Automatic article replenishment and storage system

Abstract

To provide an automatic article replenishment and storage system capable of overcoming problems such as damage to an article, abnormal conveyance on an inclined flow shelf, and restrictions on the type of articles that can be handled which are caused by the automatic replenishment of articles to a storage shelf by a traveling vehicle mounted with a belt conveyor.SOLUTION: The present invention provides an automatic article replenishment and storage system for picking out an ordered article, comprising: a storage shelf that is an inclined flow shelf on which articles for a digital picking system are sorted and waiting; and an article replenishment device that automatically replenishes the articles to the storage shelf using a traveling vehicle equipped with a belt conveyor. The automatic article replenishment and storage system includes an impact prevention device or mechanism between the storage shelf and the article replenishment device, on the roller conveyor of the storage shelf, and on the traveling vehicle, for protecting the articles from falling, a shock applied thereto, and damage caused by the shock.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to an automatic item replenishment and storage system, for example, and in particular to an automatic item replenishment and storage system in a digital picking system, which is composed of storage shelves on which items are sorted and waiting for pickers to pick up ordered items, and an item replenishment device that automatically replenishes the items in the storage shelves, and which handles a series of processes of automatically replenishing items and storing and waiting the replenished items. [Background technology]

[0002] Ordered products that are put into collection containers in the digital picking process are stored on storage shelves, particularly on inclined flow shelves, close to the pickers, in consideration of the workability of the pickers (for example, Patent Documents 1 to 3). Replenishing items on such storage shelves has traditionally been done by workers, but with the dramatic increase in the number of items handled due to the spread of electronic commerce and the like, automatic replenishment of items has begun to be done by traveling vehicles, as in large automated multi-level warehouses. In addition, there is a great demand for automatic replenishment, as it can also address the recent problem of labor shortages at logistics centers and the like.

[0003] For example, although Patent Document 4 does not refer to the automatic replenishment of articles to storage shelves, it recognizes a system in which articles are moved from a discharge conveyor provided on a transport cart traveling inside an automatic sorting device, through a discharge outlet of the automatic sorting device, to an inclined article sliding surface of a sorting container support device, and received by a sorting container supported by a sorting container support part below the sliding surface of the sorting container support device, and this system is highly similar to the automatic replenishment of articles to storage shelves by a traveling vehicle in a picking system. Based on this technical information, it is easy to conceive of replacing the sorting container support device with a storage shelf, and automatic replenishment of articles to storage shelves by a traveling vehicle can be implemented.

[0004] The automatic replenishment of items to storage shelves by the traveling vehicles of the digital picking system based on such technical information can have many favorable effects such as further improving the productivity of the digital picking system and improving the working environment, etc. However, on the other hand, there are still inherent issues such as restrictions on the shape and weight of the items to be handled, as well as the need to transport the items safely without damaging them.

[0005] The restrictions on the items to be handled have already been recognized in Patent Document 4. Items that cannot be loaded onto the transport cart are conveyed by conveyor to a work area where the items are collected in sorting containers, without using an automatic sorting device. There is also a problem with safe transport here. That is, there is no mechanism for absorbing the impact on the items when they are transferred from the discharge conveyor of the transport cart to the sorting container. There is a considerable gap between the discharge conveyor and the sliding surface of the sorting container support part of the sorting container support device, and the transfer of items with a height difference from the belt conveyor of the transport cart to the sliding surface must be performed at a speed that allows a certain flying distance using a large friction force between the belt and the items, so there are many items for which the impact when the discharged items fall onto the sliding surface cannot be ignored. Although a guide is provided between the discharge conveyor and the sliding surface of the sorting container support part of the sorting container support device, the guide does not have the function of transporting articles, but is merely a component through which articles pass, and in order not to impede the transport of articles, it is necessary to avoid contact with the articles or to increase the slope, so this guide is not given a function intended to reduce the impact on the articles discharged by the belt conveyor. Also, as suggested by the size of the article W smaller than the guide 17 shown in Figure 4, it is reasonable to consider that the purpose of this guide is primarily to prevent the missing articles from falling to the floor, even if the flying distance is not sufficient.

[0006] When this technology is applied to automatic replenishment of items to storage shelves in a digital picking system, the items to be replenished fall from the belt conveyor of the transport cart onto the storage shelf. As described in Patent Documents 1 to 3, the storage shelf is generally an inclined flow shelf from which a picker can take out items in an orderly manner, and the inclined items fall onto a gravity roller conveyor, which conveys the items by their own weight. In this case, items with large kinetic energy discharged from the belt conveyor of the transport cart are likely to be damaged by the impact of the fall, and the transport speed of the gravity conveyor is excessively increased, which causes abnormal transport that disrupts the continuous straight movement of the items so that the order of the items is not disturbed.

[0007] Furthermore, as can be seen from Patent Document 5 (e.g., Figs. 12-15) and Patent Document 6 (e.g., Fig. 1c and Figs. 4a-4c), when a transport vehicle equipped with a belt conveyor as in Patent Document 4 transfers an article to a storage shelf, there is a gap formed between the belt conveyor of the transport vehicle and the storage shelf, and the belt conveyor must impart energy to the article that can overcome this gap, which will result in the above-mentioned problems of the impact of the fall and the abnormal transport of the gravity conveyor becoming apparent. Conversely, if this kinetic energy is limited, there will be a problem of the article falling into the gap formed between the belt conveyor of the transport vehicle and the storage shelf, and a problem of the restriction of the handled article being limited to a shape that is greater than this gap. This is a problem that occurs among articles in a shape that can be loaded on the belt conveyor of the transport vehicle. Patent Document 6 employs a carrier tray for transferring articles and a telescopic arm equipped with fingers for moving the carrier tray as a means for solving this problem, but this makes the structure of the transport vehicle complicated, leading to a decrease in the transfer speed.

