Conveyor buffer system, control program of conveyor buffer system, control method of conveyor buffer system, information processor and sorting system

Abstract

To achieve efficient and cost-effective automation of sorting operations without requiring a large area in a sorting system.SOLUTION: A conveyor buffer system according to an embodiment comprises a buffer conveyor and a server that controls the buffer conveyor. The server instructs the buffer conveyor to sort a tray corresponding to at least one priority sorting destination from a plurality of trays corresponding to a plurality of sorting destinations. The server instructs the buffer conveyor to buffer the tray corresponding to a non-priority sorting destination from the plurality of trays. The server instructs the buffer conveyor to output the tray corresponding to the sorted priority sorting destination to a subsequent stage.SELECTED DRAWING: Figure 8

Description

[Technical Field]

[0001] An embodiment of the present invention relates to a conveyor buffer system, a control program for the conveyor buffer system, a control method for the conveyor buffer system, an information processing device, and a sorting system. [Background technology]

[0002] In the field of logistics, sorting systems are used to separate goods by destination. In the sorting system, large numbers of trays containing goods are sorted by destination (district) and loaded (palletized) onto a cart called a trolley. The trolleys loaded with trays are then delivered to the designated destination by a means of transportation (such as a truck). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2003-212314 Summary of the Invention [Problem to be solved by the invention]

[0004] In conventional sorting systems, the work of sorting trays by destination and palletizing them onto the corresponding trolleys is done manually. Therefore, when sorting a large number of trays (e.g., 8,000 trays) and stacking them on multi-destination trolleys (e.g., 400 destinations), a large number of workers corresponding to the number of destinations is required. Furthermore, conventional sorting systems streamline the sorting work by sorting trays by destination and storing trays with the same destination together. Therefore, a large area is required for sorting and storing, which can take up a large portion of a warehouse, etc.

[0005] The problem that this disclosure aims to solve is to realize an efficient automation of sorting work in a sorting system that is cost-effective and has high processing performance, without requiring a large area. [Means for solving the problem]

[0006] A conveyor buffer system according to an embodiment includes a buffer conveyor and a server that controls the buffer conveyor. The server causes the buffer conveyor to sort trays corresponding to at least one priority sorting destination from among multiple trays corresponding to multiple sorting destinations. The server causes the buffer conveyor to buffer trays corresponding to destinations other than the priority sorting destination. The server causes the buffer conveyor to output the sorted trays corresponding to the priority sorting destination to a subsequent stage. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a diagram illustrating an example of a schematic configuration of a sorting system according to an embodiment. [Figure 2] FIG. 2 is a diagram illustrating an example of the configuration of a buffer conveyor included in the conveyor buffer system according to the embodiment. [Figure 3] FIG. 3 is a diagram illustrating an example of the configuration of a stopper mechanism included in the buffer conveyor according to the embodiment. [Figure 4] FIG. 4 is a diagram illustrating an example of the configuration of an information processing system included in the sorting system according to the embodiment. [Figure 5] FIG. 5 is a diagram showing an example of functional blocks of a WES (Warehouse Execution System) included in the sorting system according to the embodiment. [Figure 6] FIG. 6 is a diagram for explaining an example of the operation of the conveyor buffer system according to the embodiment. [Figure 7] FIG. 7 is a diagram illustrating an example of the operation of the conveyor buffer system according to the embodiment. [Figure 8] FIG. 8 is a diagram illustrating an example of the operation of the conveyor buffer system according to the embodiment. [Figure 9] FIG. 9 is a diagram for explaining an example of the operation of the conveyor buffer system according to the embodiment. [Figure 10] FIG. 10 is a flowchart showing an example of an outline of the sorting process executed by the sorting system according to the embodiment. [Figure 11] FIG. 11 is a flowchart showing an example of details of the sorting process executed by the sorting system according to the embodiment. [Figure 12] FIG. 12 is a flowchart showing an example of details of the sorting process executed by the sorting system according to the embodiment. [Figure 13] FIG. 13 is a flowchart showing an example of details of the sorting process executed by the sorting system according to the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0008] Hereinafter, an information processing device, an information processing system, an information processing program, and an information processing method according to embodiments will be described with reference to the drawings. Note that parts with the same reference numerals perform similar operations, and redundant explanations will be omitted as appropriate. The following embodiments do not limit the disclosed technology. Furthermore, each embodiment can be combined as appropriate within the scope of not causing contradictions in the processing content.

[0009] 1 is a diagram illustrating an example of a schematic configuration of a sorting system S according to an embodiment. The sorting system S includes a conveyor buffer system 1, a palletizing system 3, and an AMR (Autonomous Mobile Robot) system 5. Specific potential adopters of the sorting system S include, for example, postal delivery companies, parcel delivery companies, and logistics companies.

[0010] As shown in FIG. 1, in the sorting system S, multiple trays Tx are input to the conveyor buffer system 1 in no particular order from the upstream side. The conveyor buffer system 1 performs sorting (replacement) or buffering of the trays Tx input from upstream, preferentially outputting trays Tx from a specific direction (which may be one direction or multiple directions) to the palletizing system 3, and buffering trays Tx from other directions. The palletizing system 3 palletizes the trays Tx input from the conveyor buffer system 1 to the corresponding trolleys 6. The AMR system 5 moves each palletized trolley 6 to the trolley placement area 7 using the AMR 50 and temporarily stores it. The AMR system 5 also moves each palletized trolley 6 to a loading area (not shown) for a transportation means such as a truck using the AMR 50. Specific configurations of the conveyor buffer system 1, the palletizing system 3, and the AMR system 5 are described below.

