Commodity extraction-collection system

Abstract

To provide a commodity extraction-collection system which can perform miss-free picking and sorting repeatedly for one order.SOLUTION: A commodity extraction-collection system comprises: a computer 1 that transmits a picking command for designating a commodity picked for one order and an open-door command; a commodity accommodation shelf 2 for picking which has a picking indication lamp and a picking number indicator in each shelf compartment; a commodity accommodation shelf 3 for sorting which has a door provided at an entrance to each shelf compartment; a first control unit 4 which indicates picking; and a second control unit 8 for opening the door; and a code reader 10. The computer 1 checks the code transmitted from the code reader 10 against the picking command and transmit an open-door command to the second control 8 unit when the check results in a match. When the check results in nonmatching, a re-picking command for shelf data related to unpicked commodities and a picking number is transmitted to the first control unit 4.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a product picking and collection system, and more particularly to a product picking and collection system capable of picking up multiple products related to an order from multiple product storage shelves for each order and storing the products in one shelf section of a product sorting shelf. [Background technology]

[0002] In a conventional product picking and sorting system in a logistics warehouse, for example, all orders received in a week are compiled in a database by an integrated computer in a logistics center. The database registers the details of all orders and various details (location ID, shelf ID, shelf section ID, product ID, product name, etc.) required for picking products stored in the vast number of product storage shelves arranged in the logistics warehouse. Then, data required for managing the picking and sorting work is downloaded from this database to the computer.

[0003] To enable multiple workers, for example 20-50 people, to handle the picking and sorting work for all orders received in a week, the computer allocates one batch of multiple orders as each worker's daily picking and sorting workload and downloads one batch's worth of data to the worker's handheld terminal.

[0004] Each worker carries a handheld terminal and picking cart and inputs the start of picking. The location ID, shelf ID, product ID, product name, etc. of the first product of the multiple products related to one order in one batch are displayed, and the products related to one order can be collected in the picking cart. When the worker inputs into the handheld terminal that they have finished picking this product, the location ID, shelf ID, product ID, product name, etc. of the next product are displayed on the handheld terminal, and in this way the number of orders for one batch can be picked.

[0005] In addition, in a system different from the above, a controller is provided that lights up lamps provided in each shelf section of the product storage shelf for picking and displays the number of items to be picked from the lit shelf position, and the controller lights up the lamp at the picking position and displays the number of items to be picked, thereby supporting the picking of products for one order.

[0006] In addition, guidance is displayed based on an algorithm that can select the shortest picking route through the aisles around the huge number of fixed shelves.

[0007] Furthermore, for sorting, sorting shelves with multiple individual sorting openings equipped with opening doors that only allow one item to be inserted are provided, and a sorting device is in practical use in which when the order ID of the items collected in the picking cart is read by a handheld terminal, a specific opening door opens, allowing the items related to one order to be stored in the individual sorting opening. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] International Publication No. 2017-175301 [Patent Document 2] JP 2010-116244 A Summary of the Invention [Problem to be solved by the invention]

[0009] According to the conventional product removal and collection system in a logistics warehouse described above, when picking multiple products related to one order, the products can be picked by walking along the aisles around the fixed shelves using the shortest picking route. However, this picking task must be repeated for one batch, which results in a large picking distance and time, and reducing the picking distance and time remains an issue.

[0010] Furthermore, with the above-mentioned conventional product removal and collection system in a logistics warehouse, when picking and sorting products for long periods of time, despite the fact that each shelf section of the product storage shelves is equipped with a lamp and a quantity indicator, the worker may become fatigued or make mistakes, resulting in the worker picking again when he or she has just picked, or in the mistaken belief that he or she has picked when he or she has not, and further in picking the wrong number of items.

[0011] The present invention has been made in consideration of the above points, and aims to provide a product picking and collection system that can perform the picking and sorting of one batch of orders in a small work station without the need to walk around, significantly reducing the distance and time required for the picking and sorting of one batch of orders, and can reduce the mental burden on workers by knowing where all of the products for one order are located on multiple shelves, confirming that the products have been picked and the number of products picked, and preventing sorting errors when storing items on one shelf section of a product sorting shelf. [Means for solving the problem]

[0012] As a premise for solving the above problems, the present invention has devised a product picking and collection system that includes a single work station, a plurality of product storage shelves for storing products related to one batch of orders, and a product sorting shelf for picking multiple products related to an order from these product storage shelves and storing them in a single shelf section.