[0008] In this way, the basic technology for digital picking systems to automatically replenish items to storage shelves using transport vehicles equipped with conveyor belts has been developed, but there are problems such as damage to items, abnormal transportation on inclined flow shelves, and restrictions on the items that can be handled. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] JP 2013-136447 A [Patent Document 2] JP 2015-129050 A [Patent Document 3] Patent Publication No. 2022-016578 [Patent Document 4] Patent Publication No. 2022-072215 [Patent Document 5] Special Publication No. 2010-515570 [Patent Document 6] US Patent Application Publication No. 2005 / 0047895 [Non-patent literature]

[0010] [Non-Patent Document 1] Taiyo Kogyo Co., Ltd., "Option Brake Roller", [on line], [Searched July 26, 2023], Internet<https: / / www.taiyokogyo-kk.co.jp / c11-c212-pm466.html> [Non-Patent Document 2] Asahi Metal Works, Ltd., "Power-free ultimate energy-saving brake roller series", [online], [searched July 26, 2023], Internet<https: / / asahikinzoku.jp / mbr / > [Non-Patent Document 3] SUS Corporation, "Brake roller", [on line], [searched July 26, 2023], Internet<https: / / fa.sus.co.jp / products / gf / broller / > Summary of the Invention [Problem to be solved by the invention]

[0011] In digital picking, with the dramatic increase in the number of items handled, the automatic replenishment of items to storage shelves by traveling vehicles has become necessary and is being implemented. However, as described in the Background Art section, the automatic replenishment of items to storage shelves by traveling vehicles equipped with conveyor belts still has problems due to the method of automatic replenishment, such as damage to items, abnormal transport on inclined flow shelves, and limitations on the items that can be handled.

[0012] In light of these problems, the main objective of the present invention is to provide an automatic item replenishment and storage system that can overcome problems such as damage to items, abnormal transport on inclined flow shelves, and restrictions on the items that can be handled that are caused by the automatic replenishment of items to storage shelves by a traveling vehicle equipped with a belt conveyor.

[0013] A subordinate object of the present invention is to construct a labor-saving, highly productive logistics system that ensures safety and security in logistics centers and the like. [Means for solving the problem]

[0014] In light of this situation, the inventors have reconsidered the traveling vehicle equipped with a conveyor belt, the inclined flow shelf, and the spacing between this traveling vehicle and the flow shelf, and have found that comprehensive and organic improvements and coordination of these can solve the above-mentioned problems and provide an automatic item replenishment and storage system that integrates automatic item replenishment and item storage functions, has few restrictions on the items that can be handled, and enables safe transportation.

[0015] That is, the automatic item replenishment and storage system according to the first aspect of the present invention is an automatic item replenishment and storage system for retrieving ordered items, comprising a storage shelf in a digital picking system on which items to be retrieved from the ordered items are sorted and waiting, and an item replenishment device that automatically replenishes the items on the storage shelf, the storage shelf being a flow shelf on which items are transferred from the item replenishment device and waiting; The article replenishing device comprises a traveling vehicle equipped with an article transfer conveyor for automatically replenishing articles on a storage shelf, and an article supplying device for supplying articles to the traveling vehicle, and is characterized in that an impact prevention device or impact prevention mechanism for protecting articles is inserted at an appropriate position in one or more of the storage shelf, the article replenishing device, and the area between the storage shelf and the article replenishing device.

[0016] As a second aspect of the present invention, in the first aspect, the article transfer conveyor of the traveling vehicle may be a belt conveyor, the article supply device may be a belt conveyor, and the flow shelf may be an inclined flow shelf that employs a gravity roller conveyor mechanism that is transported by its own weight.

[0017] As a third aspect of the present invention, in the second aspect, the shock prevention device may be a braking device having a conveying speed adjustment function and inserted into the gravity roller conveyor.

[0018] As a fourth aspect of the present invention, in the first aspect, the impact prevention device may be a bridge roller conveyor that is installed to bridge between the traveling vehicle and the flow shelf.

[0019] As a fifth aspect of the present invention, in the second aspect, the impact prevention device may be a bridge roller conveyor that is installed to bridge between the traveling vehicle and the flow shelf.

[0020] As a sixth aspect of the present invention, in the third aspect, a bridge roller conveyor may be further inserted as the impact prevention device so as to bridge between the traveling vehicle and the flow shelf.

[0021] As a seventh aspect of the present invention, in the fourth aspect, a braking device having a conveying speed adjustment function may be further inserted into the bridge-type roller conveyor as the shock prevention device.

[0022] As an eighth aspect of the present invention, in the fifth aspect, the bridge-type roller conveyor may further include a braking device having a conveying speed adjustment function as the shock prevention device.

[0023] As a ninth aspect of the present invention, in the first aspect, the impact prevention device may be a bridge belt conveyor installed so as to bridge between the traveling vehicle and the flow shelf.

[0024] As a tenth aspect of the present invention, in the second aspect, the impact prevention device may be a bridge belt conveyor that is installed so as to bridge between the traveling vehicle and the flow shelf.

[0025] As an eleventh aspect of the present invention, in the third aspect, the impact prevention device may be a bridge belt conveyor that is installed so as to bridge between the traveling vehicle and the flow shelf.

[0026] As a twelfth aspect of the present invention, in the fourth aspect, the shock prevention device may further include a roller that fills a gap between the belt conveyor of the traveling vehicle and the bridge-mounted roller conveyor.

[0027] As a thirteenth aspect of the present invention, in the ninth aspect, the shock prevention device may further include a roller that fills a gap between the belt conveyor of the traveling vehicle and the bridge-type belt conveyor.

