Article storage facility

Abstract

It is desired to realize an article storage facility capable of securing a large storage capacity for articles while suppressing an increase in cost.SOLUTION: The article storage facility 1 includes carry-in portions 10 into which articles W are carried, branching transport devices 20, automatic warehouses 30, buffer conveyors 40, merging transport devices 50, carry-out portions 61 from which articles W are carried out, and a control system. The control system controls the branching transport device 20, the automatic warehouses 30, the buffer conveyors 40, and the merging transport device 50 so as to transport a plurality of articles W to the carrying-out portion 61 in a specified order. The buffer conveyor 40 is configured to be able to transport and stop transporting the articles W, and to be able to store a plurality of articles W on the transport path of the articles W. The automated storages 30 and the buffer conveyors 40 are connected in parallel to each other between the branching transport device 20 and the merging transport device 50.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an article storage facility equipped with an automated warehouse. [Background technology]

[0002] An example of an article storage facility equipped with an automated warehouse is disclosed in Japanese Patent Publication No. 3-14721 (Patent Document 1). Hereinafter, in the description of this background art, reference numerals in Patent Document 1 will be cited in parentheses. In the article storage facility of Patent Document 1, the automated warehouse is equipped with high-rise racks (7), and pallets carrying articles to be picked are stored in the high-rise racks (7). After articles on pallets are removed from the automated warehouse, they are supplied to a case flow rack (29) that stores the articles via a conveyance / storage line (26) that stores the articles. The articles stored in the case flow rack (29) are then picked up by an automatic picking device (30). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Special Publication No. 3-14721 Summary of the Invention [Problem to be solved by the invention]

[0004] Incidentally, there are cases where it is desirable to ensure a large storage capacity for goods in an item storage facility equipped with an automated warehouse. In the item storage facility of Patent Document 1, although goods removed from pallets can be stored on a conveyor / storage line or case flow rack, the pallets (pallets with goods loaded on them; the same applies hereinafter) are stored in the automated warehouse. Therefore, in the item storage facility of Patent Document 1, if it is desired to ensure a large storage capacity for pallets as goods, it is necessary to increase the number of goods stored in the automated warehouse and the number of automated warehouses installed, which is likely to increase the cost of the item storage facility.

[0005] Therefore, it is desirable to realize an item storage facility that can ensure a large storage capacity for items while suppressing increases in costs. [Means for solving the problem]

[0006] The item storage facility according to the present disclosure is an item storage facility including an inlet section into which items are brought in, a branching conveying device, an automated warehouse, a buffer conveyor, a merging conveying device, an outlet section from which the items are brought out, and a control system, wherein the control system controls the branching conveying device, the automated warehouse, the buffer conveyor, and the merging conveying device so as to transport a plurality of the items to the outlet section in a specified order, the automated warehouse is capable of storing a plurality of the items that have been stored, and is capable of retrieving each of the stored items in a selected order, and the buffer conveyor controls the control system to transport a plurality of the items to the outlet section in a specified order. The branch conveyor is configured to be able to transport and stop transporting the items and to store multiple items on the item transport path, the branch conveying device is configured to transport the items transported to the inlet section to one selected from the automated warehouse and the buffer conveyor, the merging conveying device is configured to transport the items transported from the automated warehouse and the buffer conveyor to the outlet section, and the automated warehouse and the buffer conveyor are connected in parallel to each other between the branch conveying device and the merging conveying device.

[0007] According to this configuration, since items delivered to the loading section can be stored in both the automated warehouse and the buffer conveyor, a relatively large number of items can be stored. Here, buffer conveyors are generally cheaper than automated warehouses, so storing items using both the automated warehouse and the buffer conveyor in this way makes it easier to reduce the cost of the item storage facility compared to storing items entirely in the automated warehouse. Therefore, according to this configuration, it is possible to ensure a large storage capacity for items while suppressing increases in costs.

[0008] Furthermore, according to this configuration, the automated warehouse and the buffer conveyor are connected in parallel to each other between the branching conveying device and the merging conveying device. Therefore, an item carried into the carrying-in section can be transported from the branching conveying device to either the automated warehouse or the buffer conveyor, and an item stored in either the automated warehouse or the buffer conveyor can be transported from the merging conveying device to the carrying-out section. Therefore, according to this configuration, it is easy to appropriately select a storage destination for an item carried into the carrying-in section, taking into account the differences in characteristics between the automated warehouse and the buffer conveyor, and it is also easy to transport items stored in the automated warehouse and the buffer conveyor to the carrying-out section in a specified order.