[0013] In order to solve the above-mentioned problems, an article picking and collection system according to a first aspect of the present application comprises: a computer that performs comprehensive data management for the picking and sorting of products related to one batch of orders and transmits a picking command and a door open command that specify the total number of products picked related to one order; a picking product storage shelf having a plurality of picking shelf sections, each of which has a picking indication lamp and a picking number display, and which allocates the products related to one batch of orders to one section for each product, and which is capable of picking all of the products related to one order from the plurality of picking shelf sections at one time in accordance with the lighting of the picking indication lamp based on the picking command and the display of the picking number on the picking number display; a sorting product storage shelf having a required number of sorting shelf sections that collectively allocates all of the picked products related to one order to one section and stores them therein, and which has a door that is provided at the front of each of the sorting shelf sections and is operable to open and close; the picking command to turn on the picking indication lamps for all items related to one order and to display the number of items picked on the picking quantity display at the same shelf position; a second control unit that controls to open the door provided at the entrance of one of the sorting shelf sections required for accommodating all of the picked items related to one order based on the door open command; and a code reader that reads barcodes, QR codes (registered trademark), AR codes, or RFID codes attached to the multiple items related to one order that have been picked and transmits the read code to the computer, and the computer is configured to compare the code transmitted from the code reader with the picking command and, if they match, transmit the door open command to the second control unit, and, if they do not match, transmit shelf data for items that have not been picked and a second picking command regarding the number of items to be picked to the first control unit.

[0014] In the article picking and collecting system according to the second aspect of the present application, in the first aspect, a picking cart having wheels for easy movement and towed by a worker may be further provided.

[0015] As an item picking and collection system relating to the third aspect of the present application, in the second aspect, the picking cart may be loaded with the code reader, a first basket containing the total number of items related to an order picked from the picking item storage shelf, and a second basket for removing the items from the first basket, reading the codes affixed to the items with the code reader, and then storing the items.

[0016] As an item picking and collection system relating to the fourth aspect of the present application, in the third aspect, a mobile terminal may be carried by a contractor, and instead of an operator directly inputting information into the computer, a transmission instruction signal may be sent from the computer to the mobile terminal, instructing the computer to send the picking command.

[0017] As an item picking and collecting system according to a fifth aspect of the present invention, in the fourth aspect, the code reader may be incorporated in the mobile terminal.

[0018] As an article picking and sorting system according to the sixth aspect of the present application, in the fourth aspect, as a process for picking and sorting all the items related to one order, (Step 1) Waiting until a work start request signal is sent from the mobile terminal; (Step 2) When the computer receives the work start request signal, it transmits a signal to close the door to the second control unit, and then transmits data required for picking the ordered items to the first control unit. (Step 3) the first control unit turns on picking indication lamps attached to shelf sections in which all of the products related to one order are stored, based on data transmitted from the computer, and displays the number of products picked on a picking number display; (Step 4) A code reader reads the codes attached to the products stored in all the shelf sections whose lamps are lit, and transmits the read codes to a computer. (Step 5) the computer checks the code data against the code data of the picking instruction data, and if all items match, transmits a door open command including door data for opening a door of one assigned sorting shelf section to a second control unit; (Step 6) The second control unit opens one of the assigned doors based on a door open command from the computer. (Step 7) The picked items are stored in the sorting shelf section with the door open. (Step 8) a signal requesting the start of the next operation is sent from the portable terminal to the computer, together with a notification that sorting of the ordered items has been completed; The above steps 1 to 8 may be repeatedly executed. Effect of the Invention

[0019] According to each aspect of the present invention, it is possible to provide a product picking and collection system that can perform the picking and sorting of one batch of orders in a small work station without the need to walk around, significantly reducing the distance and time required to pick one batch of orders, and can determine where all of the products for one order are located across multiple shelves, reducing the mental burden on workers, confirming that the products have been picked and the number of products picked, and preventing sorting errors when storing items on one shelf section of a product sorting shelf. [Brief description of the drawings]

[0020] [Figure 1] 1 is a conceptual diagram showing a product pick-up and collection system according to an embodiment of the present invention; [Diagram 2] FIG. 2 is a flow chart showing the operational steps of the product picking and collecting system according to the first embodiment of the present invention. [Diagram 3] 1 is a front view of a specific example of a picking product storage shelf that constitutes a product removal and collection system according to an embodiment of the present invention. [Figure 4]1 is a front view of a specific example of a product storage shelf for sorting that constitutes a product pick-up and collection system according to an embodiment of the present invention. [Diagram 5] 5 is a perspective view of a product picking and collecting system according to an embodiment of the present invention in which the picking product storage shelves of FIG. 3 and the sorting product storage shelves of FIG. 4 are specifically arranged. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A product pick-up and collection system according to an embodiment of the present invention will be described with reference to the drawings.

