Article processing plan generating device, article processing plan generating system, and article processing plan generating program

Abstract

To provide a technology that can expand upper inventory capacity compared to normal shelves.SOLUTION: An article processing plan generating device of the embodiment includes a receiving part that receives transport work plans, a generating part that generates optimal operation plans based on the transport work plans, and an output part that outputs first operation instructions to a shelf transport robot that transports shelves with upper shelves that store upper trays on the top of shelves that can be picked by picking means at a picking station, and outputs second operation instructions to a high-rise case transport robot that retrieves the upper trays from the upper shelves or stores the upper trays on the upper shelves, based on the optimal operation plan.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] An embodiment of the present invention relates to an item processing plan generating device, an item processing plan generating system, and an item processing plan generating program. [Background technology]

[0002] In recent years, the amount of various products (hereinafter referred to as "goods") handled at warehouses such as distribution centers for logistics has increased, and automation of goods processing is being promoted to reduce the workload of staff. For example, various automated devices work together according to instructions from a higher-level device to transport equipment that stores goods. Known examples of automated devices include a shelf transport device that transports equipment such as shelves placed on the floor, and a pallet transport device that takes in and transports equipment such as pallets placed at high altitudes. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 6957690 Summary of the Invention [Problem to be solved by the invention]

[0004] Normally, when manually picking items from shelves delivered by a shelf transport robot, the shelf height is limited to approximately 2.7m (3m or less), which means that the space up to the warehouse ceiling cannot be fully utilized, resulting in a problem of reduced warehouse space utilization rate.

[0005] This invention was made in light of the above-mentioned circumstances, and its purpose is to provide a technology that enables an upper shelf to be placed above the shelf (in a position out of reach of workers) and increases the upper inventory capacity compared to normal shelves. [Means for solving the problem]

[0006] The item processing plan generation device of the embodiment includes a receiving unit that receives a transport work plan, a generation unit that creates an optimal operation plan based on the transport work plan, and an output unit that outputs a first operation instruction to a shelf transport robot that transports a shelf having an upper shelf that stores an upper tray at the top of a shelf that can be picked by a picking means at a picking station, based on the optimal operation plan, and outputs a second operation instruction to a high-rise case transport robot that retrieves an upper tray from the upper shelf or stores an upper tray on the upper shelf. [Brief description of the drawings]

[0007] [Figure 1] FIG. 1 is a conceptual diagram illustrating an example of a logistics system according to an embodiment. [Diagram 2] FIG. 2 is a diagram illustrating an example of a layout in a warehouse according to an embodiment. [Diagram 3] FIG. 3 is a diagram showing an example of a configuration of a shelf according to the embodiment. [Figure 4] FIG. 4 is a diagram showing an example of the configuration of a picking station and a shelf standby area according to the embodiment. [Diagram 5] FIG. 5 is a diagram showing an example of a retrieval process in a picking station and a shelf standby area according to the embodiment. [Figure 6] FIG. 6 is a flowchart showing an example of item processing according to an operation plan of the WES according to the embodiment. [Figure 7] FIG. 7 is a diagram showing an example of a transportation operation plan acquired from the WMS according to the embodiment. [Figure 8] FIG. 8 is a diagram showing an example of an optimal operation plan according to the embodiment. [Figure 9] FIG. 9 is a flowchart showing an example of more detailed processing of step ST103 in the shipping processing. [Figure 10] FIG. 10 is a flowchart showing an example of more detailed processing of step ST103 in the warehousing processing. [Figure 11]FIG. 11 is a flowchart showing an example of more detailed processing of step ST103 in the inventory processing. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] Hereinafter, an item processing plan generating device, an item processing plan generating method, and an item processing plan generating program will be described in detail with reference to the drawings. In the following embodiments, parts with the same numbers perform the same operations, and will not be described again. For example, when there are multiple identical or similar elements, a common symbol may be used to describe each element without distinguishing between them, and a subnumber may be used in addition to the common symbol to describe each element with distinction between them.

[0009] In the following description, the description A or B means at least one of A or B, and A, B, or C means at least one of A, B, or C. Furthermore, the description A and B also means at least one of A and B, and A, B, and C mean at least one of A, B, and C.

[0010] [Embodiment] (composition) FIG. 1 is a conceptual diagram illustrating an example of a logistics system according to an embodiment. As shown in FIG. 1, a warehouse system S includes a warehouse management system (WMS) 1 and a warehouse processing system 2.

[0011] The warehouse processing system 2 is an example of an item processing system, and includes a warehouse execution system (WES: Warehouse Execution System) 30, a shelf transport robot system (WCS: Warehouse Control System) 40, a shelf transport robot 41, a high-rise case transport robot system 50, a high-rise case transport unit (CTU: Case Transfer Unit) robot 51, and an inventory management system 60.

[0012] The WMS1 can be configured with one or more computers, i.e., a processor, a memory, an interface, etc. The processor is a central processing unit (CPU), a micro processing unit (MPU), a digital signal processor (DSP), etc. The WMS1 receives a transportation operation plan from a higher-level server and transmits it to the WES30.

