Picking system

Abstract

To provide a picking system that can be installed in a space-saving manner while improving processing capacity.SOLUTION: The picking system includes an automated warehouse 1, an upper circular conveying device 3 connected to the automated warehouse 1, a lower circular conveying device 4 connected to the automated warehouse 1 below the upper circular conveying device 3, and a plurality of picking stations 2 arranged in the longitudinal direction of the upper circular conveying device 3 or the lower circular conveying device 4. Each of the picking stations 2 has a first picking conveyor 21 and a second picking conveyor 22 on which a work area 20 is provided, a first lifting and conveying device 23, and a second lifting and conveying device 24. The first picking conveyor 21 receives a transported object from the first lifting and conveying device 23 and transfers the transported object to the second lifting and conveying device 24, and the second picking conveyor 22 receives the transported object from the second lifting and conveying device 24 and transfers the transported object to the first lifting and conveying device 23.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] One aspect of the present invention relates to a picking system. [Background technology]

[0002] For example, Patent Document 1 discloses a picking system that supports sorting (picking) by extracting items of the type and quantity according to an order from each of the item box warehouses provided for each type of item, consolidating the items, and storing them in a delivery box (container). The picking system described in Patent Document 1 includes a sorting station, a main conveyance device, and an item box warehouse. The picking system transports item boxes containing items from each of the item box warehouses that store the items to the sorting station. At the sorting station, a worker performs sorting work by extracting items of the type and quantity based on the order from the transported item boxes and storing them in a delivery box. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2023 / 189045 Summary of the Invention [Problem to be solved by the invention]

[0004] For example, in the picking system described in Patent Document 1, the processing capacity of the picking system can be increased by adding sorting stations along the longitudinal direction of the main conveyor. However, this requires additional space to install the sorting stations.

[0005] Therefore, an object of one aspect of the present invention is to provide a picking system that can be installed in a small space while increasing processing capacity. [Means for solving the problem]

[0006] (1) A picking system according to one aspect of the present invention includes an automated warehouse that stores transported objects; an upper circular transport device connected to the automated warehouse and including an upper straight portion extending linearly and including a circular transport path with the upper straight portion as its longitudinal direction; a lower circular transport device connected to the automated warehouse below the upper circular transport device and including a lower straight portion extending linearly and including a circular transport path with the lower straight portion as its longitudinal direction; and a plurality of picking stations arranged along the longitudinal direction of the upper circular transport device or the lower circular transport device, with a work area where picking work is performed being provided below the lower circular transport device, and each of the plurality of picking stations includes a first picking conveyor and a second picking conveyor on which the work area is provided. The picking conveyor includes a first lifting and conveying device that vertically connects the connecting point with the upper circular conveying device, the connecting point with the lower circular conveying device, and the connecting point with the first picking conveyor and the second picking conveyor, which are at different heights, and a second lifting and conveying device that vertically connects the connecting point with the upper circular conveying device, the connecting point with the lower circular conveying device, and the connecting point with the first picking conveyor and the second picking conveyor, which are at different heights, and the first picking conveyor receives the transported object from the first lifting and conveying device and transfers the transported object to the second lifting and conveying device, and the second picking conveyor receives the transported object from the second lifting and conveying device and transfers the transported object to the first lifting and conveying device.

[0007] In the above picking system, each of the multiple picking stations has a first picking conveyor and a second picking conveyor. This allows for an increase in the number of work locations, thereby improving the processing capacity of the picking system. Furthermore, space can be saved compared to adding picking stations along the longitudinal direction. The above picking system allows for increased processing capacity while also saving space.

[0008] (2) In the picking system described in (1) above, the first lifting and lowering transport device performs a vertical lifting operation per trip as follows: the first lifting and lowering transport device receives and delivers the transported object at the connection point with the first picking conveyor and the second picking conveyor; after receiving and delivering the transported object, the first lifting and lowering transport device ascends to the connection point with the upper circular transport device, delivers the transported object to the upper circular transport device; after delivering the transported object, the first lifting and lowering transport device descends to the connection point with the lower circular transport device, receives the transported object from the lower circular transport device, and after receiving the transported object, descends again to the connection point with the first picking conveyor and the second picking conveyor. The second lifting and lowering conveying device may lift and lower the conveyed object at the connecting point with the first picking conveyor and the second picking conveyor, and after receiving the conveyed object, may rise to the connecting point with the lower circular conveying device and deliver the conveyed object to the lower circular conveying device, and after delivering the conveyed object, may rise to the connecting point with the upper circular conveying device and receive the conveyed object from the upper circular conveying device, and after receiving the conveyed object, may again descend to the connecting point with the first picking conveyor and the second picking conveyor to deliver and receive the conveyed object.

[0009] In this case, the first lifting and conveying device can transfer an object received from the second picking conveyor to the upper circular conveying device and transfer an object received from the lower circular conveying device to the first picking conveyor in one lifting and conveying operation. Similarly, the second lifting and conveying device can transfer an object received from the first picking conveyor to the lower circular conveying device and transfer an object received from the upper circular conveying device to the second picking conveyor in one lifting and conveying operation. In this way, each of the first lifting and conveying device and the second lifting and conveying device can transport two objects in one lifting and conveying operation. This improves the efficiency of transporting objects.

[0010] (3) In the picking system described in (1) or (2) above, each of the upper and lower circular conveying devices has a plurality of first carriages that travel in one direction on the conveying path and can deliver transported objects to the automated warehouse, the first lifting conveying device, and the second lifting conveying device, and the direction of rotation of the plurality of first carriages on the upper circular conveying device may be opposite to the direction of rotation of the plurality of first carriages on the lower circular conveying device. In this case, the plurality of first carriages on the upper circular conveying device can deliver transported objects to and from the first lifting conveying device while the plurality of first carriages on the lower circular conveying device can deliver transported objects to and from the second lifting conveying device. This allows the first carriages on each of the upper and lower circular conveying devices to operate without waiting, thereby improving the efficiency of transporting transported objects.