[0022] As shown in Fig. 1, a product picking and collection system 100 according to an embodiment of the present invention includes a computer 1 that performs comprehensive data management for picking and sorting products related to one batch of orders and transmits picking commands and door-opening commands that specify all products picked for one order, a picking product storage shelf 2 having a required number of picking shelf sections 2a-2n and storing products related to one batch of orders by allocating each product to one section, a sorting product storage shelf 3 having a required number of sorting shelf sections 3a-3g and storing all products related to one order by allocating each to one section, barcodes, QR codes (registered trademark), AR codes, or RFID codes 10 attached to the products, and a picking cart 9 carried by a worker M during work, and transmits data required for mutual functions via a communication network. The computer 1 preferably has a hardware configuration that includes a communication module, a storage device such as a hard disk or SSD, a memory, a CPU, a keyboard, and a display (not shown). The mobile terminal 11 preferably includes a communication module, a memory, a CPU, and a touch panel (not shown). However, the code attached to the product for identifying the product is not limited to a barcode, a QR code (registered trademark), an AR code, or an RFID code.

[0023] The product picking and collecting system 100 of this embodiment includes a mobile terminal 11 carried by an operator M. The mobile terminal 11 is configured to transmit a transmission instruction signal to the computer 1, instructing the computer 1 to transmit a picking command, instead of the operator directly inputting the command into the computer 1.

[0024] The picking product storage shelf 2 has picking instruction lamps 5a-5n and picking number displays 6a-6n in each of the picking shelf sections 2a-2n, and a first control unit 4. The first control unit 4 controls the required multiple picking instruction lamps to be turned on based on a picking command sent from the computer 1, and also controls the picking number display at the same shelf position to display the number of pickings. The first control unit 4 includes a communication module, memory, CPU, etc. as a hardware configuration (not shown). Alternatively, the first control unit 4 may be a control processing unit of the computer 1. In this case, the picking instruction lamps 5a-5n and the picking number display 6a-6n may be controlled by the control of the first control unit 4 of the computer 1 to be turned on based on a picking command, and also controls the picking number display at the same shelf position to display the number of pickings.

[0025] In the picking shelf sections 2a-2n, products that are in short supply during pinking can be replenished from both the picking side and the opposite side.

[0026] The sorting product storage shelf 3 has shelf sections equal to or larger than the number of orders per bit. The sorting product storage shelf 3 has doors 7a-7g that are driven to open and close in each of the sorting shelf sections 3a-3g, and a second control unit 8. The doors 7a-7g are each attached to a horizontal shaft at the top so as to be tiltable, and are opened and closed by an actuator provided at one end of the horizontal shaft. The second control unit 8 is adapted to open a required door by sending a door open signal to the actuator based on a door open command sent from the computer 1. The second control unit 8 is equipped with a communication module, memory, CPU, etc. as a hardware configuration (not shown). Alternatively, the second control unit 8 may be a control processing unit of the computer 1. In this case, the doors 7a-7g that are driven to open and close in each of the sorting shelf sections 3a-3g may be adapted to open a required door by sending a door open signal to the actuator under the control of the second control unit 8 of the computer 1.

[0027] Through the doors 7a-7g, the products stored in the sorting shelf sections 3a-3g are taken out from the other side, placed in cardboard boxes, and transported to the outgoing space.

[0028] The picking cart 9 has wheels and is easily movable, and is towed along by the worker M. On the picking cart 9, there are placed a barcode reader 10, a first basket K1 that contains all the products related to one order picked from the picking product storage shelves 2, and a second basket K2 for taking out the products in the first basket K1, reading the product codes with the code reader 10, and storing the products thereafter. The code reader 10 may be incorporated in a mobile terminal 11 held by the worker M during the picking work.

[0029] The code reader 10 reads the code attached to the picked product and transmits the read code to the computer 1 so that the computer 1 can check whether there are any discrepancies or surpluses or shortages in the total number of products for one order picked from the picking product storage shelves 2.

[0030] By pressing a required button, the mobile terminal 11 outputs a work start request signal notifying the start of picking of products related to the first order and the start of picking of products related to the second and subsequent orders.

[0031] [System Operation Steps] As shown in FIG. 2, the product pick-up and collection system 100 transmits required signals between a computer 1, a first control unit 4, a second control unit 8, a barcode reader 10, and a mobile terminal 11, which constitute the system's work steps.

[0032] [Step 1] The computer 1 waits until the work of arranging the product storage shelves 2 for picking and the product storage shelves 3 for sorting at the required stations is completed and a work start request signal is sent from the mobile terminal 11 carried by the worker M. The computer 1 may also serve as the integrated computer of the logistics center.

