Automated warehouse system

Abstract

To provide an automated warehouse system which achieves reduction of costs and improves storage case transport efficiency by using automated guided vehicles capable of traveling at high speed to perform picking work reliably and quickly.SOLUTION: An automated warehouse system comprises: a plurality of racks 10; automated guided vehicles 20 for transferring and transporting the storage cases C; first travel paths 30; second travel paths 40; lifting devices 50 that transport the automated guided vehicles or the storage cases delivered from the automated guided vehicles to another level in a vertical direction; and work stations 60 at which picking work or warehousing work is performed. The work station has: a storage case passing / reception location 31 into which the automated guided vehicles can enter; and side conveyors 61a, 61b that are adjacent to the storage case passing / reception location, extend in a direction that is a direction away from the storage case passing / reception location and is parallel to a direction in which the storage case passing / reception location and the lifting device are arranged, and transport the storage cases delivered from the automated guided vehicles or the lifting device.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an automated warehouse system that saves space, improves the efficiency of transporting storage cases using an automated traveling robot, and enables picking work to be performed reliably and quickly. [Background technology]

[0002] In the past, various robots have been introduced to improve productivity in logistics warehouses and to alleviate labor shortages, leading to increased automation. For example, automated warehouse systems that use automated guided vehicles (AGVs) to pick and transport items are well known.

[0003] A conventional automated warehouse system has a storage area for storing a large number of items, a picking area for picking specified items from the storage area based on a picking list, a conveyor area for transporting the picked items to a collection area, a collection area for waiting items included in multiple picking lists until picking is complete, and a packing area for packing after picking is complete.For example, a distribution center has been proposed in which items are removed from cases and stored by type, and the items are picked and shipped according to shipping requests from delivery destinations (Patent Document 1).

[0004] The distribution center described in Patent Document 1 has an input area, an output area, a picking area for picking items from cases into transport containers, a collection area for collecting items from transport containers into boxes, and a box warehouse for storing boxes. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Laid-Open No. 2002-154620 Summary of the Invention [Problem to be solved by the invention]

[0006] However, the conventional automated warehouse system described above requires a large number of conveyors, which makes it expensive and increases the installation costs.

[0007] Furthermore, the conventional automated warehouse system described above has the problem of wasting storage space due to the large number of conveyors.

[0008] Furthermore, the conventional automated warehouse systems described above have separate storage areas, picking areas, conveyor areas, collection areas, and packaging areas, which means that loading and unloading takes time, resulting in poor work efficiency.

[0009] Therefore, an object of the present invention is to provide an automated warehouse system that is low cost, improves the efficiency of transporting storage cases by using an automated robot capable of high speed travel, and can perform picking operations reliably and quickly. [Means for solving the problem]

[0010] To achieve this object, an automated warehouse system includes a plurality of racks that extend in a first direction on a horizontal plane so that a plurality of storage cases can be arranged, have a plurality of floors in the vertical direction, and are arranged parallel to one another; an automated traveling robot that transfers and transports the storage cases; a plurality of first travel paths that extend in the first direction between the plurality of racks and are travelable by the automated traveling robot; at least one second travel path that is connected to the first travel paths and extends in a second direction on the horizontal plane perpendicular to the first direction and is travelable by the automated traveling robot; and at least one lifting device that is connected to the first travel path or the second travel path and transports the automated traveling robot or the storage case handed over from the automated traveling robot to another floor in the vertical direction. and a work station that is arranged on at least one floor of the plurality of racks and performs picking work to remove specified items from the transported storage cases or warehousing work to store items in the storage cases, wherein the work station is provided adjacent to one end face of the lifting device, has a storage case transfer position that is connected to the first running path or the second running path and into which the automatic traveling robot can enter, and a side conveyor that is adjacent to the storage case transfer position and one side face of the lifting device, is parallel to the direction in which the storage case transfer position and the lifting device are lined up, and extends toward a third direction that is a direction away from the storage case transfer position, and transports the storage cases handed over from the automatic traveling robot or the lifting device.

[0011] According to this configuration, the automated warehouse system has at least one work station located on at least one floor of the multiple racks, where picking work is performed to remove specified items from the transported storage cases or storing work is performed to store items in the storage cases. The work station floor is located at one end of the elevator device and has a storage case transfer position accessible to an automated traveling robot and a side conveyor that allows storage cases to be transferred between the automated traveling robot and the elevator device. This eliminates the need for the automated traveling robot to wait at the station during picking work, minimizing the number of automated traveling robots and conveyors and enabling low-cost implementation. Furthermore, on the station floor, storage cases transported by the automated traveling robot can be transported to the work station without using an elevator, reducing elevator usage. Space can also be saved.

[0012] In any of the above-described automated warehouse systems, it is preferable that the work station has a pair of side conveyors extending on either side of the lifting device, and an end conveyor extending in a fourth direction perpendicular to the third direction at the other end opposite the storage case transfer position of the lifting device, connecting the pair of side conveyors and transporting the storage cases.

[0013] According to the automated warehouse system of this configuration, by having a pair of side conveyors on both sides of the storage case transfer position and the lifting device that can transfer storage cases, and an end conveyor that connects the pair of side conveyors, a path can be secured for the storage cases to return to the rack after the picking operation is completed, and the transport of the next storage case will not be obstructed.

[0014] In any of the above-described automated warehouse systems, it is preferable that the work station has a retention conveyor adjacent to the end conveyor for temporarily retaining the storage cases, and that the end conveyor and the retention conveyor are composed of conveyors capable of transporting the storage cases in the third direction and the fourth direction.

[0015] According to the automated warehouse system having this configuration, by providing a retention conveyor that is attached to the end conveyor and on which storage cases are temporarily stored, the end conveyor transports the storage cases in order, and multiple storage cases can be placed in the picking area in order, which has the advantage of increasing the variety of items (products) that can be picked simultaneously.In addition, because the storage cases can be temporarily stored on the retention conveyor, multiple pickings can be made from the storage cases while they are temporarily stored.

[0016] An automated warehouse system for achieving this object includes a plurality of racks that are extended in a first direction on a horizontal plane so that a plurality of storage cases can be arranged, have a plurality of floors in the vertical direction, and are arranged parallel to one another; an automated traveling robot that transfers and transports the storage cases; a plurality of first travel paths that are extended in the first direction between the plurality of racks and along which the automated traveling robot can travel; at least one second travel path that is connected to the first travel path and extends in a second direction on the horizontal plane perpendicular to the first direction and along which the automated traveling robot can travel; at least one lifting device that is connected to the first travel path or the second travel path and transports the automated traveling robot or the storage case handed over from the automated traveling robot to another floor in the vertical direction; The system is characterized by comprising a work station arranged on one floor and performing picking work to remove specified items from the transported storage cases or warehousing work to store items in the storage cases, the work station having a mobile body, a storage case transfer position arranged adjacent to one end face of the lifting device and connected to the first running path or the second running path so that the automatic traveling robot can enter, and a lateral transport path adjacent to the storage case transfer position and one side face of the lifting device, parallel to the direction in which the storage case transfer position and the lifting device are lined up and extending toward a third direction away from the storage case transfer position, capable of storing the storage case handed over from the automatic traveling robot or the lifting device, and along which the mobile body can move even when the storage case is stored.

[0017] According to this configuration, the automated warehouse system has at least one work station located on at least one floor of the multiple racks, where picking work is performed to remove specified items from the transported storage cases or storing work is performed to store items in the storage cases. The work station floor is equipped with a mobile body and an elevator device, a storage case transfer position that an automated traveling robot can enter, and a side transport path that allows storage cases to be transferred between the automated traveling robot and the elevator device. This eliminates the need for the automated traveling robot and the mobile body to wait at the station during picking work, minimizing the number of automated traveling robots and mobile bodies and enabling low-cost implementation. Furthermore, on the station floor, storage cases transported by the automated traveling robot can be transported to the work station without using an elevator, reducing elevator usage. This also saves space.

[0018] In any of the above-described automated warehouse systems, it is preferable that the work station is composed of a pair of side conveying paths extending on either side of the lifting device, and an end conveying path that extends in a fourth direction perpendicular to the third direction at the other end opposite the storage case transfer position of the lifting device, connects the pair of side conveying paths, allows the storage cases to remain, and allows the movable body to move even when the storage cases are retained.

[0019] According to the automated warehouse system of this configuration, by having a pair of side conveying paths and end conveying paths on both sides of the storage case transfer position and the lifting device, which allow the transfer of storage cases, a path can be secured for the storage cases to return to the rack after the picking operation is completed, and the transfer of the next storage case will not be obstructed.

[0020] In any of the above-described automated warehouse systems, it is preferable that the work station is located adjacent to the end conveying path and has a retention conveying path for temporarily storing the storage cases, and that the end conveying path and the retention conveying path are composed of conveying paths along which a movable body can move in the third direction and the fourth direction.

[0021] According to the automated warehouse system having this configuration, by providing a retention conveyance path that is arranged next to the end conveyance path and that allows the storage cases to temporarily stay, and that allows the moving body to move even when the storage cases are retained, the storage cases can be conveyed in order to the end conveyance path and multiple storage cases can be placed in order in the picking area, which has the advantage of increasing the variety of items (products) that can be picked simultaneously.In addition, by providing a retention conveyance path, the storage cases can be temporarily retained, and therefore multiple pickings can be made from the storage cases while they are temporarily retained.