[0028] As a 14th aspect of the present invention, in any of the 1st to 13th aspects, the impact prevention mechanism may be configured to make the length of the belt conveyor of the traveling vehicle approximately equal to the maximum width perpendicular to the traveling direction of the traveling vehicle.

[0029] In each of these aspects, it is particularly preferable that the article transfer conveyor mounted on the traveling vehicle of the article replenishing device is a belt conveyor, and that the article supplying device that supplies articles to this traveling vehicle is a belt conveyor, because the large frictional force between the articles and the belt ensures reliable transport and transfer. Also, it is preferable that the flow shelf is an inclined flow shelf that employs a gravity roller conveyor mechanism that is transported by its own weight, because this allows the picker to continuously supply articles in an orderly manner and the transport speed can be adjusted by a simple mechanism.

[0030] When an inclined gravity roller conveyor is used as the flow shelf, the shock prevention device may be a brake device having a conveying speed adjustment function. This brake device equalizes the conveying speed that varies depending on conditions, and maintains continuous straight conveyance without abnormal conveyance that would destroy the order of the order or state of the articles in the gravity roller conveyor, thereby preventing damage to the articles. As this brake device, a motor roller or various mechanical brake rollers attached to the gravity roller conveyor are preferable, and energy-saving mechanical brake rollers that do not require electricity are more preferable.

[0031] In addition, the impact prevention device in each aspect of the present invention is a bridge roller conveyor or a bridge belt conveyor that is equipped to bridge between the running vehicle of the item replenishment device and a flow shelf that is preferable as a storage shelf, regardless of whether or not a braking device is inserted into such a gravity roller conveyor.

[0032] In order for an article to pass through the gap between the traveling vehicle and the flow shelf, the article must be transferred at a speed of the belt conveyor that allows the article to fly over the gap, and the flying distance of the article varies greatly depending on the shape and weight of the article, and the impact of landing on the flow shelf may damage the article. For this reason, it is necessary to reduce the speed at which the articles are transferred. There are various possible methods for this, but we have found that the most preferable method is to install a conveyor in the gap between the traveling vehicle and the flow shelf and reduce the speed of the belt conveyor mounted on the traveling vehicle as much as possible.

[0033] In addition, such a bridge-type roller conveyor or bridge-type belt conveyor can transfer even small items without worrying about damage or falling, thereby expanding the restrictions on the items that can be handled by the automatic item replenishment and storage system of the present invention.

[0034] In addition, such an impact prevention conveyor requires a drive mechanism in the case of a bridge-type belt conveyor, but in the case of a bridge-type roller conveyor, a drive mechanism is not necessarily required and a free roller conveyor may be used.

[0035] Furthermore, when the roller conveyor bridging between the traveling vehicle and the flow shelf is a free roller conveyor, it is preferable to further insert a braking device similar to that of a gravity roller conveyor in order to suppress the impact on the goods and to expand the restrictions on the goods to be handled. In particular, it is preferable to replace the required number of free rollers with motor rollers. On the other hand, when the conveyor bridging between the traveling vehicle and the flow shelf is a belt conveyor, the same effect can be achieved by controlling the speed.

[0036] Even if a bridge roller conveyor or a bridge belt conveyor is inserted between the traveling vehicle of the article replenishing device and the flow shelf, which is preferable as a storage shelf, as an impact prevention device, a narrow gap may remain between the belt conveyor of the traveling vehicle and the flow shelf. In such a case, it is preferable to insert a motor roller or a free roller. This roller can be attached to either the traveling vehicle side or the flow shelf.

[0037] As an impact prevention mechanism to eliminate such narrow gaps, it is more preferable to introduce into all of the automatic item replenishment and storage systems of the present invention a mechanism that makes the item transport belt conveyor mounted on the running vehicle of the item replenishment device approximately equal in length to the maximum width perpendicular to the running direction of the running vehicle.

[0038] As described above, the automatic item replenishment and storage system according to each aspect of the present invention is a highly productive system that reduces manpower because it is equipped with an impact prevention device and / or impact prevention mechanism, and is a system that ensures safety and security in logistics. Effect of the Invention

[0039] The automatic item replenishment and storage system of the present invention can overcome issues that arise from the automatic replenishment of items to storage shelves by traveling vehicles equipped with conveyor belts, such as damage to items, abnormal transportation on inclined flow shelves, and restrictions on the items that can be handled, and can construct a labor-saving, highly productive logistics system in logistics centers and the like that ensures safety and security. [Brief description of the drawings]