[0033] [Step 2] When the computer 1 receives the work start request signal, it sends a signal to the second control unit 8 to close the open door of the sorting product storage shelf 3, and then sends the data required for picking the products of each order (picking instruction data) in order for each batch of orders stored in the memory unit to the first control unit 4. For the first picking, there are no open doors, so a closing signal is not sent. For the second and subsequent pickings, one door is opened to store the first picked product, so a signal to close this door is sent. The data required for picking the products of one order includes the shelf ID that identifies which shelf section each of the products related to one order is stored in, and the number of items to be picked.

[0034] [Step 3] The first control unit 4 turns on the picking indication lamps attached to the shelf sections in which all the products related to one order are stored, based on the data transmitted from the computer 1, and displays the number of items to be picked on the picking number display. This allows the worker M to know at a glance where the multiple shelf sections to be picked are located, and how many items to pick from one shelf section.

[0035] [Step 4] The products stored in all the shelf sections with the lights on are picked by the worker M in the same number as the picking display number and stored in the first basket K1 on the picking cart 9. Next, the products stored in the first basket K1 are taken out one by one by the worker M, the codes attached to the products are read by the code reader 10 on the picking cart 9, and the products are stored in the second basket K2. In this way, the products related to one order are picked at once and collected in the first basket K1, and then the barcodes are read and the products are stored in the second basket K2, so that the codes of all the products are read reliably. Then, the code reading signal (read code) is sent one by one together with the station ID to the computer 1, and at this point, the computer 1 outputs an instruction signal to turn off the lamp and an instruction signal to end the display to the first control unit 4.

[0036] [Step 5] The computer 1 checks the code data against the code data stored internally that corresponds to the picking instruction data of step 2, and if all items match, it sends a shelf section ID to the second control unit 8 to open the door of one shelf section assigned to one order related to the picking instruction of step 2, among the sorting shelf sections 3a-3g of the sorting product storage shelf 3. If all items do not match, the computer 1 sends a re-picking command to the first control unit 4 regarding the shelf data and the number of items to be picked related to the products that have not been picked. This compensates for human errors in picking.

[0037] [STEP 6] The second control unit 8 opens the door of one of the sorting shelf sections 3a-3g that is assigned to the currently picked product, thereby eliminating human error in the sorting work.

[0038] [STEP 7] The products stored in the second basket K2 are stored in a shelf section whose door has been opened by the worker M. The products stored in this shelf section are taken out from the opposite side to the door, placed in cardboard boxes, and transported to the out-of-stock station.

[0039] [STEP 8] The mobile terminal 11 transmits a signal requesting the start of the next job to the computer 1 in response to an operation by the worker M, which also notifies the computer 1 that sorting of one ordered item has been completed.

[0040] Thereafter, the process repeats from step 1 to step 8 until the processing of one batch of orders is completed.

[0041] As the picking product storage shelves 2, for example as shown in Fig. 3, multiple shelves each having 4 sections and 5 levels each are prepared, each capable of storing 1 bit of product. Only one first control unit 4 is required to provide total control over the multiple picking product storage shelves 2.

[0042] The sorting product storage shelves 3 may be configured to have the required number of shelves, each with four sections and five levels, as shown in Fig. 4. It is sufficient to have one second control unit 8 so that it can provide total control over multiple sorting product storage shelves.

[0043] The picking product storage shelves 2 and the sorting product storage shelves 3 each have legs at the four corners and further have casters with brakes or can be moved by a traveling robot.

[0044] FIG. 5 shows an example in which three picking-use product storage shelves 2A, 2B, and 2C having the configuration shown in FIG. 3 and one picking-use product storage shelf 3 having the configuration shown in FIG. 4 are arranged in a work station.

[0045] This product picking and collection system 100 can reduce the range of movement of worker M for picking to the minimum necessary by arranging the picking product storage shelves 2 and the sorting product storage shelves 3 within a narrow range.

[0046] The computer 1, the first control unit 4, the second control unit 8, and the code reader 10 cooperate to perform coordinated control for efficiently picking and sorting the products related to one order.

[0047] When picking items related to an order, lights are turned on and the number of items to be picked is displayed simultaneously for all shelf sections among picking shelf sections 2a-2n that contain the items to be picked, allowing worker M to quickly pick items related to an order.

[0048] Furthermore, when worker M reads the code of the product he picked, the data is sent to computer 1, which then checks the code data against the original picking instruction data. This prevents worker M from making a picking mistake.

