Automatic warehousing system

Abstract

To provide an automatic warehousing system which can improve throughput.SOLUTION: An automatic warehousing system 100 can keep a load and comprises: a storage shelf part 22 which extends in a first direction and in which storage lines 24 to keep multiple loads are provided side by side in a second direction crossing the first direction; a carriage loading a load and shifting in the first direction; a move mechanism loading the carriage and shifting in the second direction; and a control part controlling delivery of the load from the storage shelf part 22. As for a first load and a second load which are available for one delivery request and kept in the storage shelf part 22, the control part controls the delivery of the load to deliver the first load when the number of other loads needing relocation for delivery of the first load is fewer than that of the second load.SELECTED DRAWING: Figure 11

Description

[Technical field]

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

[0002] There is known an automated warehouse system that can efficiently store and retrieve a large number of items in a small space. The present applicant discloses an automated warehouse system equipped with a plurality of storage shelves capable of storing a plurality of items in Patent Document 1. This automated warehouse system is configured to carry in and carry out items using a transport cart that can move in the column direction between the storage shelves and a cart that can move in the row direction. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2017-160040 A Summary of the Invention [Problem to be solved by the invention]

[0004] In an automated warehouse, multiple items of different types may be stored in one row. In such warehouses, the item to be shipped may be stored at the back of the row, and other items that are not to be shipped may be stored at the front of the row. In this case, before the item to be shipped is shipped, it is necessary to rearrange the other items to a different storage space, and if the rearrangement takes a long time, there is a problem that the shipping throughput decreases.

[0005] The present invention has been made in view of the above problems, and an object of the present invention is to provide an automated warehouse system capable of improving throughput. [Means for solving the problem]

[0006] In order to solve the above problems, an automated warehouse system according to one embodiment of the present invention is an automated warehouse system capable of storing objects, and includes a storage shelf section extending in a first direction, with storage rows for storing a plurality of objects arranged side by side in a second direction intersecting the first direction, a cart that carries the objects and moves in the first direction, a moving mechanism that carries the cart and moves in the second direction, and a control section that controls the retrieval of the objects from the storage shelf section. For a first object and a second object stored in the storage shelf section and capable of responding to one retrieval request, the control section controls the retrieval of the objects so as to retrieve the first object when the first object is smaller in number of other objects requiring rearrangement for retrieval than the second object.

[0007] Another aspect of the present invention is also an automated warehouse system. This automated warehouse system is capable of storing objects, and includes a storage shelf section extending in a first direction, with storage rows for storing a plurality of objects arranged in a line in a second direction intersecting the first direction, a cart that carries the objects and moves in the first direction, a moving mechanism that carries the cart and moves in the second direction, and a control unit that controls the retrieval of the objects from the storage shelf section. For a first object and a second object stored in the storage shelf section and capable of responding to one retrieval request, the control unit controls the retrieval of the objects so that the first object is retrieved when the first object is closer to an retrieval port in the second direction than the second object.

[0008] Any combination of the above components, or mutual substitution of the components or expressions of the present invention between methods, systems, etc. are also valid aspects of the present invention. Effect of the Invention

[0009] According to the present invention, it is possible to provide an automated warehouse system capable of improving throughput. [Brief description of the drawings]

[0010] [Figure 1] 1 is a plan view illustrating an example of an automated warehouse system according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a plan view showing the arrangement of storage shelf units in the automated warehouse system of FIG. [Diagram 3] FIG. 2 is a side view illustrating the automated warehouse system of FIG. 1. [Figure 4] 2 is a side view showing the arrangement of storage shelf units in the automated warehouse system of FIG. 1. [Diagram 5] 2 is a plan view illustrating an example of a first cart in the automated warehouse system of FIG. 1. [Figure 6] FIG. 6 is a front view of the first bogie in FIG. 5. [Figure 7] 2 is a plan view illustrating an example of a second cart in the automated warehouse system of FIG. 1. [Figure 8] FIG. 8 is a front view of the second bogie in FIG. [Figure 9] FIG. 2 is a first diagram illustrating an example of a retrieval operation of the automated warehouse system in FIG. [Figure 10] FIG. 2 is a second diagram illustrating an example of a retrieval operation of the automated warehouse system in FIG. [Figure 11] FIG. 3 is a third diagram illustrating an example of a retrieval operation of the automated warehouse system in FIG. [Figure 12] FIG. 4 is a fourth diagram illustrating an example of a retrieval operation of the automated warehouse system in FIG. [Figure 13] FIG. 5 is a fifth diagram illustrating an example of a retrieval operation of the automated warehouse system in FIG. [Figure 14] FIG. 6 is a sixth diagram illustrating an example of a retrieval operation of the automated warehouse system in FIG. [Figure 15] FIG. 7 is a seventh diagram illustrating an example of a retrieval operation of the automated warehouse system in FIG. [Figure 16] 4 is a flowchart illustrating an example of a load allocation process in the automated warehouse system of FIG. 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] The present invention will be described below based on preferred embodiments with reference to the drawings. In the embodiments and modifications, the same or equivalent components and members are given the same reference numerals, and duplicated descriptions are omitted as appropriate. The dimensions of the members in each drawing are enlarged or reduced as appropriate for ease of understanding. Some of the members that are not important for explaining the embodiments are omitted in each drawing. In addition, terms including ordinal numbers such as first, second, etc. are used to describe various components, but these terms are used only for the purpose of distinguishing one component from another component, and the components are not limited by these terms.

