Warehouse management system

Abstract

To supply a warehouse management system capable of accurately grasping a warehouse state and a carrying-in-and-out state of loads to / from the warehouse in few facilities, and smoothly performing warehouse management at a low cost.SOLUTION: A warehouse management system comprises: a LiDAR 8 which measures distance and a direction to an object 80 and outputs 3D point group data 89 of the object 80 from the distance and the direction to the object 80; stored article state detecting means for detecting installation state data of a roll sheet 3 as a stored article; stored article state storing means for storing the installation state data of the stored article detected by the stored article state detecting means; and stored article state grasping means capable of grasping a carrying-in-and-out state of the roll sheet 3 to / from a warehouse 1 and a storage position of the roll sheet in the warehouse 1.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a warehouse management system for a warehouse that stores items, and more particularly to a warehouse management system that enables the use of an existing warehouse without incurring any special costs and enables smooth inventory management within the warehouse. [Background technology]

[0002] Many automated warehouses have been proposed as warehouse management systems in the past. The automated warehouse system described in Patent Document 1 below is comprised of a storage shelf unit for storing multiple items, a cart that moves with the items loaded on it, a moving mechanism that moves with the cart loaded on it, and a control unit that controls the retrieval of items stored in the storage shelf unit, and discloses technology for efficiently and automatically retrieving items stored in the storage shelf unit. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2024-045768 Summary of the Invention [Problem to be solved by the invention]

[0004] but, The automated warehouse system described in Patent Document 1 above is a very effective means of reducing manpower because it can transport goods stored in a warehouse almost automatically, but it requires the pre-construction of large-scale storage shelves, carts, moving mechanisms, etc., which requires a huge initial investment. For this reason, it is difficult to recover this initial investment unless the warehouse is quite large. Therefore, only a limited number of companies can introduce such a system.

[0005] An object of the present invention is to provide a warehouse management system that can accurately grasp the status of a warehouse and the status of goods being carried in and out of the warehouse with a small amount of equipment, and that can smoothly manage the warehouse at low cost. [Means for solving the problem]

[0006] The invention described in claim 1 is a LiDAR that irradiates a pulse laser into a warehouse, receives reflected light or scattered light from an object in the warehouse, measures the distance and direction to the object, and outputs 3D point cloud data of the object based on the distance and direction to the object; a stored item state detection means for inputting the 3D point cloud data output from the LiDAR, recognizing stored items in the warehouse from the 3D point cloud data, calculating coordinate data of the stored items in the warehouse, and detecting installation state data of the stored items including at least center position data of the top surfaces of the stored items; a storage item state storage means for storing installation state data of the stored items detected by the storage item state detection means; a stored item status grasping means for detecting installation status data of the stored items in the warehouse at regular intervals using the stored item status detecting means and comparing the detected installation status data with the installation status data of the stored items stored in the stored item status storing means, thereby making it possible to grasp the status of carrying in and out of the stored items in the warehouse and their storage positions; The present invention is characterized by having the following.

[0007] In addition, a plurality of the LiDARs are used, and each coordinate system of each of the LiDARs is converted into one standard coordinate system, The stored item state detection means calculates coordinate data indicating the position of the stored item based on the standard coordinate system.

[0008] Further, the installation state data of the stored item includes height data of the stored item in addition to center position data of the upper surface of the stored item, The stored item status grasping means By comparing the height data of the stored items in the warehouse detected by the stored item status detection means at regular intervals with the height data of the stored items stored in the stored item status memory means, it is possible to grasp the status of items being carried in and out of the warehouse even when the stored items are stacked in multiple layers.

[0009] The LiDAR is also characterized in that it is arranged so as to be able to recognize the 3D point cloud data of the top surfaces of all the stored items stored in the warehouse.

[0010] Also, a mobile object position detection means for recognizing the position of a mobile object that transports the stored item within the warehouse from the 3D point cloud data; a mobile object position storage means for storing the position data of the mobile object detected by the mobile object position detection means; a mobile object status ascertaining means for comparing the position data of the mobile object in the warehouse detected by the mobile object position detecting means at regular intervals with the position data of the mobile object stored in the mobile object position storage means, thereby ascertaining the status of the mobile object in the warehouse; The present invention is characterized by having the following.

[0011] In addition, a server that manages the warehouse is provided via a network, In the case of claim 1, 2, 3 or 4, the server has a work instruction table in which work instructions to be given to an operator of a mobile body are stored, and in the case of claim 5, the server has a work instruction table in which work instructions to be given to an operator of the mobile body are stored, The moving body is a lift vehicle, The present invention is characterized in that work instructions to the operator are displayed on the screen of a mobile terminal held by the operator of the lift vehicle based on the work instruction table.

[0012] In addition, the server Based on the installation status data of the stored item, The layout of the stored items in the warehouse detected by the stored item state detection means is displayed on the screen of the mobile terminal.

[0013] In addition, the server Based on the installation state data of the stored items in the warehouse detected by the stored item state detection means at regular intervals and the installation state data of the stored items stored in the stored item state storage means, The system is characterized in that it performs an error check on the way the stored item is set up and the way the stored item is held when it is brought into or taken out of the warehouse, and if an error occurs, the error is displayed on the operator's mobile terminal screen.

[0014] In addition, the server Based on the center position data of the top surface of the stored item, The position of the stored item that has been brought in or the position of the stored item to be brought out is checked to see if it is in line with the work instructions, and if it is incorrect, an error message is displayed on the mobile terminal screen of the operator.

[0015] Further, when the installation state data of the stored item includes height data of the stored item, The server Based on the height data of the stored item, The stack height of the stored items that have been brought in is checked, and if the stack exceeds the allowable stack height, an error message is displayed on the screen of the mobile terminal of the operator.

[0016] In addition, the server When stacking the stored items that have been brought in, based on the center position data of the top surfaces of the stored items, The position of the stored item below the stacked items is compared with the position of the stored item itself, and if the difference between the two exceeds a predetermined tolerance, it is determined that the item has been installed eccentrically, and an error message is displayed on the operator's mobile terminal screen.

[0017] Further, the installation state data of the stored item includes width data which is a width in the left-right direction in the installation state, The server When stacking the delivered storage items, the width data of the storage item below the stacked storage items is compared with the width data of the storage item; If the width data of the stacked storage item is larger than the width data of the storage item below it by a predetermined allowable value or more, it is determined that the stacking method is incorrect, An error message is displayed on the screen of the mobile terminal of the operator.

[0018] The storage system further includes a reading means for reading the identification information, the reading means being connected to the server and reading the identification information, and the storage system being configured to read the identification information from the storage means. When the reading means reads the identification information at the time of delivery to or delivery from the warehouse and transmits the information to the server, The server confirms that the stored item is in accordance with the work instructions, and if it is different, displays an error message on the screen of the mobile terminal of the operator.

[0019] The lift vehicle further includes a mast and an attachment attached to the mast that can grasp the stored item, a sensor is provided on the mast so as to be able to recognize the height of the attachment; When carrying out the stored items stored in the warehouse, The server: Based on the height of the attachment transmitted from the sensor, The height at which the stored item is grasped by the attachment of the lift vehicle is confirmed, and it is confirmed whether the stored item is being grasped at the correct position, and if it is incorrect, an error message is displayed on the mobile terminal screen of the operator.

[0020] In addition, the server 9. The warehouse management system according to claim 8, wherein the work instructions or error messages displayed on the mobile terminal of the operator of the lift vehicle are stored as a log together with the time of display.

[0021] In addition, a server that manages the warehouse is provided via a network, In the case of claim 1, 2, 3 or 4, the server has a work instruction table in which work instructions to be given to the mobile body are stored, and in the case of claim 5, the server has a work instruction table in which work instructions to be given to the mobile body are stored, The moving body is an autonomous vehicle, The work instructions may be transmitted to the autonomous vehicle based on the work instruction table.

[0022] In addition, the server Based on the installation state data of the stored items in the warehouse detected by the stored item state detection means at regular intervals and the installation state data of the stored items stored in the stored item state storage means, The system is characterized by performing error checks on the way the stored items are set up and the way the stored items are held when they are brought into or taken out of the warehouse, and if an error occurs, sending corrected work instructions to the self-driving vehicle.