[0013] The transport operation plan includes, for example, information on the start point from which a specific cart is to be moved to the end point, time information, and other associated information. The transport operation plan is received for any of a retrieval operation, a retrieval operation, and an inventory operation. The details of the transport operation plan will be described later.

[0014] WES30 (server) is an example of an article processing plan generating device, and can be configured with one or more general-purpose computers. WES30 includes processor 301, memory 302, and interface 303. Processor 301 is a CPU, MPU, DSP, or the like. Memory 302 stores operation programs and the like for processor 301. Interface 303 communicates with WMS1, shelf transport robot system 40, high-rise case transport robot system 50, and inventory management system 60.

[0015] The processor 301 of the WES 30 includes an acquisition unit 3011, a generation unit 3012, and an output unit 3013. The processor 301 executes a program stored in the memory 302 to realize the functions of each unit.

[0016] For example, interface 303 receives a transport operation plan from WMS1. Acquisition unit 3011 acquires the transport operation plan. Generation unit 3012 generates an optimal operation plan from the transport operation plan. Output unit 3013 outputs the generated optimal operation plan. Interface 303 transmits the optimal operation plan to shelf transport robot system 40, high-rise case transport robot system 50, and inventory management system 60. Interface 303 also receives transport processing results from shelf transport robot system 40 and high-rise case transport robot system 50, and transmits the results to WMS1. Processor 301 updates the inventory management database of inventory management system 60 according to the transport processing results.

[0017] The shelf transport robot system 40 can be configured with one or more general-purpose computers, and includes a processor, a memory, and an interface. The processor is a CPU, an MPU, a DSP, or the like. The processor controls the shelf transport robot 41 based on a program stored in the memory and an optimal operation plan transmitted from the WES 30.

[0018] The shelf transport robot 41 processes items or equipment for moving items based on the control of the shelf transport robot system 40. For example, the shelf transport robot 41 is equipped with a camera, analyzes an image captured by the camera, and moves horizontally along the floor of the warehouse and moves the shelves based on the analysis results. The shelf transport robot 41 may move using the results of reading position identification information affixed to the floor of the warehouse.

[0019] The high-rise case transport robot system 50 can be configured with one or more general-purpose computers, and includes a processor, a memory, and an interface. The processor is a CPU, an MPU, a DSP, or the like. The processor controls the CTU robot 51 based on a program stored in the memory and an optimal operation plan transmitted from the WES 30.

[0020] The CTU robot 51 is a robot that picks up trays placed in the high-rise part of the shelf based on the control of the high-rise case transport robot system 50. The CTU robot 51 is also equipped with a camera, analyzes the image captured by the camera, and moves (transports) the picked-up trays by running horizontally along the warehouse based on the analysis results. The CTU robot 51 also acquires a tray placed at a predetermined position, and transports the tray to the shelf while holding the tray. Then, the CTU robot 51 stores the tray in the high-rise part of the predetermined shelf. The CTU robot 51 may run using the results of reading position identification information attached to the floor of the warehouse. Furthermore, the CTU robot 51 can identify the tray by reading code information from a two-dimensional code attached to the tray. The CTU robot 51 may be any robot that can pick up or store trays placed in the high-rise part of the shelf.

[0021] In this embodiment, an example is described in which the shelf transport robot system 40 controls the shelf transport robot 41 and the high-rise case transport robot system 50 controls the CTU robot 51, but a single control device may also control the shelf transport robot 41 and the CTU robot 51.

[0022] The inventory management system 60 can be configured with one or more general-purpose computers, and includes a processor, a memory, and an interface. The processor is a CPU, an MPU, a DSP, etc. The memory stores an inventory management database, etc.

[0023] The inventory management database includes map management information, equipment management information, and item management information. The map management information includes map data (three-dimensional coordinate data) of the warehouse, position identification information associated with the map data, and storage location identification information associated with the map data. The equipment management information includes shelf identification information given to shelves, and container identification information given to containers and the like stored on the shelves. The item management information includes item identification information given to items. Furthermore, the shelf identification information and container identification information are associated with the map data or storage location identification information, and the positions of each shelf and each container are managed. Furthermore, the item identification information of a specific item is associated with the shelf identification information and container identification information in which the specific item is stored, and the storage location of the specific item is managed.

[0024] As described above, interface 303 receives item processing results from shelf transport robot system 40 and high-rise case transport robot system 50. Processor 301 updates the inventory management database based on the item processing results, and interface 303 transmits the updated inventory management database to inventory management system 60. Inventory management system 60 stores the updated inventory management database. For example, when a specific item, a specific shelf, or a specific container is moved, an item processing result indicating this movement result is received, and processor 301 reflects the movement result in the inventory management database.

[0025] For example, position identification information that can be read by the shelf transport robot 41 and the CTU robot 51 is attached to the floor of the warehouse. Also, readable shelf identification information, container identification information, and item identification information are attached to the shelves, containers, and items, respectively. For example, each piece of identification information is a two-dimensional code such as an optically readable QR code (registered trademark).

[0026] FIG. 2 is a diagram illustrating an example of a layout in a warehouse according to the embodiment.