[0011] The conveyor buffer system 1 includes a plurality of levels (four levels in the example of FIG. 1) of buffer conveyors 10, an elevator 11, a barcode reader 13, and a conveyor buffer system 15 server, which will be described later.

[0012] Fig. 2 is a diagram illustrating an example of the configuration of the buffer conveyor 10 included in the conveyor buffer system 1. Note that Fig. 2 shows only one layer of the buffer conveyor 10, which has multiple layers, in a simplified top view.

[0013] 2, the buffer conveyor 10 includes an input conveyor 101, multiple buffer conveyors 102, a recycle conveyor 103, an input-side branching module 104a, an output-side branching module 104b, an output conveyor 105, and a stopper 106. Each conveyor included in the buffer conveyor 10 may be a roller conveyor, a belt conveyor, or another type. Each conveyor included in the buffer conveyor 10 may also be a type other than a conveyor as long as it has the same functions as those described below.

[0014] The input conveyor 101 is a belt conveyor that can move trays Tx in both directions.

[0015] The input side branching module 104a is a mechanism that connects the input conveyor 101 with a plurality of buffer conveyors 102 and a recycle conveyor 103, and changes the moving direction of the trays Tx to any direction.

[0016] The buffer conveyor 102 is a belt conveyor that is connected to the input conveyor 101 and the output conveyor 105 and moves trays Tx from the input conveyor 101 to the output conveyor 105. In this embodiment, for the sake of concrete explanation, an example is shown in FIG. 2 where there are three buffer conveyors 102a, 102b, and 102c. However, there is no limitation on the number of buffer conveyors 102, and there may be multiple lines or a single line. Furthermore, the buffer conveyor 102 may be one that moves at least trays Tx from the input conveyor 101 to the output conveyor 105, but it may also be a belt conveyor that can move trays Tx from the output conveyor 105 to the input conveyor 101 as well (i.e., that can move in both directions).

[0017] The output-side branching module 104b is a mechanism that connects the multiple buffer conveyors 102 and recycle conveyors 103 with the output conveyor 105, and changes the moving direction of the trays Tx to any direction.

[0018] The output conveyor 105 is a belt conveyor that can move the trays Tx in both directions.

[0019] The recycle conveyor 103 is a belt conveyor that moves trays Tx from the output conveyor 105 to the input conveyor 101. The recycle conveyor 103 may be one that moves at least trays Tx from the output conveyor 105 to the input conveyor 101, but may also be a belt conveyor that can move trays Tx from the input conveyor 101 to the output conveyor 105 (i.e., can move in both directions). However, there is no limit to the number of recycle conveyors 103, and it may be a single line or multiple lines. Furthermore, the position of the recycle conveyor 103 does not need to be at the end of the input conveyor 101 and the output conveyor 105, and it can be installed at any position. For example, from the perspective of optimization, which will be described later, multiple recycle conveyors 103 may be installed so that they are equidistant from each buffer conveyor.

[0020] The stopper 106 is provided at the end of the buffer conveyor 102 on the output conveyor 105 side, and stops the movement of the tray Tx from the buffer conveyor 102 to the output conveyor 105.

[0021] 3 is a diagram illustrating an example of the configuration of the stopper 106. As shown in FIG. 3, the stopper 106 is a mechanism that is movable up and down at the end of the buffer conveyor 102 on the output conveyor 105 side. When the stopper 106 protrudes from the upper surface of the buffer conveyor 102, the tray Tx moved by the buffer conveyor 102 is stopped by the stopper 106. On the other hand, when the stopper 106 does not protrude from the upper surface of the buffer conveyor 102, the tray Tx moved by the buffer conveyor 102 is output to the output conveyor 105.

[0022] Returning to FIG. 1, the elevator 11 moves the trays Tx between levels of the buffer conveyor 10.

[0023] The barcode reader 13 reads out the barcode indicating ID information attached to each tray Tx and outputs it to the WES 2 (described later). The barcode reader 13 is disposed so as to correspond to the barcode label surface attached to the tray Tx. It is also possible to provide the barcode reader 13 on both sides of the input conveyor 101 as necessary.

[0024] The palletizing system 3 includes a branching conveyor 30, a plurality of (or one) palletizer robots 33, and a palletizing system server 35, which will be described later.

[0025] The branch conveyor 30 distributes the trays Tx input from the conveyor buffer system 1 to a plurality of palletizer robots 33 according to their sorting destinations.

[0026] The palletizer robot 33 is a robot that loads the trays Tx sorted by the branch conveyor 30 onto the trolley 6. As shown in Fig. 1, a single palletizer robot 33 can be equipped with a plurality of sorting destination trolleys 6. Note that, although Fig. 1 shows a gantry-type robot provided corresponding to the branch conveyor 30 as an example of the palletizer robot 33, an articulated robot can also be used.

[0027] The AMR system 5 includes a plurality of (or one) transport AMRs 50 and an AMR system server 55, which will be described later.