[0022] In any of the above-described automated warehouse systems, it is preferable that a floor different from the work station has a running path that is connected to the first running path or the second running path, adjacent to at least one side of the lifting device, and on which the automated traveling robot can travel.

[0023] According to the automated warehouse system of this configuration, on floors different from the work stations, there is a running path adjacent to at least one side of the lifting device, so that the automated traveling robot can use the running path to transport storage cases.

[0024] In any of the above-described automated warehouse systems, it is preferable that on a floor different from the work station, there are a pair of running paths extending on either side of the lifting device, and an end running path extending in a second direction perpendicular to the first direction at the other end opposite the storage case transfer position of the lifting device to connect the running paths, and on which the automated traveling robot can travel.

[0025] According to an automated warehouse system of this configuration, on floors different from the work stations, there is an end running path that connects a pair of running paths that are extended across an elevator device, so that the automated robots can use the end running path as a detour, and even if there are multiple automated robots on the same floor, they can avoid congestion and transport storage cases.

[0026] Any of the above-described automated warehouse systems further includes a control unit that controls the automatically traveling robot, the lifting device, and the side conveyor, the end conveyor, and the retention conveyor or the moving body of the work station, and the control unit controls the automatically traveling robot or the lifting device to unload the storage case transported from the rack onto one of the side conveyors or the side transport path based on a designated picking list, transport the storage case to the end conveyor or the end transport path by the one of the side conveyors or the side transport path, and control the end conveyor or the It is preferable to transport the storage case from one end of the end conveying path to the other end, while temporarily retaining a specified storage case on the retention conveyor or the retention conveying path, and transporting the storage case for which picking work has been completed on the end conveyor or the end conveying path and / or the retention conveyor or the retention conveying path from the other end of the end conveyor or the end conveying path to the other side conveyor or the side conveying path, and then placing the storage case from the other side conveyor or the side conveying path onto the automatic traveling robot or the lifting device and returning it to the rack.

[0027] This automated warehouse system can efficiently control the entire robot system and increase the flexibility to execute specific tasks. It can also adjust the robot's behavior in real time, performing appropriate actions depending on the environment and situation. It can also improve the safety and reliability of the robot. It processes sensor data and external commands and controls motors and actuators. This allows the robot to accurately achieve its goals and adapt to its surroundings. [Effects of the Invention]

[0028] This eliminates the need for the autonomous robot to wait at the station during picking work, minimizing the number of autonomous robots and conveyors / moving objects, and allows for low-cost implementation. It also saves space and enables efficient retrieval and storage. [Brief explanation of the drawings]

[0029] [Figure 1] 1 is a perspective view showing a schematic configuration of an automated warehouse system according to one embodiment. FIG. [Figure 2] FIG. 2 is a plan view schematically illustrating an example of the configuration of a work station floor in the automated warehouse system. [Figure 3] FIG. 1 is a plan view schematically illustrating an example of the configuration of a floor different from the work station floor in an automated warehouse system. [Figure 4] FIG. 1 is a perspective view schematically illustrating an example of the configuration of an automatic traveling robot, and a first traveling path and a second traveling path in an automatic warehouse system. [Figure 5] FIG. 2 is a block diagram illustrating an example of the configuration of a control unit in the automated warehouse system. [Figure 6] FIG. 1 is a diagram for explaining the flow of warehousing in an automated warehouse system, and is a plan view showing a case where the storage location of the container is on the work station floor. [Figure 7A] FIG. 1 is a diagram for explaining the flow of warehousing in an automated warehouse system, and is a plan view showing a case (part 1) where the storage position of the container is not on the work station floor. [Figure 7B] FIG. 10 is a diagram for explaining the flow of warehousing in the automated warehouse system, and is a plan view showing a case (part 2) in which the storage position of the container is not on the work station floor. [Figure 8] FIG. 1 is a diagram for explaining the flow of retrieval in an automated warehouse system, and is a plan view showing a case where the storage position of the container is on the work station floor. [Figure 9A] FIG. 1 is a diagram for explaining the flow of retrieval in an automated warehouse system, and is a plan view showing a case (part 1) where the storage position of the container is not on the work station floor. [Figure 9B] FIG. 10 is a diagram for explaining the flow of retrieval in the automated warehouse system, and is a plan view showing a case (part 2) in which the storage position of the container is not on the work station floor. [Figure 10] FIG. 10 is a diagram for explaining a modified example (part 1) of the automated warehouse system, and is a plan view showing the configuration of the work station floor. [Figure 11] FIG. 10 is a diagram for explaining a modified example (part 2) of the automated warehouse system, and is a plan view showing the configuration of a floor different from the work station floor. [Figure 12] FIG. 10 is a diagram for explaining a modified example (third example) of the automated warehouse system, and is a plan view showing the configuration of the work station floor. [Figure 13] FIG. 10 is a diagram for explaining a fourth modified example of the automated warehouse system, and is a plan view showing the configuration of the work station floor. [Figure 14] FIG. 10 is a diagram for explaining a modified example (No. 5) of the automated warehouse system, and is a plan view showing the configuration of the work station floor. DETAILED DESCRIPTION OF THE INVENTION

[0030] Hereinafter, an embodiment of an automated warehouse system will be described with reference to the drawings.

[0031] As shown in FIGS. 1 to 5, the automated warehouse system 100 includes a plurality of racks 10 that are extended in a first direction on a horizontal plane (front-rear direction in FIGS. 2 and 3) so that a plurality of containers C (corresponding to "storage cases") can be placed thereon, have a plurality of floors in the vertical direction, and are arranged parallel to one another; an automatic guided vehicle (AGV) 20 that transfers and transports the containers C; a plurality of first travel paths 30 that are extended in the first direction between the plurality of racks 10 and along which the automatic guided robots 20 can travel; at least one second travel path 40 that is extended in a second direction on the horizontal plane orthogonal to the first direction (left-right direction in FIGS. 2 and 3) and along which the automatic guided robots 20 can travel; and a plurality of second travel paths 40 that are connected to the first travel path or the second travel path and that are used to transport the automatic guided robots or the containers handed over from the automatic guided robots. The system is equipped with at least one lifting device 50 that transports the containers C up or down to other floors, a work station 60 that is arranged on any floor of the plurality of racks 10 and performs a picking operation of removing specified items from the transported containers C or a warehousing operation of storing the items in the containers C, a packing line 70 that transports cardboard boxes CB (corresponding to "shipping boxes") according to a picking list specified by transport conveyors 70a, 70b to the vicinity of the work station 60, directly loads the items picked from the containers C transported to the work station 60, and then seals them, and a control unit 80 that controls the automatic traveling robot 20, the lifting device 50, a pair of side conveyors 61a, 61b, an end conveyor 62a, and a retention conveyor 62b of the work station 60, and the packing line 70.

[0032] In this embodiment, there are provided two work stations 60. One of them can be used as a work station for receiving goods, and the other can be used as a work station for retrieving goods.

[0033] The racks 10 are storage areas in the warehouse where a large number of containers C serving as storage cases for accommodating items are stored. The racks 10 are arranged in a first direction (front-to-back direction in FIGS. 2 and 3) on a horizontal plane so that the containers C can be placed therein. The racks 10 also have multiple floors in the vertical direction (height direction). The racks 10 are arranged in multiple parallel rows spaced at predetermined intervals. A first travel path 30 is provided between the rows. The length, number of floors, and number of rows of the racks 10 can be increased as needed. In this embodiment, the containers C have optically readable identification codes (e.g., barcodes or QR codes (registered trademark)) affixed to four side surfaces. The identification codes of the containers C are linked to the items stored therein. Cardboard boxes or the like may also be used as storage cases.

[0034] The autonomous traveling robot 20 loads and unloads a container C from a rack 10, and transports it between the rack 10 and a work station 60 on a work station floor, or between the rack 10 and an elevator 50 on a floor other than the work station floor. As shown in FIG. 4 , the autonomous traveling robot 20 includes a travel unit 21, a transfer unit 22, and a control means 23. The travel unit 21 includes wheels for the autonomous traveling robot 20 to travel in a first direction, wheels for the autonomous traveling robot 20 to travel in a second direction, drive motors for driving these wheels, and a switching mechanism for switching the travel wheels to change the travel direction. The transfer unit 22 transfers the container C between the autonomous traveling robot 20 and the rack 10 and between the autonomous traveling robot 20 and the elevator 50. The transfer unit 22 includes an arm mechanism for moving the container C, a drive motor for driving the arm mechanism, and the like. The control means 23 includes a CPU (Central Processing Unit) and controls the travel unit 21 to control the movement of the autonomous traveling robot 20, and also controls the transfer unit 22 to control the transfer of the container C. The control means 23 also includes a communication I / F and can communicate wirelessly with the control unit 80. The control means 23 is configured to receive control signals output from the control unit 80 and control the travel unit 21 and the transfer unit 22 based on the control signals. This allows the autonomous traveling robot 20 to travel at high speeds. Furthermore, accurate arrival times can be controlled based on an algorithm, and multiple autonomous traveling robots 20 can operate cooperatively based on the algorithm. Each floor of the multiple racks 10 is provided with a charging station for charging the batteries installed in the autonomous traveling robots 20.