[0027] 2, the warehouse includes a shelf inventory area 7 and a picking station section 8. The shelf inventory area 7 is an area for storing shelves 70, and the picking station section 8 includes one or more picking stations 80 and a shelf waiting area 90 arranged adjacent to the picking stations 80.

[0028] The shelf 70 is arranged in the shelf inventory area 7. The shelf 70 is a shelf for storing items. For example, the shelf 70 stands upright on four pillars. The height below the shelf 70 (height from the floor surface to the shelf bottom) is higher than the height of the shelf transport robot 41. This allows the shelf transport robot 41 to slip under the shelf 70. The shelf transport robot 41 that slips under the shelf uses a pusher to lift the shelf 70 to a position where the tips of the pillars are several centimeters away from the floor surface, and travels with the shelf 70 lifted. In this way, the shelf transport robot 41 transports the shelf 70. The shelf 70 is also higher than the height of a general shelf (approximately 2.7 m). The specific structure of the shelf 70 will be described later.

[0029] The picking station 80 receives the shelves 70 transported by the shelf transport robot 41 and the trays transported by the CTU robot 51. The picking station 80 picks up an article from the received shelves 70 or trays.

[0030] The picking station 80 is provided with, for example, a display, which shows which items and how many items are to be picked. Furthermore, the picking station 80 is provided with trays corresponding to each piece of allocated order information. The picking station 80 places the picked items into trays on a Digital Assort System (DAS) shelf. The picking station 80 provides trays corresponding to each piece of allocated order information on the DAS shelf, and when all the necessary items are present in the tray, it is ejected from the picking station 80 and a new empty tray is replenished. The ejected tray with all the necessary items is sent to the next process in the warehousing work area, where it is packed, sorted, and loaded.

[0031] The shelf waiting area 90 is an area where the shelves 70 transported by the shelf transport robot 41 wait, and is provided adjacent to each picking station 80. In the shelf waiting area 90, the CTU robot 51 can take out a tray placed on the top of the shelf from the waiting shelf 70 or store the tray.

[0032] FIG. 3 is a diagram showing an example of the configuration of a shelf 70 according to the embodiment. 3(a) is a side view of shelf 70, and (b) is a top view. As shown in (a), shelf 70 is composed of a normal shelf 71, which has the same configuration as a normal shelf, and an upper shelf 72, which is provided above normal shelf 71 and can be handled by CTU robot 51.

[0033] The normal shelf 71 has the same configuration as a general shelf. The normal shelf 71 is a shelf that can be picked by a worker (picking means) arranged at the picking station 80, and has a height of approximately 2.7 m (3 m or less). An upper shelf 72 is arranged above the normal shelf 71.

[0034] Upper trays 73 that can be handled by the CTU robot 51 are arranged on the upper shelf 72, and the upper trays 73 are picked up by the CTU robot 51 and transported to the picking station 80. Furthermore, the upper trays 73 arranged on the upper shelf 72 have a two-dimensional code 74 affixed to the front side of the upper tray 73, and the CTU robot 51 identifies the upper tray 73 by reading the two-dimensional code 74. Note that the upper trays 73 may be affixed with a one-dimensional code or an RFID tag instead of the two-dimensional code 74.

[0035] Also, as shown in Fig. 3(b), the upper shelf 72 of the shelf 70 can hold two upper trays 73 on the front and back. That is, the CTU robot 51 can handle one of the two upper trays 73 from each of the front and rear. Note that Fig. 3(b) is merely an example, and any number of upper trays 73 may be stored on the upper shelf 72.

[0036] FIG. 4 is a diagram showing an example of the configuration of a picking station 80 and a shelf standby area 90 according to the embodiment. The picking station 80 includes a picking means 81 , a DAS (Digital Assort System) shelf 82 , and a conveyor 83 .

[0037] The picking means 81 picks up an item from a normal shelf 71 among the shelves 70 in accordance with an instruction from the WES 30. In this embodiment, the picking means 81 is an operator. It goes without saying that the picking means 81 may include not only an operator, but also both an operator and a picking robot.

[0038] The DAS shelf 82 has trays for holding the items picked by the picking station 80. The DAS shelf 82 is controlled by, for example, the WES 30. When the necessary items are put into the tray, the tray is discharged and a new empty tray is replenished. When the picking means 81 scans the barcode of the item picked from the shelf 70 or the upper tray 73, the processor 301 of the WES 30 acquires the scanned information and turns on a lamp corresponding to the tray on the DAS shelf 82 to which the scanned items are to be sorted, according to the acquired information. When the picking means 81 finishes sorting the items into the tray on the DAS shelf 82, the processor 301 completes the work by having the worker press a switch at the position of the tray, and creates a work log showing the work results (work performance) such as the work time. The DAS shelf 82 may be a general DAS shelf, and a detailed description thereof will be omitted here.

[0039] The conveyor 83 is, for example, a transport device that moves the upper tray 73 from a starting point 831 to an end point 832. The starting point 831 is a location where the upper tray 73 transported by the CTU robot 51 is placed. The end point 832 is a location where the CTU robot 51 obtains the upper tray 73 after picking has been completed. A worker, who is the picking means 81, picks up the required number of items from the items in the upper tray 73 placed on the conveyor 83 and places them in a tray arranged on the DAS shelf 82. In addition, the upper tray 73 from which the required items have been picked up by the picking means 81 moves to the end point 832.