[0028] The AMR 50 is communicatively connected to the AMR system server 55, for example, via wireless LAN. The AMR 50 moves each trolley 6 to a predetermined position based on a control signal from the AMR system server 55. Specifically, the AMR 50 acquires an empty trolley 6 and places it at a predetermined position on the palletizer robot 33. The AMR 50 acquires a trolley 6 from a predetermined position in the trolley placement area 7 and places it at a predetermined position on the palletizer robot 33. The AMR 50 transports and places a trolley 6 that has completed palletizing to a predetermined position in the trolley placement area 7 in accordance with instructions from the AMR system server 55. The AMR 50 also transports and places a trolley 6 that has completed palletizing to a final destination position (for example, near the loading platform of a transportation means such as a truck) and places it at the predetermined position.

[0029] The AMR 50 may be equipped with a barcode reader that reads a label bearing ID information of the trolley 6, or may be associated with an ID for each placement position. The navigation system of the AMR 50 may use a QR Grid method, a SLAM method, or other methods.

[0030] Fig. 4 is a diagram illustrating an example of the configuration of an information processing system included in the sorting system S. As shown in Fig. 4, the sorting system S includes a WES (Warehouse Execution System) 2, a conveyor buffer system server 15 serving as a WCS (Warehouse Control System), a palletizing system server 35 serving as the WCS, and an AMR system server 55 serving as the WCS. The WES 2 is an example of an information processing device.

[0031] The WES2 is configured, for example, by a single server (computer). The WES2 comprehensively manages and controls the sorting operations of the sorting system S. The WES2 obtains ID information and information about the direction (destination) from, for example, an upstream customer IT system. The WES2 communicates various data, control instructions, and the like with the conveyor buffer system server 15, palletizing system server 35, and AMR system server 55. In particular, the WES2 executes calculations related to the sorting process and transmits the calculation results to the conveyor buffer system server 15, palletizing system server 35, and AMR system server 55.

[0032] 5 is a diagram showing an example of functional blocks of the WES 2. As shown in FIG. 5, the WES 2 includes a processor 20, a main storage device 21, an auxiliary storage device 23, a communication interface 25, and a device interface 27.

[0033] While WES2 shown in Figure 5 includes one of each component, it may include multiple of the same component. Furthermore, the software may be installed on multiple computers, with each of the multiple computers executing the same or different portions of the software. In this case, WES2 may be configured with one or more computers located on the cloud or on-premises.

[0034] The processor 20 is an electronic circuit including a control device and an arithmetic device of the WES 2. The processor 20 executes arithmetic processing based on data and software (programs) input from each device, etc., in the internal configuration of the WES 2, and outputs the arithmetic results and control signals to each device, etc.

[0035] Specifically, the processor 20 realizes the functions related to the acquisition unit 200, the sorting plan generation unit 202, and the sorting control unit 204 by reading and executing programs stored in the main memory unit 21 or the auxiliary memory unit 23, etc.

[0036] The acquisition unit 200 acquires sorting destination information from the customer IT system 9, which is a higher-level system. Here, the sorting destination information is information in which the maximum possible sorting destination (for example, 400 sorting destinations) is associated with its ID information Sx (where x is a unique number or the like indicating each sorting destination). The acquisition unit 200 also acquires sorting management information (tray sorting management information) for each tray Tx, either sequentially or all at once, from the customer IT system 9. Here, the tray sorting management information is sorting designation (SORT PLAN) information in which the ID information Tx (where x is a unique number or the like indicating each tray) for each tray is associated with the sorting destination information Sx.

[0037] The sorting plan generation unit 202 generates a sorting plan based on the sorting destination information and tray sorting management information acquired by the acquisition unit 200. Here, the sorting plan is, in a narrow sense, information for causing the conveyor buffer system 1 to execute sorting processing and buffering processing, and in a broad sense, information for linking the conveyor buffer system 1, palletizing system 3, and AMR system 5 and for overall control and management.

[0038] For example, assume that trays Tx with ID Tx are input from upstream, and tray sorting destinations Sx associated with the trays Tx are input from upstream in no particular order. In this case, the sorting plan generation unit 202 defines the number P1 of palletizer robots 33 required, the number P2 of trolleys 6 used by each palletizer robot 33 for loading, and the number A1 of AMRs 50 required, based on the assumed total number TN of trays Tx and the total number SN of sorting destinations, while maintaining a certain target work completion time.

[0039] The sorting plan generation unit 202 determines the assumed TN, SN and distribution of the number of trays Tx destined for each Sx, the number L1 and capacity L2 of the buffer conveyors 10, the configuration and control method of the buffer conveyor 10, the number P1 of palletizer robots 33 required, the number P2 of trolleys 6 used by each palletizer robot 33 for loading, the number A1 of AMRs 50 required, the time from the time the total number of trays Tx TN is received (or input into the buffer conveyor 10 is completed) to the time all processing is completed, etc., so as to optimize the above conditions with statistical accuracy.

[0040] Furthermore, the assortment plan generation unit 202 uses, for example, an evaluation function F shown in equation (1). F=ΣL(Tx) (1) Here, L(Tx) is a function that indicates the sum of the travel distances of each tray Tx within the section from the input point XS to the output point XE of the buffer conveyor 10. Also, Σ indicates the sum from x=1 to x=N (N=8,000 in this embodiment).