[0023] Further, the server performs the following based on the center position data of the top surface of the stored item: The system checks whether the position of the stored item that has been brought in or the position of the stored item that is being removed is in line with the work instructions, and if it is incorrect, sends a corrected work instruction that differs from the work instruction sent to the self-driving vehicle.

[0024] Further, when the installation state data of the stored item includes height data of the stored item, The server Based on the height data of the stored items, the stack height of the stored items that have been brought in is checked, and if the items are stacked beyond the allowable stacking value, a revised work instruction that differs from the work instruction sent to the self-driving vehicle is sent.

[0025] In addition, the server When the stored items that have been brought in are stacked, the position of the stored item below the stacked item is compared with the position of the stored item itself based on the center position data of the top surface of the stored item, and if the two are deviated by more than a predetermined tolerance, it is determined that the stored item has been placed eccentrically, and a corrected work instruction different from the work instruction sent to the autonomous vehicle is sent.

[0026] Further, the installation state data of the stored item includes width data which is a width in the left-right direction in the installation state, The server When stacking the delivered storage items, the width data of the storage item below the stacked storage items is compared with the width data of the storage item; If the width data of the stacked storage item is larger than the width data of the storage item below it by a predetermined allowable value or more, it is determined that the stacking method is incorrect, The method is characterized in that it transmits modified work instructions that differ from the work instructions transmitted to the autonomously driven vehicle.

[0027] The storage system further includes a reading means for reading the identification information, the reading means being connected to the server and reading the identification information, and the storage system being configured to read the identification information from the storage means. When the reading means reads the identification information at the time of delivery to or delivery from the warehouse and transmits the information to the server, The server confirms that the stored item is in accordance with the work instructions, and if it is different, sends revised work instructions that differ from the work instructions sent to the autonomous vehicle.

[0028] The autonomous vehicle further includes a mast and an attachment attached to the mast and capable of grasping the stored item, a sensor is provided on the mast so as to be able to recognize the height of the attachment; When carrying out the stored items stored in the warehouse, The server: Based on the height of the attachment transmitted from the sensor, the height at which the attachment of the autonomous vehicle grasps the stored item is confirmed, and it is confirmed whether the attachment is correctly grasping the position at which the stored item should be grasped. If it is incorrect, The method is characterized in that it transmits modified work instructions that differ from the work instructions transmitted to the autonomously driven vehicle.

[0029] In addition, the server The work instructions sent to the autonomous vehicle are stored as a log together with the time of the sending. [Effects of the Invention]

[0030] According to this invention, with a small amount of equipment, the state of the warehouse and the state of goods being carried in and out of the warehouse can be accurately grasped, and warehouse management can be carried out smoothly at low cost. [Brief explanation of the drawings]

[0031] [Figure 1] 1 is a block diagram of a warehouse management system showing a first embodiment of the present invention. FIG. [Figure 2] FIG. 1 is a block diagram of a LiDAR. [Figure 3] FIG. 1 is an explanatory diagram showing the layout of a warehouse. [Figure 4] FIG. 2 is an explanatory diagram showing the structure of a lift vehicle. [Figure 5] FIG. 10 is an explanatory diagram illustrating how information on the roll paper is read. [Figure 6] This is roll paper storage information obtained from the analysis results of LiDAR 3D point cloud data. [Figure 7]This is the location information of the lift vehicle obtained from the analysis of 3D point cloud data from LiDAR. [Figure 8] 10 is a timing chart showing the timing of capturing 3D point cloud data from LiDAR. [Figure 9] FIG. 10 is an explanatory diagram of a work record DB. [Figure 10] FIG. 10 is an explanatory diagram of a roll paper product specification DB. [Figure 11] FIG. 10 is an explanatory diagram of a carry-in / carry-out record DB. [Figure 12] FIG. 10 is an explanatory diagram of an installation location DB. [Figure 13] FIG. 10 is an explanatory diagram of a lift car information DB. [Figure 14] FIG. 10 is an explanatory diagram of eccentricity when the roll paper is stacked. [Figure 15] FIG. 10 is an explanatory diagram of improper stacking of roll paper. [Figure 16] FIG. 10 is an explanatory diagram of the gripping position when the roll paper is transported. [Figure 17] FIG. [Figure 18] FIG. 10 is an explanatory diagram of a warehouse management system display screen. [Figure 19] FIG. 2 is an explanatory diagram of a mobile terminal display screen. [Figure 20] 10 is a process flowchart 1 for performing recognition processing inside a warehouse at regular intervals. [Figure 21] 10 is a process flowchart 2 for performing recognition processing within a warehouse at regular intervals. [Figure 22] 10 is a process flowchart 3 for performing recognition processing inside a warehouse at regular intervals. [Figure 23] 1 is a flowchart 1 of a work process. [Figure 24] 10 is a flowchart 2 of the work process. [Figure 25] 10 is a flowchart 3 of the work process. [Figure 26] 10 is a flowchart of a DB update process. [Figure 27] FIG. 10 is an explanatory diagram showing a second embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0032] A first embodiment of a warehouse management system according to the present invention will be described with reference to the drawings.

[0033] As shown in FIG. 1, the warehouse management system generally includes a lift truck 2, a warehouse management server 4, a warehouse management control unit 6, a LiDAR 8, and a reader device 9.

[0034] The warehouse management system is mainly composed of a warehouse management server 4 and a warehouse management control unit 6 that manages each warehouse 1.

[0035] Generally, the warehouse management control unit 6 is installed inside or near the warehouse 1 to be managed, and the warehouse management server 4 is installed at a different location connected by a network 5. When managing multiple warehouses 1, a warehouse management control unit 6 is installed separately for each warehouse 1, and these are all collected in one location and the warehouse management server 4 manages all of the warehouses 1.

[0036] The lift car 2 has a structure as shown in Figure 4, and includes an attachment 23 that grips the paper roll 3 and two masts 22 for lifting the paper roll 3 gripped by the attachment 23. When transporting the paper roll 3, the attachment 23 uses a full-rotation roll clamp-like attachment 23 as shown in Japanese Patent Application Laid-Open Nos. 7-330298 and 2001-310899, making it easy to grip the paper roll 3. The lift car 2 used in this embodiment is also equipped with a sensor in the mast 22 that can determine the approximate height of the attachment 23 from the floor. In other words, it can detect the height at which the attachment 23 is gripping the paper roll 3.

[0037] 5 is an explanatory diagram of how information on the paper roll 3 is read. The lift vehicle 2 is equipped with a mast 22 and an attachment 23, and the attachment 23 holds the paper roll 3. An IC tag 31 is attached to the paper roll 3, and this IC tag 31 stores the "product ID" and "product model number" of the paper roll 3.

[0038] Additionally, each lift car 2 is equipped with a mobile terminal 21 for providing work instructions to the operator of the lift car 2. The mobile terminal 21 installed in each lift car 2 can access the warehouse management server 4 via the network 5. The contents of the IC tag 31 attached to each roll of paper 3 can be read via a reader 9 installed near the warehouse entrance 12 and warehouse exit 13 in each warehouse 1, and the data can be sent from the reader 9 to the warehouse management server 4. In this embodiment, an existing reader 9 is used as the reader 9.

[0039] The hardware configuration of the warehouse management server 4 is basically the same as that of the warehouse management control unit 6, and has components equivalent to the processor 60, bus 62, memory 61, interface 63, and communication control unit 64 of the warehouse management control unit 6, which will be described later.

[0040] The warehouse management server 4 has a memory (not shown) provided with a work instruction table 42 in which work instructions for the operators of each lift vehicle 2 are stored, and an area for a work record DB 41.

[0041] Figure 17 is an explanatory diagram showing the contents of work instructions given to the operator of each lift car 2. Work instructions to be given to the operator of each lift car 2 are stored in a work instruction table 42, and the warehouse management server 4 appropriately transmits work instructions to the operator of each lift car 2 to the mobile terminal 21 of each lift car 2 based on the work instruction table 42. The warehouse management server 4 not only gives work instructions to the operator of each lift car 2, but also displays errors resulting from error checks on the mobile terminal 21. The work instruction table 42 is created and displayed on the screen of the warehouse management server 4.