[0011] (4) In the picking system described in (3) above, the first lifting and lowering conveying device may be located downstream of the second lifting and lowering conveying device in the rotation direction of the multiple first carriages in the upper circular conveying device, and the first lifting and lowering conveying device may be located upstream of the second lifting and lowering conveying device in the rotation direction of the multiple first carriages in the lower circular conveying device. In this case, the multiple first carriages in the upper circular conveying device can receive the transported objects from the first lifting and lowering conveying device located downstream after delivering the transported objects to the second lifting and lowering conveying device located upstream. Similarly, the multiple first carriages in the lower circular conveying device can receive the transported objects from the second lifting and lowering conveying device located downstream after delivering the transported objects to the first lifting and lowering conveying device located upstream. This improves the transport efficiency of the transported objects.

[0012] (5) In the picking system described in any one of (1) to (4) above, the automated warehouse may have racks in which the loading sections on which the transported items are placed are arranged in multiple tiers in the vertical direction and in multiple rows in a horizontal direction perpendicular to the vertical direction, second carts provided for each multiple tier and running along the direction of the multiple rows to receive the transported items from the loading sections or deliver the transported items to the loading sections, an outgoing lifting and conveying device that transports the transported items being outgoing from the automated warehouse in the vertical direction, an incoming lifting and conveying device that transports the transported items being entered into the automated warehouse in the vertical direction, a first connecting conveyor connecting the upper and lower circular conveying devices to the outgoing lifting and conveying device, and a second connecting conveyor connecting the upper and lower circular conveying devices to the incoming lifting and conveying device.

[0013] In this case, the transported object received from one of the placement sections of the rack can be moved to a level of the upper or lower circular transport device by the outgoing lifting transport device, and then handed over to the upper or lower circular transport device via the first connecting conveyor. Similarly, the transported object can be received from the upper or lower circular transport device via the second connecting conveyor, moved to one of the levels of the rack by the incoming lifting transport device, and then handed over to one of the placement sections by the second cart. For example, even if the height of the placement section where the transported object is received is different from the height of the placement section where the transported object is unloaded, the transported object can be efficiently transported between the automated warehouse and the upper circular transport device, or between the automated warehouse and the lower circular transport device. [Effects of the Invention]

[0014] According to one aspect of the present invention, it is possible to provide a picking system that can increase processing capacity and can be installed in a space-saving manner. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a perspective view of a picking system according to one embodiment. [Figure 2]FIG. 2 is a plan view of the picking system of FIG. [Figure 3] Fig. 3(a) is a diagram for explaining the conveying direction of the item box between the upper circulating conveying device and the first lifting and descending conveying device and between the upper circulating conveying device and the second lifting and descending conveying device. Fig. 3(b) is a diagram for explaining the conveying direction of the item box between the lower circulating conveying device and the first lifting and descending conveying device and between the lower circulating conveying device and the second lifting and descending conveying device. Fig. 3(c) is a diagram for explaining the conveying direction of the item box on the first picking conveyor and the second picking conveyor. [Figure 4] FIG. 4 shows the flow of the lifting and lowering operation of the first lifting and conveying device. [Figure 5] FIG. 5 shows the flow of the lifting operation of the second lifting and transporting device. [Figure 6] 6(A) and 6(B) are diagrams showing two adjacent picking stations in a picking system according to a modified example. DETAILED DESCRIPTION OF THE INVENTION

[0016] A picking system according to an embodiment will be described below with reference to the drawings. In the description of the drawings, the same elements are given the same reference numerals and redundant description will be omitted. [Picking system configuration]

[0017] FIG. 1 is a perspective view of a picking system according to one embodiment, and FIG. 2 is a plan view of the picking system according to one embodiment. As shown in FIGS. 1 and 2, the picking system 100 is a system that supports sorting (picking) by picking out items of the type and quantity that match an order from a plurality of automated warehouses 1 in which items are stored by type, and consolidating these items into delivery boxes (containers). An order from a shipping destination is, for example, the items and their quantities ordered online by a purchaser of the items. Alternatively, an order from a shipping destination may be an order from a physical store or a request for parts to be prepared at a manufacturing plant.

[0018] The picking system 100 transports item boxes B containing items from each of multiple automated warehouses 1 that store items to multiple picking stations 2. The item boxes B are, for example, box-shaped plastic cases. At each of the multiple picking stations 2, a worker P performs a sorting task of removing items of a type and quantity based on an order from the transported item boxes B and preparing them for delivery. For delivery preparation, for example, the items may be stored in a delivery box (not shown) prepared separately from the item boxes B, or the items may be placed on a delivery conveyor (not shown) provided separately from the picking system 100. The picking system 100 transports the item boxes B from which items have been removed at the multiple picking stations 2 to the automated warehouse 1 from which they were removed and re-stores them in the automated warehouse 1. In other words, the picking system 100 transports the item boxes B as transported objects.

[0019] The picking system 100 comprises a plurality of automated warehouses 1, an upper circular conveying device 3, a lower circular conveying device 4 provided below the upper circular conveying device 3, and a plurality of picking stations 2 including a work area 20 provided below the lower circular conveying device 4 where picking work is performed.

[0020] The multiple automated warehouses 1 are automated warehouses that store multiple item boxes B, each containing different types of items, and can retrieve the item boxes B based on an order, and store the item boxes B that have returned after being retrieved, and then store the item boxes B again. In the example of FIGS. 1 and 2, the multiple automated warehouses 1 are lined up in one horizontal direction (the Y direction shown in FIGS. 1 and 2). The number of automated warehouses 1 included in the picking system 100 is not particularly limited. Furthermore, the type and size of the automated warehouse 1 (the number of item boxes B stored) are not particularly limited, and the types and sizes of the multiple automated warehouses 1 may be different from each other. Each of the multiple automated warehouses 1 includes a pair of racks 11A, 11B, a pair of first conveyors 12A, 12B, an in-warehouse cart 13 (second cart), an outgoing lifting and conveying device 14, an incoming lifting and conveying device 15, a pair of upper second conveyors 16A, 16B, and a pair of lower second conveyors 17A, 17B.

[0021] The pair of racks 11A, 11B are shelves for storing item boxes B. As shown in FIG. 2, the pair of racks 11A, 11B includes a plurality of placement sections 11C. Each placement section 11C stores, for example, one item box B. The placement sections 11C are arranged in a single horizontal direction, in a direction (X direction shown in FIGS. 1 and 2) perpendicular to the direction in which the multiple automated warehouses 1 are lined up (Y direction). At the same time, the placement sections 11C are arranged in multiple tiers along the vertical direction (Z direction shown in FIGS. 1 and 2). This allows the pair of racks 11A, 11B to place a plurality of item boxes B on each tier along the X direction. The pair of racks 11A, 11B are arranged facing each other in the Y direction, with the warehouse cart 13 sandwiched between them.