[0041] The sorting plan generation unit 202 generates a sorting plan including sorting processing and buffering processing for each tray Tx so that the evaluation function F is minimized as shown in equation (2) (so that the differential value takes a minimum value). In other words, the sorting plan generation unit 202 generates a sorting plan including sorting processing and buffering processing for each tray Tx, using optimization control to minimize the sum of the movement distances of each tray Tx on the buffer conveyor 10. (dF / dL)=0 (2)

[0042] The above optimization control calculation calculates the sum of L(Tx) for all combinations (brute force), and selects the combination of movement distances of each tray Tx that minimizes the evaluation function F as the optimization control. However, without being limited to this example, other optimization methods that do not use the sum of L(Tx) for brute force can also be adopted.

[0043] In the above optimization control calculation, for example, if the number of palletizer robots 33 is P1 and the number of trolleys 6 that can be placed on each palletizer robot 33 is P2, the sorting destination Sx of each tray Tx dispensed (output) from the buffer conveyor 10 can be in any order as long as it is included in the sorting destinations P1 to P2. In other words, the sorting destination Sx of each tray Tx output from the buffer conveyor 10 does not need to be consecutive (the same), and can be in any order as long as it is included in the sorting destinations P1 to P2 (the sorting destination assigned to one of the palletizer robots 33).

[0044] In addition, the above optimization control calculations also take into consideration, for example, which buffer conveyor 102 each tray Tx should be placed in, the output sequence of each tray Tx (from which buffer conveyor tray RxTx it should be dispensed via the output conveyor 105), and the rearrangement of each tray Tx to the buffer conveyor 102 (re-input: which buffer line it should be re-input to).

[0045] Furthermore, the sorting plan generation unit 202 sets new conditions according to processing results acquired at predetermined times from the conveyor buffer system 1, the palletizing system 3, and the AMR system 5, and regenerates and updates the sorting plan. For example, if an abnormality occurs in any of the conveyor buffer system 1, the palletizing system 3, and the AMR system 5 (for example, if abnormality information is acquired), the sorting plan generation unit 202 outputs a warning and prompts the supervisor to take action.

[0046] Furthermore, even when abnormality information is obtained, the sorting plan generation unit 202 determines whether operation can be continued by downgrading, and if it determines that operation can be continued, it issues a warning and notifies the supervisor, and then continues operation in accordance with the sorting plan. More specifically, when a failure or abnormality occurs in one of the multiple palletizers or AMRs, for example, the sorting plan generation unit 202 separates the object where the failure or abnormality occurred and assigns operation to an object that is operating normally.

[0047] The sorting control unit 204 controls the operation of the buffer conveyor 10 via the conveyor buffer system server 15 in accordance with the sorting plan. The sorting control unit 204 controls the branch conveyors 30, the palletizer robot 33, the placement of the trolleys 6 in the palletizing system 3, and the like via the palletizing system server 35 in accordance with the sorting plan. The sorting control unit 204 controls the issuing of transport instructions for the trolleys 4 to the AMR 50, the acquisition of empty trolleys 4, the acquisition and inventory of sorting trolleys 4 (placement in the trolley placement area 7), and the like via the AMR system server 55 in accordance with the sorting plan.

[0048] The main memory device 21 is a storage device that stores instructions to be executed by the processor 20, various data, etc. Information stored in the main memory device 21 is read by the processor 201.

[0049] The auxiliary storage device 23 is a storage device other than the main storage device 21 .

[0050] In addition, the storage device for storing various data used in the WES2 of this embodiment may be realized by the main storage device 21 or the auxiliary storage device 23, or may be realized by an internal memory built into the processor 20.

[0051] The communication interface 25 is an interface for connecting to a communication network wirelessly or by wire, and can also exchange information with an external device connected via the communication network.

[0052] The device interface 27 is an interface such as a USB (Universal Serial Bus) that directly connects to an output device (a display device, a speaker that outputs sound, a printer, etc.), an input device, and an external device.

[0053] 4, the conveyor buffer system server 15 is configured by, for example, one server (computer). The conveyor buffer system server 15 realizes the function of controlling the buffer conveyor 10 by, for example, starting a dedicated program and having the software and hardware work together.

[0054] For example, the conveyor buffer system server 15 causes the buffer conveyor 10 to sort trays corresponding to at least one priority sorting destination from among a plurality of trays corresponding to a plurality of sorting destinations.

[0055] Here, the priority sorting destination means at least one sorting destination that is given priority for output from the conveyor buffer system server 15 among all sorting destinations.

[0056] The conveyor buffer system server 15 causes the buffer conveyor 10 to buffer trays Tx corresponding to sorting destinations other than the priority sorting destinations among the multiple trays Tx. The conveyor buffer system server 15 causes the buffer conveyor 10 to output the sorted trays Tx corresponding to the priority sorting destinations to the palletizing system 3.

[0057] Furthermore, the conveyor buffer system server 15 sets a new priority sorting destination after all of the trays Tx corresponding to the priority sorting destinations among the multiple input trays Tx have been output to the palletizing system 3. The conveyor buffer system server 15 causes the buffer conveyor 10 to sort the trays corresponding to the new priority sorting destination. The conveyor buffer system server 15 causes the buffer conveyor 10 to buffer the trays corresponding to destinations other than the new priority sorting destination among the multiple input trays Tx. The conveyor buffer system server 15 causes the buffer conveyor 10 to output the sorted trays Tx corresponding to the new priority sorting destination to the palletizing system 3.