[0012] [Embodiment Mode] The configuration of an automated warehouse system 100 according to an embodiment will be described with reference to Figs. 1 to 4. Fig. 1 is a plan view that shows a schematic example of an automated warehouse system 100 according to an embodiment. Fig. 2 is a plan view showing the arrangement of a storage shelf section 22 of the automated warehouse system 100. Fig. 3 is a side view that shows a schematic example of the automated warehouse system 100. Fig. 4 is a side view showing the arrangement of the storage shelf section 22 of the automated warehouse system 100. In these figures, illustration of pillars, beams, etc. is omitted.

[0013] For convenience of explanation, as shown in the figure, an XYZ orthogonal coordinate system is defined in which a horizontal direction is the X-axis direction, a horizontal direction perpendicular to the X-axis direction is the Y-axis direction, and a direction perpendicular to both, i.e., a vertical direction, is the Z-axis direction. The positive directions of the X-axis, Y-axis, and Z-axis are defined in the directions of the arrows in each figure, and the negative directions are defined in the directions opposite to the arrows. The X-axis direction is sometimes called the "row direction." The Y-axis direction is sometimes called the "column direction." The Z-axis direction is sometimes called the "up-down direction." Such directional notations do not limit the configuration of the automated warehouse system 100, and the automated warehouse system 100 can be used in any configuration depending on the application. In the following explanation, the XYZ orthogonal coordinate system is used for explanation, but the X-axis, Y-axis, and Z-axis directions do not necessarily have to be perpendicular to each other, as long as they intersect at approximately 90 degrees.

[0014] First, the overall configuration of the automated warehouse system 100 will be described. The automated warehouse system 100 is a system including a storage shelf section 22 capable of storing a large number of loads 12. The automated warehouse system 100 includes the storage shelf section 22, a first cart 14, a second cart 16, a first rail 40, a second rail 44, a power supply section 34, and a control section 18. In the embodiment, the Y-axis direction is exemplified as the first direction, and the X-axis direction is exemplified as the second direction. In the storage shelf section 22, the first rail 40 extends in the Y-axis direction. The moving passage 47 is a travel path for the second cart 16 and is provided in the X-axis direction near the end of the storage shelf section 22. The second rail 44 and the power supply section 34 extend in the X-axis direction in the moving passage 47. In this specification, the end of the storage shelf section 22 on the moving passage 47 side is referred to as the "frontage of the storage shelf section 22". In this embodiment, a first carriage 14 is exemplified as the carriage, and a second carriage 16 is exemplified as the moving mechanism.

[0015] The control unit 18 includes an MPU (Micro Processing Unit) and controls the movement of the load 12 based on the operation result from the user. The control unit 18 can control the operation of the first cart 14 and the second cart 16 in order to control the movement of the load 12.

[0016] In this embodiment, the load 12 is handled while placed on a pallet (not shown), but this is not limited thereto, and the load 12 may be handled independently without using a pallet. Transporting the load 12 while placed on a pallet is simply referred to as transporting the load 12.

[0017] (Storage shelf section) The storage shelf section 22 is installed in a plurality on the floor section Lg, and is a so-called high-density storage type storage space capable of storing a large number of loads 12. In this embodiment, the storage shelf section 22 is provided on both sides in the Y-axis direction across the moving passage 47. The configuration of the storage shelf section 22 is not particularly limited as long as it is capable of storing and storing a plurality of loads 12. The automated warehouse system 100 has N (N≧2) levels of storage shelf section 22 stacked in layers in the vertical direction. In this embodiment, the storage shelf section 22 has three levels. The N levels of storage shelf section 22 stacked in layers are referred to as a storage shelf group 20. The first level storage shelf section 22 closest to the floor section Lg may be simply referred to as the "first level", the second level storage shelf section 22 may be simply referred to as the "second level", and the third level storage shelf section 22 may be simply referred to as the "third level".

[0018] The storage shelf section 22 at each level includes multiple storage rows 24 aligned in the X-axis direction, and each storage row 24 includes multiple storage sections 26 connected in the Y-axis direction. The storage sections 26 are units for storing the loads 12. The frontage of each storage row 24 on the side of the second rail 44 is the frontage of the storage shelf section 22, and functions as an entrance / exit for the first cart 14 to enter and exit.

[0019] The first rail 40 is a runway along which the first carriage 14 runs. The first rail 40 extends in the Y-axis direction in each storage row 24. The second rail 44 is a rail along which the second carriage 16 runs. The second rail 44 extends in the X-axis direction so as to cross each storage row 24. The second rail 44 in this embodiment is provided in a position close to the frontage of the storage row 24. The first rail 40 and the second rail 44 are collectively referred to simply as rails. The first rail 40 is supported on a first support member 42 extending in the X-axis direction. The second rail 44 is supported on a cross beam 46 extending in the Y-axis direction. The first support member may be supported on the cross beam 46.