[0022] An intra-warehouse cart 13 is provided on each tier of the pair of racks 11A, 11B. The intra-warehouse cart 13 travels along the arrangement direction (X direction) in which multiple mounting sections 11C are arranged in series on each tier. When an item box B is to be removed from the automated warehouse 1, the intra-warehouse cart 13 receives the item box B from one mounting section 11C of the pair of racks 11A, 11B and hands it over to the first conveyor 12A. When an item box B is to be brought into the automated warehouse 1, the intra-warehouse cart 13 receives the item box B from the first conveyor 12B and hands it over to one mounting section 11C of the pair of racks 11A, 11B. Alternatively, the intra-warehouse cart 13 may transport the item box B received from the pair of racks 11A, 11B to another location on the pair of racks 11A, 11B.

[0023] The pair of first conveyors 12A, 12B are respectively disposed at positions corresponding to the respective stages of the pair of racks 11A, 11B. The first conveyor 12A transports the item box B along the extension direction of the rack 11A and delivers the item box B to the outgoing lifting and transporting device 14. The first conveyor 12B transports the item box B along the extension direction of the rack 11B and delivers the item box B received from the incoming lifting and transporting device 15 to the warehouse cart 13. The type of the pair of first conveyors 12A, 12B is not particularly limited and may be, for example, a roller conveyor or a belt conveyor.

[0024] The outgoing lifting and conveying device 14 and the incoming lifting and conveying device 15 convey the article boxes B in the vertical direction (Z direction). In the example of FIGS. 1 and 2, the inlet of the outgoing lifting and conveying device 14 is connected to the first conveyor 12A of each stage. The outlet of the outgoing lifting and conveying device 14 is connected to the upper second conveyor (first connecting conveyor) 16A and the lower second conveyor (first connecting conveyor) 17A. The inlet of the incoming lifting and conveying device 15 is connected to the upper second conveyor (second connecting conveyor) 16B and the lower second conveyor (second connecting conveyor) 17B. The outlet of the incoming lifting and conveying device 15 is connected to the first conveyor 12B of each stage. The outgoing lifting and transporting device 14 transports the item box B received from the first conveyor 12A along the Z direction and hands it over to the upper second conveyor 16A or the lower second conveyor 17A. The incoming lifting and transporting device 15 transports the item box B2 received from the upper second conveyor 16B or the lower second conveyor 17B in the Z direction and hands it over to the first conveyor 12B. In the example of FIG. 1, the pair of upper second conveyors 16A, 16B and the pair of lower second conveyors 17A, 17B are provided at a position higher than the ground floor.

[0025] The pair of upper second conveyors 16A, 16B transport article boxes B in the X direction between the upper circulating conveying device 3 and the unloading lifting conveying device 14 and the receiving lifting conveying device 15. The upper second conveyor 16A connects the upper circulating conveying device 3 and the unloading lifting conveying device 14. The upper second conveyor 16B connects the upper circulating conveying device 3 and the receiving lifting conveying device 15. The upper second conveyor 16A transports article boxes B received from the unloading lifting conveying device 14 in the X direction and delivers them to the upper circulating conveying device 3. The upper second conveyor 16B transports article boxes B received from the upper circulating conveying device 3 in the X direction and hands them over to the receiving lifting conveying device 15.

[0026] The pair of lower second conveyors 17A, 17B transport article boxes B in the X direction between the lower circular conveying device 4 and the outgoing lifting conveying device 14 and the incoming lifting conveying device 15. The lower second conveyor 17A connects the lower circular conveying device 4 and the outgoing lifting conveying device 14. The lower second conveyor 17B connects the lower circular conveying device 4 and the incoming lifting conveying device 15. The lower second conveyor 17A transports article boxes B received from the outgoing lifting conveying device 14 in the X direction and delivers them to the lower circular conveying device 4. The lower second conveyor 17B transports article boxes B received from the lower circular conveying device 4 in the X direction and hands them over to the incoming lifting conveying device 15.

[0027] The upper circular conveying device 3 includes an upper conveying path 31, which is a circular conveying path. The upper conveying path 31 is supported by, for example, a base. The upper conveying path 31 includes an upper straight portion 31a that extends linearly in the Y direction. The direction in which the upper straight portion 31a extends of the upper conveying path 31 is the longitudinal direction. The upper straight portion 31a is connected to the upper second conveyors 16A and 16B.

[0028] The lower circulating conveying device 4 is disposed below the upper circulating conveying device 3 in the Z direction. In the example of FIG. 1, the lower circulating conveying device 4 has the same shape as the upper circulating conveying device 3. In a plan view, the upper circulating conveying device 3 and the lower circulating conveying device 4 may coincide. In the example of FIG. 2, a case is illustrated in which the upper circulating conveying device 3 and the lower circulating conveying device 4 coincide.

[0029] The lower circular conveying device 4 includes a lower conveying path 41, which is a circular conveying path. The lower conveying path 41 is supported, for example, by a base. The lower conveying path 41 includes a lower straight portion 41a extending linearly in the Y direction. The direction in which the lower straight portion 41a extends of the lower conveying path 41 is the longitudinal direction. The lower circular conveying device 4 is connected to the automated warehouse 1 below the upper circular conveying device 3. Specifically, the lower straight portion 41a of the lower circular conveying device 4 is connected to the lower second conveyor 17A and the lower second conveyor 17B. In the example of FIG. 1, the lower circular conveying device 4 is provided above the ground floor. The height of the lower circular conveying device 4 is preferably high enough to ensure space for a work area 20 below the lower circular conveying device 4 where a worker P can perform sorting work.

[0030] The upper circulating conveying device 3 further has a plurality of upper circulating carriages 32 (a plurality of first carriages) that travel in a circle on the upper conveying path 31. The lower circulating conveying device 4 further has a plurality of lower circulating carriages 42 (a plurality of first carriages) that travel in a circle on the lower conveying path 41. The plurality of upper circulating carriages 32 and the plurality of lower circulating carriages 42 deliver and receive article boxes B between the automated warehouse 1 and the plurality of picking stations 2. Details will be described later.