[0040] The shelf standby area 90 includes a shelf stop position 91 and a shelf standby position 92. The shelf stop position 91 is a position where the shelf 70 transported by the shelf transport robot 41 stops and where picking work is performed by the picking means 81 in the picking station 80. The shelf standby position 92 is a place where the shelf 70 waits when there is a shelf 70 at the shelf stop position 91. When the shelf transport robot 41 transports the shelf 70 from the shelf inventory area 7 and moves to the shelf stop position 91, the shelf transport robot 41 transporting the shelf 70 passes through the shelf standby position 92 and moves to the shelf stop position 91, as shown by the arrow in FIG. 4.

[0041] In addition, at the shelf stop position 91 and the shelf standby position 92, the CTU robot 51 may obtain an upper tray 73 from the upper shelf 72 of the shelf 70 or store the upper tray 73.

[0042] (operation) First, a series of steps from acquisition of the upper tray 73 by the CTU robot 51 to storage will be described.

[0043] FIG. 5 is a diagram showing an example of a retrieval process in the picking station 80 and the shelf standby area 90 according to the embodiment. 5, the CTU robot 51 moves to the rear of the shelf 70 stopped at the shelf stop position 91 (the side facing the picking station 80 is the front). Note that, if there is space at the shelf standby position 92, the CTU robot 51 may move to the front of the shelf 70 as well as the rear.

[0044] Thereafter, as shown in 2, the CTU robot 51 identifies the upper tray 73 from the two-dimensional code attached to the upper tray 73, and acquires the upper tray 73 stored on the upper shelf 72 of the shelf 70. As shown in 3, the CTU robot 51 moves to the start point 831 (predetermined position) of the conveyor 83. As shown in 4, the CTU robot 51 supplies the upper tray 73 acquired from the shelf 70 onto the conveyor 83. That is, the CTU robot 51 places the upper tray 73 at the start point 831. As shown in 5, a person in the picking station 80 picks up an item from the upper tray 73 on the conveyor 83. Meanwhile, the CTU robot 51 moves to the end point 832 (predetermined position) of the conveyor 83. As shown in 6, the CTU robot 51 acquires the upper tray 73 that has moved to the end point 832 of the conveyor 83, and as shown in 7, moves to the waiting position 93 where the shelf 70 is waiting. Finally, as shown in 8., the CTU robot 51 stores the upper tray 73 on the upper shelf 72 of the shelf 70. The shelf 70 waiting at the waiting position 93 is not limited to the shelf 70 from which the upper tray 73 was acquired. For example, the shelf 70 from which the CTU robot 51 acquires and stores the upper tray 73 is determined based on the optimal operation plan. Furthermore, the CTU robot 51 that supplies the upper tray 73 to the conveyor 83 in 4. and the CTU robot 51 that acquires the upper tray 73 from the conveyor 83 in 6. may be the same or different.

[0045] Here, the standby position 93 may be the shelf stop position 91, the shelf standby position 92, or any location within the shelf inventory area 7. For example, the location where the shelf transport robot 41 is waiting may be the standby position 93. For example, when the shelf transport robots 41 temporarily stop to avoid contact with each other, that location may be the standby position 93. As described above, when the shelf transport robot 41 is waiting or stopped, the CTU robot 51 may acquire the upper tray 73 arranged on the upper shelf 72 or store the upper tray 73.

[0046] Next, a series of processing steps based on an operation plan by the WES 30 will be described. FIG. 6 is a flowchart showing an example of article processing according to an operation plan of the WES 30 according to the embodiment. The operation of this flowchart is realized by processor 301 of WES 30 reading and executing a program stored in memory 302. Furthermore, in the following operations, it is assumed that WES 30 constantly or periodically receives transport process results as necessary from shelf transport robot system 40 and high-rise case transport robot system 50. Therefore, even if not explicitly stated in the following explanation, processor 301 naturally issues operation instructions or performs determination processing to shelf transport robot 41 and CTU robot 51 based on the received transport process results.

[0047] In step ST101, the acquisition unit 3011 acquires a transportation work plan. The acquisition unit 3011 acquires the transportation work plan from the WMS 1. As described above, the transportation work plan is acquired for any of the actions of warehousing an item, warehousing an item, and inventory.

[0048] FIG. 7 is a diagram showing an example of a transportation operation plan acquired from the WMS 1 according to the embodiment. 7, the information includes, from the left, list number, destination code, destination, number of items to be shipped, product ID (Jancode), product name, stock, tray, position, handling, sequence, etc. The transport work plan may also include information such as the product's weight and dimensions such as length, width, and depth. Stock indicates which shelf 70 in the warehouse the target product is on, tray indicates either the normal shelf 71 or the upper shelf 72, position indicates the inventory position of the product, i.e., where on the shelf 70 it is located, handling indicates which of the shelf transport robot 41 or the CTU robot 51 can handle it, and sequence is the order of operations determined by an optimal operation plan described later.