[0020] (First cart) Next, the first carriage 14 will be described with reference to Figs. 5 and 6. Fig. 5 is a plan view that shows a schematic diagram of an example of the first carriage 14. Fig. 6 is a front view of the first carriage 14. The first carriage 14 travels on the first rail 40 in the storage row 24 in the Y-axis direction in order to transport the load 12. The first carriage 14 puts the load 12 in and takes it out from the storage section 26. The first carriage 14 travels on the second carriage 16 in the Y-axis direction in order to get on and off the second carriage 16.

[0021] The first cart 14 mainly includes a car body 14b, a mounting platform 14c, a lift mechanism 14d, and a plurality of (for example, four) wheels 14f. The car body 14b has a contour of a substantially rectangular parallelepiped shape that is flat in the vertical direction. Inside the car body 14b, a motor (not shown) that drives the plurality of wheels 14f, a control circuit (not shown) that controls the motor, and a battery 14g are mounted. The first cart 14 is configured to drive the motor with the power of the battery 14g. The battery is a secondary battery such as a repeatedly rechargeable lithium ion battery. In this embodiment, the battery 14g is charged by the second cart 16 while being placed on the second cart 16.

[0022] The platform 14c is a portion that lifts and holds the load 12. The lift mechanism 14d is a mechanism that raises and lowers the platform 14c. In FIG. 6, the platform 14c in the raised state is shown by a dashed line, and the platform 14c in the lowered state is shown by a solid line. The lift mechanism 14d can raise the platform 14c and lift the load 12 from the loading surface of the storage section 26. The lift mechanism 14d can lower the platform 14c and lower the load 12 onto the loading surface of the storage section 26. The multiple wheels 14f can roll on the first rail 40 and the second cart 16.

[0023] (Second bogie) Next, the second carriage 16 will be described with reference to Figs. 7 and 8. Fig. 7 is a plan view that shows a schematic example of the second carriage 16. Fig. 8 is a front view of the second carriage 16, showing the state in which the first carriage 14 is mounted. The second carriage 16 travels on the second rail 44 in the X-axis direction. The second carriage 16 transports the first carriage 14 in an empty state or in a state in which the load 12 is mounted.

[0024] The second bogie 16 mainly includes a base 16a, a bogie mounting part 16c, a first end cover 16d, a second end cover 16e, a plurality of (for example, four) wheels 16f, and a current collecting unit 38. The base 16a is a base for mounting each component of the second bogie 16. The base 16a is a plate-shaped member extending in the X-axis direction and the Y-axis direction at the lower part of the second bogie 16. The first end cover 16d is provided on the base 16a at one end of the second bogie 16 in the X-axis direction. The second end cover 16e is provided on the base 16a at the other end of the second bogie 16 in the X-axis direction. The bogie mounting part 16c is provided on the base 16a at the center of the second bogie 16 in the X-axis direction. Therefore, the bogie mounting part 16c is disposed between the first end cover 16d and the second end cover 16e.

[0025] (Cart mounting section) The carriage mounting portion 16c is a portion for mounting the first carriage 14, and has a pair of guide portions 16j that guide the first carriage 14. The pair of guide portions 16j are arranged on the upper surface of the base 16a, spaced apart from each other so as to sandwich a space in the X-axis direction in which the first carriage 14 is mounted. The cross section of each guide portion 16j in a front view has an angular sideways U-shape. The carriage mounting portion 16c is recessed downward from the end covers at both ends of the second carriage 16 in the X-axis direction, and the second carriage 16 has a substantially concave shape in a front view.

[0026] The first end cover 16d functions as a casing that houses the motor 16k for driving the wheels 16f, the gear device 16g that transmits the rotation of the motor 16k to the wheels 16f, a control circuit (not shown) that controls the motor 16k, and the two wheels 16f on one end side on the base 16a. The first end cover 16d is configured to cover these elements at least from above.

[0027] The second end cover 16e functions as a casing that houses the two wheels 16f on the other end side on the base 16a. The second end cover 16e is configured to cover the wheels 16f at least from above. The wheels 16f are for running on the second rail 44. The two wheels 16f on the first end cover 16d side are driving wheels driven by the motor 16k, and the two wheels 16f on the second end cover 16e side are driven wheels that are not driven by the motor.

[0028] Although one motor may drive two wheels 16f, in this embodiment, two motors 16k are provided corresponding to the two wheels 16f. The two motors 16k are spaced apart from each other in the Y-axis direction and disposed near each wheel 16f. The motor 16k is disposed horizontally at the bottom of the first end cover 16d such that its longitudinal direction extends in the X-axis direction. The gear device 16g changes the direction of the rotation shaft to transmit the rotation of the motor 16k to the wheels 16f. Since the motor 16k is disposed near the wheels 16f, the transmission mechanism is simplified, and the first end cover 16d can be made smaller in size.