[0035] The first running path 30 extends in a first direction (front-to-back direction in FIGS. 2 and 3) between two rows of racks 10, and is configured to allow the autonomous traveling robot 20 to travel along it. Two rows of racks 10 are provided between the two first running paths 30. The first running path 30 (the front end in the front-to-back direction in FIGS. 2 and 3) is connected to the second running path 40. The autonomous traveling robot 20 can travel freely between the first running path 30 and the second running path 40 and change direction.

[0036] The second travel path 40 extends in a second direction (left-right direction in FIGS. 2 and 3 ) perpendicular to the first direction on a horizontal plane, and is configured to allow the autonomous traveling robot 20 to travel on it. As shown in FIGS. 2 and 3 , this second travel path 40 is connected to multiple first travel paths 30, and is connected to a container transfer position 31 (corresponding to the "storage case transfer position") on the work station floor, and is connected to a pair of side travel paths 31 a, 31 b on floors other than the work station floor. In this embodiment, two second travel paths 40 are provided between multiple racks 10 and the lifting device 50. This allows multiple autonomous traveling robots 20 to transport containers C without congestion when multiple racks 10 (i.e., a storage area of ​​a warehouse) are placed on the same floor.

[0037] The number of second travel paths 40 is not particularly limited and may be set appropriately as needed. For example, when one autonomous traveling robot 20 is placed on the same floor as multiple racks 10, one second travel path 40 may be provided between the multiple racks 10 and the lifting device 50. Furthermore, the position of the second travel path 40 is not limited to between the multiple racks 10 and the lifting device 50.

[0038] The lifting device 50 is provided (at the front end side in the fore-and-aft direction in Figures 2 and 3) so as to be connected to the first travel path 30 or the second travel path 40. This lifting device 50 is configured to transport in the vertical direction a container C handed over from one of the pair of side conveyors 61a, 61b on a work station floor and hand it over to the automatic traveling robot 20 at a designated floor, and also to load a container C unloaded from the automatic traveling robot 20 on a floor other than the work station floor, move it in the vertical direction (height direction), and transport it to the work station floor. In addition, the lifting device 50 can move in the vertical direction at high speed.

[0039] The loading platform of the lifting device 50 is provided with a discharge conveyor 51 for transferring the placed container C to one of the pair of side conveyors 61a, 61b. Note that the discharge means of the lifting device 50 is not limited to a conveyor. Furthermore, the discharge means does not have to be a part of the lifting device.

[0040] On floors other than the work station floor, a pair of lateral running paths 31a, 31b are provided on both sides of the lifting device 50, extending in a first direction (front-to-back direction in Figure 3), on which the automatic traveling robot 20 can run, allowing the automatic traveling robot 20 to reach either side of the lifting device 50 and transfer the container C between it and the lifting device 50.

[0041] Furthermore, on floors other than the work station floors, an end travel path 41 is provided that extends in a second direction (left and right direction in FIG. 3 ) in front of the lifting device 50 and is connected to the pair of side travel paths 31a, 31b. As a result, when multiple autonomous traveling robots 20 are provided on the same floor, if the autonomous traveling robot 20 that first reaches the lifting device 50 is detoured from the side travel path 31a or 31b to the end travel path 41, there is no need to turn back along the route it has taken, and the next autonomous traveling robot 20 can follow and arrive at the lifting device 50 from the side travel path 31a or 31b. In other words, on floors other than the work station floors, the autonomous traveling robot 20 can use the end travel path 41, allowing the container C to be transported without congestion.

[0042] The work station 60 is arranged on one of the floors (for example, the first floor) of the multiple racks 10, and is used for picking work to remove specified items from transported containers C, or for warehousing work to store items in containers C. The work station 60 has a container transfer position 31 (corresponding to the "storage case transfer position") into which the autonomous traveling robot 20 can enter. On both sides (on both sides in the left-right direction in FIG. 2) of the container transfer position 31 and the lifting device 50, the work station 60 has a pair of side conveyors 61a, 61b that extend in a third direction (in this embodiment, the same direction as the first direction, i.e., the front-to-rear direction in FIG. 2) and can transfer containers C between the autonomous traveling robot 20 and the lifting device 50. The work station 60 also includes an end conveyor 62a connected to the pair of side conveyors 61a, 61b and extending in a fourth direction (the same direction as the second direction, i.e., the left-right direction in FIG. 2) in front of the lifting device 50 (front in the front-rear direction in FIG. 2), and a retention conveyor 62b (end conveyor) provided alongside the end conveyor 62a for temporarily retaining containers C. That is, as shown in FIG. 2, the end conveyor in the work station 60 is composed of a combination of two rows (horizontal) and three columns (vertical) of right-angle transfer conveyor units. In the work station 60, the inner end conveyor 62a transports containers C sequentially in the first or second direction. In this way, by providing the end conveyor 62a, multiple containers C can be sequentially placed in the picking area from one end, and containers C that have been picked can be moved from the other end back to the side conveyor 61a or 61b. The outer retention conveyor 62b is used to temporarily retain containers C transported by the end conveyor 62a. While a container C is temporarily retained, multiple pickings can be performed from that container C. The retention conveyor 62b can temporarily retain up to three containers C. Together with the three containers C continuously transported horizontally by the end conveyor 62a, up to six containers C can be picked, which has the advantage of increasing the variety of items (commodities) that can be picked simultaneously.

[0043] In the work station 60, the pair of side conveyors 61a, 61b are configured such that the portions corresponding to the openings on both sides of the lifting device 50 are roller conveyors capable of moving the container C in a first direction and a second direction (i.e., vertical (front-back) and horizontal (left-right) directions), and the other portions are roller conveyors that move the container C in the first direction (i.e., vertical (front-back) direction). This allows the container C to be placed on the lifting device 50 from the side conveyor 61a or 61b. In the work station 60, the end conveyor 62a and the retention conveyor 62b are roller conveyors that are capable of moving the container C in the first direction and the second direction (i.e., vertical (front-back) and horizontal (left-right) directions). This allows the positions of the containers C on the end conveyor 62a and the retention conveyor 62b to be freely moved and arranged in the picking area of ​​the work station 60 depending on the item (goods) to be picked.

[0044] Furthermore, the end conveyor 62a and the retention conveyor 62b of the work station 60 are provided with a plurality of identification code reading means 63 capable of reading the identification codes of the containers C. This makes it possible to identify the containers C transported to the picking area (end conveyor 62a and retention conveyor 62b) of the work station 60, and to manage the items to be picked, the number of items to be picked, etc. This makes it possible to prevent incorrect picking.

[0045] The packaging line 70 includes conveyors 70a and 70b, a box-making machine 71 that assembles blank sheets for packaging containers and forms cardboard boxes CB as shipping boxes, an identification code issuing device 72 that prints or attaches an identification code (e.g., a barcode or a QR code (registered trademark)) to the side of the cardboard box CB, a plurality of identification code reading means 73 (e.g., a barcode reader or a QR code (registered trademark) reader) that is provided on the conveyor 70a and that reads the identification code of the CB, and a plurality of identification code reading means 73 that is provided above the conveyor 70a near the work station 60. The packaging line 70 is equipped with a plurality of openable and closable flaps 74 that close or open at least a portion of the openings of the plurality of cardboard boxes CB to indicate the cardboard boxes CB that will contain picked items for the plurality of cardboard boxes CB that have been transported, a plurality of information display means 75 that display information related to the cardboard boxes CB below each of the plurality of flaps 74, a delivery note printer 76, a sealing machine 77 that seals the cardboard boxes CB after the picked items have been loaded into them, and an automatic shipping labeler 78 that creates shipping labels and attaches them to the sealed cardboard boxes CB. In the packaging line 70, the transport conveyor 70a is a supply conveyor that supplies the cardboard boxes CB to a plurality of sorting positions L1 near the work stations 60, and the transport conveyor 70b is an unloading conveyor that transports the cardboard boxes CB to the sealing machine 77.

[0046] The transport conveyor 70b is provided adjacent to the multiple sorting positions L1 of the transport conveyor 70a and has an evacuation conveyor L2 for temporarily evacuating cardboard boxes CB discharged from one of the multiple sorting positions L1. This evacuation conveyor L2 is composed of a combination of multiple right-angle transfer conveyor units and is configured to return cardboard boxes CB discharged from the sorting position L1 to one of the multiple sorting positions L1 of the transport conveyor 70a as needed. In this case, the conveyors for the multiple sorting positions L1 are composed of a combination of multiple right-angle transfer conveyor units. The conveyor for the sorting position L1 can transfer the cardboard boxes CB to the evacuation conveyor L2, and the evacuation conveyor L2 can transfer the cardboard boxes CB to the sorting position L1. The evacuation conveyor L2, which is part of the transport conveyor 70b, can transport cardboard boxes CB that have been sorted to the sealing machine 77.

[0047] The control unit 80 controls the overall operation of the automated warehouse system 100. As shown in Fig. 5, the control unit 80 includes a receiving unit 81, an input unit 82, an output means 83, a data bus 84, a storage unit 85, and a processing unit 86.

[0048] The receiving unit 81 is configured to receive detection signals from the identification code reading means 63, 73 of the work station 60 and the packaging line 70, and from the sensors S of each unit, via a wired or wireless communication network. Various data acquired by this receiving unit 81 is stored in a storage unit 85.