[0049] In step ST102, the generation unit 3012 formulates an operation plan. That is, the generation unit 3012 formulates an optimal operation plan. The generation unit 3012 formulates the optimal operation plan based on the transport work plan. The generation unit 3012 formulates the optimal operation plan so that F=αT+βE is minimized. T is the total processing time, and E is the processing energy of the shelf transport robot 41 and the CTU robot 51, and details will be described later. In addition, α and β are coefficients that can be set arbitrarily. Here, when β=0, the plan is one in which the processing time (T) is the fastest, and when α=0, the plan is one in which the processing energy (E) is the minimum (local minimum value).

[0050] The processing energy E is expressed, for example, as the sum of the energy amounts obtained by multiplying the energy coefficients (for example, power consumption) of each of the shelf transport robot 41 and the CTU robot 51 by the transport distance, and is defined by the following formula.

[0051] E=L1+L2 Here, L1 and L2 are defined by the following formula. L1=Σ i (A×L1 i ), L2=Σ i (B×L2 i ) Here, A and B are coefficients that are set based on, for example, the power consumption according to the operating distance of the CTU robot 51. That is, L1 is a value obtained by multiplying a predetermined coefficient (A) by the sum of the operating distances of each of the shelf transport robots 41, and L2 is a value obtained by multiplying a predetermined coefficient (B) by the sum of the operating distances of each of the CTU robots 51.

[0052] For example, a picking list for one day is allocated to n shelf transport robots 41, m CTU robots 51, shelves 70, upper trays 73, and picking stations 80, and a combination L (allocation of shelf transport robots 41, allocation of CTU robots 51, and order of the list) that obtains the minimum value of F when the list is sorted is searched for. Here, n and m are any positive integers and represent the numbers of shelf transport robots 41 and CTU robots 51 arranged in the warehouse. For example, the generation unit 3012 formulates an operation plan (optimum operation plan) that satisfies the following formula.

[0053]

number

[0054] 7 based on the above formula. Output unit 3013 transmits the formulated optimal operation plan to shelf transport robot system 40 and high-rise case transport robot system 50 via interface 303. Processor 301 of shelf transport robot system 40 and high-rise case transport robot system 50 transmits necessary signals to shelf transport robot 41 and CTU robot 51, respectively, based on this optimal operation plan.

[0055] FIG. 8 is a diagram showing an example of an optimal operation plan according to the embodiment. 8, POD is a normal shelf 71, and TRAY refers to an upper tray 73. Furthermore, shelf ROBO refers to a shelf transport robot 41, and CTU refers to a CTU robot 51.

[0056] Here, the tray, position, and handling are determined by a combination that statistically minimizes formula 1 based on the processing results for a certain period in the past, for example, the past year. Then, as shown in Fig. 8, the optimal sequence order is determined based on the tray, position, and handling, using the above-mentioned formula (1).

[0057] In step ST103, the output unit 3013 outputs an operation instruction to the shelf transport robot 41 and the CTU robot 51. For example, the output unit 3013 outputs an operation instruction to the shelf transport robot system 40 and the high-rise case transport robot system 50 based on the optimal operation plan. Having received the instruction, the shelf transport robot system 40 and the high-rise case transport robot system 50 output the operation instruction to the shelf transport robot 41 and the CTU robot 51, and control the shelf transport robot 41 and the CTU robot 51 to perform a predetermined operation.

[0058] The operation instructions differ for each of the outgoing process, the incoming process, and the inventory process. Therefore, the outgoing process, the incoming process, and the inventory process in step ST103 will be described in detail below.

[0059] FIG. 9 is a flowchart showing an example of more detailed processing of step ST103 in the shipping processing. In step ST201, the shelf transport robot 41 moves to an inventory position and acquires a shelf 70. The output unit 3013 outputs an operation instruction to the shelf transport robot 41 based on the optimal operation plan. The shelf transport robot 41 that has received the operation instruction moves to the shelf 70 (inventory position) to be transported to the picking station 80 and acquires the shelf 70.

[0060] In step ST202, the shelf transport robot 41 transports the shelf 70 to the shelf standby position 92. Here, the output unit 3013 may output an operation instruction again to the shelf transport robot 41, or the operation instruction output in step ST201 may include the instruction of step ST202.

[0061] In step ST203, the processor 301 determines whether or not to acquire the upper tray 73 from the upper shelf 72. The processor 301 operating as a determination unit determines, based on the optimal operation plan, whether or not it is necessary to acquire the upper tray 73 arranged on the upper shelf 72 of the shelf 70 that has moved to the shelf standby position 92. If it is determined that acquisition is not necessary, the process proceeds to step ST212. On the other hand, if it is determined that acquisition is necessary, the process proceeds to step ST204.

[0062] In step ST204, the processor 301 determines whether the upper tray 73 can be acquired from the upper shelf 72. For example, the processor 301 determines whether the upper tray 73 to be acquired by the CTU robot 51 can be acquired based on the transport process result, etc. For example, if the upper tray 73 is on the picking station 80 side (front), the CTU robot 51 cannot acquire it. In such a case, it is determined that it cannot be acquired. In this case, the process proceeds to step ST205. On the other hand, if the required upper tray 73 is at the rear of the shelf 70, it is determined that the CTU robot 51 can acquire the upper tray 73. In this case, the process proceeds to step ST206.