[0049] After checking that the picking has been performed accurately, the computer 1 opens the door of one of the sorting shelf sections 3a-3g of the sorting product storage shelf 3. This allows all the products related to one order picked by the worker M to be stored in the correct shelf section. This prevents mistakes in sorting.

[0050] According to the item picking and collection system of the present invention, the items to be picked for one order batch are prepared and stored in a small number, for example, on several product storage shelves for picking, and these product storage shelves and one product sorting shelf are arranged in a narrow work station for each worker so that the worker does not have to walk around. The picking positions and numbers of items to be picked for all of the items related to one order are clearly displayed at once on the several product storage shelves for picking, so that all of the items related to one order can be picked quickly without the worker having to walk around much and collected in a picking cart. The codes attached to the items are read by a code reader and compared by a computer. If the codes are correct, one door is opened and the picked items are stored (sorted) in one sorting shelf section, so that picking and sorting can be performed repeatedly for one order without any mistakes, and one batch can be processed accurately and quickly. [Explanation of symbols]

[0051] 1. Computer 2…Picking product storage shelves 2a-2n: Picking shelf section 3…Product sorting shelves 3a-3g…Sorting shelf section 4...First control section 5a-5n…Picking indicator lamp 6a-6n…Picking quantity indicator 7a-7g…door 8...Second control section 9. Picking cart 10...Code reader 11. Mobile devices 100…Product pick-up and collection system K1: First cage K2: Second cage M…Worker

Claims

1. a computer that performs comprehensive data management for picking and sorting items related to one batch of orders and transmits picking commands and door opening commands specifying the total number of items picked for one order; a picking product storage shelf having a plurality of picking shelf sections, each of which has a picking instruction lamp and a picking number indicator, and which stores products related to one batch of orders by allocating each product to one section, and which can pick all of the products related to one order from the plurality of picking shelf sections at one time in accordance with the lighting of the picking instruction lamp based on the picking command and the display of the picking number indicator; a sorting shelf having a required number of sorting shelf sections for storing all the picked products for one order, the sorting shelf having a door that is provided at the front of each sorting shelf section and can be opened and closed; a first control unit that controls the picking instruction lamps for all of the orders to be turned on based on the picking command and to display the number of pickings on the picking number display unit at the same shelf position; a second control unit that controls to open the door provided at an entrance of one of the sorting shelf sections required to accommodate all of the picked products related to one order based on the door opening command; and a code reader that reads bar codes, OR codes, AR codes, or RFID codes attached to the multiple products in one order that have been picked, and transmits the read codes to the computer; The computer is adapted to compare the code transmitted from the code reader with the picking command, and if they match, transmit the door open command to the second control unit, and if they do not match, transmit shelf data regarding the products that have not been picked and a re-picking command regarding the number of products to be picked to the first control unit. An article pick-up and collection system.

2. 2. An article picking and collecting system according to claim 1, further comprising a picking cart having wheels for easy movement and towed by a worker.

3. The item picking and collection system described in claim 2, wherein the picking cart is equipped with the code reader, a first basket for storing all of the items related to an order picked from the picking item storage shelf, and a second basket for removing the items from the first basket, reading the codes attached to the items with the code reader, and then storing the items.

4. The item picking and collection system of claim 3, further comprising a mobile terminal carried by a vendor, and capable of sending a transmission instruction signal to the computer from the mobile terminal instructing the computer to send the picking command, instead of the worker directly inputting the command into the computer.

5. 5. An article picking and collecting system according to claim 4, wherein the code reader is incorporated in the portable terminal.

6. As part of the process of picking and sorting all items related to one order, (Step 1) Waiting until a work start request signal is sent from the mobile terminal; (Step 2) When the computer receives the work start request signal, it transmits a signal to close the door to the second control unit, and then transmits data required for picking the ordered items to the first control unit. (Step 3) the first control unit turns on picking indication lamps attached to shelf sections in which all the products related to one order are stored, based on the data transmitted from the computer, and displays the number of products picked on a picking number display; (Step 4) A code reader reads the codes attached to the products stored in all the shelf sections whose lamps are lit, and transmits the read codes to a computer. (Step 5) the computer checks the code data against the code data of the picking instruction data, and if all items match, transmits a door open command including door data for opening a door of one assigned sorting shelf section to a second control unit; (Step 6) The second control unit opens one of the assigned doors based on a door open command from the computer. (Step 7) The picked items are stored in the sorting shelf section with the door open. (Step 8) a signal requesting the start of the next operation is sent from the portable terminal to the computer, together with a notification that sorting of the ordered items has been completed; 5. The article picking and collecting system according to claim 4, wherein the process of steps 1 to 8 is repeatedly executed.

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