[0049] The input unit 82 comprises a keyboard, a touch panel, or identification code reading means (for example, a barcode reader or a QR code (registered trademark) reader), and is used to input registration information such as stored items and delivery destinations, processing operation start commands, and other necessary information. For example, on the packaging line 70, if a cardboard box for packaging cannot be produced due to a malfunction of the box former 71, or if the cardboard box does not fit an item of a specified size, it is possible to manually assemble a cardboard box CB, attach a QR code (registered trademark), and input information about this cardboard box CB using the QR code (registered trademark) reading means.

[0050] The output means 83 constitutes the transmitting unit of this embodiment, and is configured to transmit output signals such as various controls processed in the control unit 80 to the automatic traveling robot 20, the lifting device 50, the pair of side conveyors 61a, 61b, the end conveyor 62a and the retention conveyor 62b, and the packaging line 70 via a wired or wireless communication network.

[0051] The data bus 84 is connected between the receiving unit 81, the input unit 82, the output means 83, the data bus 84, the storage unit 85 and the processing unit 86, and is provided to enable data transfer among them according to a control program.

[0052] The storage unit 85 is mainly composed of, for example, a hard disk (HDD) and memories such as RAM and ROM. The storage unit 85 has a control program storage unit 85a, a stored item data storage unit 85b, a picking list storage unit 85c, and a shipping destination data storage unit 85d. The control program storage unit 85a stores a program for controlling the operation of the automated warehouse system 100. The stored item data storage unit 85b stores data related to items stored in a large number of containers C arranged on a plurality of racks 10 in the warehouse. The picking list storage unit 85c stores a picking list, which is a shipping instruction. Items to be shipped are picked based on this. The shipping destination data storage unit 85d stores data related to the shipping destination corresponding to each shipping order (picking list). Invoices are created based on this.

[0053] The processing unit 86 is mainly composed of a microcomputer and includes a CPU (Central Processing Unit), which controls the overall operation of the automated warehouse system 100 according to a control program, and which also includes an automated traveling robot control means 86a, an elevator control means 86b, a conveyor control means 86c, a picking management means 86d, a sorting management means 86e, and a packaging line control means 86f, all of which are controlled by this control program. The automated traveling robot control means 86a is configured to generate and transmit control signals to the automated traveling robot 20 in accordance with a storage instruction or a delivery instruction, so as to transport a specified container C to a specified location. The elevator control means 86b receives the container C at a specified floor in accordance with a storage instruction or a delivery instruction, and controls the transport of the delivered container C to a specified destination floor. The conveyor control means 86c is configured to control the pair of side conveyors 61a, 61b, the end conveyor 62a, and the retention conveyor 62b so as to move the container C transported to the work station 60 to the picking position and then move the container C after the picking operation to the elevator device 50 or the container transfer position 31. The picking management means 86d is configured to manage the picking target, the number of items to be picked, etc. The sorting management means 86e is configured to manage the multiple flaps 74 and multiple information display means 75 so as to insert the items picked from the container C into cardboard boxes CB to accommodate them, based on multiple specified picking lists. The packaging line control means 86f is configured to control the operation of the transport conveyors 70a, 70b, the box former 71, the box sealing machine 77, the invoice automatic labeler 78, etc.

[0054] The flow of warehousing in the automated warehouse system 100 will be described below with reference to FIGS. 6, 7A, and 7B.

[0055] Figure 6 shows the flow of receiving goods in the automated warehouse system 100 when the storage location of container C is on the work station floor. Figure 7A shows the flow of receiving goods in the automated warehouse system 100 (part 1) when the storage location of container C is not on the work station floor, and Figure 7B shows the flow of receiving goods in the automated warehouse system 100 (part 2) when the storage location of container C is not on the work station floor. In this embodiment, the work station 60 on the right side in Figures 6 and 7A will be described as the receiving work station.

[0056] (1) If the storage location of container C is on the work station floor, when storing container C, as shown in FIG. 6, picker P (worker or robot) puts an item (goods) into container C. Next, container C is moved from retention conveyor 62b of work station 60 to end conveyor 62a, and then to side conveyor 61a or 61b, and side conveyor 61a or 61b moves container C to the side of container transfer position 31. Next, automatic traveling robot 20 that has arrived at container transfer position 31 receives container C. Next, automatic traveling robot 20 transports container C to the position of the designated rack 10 and lowers it onto rack 10. This completes the storing of container C.

[0057] (2) If the storage location of container C is not on the work station floor, when storing container C, first, as shown in FIG. 7A, picker P puts the item (goods) into container C. Next, the container C is moved from retention conveyor 62b of work station 60 to end conveyor 62a and then to side conveyor 61a or 61b, and then side conveyor 61a or 61b moves container C to one side of lifting device 50. Next, side conveyor 61a or 61b loads container C onto lifting device 50. Next, lifting device 50 transports container C to the floor where the destination location is located.

[0058] 7B, the autonomous traveling robot 20 arrives at the side travel path 31a or 31b on the side of the lifting device 50, removes the container C from the lifting device 50, and places it on the transfer section 22. Next, the autonomous traveling robot 20 transports the container C to the designated position on the rack 10 and unloads it onto the rack 10. This completes the warehousing process.

[0059] The flow of retrieval in the automated warehouse system 100 will be described below with reference to FIGS. 8, 9A, and 9B.

[0060] Figure 8 shows the flow of retrieval in the automated warehouse system 100 when the storage location of container C is on the work station floor. Figure 9A shows the flow of retrieval (part 1) in the automated warehouse system 100 when the storage location of container C is not on the work station floor, and Figure 9B shows the flow of retrieval (part 2) in the automated warehouse system 100 when the storage location of container C is not on the work station floor. In this embodiment, the work station 60 on the left in Figures 8 and 9B will be described as the retrieval work station.

[0061] (1) If the storage location of container C is on the work station floor, when the items (goods) in container C are to be removed from storage, as shown in FIG. 8, the autonomous traveling robot 20 retrieves container C from the designated position on rack 10 and places it on the transfer section 22. Next, the autonomous traveling robot 20 transports container C to container transfer position 31. Next, the autonomous traveling robot 20 hands container C to side conveyor 61a or 61b. Next, side conveyor 61a or 61b transports container C to end conveyor 62a. Next, end conveyor 62a moves container C to retention conveyor 62b (picking position).

[0062] Next, as shown in FIG. 2, an empty cardboard box CB made on the packaging line 70 is transported by the transport conveyor 70a to the vicinity of the work station 60, and a picker P (a worker or a robot) places items (products) picked from a container C into the cardboard box CB. Here, a picking management means 86d manages the picking target, the number of items to be picked, etc. In addition, a sorting management means 86e controls the opening and closing of multiple flaps 74 so that the items picked from the container C are inserted into the cardboard box CB based on multiple specified picking lists, and simultaneously manages the display of information such as the ID of the cardboard box CB and the number of items inserted on the information display means 75. Next, when all the items (products) are collected (i.e., when picking is completed), a delivery note printed from the delivery note printer 76 is inserted into the cardboard box CB, and the cardboard box CB is moved from the transport conveyor 70a to the transport conveyor 70b. Next, the cardboard box CB is transported by the transport conveyor 70b to the sealing machine 77 and packed. Finally, an invoice is created by an invoice auto-labeler 78 and attached to the sealed cardboard box CB, thereby completing the shipping process.

[0063] (2) If the storage location of container C is not the work station floor, when the goods (products) in container C are to be removed, first, as shown in FIG. 9A, automatic traveling robot 20 retrieves container C from the designated position on rack 10 and places it on transfer section 22. Next, automatic traveling robot 20 transports container C to one side (side travel path 31a or 31b) of lifting device 50. Next, automatic traveling robot 20 loads container C onto lifting device 50. Next, lifting device 50 transports container C to the work station floor.

[0064] 9B, the discharge conveyor 51 of the lifting device 50 discharges the container C and hands it over to the side conveyor 61a or 61b. The side conveyor 61a or 61b then transports the container C to the end conveyor 62a. The end conveyor 62a then moves the container C to the retention conveyor 62b (picking position).

[0065] Next, shipping work is carried out on the packaging line 70. Since this is the same as the shipping work described above in (1), a detailed description thereof will be omitted.

[0066] Hereinafter, the picking operation at the time of retrieval in the automated warehouse system 100 will be described with reference to FIG.

[0067] When items (products) are shipped one shipping order at a time, the autonomous traveling robot 20 transports the container C to the work station 60 in the order of the picking list. In this case, the items (products) arrive at the work station 60 in order. At the same time, the packing line 70 places an empty cardboard box CB corresponding to the shipping order near the work station 60 (work position). A picker P (worker or robot) places the items (products) picked from the container C into the cardboard box CB in the order in which they arrived at the work station 60. Once all the items (products) are collected (i.e., once picking is complete), the delivery note printed by the delivery note printer 76 is inserted, and the cardboard box CB is moved from the transport conveyor 70a to the transport conveyor 70b and transported to the box sealing machine 77. Then, by pressing the swap button displayed on the information display means 75, an empty cardboard box CB corresponding to the next shipping order is placed.

