Automated warehouse

Abstract

To provide an automated warehouse that can clean a received component at a fixed point.SOLUTION: An automated warehouse 1 includes racks 2 having multiple frontages 4, a stacker crane 10 that transfers an article A between the racks 2. The frontage 4 has a placement part 5 on which the article A is placed, a support part 6 provided at a position below the placement part 5, and a dust pan 8 supported by the support part 6. The dust pan 8 can be removed from the support part 6 by the stacker crane 10 and can be attached to the support part 6.SELECTED DRAWING: Figure 2

Description

[Technical field]

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

[0002] There is a known technology for cleaning the tops of item storage shelves in an automated warehouse. The cleaning device described in Patent Document 1 has a base frame attached to the slide fork of a stacker crane and a sweeping tool provided on the base frame. For shelves on which no items are present (no items are stored), the slide fork is moved back and forth to bring the bottom end of the sweeping tool into contact with an item support piece, thereby cleaning the shelves. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 6-061814 Summary of the Invention [Problem to be solved by the invention]

[0004] In some racks in automated warehouses, a dust pan is provided separately from the item storage shelves. The dust pan is provided, for example, directly below the item storage shelves to receive foreign matter such as dust generated by the sliding forks or items. In such automated warehouses, the dust pan (receiving member) is placed on a support member and is usually fixed in place. When foreign matter accumulates in the dust pan, for example, an operator accesses the dust pan and manually cleans it.

[0005] When such a configuration is adopted, the worker must use the ladder of the stacker crane or the like to access each shelf (more specifically, the support member). When cleaning multiple dust pans, the worker must also move from shelf to shelf. Manually operating a stacker crane is not easy and leads to an increase in labor hours. If the dust pans could be cleaned at fixed locations, i.e., at fixed points, such labor hours would be reduced.

[0006] The present disclosure describes an automated warehouse that can clean receiving members at fixed points. [Means for solving the problem]

[0007] [1] An automated warehouse according to one embodiment of the present disclosure includes a rack having a plurality of openings, and a conveying device that transfers items between the racks, the opening having a loading section on which the items are placed, a support section provided below the loading section, and a receiving member supported by the support section, and the receiving member is removable from the support section by the conveying device and attachable to the support section.

[0008] According to this automated warehouse, the receiving member can be removed and attached by a conveying device. The conveying device can clean the receiving member at a fixed point by conveying the receiving member to the fixed point. In this specification, unless otherwise intentionally limited, "cleaning" includes both automatic cleaning using a device or unit and manual cleaning by an operator.

[0009] [2] The automated warehouse described in [1] above may further include a cleaning station for cleaning the receiving member at a position where the receiving member can be transported by the transport device. In this case, the receiving member can be cleaned at the cleaning station as a fixed point. Since a cleaning station dedicated to cleaning is prepared at a predetermined position, it is also easy to control the movement of the transport device and plan cleaning.

[0010] [3] The automated warehouse of [1] or [2] above may further include a controller. The controller may have a storage unit that stores the cleaning history of the receiving member, and may determine the receiving member to be cleaned based on the cleaning history. In this case, the receiving member to be cleaned can be appropriately selected.

[0011] [4] In the automated warehouse described in [3] above, when the controller detects that an item is stored on a placement section located below the receiving member to be cleaned, the controller may control the conveying device to move the item present below the receiving member before removing the receiving member from the placement section. In this case, it is possible to prevent foreign matter from descending onto the item and adhering thereto (damaging the item).

[0012] [5] Any one of the automated warehouses [1] to [4] above may further include a storage unit that is provided at a position different from the frontage where the placement unit is provided and is capable of storing a plurality of receiving members. In this case, the receiving members stored in the storage unit can be replaced with receiving members to be cleaned. This allows (dirty) receiving members to be replaced immediately when cleaning is required. The period during which receiving members are absent can also be shortened, thereby reducing the impact on items on the lower levels.