[0029] The current collecting unit 38 is in contact with the power supply unit 34 (see also FIG. 1) to receive the supply of electric power. The second bogie 16 receives electric power from the power supply unit 34 via the current collecting unit 38. The second bogie 16 is configured to drive the motor 16k with the received electric power. The second bogie 16 can charge the battery of the first bogie 14 with the received electric power.

[0030] (Enter / Exit) Next, the entrance 28 and the exit 30 will be described with reference to FIG. 1 and FIG. 2. The automated warehouse system 100 is provided with the entrance 28 for carrying in the goods 12 from outside the warehouse, and the exit 30 for carrying out the goods 12 to outside the warehouse. In FIG. 1, the entrance 28 and the exit 30 are arranged near the moving passage 47 on the X-axis negative direction side of the storage shelf section 22. In a storage operation, the goods 12 from outside the warehouse are carried into the entrance 28 by a forklift or the like. The goods 12 carried into the entrance 28 are transported to a predetermined storage section 26 by the first cart 14 and the second cart 16 and stored therein. In a retrieval operation, the goods 12 stored in the predetermined storage section 26 are transported to the exit 30 by the first cart 14 and the second cart 16. The goods 12 transported to the exit 30 are carried out to the outside of the warehouse by a forklift or the like. The above is a description of the overall configuration of the automated warehouse system 100.

[0031] Next, an example of the retrieval operation of the automated warehouse system 100 will be described with reference to FIG. 1 and FIG. 9 to FIG. 15. FIG. 9 to FIG. 15 are diagrams for explaining an example of the retrieval operation of the automated warehouse system 100. In these diagrams, each storage section 26 of the storage shelf section 22 in a plan view is typically shown by a grid. In the storage shelf section 22 of this example, 12 storage rows 24 for storing a plurality of loads 12 are arranged in the X-axis direction. Each storage row 24 includes five storage sections 26 arranged in the Y-axis direction. An exit port 30 is provided on the negative side of the X-axis of the storage shelf section 22. A transfer passage 47 extending in the X-axis direction is provided near the exit port 30 and the end of each storage row 24 on the negative side of the Y-axis (hereinafter referred to as the "frontage").

[0032] The first cart 14 moves in the Y-axis direction in each storage row 24. The load 12 is loaded onto the first cart 14 and transported in the Y-axis direction in the storage row 24. The second cart 16 moves in the X-axis direction on the transfer passage 47. The load 12 loaded onto the first cart 14 is transported to the outgoing entrance 30 by the second cart 16. The load 12 transported to the outgoing entrance 30 is transferred to the outgoing entrance 30. The load 12 transferred to the outgoing entrance 30 is carried out by an external transport mechanism such as a forklift.

[0033] In these figures, the storage shelf section 22 stores cargoes 12 to be shipped, indicated by an alphabet and a number, and cargoes 12 indicated by the alphabet X. The cargoes 12 to be shipped are those included in the shipping plan at this point in time, and the cargoes 12 indicated by X are those not included in the shipping plan at this point in time. The cargoes indicated by A, B, C, D, E, F, G, H, and X are of different types. In this specification, different types of cargoes include cargoes with different contents, as well as cargoes with the same contents but different attributes that are preset to distinguish shipping lots, such as manufacturing lots and receiving lots.

[0034] The numbers attached to the letters A to H are used to distinguish cargo of the same type from one another. For example, C1 and C2 are the same type of cargo, and either one can be shipped in response to a shipping request for cargo C. In other words, each of the cargoes with the same alphabet attached is a cargo that can respond to one shipping request in the shipping plan. Hereinafter, cargoes indicated by an alphabet and a number will be represented by the alphabet and number, for example, "Cargo A", "Cargo C1", and "Cargo X".

[0035] The outgoing procedure will be described using as an example a case where the outgoing plan includes one outgoing request for item A. In each storage row 24, the side furthest from the frontage is referred to as the "rear side," and the side closest to the frontage is referred to as the "front side." Item A is stored fourth on the rear side from the frontage of the storage row 24, and three items X are stored in front of item A. In this case, before item A is outgoing, a rearrangement is performed to move the three items X in front of item A to an intermediate storage area (not shown).

[0036] Specifically, the loads X are moved one by one from the front to an intermediate storage area by the first cart 14 and the second cart 16. After the three loads X at the front have been rearranged, load A is carried by the first cart 14 and the second cart 16 to the outgoing gate 30 and is taken out. In this way, the number of other loads (in this example, the three loads X at the front) that need to be rearranged in order for one load (load A in this example) to be taken out is called the "number of rearrangements." In other words, the number of rearrangements required to take load A out is three.

[0037] Next, allocation of goods to correspond to each outgoing request included in the outgoing plan will be described. Here, as an example, it will be described which goods are allocated to each outgoing request in response to eight outgoing requests to outgo one each of goods A to H. The control unit 18 of this embodiment allocates goods corresponding to each of the input outgoing requests of goods A to H. In this embodiment, each outgoing request of goods A to H is input to the control unit 18, and the control unit 18 allocates the corresponding goods based on each input outgoing request. The control unit 18 controls outgoing of the allocated goods from the storage shelf unit 22.