[0068] On the other hand, when items (products) for multiple shipping orders are simultaneously shipped out of the warehouse, the autonomous traveling robot 20 transports containers C to the work station 60 in the order of each picking list based on multiple picking lists. At the work station 60, the transported multiple containers C are arranged on a retention conveyor 62b (picking position). At the same time, the packing line 70 places multiple empty cardboard boxes CB corresponding to each shipping order at multiple sorting positions L1 near the work station 60. A picker P (worker or robot) picks items (products) from the container C and places them in the corresponding cardboard box CB in accordance with instructions from the picking management means 86d. A delivery note printed from the delivery note printer 76 is placed in the cardboard box CB once it has collected all the items (products) (i.e., picking has been completed), and the cardboard box CB is moved from the transport conveyor 70a to the transport conveyor 70b and transported to the box sealing machine 77. Then, when the replacement button displayed on the information display means 75 is pressed, the cardboard boxes CB are rearranged, and then an empty cardboard box CB corresponding to the next shipping order is placed in the last empty position.

[0069] This makes it possible to reduce the number of buffer devices and conveyors required from picking at the work station 60 to shipping, and also to reduce the number of pickers P (workers or robots), thereby reducing equipment costs and labor costs. Also, picking, consolidation, and packaging can be done in one place, making it possible to achieve one-stop packaging.

[0070] The sorting operation at the time of retrieval in the automated warehouse system 100 will be described below with reference to FIG.

[0071] In the sorting work at the time of retrieval in the automated warehouse system 100, based on multiple specified picking lists, multiple empty cardboard boxes CB that have been packed on the packing line 70 are transported from the transport conveyor 70a to multiple sorting positions L1 near the work station 60 and placed respectively under multiple flaps 74, and at the same time, information (ID, etc.) of each cardboard box CB is read by the identification code reading means 73 located at each sorting position L1 and displayed on the information display means 75.

[0072] Next, when a picker P (worker or robot) places an item (goods) picked from a container C on the work station 60 into a cardboard box CB, the sorting management means 86e controls the flap mechanism to open only the flap 74 corresponding to the cardboard box CB to accommodate the picked item, and to close the other flaps 74. At the same time, information such as the ID of the cardboard box CB and the number of items to be inserted is displayed on the information display means 75, so that the picker P can move the item (goods) from the container C on the work station 60 into the open cardboard box CB while checking the information such as the number of items to be inserted displayed on the information display means 75. For example, when moving an item (goods) from the container C, if the barcode of the item is scanned, the corresponding flap 74 automatically opens, and the number of items displayed on the information display means 75 is inserted.

[0073] Next, the delivery note output from the delivery note printer 76 is placed in the cardboard box CB that has been filled with items (products) (i.e., picking has been completed), and the cardboard box CB is discharged from the transport conveyor 70a to the transport conveyor 70b. As a result, the sorting position L1 becomes vacant, and when another cardboard box CB (for example, the cardboard box CB on the upstream side) is transported to this vacant position by the transport conveyor 70a, the sorting management means 86e displays information such as the ID and quantity of items inserted of the new cardboard box CB, and controls the opening and closing of the corresponding flap 74 using the new information, managing it so that it operates in accordance with the cardboard box CB. In this way, the cardboard boxes CB are swapped around so that there are always multiple cardboard boxes CB at the sorting position.

[0074] The information display means 75 is configured to display the identification code of a cardboard box CB that is scheduled to arrive soon, so that when a cardboard box CB cannot be assembled by the box-making machine due to a malfunction or when the assembled cardboard box CB is not the right size and cannot be used, the picker P (worker) can prepare the cardboard box CB himself, print and attach an identification code to it, and replace it (for example, by pressing a replacement button on the information display means 75), and the sorting management means 86e can manage the cardboard box CB so that it can be used on the packing line 70.

[0075] This allows the work station 60 to pick up the items (products) of multiple shipping orders at the same time, and sort them by shipping order.

[0076] Furthermore, during sorting work, cardboard boxes CB being sorted are temporarily evacuated to an evacuation conveyor L2 provided next to multiple sorting positions L1, other cardboard boxes CB are placed at sorting positions L1, sorting is performed, and if the cardboard box CB at sorting position L1 is moved to the evacuation conveyor L2 during or after sorting is completed, the temporarily evacuated cardboard box CB can be returned to one of the sorting positions L1, and sorting can continue.

[0077] A modification of this embodiment will now be described.

[0078] In the above-described embodiment, an example has been described in which the work station 60 has one line of retention conveyor 62b, and a floor other than the work station floor has one end runway 41, but the present invention is not limited to this. For example, the following modified configurations may also be used.

[0079] "Variation 1" Fig. 10 shows an automated warehouse system 100A as Modification 1. Fig. 10 shows the configuration of the work station floor of the automated warehouse system 100A. Note that in the automated warehouse system 100A, floors other than the work station floor have the same configuration as in the above-described embodiment, and therefore detailed description thereof will be omitted.

[0080] The automated warehouse system 100A is provided with two work stations 60A. For example, one of them can be used as a storage work station and the other as a retrieval work station.

[0081] 10, the work station 60A of the automated warehouse system 100A is provided between the second travel path 40 and the lifting device 50, and has a container transfer position 31 into which the automatic traveling robot 20 can enter. The work station 60A has a pair of side conveyors 61a, 61b that extend in a first direction on both sides of the container transfer position 31 and the lifting device 50 and that can transfer a container C between the automatic traveling robot 20 or the lifting device 50. The work station 60A has an end conveyor 62a that extends in a second direction in front of the lifting device 50 and is connected to the pair of side conveyors 61a, 61b, and two rows of retention conveyors 62b, 62c that are provided next to the end conveyor 62a and on which the container C can temporarily stay.

[0082] In the work station 60A, the pair of side conveyors 61a, 61b are composed of roller conveyors capable of moving containers C in a first direction and a second direction (i.e., vertical (front-to-back) and horizontal (left-to-right) directions) in the portions corresponding to the openings on both sides of the lifting device 50, and the other portions are composed of roller conveyors that move containers C in the first direction (i.e., vertical (front-to-back) direction).

[0083] In addition, in the work station 60A, the end conveyor 62a and the retention conveyors 62b, 62c are composed of roller conveyors capable of moving the container C in the first direction and the second direction (i.e., the vertical (front-back) and horizontal (left-right) directions). That is, the end conveyor in the work station 60A is composed of a combination of 3 rows (horizontal direction) x 3 columns (vertical direction) of right-angle transfer conveyor units.

[0084] In this way, by providing the end conveyor 62a, multiple containers C can be sequentially placed in the picking area from one end, and the containers C that have been picked can be moved from the other end back to the side conveyor 61a or 61b. The outer retention conveyors 62b and 62c are used to temporarily retain the containers C transported from the end conveyor 62a. While a container C is temporarily retained, multiple pickings can be performed from that container C. Another advantage is that a greater variety of items (products) can be picked simultaneously. For example, the two most frequently used containers (e.g., products A and B) can be fixedly stored in two spaces of the storage conveyor 62b in the front row, and the next five most frequently used containers (e.g., products C to F) can be stored in the storage conveyor 62c and end conveyor 62a in the second and third rows, while the second and third rows can be circulated to bring the desired container (e.g., products C to F, or new container C) to the remaining space in the front row.

[0085] Furthermore, the retention conveyor 62b is provided with a plurality of identification code reading means 63 capable of reading the identification codes of the containers C. This makes it possible to control the placement positions of the containers C on the retention conveyor 62b based on the picking list.

[0086] As described above, the work station 60A includes the end conveyor 62a and the retention conveyors 62b and 62c, which are provided adjacent to the end conveyor 62a and allow containers C to be temporarily retained. The end conveyor 62a sequentially transports containers C, allowing multiple containers C to be sequentially placed in the picking area. In this case, the retention conveyors 62b and 62c can temporarily retain up to six containers C. This allows picking from up to nine containers C, including the three containers C continuously transported laterally by the end conveyor 62a, which has the advantage of increasing the variety of items (products) that can be picked simultaneously. In this way, the outer and middle retention conveyors 62b and 62c can temporarily retain more containers C. While a container C is temporarily retained, multiple picking operations can be performed from a larger number of containers C.

[0087] In addition, four or more rows of end conveyors may be arranged at each work station. For example, in the case of four rows, the inner end conveyor 62a may be used to transport the containers C in sequence, and the outer three rows of end conveyors may be used as retention conveyors.

[0088] Furthermore, each work station may have a retention conveyor that is provided adjacent to a part of the end conveyor 62a and that temporarily retains the containers C. In this case, the retention conveyor is made up of one or two rows (vertical) of right-angle transfer conveyors.

[0089] "Variation 2" Fig. 11 shows an automated warehouse system 100B as Modification 1. Fig. 11 shows the configuration of a floor that is different from the work station floor of the automated warehouse system 100B. Note that in the automated warehouse system 100B, the work station floor has a configuration similar to that of the above-described embodiment, and therefore detailed description thereof will be omitted.

[0090] The automated warehouse system 100B is provided with two work stations, one of which can be used as a storage work station and the other as a retrieval work station, for example.

[0091] As shown in Figure 11, on floors other than the work station floor of the automated warehouse system 100B, a pair of lateral running paths 31a, 31b are provided on both sides of the lifting device 50, extending in a first direction (front-to-back direction in Figure 11), on which the automatic traveling robot 20 can run, allowing the automatic traveling robot 20 to reach either side of the lifting device 50 and transfer the container C between it and the lifting device 50.