[0042] In the work instruction table 42, the name of the lift vehicle 2 that sends the "work instruction" is stored in "designated lift vehicle" 91. The identification number of the mobile terminal 21 mounted on the lift vehicle 2 that sent the "work instruction" is stored in "mobile terminal number" 92. The category, product ID, installation location ID, and comments are stored in "delivery-in / delivery-out instructions" 93.

[0043] "Category" is used to identify the type of work instruction to be sent, and stores three types of information: carry-in, carry-out, and end. Here, "carry-in" is a work instruction to carry the paper roll 3 into a specified location within the warehouse 1, "carry-out" is a work instruction to carry the paper roll 3 out from a specified location within the warehouse 1, and "end" is a work instruction to move the lift car 2 to a specified location outside the warehouse 1 and end the work. "Product ID" is identification information unique to each paper roll 3. "Location ID" is identification information that specifies the installation location of the paper roll 3 within the warehouse 1. "Comment" is the content of the work instruction to be displayed on the screen of the mobile terminal 21 of the lift car 2.

[0044] As shown in FIG. 1, the warehouse management server 4 has an area for a work record DB 41 in a memory (not shown) for recording the contents transmitted to the operators of each lift car 2.

[0045] The work record DB41 records work instructions given to the operator of the lift vehicle 2 or a log of errors that have occurred, and stores the date and time, lift vehicle name, mobile terminal number, category, product ID, installation location ID, and comments, as shown in Figure 9.

[0046] The "date and time" field stores the date and time when a "work instruction" or "error message" was sent to the mobile terminal 21 of the lift vehicle 2. The "lift vehicle" field stores the name of the lift vehicle 2 that sent the "work instruction." The name of the lift vehicle 2 is the name of the lift vehicle 2 stored in the designated lift vehicle 91 of the work instruction shown in Figure 17. The "mobile terminal number" field stores the identification number of the mobile terminal 21 installed on the lift vehicle 2 that sent the "work instruction." The "category" field identifies the type of work instruction sent and stores four types of information: delivery, removal, completion, and error. Here, "delivery" is a work instruction to deliver the paper roll 3 to a designated location within the warehouse 1. "Removal" is a work instruction to remove the paper roll 3 from a designated location within the warehouse 1. "Completion" is a work instruction to move the paper roll 2 to a designated location outside the warehouse 1 and complete the work. "Error" is a work instruction to display an error on the screen of the mobile terminal 21 and prompt the operator of the lift vehicle 2 to take action. The "product ID" field is identification information unique to each paper roll 3. The "location ID" is identification information that identifies the installation location of the roll paper 3 within the warehouse 1. The "comment" is a work instruction or error content that is displayed on the screen of the mobile terminal 21 of the lift car 2.

[0047] The warehouse management control unit 6 shown in Figure 1 includes a processor 60, which is connected to a memory 61 and an interface 63 via a bus 62, and which is connected to a communication control unit 64 and a LiDAR control unit 65. The operation of each unit is controlled by the processor 60, which operates according to a program. The processor 60 also executes the processes required for warehouse management, as shown in the flowcharts of Figures 20 to 26, which will be described later, based on pre-stored program software. The memory 61 contains areas for a roll paper product specification DB 66, a carry-in / carry-out record DB 67, an installation location DB 68, and a lift vehicle information DB 69.

[0048] The roll paper product specification DB 66 stores catalog information for the roll paper 3 stored in the warehouse 1, and as shown in Figure 10, stores the product model number, product name, manufacturer name, total weight, total diameter, length, width, paper thickness, and basis weight.

[0049] "Product model number" stores the product model number determined by the manufacturer of the paper roll 3. "Product name" stores the product name of the paper roll 3. "Manufacturer name" stores the manufacturer name of the paper roll 3. "Total weight" stores the weight [kg] of the entire paper roll 3. "Total diameter" stores the diameter [cm] of the entire paper roll 3. "Length" stores the length [m] of the entire paper roll 3. "Width" stores the width [cm] of the entire paper roll 3. "Paper thickness" stores the thickness [μ] of the paper roll 3. "Basis weight" stores the basis weight [g / m2] of the paper roll 3.

[0050] The import / export record DB 67 stores the import / export records of roll paper 3 that have been imported into or exported from the warehouse 1, and as shown in Figure 11, stores the product ID, product model number, import date and time, export date and time, installation location ID, and number of stacked layers.

[0051] "Product ID" is information unique to each paper roll 3, and stores the information read by the reader 9 from the IC tag 31 attached to the paper roll 3 when the paper roll 3 is brought into warehouse 1. "Product model number" is the product model number determined by the manufacturer of each paper roll 3, and stores the information read by the reader 9 from the IC tag 31 attached to the paper roll 3 when the paper roll 3 is brought into warehouse 1. "Delivery date and time" stores the date and time when each paper roll 3 is brought into warehouse 1. "Removal date and time" stores the date and time when each paper roll 3 is removed from warehouse 1. "Installation location ID" is information that identifies the location within warehouse 1 where each paper roll 3 is installed, and is used in relation to the installation location ID in the installation location DB shown in Figure 12. "Number of stacked layers" indicates the number of layers when multiple paper rolls 3 are stacked in the same location. If no paper rolls 3 are stacked, it is 0.

[0052] The installation location DB 68 stores information that identifies the location where the roll paper 3 is installed within the warehouse 1, and as shown in Figure 12, stores the installation location ID, overall height, total number of stacked upper tiers, confirmed number of tiers, eccentricity, over height, incorrect stacking direction, initial X coordinate value, initial Y coordinate value, and initial diameter of the top tier.

[0053] The "installation location ID" is information that identifies the location within the warehouse 1 where each roll of paper 3 is installed, and each time a new roll of paper 3 is installed within the warehouse 1 (except when a roll of paper 3 is stacked on top of another roll of paper 3), an installation location ID is assigned.

[0054] The installation location ID can use the identification information of the installation location, such as "P20240415-***". The first four digits, "2024", indicate the year 2024, the next two digits, "04", indicate the month of April, and the next two digits, "15", indicate the 15th day of the month, which represents the date of installation. The next three digits are a sequence number (001 to 999), and the number of digits can be determined based on the maximum number of installation locations per day.

[0055] "Total height" is the height of all the stacked paper rolls 3; if there is only one layer of paper roll 3, it is the "width" of the paper roll 3 itself; if there are multiple layers of paper roll 3, it is the sum of the "widths" of each roll 3. "Total number of stacked layers" is the total number of layers of paper roll 3; if there is only one layer of paper roll 3, it is set to 1. "Number of layers confirmed" indicates whether the number of layers of stacked paper rolls 3 has been confirmed. If the number of layers has been confirmed, it is set to "1," and if it has not been confirmed, it is set to "0." If paper rolls 3 are already installed in warehouse 1 when the warehouse management system starts up, the number of layers cannot be determined, so it is set to "0." If new paper rolls 3 are being installed in an empty space, the number of layers of paper roll 3 can be determined, so it is set to "1." "Eccentricity" indicates whether the stacked paper rolls 3 are eccentric. If they are eccentric, it is set to "1," and if they are not, it is set to "0." "Over height" indicates whether the overall height of the stacked paper rolls 3 exceeds the tolerance. If it exceeds the tolerance, "1" is set, and if it is within the tolerance, "0" is set. "Incorrect stacking" indicates whether the diameter of the top paper roll 3 is larger than the bottom paper roll 3 in the stack. If it is too large, "1" is set, and if not, "0" is set. "Initial X coordinate value" is the X coordinate value within warehouse 1 when the paper roll 3 was first measured by LiDAR 8. "Initial Y coordinate value" is the Y coordinate value within warehouse 1 when the paper roll 3 was first measured by LiDAR 8. "Initial top diameter" is the diameter value of the top surface of the topmost paper roll 3 when the paper roll 3 was first measured by LiDAR 8.