[0038] Specifically, in this embodiment, loads A to H are handed out one by one by the following control. First, when there is only one load that can be handled for one outgoing request, that one load is handed out. Next, when there are two loads that can be handled for one outgoing request, the load that requires fewer rearrangements for outgoing is handed out. Then, when there are two loads that can be handled for one outgoing request and the number of rearrangements required for outgoing is the same, the load that is closer to the outgoing gate 30 in the X direction is handed out. Hereinafter, the control for handed out loads A to H in this embodiment will be described in detail with reference to first to sixth control examples.

[0039] (First control example) In this embodiment, when only one load that can correspond to one outgoing request is stored, the control unit 18 controls the outgoing of the load so that the load is outgoing. An example of this control will be described with reference to FIG. 10. As shown in this figure, in response to the outgoing requests of load A and load B, one load A and one load B are stored in the storage shelf unit 22, so that the allocation target is uniquely determined. That is, the control unit 18 allocates load A and load B in FIG. 10 in response to the outgoing requests of load A and load B. In FIGS. 10 to 15, the allocated load is indicated by a double circle, the unallocated load is indicated by a dashed circle, and the load related to the description is indicated by a square. Load A is outgoing after the three loads X in front of it are rearranged. Load B is outgoing after the two loads X and load D1 in front of it are rearranged.

[0040] Hereinafter, a case where there are two loads that can be handled in response to one outgoing request will be described with reference to the second to fifth control examples. In this case, as described above, the load that requires the least number of rearrangements for outgoing is outgoing.

[0041] (Second control example) In this embodiment, when multiple items are stored that can accommodate one outgoing request, the control unit 18 controls the outgoing of the items so that the items closest to the moving passage 47 in the Y-axis direction are given priority for outgoing.

[0042] An example of this control will be described with reference to FIG. 11. As shown in this figure, two loads, C1 and C2, are stored in the storage shelf section 22 in response to a request for retrieval of load C. Here, load C1 and load C2 are loads that have no other loads to be retrieval in the same storage row, and load X in front must be rearranged in order to retrieval of load C1 and load C2, respectively. Therefore, loads located closer to the moving passage 47 in the Y-axis direction (closer to the second cart 16 in the Y-axis direction) have fewer loads X in front, and the number of rearrangements for retrieval is also smaller. Specifically, the number of rearrangements when load C1 is retrieval is 1, and the number of rearrangements when load C2 is retrieval is 2. Therefore, the control section 18 allocates load C1, which is located closer to the moving passage 47 in the Y-axis direction, in response to a request for retrieval of load C. Load C1 is retrieval after one load X in front of it is rearranged.

[0043] By controlling the delivery of goods in this manner, it is possible to reduce the total number of re-allocations compared to the case where goods are allocated regardless of the number of re-allocations, and therefore it is possible to improve the delivery throughput.

[0044] (Third control example) In this embodiment, when a plurality of loads that can correspond to one outgoing request includes a load adjacent in the Y-axis direction to another load to be outgoing in response to another outgoing request, the control unit 18 controls the outgoing of the loads so that the adjacent load is outgoing in priority to the loads other than the adjacent loads among the plurality of loads. An example of this control will be described with reference to FIG. 12. As shown in this figure, two loads, D1 and D2, are stored in the storage shelf unit 22 in response to the outgoing request of load D. In a simple calculation assuming that load B is not outgoing, the number of reassignments when load D1 is outgoing is 2, and the number of reassignments when load D2 is outgoing is 1, so load D2 is allocated.

[0045] However, the load D1 is adjacent to another load B scheduled to be released in accordance with another outgoing request in the Y-axis direction, and the control unit 18 allocates the load D1 adjacent to the other load B in preference to the load D2. In other words, the load D1 is relocated when the load B is released in accordance with another outgoing request, so the number of relocations required for the outgoing of the load D1 by the outgoing at the time of this relocation is 0, which is smaller than the number of relocations required for the outgoing of the load D2. In other words, since the load D1 is adjacent to the load B scheduled to be released in accordance with another outgoing request, relocation for the outgoing of the load B is performed regardless of whether the load D1 is released or not, so the number of relocations for the outgoing of the load D1 is 0. For this reason, the control unit 18 allocates the load D1 adjacent to the other load released in accordance with the outgoing request for the load D. Specifically, the load D1 is released by setting the destination of the relocation to the outgoing port 30. In this way, by controlling the outgoing of the loads, the total number of relocations can be further reduced.

[0046] In the third control example, the load D1 is adjacent to the load B scheduled to be released due to a different release request in the negative direction of the Y axis, i.e., on the side of the moving passage 47, but they do not necessarily have to be adjacent. For example, even if load B is stored in a position shifted by one position in the positive direction of the Y axis from that in FIG. 12, i.e., in a position where load B and load D1 are not adjacent, the number of rearrangements for the release of load D1 will be 0 because load B will be released. In this way, even if they are not necessarily adjacent, if load B scheduled to be released due to a different release request is located in the same storage row on the positive side of the Y axis than load D1, the number of rearrangements for the target load will be 0, so the total number of rearrangements can be reduced by controlling the release of the loads so that load D1 is released.