[0009] Further features and advantages of the storage facility will become apparent from the following description of the embodiments, which proceeds with reference to the drawings. [Brief explanation of the drawings]

[0010] [Figure 1] Schematic diagram of an item storage facility according to an embodiment. [Figure 2] Schematic diagram of a first layer of an item storage facility according to an embodiment. [Figure 3] Schematic diagram of a second floor of an item storage facility according to an embodiment. [Figure 4] Schematic diagram of a third floor of an item storage facility according to an embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] An embodiment of an article storage facility will be described with reference to the drawings. As shown in Fig. 1, the article storage facility 1 includes an inlet section 10 into which articles W are brought in, a branching conveying device 20, an automated warehouse 30, a buffer conveyor 40, a merging conveying device 50, an outlet section 61 from which articles W are brought out, and a control system 2 (see Fig. 2). While the article storage facility 1 can be configured to include only one buffer conveyor 40, in this embodiment, the article storage facility 1 includes multiple buffer conveyors 40. Note that in Figs. 1 to 4, arrows indicate the direction of movement of articles W due to transport operations, transfer operations, etc., and in Figs. 2 to 4, arrows also indicate the direction of movement of a transport vehicle 36, which will be described later.

[0012] In this embodiment, there are multiple types of items W. That is, the item storage facility 1 of this embodiment handles multiple types of items W. In this embodiment, the items W are containers (containers, cardboard boxes, etc.) that store loads (goods, etc.), and the type of item W is determined according to the type of load stored in the item W. The type of item W is classified, for example, based on the minimum management unit (SKU: Stock Keeping Unit) of the load stored in the item W. In Figures 2 to 4, for some items W, an alphabet representing the type of item W is shown inside a rectangle representing the item W. Items W with the same alphabet are of the same type. Hereinafter, an item W of type N (N = A, B, C, D, E, F, X) will be referred to as item W[N].

[0013] Multiple types of items W are carried into the carry-in section 10, for example, from a production line. In this embodiment, the items W are carried into the carry-in section 10 by a conveyor (such as a belt conveyor or a roller conveyor, the same applies below). In the example shown in FIGS. 1 and 2, the downstream end of the conveyor (carry-in conveyor) constitutes the carry-in section 10. Note that the manner in which the items W are carried into the carry-in section 10 is not limited to being carried in by a conveyor, and may be, for example, a manner in which the items W are carried in by an unmanned guided vehicle or a manned guided vehicle, or a manner in which the items W are carried in by a worker.

[0014] In this embodiment, an article W is carried out from the carrying-out section 61 by a conveyor (an output conveyor 60). In the example shown in FIGS. 1 and 2, the upstream end of the output conveyor 60 constitutes the carrying-out section 61. In this embodiment, the output conveyor 60 is connected to a work area where the article W is stacked on a support S (see FIG. 2) such as a cart or a pallet, and the output conveyor 60 is configured to transport the article W carried out from the carrying-out section 61 to the work area. In the example shown in FIGS. 1 and 2, a conveyor forming a dispensing path 70 (described later) is arranged to branch off from the output conveyor 60. Note that the manner in which the article W is carried out from the carrying-out section 61 is not limited to being carried out by a conveyor, and may be, for example, a manner in which the article W is carried out by an unmanned guided vehicle or a manned guided vehicle, or a manner in which the article W is carried out by a worker.

[0015] The automated warehouse 30 is configured to be able to store a plurality of stored items W. The automated warehouse 30 is also configured to be able to retrieve each of the stored items W in a selected order. The order in which the items W are to be retrieved from the automated warehouse 30 is selected by the control system 2. The control system 2 selects the order in which the items W are to be retrieved from the automated warehouse 30, for example, based on the order in which the items W are stacked on the support body S. The automated warehouse 30 is a warehouse that automatically retrieves and stores the items W. Examples of the automated warehouse 30 include a warehouse that uses shuttle carts and a warehouse that uses stacker cranes.

[0016] In the example shown in FIGS. 2 to 4, the automated warehouse 30 is a warehouse that uses shuttle carts. The automated warehouse 30 includes an entry section 34 where items W are stored, an outgoing section 35 where items W are retrieved, a shelf 31 that stores the items W, and a transport vehicle 36 (shuttle cart) that travels along the shelf 31 to transport the items W. In the example shown, the transport vehicle 36 travels between a pair of shelves 31. The entry section 34 and the outgoing section 35 are provided with, for example, conveyors. An item W to be stored in the automated warehouse 30 is transported from the entry section 34 to the shelf 31 by the transport vehicle 36 and stored on the shelf 31. In addition, an item W to be retrieved from the automated warehouse 30 is transported by the transport vehicle 36 from the shelf 31 where the item W is stored to the outgoing section 35 from the shelf 31 where the item W is stored.