[0063] In step ST205, the shelf transport robot 41 adjusts the orientation of the shelf 70. The output unit 3013 outputs an operation instruction to the shelf transport robot 41 based on the optimal operation plan. The shelf transport robot 41 that has received the operation instruction adjusts the orientation of the shelf 70 to an orientation that enables the CTU robot 51 to acquire the upper tray 73 arranged on the upper shelf 72. For example, the shelf transport robot 41 rotates the orientation of the shelf 70 by 180 degrees.

[0064] In step ST206, the CTU robot 51 acquires the upper tray 73 placed on the upper shelf 72 at the shelf standby position 92. The output unit 3013 outputs an operation instruction to the CTU robot 51 based on the optimal operation plan. The CTU robot 51 that has received the operation instruction moves to the shelf standby position 92 where the shelf 70 is waiting, and acquires the upper tray 73 placed on the upper shelf 72.

[0065] In step ST207, the CTU robot 51 places the upper tray 73 at the start point 831 (predetermined position) of the conveyor 83. The output unit 3013 outputs an operation instruction to the CTU robot 51 based on the optimal operation plan. The CTU robot 51 that receives the operation instruction moves to the start point 831 of the conveyor 83 and places the upper tray 73 on the start point 831. As a result, the CTU robot 51 supplies the upper tray 73 to the picking station 80.

[0066] In step ST208, the output unit 3013 outputs a picking instruction to the picking station 80. The output unit 3013 outputs a picking instruction to the picking station 80 for the upper tray 73 moving on the conveyor 83.

[0067] In step ST209, the picking means 81 picks the required number of articles from the upper tray 73 on the conveyor 83 in accordance with the picking instruction, and places them in a tray on the DAS shelf 82. In addition, the upper tray 73 from which the required articles have been picked moves on the conveyor 83 to the end point 832.

[0068] In step ST210, the CTU robot 51 acquires the upper tray 73 from the picking station 80. The output unit 3013 outputs an operation instruction to the CTU robot 51 based on the operation plan. The CTU robot 51 that has received the operation instruction moves to the end point 832 of the conveyor 83 and acquires the upper tray 73.

[0069] In step ST211, the CTU robot 51 stores the upper tray 73 on the upper shelf 72 of the shelf 70. The output unit 3013 outputs operation instructions to the shelf transport robot 41 and the CTU robot 51 based on the optimal operation plan, and moves the shelf transport robot 41 and the CTU robot 51 to the standby position 93. As described above, the standby position 93 may be the shelf stop position 91, the shelf standby position 92, or the shelf inventory area 7. Then, the CTU robot 51 stores the upper tray 73 on the upper shelf 72 of the shelf 70. After that, the process returns to step ST203. If the upper tray 73 cannot be stored on the upper shelf 72 due to the orientation of the shelf 70 waiting at the standby position 93, the same process as step ST205 may be performed.

[0070] In step ST212, the shelf 70 is moved to the shelf stop position 91. The output unit 3013 moves the shelf transport robot 41 to the shelf stop position 91 based on the optimal operation plan, thereby moving an article from the shelf 70 to the shelf stop position 91 where it can be picked.

[0071] In step ST213, the output unit 3013 outputs a picking instruction to the picking station 80. The output unit 3013 outputs a picking instruction for the shelf 70 that has moved to the shelf stop position 91.

[0072] In step ST214, the picking means 81 picks the required number of articles from the shelf 70 in accordance with the picking instruction, and places them on a tray on the DAS shelf 82.

[0073] In step ST215, the processor 301 determines whether the work is completed. For example, the processor 301 determines whether the picking means 81 has pressed a switch at the position of the tray on the DAS shelf 82. If it is detected that the work is completed, that is, that the picking means 81 has pressed the switch, the process proceeds to step ST216. On the other hand, if the work is not completed, the process returns to step ST213.

[0074] In step ST216, the processor 301 determines whether or not to store the upper tray 73 on the upper shelf 72. For example, the processor 301 determines whether or not to store the upper tray 73 on the upper shelf 72 at the standby position 93 based on the optimal operation plan. If it is determined that it is necessary to store it, the process proceeds to step ST217. On the other hand, if it is determined that it is not necessary to store it, the process proceeds to step ST218.

[0075] In step ST217, the output unit 3013 moves the shelf 70 to the standby position 93. The output unit 3013 moves the shelf transport robot 41 having the shelf 70 to the shelf stop position 91 based on the optimal operation plan. Then, similar to step ST211, the output unit 3013 outputs an operation instruction to the CTU robot 51. The CTU robot 51 that has received the operation instruction stores the upper tray 73 on the upper shelf 72 of the shelf 70.

[0076] In step ST218, the output unit 3013 returns the shelf 70 to its original position. The output unit 3013 outputs an operation instruction to the shelf transport robot 41. The shelf transport robot 41 returns the shelf 70 from which picking has been completed to its original position.