[0013] [6] In any one of the automated warehouses [1] to [5] above, the conveying device may move the article present below the receiving member before removing the receiving member from the support part. In this case, even if the receiving member is removed and is no longer present on the support part, the article below has already been moved. This makes it possible to prevent foreign matter from falling onto and adhering to the article below (damage to the article). Effect of the Invention

[0014] According to the present invention, the receiving member can be cleaned at a fixed point. [Brief description of the drawings]

[0015] [Figure 1] FIG. 1 is a side view showing an automated warehouse according to one embodiment of the present disclosure. [Diagram 2] FIG. 2 is a diagram for comparing the sizes of the conveying device, the articles, and the receiving members in the automated warehouse of FIG. [Diagram 3] FIG. 3 is a functional block diagram of a controller provided in the automated warehouse. [Figure 4] FIG. 4 is a flow diagram showing an example of a cleaning process for receiving members in an automated warehouse. [Diagram 5] FIG. 5 is a side view showing an example of a modified form of the rack. [Figure 6] 6(a) and 6(b) are side views showing another example of a modified form of the rack. [Figure 7] FIG. 7 is a side view showing an automated warehouse according to a modified example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In the description of the drawings, the same elements are given the same reference numerals, and duplicated description will be omitted. For convenience of description, XYZ orthogonal axes are also shown in some drawings.

[0017] First, referring to FIG. 1, the overall configuration of an automated warehouse 1 of this embodiment will be described. The automated warehouse 1 includes a rack 2 on which a plurality of items A are stored, and a stacker crane (conveyor) 10 that transfers the items A between the rack 2. The rack 2 is installed on, for example, a floor surface F. The rack 2 extends in the X direction and the Z direction (up and down directions), and has a plurality of openings 4 in each of the X direction and the Z direction. Each opening 4 is a storage space for the items A. The items A stored (or housed) in the automated warehouse 1 may include, for example, a pallet P and a parcel B on the pallet P. The shape of the items A is not limited to this, and may take any shape. The pallet P may be omitted. In the illustrated example, the parcel B is rectangular or cubic, but the shape of the items A may be changed as appropriate.

[0018] In the automated warehouse 1, for example, a pair of racks 2, 2 face each other in the Y direction (i.e., the depth direction of the paper in FIG. 1), and a stacker crane 10 can travel between these racks 2, 2 in the X direction (travel direction). For example, a rail 3 extends between the racks 2, 2. The stacker crane 10 has a running part (not shown) at its lower end and / or upper end. One or a pair of upper and lower rails 3 are provided at least on the upper and lower sides corresponding to the running part. The stacker crane 10 has, for example, a pair of masts 11, 11 and a lifting part 12 that can be raised and lowered between the masts 11, 11. The masts 11, 11 travel in the X direction along the rail 3, and the lifting part 12 rises and falls (rises or falls) along the Z direction.

[0019] The stacker crane 10 further has a slide fork 13 capable of transferring the article A. The slide fork 13 is attached to the lifting section 12 and moves up and down integrally with the lifting section 12. The slide fork 13 is capable of advancing in the Y direction (towards both of the pair of racks 2, 2) relative to the lifting section 12. The configuration of the slide fork 13 is not particularly limited and may have any known configuration. Not only the slide fork 13 but the entire stacker crane 10 may have any known configuration.

[0020] Each opening 4 has a placement section 5 on which an article A is placed. The placement sections 5 may be, for example, a pair of plate-like members fixed to the pillar members 2a of the rack 2 and spaced apart in the X direction. The slide fork 13 of the stacker crane 10 is inserted between the placement sections 5 to lift up the bottom surface of the article A (for example, a pallet P). The action of placing the article A on the placement sections 5 is the reverse of the action of lifting it up.

[0021] Each opening 4 further has a support part 6 provided at a position below the placement part 5 and a dust pan (receiving member or horizontal member) 8 supported by the support part 6. In the rack 2, for example, when the slide fork 13 is driven or when the item A is moved, foreign objects may scatter or fall due to some cause. There are various possibilities (or variations) for the type and characteristics of the foreign object, but for example, the foreign object is dust, splashes, or other scattered objects. The foreign object may be caused by a machine such as the slide fork 13 or by the item A (luggage B or pallet P). Therefore, the dust pan 8 installed at each opening 4 receives the foreign object that may be generated above it. The dust pan 8 has a tray shape including, for example, a rectangular or square flat plate part and an edge part (or side wall part) rising from the peripheral part of the plate part.