[0056] The lift car information DB 69 stores information about each lift car 2 operating within each warehouse 1. As shown in FIG. 13, the information includes the lift car name, mobile terminal number, P1 (X coordinate value), P1 (Y coordinate value), P2 (X coordinate value), and P2 (Y coordinate value). The "lift car name" is a unique name assigned to each lift car 2. The "mobile terminal number" indicates the identification number of the mobile terminal 21 of the lift car 2. As shown in FIG. 7, P1 and P2 indicate the center position of the lift car 2 in the coordinate system within the warehouse 1, and P2 indicates, for example, the midpoint between two masts 22. The midpoint of the masts 22 is used as P2 because, when detecting the lift car 2 with the LiDAR 8, the mast 22 is usually the highest point of the lift car 2, making it easy to calculate the position of P2, which is the midpoint between the two masts 22. The vector P1P2 indicates the direction in which the lift car 2 is facing. "P1 (X coordinate value)" indicates the position (X coordinate value) of each lift vehicle 2 within warehouse 1, and becomes "0" when the lift vehicle 2 has left warehouse 1. "P1 (Y coordinate value)" indicates the position (Y coordinate value) of each lift vehicle 2 within warehouse 1, and becomes "0" when the lift vehicle 2 has left warehouse 1. "P2 (X coordinate value)" indicates the X coordinate value of the midpoint between the two masts 22. "P2 (Y coordinate value)" indicates the Y coordinate value of the midpoint between the two masts 22. "Status" is used to identify the status of the lift vehicle 2, with "0" indicating that the lift vehicle 2 is outside the warehouse, "1" indicating that the lift vehicle 2 has entered the warehouse, "2" indicating that the lift vehicle 2 is moving within warehouse 1, and "3" indicating that the lift vehicle 2 is parked within warehouse 1.

[0057] As shown in FIG. 2 , the LiDAR 8 includes a power supply 81, an MCU 82 that controls all operations of the LiDAR 8, a laser oscillator 83 that emits a pulsed laser, and a scanning mechanism 84 that scans the pulsed laser emitted from the laser oscillator 83 along the surface of the object 80. The scanning mechanism 84 deflects the light beam emitted from the laser oscillator 83 by bending, moving, or tilting a mirror at a constant cycle, for example, by operating a piezoelectric element. This causes the pulsed laser light beam to scan the object 80 at a constant cycle. In this embodiment, the object 80 is a lift truck 2 or a roll of paper 3 installed in the warehouse 1. The LiDAR 8 further includes a light-receiving element 86 that receives scattered light and reflected light of the pulsed laser irradiated onto the object 80 through a condenser lens 85, a measurement circuit 87 that measures the distance to the object 80 based on the light-receiving signal output from the light-receiving element 86, and a 3D point cloud data output unit 88.

[0058] Here, 3D point cloud data (3D Point Cloud) is information such as the distance and direction to an object 80 detected by the LiDAR 8 expressed as a collection of three-dimensional points.

[0059] The measurement circuit 87 receives a pulsed light receiving signal output from the light receiving element 86 in response to light reflected from the object 80, calculates the time difference between the irradiated pulse laser and the light receiving signal for all scanning points (points irradiated with the light beam), and measures the distance to the object 80 from the time difference. The measurement circuit 87 calculates the X, Y, and Z coordinates of each scanning point based on the distance to the object 80 and the direction of the scanning point during scanning. The X, Y, and Z coordinate data of all scanning points calculated in this manner is sent to a 3D point cloud data output unit 88, which outputs the 3D data of all scanning points in each scanning period sent from the measurement circuit 87 as 3D point cloud data 89.

[0060] As shown in Fig. 1, multiple LiDARs 8 are connected to the interface 63 via the HUB 7 and the LiDAR control unit 65, and the LiDAR control unit 65 controls the operation of these LiDARs 8. For example, when four LiDARs 8 are used, as shown in Fig. 3, each LiDAR 8 is installed on a support pole (not shown) erected at the four corners of the warehouse 1. Furthermore, each LiDAR 8 is positioned so that it can recognize 3D point cloud data 89 of the top surface of all the rolls of paper 3 stored in the warehouse 1.

[0061] A LiDAR 8 configured in this way has high azimuth resolution (the ability to distinguish between two or more objects 80 lined up in the direction of measurement) and can accurately detect the distance and relative positions of surrounding obstacles, allowing the roll paper 3 and lift truck 2 in the warehouse 1 to be detected more quickly and accurately than images captured by a normal surveillance camera.

[0062] When multiple LiDARs 8 are used, the coordinate system of the 3D point cloud data 89 output by each LiDAR 8 will be different. Therefore, in order to combine all the 3D point cloud data 89 and manage them on the same coordinate system, coordinate conversion is required. Therefore, it is necessary to calibrate the coordinate system of the LiDARs 8 in advance. When calibrating the coordinate system of the LiDARs 8, one lift truck 2 is placed in the warehouse 1, and the lift truck 2 is recognized by multiple LiDARs 8, and the position and direction (P1) and (P2) of the lift truck 2 are detected as shown in FIG. 7.

[0063] For example, with the position and direction of the lift truck 2 recognized by two LiDARs, LiDAR-1 and LiDAR-2, a transformation equation is determined to convert the vehicle position vector data (P1·P2) in the LiDAR-2 coordinate system into the vehicle position vector data (P1·P2) in the LiDAR-1 coordinate system. Since the vehicle position and direction of the same lift truck 2 located in the same location are identified, the final vehicle position and direction 201 must be identical. Therefore, if the LiDAR-1 coordinate system is the standard coordinate system, the vehicle position vector data (P1·P2) in the LiDAR-2 coordinate system is converted to the exact same vector as the vehicle position vector data (P1·P2) in the LiDAR-2 coordinate system by shifting, rotating, scaling, etc. By memorizing this transformation equation, it is possible to convert the LiDAR-2 coordinate system to the LiDAR-1 coordinate system. All data obtained when detecting the position and direction of the lift truck 2 is obtained using values ​​in the standard coordinate system converted in this way. Even when three or more LiDARs are used, they can all be converted to the standard coordinate system by performing the same coordinate conversion.

[0064] FIG. 3 is an explanatory diagram showing the layout of a warehouse 1 to be managed according to this embodiment. The warehouse 1 has a warehouse entrance 12 and a warehouse exit 13, and at each entrance and exit, a reader 9 for the IC tag 31 attached to each paper roll 3 is installed. The warehouse 1 has a location for placing the paper roll 3 and an aisle 11 for the lift truck 2 to move through. The paper roll 3 can be placed anywhere other than the aisle 11; the approximate placement location is specified in the "work instruction," so the paper roll 3 can be placed near the specified location. A LiDAR 8 is installed to constantly monitor the location of the paper roll 3 and the lift truck 2. Multiple LiDARs 8 are installed to ensure there are no blind spots for the LiDAR 8 so that all paper rolls 3 and all lift trucks 2 within the warehouse 1 can be monitored.

[0065] The warehouse management server 4 shown in FIG. 1 is connected to a warehouse management control unit 6 via a network 5. The communication control unit 64 is a communication module for communicating with external devices, and may be, for example, a wired LAN or wireless LAN module. The network 5 is constructed using the Internet or a wide area communication network. From the warehouse management server 4, it is possible to read the contents of the roll paper product information DB 66, the delivery / removal record DB 67, the installation location DB 68, and the lift vehicle information DB 69 in the warehouse management control unit 6 corresponding to each warehouse 1 via the network 5.

[0066] As shown in Figure 8, the processor 60 shown in Figure 1 periodically receives 3D point cloud data 89 via the LiDAR control unit 65 at a fixed time t interval, performs data reception 100, and identifies the lift trucks 2 and rolls of paper 3 present in the warehouse 1 from this 3D point cloud data 89. It extracts lift truck data 101 for the identified lift truck 2 and roll paper installation data 102 for the roll paper 3, and updates the installation location DB 68 and lift truck information DB 69 based on this data.

[0067] From the above, the warehouse management control unit 6, which includes the processor 60 and memory 61, together with the LiDAR 8, constitutes a stored item status detection means, a stored item status storage means, a stored item status understanding means, a mobile object position detection means, a mobile object position storage means, and a mobile object status understanding means.