[0077] Here, the order of steps ST204 to ST211 and steps ST212 to ST214 may be interchanged or may be performed in parallel. For example, while the picking means 81 is picking from the shelf 70, the CTU robot 51 may obtain the upper tray 73 from the shelf 70 and place it at the start point 831 of the conveyor 83.

[0078] FIG. 10 is a flowchart showing an example of more detailed processing of step ST103 in the warehousing processing. Steps ST301 to ST308 may be the same as steps ST201 to ST208 described with reference to Fig. 9. Therefore, the duplicated description will be omitted here. However, the picking instruction in step ST308 is a warehousing instruction to put an article on the shelf 70 or the upper tray 73.

[0079] In step ST309, the picking means 81 stores the required number of articles in the warehouse. For example, the picking means 81 puts the required number of articles into the upper tray 73 in accordance with the picking instruction.

[0080] Moreover, steps ST310 to ST313 may be the same as steps ST210 to ST212 described with reference to Fig. 9. Therefore, a duplicated description will be omitted here. However, the picking instruction in step ST313 is a warehousing instruction to put an article on the shelf 70 or the upper tray 73.

[0081] In step ST314, the picking means 81 stores the required number of articles in stock. For example, the picking means 81 puts the required number of articles into the normal shelf 71 of the shelf 70 in accordance with the picking instruction.

[0082] Moreover, steps ST315 to ST318 may be the same as steps ST215 to ST218 described with reference to Fig. 9. Therefore, a duplicated description will be omitted here.

[0083] FIG. 11 is a flowchart showing an example of more detailed processing of step ST103 in the inventory processing. Steps ST401 to ST407 may be the same as steps ST201 to ST207 described with reference to Fig. 9. Therefore, a duplicated description will be omitted here.

[0084] In step ST408, the processor 301 outputs an instruction to check the number of items in stock. The processor 301 outputs an instruction to check the number of items in stock to the picking station 80 based on the optimal operation plan.

[0085] In step ST409, the picking means 81 inputs the number of items. In accordance with the stock quantity confirmation instruction, the picking means 81 confirms the stock quantity of items in the upper tray 73. Then, the picking means 81 inputs the stock quantity to an input device installed in the picking station 80 and connected to the WES 30. The processor 301 updates the stock quantity in the inventory management database based on the received input information.

[0086] Moreover, steps ST410 to ST412 may be the same as steps ST210 to ST212 described with reference to Fig. 9. Therefore, a duplicated description will be omitted here.

[0087] In step ST413, the processor 301 outputs an instruction to check the number of items in stock. The processor 301 outputs an instruction to check the number of items in stock in a tray arranged on the normal shelf 71 of the shelf 70 to the picking station 80 based on the optimal operation plan.

[0088] In step ST414, the picking means 81 inputs the number of items. In accordance with the stock quantity confirmation instruction, the picking means 81 confirms the stock quantity of items on the trays arranged on the normal shelves 71 of the shelves 70. Then, the picking means 81 inputs the stock quantity to an input device installed in the picking station 80 and connected to the WES 30. The processor 301 updates the stock quantity in the inventory management database based on the received input information.

[0089] Steps ST415 to ST418 may be the same as steps ST215 to ST218 described with reference to Fig. 9. Therefore, a duplicated description will be omitted here.

[0090] Returning to FIG. 6, in step ST104, the processor 301 determines whether the work is complete. The processor 301 determines whether all the work according to the optimal operation plan is complete. If the result of the determination is that the work is not completed, the process returns to step ST103. On the other hand, if the result is that the work is completed, the process ends. When the work is completed, the WES30 may notify the WMS1 of the work result.

[0091] Note that the above-mentioned operation has been described as an example in which WES30 controls the shelf transport robot 41 and the CTU robot 51, but it goes without saying that after generating an optimal operation plan, the optimal operation plan can be sent to the shelf transport robot system 40 and the high-rise case transport robot system 50, and the shelf transport robot system 40 and the high-rise case transport robot system 50 can control the shelf transport robot 41 and the CTU robot 51, respectively.

[0092] (Effects of the embodiment) According to the embodiment described above, the shelf 70 includes an upper shelf 72 above a normal shelf 71 that can be picked by a picking means 81 (a worker or a picking robot). The upper trays 73 placed on the upper shelf 72 are placed on a conveyor 83 arranged in a picking station 80 by the CTU robot 51, and the picking means 81 can pick up the items. This makes the shelf 70 a higher shelf than a general shelf, thereby increasing the utilization rate of the warehouse space.

[0093] Furthermore, the transportation efficiency increases as the number of articles that can be mounted on one shelf 70 increases.

[0094] [Other embodiments] In the present embodiment, an example has been described in which only the CTU robot 51 acquires or stores the upper tray 73 arranged on the upper shelf 72, but this is not limited to the above. For example, a worker at the picking station 80 may climb a stepladder or the like to acquire the upper tray 73. For example, when it is necessary to pick an item from the upper tray 73 that is in the same direction as the worker at the picking station 80 is picking, if the CTU robot 51 tries to acquire it, it will need to reverse its direction, which is inefficient. In such a case, the worker may acquire the upper tray 73 using a stepladder or the like.