[0047] (Fourth control example) In this embodiment, when a plurality of articles that can correspond to one retrieval request are stored, the control unit 18 controls the retrieval of the articles so that the article that is closest in the Y-axis direction to the moving passage along which the second cart 16 moves is retrieved. An example of this control will be described with reference to FIG. 13. As shown in this figure, in response to the retrieval requests for articles E and F, two articles each, articles E1 and E2 and articles F2 and F2, are stored in the storage shelf unit 22. Since articles E1 and F1 are stored at the front side of each storage row 24 and are closer to the moving passage 47 in the Y-axis direction than articles E2 and F2, the control unit 18 controls the retrieval of the articles so that articles E1 and F1 are retrieved.

[0048] In response to a retrieval request for loads E and F, the control unit 18 allocates loads E1 and F1 that are close to the transfer path 47. Loads E1 and F1 are retrieval without rearranging other loads. The number of rearrangements required to retrieval of loads E1 and F1 is 0, which is smaller than the number of rearrangements required to retrieval of loads E2 and F2, improving retrieval throughput. By controlling the retrieval of loads in this way, the total number of rearrangements can be further reduced.

[0049] (Fifth control example) In this embodiment, when a plurality of articles that can correspond to one outgoing request includes an article stored behind another article to be outgoing in response to another outgoing request, the control unit 18 controls the outgoing of the articles so as to outgo the article that has the smallest number of articles to be rearranged for outgoing among the plurality of articles in a state in which the other article has been outgoing. An example of this control will be described with reference to FIG. 15. As shown in this figure, two articles, H1 and H2, are stored in the storage shelf unit 22 in response to an outgoing request for article H. In a simple calculation assuming that article F1 is not outgoing, the number of rearrangements when article H1 and article H2 are outgoing is equal, being 1 each.

[0050] However, load F1 in front of load H1 is allocated for delivery, and the number of reassignments for load H1 after load F1 is delivered is 0, which is smaller than the number of reassignments for H2, which is 1. For this reason, the control unit 18 allocates load H1, which has a smaller number of reassignments after load F1 is delivered, in response to the delivery request for load H. After load F1 is delivered, load H1 is delivered without reassigning any other loads. In this way, by controlling the delivery of loads, the total number of reassignments can be further reduced.

[0051] In this way, according to the second to fifth control examples, when there are two loads that can be handled in response to one shipping request, the load that requires fewer rearrangements for shipping is shipped, thereby improving throughput.

[0052] (Sixth control example) In this embodiment, when multiple loads capable of handling one outgoing request are stored, and there are two or more loads among the multiple loads that have the smallest number of other loads requiring rearrangement, the control unit 18 controls the outgoing of the loads so that the load that is closest to the outgoing port 30 in the X-axis direction among the two or more loads is outgoing. An example of this control will be described with reference to Fig. 14. As shown in this figure, two loads, load G1 and load G2, are stored in the storage shelf unit 22 in response to the outgoing request for load G.

[0053] The number of rearrangements when the load G1 and the load G2 are handed out is equal to 2, and since both are the minimum, it can be said that there are two or more loads with the minimum number of rearrangements. The control unit 18 controls the handed out of the load G1 and the load G2 so that the load G1, which is the closest to the exit gate 30 in the X-axis direction, is handed out. Specifically, the control unit 18 calculates the distance from the front of each storage row 24 in which the load G1 and the load G2 are stored to the exit gate 30, and allocates the load of the storage row 24 with the smallest calculated distance to the handed out request. Since the load G1 is closer to the exit gate 30 than the load G2, in this example, the control unit 18 allocates the load G1, which is closer to the exit gate 30, to the handed out request of the load G. The load G1 is handed out after the two loads X in front of the load G1 are rearranged. In this way, by giving priority to handed out of the load closest to the exit gate 30, the movement time of the second cart 16 can be shortened.

[0054] According to the sixth control example, when there are two loads that can be handled in response to one out-of-stock request and the number of rearrangements for those loads is the same, it is possible to further improve throughput by out-shipping the load that is closer to the out-of-stock entrance and shortening the travel time of the second cart.

[0055] Next, a process for allocating a load corresponding to a warehousing request will be described with reference to Fig. 16. Fig. 16 is a flowchart for explaining an example of the load allocation process of this embodiment. This process S110 realizes the above-mentioned first to sixth controls as a series of processes.

[0056] When the process S110 starts, the control unit 18 determines whether or not there is a request to take out an item (step S111). If there is no request to take out an item (N in step S111), the control unit 18 returns the process to the beginning of step S111 and repeats step S111.