[0040] [Figure 1] FIG. 1 is a schematic plan view of a first automatic item replenishment storage system (I) according to one embodiment of the present invention. [Diagram 2] FIG. 2 is a schematic front view of the item storage line viewed from the picking line in FIG. 1. [Diagram 3]This is a schematic perspective view of the main parts of the automatic article replenishment and storage system shown in Figure 1, in which an impact prevention roller conveyor is provided between the storage shelf, which is an inclined flow shelf, and the article replenishment device. In particular, the surface where the 9th to 12th storage shelves, the impact prevention roller conveyor for the 9th storage shelf, and the article replenishment device are connected is shown, and other components have been removed. [Figure 4] This is a schematic cross-sectional view of the first automatic item replenishment storage system (I) shown in Figure 1, taken along the C1 cutting line, in which an impact prevention conveyor is provided between the storage shelf, which is an inclined flow shelf, and the item replenishment device. [Diagram 5] This is a schematic plan view of a second automatic item replenishment storage system (II) in which a picking line that shares an item replenishment device is installed in parallel to a first automatic item replenishment storage system (I) according to one embodiment of the present invention. [Figure 6] 6 is a schematic cross-sectional view of the second automatic item replenishment and storage system (II) shown in FIG. 5 taken along the C2 cutting line. [Figure 7] This is a schematic diagram of a cross-sectional main portion of a third automatic item replenishment and storage system (III) in which the impact-proof roller conveyor of the first automatic item replenishment and storage system (I) is replaced with an impact-proof belt conveyor according to one embodiment of the present invention. [Figure 8] This is a schematic diagram of the cross-sectional essential parts of a fourth automatic item replenishment storage system (IV) according to one embodiment of the present invention, in which the impact-proof roller conveyor of the first automatic item replenishment storage system (I) is replaced with an impact-proof belt conveyor, and the item replenishment device is replaced from a system in which replenishment items are supplied from a replenishment item supply conveyor via a lifter conveyor to an item transport shuttle to a system in which replenishment items supplied to a replenishment item relay conveyor via a lifter conveyor from the replenishment item supply conveyor are supplied to the item transport shuttle. [Figure 9]This is a schematic diagram of the cross-sectional main parts of a fifth automatic item replenishment storage system (V) in which the item replenishment device of the second automatic item replenishment storage system (II) according to one embodiment of the present invention has been replaced from a system in which replenishment items are supplied from a replenishment item supply conveyor via a lifter conveyor to an item transport shuttle to a system in which replenishment items supplied to a replenishment item relay conveyor via a lifter conveyor from the replenishment item supply conveyor are supplied to the item transport shuttle. [Figure 10] 1 is a schematic diagram showing two types of article transport shuttles suitable for an automatic article replenishment and storage system according to an embodiment of the present invention, in which (a) is a schematic plan view of a first article transport shuttle (I) equipped with two belt conveyors, (b) is a schematic plan view of a second article transport shuttle (II) equipped with one belt conveyor, (c) is a schematic side view of (a), (d) is a schematic side view of (b), and (e) is a schematic front view of (a) and (b). [Figure 11] FIG. 2 is a schematic perspective view showing an example of a tilting flow shelf suitable for the storage shelf of the automatic article replenishment storage system of the present invention. [Figure 12] 1 is a schematic diagram of a first mechanical brake roller (I) attached to a gravity roller conveyor adopted as an inclined flow shelf in a storage shelf of an automatic article replenishment storage system of the present invention, (a) is a diagram showing a brake mechanism, and (b) is a schematic side view of a gravity roller conveyor equipped with the first mechanical brake roller (I). [Figure 13] 1 is a schematic diagram of a second mechanical brake roller (II) installed on a gravity roller conveyor adopted as an inclined flow shelf in a storage shelf of an automatic article replenishment storage system of the present invention, where (a) is a diagram showing the brake mechanism, and (b) is a schematic side view of a gravity roller conveyor equipped with the second mechanical brake roller (II). [Figure 14]1 is a schematic side view of a third mechanical brake roller (III) installed on a gravity roller conveyor adopted as an inclined flow shelf in a storage shelf of an automatic article replenishment storage system of the present invention, (a) is a diagram showing a brake mechanism, and (b) is a schematic side view of a gravity roller conveyor equipped with the third mechanical brake roller (III). DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0041] The present invention will be described in more detail below using the embodiments shown in the drawings. However, the present invention is not limited to these embodiments and can be implemented in various modifications within the scope that does not deviate from the gist of the present invention. The present invention is limited only by the technical ideas described in the claims.

[0042] FIG. 1 is a schematic plan view of a first automatic item replenishment and storage system (I) 100 according to one embodiment of the present invention, and FIG. 2 is a schematic front view of the item storage line 130 viewed from the picking line 110 in FIG. 1.

[0043] In the picking line 110, the following sorting is performed. Collection containers 117 supplied from a collection container supply conveyor 113 to a collection container preparation area 114 are subjected to preparation work such as affixing an order number label 118. Then, a collection container 119 with the order number label 118 affixed is transported by a belt conveyor 111 equipped with a guide display 112, and, for example, in the m-th picking zone 120m and the n-th picking zone 120n, ordered products taken out by an operator P from the inclined flow storage shelf 130m of the m-th picking zone and the inclined flow storage shelf 130n of the n-th picking zone are placed into the collection container 119. To explain the sorting of the ordered items in more detail, for example, in the mth picking zone 120m, the ordered items are picked as instructed by the illumination of the first bay indicator 141 and the second bay indicator 142m of the further divided first bay 121m and second bay 122m, and the illumination of the first storage shelf indicator to the twelfth storage shelf indicator of the mth picking zone, and are then placed into the collection container 119 instructed by the illumination of the guide indicator 112.

[0044] Once the collection work is completed, the container is transported via a collection container inspection area 115 to the shipping process on a collection container shipping conveyor 116.

[0045] Meanwhile, automatic replenishment of goods to the goods storage line 130 is performed by goods replenishment device 160 consisting of goods transport shuttle 161 on which belt conveyor 161-2 is mounted, rails 162 on which the goods transport shuttle runs, replenishment goods supply conveyor 163, and lifter 164 equipped with lifter conveyor 164-1. For example, automatic replenishment of goods to the ninth storage shelf 139m of the mth picking zone 120m is performed in such a way that goods supplied from replenishment goods supply conveyor 163 are transferred to belt conveyor 161-2 of goods transport shuttle 161 via lifter conveyor 164-1, and when the goods transport shuttle 161 moves to the ninth storage shelf 139m, the goods are transferred to the ninth storage shelf of the mth picking zone by belt conveyor 161-2. The first automatic article replenishment and storage system (I) of the present invention is characterized in that an impact prevention roller conveyor 179m for the ninth storage shelf is inserted between the belt conveyor 161-2 and the ninth storage shelf. This impact prevention roller conveyor 179m can reduce the speed of the belt conveyor 161-2 of the article transport shuttle 161 to transfer the article to the ninth storage shelf, and can greatly reduce the impact on the article. In addition, the gap between the belt conveyor 161-2 and the ninth storage shelf is narrowed, making it possible to transport small articles. Note that the automatic replenishment of articles is not limited to an article unit, and the same effect can be obtained even in a form in which a large number of identical articles are stored in a case such as a cardboard box. When a case such as a cardboard box is used, it is preferable that one side of the case is cut with a cutter and opened and loaded on the article transport shuttle 161. This is because the open side can be dropped into the inclined conveyor from an input port corresponding to each opening of the storage shelf and transferred.