[0031] The types of the upper and lower circulating carriages 32 and 42 are not particularly limited, and may be carriages that rotate at high speed using linear motors, for example. In the examples shown in Fig. 1 and Fig. 2, the upper and lower circulating carriages 32 and 42 may include movers. In this case, stators may be provided on tracks on the upper and lower conveying paths 31 and 41, and the upper and lower circulating carriages 32 and 42 may be caused to travel by changing the magnetic force of the stators.

[0032] The multiple picking stations 2 are arranged along the Y direction, which is the longitudinal direction of the upper circular conveying device 3 or the lower circular conveying device 4. In each of the multiple picking stations 2, a work area 20 where an operator P performs sorting work is provided below the lower circular conveying device 4 in the Z axis direction. Here, the work area 20 may be located directly below the lower circular conveying device 4 (the work area 20 and the lower circular conveying device 4 are aligned in the X axis direction), or may be located offset from directly below the lower circular conveying device 4 (the work area 20 and the lower circular conveying device 4 are not aligned in the X axis direction). Each of the multiple picking stations 2 has a first picking conveyor 21, a second picking conveyor 22, a first elevating conveying device 23, and a second elevating conveying device 24.

[0033] 1 and 2, the first picking conveyor 21 and the second picking conveyor 22 are arranged to face each other in the X direction, which is a direction perpendicular to the Y direction, which is the longitudinal direction of the upper circular transport device 3 or the lower circular transport device 4. The first picking conveyor 21 is arranged on the automated warehouse 1 side in the X direction. The second picking conveyor 22 is arranged on the opposite side of the automated warehouse 1 in the X direction.

[0034] 1 and 2, each of the first picking conveyor 21 and the second picking conveyor 22 has a U-shape in plan view. The first picking conveyor 21 includes a receiving opening 21a at one end of the U-shape and a delivery opening 21b at the other end of the U-shape. The first picking conveyor 21 is connected to the first lifting and conveying device 23 at the receiving opening 21a and is connected to the second lifting and conveying device 24 at the delivery opening 21b. The first picking conveyor 21 conveys the item box B received from the first lifting and conveying device 23 at the receiving opening 21a in one direction toward the delivery opening 21b. The first picking conveyor 21 then delivers the item box B to the second lifting and conveying device 24 at the delivery opening 21b.

[0035] The second picking conveyor 22 includes a receiving opening 22a at one end of the U-shape and a delivery opening 22b at the other end of the U-shape. The second picking conveyor 22 is connected to the second lifting and conveying device 24 at the receiving opening 22a, and is connected to the first lifting and conveying device 23 at the delivery opening 22b. The second picking conveyor 22 conveys the item box B received from the second lifting and conveying device 24 at the receiving opening 22a in one direction toward the delivery opening 22b. The second picking conveyor 22 then delivers the item box B to the first lifting and conveying device 23 at the delivery opening 22b. The conveying direction of the item box B on the second picking conveyor 22 is point-symmetrical to the conveying direction of the item box B on the first picking conveyor 21.

[0036] Each of the first picking conveyor 21 and the second picking conveyor 22 includes a straight conveying path and a diversion conveying path. The straight conveying path supports the bottom of the item box B from below and conveys the item box B only in the X direction. The type of straight conveying path is not particularly limited and may be, for example, a roller conveyor or a belt conveyor. The diversion conveying path conveys the item box B in one direction and also switches the conveying direction to a direction perpendicular to the one direction (from the X direction to the Y direction, or from the Y direction to the X direction) to convey the item box B. The diversion conveying path may include, for example, two types of rotating rollers, and the conveying direction of the item box B may be switched by switching the rotational drive of each rotating roller.

[0037] The work area 20 is provided in a portion of the first picking conveyor 21 and a portion of the second picking conveyor 22, respectively. In the example of FIGS. 1 and 2, the work area 20 is located on the diversion conveyor path. For example, the diversion conveyor path has a stopping position for item box B, and a space for a worker to work is located nearby. The work area 20 may also be provided with a terminal device 80 and a completion button for inputting completion of work. The display unit (display) of the terminal device 80 displays the type (product name) and number of items that worker P should remove from item box B based on the order described above. Based on the content displayed on the display unit of the terminal device, worker P removes items from item box B and places the items in a delivery box, and presses the completion button. When the completion button is pressed, the type and number of items to be next placed in the delivery box are displayed on the display unit.

[0038] 1, the first lifting and conveying device 23 and the second lifting and conveying device 24 have a moving body 250 that moves along the Z direction. The moving body 250 may convey an article box B placed on the moving body 250 in the Z direction by transmitting a driving force from a driving unit (not shown).

[0039] The first lifting and conveying device 23 and the second lifting and conveying device 24 convey the item box B in the Z direction. As shown in FIG. 1, the first lifting and conveying device 23 connects a connection point 231 with the upper circulating conveying device 3, a connection point 232 with the lower circulating conveying device 4, and a connection point 233 with the first picking conveyor 21 and the second picking conveyor 22 in the Z direction. The connection points 231 to 233 are at different heights. The first lifting and conveying device 23 moves a moving body 250 between the connection points 231 to 233, and delivers and receives the item box B at each of the connection points 231 to 233. 1, the second lifting and conveying device 24 connects a connection point 241 with the upper circular conveying device 3, a connection point 242 with the lower circular conveying device 4, and a connection point 243 with the first picking conveyor 21 and the second picking conveyor 22 in the Z direction. The connection points 241 to 243 are at different heights. The second lifting and conveying device 24 moves a moving body 250 between the connection points 241 to 243, and delivers and receives item boxes B at each of the connection points 241 to 243.

[0040] The first lifting and conveying device 23 and the second lifting and conveying device 24 face each other in the Y direction. The direction in which the first lifting and conveying device 23 and the second lifting and conveying device 24 face each other is perpendicular to the direction in which the first picking conveyor 21 and the second picking conveyor 22 face each other. The first picking conveyor 21 and the second picking conveyor 22 are arranged symmetrically with respect to each other when the direction in which the first lifting and conveying device 23 and the second lifting and conveying device 24 face each other is taken as an axis.