[0068] The processing performed at regular intervals t is explained using the flowcharts shown in Figures 20 to 22. In step S101 of Figure 20, 3D point cloud data 89 from each LiDAR 8 is input. In step S102, the lift vehicle 2 and the paper roll 3 are recognized separately using the 3D point cloud data 89 from each LiDAR 8. In other words, if four LiDARs 8 are connected, recognition is performed separately using four types of 3D point cloud data 89. In step S103, lift vehicle data 101 and paper roll installation data 102 for the recognized lift vehicle 2 and paper roll 3 are extracted for each LiDAR 8. As shown in Figure 7, the lift vehicle data 101 extracts the position and direction (P1), (P2) of the lift vehicle 2. As shown in Figure 6, the paper roll installation data 102 extracts the overall height (H), the diameter (D) of the top surface of the top, and the center position (X, Y) of the top surface of the top of the installed roll paper 3. In step S104, the data obtained in step S103 is output in a different coordinate system for each LiDAR 8, so it is converted to a unified coordinate system using the results of calibration performed in advance, and the data is combined. In step S105, lift car data 101 and roll paper installation data 102 in the unified coordinate system are extracted from the data combined in step S104. That is, if the position and orientation of the lift car 2 are similar and below a threshold, they are considered to be the same lift car 2, and if the position of the roll paper 3 is similar and below a threshold, they are considered to be the same roll paper 3. In step S106, it is determined whether the detected data includes data for the roll paper 3. If so, processing for the roll paper 3 is performed in step S107. If not, processing is performed in step S108. In step S108, it is determined whether the detected data includes data for the lift car 2. If so, processing for the lift car 2 is performed in step S109. If not, processing ends.

[0069] 21 is the processing flow for the paper roll 3, and the determination in step S201 is repeated to process all detected paper rolls 3. If processing has not finished for all paper rolls 3, in step S204, if the difference between the detected position of the paper roll 3 and the position stored in the installation location DB 68 is within a threshold, step S205 is executed to update the data in the installation location DB 68; if not, the paper roll 3 is considered to have been newly installed in warehouse 1, and data is added to the installation location DB 68 in step S206. The reason for adding a determination of whether the difference is within the threshold when comparing positions is that there may be a slight measurement error when the paper roll 3 is detected by the LiDAR 8, and the measurement value of the LiDAR 8 may differ even if the paper roll 3 itself is in the exact same position.

[0070] The installation location DB 68 is updated in step S205 using the procedure shown in Figure 26. In step S501, a check is made to see if the total height is "0." If it is not "0," steps S504 and onward are executed. If the total height is "0," this means that the roll paper 3 was initially installed in the location specified in the work instruction, and a new roll paper 3 was installed in a location where no roll paper 3 existed. In this case, in step S502, the detected center position (X, Y) of the top surface of the top of the roll paper 3 is stored as the initial X coordinate value and initial Y coordinate value in the installation location DB 68. Next, in step S503, the diameter (D) of the top surface of the top of the extracted roll paper 3 is stored as the initial top diameter in the installation location DB 68. In step S504, if the detected height of the roll paper 3 is not the same as the height stored in the installation location DB 68, step S505 is executed. If they are the same, processing ends. If these heights are the same, no new roll paper 3 has been added. In step S505, the detected overall height (H) of the roll paper 3 is stored in the overall height of the installation location DB 68. In step S506, the value of the total number of upper stacked layers in the installation location DB 68 is incremented by one.

[0071] Returning to FIG. 21, step S206 is executed when a roll paper 3 already present in the warehouse 1 is detected when the warehouse management system of the present invention is first started. In this case, as shown in FIG. 6, the overall height (H), the diameter (D) of the top surface, and the center position (X, Y) of the top surface of the top surface of the installed roll paper 3 are extracted, but the number of layers cannot be determined. Therefore, the following data is set in the installation location DB 68. A new installation location ID is assigned and stored. The overall height (H) of the roll paper 3 extracted in step S104 is stored in the overall height field in the installation location DB 68. Since the value of the total number of layers is unknown, the total number of layers is set to "1," meaning that it is 1 or greater. Since the actual value of the total number of layers is unknown, the confirmed number of layers is set to "0." It is assumed that there is no eccentricity, so the eccentricity is set to "0." If the overall height in the installation location DB 68 does not exceed the allowable value, the over-height field is set to "0." If it does exceed the allowable value, the over-height field is set to "1." It is assumed that there is no stacking irregularity, and the stacking irregularity is set to "0". The extracted center position (X, Y) of the top surface of the top of the roll paper 3 is stored in the initial X coordinate value and initial Y coordinate value of the installation location DB 68. The extracted diameter (D) of the top surface of the top of the roll paper 3 is stored in the initial top diameter of the installation location DB 68.

[0072] By repeatedly making the determination in step S202, data on the roll paper 3 stored in the installation location DB 68 that does not exist in all of the roll paper 3 identified in step S103 is extracted. This data means that the roll paper 3 has been completely removed from its installation location in the warehouse 1, so the data is deleted from the installation location DB 68 in step S203. If there is no more corresponding data in step S202, the process ends.

[0073] FIG. 22 shows the processing flow for the lift car 2. By repeatedly executing the judgment in step S301, processing is performed for all detected lift cars 2. If processing for all detected lift cars 2 has not been completed, in step S302, if the difference between the detected position of the identified lift car 2 and the position stored in the lift car information DB 69 is within a threshold, step S303 is executed to place the lift car 2 in a stopped state. To place the lift car 2 in a stopped state, the "state" of the corresponding lift car 2 data in the lift car information DB 69 is set to "3." In step S304, if the difference between the detected position of the identified lift car 2 and the position stored in the lift car information DB 69 is equal to or less than the value determined to be close, step S305 is executed to place the lift car 2 in a moving state. To place the lift car 2 in a moving state, the values ​​of "P1, P2" of the corresponding lift car 2 data in the lift car information DB 69 are replaced with the values ​​of P1, P2 of the corresponding lift car 2 extracted in step S104, and the "state" is set to "2." If not, step S306 is executed to put the lift vehicle 2 into a stocked state. To put the lift vehicle 2 into a stocked state, the values ​​of "P1, P2" of the corresponding lift vehicle 2 data in the lift vehicle information DB 69 are replaced with the values ​​of P1, P2 of the corresponding lift vehicle 2 extracted in step S104, and the "state" is set to "1".

[0074] If processing of all detected lift cars 2 has been completed, the determination in step S307 is repeatedly executed to extract data of lift cars 2 stored in the lift car information DB 69 that does not exist in the lift car 2 identified in step S103. This data means that the lift car 2 has completely left the warehouse 1, so in step S308 the corresponding lift car 2 is reset to its initial state. To reset to its initial state, the values ​​of "P1, P2" of the corresponding lift car 2 data in the lift car information DB 69 are each set to "0", and the "state" is set to "0". In step S307, if there is no more corresponding data, the processing ends.

[0075] The workflow of a warehouse management system according to the present invention is described using the flowcharts shown in Figures 23 to 25. Figure 18 shows an example of a warehouse management server screen 40. If there are multiple warehouses 1, the operator can select the warehouse 1 to display on the screen. The layout display section 43 displays the layout of the specified warehouse 1 and the positions of the lift truck 2 and paper rolls 3 recognized by the LiDAR 8. This allows the operator of the warehouse management server 4 to easily check the work status within the specified warehouse 1. In Figure 18, the roll paper storage information section 44 displays the number of installation positions for the paper rolls 3 stored in the warehouse 1 and the total number of paper rolls 3. The roll paper information section 45 displays the position information of the paper rolls 3 to be brought in or taken out. The position information of the paper roll 3 includes the position (X, Y) of the paper roll 3 within the warehouse 1, the diameter of the topmost paper roll 3, the total height of the stacked paper rolls 3, and the number of layers of paper rolls 3. Regarding the number of stacked layers of paper rolls 3, if the number is confirmed, the number itself is displayed; if it is uncertain, a notation such as "3+" is displayed to indicate a number greater than the confirmed number. The lift truck information 46 displays the location information of the lift truck 2 being transported or removed within the warehouse 1. For lift trucks 2 within the warehouse 1, selecting the lift truck 2 displayed in the warehouse layout 43 section on the warehouse management server screen 40 with the mouse can display information on the target lift truck 49. Lift trucks 2 outside the warehouse 1 can also be selected on a separate screen (not shown). Furthermore, selecting any roll of paper 3 displayed in the layout display section 43 with the mouse can display information on rolls 3 other than the target roll of paper 48. The work instructions 47 display the work instructions for the operator of the lift truck 2.