[0046] FIG. 3 is shown to facilitate understanding of the manner in which articles are transferred from the article replenishment device 160 to the storage shelf line 130 in the first automatic article replenishment and storage system (I) 100 of the present invention. FIG. 3 is a schematic perspective view of the main parts of the first automatic article replenishment and storage system (I) shown in FIG. 1, in which a shock-preventing roller conveyor 179m-1712m for the ninth storage shelf is provided between the ninth to twelfth storage shelves 139m-1312m, which are inclined flow shelves, and the article transport shuttle 161 of the article replenishment device 160. In particular, the surface where the ninth to twelfth storage shelves 139m-1312m, the shock-preventing roller conveyors 179m-1712m for the ninth to twelfth storage shelves, and the article transport shuttle 161 of the article replenishment device 160 are connected is shown, and other components have been omitted. In this figure, for example, even if the belt conveyor 161-2 of the article transport shuttle 161 is moving at a low speed, the article is transferred to the ninth storage shelf 139m without being subjected to shock because the shock-prevention roller conveyor 179m for the ninth storage shelf is inserted. Even if the inclined flow shelf of the ninth storage shelf 139m is a gravity roller conveyor consisting of rollers 139m-1, guide rails 139m-2, stoppers 139m-3, etc., the shock-prevention roller conveyor 179m for the ninth storage shelf is inserted, so that the article is not thrown into the ninth storage shelf with force, and orderly transport is performed without impairing the function of the gravity roller conveyor. Furthermore, in order to maintain the function of the gravity roller conveyor, it is preferable to provide a braking device capable of controlling the rotation speed of the gravity roller conveyor, as described later.

[0047] Furthermore, similar to Figure 3, in order to easily understand the manner in which items are transferred from the item replenishment device 160 to the storage shelf line 130 in the first automatic item replenishment and storage system (I) 100 of the present invention, a schematic cross-sectional view taken along the C1 cutting line of the first automatic item replenishment and storage system (I) 100 shown in Figure 1 is shown in Figure 4.

[0048] In this diagram, the situation of the fourth storage shelf 134m, the eighth storage shelf 138m in the mth picking zone 120m, and the impact prevention roller conveyor 174m for the fourth storage shelf, the impact prevention roller conveyor 178m for the eighth storage shelf, and the impact prevention roller conveyor 1712m for the 12th storage shelf, which are inserted between the 12th storage shelf and the belt conveyor 161-2 mounted on the item transport shuttle 161 of the item replenishment device 160, can be understood.

[0049] The shock-prevention roller conveyor 170, which is a feature of the first automatic article replenishment and storage system (I) 100, is also provided in the same manner when the picking lines 210mn and 210st are arranged in parallel to share the article replenishment device 260 consisting of an article transport shuttle 261, a rail 262 on which the article transport shuttle runs, a replenishment article supply conveyor 263, and a lifter 264, as shown in Figures 5 and 6, and a second automatic article replenishment and storage system (II) 200 according to one embodiment of the present invention can be provided. Figure 5 is a schematic plan view of the second automatic article replenishment and storage system (II) 200 corresponding to Figure 1, and Figure 6 is a schematic cross-sectional view taken along the C2 cutting line in Figure 5, corresponding to Figure 4.

[0050] Furthermore, Fig. 7 is a schematic diagram of a cross-sectional main part of a third automatic article replenishing and storing system (III) 300 in which the shock prevention roller conveyor 170 of the first automatic article replenishing and storing system (I) 100 according to an embodiment of the present invention is replaced with a shock prevention belt conveyor 180. The shock prevention roller conveyor 174m for the fourth storage shelf, the shock prevention roller conveyor 178m for the eighth storage shelf, and the shock prevention roller conveyor 1712m for the twelfth storage shelf shown in Fig. 4 are replaced with a shock prevention belt conveyor 184m for the fourth storage shelf, a shock prevention belt conveyor 188m for the eighth storage shelf, and a shock prevention belt conveyor 1812m for the twelfth storage shelf in Fig. 7. This shock prevention belt conveyor 180 can also exhibit the same function as the shock prevention roller conveyor 170, but since it requires a driving force, the mechanism becomes complicated, but on the other hand, it has the effect of dramatically improving the shock prevention function. In this embodiment, the automatic article replenishment and storage system is named the third automatic article replenishment and storage system (III) 300, but the reference numerals used are the same as those of the first automatic article replenishment and storage system (I) 100.