[0022] As shown in FIG. 2, the size of the bottom surface of the item A and the size of the dust pan 8 are almost equal in the X direction. In the Y direction, which is the illustrated depth direction, the size of the bottom surface of the item A and the size of the dust pan 8 are also almost equal. In a plan view, the item A and the dust pan 8 are arranged in almost the same area. The size of the bottom surface of the item A and the size of the dust pan 8 may be different, but both the item A and the dust pan 8 can be accommodated in the lifting section 12. In a plan view, the dust pan 8 may be larger than the item A and arranged in an area that includes the item A. By having a sufficient size and shape that corresponds to the bottom surface of the item A, the dust pan 8 receives as many foreign objects as possible and accumulates them inside. In this embodiment, the bottom surface of the item A corresponds to the pallet P.

[0023] The support portion 6 may be, for example, a pair of plate-like members fixed to the column member 2a of the rack 2 and spaced apart in the X direction. The flat bottom surface of the dustpan 8 is placed on the support portion 6. The dustpan 8 is not fixed to the support portion 6 and can be freely separated from the support portion 6. The dustpan 8 is placed on the support portion 6 in an unfixed state. The bottom surface of the dustpan 8 is not particularly fitted to the support portion 6, for example, but simply placed on the support portion 6. In the automated warehouse 1, the dustpan 8 is subject to transfer and transportation in the same way as the item A. The slide fork 13 of the stacker crane 10 is inserted between the support portions 6 to support the lower surface of the dustpan 8 and lift the dustpan 8. The operation of placing the dustpan 8 on the support portion 6 is the opposite to the operation of lifting it.

[0024] In this way, in the automated warehouse 1, the dust pan 8 can be removed from the support part 6 by the stacker crane 10. Also, the dust pan 8 can be attached to the support part 6 by the stacker crane 10. A plurality of placement parts 5 and support parts 6 are provided repeatedly at regular intervals in the Z direction, but the distance between the placement part 5 and the support part 6 directly below it, and the distance between the placement part 5 and the support part 6 directly above it (the distance between the top surface of the article A placed on the placement part 5 and the support part 6) are appropriately set in consideration of transfer by the slide fork 13.

[0025] In the stacker crane 10, the operation of transferring the article A on the placement section 5 and the operation of transferring the dust pan 8 on the support section 6 are the same or nearly the same except for the spatial height to which the slide fork 13 is moved. In other words, in the automated warehouse 1, the dust pan 8 is a transport object similar to the article A, but differs from the article A in that the dust pan 8 is thinner than the article A.

[0026] The automated warehouse 1 includes a controller 20 that controls the stacker crane 10. The controller 20 is a computer having a ROM (Read Only Memory) in which programs and the like are stored, a RAM (Random Access Memory) in which data is temporarily stored, a storage medium such as a HDD (Hard Disk Drive), a processor such as a CPU (Central Processing Unit), and a communication circuit, etc. The controller 20 stores input data in the RAM based on a signal output by the CPU, loads a program stored in the ROM into the RAM, and executes the program loaded into the RAM to realize various functions.

[0027] The functional configuration of the controller 20 will be described with reference to Fig. 3. The controller 20 has an information acquisition unit 21, a crane control unit 22, a cleaning management unit 23, and a memory unit 24. The information acquisition unit 21 acquires information (transportation command) related to the transport of the item A and information (cleaning command, replacement command, etc.) related to the transport of the dust pan 8. The crane control unit 22 controls the traveling unit, the lifting unit 12, and the slide fork 13 of the stacker crane 10.

[0028] The crane control unit 22 may appropriately adjust the transport speed during transport of the dust pan 8. For example, when there is a possibility that easily scattering foreign matter such as dust or dirt has adhered to or accumulated in the dust pan 8, the crane control unit 22 may reduce the transport speed (travel speed).

[0029] The memory unit 24 stores, for example, the cleaning history of the dust pans 8 on the entire rack 2. The number of dust pans 8 that can be cleaned on the rack 2 corresponds to the number of openings 4 (i.e. the maximum number of items A that can be stored). The memory unit 24 stores the cleaning history for all dust pans 8 over a certain period of time. The cleaning management unit 23 manages various matters related to cleaning in the automated warehouse 1. The cleaning management unit 23 determines the dust pans 8 to be cleaned based on the cleaning history stored in the memory unit 24.