[0041] As shown in FIG. 1 , the picking system 100 further includes a connection conveyor 51 disposed between the upper conveying path 31 and the first elevating conveying device 23, a connection conveyor 52 disposed between the upper conveying path 31 and the second elevating conveying device 24, a connection conveyor 53 disposed between the lower conveying path 41 and the first elevating conveying device 23, and a connection conveyor 54 disposed between the lower conveying path 41 and the second elevating conveying device 24. The types of the connection conveyors 51 to 54 are not particularly limited and may be, for example, roller conveyors or belt conveyors. The connection conveyors 51 to 54 transport the item boxes B along the X direction. The connection conveyors 51 to 54 may also function as buffer areas capable of temporarily storing the item boxes B. [Picking system operation]

[0042] Next, with reference to Figures 3 to 5, the transport operation of the article box B centered around the first lifting and lowering conveying device 23 and the second lifting and lowering conveying device 24 will be described. Figure 3(a) is a diagram for explaining the transport direction of the article box B between the upper circulatory conveying device 3 and the first lifting and lowering conveying device 23 and between the upper circulatory conveying device 3 and the second lifting and lowering conveying device 24. Figure 3(b) is a diagram for explaining the transport direction of the article box B between the lower circulatory conveying device 4 and the first lifting and lowering conveying device 23 and between the lower circulatory conveying device 4 and the second lifting and lowering conveying device 24. Figure 3(c) is a diagram for explaining the transport direction of the article box B on the first picking conveyor 21 and the second picking conveyor 22.

[0043] The upper circulating carriages 32 travel in one direction on the upper conveying path 31 along a circulating direction A1, and deliver the article boxes B to the automated warehouse 1, the first lifting and lowering conveying device 23, and the second lifting and lowering conveying device 24. The lower circulating carriages 42 travel in one direction on the lower conveying path 41 along a circulating direction A2, and deliver the article boxes B to the automated warehouse 1, the first lifting and lowering conveying device 23, and the second lifting and lowering conveying device 24. As shown in FIG. 3, the circulating direction A1 of the upper circulating carriages 32 on the upper circulating conveying device 3 is opposite to the circulating direction A2 of the lower circulating carriages 42 on the lower circulating conveying device 4. In the example of FIG. 3(a), the upper circulating carriages 32 travel in the circulating direction A1 on the upper conveying path 31. In the example of FIG. 3(b), the lower circulating carriages 42 travel in the circulating direction A2 on the lower conveying path 41. The rotation direction A1 is clockwise, and the rotation direction A2 is counterclockwise.

[0044] In the circulating direction A1 of the upper circulating carriage 32 of the upper circulating conveying device 3, the first lifting and lowering conveying device 23 is located downstream of the second lifting and lowering conveying device 24, and the second lifting and lowering conveying device 24 is located upstream of the first lifting and lowering conveying device 23. In the circulating direction A2 of the lower circulating carriage 42 of the lower circulating conveying device 4, the first lifting and lowering conveying device 23 is located upstream of the second lifting and lowering conveying device 24, and the second lifting and lowering conveying device 24 is located downstream of the first lifting and lowering conveying device 23. In this case, the upper circulating carriage 32 delivers the item box B to the second lifting and lowering conveying device 24 located upstream, and then receives the item box B from the first lifting and lowering conveying device 23 located downstream. In this way, the upper circulating carriage 32 can continuously deliver and receive the item box B1 while traveling in the circulating direction A1. Similarly, the lower circulating carriage 42 delivers the article box B to the first lifting and conveying device 23 located upstream, and then receives the article box B from the second lifting and conveying device 24 located downstream. In this way, the lower circulating carriage 42 can continuously deliver and receive the article box B1 while traveling along the circulating direction A2.

[0045] Fig. 4 shows the lifting operation flow of the first lifting and conveying device 23. First, the first lifting and conveying device 23 receives and delivers an article box B at the connection point 233 between the first picking conveyor 21 and the second picking conveyor 22 (step ST11). As shown in Fig. 3(c), the first lifting and conveying device 23 delivers the article box B to the first picking conveyor 21 and receives the article box B from the second picking conveyor 22. After step ST11, the article box B received from the second picking conveyor 22 is placed on the moving body 250 of the first lifting and conveying device 23.

[0046] Next, the first lifting and conveying device 23 raises the moving body 250 to the connection point 231 with the upper circulating conveying device 3 (step ST12). Next, as shown in FIG. 3(a), the first lifting and conveying device 23 hands over the article box B to the upper circulating conveying device 3 at the connection point 231 (step ST13). The article box B handed over from the moving body 250 of the first lifting and conveying device 23 in step ST13 is conveyed by the upper circulating cart 32 along the upper conveying path 31 in the circulating direction A1, and is stored in the automated warehouse 1. After step ST13, the article box B is not placed on the moving body 250 of the first lifting and conveying device 23.

[0047] Next, the first lifting and conveying device 23 lowers the movable body 250 to the connection point 232 with the lower circulating conveying device 4 (step ST14). Next, as shown in FIG. 3(b), the first lifting and conveying device 23 receives the article box B from the lower circulating conveying device 4 at the connection point 232 (step ST15). In step ST15, the article box B that has been delivered from the automated warehouse 1 to the lower circulating conveying device 4 is conveyed by the lower circulating cart 42 along the lower conveying path 41 in the circulating direction A2, and is handed over to the movable body 250 of the first lifting and conveying device 23. After step ST15, the article box B received from the lower circulating conveying device 4 is placed on the movable body 250 of the first lifting and conveying device 23.

[0048] Next, the first lifting and transporting device 23 again lowers the moving body 250 to the connection point 233 with the first picking conveyor 21 and the second picking conveyor 22 (step ST16). Next, it is determined whether or not to stop the transport of the article box B (step ST17). Step ST17 may be determined, for example, by a controller that manages and controls the overall operation of the picking system 100. In step ST17, it may be determined, for example, to stop the transport when inspecting the picking system 100. Step ST17 is not limited to being performed after step ST16, and may be performed at any timing in the operation flow of FIG. 4.