[0092] Furthermore, in the automated warehouse system 100B, no end travel paths connected to the pair of side travel paths 31a, 31b are provided in the second direction (left and right direction in FIG. 11) in front of the lifting device 50. This configuration is suitable for cases where one or two automatic traveling robots 20 are arranged on each floor. Because the number of automatic traveling robots 20 is small, it is possible to omit the space for the end travel paths as detours.

[0093] In the automated warehouse system, on a floor other than the work station floor, if there are a large number of automatic traveling robots 20, two or more rows of end traveling paths 41 may be provided. Also, on a floor other than the work station floor, a side traveling path may be provided on only one side of the lifting device 50.

[0094] "Variation 3" Fig. 12 shows an automated warehouse system 100C as Modification 3. Fig. 13 shows the configuration of the work station floor of the automated warehouse system 100C. Note that in the automated warehouse system 100C, floors other than the work station floor have the same configuration as in the above-described embodiment, and therefore detailed description thereof will be omitted.

[0095] The automated warehouse system 100C is provided with two work stations 60C. For example, one of them can be used as a storage work station and the other as a retrieval work station.

[0096] 12, each work station 60C of the automated warehouse system 100C is configured to have two lifting devices 50 arranged in series. This work station 60C is provided between the second travel path 40 and the two lifting devices 50, and has a container transfer position 31 into which the automatic traveling robot 20 can enter. The work station 60C has a pair of side conveyors 61a, 61b that extend in the first direction on both sides of this container transfer position 31 and the two lifting devices 50, and can transfer a container C between the automatic traveling robot 20 or the two lifting devices 50.

[0097] Each work station 60C also has an end conveyor 62a extending in the second direction in front of the lifting device 50 and connected to the pair of side conveyors 61a, 61b, and a retention conveyor 62b provided alongside the end conveyor 62a for temporarily retaining containers C. The pair of side conveyors 61a, 61b are configured such that portions corresponding to the openings on both sides of the two lifting devices 50 are made up of roller conveyors capable of moving containers C in the first direction and the second direction (i.e., vertical (front-back) and horizontal (left-right) directions), and the other portions are made up of roller conveyors that move containers C in the first direction (i.e., vertical (front-back) direction). The end conveyor 62a and the retention conveyor 62b are made up of roller conveyors capable of moving containers C in the first direction and the second direction (i.e., vertical (front-back) and horizontal (left-right) directions). That is, the end conveyor in the work station 60C is made up of a combination of two rows (horizontal direction) and three columns (vertical direction) of right-angle transfer conveyor units.

[0098] In this way, by having two lifting devices 50 at the work station 60C, more containers C can be transported in the vertical direction, and the efficiency of the warehousing and unloading operations can be improved.

[0099] In the automated warehouse system, three or more lifting devices 50 may be arranged in series at each work station, if necessary.

[0100] "Variation 4" Fig. 13 shows an automated warehouse system 100D as Modification 4. Fig. 13 shows the configuration of the work station floor of the automated warehouse system 100D. Note that in the automated warehouse system 100D, floors other than the work station floor have the same configuration as in the above-described embodiment, and therefore detailed description thereof will be omitted.

[0101] The automated warehouse system 100D is provided with two work stations 60D. For example, one of them can be used as a storage work station and the other as a retrieval work station.

[0102] 13, a work station 60D of the automated warehouse system 100D has two lifting devices 50, and is configured so that the two lifting devices 50 are arranged in parallel via a side conveyor 61c. This work station 60D is provided between the second travel path 40 and the two lifting devices 50, and has two container transfer positions 31 into which the automatic traveling robot 20 can enter. The work station 60D has two pairs (three rows) of side conveyors 61a, 61c and 61c, 61b that extend in the first direction on both sides of the container transfer positions 31 and the lifting devices 50, and can transfer containers C between the automatic traveling robot 20 or the two lifting devices 50. The side conveyors 61a, 61b and 61c are composed of roller conveyors capable of moving containers C in a first direction and a second direction (i.e., vertical (front-to-back) and horizontal (left-to-right) directions) in the portions corresponding to the openings on both sides of the two lifting devices 50, and the other portions are composed of roller conveyors that move containers C in the first direction (i.e., vertical (front-to-back) direction).

[0103] Each work station 60D also includes an end conveyor 62a extending in the second direction in front of the lifting device 50 and connected to the side conveyors 61a, 61b, and 61c, and a retention conveyor 62b adjacent to the end conveyor 62a for temporarily retaining containers C. The end conveyor 62a and retention conveyor 62b are composed of roller conveyors capable of moving containers C in the first and second directions (i.e., vertical (front-back) and horizontal (left-right) directions). That is, the end conveyor in the work station 60D is composed of a combination of two rows (horizontal) and five columns (vertical) of right-angle transfer conveyor units. In this case, the retention conveyor 62b can temporarily retain up to five containers C. Together with the five containers C continuously transported horizontally by the end conveyor 62a, up to 10 containers C can be picked from, which has the advantage of increasing the variety of items (products) that can be picked simultaneously.

[0104] In this way, at the work station 60D, by arranging two lifting devices 50 in parallel via the side conveyor 61c, the number of work stations can be increased, allowing more containers C to be transported in the vertical direction, thereby improving the efficiency of warehousing and unloading operations.

[0105] It should be noted that at each work station, three or more lifting devices 50 may be arranged in parallel with one another via side conveyors.

[0106] "Variation 5" Fig. 14 shows an automated warehouse system 100E as Modification 4. Fig. 14 shows the configuration of the work station floor of the automated warehouse system 100E. Note that in the automated warehouse system 100E, floors other than the work station floor have the same configuration as in the above-described embodiment, and therefore detailed description thereof will be omitted.

[0107] The automated warehouse system 100E is provided with two work stations 60E. For example, one of them can be used as a storage work station and the other as a retrieval work station.

[0108] As shown in FIG. 14, a work station 60E of the automated warehouse system 100E is configured to have two lifting devices 50 arranged in parallel. This work station 60E is provided between the second travel path 40 and the two lifting devices 50, and has two container transfer positions 31 into which the automatic traveling robot 20 can enter. A pair of side conveyors 61a, 61b are provided on both sides of the container transfer position 31 and the two parallel-arranged lifting devices 50, extending in a first direction, and capable of transferring containers C between the automatic traveling robot 20 or the two lifting devices 50. The side conveyors 61a, 61b are configured such that the portions of the side conveyors 61a, 61b corresponding to the openings on both sides of the two parallel-arranged lifting devices 50 are roller conveyors capable of moving containers C in a first direction and a second direction (i.e., vertical (front-back) and horizontal (left-right) directions), and the other portions are roller conveyors that move containers C in the first direction (i.e., vertical (front-back) direction).

[0109] Each work station 60E also includes an end conveyor 62a extending in the second direction in front of the lifting device 50 and connected to the pair of side conveyors 61a, 61b, and a retention conveyor 62b adjacent to the end conveyor 62a for temporarily retaining containers C. The end conveyor 62a and retention conveyor 62b are configured as roller conveyors capable of moving containers C in the first and second directions (i.e., vertical (front-back) and horizontal (left-right) directions). That is, the end conveyor in the work station 60E is configured as a combination of two rows (horizontal) and four columns (vertical) of right-angle transfer conveyor units. In this case, the retention conveyor 62b can temporarily retain up to four containers C. Together with the four containers C continuously transported horizontally by the end conveyor 62a, it is possible to pick from a maximum of eight containers C, which has the advantage of increasing the variety of items (products) that can be picked simultaneously.

[0110] In this way, by arranging two lifting devices 50 in parallel at the work station 60E, more containers C can be transported in the vertical direction, thereby increasing the efficiency of storage and retrieval operations.

[0111] Although the above-described embodiment and modified examples have been described with respect to a number of layout examples of the automated warehouse system, the present invention is not limited to these examples and can flexibly accommodate various layouts as required.

[0112] Furthermore, in the above-described embodiment and modified example, an example has been described in which the flap 74 is used as the sorting guide means, but the present invention is not limited to this. For example, an LED light or the like may be used as the sorting guide means. In this case, the location where the LED light or the like is installed is not limited to above the sorting position.

[0113] Furthermore, in the above-described embodiment and modified examples, the second travel path 40 is disposed between the racks 10 and the lifting device 50 on the work station floor and on a floor other than the work station floor, but the present invention is not limited to this. For example, on a floor other than the work station floor, the second travel path 40 may be disposed in front of the lifting device 50 (forward in the front-to-rear direction in FIG. 3).

[0114] In the above-described embodiment and modified examples, the work stations 60, 60A, 60C, 60D, and 60E have a pair of side conveyors 61a, 61b on both sides of the lifting device 50 and an end conveyor 62a connected to the pair of side conveyors 61a, 61b in front of the lifting device 50, but the present invention is not limited to this. For example, the lifting device 50 may have a side conveyor on only one side. Alternatively, the lifting device 50 may have a side conveyor on only one side and an end conveyor connected to this side conveyor. In addition, the third direction is the same as the first direction and the fourth direction is the same as the second direction, but the present invention is not limited to this.

[0115] Furthermore, in the above-described embodiment and modified examples, the work stations 60, 60A, 60C, 60D, and 60E are installed on the first floor of the multiple racks 10, but the present invention is not limited to this. For example, the work stations may be installed on other floors of the warehouse. Furthermore, work stations may be installed on multiple floors of the multiple racks 10. Furthermore, two work stations on the same floor may be configured as one unit with no gap between them.