[0030] The method of determining the cleaning timing by the cleaning management unit 23 is not particularly limited and may be set or designed appropriately. For example, the cleaning management unit 23 may manage the cleaning timing (or cleaning cycle) for a certain dust pan 8 so that cleaning is performed every time a predetermined time has elapsed. Alternatively, the cleaning management unit 23 may manage the cleaning timing for a certain dust pan 8 so that cleaning is performed when the item A placed on the placement unit 5 directly above (near the upper part) has been transferred a predetermined number of times or more. In the rack 2, the controller 20 basically recognizes the ID of the item A and the ID of each opening 4. The controller 20 recognizes, for example, the ID of the dust pan 8 and manages the number of cleanings for each dust pan. The controller 20 does not identify each individual dust pan 8, but at least recognizes the presence or absence of the dust pan 8 at each opening 4.

[0031] Returning to FIG. 1, the automated warehouse 1 is provided with one or more cleaning stations 30 for cleaning the dust pans 8, at a position where the stacker crane 10 can transport the dust pans. The cleaning station 30 may be provided, for example, in one section of the rack 2. When multiple cleaning stations 30 are provided, the cleaning stations 30 may be disposed in discrete positions or adjacent positions. When multiple cleaning stations 30 are provided, the area of ​​multiple dust pans 8 (i.e., the area of ​​multiple openings 4) that each cleaning station 30 is responsible for (cleans) may be determined.

[0032] The cleaning station 30 may be provided at the lowest opening 4 among the openings 4 in the rack 2. For example, by providing the cleaning station 30 at the lowest level as shown in Fig. 1, work can be performed on the floor surface F, improving maintainability.

[0033] The cleaning station 30 is provided with a cleaning unit 31 including, for example, a suction robot. When cleaning is performed automatically, the cleaning unit 31 is controlled by the cleaning management unit 23 and starts suctioning the dust pan 8 when the dust pan 8 is placed on the support part 32 of the cleaning station 30. The cleaning unit 31 may be a fully automated automatic cleaning unit, or may be a semi-automatic cleaning unit that requires some manual operation.

[0034] Next, a process flow (cleaning process example) executed by the controller 20 will be described with reference to FIG. 4. First, the cleaning management unit 23 determines the dust pan 8 to be cleaned (the dust pan 8 to be cleaned) based on the cleaning history and the like (step S01). Next, if a load B (item A) is stored in the opening 4 (mounting unit 5) below the dust pan 8, the crane control unit 22 controls the stacker crane 10 to move the load B (step S02). That is, the stacker crane 10 moves (evacuates) the item A present below the support unit 6 before removing the dust pan 8 from the support unit 6. The destination (evacuation destination) of the item A to be moved (evacuated) under the control of the controller 20 may be an appropriate empty opening 4 (an opening 4 where the item A is not stored). For this purpose, the information acquisition unit 21 constantly acquires information on the presence or absence of the item A at each opening 4. Furthermore, the destination (evacuation destination) of the article A under the control of the controller 20 may be under the opening 4 where cleaning of the dust pan 8 has been completed (or cleaning does not need to be performed immediately).

[0035] Next, the crane control unit 22 controls the stacker crane 10 to lift and remove the dust pan 8 from the support 6, and transport it to the cleaning station 30 (step S03). The dust pan 8 is placed on the support 32 of the cleaning station 30 by the slide fork 13 of the stacker crane 10. In FIG. 1, a special symbol "8C" is attached to indicate that it is a target for cleaning.

[0036] The cleaning management section 23 controls the cleaning unit 31 to clean the dust pan 8C (step S04). After the cleaning is completed, the crane control section 22 controls the stacker crane 10 to transport the dust pan 8C and transfer it to the placement section 5 of the original frontage 4 (step S05). Then, the crane control section 22 controls the stacker crane 10 to return the evacuated item A to below the dust pan 8 (step S06).

[0037] According to the automated warehouse 1 of this embodiment, the dust pan 8 can be removed and attached by the stacker crane 10. The stacker crane 10 transports the dust pan 8 to a predetermined fixed point, so that the dust pan 8 can be cleaned at the fixed point.