[0076] In step S401 of Fig. 23, a work instruction is sent to the operator of the lift vehicle 2 based on the work instruction content shown in Fig. 17, and the work instruction is displayed on the screen of the mobile terminal 21. In step S402, if the work instruction displayed on the screen of the mobile terminal 21 is "carry-in," the operator performs step S403 and subsequent steps, and if not, performs step S413 and subsequent steps.

[0077] Figure 19 shows an example of a mobile device display screen. The layout display section 43 on the screen of the mobile device 21 corresponding to the lift truck 2 displays the layout of the warehouse 1 and the positions of the lift truck 2 and paper roll 3 recognized by the LiDAR 8. This allows the operator of the lift truck 2 to check the work status within the warehouse 1 for which the work instruction has been issued. In other words, the operator can easily understand where in the warehouse 1 the lift truck 2 they are operating is located, and the location within the warehouse 1 of the paper roll 3 to be brought in or removed. Specific work instructions are also displayed in the work instruction section 47. Furthermore, the status of the paper roll 3 to be brought in or removed is displayed in the paper roll information section 45. The status of the paper roll 3 includes the location within the warehouse 1 where the paper roll 3 is located, and the diameter, height, and number of stacked paper rolls 3. Regarding the number of layers of roll paper 3 stacked, if the number is confirmed, the number itself will be displayed, if it is uncertain, it will be displayed as "3+" indicating the number of layers greater than the known number, and if a new roll paper 3 is to be placed in that location, i.e. if a roll paper 3 is not currently present in that location, the number of layers will be displayed as "0".

[0078] Steps S403 and onward in Figure 23 are work steps for transporting the paper roll 3 from outside warehouse 1 into warehouse 1. In step S403, the lift truck 2 grasps the paper roll 3 at a designated location outside warehouse 1. In step S404, the lift truck 2 moves toward warehouse 1. In step S405, the reader device 9 reads the contents of the IC tag 31 attached to the paper roll 3 grasped by the lift truck 2 near the warehouse entrance 12 of warehouse 1. In step S406, the reader device 9 transmits the data read from the IC tag 31 to the warehouse management server 4 via network 5. In step S407, the warehouse management server 4 determines, based on the data sent from the reader device 9, whether the paper roll 3 grasped by the lift truck 2 is the paper roll 3 specified in the work instructions.

[0079] The determination is made based on whether the "product ID" in the work instruction table 42 matches the "product ID" stored in the IC tag 31 read by the reader device 9. If the roll paper 3 is as specified in the work instructions, step S408 is carried out; if not, step S409 is carried out.

[0080] The processing from step S408 onwards is the work procedure for carrying in the paper roll 3 according to the work instructions, and in step S408 a record is added to the carry-in / carry-out record DB 67. A new record is added to the carry-in / carry-out record DB 67 shown in Figure 11, and the "product ID" and "product model number" of the paper roll 3 read by the reader device 9, as well as the current date and time, are stored as the carry-in date and time. The installation location ID of the work instruction is also stored as the installation location ID in the carry-in / carry-out record DB 67. Furthermore, the value of the total number of stacked tiers is extracted from the installation location DB 68 based on the installation location ID of the work instruction, and stored as the number of stacked tiers. The carry-out date and time is left blank. Next, proceed to step S415.

[0081] The processing from step S409 onwards deals with the case where an attempt was made to bring in a roll of paper 3 that is different from the work instructions. In step S409, an error message is displayed on the screen of the mobile terminal 21 of the lift car 2, and the operator of the lift car 2 is notified that an incorrect roll of paper 3 is being brought in. In step S410, the work instructions are corrected on the warehouse management server 4 side.

[0082] In step S411, the corrected work instruction is sent to the mobile terminal 21. In step S412, if the work instruction resent from the warehouse management server 4 and displayed on the screen of the mobile terminal 21 is for carry-in, the operator carries out step S403 and subsequent steps, otherwise, the operator carries out step S445 and subsequent steps. In step S413, if the work instruction displayed on the screen of the mobile terminal 21 is for carry-out, the operator carries out step S415 and subsequent steps, otherwise, the operator carries out step S414 and subsequent steps. Step S414 and subsequent steps are work termination processing, and in step S414, the lift car 2 is moved to a specified location outside the warehouse 1, thereby completing the work.

[0083] In step S415 of Figure 24, the lift car 2 enters the warehouse 1. In step S416, the lift car 2 is moved to a specified position within the warehouse 1. In step S417, if the work instruction displayed on the screen of the mobile terminal 21 is to carry in, the operator carries out step S418 and subsequent steps, and if not, carries out step S434 and subsequent steps.

[0084] Steps S418 and onwards are work steps for the loading process of the paper roll 3. In step S418, the paper roll 3 loaded on the lift car 2 is placed in the specified position. In step S419, it is determined whether the location where the paper roll 3 is placed is the location specified in the work instructions. This determination is made by determining whether this location is the location specified in the work instructions, as the warehouse management server 4 can determine the location where the paper roll 3 is placed based on the update status of the installation location DB 68. If the installation location of the paper roll 3 differs from the work instructions, steps S420 and onwards are carried out; if it is the same, step S421 is carried out.

[0085] In step S421, it is checked whether the installed paper roll 3 is eccentric. If it is eccentric, steps S422 and onwards are carried out; if it is not eccentric, step S423 is carried out. As shown in Figure 14, eccentricity means that the paper roll 3 is determined to be eccentric if the center position of the previously installed paper roll 3 and the center position of the newly stacked paper roll 3 deviate by more than the allowable value. If the paper rolls 3 are stacked eccentrically, the balance of the paper rolls 3 will be lost, and there is a risk that the paper rolls 3 will collapse, leading to a serious accident. To prevent this from happening, the check in step S421 is carried out.

[0086] In step S423, it is checked whether the height of the stacked paper rolls 3 exceeds the allowable value. If the height is exceeded, steps S424 and onwards are carried out, and if it is not exceeded, step S425 is carried out. An excessive height means that the total height of the installed paper rolls 3 exceeds the allowable value. If the paper rolls 3 are stacked so that they exceed the allowable value, the paper rolls 3 will lose their balance, and there is a risk that they will collapse, leading to a serious accident. To prevent this from happening, the check in step S423 is carried out.

[0087] In step S425, it is checked whether the way the installed paper rolls 3 are stacked is incorrect. If it is incorrect, steps S426 and onward are executed; if it is not incorrect, step S430 is executed. As shown in Figure 15, incorrect stacking is determined when a paper roll 3 with a diameter D2 larger than the diameter D1 of the previously installed paper roll 3 is stacked, exceeding the allowable value. If the paper rolls 3 are stacked incorrectly in this way, the balance of the paper rolls 3 will be lost, and there is a risk that the paper rolls 3 will collapse, leading to a serious accident. To prevent this from happening, the check in step S425 is executed.

[0088] In step S430, the delivery of the specified roll of paper 3 is completed, so the installation location DB 68 is updated. The update process is performed as shown in the processing flow in Figure 26. In step S431, the "delivery process" work instruction is completed, so a new work instruction is sent to the mobile terminal 21 of the lift truck 2. In step S432, if the work instruction displayed on the screen of the mobile terminal 21 is delivery, the operator performs step S433 and subsequent steps; otherwise, step S416 and subsequent steps are performed. In step S433, since the work instruction is "delivery," the new roll of paper 3 is removed from warehouse 1 so that it can be delivered from outside warehouse 1. Next, step S403 and subsequent steps are performed.

[0089] The following is the workflow when an error occurs when stacking the paper roll 3 in the installation location. In step S420, a location error message is displayed on the mobile device screen, prompting the operator of the lift car 2 to reinstall the paper roll 3 in the correct installation location specified in the work instructions. In step S422, an eccentricity error message is displayed on the mobile device screen, prompting the operator of the lift car 2 to correct the installation of the paper roll 3, i.e., to reinstall the paper roll 3 so that it is not eccentric. In this case, the operator of the lift car 2 attempts to re-install the paper roll 3 in step S418, in an effort to avoid the error. In step S424, a height error message is displayed on the mobile device 21 screen, and in step S426, an incorrect stacking error message is displayed on the mobile device screen, prompting the operator of the lift car 2 to follow the corrected work instructions. This is because these errors are due to a problem with the work instructions themselves and are errors that the operator cannot handle on their own. In step S427, the operator of the warehouse management server 4 reviews the work instruction itself and creates a new, appropriate work instruction. In step S428, the revised new work instruction is sent to the mobile terminal 21. In step S429, if the work instruction displayed on the screen of the mobile terminal 21 is for delivery, the operator carries out step S416 and subsequent steps; otherwise, the operator carries out step S440 and subsequent steps.