[0017] In this example, the shelves 31 are arranged in a vertical line on multiple levels, and the travel path of the transport vehicle 36 is formed on multiple levels corresponding to the shelves 31 arranged on multiple levels. The storage section 34 and the delivery section 35 are also arranged on multiple levels corresponding to the shelves 31 arranged on multiple levels. The automated warehouse 30 further includes a storage lifting device 32 that lifts and lowers the items W, and a delivery lifting device 33 that lifts and lowers the items W. These lifting devices (32, 33) include a lifting platform that supports and lifts and lowers the items W. The lifting platform is provided with, for example, a conveyor that transports the items W.

[0018] The receiving lifting device 32 raises and lowers the lifting platform to a height corresponding to a sixth conveyor 46 (see FIGS. 1 and 3) described later, and receives the item W to be received into the automated warehouse 30 from the sixth conveyor 46. The receiving lifting device 32 then raises and lowers the lifting platform to a height corresponding to the shelf 31 on which the item W is to be stored, and delivers the item W to the receiving section 34 located on the same level as the shelf 31. The outgoing lifting device 33 raises and lowers the lifting platform to a height corresponding to the shelf 31 on which the item W to be delivered is stored, and receives the item W from the outgoing section 35 located on the same level as the shelf 31. The outgoing lifting device 33 then raises and lowers the lifting platform to a height corresponding to a seventh conveyor 47 (see FIGS. 1 and 2) described later, and delivers the item W to the seventh conveyor 47.

[0019] As will be described later, in this embodiment, the buffer conveyors 40 are arranged on multiple levels. In the example shown in Fig. 1, the buffer conveyors 40 are arranged on three levels: a first level L1, a second level L2 above the first level L1, and a third level L3 above the second level L2. The shelves 31 and the buffer conveyors 40 may be arranged at the same height or at different heights, but Figs. 2 to 4, which show an outline of each level (L1 to L3) of the item storage facility 1, show the shelves 31 in addition to the buffer conveyors 40.

[0020] Each of the multiple buffer conveyors 40 is configured to be able to transport and stop transporting the items W. Furthermore, each of the multiple buffer conveyors 40 is configured to be able to store multiple items W on the transport path of the items W. The buffer conveyor 40 is a conveyor that functions as a buffer for temporarily storing the items W. In this embodiment, the buffer conveyor 40 is configured to be able to store the items W in a line.

[0021] 1, in this embodiment, the article storage facility 1 includes a first conveyor 41, a second conveyor 42, a third conveyor 43, a fourth conveyor 44, a fifth conveyor 45, a sixth conveyor 46, and a seventh conveyor 47. The first conveyor 41, the second conveyor 42, the third conveyor 43, the fourth conveyor 44, and the fifth conveyor 45 are used as buffer conveyors 40. The sixth conveyor 46 is used as an in-stock conveyor for storing an article W into the automated warehouse 30, and the seventh conveyor 47 is used as an out-stock conveyor for retrieving the article W from the automated warehouse 30. In this embodiment, the first conveyor 41 and the seventh conveyor 47 are arranged on the first layer L1, the second conveyor 42, the third conveyor 43 and the sixth conveyor 46 are arranged on the second layer L2, and the fourth conveyor 44 and the fifth conveyor 45 are arranged on the third layer L3.

[0022] Each of the multiple buffer conveyors 40 (specifically, the first conveyor 41, the second conveyor 42, the third conveyor 43, the fourth conveyor 44, and the fifth conveyor 45) is arranged to connect the branching conveying device 20 and the merging conveying device 50. Furthermore, the sixth conveyor 46 is arranged to connect the branching conveying device 20 and the automated warehouse 30 (specifically, the receiving lifting device 32), and the seventh conveyor 47 is arranged to connect the automated warehouse 30 (specifically, the outgoing lifting device 33) and the merging conveying device 50. In other words, the automated warehouse 30 is arranged to connect the branching conveying device 20 and the merging conveying device 50 via the sixth conveyor 46 and the seventh conveyor 47. Therefore, with regard to the connection relationship between the branching conveying device 20 and the merging conveying device 50, the automated warehouse 30 and the multiple buffer conveyors 40 are connected in parallel to each other between the branching conveying device 20 and the merging conveying device 50. That is, the automated warehouse 30 and the buffer conveyor 40 are connected in parallel to each other between the branching conveying device 20 and the merging conveying device 50. In this embodiment, a plurality of buffer conveyors 40 are connected in parallel to each other between the branching conveying device 20 and the merging conveying device 50.