[0038] In addition, the dust pan 8 can be cleaned at the cleaning station 30 as a fixed point. Since the cleaning station 30 dedicated to cleaning is prepared at a predetermined position, movement control of the stacker crane 10 and cleaning planning are also facilitated.

[0039] The stacker crane 10 determines the dust pan 8 to be cleaned based on the cleaning history of the dust pan 8. This makes it possible to appropriately select the dust pan 8 to be cleaned.

[0040] The stacker crane 10 moves any items present below the dust pan 8 before removing the dust pan 8 from the support part 6. As a result, even when the dust pan 8 is removed and no longer exists on the support part 6, the item A below has already been moved. This makes it possible to prevent foreign objects from falling onto and adhering to the item A below (damage to the item A).

[0041] The same effect is achieved from the viewpoint of control by the controller 20. That is, when the controller 20 detects that an item A is stored on the placement unit 5 located below the dust pan 8 to be cleaned, the controller 20 controls the stacker crane 10 to move the item A present below the dust pan 8 before removing the dust pan 8 from the placement unit 5. This makes it possible to prevent a foreign object from descending onto and adhering to the item A (damage to the item).

[0042] Although the embodiment of the present invention has been described above, the present invention is not limited to the above embodiment. For example, as shown in FIG. 5, a dust collection hopper 9 may be provided between the placement portion 5 and the support portion 6. The dust collection hopper 9 is made of a pair of plate-shaped members spaced apart in the X direction, for example. The dust collection hopper 9 has a tapered shape such that the pair of plate-shaped members approach each other as they move downward. The dust collection hopper 9 may be provided in a region that overlaps the range of the thickness of the placement portion 5 in the height direction, for example. In this case, a recess or hole for receiving the dust collection hopper 9 is formed in the placement portion 5.

[0043] In the above embodiment, the bottom surface of the dust pan 8 is not particularly fitted to the support part 6, but simply rests on the support part 6. However, as long as the dust pan 8 is separable from the support part 6, a guide structure, engagement structure, or engagement structure for positioning may be provided between the dust pan 8 and the support part 6. For example, as shown in FIG. 6(a), the dust pan 8 may be positioned by a plurality of pins 6f provided on the support part 6 entering a plurality of engagement holes 8e provided in the dust pan 8. Alternatively, as shown in FIG. 6(b), a pair of guides 6g provided on the support part 6 may guide both side edges 8b of the dust pan 8, thereby guiding and positioning the dust pan 8.

[0044] As shown in FIG. 7, an automated warehouse 1A may be adopted that is provided with a storage unit 40 that is provided at a position different from the frontage 4 where the placement unit 5 is provided and can store a plurality of dustpans 8. In practice, one (or more) of the multiple frontages 4 provided on the rack 2 in the automated warehouse 1 of the previous embodiment is used as a space for the storage unit 40 instead of the frontage 4. For example, the storage unit 40 may be provided on the lowest floor, similar to the cleaning station 30. In the example shown in FIG. 7, the storage unit 40 is provided at a position adjacent to the cleaning station 30. The storage unit 40 may be adjacent to the cleaning station 30 in the X direction, or may be adjacent to the cleaning station 30 in the Y direction. In that case, the cleaning station 30 and the storage unit 40 face each other in the Y direction across the travel space of the stacker crane 10.

[0045] In the automated warehouse 1A equipped with the storage unit 40, one or more spare dust pans 8X stored on the support unit 41 of the storage unit 40 can be replaced with the dust pan 8 to be cleaned (in the figure, the dust pan 8C is transported to the cleaning station 30 and undergoes cleaning work). This allows the (dirty) dust pan 8 to be replaced immediately when cleaning is required. According to the automated warehouse 1A, the cleaning work of the dust pan 8 and the replacement work of the dust pan 8 can be concentrated and consolidated. For example, the dust pans 8 can be replaced all at once during a time period when there are few items entering and leaving the warehouse, and the dust pans 8 can be cleaned at a time convenient for the worker. In addition, the period during which the dust pan 8 is absent can be shortened, so that the impact on the item A on the lower level can be reduced. In particular, if the storage unit 40 is adjacent to the cleaning station 30, after the dust pan 8 (dust pan 8C) is placed on the support unit 32 of the cleaning station 30 (after step S03 in FIG. 4), the crane control unit 22 can control the stacker crane 10 to replenish the spare dust pan 8X. This shortens the period during which the dust pan 8 is absent. While the cleaning in step S04 is being performed, the stacker crane 10 may transport the spare dust pan 8X without waiting for the cleaning to be completed. Step S05 may be omitted. Furthermore, step S06 may be omitted.