[0090] In step S434 of FIG. 25, if the work instruction displayed on the screen of the mobile terminal 21 is carry-out, the operator carries out step S435 and subsequent steps, and if not, carries out step S450 and subsequent steps.

[0091] Steps S435 and onward are work steps for grasping the paper rolls 3 stacked in the warehouse 1 in order to transport them. In step S435, the position of the attachment 23 of the lift vehicle 2 from the floor is checked. As shown in Figure 16, it is confirmed that the grasping position of the topmost paper roll 3 is exactly in the middle of the topmost paper roll 3. This is because if the paper roll 3 is not grasped exactly in the middle, the weight balance of the paper roll 3 may be lost, causing an accident such as a fall. In step S436, it is determined whether the grasping position of the paper roll 3 is appropriate. If it is inappropriate, step S437 is executed. If the grasping position is correct, step S438 and onward are executed. In step S437, a grasping position error message is displayed on the screen of the mobile terminal 21, prompting the operator of the lift vehicle 2 to grasp the paper roll 3 in the correct grasping position. The operator of the lift vehicle 2 re-grabs the paper roll 3 in the correct gripping position and starts again from step S435. In step S438, the paper roll 3 is removed from the position specified in the work instruction. In step S439, since the removal of the specified paper roll 3 has been completed, an update process is performed on the installation location DB 68. In the update process, the value of the total number of stacked layers in the installation location DB 68 is decreased by 1.

[0092] In step S440, the lift truck 2 leaves the warehouse 1. In step S441, the reader 9 near the warehouse exit 13 of the warehouse 1 reads the contents of the IC tag 31 attached to the paper roll 3 held by the lift truck 2. In step S442, the reader 9 transmits the data read from the IC tag 31 to the warehouse management server 4 via the network 5. In step S443, the warehouse management server 4 determines, based on the data sent from the reader 9, whether the paper roll 3 held by the lift truck 2 is the paper roll 3 specified in the work instructions. If it is the paper roll 3 specified in the work instructions, step S444 is carried out; if not, step S446 is carried out. The processing from step S444 onwards is the work procedure for unloading the paper roll 3 specified in the work instructions, and in step S444, this is added to the relevant section of the delivery / removal record DB. The added content is stored as the delivery date and time at that time. In step S445, the loaded roll paper 3 is transported to the location specified in the work instruction, the roll paper 3 is placed, and step S401 is performed. In step 446, a roll paper error is displayed on the screen of the mobile terminal 21, and the operator of the lift truck 2 is prompted to follow the corrected work instruction. In step S447, the operator of the warehouse management server 4 reviews the work instruction itself and creates a new, appropriate work instruction. In step S448, the new, corrected work instruction is sent to the mobile terminal 21. In step S449, if the work instruction displayed on the screen of the mobile terminal 21 is carry-in, the operator performs step S404 and subsequent steps; otherwise, the operator performs step S445 and subsequent steps.

[0093] Steps S450 and onward are processing steps for completing the work. In step S450, the lift truck 2 is taken out of the warehouse 1.

[0094] In step S451, the lift vehicle 2 is moved to the position specified in the work instruction, and the work is completed.

[0095] The warehouse management system configured as above can accurately grasp the status of the warehouse 1 and the status of goods being carried in and out of the warehouse 1 with a small amount of equipment, and can smoothly manage the warehouse at low cost.

[0096] Second Embodiment In the first embodiment, roll paper 3 was used as an example of the object 80 to be carried in and out of the warehouse 1, but according to the present invention, the object 80 (storage item) can be something other than roll paper 3. For example, it can be applied to a stored item having a rectangular parallelepiped shape as shown in Figure 27. In this case, by calculating the coordinate values ​​(X, Y, Z) in three-dimensional space of points P1, P2, P3, and P4 at the four corners of the top surface of the rectangular parallelepiped, and using these values ​​to perform the same processing as for roll paper 3, management of such a stored item having a rectangular parallelepiped shape can be performed in exactly the same way as for roll paper 3.

[0097] Data corresponding to the position (P) and height (H) in the case of roll paper 3 can be calculated as follows from the coordinate values ​​(X, Y, Z) in three-dimensional space of points P1, P2, P3, and P4.

[0098] P(X)=(P1(X)+P2(X)+P3(X)+P4(X)) / 4 P(Y)=(P1(Y)+P2(Y)+P3(Y)+P4(Y)) / 4 P(H)=(P1(Z)+P2(Z)+P3(Z)+P4(Z)) / 4 In addition, the determination of eccentricity and incorrect stacking orientation, which was done in the case of roll paper 3, can be performed by comparing the X and Y coordinate values ​​of points P1, P2, P3, and P4 on the bottom row with the X and Y coordinate values ​​of points P1, P2, P3, and P4 on the top surface of the stacked storage item, and if each does not fall within a certain range, an error is detected, thereby performing an equivalent error check. Third Embodiment In the first embodiment, the lift car 2 is an example of a manned lift car (one operated by an operator), but it can also be applied to an unmanned lift car (autonomous driving car). In this case, the mobile terminal 21 that gave instructions to the operator and the error display to the operator are no longer necessary, and the warehouse management server 4 can directly send corrected "work instructions" to the control part of the unmanned lift car, in other words, it can send corrected work instructions that are different from the work instructions previously sent to the unmanned lift car, so the present invention can be applied to unmanned lift cars without any problems.

[0099] The warehouse management system of the present invention is not limited to the above configuration, and various design changes are possible without departing from the gist of the present invention. [Explanation of symbols]

[0100] 1 warehouse 2 lift trucks 3 rolls of paper 4. Warehouse Management Server 5. Network 6 Warehouse Management Control Unit 7 HUB 8. LiDAR 9 Leader Machine 11 Passage 12 Warehouse entrance 13 Warehouse export exit 21 Mobile devices 22 Mast 23 Attachment 31 IC tag 40 Warehouse Management Server Screen 41 Work Record DB 42 Work Instruction Table 43 Warehouse layout 44 Roll paper storage information 45 Roll Paper Information 46 Lift vehicle information 47 Work instructions 48 Target roll paper 49 Target lift vehicle 60 processors 61 memory Bus 62 63 Interface 64 Communication control unit 65 LiDAR control unit 66 Roll Paper Product Information DB 67 Loading and unloading record DB 68 Installation location DB 69 Lift vehicle information DB 80 Objects 81 Power supply 82 MCU 83 Laser Oscillator 84 Scanning mechanism 85 Condenser Lens 86 Photodetector 87 Measurement Circuit 88 3D point cloud data output section 89 3D point cloud data 91 Designated lift vehicle 92 Mobile phone number 93 Loading and unloading instructions 100 Data Received 101 Lift vehicle data 102 Roll paper data

Claims

1. A LiDAR that irradiates a pulsed laser into the warehouse, receives reflected light or scattered light from an object in the warehouse, measures the distance and direction to the object, and outputs 3D point cloud data of the object based on the distance and direction to the object; a stored item state detection means for inputting the 3D point cloud data output from the LiDAR, recognizing stored items in the warehouse from the 3D point cloud data, calculating coordinate data of the stored items in the warehouse, and detecting installation state data of the stored items including at least central position data of the top surface of the stored items; a storage item state storage means for storing installation state data of the stored items detected by the storage item state detection means; a stored item status grasping means for detecting installation status data of the stored items in the warehouse at regular intervals using the stored item status detecting means and comparing the detected installation status data with the installation status data of the stored items stored in the stored item status memory means, thereby making it possible to grasp the status of carrying in and out of the stored items in the warehouse and their storage locations; A warehouse management system comprising:

2. A plurality of the LiDARs are used, and each coordinate system of each of the LiDARs is converted into one standard coordinate system; 2. The warehouse management system according to claim 1, wherein the stored item state detection means calculates coordinate data indicating the position of the stored item based on the standard coordinate system.