[0023] Here, as shown in FIGS. 1 to 4, two horizontal directions perpendicular to each other are defined as the X direction and the Y direction. One side in the X direction is defined as the X direction first side X1, and the other side in the X direction is defined as the X direction second side X2. One side in the Y direction is defined as the Y direction first side Y1, and the other side in the Y direction is defined as the Y direction second side Y2. In this embodiment, the first conveyor 41, the second conveyor 42, and the fourth conveyor 44 are arranged to extend in the X direction on the Y direction first side Y1 with respect to the automated warehouse 30. Here, the first conveyor 41, the second conveyor 42, and the fourth conveyor 44 are arranged at the same position in the Y direction. Furthermore, partial sections of the third conveyor 43, the fifth conveyor 45, and the seventh conveyor 47 are arranged to extend in the X direction on the Y direction second side Y2 with respect to the automated warehouse 30. Here, the partial sections of the third conveyor 43, the fifth conveyor 45, and the seventh conveyor 47 are arranged at the same position in the Y direction.

[0024] The branch conveying device 20 is configured to transport the item W that has been brought into the receiving section 10 to one selected from the automated warehouse 30 and a plurality of buffer conveyors 40 (five buffer conveyors 40 in this embodiment). The destination of the item W is selected by the control system 2. When the automated warehouse 30 is selected as the destination of the item W, the branch conveying device 20 transports the item W that has been brought into the receiving section 10 to the sixth conveyor 46 connected to the automated warehouse 30.

[0025] In this embodiment, as shown in Fig. 1, the branch conveying device 20 includes a branch lifting device 21 and branch conveyors 22 arranged on multiple levels. The branch lifting device 21 includes a lifting platform that supports and raises and lowers the article W. This lifting platform is provided with, for example, a conveyor that transports the article W. The branch lifting device 21 raises and lowers the lifting platform to a height corresponding to the carry-in section 10, and receives the article W from the carry-in section 10. The branch lifting device 21 then raises and lowers the lifting platform to a height corresponding to the branch conveyor 22 connected to the destination of the article W, and delivers the article W to the branch conveyor 22.

[0026] The branch conveyor 22 is connected to an end of the buffer conveyor 40 on the upstream side (here, the first side X1 in the X direction). In this embodiment, the branch conveying device 20 includes a first branch conveyor 22 (see FIG. 2) connected to the first conveyor 41, a second branch conveyor 22 (see FIG. 3) connected to the second conveyor 42, the third conveyor 43, and the sixth conveyor 46, and a third branch conveyor 22 (see FIG. 4) connected to the fourth conveyor 44 and the fifth conveyor 45. As shown in FIG. 1, the first branch conveyor 22 is arranged on the first level L1, the second branch conveyor 22 is arranged on the second level L2, and the third branch conveyor 22 is arranged on the third level L3. Also, as shown in FIGS. 3 and 4, the second and third branch conveyors 22 are arranged to extend in the Y direction on the first side X1 in the X direction relative to the automated warehouse 30. Here, the first to third branch conveyors 22 are arranged at the same position in the X direction.

[0027] The control system 2 controls the operation of the second branch conveyor 22 so that the article W delivered from the branch lifting device 21 to the second branch conveyor 22 is transported to a conveyor selected as a destination from among the second conveyor 42, the third conveyor 43, and the sixth conveyor 46. The control system 2 also controls the operation of the third branch conveyor 22 so that the article W delivered from the branch lifting device 21 to the third branch conveyor 22 is transported to a conveyor selected as a destination from among the fourth conveyor 44 and the fifth conveyor 45.

[0028] As shown in Fig. 3, in this embodiment, the connection portion of the second branch conveyor 22 with the sixth conveyor 46 is located downstream of the connection portion of the second branch conveyor 22 with the second conveyor 42 (here, on the second side Y2 in the Y direction). The connection portion of the second branch conveyor 22 with the third conveyor 43 is located downstream of the connection portion of the second branch conveyor 22 with the sixth conveyor 46. Therefore, the portion of the second branch conveyor 22 downstream of the connection portion with the sixth conveyor 46 may be included in the third conveyor 43. In this case, the storage area for the articles W on the third conveyor 43 can be expanded upstream compared to the example shown in Fig. 3.