[0057] If there is a shipping request (Y in step S111), the control unit 18 judges whether there are multiple loads that can handle the shipping request (step S112). If the number of loads that can handle the shipping request is 0 or 1 and not multiple (N in step S112), the control unit 18 assigns one load that can handle the shipping request to the shipping request (step S113). In this step, if there are 0 loads (no loads at all) that can handle the shipping request, the control unit 18 provides information to the worker or a higher-level control system that there are no loads that can be handled. When this step is completed, the control unit 18 shifts the process to step S122. Step S122 will be described later.

[0058] When there are multiple loads that can fulfill the outgoing request (Y in step S112), the control unit 18 judges whether the multiple loads include a load adjacent to the moving aisle 47 (step S114). The load adjacent to the moving aisle 47 is a load stored in the storage unit 26 that is closest to the moving aisle 47 in the storage row 24. When a load adjacent to the moving aisle 47 is included (Y in step S114), the control unit 18 assigns the load adjacent to the moving aisle 47 to the outgoing request (step S115). When this step is completed, the control unit 18 transitions the process to step S122.

[0059] If the moving passage 47 does not include an adjacent load (N in step S114), the control unit 18 judges whether the multiple loads include a load adjacent in the Y-axis direction to another load that is to be released in response to another release request (step S116). In this step, the control unit 18 judges whether there is a load adjacent to the front or back of the other load.

[0060] If adjacent loads are included (Y in step S116), the control unit 18 allocates the adjacent loads to the outgoing request (step S117). After completing this step, the control unit 18 shifts the process to step S122.

[0061] If adjacent loads are not included (N in step S116), the control unit 18 calculates the number of rearrangements for each of the loads (step S118). After completing this step, the control unit 18 determines whether there are two or more loads with the smallest number of rearrangements (step S119).

[0062] If there are two or more loads with the smallest number of rearrangements (Y in step S119), the control unit 18 calculates the distance in the X-axis direction to the outgoing port 30 for each load with the smallest number of rearrangements, and assigns the load with the shortest distance to the outgoing request (step S120). When this step is completed, the control unit 18 shifts the process to step S122.

[0063] If the load with the smallest number of reassignments is 1 (not 2 or more) (N in step S119), the control unit 18 allocates the load with the smallest number of reassignments to the outgoing request (step S121). After completing this step, the control unit 18 shifts the process to step S122.

[0064] In step S122, the control unit 18 controls the outgoing of the goods so that the goods allocated to the outgoing request are outgoing. Specifically, the control unit 18 first controls the first cart 14 and the second cart to move the goods in front of the allocated goods. After the outgoing movement is completed, the control unit 18 controls the first cart 14 and the second cart to move the allocated goods to the outgoing gate 30.

[0065] When step S122 is completed, the control unit 18 ends the process S110. The above-mentioned process S110 is merely an example, and a different process may be used as long as the same effect as that of the first to sixth embodiments described above can be obtained. For example, other steps may be added, some steps may be changed or deleted, or the order of steps may be changed. In addition, for example, after S111, a process may be performed in which the number of reassignments required to release each of the multiple loads is calculated, and if there is only one load with the minimum number of reassignments, the load with the minimum number of reassignments is allocated, and if there are multiple loads with the minimum number of reassignments, the load closer to the exit is allocated.

[0066] The above description is based on the embodiment of the present invention. This embodiment is an example, and various modifications and changes are possible within the scope of the claims of the present invention, and it is understood by those skilled in the art that such modifications and changes are also within the scope of the claims of the present invention. Therefore, the description and drawings in this specification should be treated as illustrative rather than restrictive.

[0067] (Modification) The following describes the modified examples. In the drawings and description of the modified examples, the same or equivalent components and members as those in the embodiment are denoted by the same reference numerals. Descriptions that overlap with the embodiment will be omitted as appropriate, and the description will focus on the configurations that differ from the embodiment.

[0068] In the description of the embodiment, an example has been shown in which the cart travels on a road having rails, but the present invention is not limited to this. The cart may travel on a road not having rails.

[0069] In the description of the embodiment, an example has been shown in which the automated warehouse system 100 is provided with three storage shelf sections 22, but the present invention is not limited to this. The automated warehouse system may be provided with two or less storage shelf sections or four or more storage shelf sections.

[0070] It is not essential that a first carriage 14 be provided in each row of each stage, and the first carriage 14 does not have to be provided in each row.

[0071] A lifting mechanism may be provided for lifting and lowering the load 12 between the multiple levels of the storage shelf sections 22.

[0072] It is not essential that the number of storage sections 26 in the storage row 24 be uniform. The number of storage sections 26 constituting the storage row 24 may be greater or less depending on the irregularities of the walls of the building that houses the storage shelf section 22.

[0073] It is not essential that the number of stages of the vertically stacked storage rows 24 be uniform. The number of stages of the storage rows 24 may be such that some areas have more stages than others, depending on the ceiling height of the building that houses the storage shelf section 22.

[0074] It is not essential that the load 12 includes a pallet, and the automated warehouse system may be adapted to handle loads that do not include a pallet.

[0075] Instead of a forklift, the load 12 may be carried in and out by another type of transfer device, such as a transfer device equipped with a crane.