[0058] In addition, the conveyor buffer system server 15 receives an abnormality signal received from the buffer conveyor 10 and the barcode of each tray Tx output from the barcode reader 13.

[0059] The palletizing system server 35 is configured by, for example, one server (computer). The palletizing system server 35 controls the branch conveyors 30 and the palletizer robot 33 in accordance with control signals and sorting destination information Sx from the WES 2.

[0060] The AMR system server 55 is configured by, for example, one server (computer). The AMR system server 55 controls each AMR 50 in accordance with a control signal from the WES 2, sorting destination information Sx, and ID information of the trolley 6.

[0061] (Conveyor buffer system 1 operation) Next, a description will be given of the operation of the conveyor buffer system 1 according to the embodiment. The operation of the conveyor buffer system 1 includes a sorting process and a buffering process for the trays Tx.

[0062] 6 to 9 are diagrams for explaining an example of the operation of the conveyor buffer system 1. In the following, for the sake of specificity, the following will be exemplified by an operation of executing a sorting process in which trays Tx corresponding to the sorting destination S5 are preferentially sorted and output, and a buffering process in which trays Tx corresponding to destinations other than S5 are buffered on the buffer conveyor 102.

[0063] As shown in Figure 6, trays Tx, for example, with a total number TN = 8,000, are input in no particular order from upstream to the buffer conveyor 10. Each tray Tx has a label (barcode) with a unique ID number Tx affixed to it. The barcode reader 13 reads the barcode of each tray Tx and outputs it to the conveyor buffer system server 15.

[0064] As a result of the sequential input of trays Tx, as shown in FIG. 6, trays T1 (sorting destination S1), Tray T2 (sorting destination S4), and Tray T3 (sorting destination S5) are carried into buffer conveyor 102a, trays T4 (sorting destination S3), Tray T6 (sorting destination S5), and Tray T7 (sorting destination S3) are carried into buffer conveyor 102b, and trays T5 (sorting destination S6) and T8 (sorting destination S7) are carried into buffer conveyor 102c.

[0065] 7, among the trays Tx on the buffer conveyor 102a, only tray T3, which is sorted to S5, is redirected by the output-side branching module 104b and discharged from the output conveyor 105 to the palletizing system 3. On the other hand, tray T1, which is sorted to S1, and tray T2, which is sorted to S4, are redirected by the output-side branching module 104b and discharged to the recycle conveyor 103.

[0066] 8, among the trays Tx on the buffer conveyor 102b, only tray T6, which is sorted to S5, is redirected by the output-side branching module 104b and discharged to the palletizing system 3. On the other hand, tray T4, which is sorted to S3, is redirected by the output-side branching module 104b and discharged from the output conveyor 105 to the recycle conveyor 103. Tray T7, which is sorted to S3, remains on the buffer conveyor 102b due to the stopper 106 and is not discharged to the output conveyor 105. Furthermore, trays Tx on the buffer conveyor 102c, which does not have a tray sorted to S5, are not moved by the buffer conveyor 102c.

[0067] 9, tray T1, which is sorted to S1 and discharged onto recycle conveyor 103, and tray T2, which is sorted to S4, are buffered again on buffer conveyor 102a via input conveyor 101. Similarly, tray T4, which is sorted to S3 and discharged onto recycle conveyor 103, is buffered again on buffer conveyor 102b via input conveyor 101.

[0068] After that, after all trays Tx corresponding to the sorting destination S5 have been sorted and output preferentially, the sorting destination is changed to another sorting destination, and the same process is repeated. As a result, the conveyor buffer system 1 can output trays Tx in specific sorting destination units.

[0069] It is also possible to set multiple prioritized sorting destinations depending on the capacity of the downstream palletizing system 3.

[0070] (Sorting process by sorting system S) Next, we will explain the sorting process executed by the entire sorting system S. First, we will explain the outline of the sorting process executed by the sorting system S with reference to Fig. 10, and then we will explain the details of the sorting process executed by the sorting system S with reference to Figs. 11 to 13.

[0071] Fig. 10 is a flowchart showing an example of an outline of the sorting process executed by the sorting system S. Note that Fig. 10 is merely an example of an outline of the sorting process. In the actual sorting process, predetermined processes (steps) can also be executed in parallel as necessary.

[0072] Furthermore, as pre-processing for the sorting process, the WES2 of the sorting system S acquires sorting destination information from the upper system of the sorting system S at a predetermined timing. The WES2 also acquires the current location of each trolley 6, information on the availability of the trolleys 6, and sorting destination information Sx for each trolley from the upper system of the sorting system S. If this information cannot be acquired from the upper system, the WES2 can acquire the current location and sorting destination information of each trolley 6 by reading the barcode on the label affixed to each trolley 6 using the barcode reader provided in the AMR 50 and acquiring that information from the AMR system 5.

[0073] As shown in FIG. 10, the WES 2 controls the AMR 50 to place the trolleys 6 at a plurality of predetermined positions of the palletizer robot 33 (step S1).

[0074] From the upstream side, a plurality of trays Tx are input to the sorting system S in no particular order (step S2).

[0075] Individual tracking of each tray Tx is started (step S3). Here, tracking refers to a process of individually checking each tray Tx at a predetermined position in the conveyor buffer system 1 (each input position XS, branch position, output position XE, position of the barcode reader 13, etc.), a branch position in the palletizing system 3, etc. Note that any tracking method may be used.