[0051] 8 is a schematic diagram of a cross-sectional main part of a fourth automatic article replenishment and storage system (IV) 400 according to an embodiment of the present invention. This is a system in which the shock-proof roller conveyor 174m for the fourth storage shelf, the shock-proof roller conveyor 178m for the eighth storage shelf, and the shock-proof roller conveyor 1712m for the twelfth storage shelf of the m-th picking zone 130m shown in FIG. 4 of the first automatic article replenishment and storage system (I) 100 are replaced with a shock-proof belt conveyor 184m for the fourth storage shelf, a shock-proof belt conveyor 188m for the eighth storage shelf, and a shock-proof belt conveyor 1812m for the twelfth storage shelf, and the method of supplying replenishment articles to the article transport shuttle 161 from the replenishment article supply conveyor 163 via the lifter conveyor 164-1 of the article replenishment device 160 is changed. The changed supply method is a method in which replenishment articles are transported from replenishment article supply conveyor 163 via lifter conveyor 164-1, through replenishment article relay conveyor 165-1 arranged parallel to article storage line 130, and replenishment article relay conveyor 165-2 attached at right angles thereto, and the replenishment articles are supplied to article transport shuttle 161. Note that here too, except for changing the name of the automatic article replenishment storage system to fourth automatic article replenishment storage system (IV) 400, the same reference numerals as those of the first automatic article replenishment storage system are used.

[0052] 9 is a schematic diagram of a cross-sectional main part of a fifth automatic article replenishment and storage system (V) 500 according to an embodiment of the present invention. This is a change of the article replenishment device 160 of the second automatic article replenishment and storage system (II) 200 from a system in which replenishment articles are supplied to the article transport shuttle 261 from the replenishment article supply conveyor 263 via the lifter conveyor 264-1 to a system in which replenishment articles are transported from the replenishment article supply conveyor 263 via the lifter conveyor 264 through the replenishment article relay conveyor 165-1 arranged parallel to the article storage line 130 and the replenishment article relay conveyor 165-2 attached at right angles thereto, and then supplied to the article transport shuttle 161. Note that here too, except for the name of the automatic article replenishment and storage system being changed to the fifth automatic article replenishment and storage system (V) 500, the symbols are the same as those of the second automatic article replenishment and storage system (II) 200.

[0053] 10 is a schematic diagram of two types of article transport shuttles that can be applied to any of the first to fifth article automatic replenishment and storage systems (I) to (V) 100 to 500 according to one embodiment of the present invention. (a) is a schematic plan view of the first article transport shuttle (I) equipped with two belt conveyors, (b) is a schematic plan view of the second article transport shuttle (II) equipped with one belt conveyor, (c) is a schematic side view of (a), (d) is a schematic side view of (b), and (e) is a schematic front view of (a) and (b).

[0054] The area of ​​interest here is shuttle side surface K. For example, both ends of belt conveyor 161(I)-2 in the conveying direction of the replenishment items are approximately aligned with shuttle side surface K. By using article conveying shuttle 161 with such a mechanism, the gap between article conveying shuttle 161 and impact prevention roller conveyor 170 or impact prevention belt conveyor 180 can be shortened, and the impact received by replenishment items transferred from belt conveyor 161-2 of article conveying shuttle 161 to impact prevention roller conveyor 170 or impact prevention belt conveyor 180 can be mitigated.

[0055] FIG. 11 shows a schematic perspective view of a gravity roller conveyor type storage shelf, which is an example of an inclined flow shelf that can be applied to any of the first to fifth automatic item replenishment and storage systems (I) to (V) 100 to 500 according to one embodiment of the present invention.

[0056] As is clear from the figure, a storage shelf made up of side frames 640, front frame 650, rear frame 660, and support columns 670 is provided with free rollers 610 clamped between guide rails 620, and stoppers 630 for stopping transported articles. By adjusting the diameter, interval, and inclination angle of rollers 610, etc., restrictions on the shape of articles that can be handled can be alleviated.

[0057] However, when a gravity roller conveyor is used as a storage shelf as an inclined flow shelf, the transport speed is determined by the shape and weight of the articles, and this may lead to the order and state of the replenishment articles being disturbed, leading to the disruption of the order of transport and the cause of damage or dropping of the replenishment articles. Therefore, in any of the first to fifth automatic article replenishment and storage systems (I) to (V) 100 to 500 according to one embodiment of the present invention, in the case of a gravity roller conveyor, a braking device is inserted to maintain continuous straight transport without abnormal transport, thereby protecting the articles. As this braking device, a motor roller or various mechanical brake rollers attached to the gravity roller conveyor are preferable, and energy-saving mechanical brake rollers that do not require electricity are more preferable.

[0058] Brake rollers for gravity roller conveyors include mechanical brake rollers and flywheel brake rollers (Non-Patent Documents 1 to 3). Figures 12 to 14 show three types of mechanical brake rollers 700, 800, and 900 as examples. Figure 12 shows a brake mechanism that indirectly brakes an article, and Figures 13 and 14 show brake mechanisms that directly brake an article.

[0059] 12 is a schematic diagram of a first mechanical brake roller (I) 700 attached to a gravity roller conveyor that can be used as an inclined flow shelf in a storage shelf in any of the first to fifth article automatic replenishment and storage systems (I) to (V) 100 to 500 according to an embodiment of the present invention. (a) is a schematic side view of a gravity roller conveyor attached thereto, showing a brake mechanism, and (b) is a schematic side view of a gravity roller conveyor to which the first mechanical brake roller (I) 700 is attached. In the first mechanical brake roller (I) 700, when the rotation speed of the roller 610 associated with the movement D2 of the article increases, the pivot speed of the brake roller 710 and the arm 730 in contact with the roller 610 about the brake roller-arm rotation axis 711 also increases, but the rotation speed of the roller 610 is suppressed by the spring 720, and the gravity conveyor can be braked.

[0060] 13 is a schematic diagram of the second mechanical brake roller (II) 800 mounted on a gravity roller conveyor, as in FIG. 2. (a) is a schematic side view of the brake roller (II) 800 mounted on a gravity roller conveyor showing the brake mechanism, and (b) is a schematic side view of the roller conveyor of the inclined flow shelf on which the second mechanical brake roller (II) 800 is mounted. In this case, when the rotation speed of the brake roller 810 increases due to the movement D2 of the article, the pivot speed of the brake roller 810 and the arm 830 about the brake roller-arm rotation axis 811 also increases, but since the pivot speed of the brake roller 810 is suppressed by the spring 820, the rotation speed of the roller 610 is also suppressed, and the gravity conveyor can be braked.