[0049] If it is determined that the transport of the article box B will not be stopped (step ST17: NO), the operation flow returns to step ST11, and steps ST11 to ST16 are repeated. If it is determined that the transport of the article box B will be stopped (step ST17: YES), the operation flow ends. As described above, one lifting and lowering operation of the first lifting and conveying device 23 is made up of steps ST11 to ST16.

[0050] In the lifting operation flow of the first lifting and conveying device 23, some steps may be omitted if the number of item boxes B to be conveyed is small. For example, in step ST11, if the first lifting and conveying device 23 delivers an item box B to the first picking conveyor 21 but does not receive an item box B from the second picking conveyor 22, steps ST12 and ST13 may be omitted. That is, the first lifting and conveying device 23 may convey an item box B only between the first picking conveyor 21 and the lower circular conveying device 4. Alternatively, in step ST11, if the first lifting and conveying device 23 receives an item box B from the second picking conveyor 22 without delivering an item box B to the first picking conveyor 21, steps ST14 and ST15 may be omitted. That is, the first lifting and conveying device 23 may convey an item box B only between the second picking conveyor 22 and the upper circular conveying device 3.

[0051] Fig. 5 shows the lifting operation flow of the second lifting and conveying device 24. First, the second lifting and conveying device 24 receives and delivers the item box B at the connection point 243 between the first picking conveyor 21 and the second picking conveyor 22 (step ST21). As shown in Fig. 3(c), the second lifting and conveying device 24 delivers the item box B to the second picking conveyor 22 and receives the item box B from the first picking conveyor 21. After step ST21, the item box B received from the first picking conveyor 21 is placed on the moving body 250 of the second lifting and conveying device 24.

[0052] Next, the second lifting and conveying device 24 raises the movable body 250 to the connection point 242 with the lower circulating conveying device 4 (step ST22). Next, as shown in FIG. 3(b), the second lifting and conveying device 24 hands over the article box B to the lower circulating conveying device 4 at the connection point 242 (step ST23). The article box B handed over from the movable body 250 of the second lifting and conveying device 24 in step ST23 is conveyed by the lower circulating cart 42 along the lower conveying path 41 in the circulating direction A2, and is stored in the automated warehouse 1. After step ST23, the article box B is not placed on the movable body 250 of the second lifting and conveying device 24.

[0053] Next, the second lifting and conveying device 24 raises the moving body 250 to the connection point 241 with the upper circulating conveying device 3 (step ST24). Next, as shown in FIG. 3(a), the second lifting and conveying device 24 receives the article box B from the upper circulating conveying device 3 at the connection point 241 (step ST25). In step ST25, the article box B that has been delivered from the automated warehouse 1 to the upper circulating conveying device 3 is conveyed by the upper circulating cart 32 along the upper conveying path 31 in the circulating direction A1, and is handed over to the moving body 250 of the second lifting and conveying device 24. After step ST25, the article box B received from the upper circulating conveying device 3 is placed on the moving body 250 of the second lifting and conveying device 24.

[0054] Next, the second lifting and conveying device 24 again lowers the moving body 250 to the connection point 243 with the first picking conveyor 21 and the second picking conveyor 22 (step ST26). Next, it is determined whether or not to stop the conveyance of the article box B (step ST27). If it is determined that the conveyance of the article box B will not be stopped (step ST27: NO), the operation flow returns to step ST21, and steps ST21 to ST27 are repeated. If it is determined that the conveyance of the article box B will be stopped (step ST27: YES), the operation flow ends. As described above, one lifting and conveying operation of the second lifting and conveying device 24 is made up of steps ST21 to ST26.

[0055] In the lifting operation flow of the second lifting and conveying device 24, some steps may be omitted if the number of item boxes B to be conveyed is small. For example, in step ST21, if the second lifting and conveying device 24 delivers an item box B to the second picking conveyor 22 and does not receive an item box B from the first picking conveyor 21, steps ST22 and ST23 may be omitted. That is, the second lifting and conveying device 24 may convey an item box B only between the second picking conveyor 22 and the upper circular conveying device 3. Alternatively, in step ST21, if the second lifting and conveying device 24 receives an item box B from the first picking conveyor 21 without delivering an item box B to the second picking conveyor 22, steps ST24 and ST25 may be omitted. That is, the second lifting and conveying device 24 may convey an item box B only between the first picking conveyor 21 and the lower circular conveying device 4.

[0056] As described above, the first lifting and conveying device 23 transfers an article box B to the upper circulatory conveying device 3 (step ST13) and receives an article box B from the lower circulatory conveying device 4 (step ST15) during one lifting and lowering operation (steps ST11 to ST16). Similarly, the second lifting and conveying device 24 transfers an article box B to the lower circulatory conveying device 4 (step ST23) and receives an article box B from the upper circulatory conveying device 3 (step ST25) during one lifting and lowering operation (steps ST21 to ST26). In this way, each of the first lifting and conveying device 23 and the second lifting and conveying device 24 transports two article boxes B during one lifting and lowering operation. [Action and effect]

[0057] As described above, in the picking system 100 of the above embodiment, each of the multiple picking stations 2 has the first picking conveyor 21 and the second picking conveyor 22. This allows the number of work locations 20 to be increased, thereby improving the processing capacity of the picking system 100. Furthermore, space can be saved compared to when additional picking stations 2 are installed along the longitudinal direction.

[0058] In the picking system 100 of the above embodiment, the direction in which the first lifting and lowering conveying device 23 and the second lifting and lowering conveying device 24 face each other is perpendicular to the direction in which the first picking conveyor 21 and the second picking conveyor 22 face each other. Additionally, the first lifting and lowering conveying device 23 and the second lifting and lowering conveying device 24 connect the connection points 231 and 241 with the upper circular conveying device 3, the connection points 232 and 242 with the lower circular conveying device 4, and the connection points 233 and 243 with the first picking conveyor 21 and the second picking conveyor 22, which are at different heights in the Z direction. This allows the first picking conveyor 21 and the second picking conveyor 22, the first lifting and lowering conveying device 23 and the second lifting and lowering conveying device 24, and the upper circular conveying device 3 and the lower circular conveying device 4 to be arranged effectively utilizing three-dimensional space. This further facilitates space saving.