[0076] The ID information of each tray Tx is acquired by the barcode reader 13 (step S4). The ID information of each tray Tx can also be acquired from a higher-level system such as the customer IT system 9. Furthermore, the ID information of each tray Tx may be acquired from both the higher-level system such as the customer IT system 9 and the barcode reader 13.

[0077] The WES 2 generates a sorting plan and transmits it to the conveyor buffer system server 15, the palletizing system server 35, and the AMR system server 55 (step S5).

[0078] In the conveyor buffer system 1, sorting and buffering processes are performed on a plurality of trays Tx based on the sorting plan, and the order of the trays Tx is changed so that the trays Tx destined for Sx are output in order from the output conveyor 105 (step S6).

[0079] In the palletizing system 3, the trolley 6 with the sorting destination Sx is placed (step S7).

[0080] In the palletizing system 3, according to the sorting plan, a branching process is performed by the branching conveyor 30 for each tray Tx output from the conveyor buffer system 1, and the trays are transported to a predetermined palletizer robot 33 (step S8).

[0081] In the palletizing system 3, the palletizer robot 33 palletizes the target trays Tx whose sorting destination is Sx onto the trolleys 6 whose sorting destination is Sx according to the sorting plan (step S9).

[0082] In the AMR system 5, the AMR 50 transports the trolley 6 that has been palletized to the trolley placement area 7 and places it there in accordance with the sorting plan (step S10).

[0083] In the AMR system 5, the AMR 50 acquires the trolley 6 placed in the trolley placement area 7 according to the sorting plan generated in the WES 2, and transports and places it at the final destination position (such as the loading position onto the loading platform of the transportation means) (step S11).

[0084] 11 to 13 are flowcharts showing an example of the details of the sorting process executed by the sorting system S. As shown in Fig. 11, the WES 2 determines whether or not there is a tray Tx to be input to the conveyor buffer system 1 (step S101).

[0085] If the WES2 determines that there is a tray Tx to be input into the conveyor buffer system 1 (Yes in step S101), it acquires the ID information of the tray Tx and instructs the barcode reader 13 of the conveyor buffer system 1 to read the ID information and sorting destination information of the tray Tx (step S102).On the other hand, if it determines that there is no tray Tx to be input into the conveyor buffer system 1 (No in step S101), the WES2 continues to determine whether there is a tray Tx to be input into the conveyor buffer system 1.

[0086] The barcode reader 13 of the conveyor buffer system 1 reads the ID information and sorting destination information of the tray Tx and transmits it to the WES2 (step S103). The WES2 acquires the ID information of the tray Tx from the barcode reader 13. At the same time, the WES2 acquires the sorting destination information associated with all the trays Tx from the upper system (step S104).

[0087] The WES2 generates a sorting plan based on the acquired ID information and sorting destination information of the tray Tx and the sorting destination information of all trays (step S105), and transmits the generated sorting plan to the palletizing system 3 (step S106) and the AMR system 5 (step S107). In this embodiment, a temporary sorting plan is used until new ID information and sorting destination information of the tray Tx is acquired, and when new ID information and sorting destination information of the tray Tx is acquired, a new sorting plan is generated and updated. However, the generation and updating of the sorting plan can be performed at any time. The updated sorting plan is transmitted to the palletizing system 3 and the AMR system 5 as needed.

[0088] As shown in FIG. 12, the palletizing system server 35 of the palletizing system 3 controls the branch conveyor 30 (step S117), the placement of the palletizer robot 33, etc. (assigns the sorting plan) based on the sorting plan received from the WES 2 (step S118).

[0089] The AMR system server 55 of the AMR system 5 executes control (assignment of the sorting plan) such as the placement of the trolleys 6 using each AMR 50 based on the sorting plan received from the WES 2 (steps S120 to S122).

[0090] As shown in FIG. 11, the WES 2 instructs the conveyor buffer system 1 to select the buffer conveyor 10 to which the tray Tx should be sent in accordance with the generated sorting plan (step S108).

[0091] The conveyor buffer system server 15, in accordance with the instruction from the WES 2, controls the tray Tx to be guided to the corresponding buffer conveyor 102 (step S109).

[0092] As shown in FIG. 12, the WES 2 determines whether the sorting destination (destination) of the tray Tx is to be output to the palletizing system 3 (step S110).

[0093] If WES2 determines that the sorting destination (destination) of the tray Tx is to be output to the palletizing system 3 (Yes in step S110), it sends an instruction to the conveyor buffer system 1 to output the tray Tx from the output conveyor 105 to the palletizing system 3 (step S111).

[0094] On the other hand, if WES2 determines that the sorting destination (destination) of the tray Tx is not to be output to the palletizing system 3 (No in step S110), it guides the tray Tx onto the recycle conveyor 103 to the conveyor buffer system 1 (step S112), and then sends an instruction to output the tray Tx on the recycle conveyor 103 to the buffer conveyor 102 (step S113).

[0095] The conveyor buffer system 1 controls the buffer conveyor 102, output conveyor 105, etc. in accordance with the instruction received from the WES 2, and outputs the tray Tx to the output point XE to the palletizing system 3 (step S114).

[0096] The conveyor buffer system 1 controls the buffer conveyor 102, the output side branching module 104b, etc. in accordance with the instruction received from the WES 2, and outputs the tray Tx to the recycle conveyor 103 (step S115).