[0076] It is not essential to provide the second cart 16. Any moving mechanism capable of mounting the first cart 14 and moving in the second direction may be used. For example, a stacker crane may be provided instead of the second cart 16.

[0077] Each of these modified examples provides the same effects as the embodiment.

[0078] Any combination of the above-described embodiments and modifications is also useful as an embodiment of the present invention. A new embodiment resulting from the combination has the combined effects of the respective embodiments and modifications.

[0079] The present invention can also be defined by the features described in the following items. (Item 1) An automated warehouse system capable of storing cargo, A storage shelf section extending in a first direction, in which a plurality of storage rows for storing a plurality of items are arranged in a second direction intersecting the first direction; A dolly carrying a load and moving in the first direction; A moving mechanism that carries the carriage and moves in the second direction; A control unit that controls the removal of items from the storage shelf unit, An automated warehouse system characterized in that, for a first and a second load stored in the storage shelf section and capable of responding to one outgoing request, the control section controls the outgoing of the load so that the first load is outgoing when the first load is smaller in number than the second load that requires rearrangement for outgoing.

[0080] (Item 2) The control unit controls the outgoing of an item to outgo the first item when another item to be outgoing in response to a different outgoing request is stored in a position farther in the first direction from the moving mechanism than the first item in the same storage row and when another item to be outgoing in response to a different outgoing request is not stored in a position farther in the first direction from the moving mechanism than the second item in the same storage row.

[0081] (Item 3) The automated warehouse system according to item 1 or 2, wherein the control unit controls the removal of an item from the warehouse so as to remove the first item from the warehouse when the first item is closer to the moving mechanism in the first direction than the second item.

[0082] (Item 4) When each of the plurality of loads requires the reassignment of other loads for retrieval from the warehouse, The automated warehouse system according to any one of claims 1 to 3, characterized in that the control unit controls the removal of an item from storage so as to remove the first item from storage when the first item is closer to the moving mechanism in the first direction than the second item.

[0083] (Item 5) The automated warehouse system described in item 1, characterized in that the control unit controls the outgoing of goods so as to outgo the first goods when the number of other goods that need to be rearranged for the outgoing of the first goods is the same as the number of other goods that need to be rearranged for the outgoing of the second goods and when the first goods are closer to the outgoing port in the second direction than the second goods.

[0084] (Item 6) An automated warehouse system capable of storing cargo, A storage shelf section extending in a first direction, in which a plurality of storage rows for storing a plurality of items are arranged in a second direction intersecting the first direction; A dolly carrying a load and moving in the first direction; A moving mechanism that carries the carriage and moves in the second direction; A control unit that controls the removal of items from the storage shelf unit, An automated warehouse system characterized in that, for a first and a second load stored in the storage shelf section and capable of responding to one outgoing request, the control section controls the outgoing of the loads so that the first load is outgoing when the first load is closer to an outgoing port in the second direction than the second load. [Explanation of symbols]

[0085] 14 first cart, 16 second cart, 18 control unit, 22 storage shelf unit, 24 storage row, 26 storage unit, 30 exit gate, 40 first rail, 44 second rail, 47 moving aisle, 100 automated warehouse system.

Claims

1. A moving passage extending in a first direction, a plurality of storage shelf sections provided with a plurality of storage rows in which a plurality of loads can be juxtaposed, extending in a second direction intersecting the first direction from the moving passage, a conveying means having a mechanism for moving a loading table in the first direction and the second direction, and capable of conveying the loads in the plurality of storage rows to an outlet via the moving passage, comprising: When there are a first storage row and a second storage row in which a plurality of loads of a first type and a plurality of loads of a second type different from the first type are mixed and arranged respectively among the plurality of storage rows, the conveying means is operated so as to preferentially discharge the loads of the first type that can be discharged earlier among the plurality of loads of the first type. An automated warehouse system characterized by this.

2. For the first load of the first type stored in the first storage row and the second load of the first type stored in the second storage row, when a first condition that the number of loads requiring rearrangement for discharging the first load is less than the number of loads requiring rearrangement for discharging the second load is satisfied, the conveying means is operated to discharge the first load. The automated warehouse system according to claim 1.

3. Even when the first condition is not satisfied, when the first load is closer to the moving passage in the first direction than the second load, the conveying means is operated to discharge the first load. The automated warehouse system according to claim 2.

4. Even when the first condition is not satisfied, when the first load is closer to the outlet in the second direction than the second load, the conveying means is operated to discharge the first load. The automated warehouse system according to claim 2 or 3, characterized by this.

5. The moving passage communicates with each end of the plurality of storage rows respectively, The loading table moves along the moving passage. The automated warehouse system according to any one of claims 1 to 4.

6. The storage shelf section is provided with a plurality of layers stacked vertically, The moving passage is provided in each stage, The mechanism is provided in each stage, The outlet is provided in the first stage, The automated warehouse system according to claim 5, having a lifting mechanism for lifting loads between the stages of the storage shelf section and between the plurality of stages of the storage shelf section.

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