[0061] Fig. 14, like Fig. 12, is a schematic diagram of a third mechanical brake roller (III) 900 attached to a gravity roller conveyor adopted as an inclined flow shelf in a storage shelf of the automatic article replenishing and storage system of the present invention. (a) is a schematic cross-sectional view of the third mechanical brake roller (III) 900 showing the brake mechanism, and (b) is a schematic side view of a gravity roller conveyor equipped with the third mechanical brake roller (III) 900. In this case, when the rotation speed of the brake roller 910 increases, the arm 930 rotates in the direction of the broken line with the arm rotation shaft 931 as a fulcrum due to centrifugal force, and the rotation of the brake roller 910 is suppressed by the stopper 933 attached to the arm 930, so that the rotation speed of the roller 610 is also suppressed, and the gravity conveyor can be braked.

[0062] In this way, when a gravity roller conveyor is used as the inclined flow shelf of the storage shelf, the shock to the articles can be reduced by inserting a braking device.

[0063] However, in the automatic item replenishment system of the present invention, when automatic replenishment is performed on cases such as cardboard boxes containing many identical items, a different problem occurs. This is that when all the items in a case are picked, many empty cases are generated, and if these cases are not efficiently collected, the effect of automatic replenishment may be lost. In contrast, in the automatic item replenishment system of the present invention, since there is space above the inclined flow shelf which is the automatic item replenishment storage shelf, a system for retrieval can be constructed by utilizing this. That is, in this upper space, a flow shelf is provided which is higher on the picking front side than the inclined flow shelf and is inclined toward the item transport shuttle which automatically replenishes items, forming a path for reversing the empty cases to the travel path of the item transport shuttle, and the empty case retrieval item transport shuttle carries out the empty cases. This system makes it possible to automatically retrieve a large number of empty cases, thereby solving the above problem. [Industrial Applicability]

[0064] The present invention can automatically replenish and store items to be sorted, which supports a digital picking system, and can transport the items safely and securely, and therefore can be used not only in warehouses and logistics centers, but also in manufacturing plants for automobiles, electronic devices, etc., and has extremely high industrial applicability. In addition, this shock prevention technology is also considered to have high industrial applicability from the viewpoint that it can be applied to various devices for transporting items. [Explanation of symbols]

[0065] 100 First item automatic replenishment and storage system (I) 110 Picking Line 111 Conveyor Belt 112 Guide indicator 113 Collection container supply conveyor 114 Collection container preparation area 115 Collection container inspection area 116 Collection container shipping conveyor 117 Collection container 118 Order number label 119 Collection containers labeled with order numbers 120 Picking Zone 120m mth picking zone 121m, 122m Bays 1 and 2 of the mth picking zone 120n nth picking zone 121n, 122n Bays 1 and 2 of the nth picking zone 130 Goods Storage Line 130m 2nd picking zone with inclined flow storage shelves 131m~1312m Picking zone No. 1~12 storage shelves 139m-1 Laura 139m-2 Guide rail 139m-3 Stopper 130n: The nth picking zone's inclined flow storage shelf 131n~1312n: 1st~12th storage shelves in the nth picking zone 140 Bay Indicator 140m Bay indicator for mth picking zone 141m, 142m 1st and 2nd bay indicators for the mth picking zone 141n, 142n 1st and 2nd bay indicators for nth picking zone 150 Storage shelf indicator 150m Storage shelf indicator for the mth picking zone 151m~1512m No. m picking zone, No. 1~12 storage shelf indicator 150n Storage shelf indicator for nth picking zone 151n~1512n 1st~12th storage shelf indicators for nth picking zone 160 Goods replenishment device 161(I) First Goods Transport Shuttle(I) 161(I)-1 Wheel 161(I)-2 Belt conveyor 161(II) Second cargo shuttle 161(II)-1 Wheel 161(II)-2 Belt conveyor 162 Rail 163 Replenishment item supply conveyor 164 Lifter 164-1 Lifter conveyor 165 Replenishment item relay conveyor 165-1 Parallel relay conveyor for storage line 165-2 Item storage line cross relay conveyor 170 Shock-proof roller conveyor 170m Shock-proof roller conveyor for the mth picking zone 171m~1712m Shock-proof roller conveyor for storage shelves 1~12 in picking zone m 170n Shock-proof roller conveyor for nth picking zone 171n~174n Shock-proof roller conveyor for 1st to 4th storage shelves in nth picking zone 180 Shock-proof belt conveyor 180m Shock-proof roller conveyor for the mth picking zone 184m, 188m, 1812m Shock-proof belt conveyor for the 4th, 8th, and 12th storage shelves in the mth picking zone 200 Second item automatic replenishment and storage system (II) 210mn, 210st picking line 211mn, 211st belt conveyor 212mn, 212st guide indicator 213 Collection container supply conveyor 214mn, 214st Collection container preparation area 215mn, 215st Collection and container inspection area 216 Collection container shipping conveyor 217 Collection Container 218 Order number label 219 Collection containers labeled with order numbers 220 Picking Zone 220m mth picking zone 221m~223m Bays 1~3 of picking zone m 220n nth picking zone 221n~223n Bays 1~3 of the nth picking zone 220s Picking Zone 221s~223s Picking Zone, Bays 1~3 220t Picking Zone 221t~223t Picking Zone 1st~3rd Bay 230mn, 230st goods storage line 230m, 230n, 230s, 230t Inclined flow storage shelves in the m, n, s, t picking zones 231m, 239m, 2318m, 2327m Storage shelves 1, 9, 18, 27 of picking zone m 231s, 239s, 2318s, 2327s, 1st, 9th, 18th, 27th storage shelves in picking zone s 240m, 240n, 240s, 240t bay indicator 241m, 243m 1st and 3rd bay indicators for mth picking zone 241s, 243s Picking Zone 1st and 3rd Bay Indicators 250m, 250n, 250s, 250t storage shelf indicator 251m, 259m, 2518m, 2527m Storage shelf indicators for picking zone m, 1st, 9th, 18th, 27th 251s, 259s, 2518s, 2527s 1st, 9th, 18th, 27th storage shelf indicators for picking zone s 260 Goods replenishment device 261 Goods Transport Shuttle 262 Rail 263 Replenishment item supply conveyor 264 Lifter 264-1 Lifter Conveyor 265 Replenishment item relay conveyor 265-1 Parallel relay conveyor for storage of goods 265-2 Item storage line cross relay conveyor 270mn, 270st shock-proof roller conveyor 270m, 270n, 270s, 270t Shockproof roller conveyors for m, n, s, t picking zones 279m, 2718m, 2727m Shock-proof roller conveyor for the 9th, 18th, and 27th storage shelves in the mth picking zone 279s, 2718s, 2727s Shockproof roller conveyor for 9th, 18th and 27th storage shelves in picking zone s 300 Third item automatic replenishment and storage system (III) 400 Fourth Item Automatic Replenishment and Storage System (IV) 500 Fifth Item Automatic Replenishment and Storage System (V) 600 Gravity roller conveyor type storage shelf 610 Lola 620 Guide Rail 630 Stopper 640 Side Frame 650 Front Frame 660 Rear Frame 670 Post 700 First Mechanical Brake Roller (I) 710 Brake roller 711 Brake roller-arm rotating shaft 720 Spring 721 Spring roller conveyor side fixing part 730 Arm 731 Spring arm side fixing part 800 Second Mechanical Brake Roller (II) 810 Brake roller 811 Brake roller-arm rotating shaft 820 Spring 821 Spring roller conveyor side fixing part 830 Arm 831 Spring arm side fixing part 900 Third Mechanical Brake Roller (III) 910 Brake roller 911 Brake roller rotating shaft 920 Spring 930 Arm 931 Arm rotation axis 932 Spring fixing part 933 Stopper D1, D2 Picking conveyor, storage shelf item movement direction C cutting line K Item transport shuttle side R Roller rotation direction B Brake action direction P Operator