[0097] The conveyor buffer system 1 controls the recycle conveyor 103, the input conveyor 101, and the input-side branching module 104a in accordance with the instruction received from the WES 2, and outputs the tray Tx to the buffer conveyor 102 (step S116).

[0098] The branching conveyor 30 of the palletizing system 3 performs branching control to transport the tray Tx received from the conveyor buffer system 1 to the corresponding palletizer robot 33 (step S117).

[0099] The palletizer robot 33 of the palletizing system 3 performs palletizing using the tray Tx transported by the branch conveyor 30 and the corresponding trolley 6 (step S118).

[0100] The palletizer robot 33 of the palletizing system 3 determines whether the planned number of pallets has been completed (step S119), and if it determines that the planned number of pallets has been completed (Yes in step S119), it completes palletizing of the trays Tx related to the sorting destination trolley 6. On the other hand, the palletizer robot 33 of the palletizing system 3 determines whether the planned number of pallets has been completed (step S119), and if it determines that the planned number of pallets has not been completed (No in step S119), it does not complete palletizing of the trays Tx related to the sorting destination trolley 6.

[0101] The AMR system 5 uses the AMR 50 to obtain the necessary trolleys 6 from the trolley placement area 7 according to the sorting plan (step S120).

[0102] The AMR system 5 transports the trolley 6 acquired from the trolley placement area 7 to a predetermined position in the palletizing system 3 by the AMR 50 (step S121), and places the trolley 6 (step S122).

[0103] The AMR system 5 acquires the trolley 6 for which the AMR 50 has determined that the planned number of pallets has been completed (step S123). As shown in Figure 13, the AMR system 5 transports the trolley 6 from a predetermined position in the palletizing system 3 to the trolley placement area 7 (step S124) and places it there (step S125).

[0104] 13, the WES2 determines whether palletizing has been completed for all trays Tx (step S126). If it determines that palletizing has not been completed for all trays Tx (No in step S126), the WES2 repeats the processing of steps S101 to S125 based on the corresponding sorting destination for newly input trays Tx. On the other hand, if it determines that palletizing has been completed for all trays Tx (Yes in step S126), the WES2 sends instructions to the AMR system 5 to move and place all trolleys.

[0105] In response to the instruction from the WES 2, the AMR system 5 executes the movement and placement of all the trolleys by the AMR 50 (step S127).

[0106] The AMR system 5 determines whether the movement and placement of all trolleys has been completed (step S128). If the AMR system 5 determines that the movement and placement of all trolleys has not been completed (No in step S128), it continues to move and place the trolleys. On the other hand, if the AMR system 5 determines that the movement and placement of all trolleys has been completed (Yes in step S128), it outputs a completion notification to the WES2.

[0107] In response to the completion notification from the AMR system 5, the WES 2 outputs a completion notification indicating that the sorting process for all trays Tx has been completed (step S129).

[0108] As described above, the conveyor buffer system 1 according to the embodiment includes the buffer conveyor 10 and the conveyor buffer system server 15 that controls the buffer conveyor 10. The conveyor buffer system server 15 causes the buffer conveyor 10 to sort trays corresponding to at least one priority sorting destination from among multiple trays Tx corresponding to multiple sorting destinations. The conveyor buffer system server 15 causes the buffer conveyor 10 to buffer trays corresponding to destinations other than the priority sorting destinations among the multiple trays Tx. The conveyor buffer system server 15 causes the buffer conveyor 10 to output the sorted trays corresponding to the priority sorting destinations to the downstream palletizing system 3.

[0109] According to the conveyor buffer system 1 of the embodiment, trays corresponding to priority sorting destinations are sorted and automatically output preferentially, so all that is required is to place the trolley corresponding to the priority sorting destination in the downstream palletizing system 3. Furthermore, after all trays Tx corresponding to a priority sorting destination have been output to the palletizing system 3, a new priority sorting destination can be set and similar sorting and buffering processes can be performed to sort trays for a different sorting destination. Therefore, there is no need to place trolleys corresponding to all sorting destinations in the downstream palletizing system 3, and there is no need to store multiple trays sorted by destination. As a result, the sorting system S can be optimally configured and controlled to suit the expected input targets and specifications.

[0110] Also, overall, it is possible to realize a space-saving sorting system S with high cost efficiency and processing performance. Furthermore, if many trolleys can be placed in the palletizing system 3 depending on the space of the warehouse, etc., it is also possible to increase the number of priority sorting destinations according to the number of trolleys that can be placed. Therefore, it is possible to realize a system that can expand the sorting destinations without limit and achieve short processing times.

[0111] (Variation 1) In the above embodiment, the objects to be sorted are trays, but the objects to be sorted may be packages (cardboard boxes) or the like.

[0112] (Variation 2) In the above embodiment, an automated sorting system S is exemplified by combining the conveyor buffer system 1, the palletizing system 3, and the AMR system 5. However, for example, the automatic processing in the palletizing system 3 may be replaced by manual processing (including processing using a forklift). That is, the work of palletizing the trays Tx carried out from the conveyor buffer system 1 onto the trolleys 6 may be performed manually. Furthermore, the automatic processing in the AMR system 5 may be replaced by manual processing. That is, after the trays Tx have been palletized onto the trolleys 6, the work of discharging (delivering) the trolleys 6 to a predetermined position may be performed manually. Furthermore, the work of placing the next trolley 6 (empty trolley 6) at a predetermined position may be performed manually.