[0046] A receiving member having a different configuration from the dust pan 8 may be provided on the support portion 6. The receiving member may be a dust pan 8, a dust cover, a simple horizontal plate, etc. A mechanism or structure for attaching (by adsorption or adhesion, etc.) or holding foreign objects may be provided on the upper surface of the receiving member. The upper surface of the receiving member may be processed for attaching or holding foreign objects, or a sheet-like body for this purpose may be provided. For example, if the article A includes an electronic component, an adhesive or adsorption sheet of electronic material may be attached to the upper surface of the receiving member. If metallic foreign objects are expected, a magnetic mat or the like may be attached to the upper surface of the receiving member.

[0047] During the procedure of removing the receiver member, prior to removal of the receiver member, any items present underneath may remain unmoved and stored in the same location.

[0048] The controller does not need to store the cleaning history. For example, the conveying device may sequentially remove a plurality of receiving members according to a certain rule and provide them for cleaning.

[0049] As a configuration for detecting dirt on the dust pan 8, for example, a camera may be attached to the stacker crane 10 or the like to monitor the degree of dirt.

[0050] The cleaning station may be provided outside the rack 2. In that case, the rack 2 and the cleaning station may be connected by an appropriate transport means such as a conveyor. In the cleaning station, automatic cleaning by the cleaning unit and manual cleaning by an operator may be used in combination.

[0051] In the above embodiment, in step S06, the crane control unit 22 returns the retreated item A to below the dust pan 8, but this control does not have to be executed. In that case, since the controller 20 can always grasp the position of the item A, the controller 20 only needs to update the data of the item A, i.e., the position information.

[0052] In the above embodiment, the controller 20 recognizes the ID of the dust pan 8 and manages the number of cleanings for each dust pan. However, the controller 20 does not need to have unique identification information for each dust pan 8 arranged in each entrance 4.

[0053] The cleaning station may be omitted. Instead of a station dedicated to cleaning, the receiving member to be cleaned may be transported to a general placement part or a general support part (a support part from which the receiving member has been removed in advance) and cleaning may be performed there. In that case, the general placement part or the general support part corresponds to the "fixed point".

[0054] The above-described variations of the rack, the embodiments and variations of the automated warehouse, and the variations of the control by the controller can be combined as appropriate. [Explanation of symbols]

[0055] 1,1A...automated warehouse, 2...rack, 4...frontage, 5...loading section, 6...support section, 8...dust pan (receiving member), 10...stacker crane (conveying device), 13...slide fork, 20...controller, 23...cleaning management section, 24...memory section, 30...cleaning station, 31...cleaning unit, 40...storage section, A...item, B...luggage, P...pallet.

Claims

1. A rack having a plurality of openings; A conveying device that transfers an article between the rack and the conveying device, The frontage is, A placement section on which the article is placed; A support portion provided below the placement portion; a receiving member supported by the support portion, An automated warehouse, wherein the receiving member is removable from the support portion by the conveying device and attachable to the support portion.

2. The automated warehouse according to claim 1 , further comprising a cleaning station for cleaning the receiving member at a position that can be transported by the transport device.

3. Further comprising a controller, The automated warehouse according to claim 1 or 2, wherein the controller has a storage unit that stores a cleaning history of the receiving member, and determines the receiving member to be cleaned based on the cleaning history.

4. The automated warehouse of claim 3, wherein when the controller detects that the item is stored in a placement section located below the receiving member to be cleaned, the controller controls the conveying device to move the item located below the receiving member before removing the receiving member from the placement section.

5. The automated warehouse according to claim 1 or 2, further comprising a storage section provided at a position different from the opening where the loading section is provided and capable of storing a plurality of the receiving members.

6. The automated warehouse according to claim 1 or 2, wherein the conveying device moves an article present below the receiving member before removing the receiving member from the support portion.

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