Claims

1. In a digital picking system, an automatic item replenishment storage system for retrieving ordered items includes a storage shelf in which items to be retrieved are sorted and waiting, and an item replenishment device that automatically replenishes the items to the storage shelf, the storage shelf is a flow shelf onto which the article is transferred from the article replenishment device and on standby, the article replenishing device comprises a traveling vehicle equipped with an article transfer conveyor for automatically replenishing the article on the storage shelf, and an article supplying device for supplying the article to the traveling vehicle, An automatic item replenishment and storage system, characterized in that an impact prevention device or impact prevention mechanism for protecting the items is inserted at an appropriate position in one or more of the storage shelf, the item replenishment device, and between the storage shelf and the item replenishment device.

2. The article transfer conveyor of the traveling vehicle is a belt conveyor, The article supply device is a belt conveyor, 2. The automatic article replenishment storage system according to claim 1, wherein the flow shelf is an inclined flow shelf that employs a gravity roller conveyor mechanism that is moved by its own weight.

3. 3. The automatic article replenishment and storage system according to claim 2, wherein the shock prevention device is a braking device having a conveying speed adjustment function and inserted into the gravity roller conveyor.

4. 2. The automatic article replenishment and storage system according to claim 1, wherein the shock prevention device is a bridge roller conveyor provided so as to bridge between the traveling vehicle and the flow shelf.

5. 3. The automatic article replenishment and storage system according to claim 2, wherein the shock prevention device is a bridge roller conveyor provided so as to bridge between the traveling vehicle and the flow shelf.

6. 4. The automatic article replenishment and storage system according to claim 3, further comprising a bridge roller conveyor installed to bridge between the traveling vehicle and the flow shelf as the shock prevention device.

7. 5. The automatic article replenishment and storage system according to claim 4, wherein a braking device having a conveying speed adjustment function is further inserted into the bridge roller conveyor as the shock prevention device.

8. 6. The automatic article replenishment and storage system according to claim 5, wherein the bridge roller conveyor further includes a braking device having a transport speed adjustment function as the shock prevention device.

9. 2. The automatic article replenishment and storage system according to claim 1, wherein the shock prevention device is a bridge belt conveyor provided so as to bridge between the traveling vehicle and the flow shelf.

10. 3. The automatic article replenishment and storage system according to claim 2, wherein the shock prevention device is a bridge belt conveyor provided so as to bridge between the traveling vehicle and the flow shelf.

11. 4. The automatic article replenishment and storage system according to claim 3, wherein the shock prevention device is a bridge belt conveyor provided so as to bridge between the traveling vehicle and the flow shelf.

12. 5. The automatic article replenishment and storage system according to claim 4, further comprising a roller inserted as said shock prevention device to fill a gap between said belt conveyor of said traveling vehicle and said bridge roller conveyor.

13. 10. The automatic article replenishment and storage system according to claim 9, further comprising a roller inserted as the shock prevention device to fill a gap between the belt conveyor of the traveling vehicle and the bridge belt conveyor.

14. The automatic item replenishment and storage system according to any one of claims 1 to 13, characterized in that the impact prevention mechanism is configured to make the length of the belt conveyor of the traveling vehicle approximately equal to the maximum width perpendicular to the traveling direction of the traveling vehicle.

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