3. The installation state data of the stored item includes height data of the stored item in addition to center position data of the top surface of the stored item, The stored item status grasping means 2. The warehouse management system according to claim 1, wherein height data of the stored items in the warehouse detected by the stored item status detection means at regular intervals is compared with height data of the stored items stored in the stored item status memory means, thereby making it possible to grasp the status of items being carried in and out of the warehouse even when the stored items in the warehouse are stacked in multiple layers.

4. The warehouse management system according to claim 1, characterized in that the LiDAR is arranged so as to be able to recognize the 3D point cloud data of the top surfaces of all the stored items stored in the warehouse.

5. a mobile object position detection means for recognizing the position of a mobile object that transports the stored item within the warehouse from the 3D point cloud data; a mobile object position storage means for storing the position data of the mobile object detected by the mobile object position detection means; a mobile object status ascertaining means for comparing the position data of the mobile object in the warehouse detected by the mobile object position detecting means at regular intervals with the position data of the mobile object stored in the mobile object position storage means, thereby ascertaining the status of the mobile object in the warehouse; 2. The warehouse management system according to claim 1, further comprising:

6. a server that manages the warehouse is provided via a network, In the case of any one of claims 1, 2, 3, and 4, the server has a work instruction table in which work instructions to be given to an operator of a mobile body are stored, and in the case of claim 5, the server has a work instruction table in which work instructions to be given to an operator of the mobile body are stored, The moving body is a lift vehicle, A warehouse management system as described in any one of claims 1, 2, 3, 4, or 5, characterized in that work instructions to the operator are displayed on the screen of a mobile terminal held by the operator of the lift vehicle based on the work instruction table.

7. The server Based on the installation status data of the stored item, 7. The warehouse management system according to claim 6, wherein a layout of the stored items in the warehouse detected by the stored item state detection means is displayed on the screen of the mobile terminal.

8. The server Based on the installation state data of the stored items in the warehouse detected by the stored item state detection means at regular intervals and the installation state data of the stored items stored in the stored item state storage means, 7. The warehouse management system according to claim 6, wherein an error check is performed on the way the stored items are set up or held for the stored items to be brought into or taken out of the warehouse, and if an error occurs, an error message is displayed on the screen of the mobile terminal of the operator.

9. The server Based on the center position data of the top surface of the stored item, 9. The warehouse management system according to claim 8, wherein the location of the stored item that has been brought in or the location of the stored item to be brought out is confirmed to be the location specified in the work instructions, and if the location is incorrect, an error message is displayed on the screen of the mobile terminal of the operator.

10. When the installation state data of the stored item includes height data of the stored item, The server Based on the height data of the stored item, 9. The warehouse management system according to claim 8, wherein the stack height of the stored items brought in is checked, and if the stack height exceeds the stack tolerance, an error message is displayed on the mobile terminal screen of the operator.

11. The server When stacking the stored items that have been brought in, based on the center position data of the top surfaces of the stored items, 9. The warehouse management system according to claim 8, wherein the position of the stored item below the pile of stored items is compared with the position of the stored item, and if the deviation between the two exceeds a predetermined tolerance, it is determined that the stored item has been placed eccentrically, and an error message is displayed on the screen of the mobile terminal of the operator.

12. The installation state data of the stored item includes width data representing the width in the left-right direction in the installation state, The server When stacking the delivered storage items, the width data of the storage item below the stacked storage items is compared with the width data of the storage item; If the width data of the stacked storage item is larger than the width data of the storage item below it by a predetermined allowable value or more, it is determined that the stacking method is incorrect, 9. The warehouse management system according to claim 8, wherein an error message is displayed on the screen of the portable terminal of the operator.

13. Unique identification information is assigned to the stored items stored in the warehouse, and a reading means is provided that is connected to the server and reads the identification information, When the reading means reads the identification information at the time of delivery to or delivery from the warehouse and transmits the information to the server, 9. The warehouse management system according to claim 8, wherein the server verifies that the stored items are in accordance with the work instructions, and if they are not, displays an error message on the screen of the mobile terminal of the operator.

14. The lift vehicle includes a mast and an attachment attached to the mast and capable of grasping the stored item, a sensor is provided on the mast so as to be able to recognize the height of the attachment; When carrying out the stored items stored in the warehouse, The server: Based on the height of the attachment transmitted from the sensor, The warehouse management system according to claim 8, characterized in that the height at which the attachment of the lift vehicle grasps the stored item is confirmed, and whether the stored item is being grasped at the correct position, and if it is incorrect, an error message is displayed on the mobile terminal screen of the operator.

15. The server 9. The warehouse management system according to claim 8, wherein the work instructions or error messages displayed on the mobile terminal of the operator of the lift vehicle are stored as a log together with the time of display.

16. a server that manages the warehouse is provided via a network, In the case of any one of claims 1, 2, 3 and 4, the server has a work instruction table in which work instructions to be given to the mobile body are stored, and in the case of claim 5, the server has a work instruction table in which work instructions to be given to the mobile body are stored, The moving body is an autonomous vehicle, 6. The warehouse management system according to claim 1, wherein the work instructions are transmitted to the self-driving vehicle based on the work instruction table.

17. The server Based on the installation state data of the stored items in the warehouse detected by the stored item state detection means at regular intervals and the installation state data of the stored items stored in the stored item state storage means, The warehouse management system according to claim 16, characterized in that an error check is performed on the way the storage object is installed or the way the storage object is held when the stored item is to be brought into or taken out of the warehouse, and if an error occurs, a corrected work instruction is sent to the self-driving vehicle.

18. The server, based on the center position data of the top surface of the stored item, The warehouse management system according to claim 17, characterized in that it checks whether the position of the stored item that has been brought in or the position of the stored item that is to be taken out is as specified in the work instruction, and if it is incorrect, it sends a corrected work instruction that differs from the work instruction sent to the autonomous vehicle.

19. When the installation state data of the stored item includes height data of the stored item, The server The warehouse management system according to claim 17, characterized in that the stack height of the stored items that have been brought in is confirmed based on the height data of the stored items, and if the stack height exceeds the stacking tolerance, a modified work instruction different from the work instruction sent to the self-driving vehicle is sent.

20. The server 18. The warehouse management system according to claim 17, wherein when the stored items that have been brought in are stacked, the position of the stored item below the stacked items is compared with the position of the stored item itself based on center position data of the top surfaces of the stored items, and if the deviation between the two exceeds a predetermined tolerance, it is determined that the items have been placed eccentrically, and a corrected work instruction that differs from the work instruction sent to the autonomous vehicle is sent.

21. The installation state data of the stored item includes width data representing the width in the left-right direction in the installation state, The server When stacking the delivered storage items, the width data of the storage item below the stacked storage items is compared with the width data of the storage item; If the width data of the stacked storage item is larger than the width data of the storage item below it by a predetermined allowable value or more, it is determined that the stacking method is incorrect, The warehouse management system according to claim 17, characterized in that it transmits a modified work instruction that is different from the work instruction transmitted to the autonomous vehicle.

22. Unique identification information is assigned to the stored items stored in the warehouse, and a reading means is provided that is connected to the server and reads the identification information, When the reading means reads the identification information at the time of delivery to or delivery from the warehouse and transmits the information to the server, 18. The warehouse management system according to claim 17, wherein the server verifies that the stored item is in accordance with the work instructions, and if it is different, transmits a corrected work instruction that differs from the work instruction transmitted to the autonomous vehicle.

23. The autonomous vehicle includes a mast and an attachment attached to the mast and capable of grasping the stored item; a sensor is provided on the mast so as to be able to recognize the height of the attachment; When carrying out the stored items stored in the warehouse, The server: Based on the height of the attachment transmitted from the sensor, the height at which the attachment of the autonomous vehicle grasps the stored item is confirmed, and it is confirmed whether the attachment is correctly grasping the position at which the stored item should be grasped. If it is incorrect, The warehouse management system according to claim 17, characterized in that it transmits a modified work instruction that is different from the work instruction transmitted to the autonomous vehicle.

24. The server The warehouse management system according to claim 17, wherein the work instructions sent to the self-driving vehicle are stored as a log together with the time of the sending.

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