[0029] 4, in this embodiment, the connection portion of the third branch conveyor 22 with the fifth conveyor 45 is located downstream (here, on the second side Y2 in the Y direction) of the connection portion of the third branch conveyor 22 with the fourth conveyor 44. Therefore, the portion of the third branch conveyor 22 downstream of the connection portion with the fourth conveyor 44 may be included in the fifth conveyor 45. In this case, the storage area for the articles W on the fifth conveyor 45 can be expanded upstream compared to the example shown in FIG.

[0030] The configuration of the branch conveying device 20 is not limited to that shown in Figure 1, and for example, the branch conveying device 20 can be configured to be equipped with a conveyor whose posture can be changed instead of the branch lifting device 21, and by changing the posture of the conveyor, the branch conveyor 22 to which the item W is to be conveyed can be switched.

[0031] The junction conveying device 50 is configured to convey the articles W conveyed from each of the automated warehouse 30 and the multiple buffer conveyors 40 to the unloading section 61. In this embodiment, the junction conveying device 50 is configured to be able to change the order in which the articles W are delivered to the unloading section 61 from the order in which the articles W arrive from the automated warehouse 30 or the buffer conveyors 40. Specifically, as will be described in detail later, the junction conveying device 50 is configured to deliver the articles W to the unloading section 61 in the order in which the junction lifting device 51 receives the articles W from the junction conveyor 52, regardless of the order in which the articles W arrive from the automated warehouse 30 or the buffer conveyors 40.

[0032] In this embodiment, as shown in FIG. 1 , the junction conveying device 50 includes a junction lifting device 51 and junction conveyors 52 arranged on multiple floors. The junction lifting device 51 includes a lifting platform that supports and lifts the article W. This lifting platform is provided with, for example, a conveyor that transports the article W. The junction lifting device 51 raises and lowers the lifting platform to a height corresponding to the junction conveyor 52 connected to the source of the article W (either the automated warehouse 30 or one of the multiple buffer conveyors 40), and receives the article W from the junction conveyor 52. The junction lifting device 51 then raises and lowers the lifting platform to a height corresponding to the discharge section 61, and delivers the article W to the discharge section 61.

[0033] The junction conveyor 52 is connected to an end of the buffer conveyor 40 on the downstream side (here, the second side X2 in the X direction). In this embodiment, the junction conveying device 50 includes a first junction conveyor 52 (see FIG. 2) connected to the first conveyor 41 and the seventh conveyor 47, a second junction conveyor 52 (see FIG. 3) connected to the second conveyor 42 and the third conveyor 43, and a third junction conveyor 52 (see FIG. 4) connected to the fourth conveyor 44 and the fifth conveyor 45. As shown in FIG. 1, the first junction conveyor 52 is arranged on the first layer L1, the second junction conveyor 52 is arranged on the second layer L2, and the third junction conveyor 52 is arranged on the third layer L3. 2 to 4, the first to third merging conveyors 52 are arranged to extend in the Y direction on the second side X2 in the X direction with respect to the automated warehouse 30. Here, the first to third merging conveyors 52 are arranged at the same position in the X direction.

[0034] 3, in this embodiment, the connection portion of the second merging conveyor 52 with the third conveyor 43 is located upstream of the connection portion of the second merging conveyor 52 with the second conveyor 42 (here, on the second side Y2 in the Y direction). Therefore, the portion of the second merging conveyor 52 upstream of the connection portion with the second conveyor 42 may be included in the third conveyor 43. In this case, the storage area for the articles W on the third conveyor 43 can be expanded downstream compared to the example shown in FIG.

[0035] 4, in this embodiment, the connection portion of the third merging conveyor 52 with the fifth conveyor 45 is located upstream (here, on the second side Y2 in the Y direction) of the connection portion of the third merging conveyor 52 with the fourth conveyor 44. Therefore, the portion of the third merging conveyor 52 upstream of the connection portion with the fourth conveyor 44 may be included in the fifth conveyor 45. In this case, the storage area for the articles W on the fifth conveyor 45 can be expanded downstream compared to the example shown in FIG.