[0116] Furthermore, in the above-described embodiment and modified example, the work stations 60, 60A, 60C, 60D, and 60E are arranged in two locations, one of which is a storage work station and the other is a retrieval work station, but the present invention is not limited to this. If necessary, both locations may be used as a storage work station or a retrieval work station. Furthermore, depending on the storage capacity of the warehouse (the number of racks 10), for example, only one location may be arranged, or three or more locations may be arranged. Note that multiple work stations may also be integrated. In other words, the layout can be freely designed.

[0117] In the above-described embodiment and modified example, the side conveyors 61a, 61b, and 61c, the end conveyor 62a, and the retention conveyor 62b are roller conveyors. However, the present invention is not limited to this. For example, the side conveyors, end conveyors, and retention conveyors may be configured as a transport path that can retain the moving body and storage cases, and that allows the moving body to move even when the storage cases are retained. The moving body has an upper transfer unit that can transfer containers (storage cases) from a lifting device or an automatic traveling robot at the storage case transfer position, and a lower moving body that can run on a moving and running surface. The moving and running surface has a transport path (including the ground) along which the moving body can move and a holding structure for the storage cases.

[0118] In this way, by providing a transport path along which the mobile body can move while the storage cases are parked, the automated traveling robot and the mobile body do not need to wait at the station during picking work, minimizing the number of automated traveling robots and the number of mobile bodies, and introducing the system at low cost. Furthermore, by not providing a roller conveyor at the work station, the required number of drive system devices can be minimized. Furthermore, the work station is easy to install and maintain, which leads to improved installation efficiency.

[0119] It is not desirable to allow an autonomous robot to move along its travel path even when a storage case is stuck in it, because the autonomous robot will not be able to travel along a travel path where a storage case is stuck while holding the storage case, and it may not necessarily be possible to secure a detour route.

[0120] In the above-described embodiment and modified example, an example has been described in which, on floors other than the work station floors, the end runway 41 extends in the second direction (the left-right direction in FIG. 3) in front of the lifting device 50 and is connected to the pair of side runways 31a, 31b, but the present invention is not limited to this. For example, the end runway 41 may be provided as a detour between a plurality of stations (between 31a and 31b of different stations).

[0121] (Other embodiments) To achieve this object, an automated warehouse system includes a plurality of racks that extend in a first direction on a horizontal plane so that a plurality of storage cases can be arranged, have a plurality of floors in the vertical direction, and are arranged parallel to one another; an automated traveling robot that transfers and transports the storage cases; a plurality of first travel paths that extend in the first direction between the plurality of racks and are travelable by the automated traveling robot; at least one second travel path that is connected to the first travel path and is extended in a second direction on the horizontal plane perpendicular to the first direction and is travelable by the automated traveling robot; at least one lifting device that is connected to the first travel path or the second travel path and transports the automated traveling robot or the storage case handed over from the automated traveling robot to another floor in the vertical direction; and a lifting device that is arranged on at least one floor of the plurality of racks. and at least one work station for performing picking work to remove specified items from the transported storage cases or warehousing work to store items in the storage cases, wherein the work station includes a pair of side conveyors extending in a third direction on both sides of the lifting device and transporting the storage cases handed over from the automatic traveling robot or the lifting device, an end conveyor extending in a fourth direction perpendicular to the third direction to connect the pair of side conveyors and transporting the storage cases, and at least one line of retention conveyor extending in the fourth direction perpendicular to the third direction and adjacent to the end conveyor for temporarily retaining the storage cases, wherein the end conveyor and the retention conveyor are composed of conveyors capable of transporting the storage cases in the third direction and the fourth direction.

[0122] According to this automated warehouse system, the work station has a pair of side conveyors on both sides of the lifting device that can transfer storage cases to and from the automatic traveling robot or the lifting device, an end conveyor connected to the pair of side conveyors, and at least one row of retention conveyors that are attached to the end conveyors and allow the storage cases to temporarily stay, so that the storage cases can be transported to the work station in the order of the specified picking list and the storage cases that have been picked can be returned to the rack in order.In addition, because the storage cases can temporarily stay on the retention conveyor, multiple pickings can be made from the storage cases while they are temporarily staying.

[0123] In any of the above-described automated warehouse systems, it is preferable that the end conveyors are provided in at least two rows adjacent to each other.

[0124] According to the automated warehouse system having this configuration, some containers can be retained while other containers can be circulated.

[0125] Furthermore, an automated warehouse system for achieving this object includes a plurality of racks that are extended in a first direction on a horizontal plane so that a plurality of storage cases can be arranged, have a plurality of floors in the vertical direction, and are arranged parallel to one another; an automated traveling robot that transfers and transports the storage cases; a plurality of first travel paths that are extended in the first direction between the plurality of racks and along which the automated traveling robot can travel; at least one second travel path that is connected to the first travel path and extends in a second direction on the horizontal plane perpendicular to the first direction and along which the automated traveling robot can travel; at least one lifting device that is connected to the first travel path or the second travel path and transports the automated traveling robot or the storage case handed over from the automated traveling robot to another floor in the vertical direction; and a lifting device that is arranged on at least one floor of the plurality of racks and transports the storage cases. and at least one work station for performing picking work to remove specified items from the storage case that has arrived or for performing warehousing work to store the items in the storage case, wherein the work station comprises a mobile body, a side conveying path extending in a third direction on both sides of the lifting device, capable of storing the storage case handed over from the automatic traveling robot or the lifting device and along which the mobile body can move, an end conveying path extending in a fourth direction perpendicular to the third direction, connecting the pair of side conveying paths, capable of storing the storage case and along which the mobile body can move, and at least one retention conveying path extending in the fourth direction perpendicular to the third direction, adjacent to the end conveying path, for temporarily storing the storage case, wherein the end conveying path and the retention conveying path are composed of conveying paths along which the mobile body can move in the third direction and the fourth direction.

[0126] According to this configuration, the automated warehouse system has at least one work station located on at least one floor of the multiple racks, where picking work is performed to remove specified items from the transported storage cases or storing work is performed to store items in the storage cases. The work station floor has a mobile body, a storage case transfer position located on one end of the elevator, which is accessible by an automated traveling robot, and a side conveyance path that allows the storage cases to be transferred between the automated traveling robot and the elevator. This eliminates the need for the automated traveling robot and the mobile body to wait at the station during picking work, minimizing the number of automated traveling robots and mobile bodies, and enabling low-cost implementation. Furthermore, on the station floor, storage cases transported by the automated traveling robot can be transported without using the elevator, thereby reducing elevator utilization. It also saves space. Furthermore, by providing a pair of side and end conveyance paths on both sides of the storage case transfer position and the elevator, a path is secured for the storage case to return to the rack after the picking work is completed, preventing the transport of the next storage case. Furthermore, by providing a retention conveyance path that is arranged next to the end conveyance path and that allows the storage cases to temporarily stay, and that allows the moving body to move even when the storage cases are retained, the storage cases can be conveyed in order to the end conveyance path and multiple storage cases can be placed in order in the picking area, which has the advantage of increasing the variety of items (products) that can be picked simultaneously.In addition, by providing a retention conveyance path, the storage cases can be temporarily retained, so that multiple pickings can be made from the storage cases while they are temporarily retained.

[0127] In any of the above-described automated warehouse systems, it is preferable that the end conveying paths are provided adjacent to each other in at least two rows.

[0128] According to the automated warehouse system having this configuration, some containers can be retained while other containers can be circulated.

[0129] In any of the above-described automated warehouse systems, it is preferable to have a packaging line in which shipping boxes according to a specified picking list are transported to the vicinity of the work station by a transport conveyor, and the items picked from the storage cases transported to the work station are directly loaded into the boxes and then sealed.

[0130] With this automated warehouse system, by transporting shipping boxes near the work station, items picked from the storage cases at the work station can be loaded directly into the shipping boxes. Furthermore, the buffer device and transport conveyor can be omitted from the process from the work station to packaging and shipping. Conventionally, workers were required to perform the tasks of consolidating, inspecting, and packing. In contrast, the present invention allows one person to perform the tasks of consolidating, inspecting, and packing by installing a packing line near the picking work station.

[0131] Any of the above-described automated warehouse systems further includes a control unit that controls the automatically traveling robot, the lifting device, the pair of side conveyors, the end conveyor, and the retention conveyor of the work station or the moving body, and the packing line, and the packing line has an identification code issuing means that issues an identification code corresponding to a picking list specified for each shipping box, and a plurality of identification code reading means that are provided at sorting positions of the transport conveyor and read the identification codes, and the control unit unloads the storage case transported from the rack from the automatically traveling robot or the lifting device onto one of the side conveyors or the side transport path, transports it to the end conveyor or the end transport path by the one side conveyor or the side transport path, and reads the storage case from the end conveyor or the end transport path based on the specified picking list. It is preferable to control the system so that the storage cases are transported from one end of the transport path to the other end, and a specified storage case is temporarily held on the retention conveyor or the retention transport path, and the storage case for which picking work has been completed on the end conveyor or the end transport path and / or the retention conveyor or the retention transport path is transported from the other end of the end conveyor or the end transport path to the other side conveyor or the side transport path, and the storage case is then placed on the automatic traveling robot or the lifting device from the other side conveyor or the side transport path and returned to the rack, and also control the system so that the packaging line forms the shipping box corresponding to the picking list, affixes the identification code, transports the shipping box to a sorting position near the work station, seals the shipping box for which picking has been completed, and creates and affixes a corresponding waybill.