[0095] The program according to the present embodiment may be transferred in a state where it is stored in an electronic device (computer) such as the WES30, or may be transferred in a state where it is not stored in the electronic device. In the latter case, the program may be transferred via a network, or may be transferred in a state where it is stored in a storage medium. The storage medium is a non-transitory tangible medium. The storage medium is a medium that can be read by a computer such as the WES30 (computer-readable medium). The storage medium may be any medium capable of storing a program and being readable by a computer, such as an optical disk (e.g., a CD-ROM), a magnetic disk, or a semiconductor memory (e.g., a memory card), and the form of the storage medium is not important.

[0096] Although some embodiments of the present invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included in the scope and spirit of the invention, and are included in the scope of the invention and its equivalents described in the claims. [Explanation of symbols]

[0097] 1. WMS 2. Warehouse processing system 30…W.E.S. 301...Processor 3011…Acquisition Department 3012...Generation section 3013...Output section 302…Memory 303...Interface 40...Shelf transport robot system 41...Shelf transport robot 50…High-rise case transport robot system 51…CTU robot 60...Inventory control system 7…Shelf inventory area 70…Shelf 71…Normal shelf 72…Upper shelf 73…Upper tray 74...2D code 8. Picking station 80…Picking station 81...Picking method 82…DAS shelf 83...Conveyor 831…Start point 832…End point 90…Shelf standby area 91…Shelf stop position 92…Shelf standby position 93…Standby position

Claims

1. A receiving unit that receives a transportation operation plan; A generation unit that creates an operation plan based on the transportation operation plan; an output unit that outputs a first operation instruction to a shelf transport robot that transports a shelf having an upper shelf that stores an upper tray on an upper part of a shelf that can be picked by a picking means at a picking station based on the operation plan, and outputs a second operation instruction to a high-rise case transport robot that retrieves the upper tray from the upper shelf or stores the upper tray on the upper shelf; An article processing plan generating device comprising:

2. the first operation instruction includes an instruction to the shelf transport robot to move the shelf to a standby position in a warehouse; The material processing plan generating apparatus according to claim 1 .

3. the second operation instruction further includes an instruction to the high-rise case transport robot to retrieve the upper tray from the upper shelf waiting at the waiting position. The material processing plan generating apparatus according to claim 2 .

4. the first operation instruction includes an instruction to the shelf transport robot to move the shelf to a shelf waiting area adjacent to the picking station; The material processing plan generating apparatus according to claim 1 .

5. the second operation instruction further includes an instruction to the high-rise case transport robot to retrieve the upper tray from the upper shelf waiting in the shelf waiting area. The material processing plan generating apparatus according to claim 4.

6. the first operation instruction further includes an instruction to the shelf transport robot to adjust an orientation of the shelf when the high-rise case transport robot cannot acquire the upper tray from the upper shelf in the shelf waiting area. The material processing plan generating apparatus according to claim 4.

7. The second operation instruction further includes an instruction to place the acquired upper tray at a first predetermined position of a conveyor included in the picking station.

6. An apparatus for generating an item processing plan according to claim 3 or 5.

8. the second operation instruction further includes an instruction to obtain an upper tray that is at a second position of the conveyor and has been picked by a picking means; The material processing plan generating apparatus according to claim 7.

9. the first operation instruction includes an instruction to the high-rise case transport robot to move the shelf to a shelf stop position in the picking station where the picking means can pick up an item, and then to move the shelf to a standby position; The material processing plan generating apparatus according to claim 1 .

10. the second operation instruction includes an instruction to move the high-rise case transport robot to the standby position and store the upper tray on the upper shelf. The material processing plan generator of claim 9.

11. Warehouse operation system, a shelf transport robot system and a high-rise case transport robot system connected to the warehouse operation system; The warehouse operation system includes: A receiving unit that receives a transportation operation plan; A generation unit that creates an operation plan based on the transportation operation plan; an output unit that outputs the operation plan to the shelf transport robot system and the high-rise case transport robot system; Equipped with the shelf transport robot system includes an output unit that outputs a first operation instruction to a shelf transport robot that transports a shelf including an upper shelf that stores an upper tray above a shelf that can be picked by a picking means at a picking station based on the operation plan; the high-rise case transport robot system further includes an output unit that outputs a second operation instruction to the high-rise case transport robot that retrieves an upper tray from the upper shelf or stores an upper tray on the upper shelf; Material handling plan generation system.

12. 1. An article processing plan generation program comprising instructions for execution by a processor of an article processing plan generation apparatus, the instructions comprising: Receiving a transportation operation plan; Creating an operation plan based on the transportation operation plan; outputting a first operation instruction to a shelf transport robot that transports a shelf having an upper shelf that stores an upper tray above a shelf that can be picked by a picking means at a picking station based on the operation plan; outputting a second operation instruction to a high-rise case transport robot that retrieves an upper tray from the upper shelf or stores an upper tray on the upper shelf; An article processing plan generating program comprising:

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