[0059] In the picking system 100 of the above embodiment, the first lifting and conveying device 23 is connected to the receiving opening 21a of the first picking conveyor 21 and the delivery opening 22b of the second picking conveyor 22, and the second lifting and conveying device 24 is connected to the delivery opening 21b of the first picking conveyor 21 and the receiving opening 22a of the second picking conveyor 22. This allows the first lifting and conveying device 23 to continuously transfer the item box B to the first picking conveyor 21, and the second picking conveyor 22 to continuously transfer the item box B from the second picking conveyor 22 to the first lifting and conveying device 23. In parallel with this, the second lifting and conveying device 24 to continuously transfer the item box B to the second picking conveyor 22, and the first picking conveyor 21 to the second lifting and conveying device 24 can continuously transfer the item box B. This further increases the processing capacity of the picking system 100.

[0060] In the picking system 100 of this embodiment, as described above, in one lifting and lowering operation, the first lifting and lowering conveying device 23 and the second lifting and lowering conveying device 24 each transport two item boxes B. In the picking system 100 of this embodiment, two item boxes B are transported in six operation steps consisting of steps ST11 to ST16, or six operation steps consisting of steps ST21 to ST26, so that the item boxes B can be transported efficiently.

[0061] In the picking system 100 of the above embodiment, the circulating direction A1 of the upper circulating carriage 32 of the upper circulating conveying device 3 and the circulating direction A2 of the lower circulating carriage 42 of the lower circulating conveying device 4 may be opposite to each other. In this case, the upper circulating carriages 32 of the upper circulating conveying device 3 can transfer the article box B to and from the first lifting and lowering conveying device 23, while the lower circulating carriages 42 of the lower circulating conveying device 4 can transfer the article box B to and from the second lifting and lowering conveying device 24. This allows the upper circulating carriages 32 and the lower circulating carriages 42 to operate without waiting, thereby improving the efficiency of transporting the article boxes B.

[0062] In the picking system 100 of the above embodiment, the first lifting and lowering conveying device 23 may be located downstream of the second lifting and lowering conveying device 24 in the circulating direction A1 of the upper circulating carriage 32 of the upper circulating conveying device 3, and the first lifting and lowering conveying device 23 may be located upstream of the second lifting and lowering conveying device 24 in the circulating direction A2 of the lower circulating carriage 42 of the lower circulating conveying device 4. In this case, the upper circulating carriage 32 can deliver the item box B to the second lifting and lowering conveying device 24 located upstream, and then receive the item box B from the first lifting and lowering conveying device 23 located downstream. Similarly, the lower circulating carriage 42 can deliver the item box B to the first lifting and lowering conveying device 23 located upstream, and then receive the item box B from the second lifting and lowering conveying device 24 located downstream. This improves the efficiency of transporting the item box B.

[0063] In the picking system 100 of the above embodiment, an article box B received from one of the placement sections 11C of the pair of racks 11A, 11B can be moved to a level of the upper circular conveying device 3 or the lower circular conveying device 4 by the unloading lifting conveying device 14, and then handed over to the upper circular conveying device 3 or the lower circular conveying device 4 via the first connecting conveyor. Similarly, an article box B can be received from the upper circular conveying device 3 or the lower circular conveying device 4 via the second connecting conveyor, moved to a level of one of the pair of racks 11A, 11B by the loading lifting conveying device 15, and then handed over to one of the placement sections 11C by the warehouse cart 13. For example, even when the height of the placement section 11C where the article box B is received is different from the height of the placement section 11C where the article box B is removed, the article box B can be efficiently transported between the automated warehouse 1 and the upper circular conveying device 3 or the lower circular conveying device 4. Furthermore, the item box B can be transported at a position higher than the ground floor without the need to move the item box B to the ground floor.

[0064] [Variations] Although the embodiments of the present invention have been described above, the present invention is not necessarily limited to the above-described embodiments, and various modifications are possible without departing from the spirit of the present invention.

[0065] In multiple picking stations 2, the conveying direction of the item boxes B may differ for each picking station 2. In the above embodiment, the conveying direction of the item boxes B on the second picking conveyor 22 side in each picking station 2 is the same, i.e., clockwise. However, for example, the conveying direction of the item boxes B on the second picking conveyor 22 side may be alternately clockwise and counterclockwise for each picking station 2. FIGS. 6(A) and 6(B) are diagrams showing two adjacent picking stations 2, 2 in a picking system according to a modified example. Here, the clockwise picking station 2 is referred to as the first picking station 2A, and the counterclockwise picking station 2 is referred to as the second picking station 2B. The positions of the first lifting and conveying device 23 and the second lifting and conveying device 24 in the Y direction in the first picking station 2A are opposite to those in the second picking station 2B.

[0066] When we look at the clockwise first picking station 2A and the counterclockwise second picking station 2B, which are positioned as shown in Figure 6(A), we see that there is a section where the conveying paths going in the same direction (leftward in Figure 6(A)) are adjacent to each other on the second picking conveyor 22 side of the first picking station 2A and the second picking station 2B. By arranging a worker in this section, sorting work can be performed even if only one worker P is stationed on the second picking conveyor 22 side of the first picking station 2A and the second picking station 2B.

[0067] Similarly, when we look at the second picking station 2B rotating counterclockwise and the first picking station 2A rotating clockwise, which are positioned as shown in Figure 6(B), there is a section where the conveying paths going in the same direction (to the right in Figure 6(B)) are adjacent to each other on the first picking conveyor 21 side of the second picking station 2B and the first picking station 2A. By arranging a worker in this section, sorting work can be performed even if only one worker P is stationed on the first picking conveyor 21 side of the first picking station 2A and the second picking station 2B.

[0068] Instead of a configuration in which multiple upper circular carriages 32 travel in a circular motion on the upper conveying path 31, the upper circular conveying device 3 may employ a circular conveying device such as a cross belt conveyor provided with a belt conveyor that moves the item boxes B in the width direction, a tilt tray conveyor in which the loading surface on which the item boxes B are placed tilts in the width direction to slide the item boxes B in the width direction, or a slide shoe conveyor in which a shoe provided to be movable in the width direction on the conveying surface pushes the item boxes B in the width direction. Also, a circular conveying device configured to include a general belt conveyor or roller conveyor and an appropriate device for moving the item boxes in the width direction may be employed. A circular conveying device with a similar configuration may also be employed for the lower circular conveying device 4.