[0132] With this automated warehouse system, storage cases can be quickly transported from multiple racks (storage areas) to the work station, eliminating the need for buffer devices and transport conveyors from the work station to packaging and shipping, minimizing the number of conveyors and enabling low-cost implementation. Furthermore, by using part of the packaging line as a sorting area, the equipment installation area can be reduced. Picking and packaging operations can be performed in one stop.

[0133] The sorting device is characterized by having a transport conveyor that transports multiple shipping boxes according to multiple pre-specified picking lists to multiple sorting positions near the picking work station, multiple sorting guide means that are arranged at the multiple sorting positions on the transport conveyor and that indicate the shipping boxes to accommodate the picked items, and multiple information display means that display information related to the shipping boxes that correspond to the multiple sorting guide means.

[0134] According to the sorting device having such a configuration, by having a plurality of sorting guide means arranged at a plurality of sorting positions on the transport conveyor and a plurality of information display means that display information related to the shipping boxes corresponding to the plurality of sorting guide means, it is possible to pick up items (products) for a plurality of shipping orders together and sort them by shipping order. In addition, sorting can be performed on the transport conveyor near the picking work station, and sorting errors can be prevented.

[0135] In any of the above-described sorting devices, it is preferable that the sorting device further comprises an identification code issuing means for issuing an identification code corresponding to a picking list specified for each shipping box, and a plurality of identification code reading means provided at positions corresponding to the plurality of sorting guide means for reading the identification codes, and when the shipping box is moved from one sorting position to another by the transport conveyor, the information display means and the sorting guide means at that sorting position display information related to the shipping box based on the identification code of the shipping box and guide the item to be placed into the shipping box.

[0136] With this configuration, when a shipping box is moved from one sorting position to another by the conveyor, the information display means and sorting guide means at that sorting position display information related to the shipping box based on the shipping box's identification code and guide items into the shipping box. As a result, when a shipping box that has been picked is removed from multiple sorting positions, the information display means displays information such as the new shipping box's identification code when another shipping box is moved, and the sorting guide means operates accordingly. Therefore, even when there are many shipping orders, there is no need to increase the number of sorting positions, and sorting can be performed continuously. In other words, a large number of shipping orders can be handled with a small number of sorting positions.

[0137] In any of the sorting devices described above, the transport conveyor has an evacuation conveyor that is arranged adjacent to the multiple sorting positions and for temporarily evacuating the shipping boxes that have been discharged from any of the multiple sorting positions, and it is preferable that the evacuation conveyor is composed of a combination of multiple right-angle transfer conveyor units and is configured so that the shipping boxes that have been discharged from the sorting positions and temporarily evacuated can be returned to any of the multiple sorting positions as needed.

[0138] According to the sorting device of this configuration, by having an evacuation conveyor arranged next to the multiple sorting positions and for temporarily evacuating shipping boxes discharged from one of the multiple sorting positions, the evacuation conveyor is made up of a combination of multiple right-angle transfer conveyor units, and can return temporarily evacuated shipping boxes discharged from a sorting position to one of the multiple sorting positions as needed. Therefore, shipping boxes can be handled with a small number of sorting positions, and more shipping boxes can be sorted than the number of sorting positions.

[0139] In any of the above-described sorting devices, the sorting guide means is preferably a plurality of openable / closable flaps that are arranged above the plurality of sorting positions on the conveyor and that close or open at least a portion of the openings of the plurality of shipping boxes to indicate the shipping boxes to be used to store the items picked from the storage case, and the plurality of information display means are preferably configured to display information related to the shipping boxes under each of the plurality of flaps.

[0140] According to the sorting device of this configuration, the device has a plurality of openable flaps that are arranged above the transport conveyor at the sorting position and that close or open at least a portion of the openings of the plurality of shipping boxes to indicate the shipping boxes that will contain the picked items for the plurality of transported shipping boxes, and a plurality of information display means that display information related to the shipping boxes below each of the plurality of flaps, so that items (products) for a plurality of shipping orders can be picked together and sorted by shipping order.Furthermore, by using a sorting mechanism that includes flaps arranged above the transport conveyor at the plurality of sorting positions on the transport conveyor and a plurality of information display means that correspond to those flaps, sorting can be performed on the transport conveyor near the work station, and sorting errors can be reliably prevented.

[0141] The automated warehouse system comprises any one of the sorting devices described above and a control unit that controls the sorting device, and the control unit transports a plurality of the shipping boxes corresponding to the plurality of picking lists to a sorting position near a work station, operates only the sorting guide means corresponding to the shipping boxes to accommodate the picked items, and simultaneously controls the information display means to display information about the shipping boxes.

[0142] In an automated warehouse system with this configuration, the control unit transports shipping boxes to sorting positions near the picking work station, and at the multiple sorting positions on the transport conveyor, only the sorting guide means corresponding to the shipping box operates to accommodate the picked items, while simultaneously controlling the information display means to display information about the shipping box, allowing the picked items to be loaded directly into the shipping box, enabling efficient retrieval and preventing sorting errors.

[0143] In any of the above-described automated warehouse systems, the information display means is configured to display the identification code of the shipping box that is about to arrive and information indicating that picking has been completed, and if the identification code of the shipping box that is about to arrive is not displayed on the information display means or if the shipping box being sorted needs to be replaced, the control unit preferably controls the operation of the sorting guide means and the information display means based on the new identification code issued to the manually prepared shipping box that has been input, and processes the shipping box to be applied to the sorting device as a replacement.

[0144] In an automated warehouse system with this configuration, the information display means displays the identification code of a shipping box that is scheduled to arrive, allowing the picker (worker) to check the shipping box that is scheduled to arrive. Furthermore, because information indicating that picking is complete is displayed, the picker (worker) can instruct the shipping box to be removed from the sorting device when picking completion is displayed. Furthermore, when a shipping box cannot be assembled by the box-making machine due to a malfunction or when the assembled shipping box is not the right size and cannot be used, the picker (worker) can prepare a shipping box themselves, print an identification code on it, and attach it to replace it, allowing it to be managed so that it can be used by the sorting device.

[0145] The above-described embodiments are illustrative of the present invention and are not intended to limit it, and various other modifications and variations are possible. Therefore, the scope of the present invention is defined only by the claims and their equivalents. [Industrial Applicability]

[0146] The automated warehouse system of the present invention can be used for the purpose of performing picking work reliably and quickly at low cost and in a space-saving manner. [Explanation of symbols]

[0147] 10 racks 20 Self-driving robot 30 First Track 31 Container receiving position (storage case receiving position) 31a, 31b Sideways 40 Second Track 41 End road 50 Lifting device 51 Discharge conveyor (discharge means) 60, 60A, 60C, 60D, 60E Work Station 61a, 61b, 61c Side conveyors (side conveying means) 62a End conveyor (end conveying means) 62b Retention conveyor (end conveyor) (retention conveying means (end conveying means)) 63 Identification code reading means 70 Packaging Line (Packaging Line) 70a, 70b Transport conveyor 71 Box making machine 72 Identification code issuing device 73 Identification code reading means 74 Flap 75 Information display means 76 Delivery Note Printer 77 Box sealing machine 78 Waybill Auto Labeler 80 Control Unit 81 Receiving unit 82 Input section 83 Output Method 84 data bus 85 Storage area 85a Control program storage section 85b Storage item data storage unit 85c Picking list storage area 85d Shipping destination data storage section 86 Processing section 86a Automatic driving robot control means 86b Lifting device control means 86c Conveyor control means 86d Picking control measures 86e Sorting management methods 86f Packaging line control means 100, 100A, 100B, 100C, 100D, 100E automated warehouse system C Container (storage case) CB cardboard box (shipping box) L1 sorting position L2 Evacuation conveyor P Picker (worker or robot) S sensor

Claims

[Claim 1] a plurality of racks extending in a first direction on a horizontal plane so that a plurality of storage cases can be arranged, the racks having a plurality of floors in the vertical direction, and arranged parallel to each other; a plurality of first travel paths extending in the first direction between the plurality of racks, on which an automatic traveling robot that transfers and transports the storage cases can travel; at least one second travel path connected to the first travel path and extending in a second direction perpendicular to the first direction on a horizontal plane, on which the autonomous traveling robot can travel; At least one lifting device connected to the first travel path or the second travel path and configured to transport the automatic traveling robot or the storage case handed over from the automatic traveling robot to another floor in the vertical direction; a work station that is arranged on at least one floor of the plurality of racks and performs a picking operation of removing a specified item from the transported storage case or a warehousing operation of storing the item in the storage case, The work station comprises: a storage case transfer position that is provided adjacent to one end face of the lifting device, is connected to the first travel path or the second travel path, and is enterable by the automatic traveling robot; an automatic warehouse system characterized by having a lateral conveyor adjacent to the storage case transfer position and one side of the lifting device, parallel to the direction in which the storage case transfer position and the lifting device are arranged, and extending toward a third direction that is a direction away from the storage case transfer position, for transporting the storage case handed over from the automatic traveling robot or the lifting device.

Images