 is a plan view showing the periphery of the storage section 50 and the delivery section 52 of the first modified example. This figure shows a configuration in which the lifting device 34 is connected to each storage section 50 and delivery section 52. In this case, the loading pallet 12 to be stored is carried into the storage section 50 from the external transport means 56 by the forklift 54, and is transferred to the target tier by the lifting device 34. In addition, the loading pallet 12 to be unloaded is transferred from the tier in which it was stored to the delivery section 52 by the lifting device 34, and is unloaded from the delivery section 52 to the transport means 56.

[0076] In the first modified example, the lifting device 34 is disposed between the storage section 50 / outlet section 52 and the second rail 44, but the lifting device 34 may be disposed on the opposite side of the second rail 44 of the storage section 50 or the outlet section 52. The lifting device 34 may also be disposed on the positive or negative side of the X-axis direction of the storage section 50 or the outlet section 52. In this case, a position advantageous for storage and retrieval operations can be selected.

[0077] [Second modified example] In the description of the first embodiment, an example was shown in which the lifting device 34 is disposed in the Y-axis direction of the end of the second rail 44, but the present invention is not limited thereto. For example, another lifting device 36 may be provided on the positive side of the end of the second rail 44 in the X-axis direction. FIG. 16 is a plan view showing the periphery of the loading section 50 and the unloading section 52 of the second modified example. This figure shows a configuration in which another lifting device 36 is provided at the end of the second rail 44. In the second modified example, the lifting device 36 can lift and lower the second cart 16 carrying the first cart 14 from one stage to another stage.

[0078] [Other variations] In the description of the first embodiment, an example was shown in which the storage shelves 22a, 22b, and 22c have the same number of stages, but the present invention is not limited to this. The storage shelf 22 may include a portion with a different number of stages from the others. For example, the portion of the storage shelf 22 where the picking device 18 is installed may be provided with a portion with a different number of stages from the others in order to ensure space for installing the picking device 18.

[0079] In the description of the first embodiment, an example has been shown in which the holding unit 18h of the picking device 18 holds the load 10 by suction force, but the present invention is not limited to this. For example, the holding unit of the picking device may be configured to hold the load by an arm and a hand.

[0080] In the description of the first embodiment, an example was shown in which the picking device 18 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 attached to a side wall on the side and supported from the side.

[0081] In the explanation of the first embodiment, the operation of the carry-out device 28, the operation of the transfer mechanism 32, the storing operation, the picking operation, and the retrieval operation are shown as examples, but the present invention is not limited to these. These operations are merely examples, and other operations may be added, some operations may be deleted or changed, and the order of the operations may be changed.

[0082] In the explanation of the first embodiment, an example was shown in which the picking operation removes the load 10 from the single-loading pallet 12S to create a mixed load pallet 12M, but the present invention is not limited to this. The picking operation may include an operation of removing the load 10 from the mixed load pallet 12M, or an operation of creating a single load pallet 12S from the removed load 10. In addition, the single load pallet 12S created by picking may be shipped out.

[0083] In the description of the first embodiment, an example was shown in which picking is performed from the multiple first storage units 26p-A, 26p-B, and 26p-C to a single second storage unit 26s in the picking operation, but the present invention is not limited to this. Picking may be performed from the multiple first storage units 26p to the multiple second storage units 26s.

[0084] In the description of the first embodiment, an example in which the multiple first storage sections 26p-A, 26p-B, and 26p-C are arranged in a line in the Y-axis direction is shown in Fig. 14, but the present invention is not limited to this. It is not essential to arrange the multiple first storage sections in a line, and they may be arranged separately from each other.

[0085] In the explanation of the first embodiment, an example was shown in which the picking device 18 has a movable range that is a part of a storage shelf divided into multiple parts, but the present invention is not limited to this. For example, a picking device 18 having a movable range that is the entire storage shelf may be provided in a non-divided storage shelf.

[0086] In the description of the first embodiment, an example has been shown in which the entire picking device 18 overlaps with the storage shelf 22 in a plan view, but the present invention is not limited to this. A part of the picking device 18 may extend outward from the planar range of the storage shelf 22.

[0087] Instead of the forklift 54, the loading pallet 12 may be carried in and out by another type of transfer device, such as a transfer device equipped with a crane.

[0088] Each of these modified examples provides the same effects as the first embodiment.

[0089] 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.

[0090] The present invention can also be defined by the following features. (Item 1) A storage shelf having a plurality of storage sections for storing cargo; a picking device that moves a first item stored in a first storage unit to a second storage unit in which a second item is stored; a carrying-out device that carries out the first load and the second load stored in the second storage unit together from the storage shelf; An automated warehouse system comprising:

[0091] (Item 2) The storage shelf has a storage stage in which a plurality of the storage sections are arranged in a horizontal direction, The storage stage is provided in a plurality of rows in a vertical direction, The automated warehouse system according to item 1, characterized in that the first storage section and the second storage section are provided on the uppermost storage shelf among the plurality of storage shelves.

[0092] (Item 3) The automated warehouse system described in item 2, characterized in that the picking device removes the first item from above the first storage section and loads the first item into the second storage section from above the second storage section.

[0093] (Item 4) a transfer mechanism that transfers a third load in a storage stage other than the uppermost storage stage among the plurality of storage stages to the first storage section; The automated warehouse system according to item 2 or 3, wherein the picking device moves the third load to the second storage section.

[0094] (Item 5) 5. The automated warehouse system according to any one of items 1 to 4, wherein the picking device is provided at a position overlapping with the storage shelf in a plan view.

[0095] (Item 6) An operation method of an automated warehouse system having a storage shelf having a plurality of storage sections for storing items, comprising: moving a first load stored in a first storage unit to a second storage unit in which a second load is stored, and picking the first load; removing the first load and the second load stored in the second storage unit from the storage shelf together; A method for operating an automated warehouse system, comprising:

[0096] (Item 7) The storage shelf has a storage stage in which a plurality of the storage sections are arranged in a horizontal direction, The storage stage is provided in a plurality of rows in a vertical direction, The picking is performed on the topmost storage stage among the plurality of storage stages. 7. A method for operating an automated warehouse system according to item 6.

[0097] (Item 8) The method further includes transferring a third load from a storage stage other than the top storage stage among the plurality of storage stages to the top storage stage; The picking includes moving the third load transferred to the uppermost storage stage to the second storage section. 8. A method for operating an automated warehouse system according to item 7.

[0098] (Item 9) While the picking is performed in the storage shelf, a load other than the first load and the second load is carried into or removed from the storage shelf. 9. A method for operating an automated warehouse system according to any one of items 6 to 8.

[0099] (Item 10) We receive a single pallet containing multiple items of the same kind, The received single pallets are stored in the automated warehouse system. In the automated warehouse system, the load to be shipped is removed from the single pallet and placed on a single pallet, and a mixed pallet on which multiple types of loads are loaded is created. The mixed pallet is removed from the automated warehouse system and shipped. A method for receiving and shipping cargo, comprising: [Explanation of symbols]

[0100] 10...load, 12...loaded pallet, 12M...mixed pallet, 12S...single pallet, 18...picking device, 20...load sorting section, 24p...top storage shelf, 24, 24s...storage shelf, 26...storage section, 26p...first storage section, 26s...second storage section, 28...unloading device, 32...transport mechanism, 100...automated warehouse system.

Claims

[Claim 1] A storage shelf having a plurality of storage sections for storing cargo; a picking device that moves a first item stored in a first storage unit to a second storage unit in which a second item is stored; a carrying-out device that carries out the first load and the second load stored in the second storage unit together from the storage shelf; An automated warehouse system comprising:

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