[0069] The lower circular conveying device 4 does not have to have the same shape as the upper circular conveying device 3. In the example of FIG. 1 , both the upper circular conveying device 3 and the lower circular conveying device 4 have an elliptical shape in a plan view. However, for example, the lower circular conveying device 4 may have a rectangular shape. In this case, the lower conveying path 41 may be a rectangular circular conveying path. Alternatively, the length of the major axis or minor axis of the ellipse of the lower circular conveying device 4 may be different from the length of the major axis or minor axis of the ellipse of the upper circular conveying device 3. Alternatively, the lower straight portion 41a of the lower conveying path 41 does not have to be parallel to the upper straight portion 31a of the upper conveying path 31 when viewed from the X direction. However, in this case, the connection point 232 of the lower circular conveying device 4 with the first elevating conveying device 23 may be parallel to the connection point 231 of the upper circular conveying device 3 with the first elevating conveying device 23. A connection point 242 between the lower circular transfer device 4 and the second lifting and transferring device 24 may be parallel to a connection point 241 between the upper circular transfer device 3 and the second lifting and transferring device 24 .

[0070] Each of the first picking conveyor 21 and the second picking conveyor 22 may be U-shaped in a plan view. The automated warehouse 1 may have a stacker crane, instead of the in-warehouse cart 13, that is capable of traveling along the extension direction of the pair of racks 11A, 11B and has a transfer device that is capable of transferring the item box B2 to the placement portions 11C of the pair of racks 11A, 11B and the pair of first conveyors 12A, 12B. [Explanation of symbols]

[0071] 1...automated warehouse, 2, 2A...picking station, 3...upper circular conveying device, 4...lower circular conveying device, 11A, 11B...pair of racks (racks), 11C...loading section, 13...warehouse cart (second cart), 14...lifting conveying device for outgoing goods, 15...lifting conveying device for incoming goods, 20...work area, 21...first picking conveyor, 22...second picking conveyor, 23...first lifting conveying device, 24...second lifting conveying device, 31a...upper straight section, 32...upper circular cart (first cart), 41a...lower straight section, 42...lower circular cart (first cart), 100...picking system, 231, 232, 233, 241, 242, 243...connection point, A1, A2...circulation direction.

Claims

1. an automated warehouse for storing transported items; an upper circular conveying device connected to the automated warehouse, including an upper linear portion extending linearly, and including a circular conveying path with the upper linear portion as a longitudinal direction; a lower circular conveying device connected to the automated warehouse below the upper circular conveying device, including a lower straight portion extending linearly, and including a circular conveying path with the lower straight portion as a longitudinal direction; a plurality of picking stations arranged along the longitudinal direction of the upper circular conveying device or the lower circular conveying device, with a work location where a picking operation is performed being provided below the lower circular conveying device; Each of the plurality of picking stations comprises: a first picking conveyor and a second picking conveyor on which the work area is provided; a first lifting and lowering conveying device that vertically connects a connection point with the upper circular conveying device, a connection point with the lower circular conveying device, and a connection point with the first picking conveyor and the second picking conveyor, which are at different height positions from each other; a second lifting and lowering transport device that connects, in the vertical direction, a connection point with the upper circular transport device, a connection point with the lower circular transport device, and a connection point with the first picking conveyor and the second picking conveyor, which are at different height positions from each other; the first picking conveyor receives the transported object from the first lifting and transporting device and transfers the transported object to the second lifting and transporting device; The second picking conveyor receives the transported object from the second lifting and transporting device and delivers the transported object to the first lifting and transporting device.

2. The lifting and lowering operation in the vertical direction per one time of the first lifting and conveying device is The conveyed object is delivered at a connection point between the first picking conveyor and the second picking conveyor, After receiving and delivering the transported object, the robot moves up to a connection point with the upper circular transport device and delivers the transported object to the upper circular transport device; After the transfer of the transported object, the robot descends to a connection point with the lower circular transport device and receives the transported object from the lower circular transport device; After receiving the transported object, the conveyor again descends to a connecting point with the first picking conveyor and the second picking conveyor to receive and deliver the transported object; The lifting and lowering operation in the vertical direction per one time of the second lifting and conveying device is The conveyed object is delivered at a connection point between the first picking conveyor and the second picking conveyor, After receiving and delivering the transported object, the robot moves up to a connection point with the lower circular transport device and delivers the transported object to the lower circular transport device; After the transfer of the transported object, the transporter ascends to a connection point with the upper circular transport device and receives the transported object from the upper circular transport device; 2. The picking system according to claim 1, wherein after receiving the transported object, the picking system descends again to a connection point between the first picking conveyor and the second picking conveyor to receive and deliver the transported object.

3. each of the upper circular conveying device and the lower circular conveying device has a plurality of first carriages that travel in a circular direction on the conveying path and can deliver the conveyed object to the automated warehouse, the first lifting and conveying device, and the second lifting and conveying device; 3. The picking system according to claim 1, wherein the rotation direction of the plurality of first carriages on the upper circular conveying device is opposite to the rotation direction of the plurality of first carriages on the lower circular conveying device.

4. the first lifting and transporting device is located downstream of the second lifting and transporting device in a rotation direction of the plurality of first carriages in the upper circulating transporting device, The picking system according to claim 3 , wherein the first lifting and transporting device is located upstream of the second lifting and transporting device in a direction in which the plurality of first carriages of the lower circulating transport device rotate.

5. The automated warehouse comprises: a rack, in which the loading sections on which the transported objects are placed are arranged in a plurality of stages in the vertical direction and in a plurality of rows in a horizontal direction perpendicular to the vertical direction; a second carriage provided for each of the plurality of stages, traveling along the arrangement direction of the plurality of stages, and receiving the transported object from the placement unit or delivering the transported object to the placement unit; an outgoing lifting and conveying device that conveys the transported object to be unloaded from the automated warehouse in the vertical direction; an entrance elevator conveying device that conveys the object entered into the automated warehouse in the vertical direction; a first connecting conveyor that connects the upper and lower circular conveying devices to the out-of-stock lifting conveying device; The picking system according to claim 1 or 2, further comprising a second connecting conveyor that connects the upper and lower circular transport devices to the storage lifting transport device.

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