[0113] (Variation 3) In the above embodiment, an example is given in which the sorted trays Tx are palletized onto the trolleys 6. The objects onto which the sorted trays Tx are palletized are not limited to trolleys, and for example, pallets or the like can also be used.

[0114] The information processing described in each of the above embodiments can also be realized by a program executable by a computer. That is, it is possible to store a program that realizes the transmission method described in each of the above embodiments in a memory, read the program from the memory using a processing circuit of a computer, and configure the transmission system or transmission method described in each of the above embodiments by using software and hardware resources in cooperation with each other.

[0115] Although several embodiments (and variations) of the present invention have been described above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be embodied in various other forms, and various omissions, substitutions, modifications, and combinations can be made without departing from the spirit of the invention. These embodiments and variations thereof are included within the scope and spirit of the invention, and are also included in the inventions and their equivalents as defined in the claims. [Explanation of symbols]

[0116] 1. Conveyor buffer system 2 WES 3 Palletizing System 5. AMR system 6. Trolley 10 Buffer Conveyor 11 Elevator 13 Barcode reader 20 processors 21 Main memory 23 Auxiliary storage device 25 Communication Interface 27 Device Interface 30 Branch Conveyor 33 Palletizer robot 50 AMR 101 Input conveyor 102 Buffer Conveyor 103 Recycling Conveyor 104a Input branch module 104b Output branch module 105 Output Conveyor 106 Stopper 200 Acquisition Department 202 Sorting Plan Generation Unit 204 Sorting control unit

Claims

1. a buffer conveyor and a server that controls the buffer conveyor; The server may provide the buffer conveyor with: sorting trays corresponding to at least one priority sorting destination from a plurality of trays corresponding to a plurality of sorting destinations; Among the plurality of trays, the trays corresponding to sorting destinations other than the priority sorting destination are buffered; outputting the trays corresponding to the prioritized sorting destinations to a subsequent stage; Conveyor buffer system.

2. The server After all of the trays corresponding to at least one of the priority sorting destinations among the plurality of trays have been output to the subsequent stage, a new priority sorting destination is set; causing the buffer conveyor to sort trays corresponding to the new priority sorting destination; causing the buffer conveyor to buffer trays corresponding to sorting destinations other than the new priority sorting destination among the plurality of trays; outputting the tray corresponding to the new sorted priority sorting destination to the subsequent stage; 2. The conveyor buffer system of claim 1.

3. The buffer conveyor a first conveyor that inputs the plurality of trays to the plurality of sorting destinations in no particular order and is capable of moving the trays in both directions; a second conveyor that outputs the tray to the subsequent stage and is capable of moving the tray in both directions; at least one third conveyor capable of moving the trays from the first conveyor to the second conveyor; at least one fourth conveyor movable from the second conveyor to the first conveyor; and the server controls the first conveyor, the second conveyor, the third conveyor, and the fourth conveyor to output the trays corresponding to the priority sorting destination to the second conveyor and buffer the trays corresponding to destinations other than the priority sorting destination to the third conveyor; 3. The conveyor buffer system according to claim 1 or 2.

4. the buffer conveyor has at least one stopper that stops the movement of the tray from the third conveyor to the second conveyor; the server controls the movement of the tray from at least one of the third conveyors to the second conveyor using the stopper; 4. The conveyor buffer system of claim 3.

5. The conveyor buffer system has a server as a computer. The buffer conveyor of the conveyor buffer system has a function of sorting trays corresponding to at least one priority sorting destination from a plurality of trays corresponding to a plurality of sorting destinations; The buffer conveyor has a function of buffering trays corresponding to sorting destinations other than the priority sorting destination among the plurality of trays; a function of the buffer conveyor outputting the trays corresponding to the sorted priority sorting destinations to a subsequent stage; A control program for a conveyor buffer system that achieves the above.

6. A control method for a conveyor buffer system including a buffer conveyor and a server that controls the buffer conveyor, comprising: the server causes the buffer conveyor to sort trays corresponding to at least one priority sorting destination from a plurality of trays corresponding to a plurality of sorting destinations; the server causes the buffer conveyor to buffer the trays corresponding to sorting destinations other than the priority sorting destinations among the plurality of trays; causing the buffer conveyor to output the trays corresponding to the prioritized sorting destinations to a subsequent stage; Control method.

7. A conveyor buffer system including a buffer conveyor and a server for controlling the buffer conveyor, sorting trays corresponding to at least one priority sorting destination from a plurality of trays corresponding to a plurality of sorting destinations; Among the plurality of trays, the trays corresponding to sorting destinations other than the priority sorting destination are buffered; outputting the trays corresponding to the prioritized sorting destinations to a subsequent stage; Information processing device.

8. A sorting system including at least a conveyor buffer system and a palletizing system, The conveyor buffer system includes: sorting trays corresponding to at least one priority sorting destination from a plurality of trays corresponding to a plurality of sorting destinations; buffering the trays corresponding to sorting destinations other than the priority sorting destinations among the plurality of trays; outputting the trays corresponding to the sorted priority sorting destinations to the palletizing system; The palletizing system palletizes the trays output from the conveyor buffer system onto trolleys corresponding to the sorted priority sorting destinations. Sorting system.

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