[0036] The configuration of the junction conveying device 50 is not limited to that shown in Figure 1, and for example, the junction conveying device 50 can be configured to be equipped with a conveyor whose posture can be changed instead of the junction lifting device 51, and by changing the posture of the conveyor, the junction conveyor 52 from which the item W is conveyed can be switched.

[0037] The control system 2 controls the branching conveying device 20, the automated warehouse 30, the multiple buffer conveyors 40, and the merging conveying device 50. The control system 2 controls the operation of the device to be controlled by controlling the driving of a drive power source (e.g., an electric motor) provided in the device. The control system 2 includes an arithmetic processing device such as a CPU (Central Processing Unit) and peripheral circuits such as a memory, and the functions of the control system 2 are realized by cooperation between hardware such as the arithmetic processing device and a program executed on the hardware. The control system 2 may be realized not by a single device (e.g., a computer such as a personal computer or a workstation), but by multiple devices that can communicate with each other.

[0038] The control system 2 controls the branching conveying device 20, the automated warehouse 30, the multiple buffer conveyors 40, and the merging conveying device 50 so that the multiple items W are transported to the discharge section 61 in a specified order. The control system 2 controls each of the above devices so that the multiple items W are transported from the merging conveying device 50 to the discharge section 61 in a specified order. In this embodiment, the multiple items W are stacked on the support body S in the order in which they are transported to the discharge section 61. The above "specified order" is specified, for example, based on order information that specifies the types of items W and the number of items W of each type.

[0039] Although it is possible to configure the system so that multiple types of items W are stacked on one support S, in this embodiment, multiple items W of the same type are stacked on one support S. FIG. 2 shows how multiple items W[X] carried out from the discharge section 61 are stacked on one support S. In this embodiment, the control system 2 stores the items W in the automated warehouse 30 or buffer conveyor 40 until the required number of items W (e.g., the number specified in the order information) is collected, and controls each device to transport the required number of items W of the type together to the discharge section 61. Therefore, in this embodiment, the above-mentioned "specified order" specifies the order of the types of items W, and for example, the order of the types of items W is specified in the order in which the required number of items W is collected. When multiple types of items W are stacked on one support S, the control system 2 stores the items W in the automated warehouse 30 or buffer conveyor 40 until the required number of items W for each type is collected, and controls each device to transport the required number of items W of each type together to the discharge section 61. In this case, for example, the order in which the items W are stacked on the support S is the "specified order" described above.

[0040] Here, multiple items W of one type are referred to as a same-type item group WG. In this embodiment, multiple items W are stored in each of the multiple buffer conveyors 40, each consisting of a same-type item group WG. The number of items W that make up one same-type item group WG is arbitrary, but may be predetermined according to the type of item W.

[0041] Figure 2 shows a same-type item group WG consisting of multiple items W[A] stored on the first conveyor 41. Figure 3 shows a same-type item group WG consisting of multiple items W[B] stored on the second conveyor 42, and a same-type item group WG consisting of multiple items W[C] stored on the third conveyor 43. Figure 4 shows a same-type item group WG consisting of multiple items W[D] (first item group WG1 described below) and a same-type item group WG consisting of multiple items W[E] (second item group WG2 described below) stored on the fourth conveyor 44, and a same-type item group WG consisting of multiple items W[F] stored on the fifth conveyor 45.

[0042] There are cases where the number of items in the same-type item group WG to be stored on a target conveyor, which is one of the multiple buffer conveyors 40, is greater than the maximum number of items that can be stored on the target conveyor. For example, FIG. 3 illustrates a situation where the number of items in the same-type item group WG to be stored on the second conveyor 42 is greater than the maximum number of items that can be stored on the second conveyor 42. That is, in the situation illustrated in FIG. 3, the second conveyor 42 is the target conveyor. In this case, when the number of items in the same-type item group WG to be stored on the target conveyor is greater than the maximum number of items that can be stored on the target conveyor, the control system 2 can be configured to execute a process to store surplus items W that cannot be stored on the target conveyor, among the items W that make up the same-type item group WG, in the automated warehouse 30. In the example illustrated in FIG. 3, as a result of the control system 2 executing such a process, surplus items W[B] are stored in the automated warehouse 30.

[0043] In addition, when the number of items of the same-type item group WG to be stored on the target conveyor is greater than the maximum number of items that can be stored on the target conveyor, the control system 2 can be configured to store the surplus items W on a buffer conveyor 40 separate from the target conveyor instead of storing the surplus items W in the automated warehouse 30. However, by configuring the control system 2 to prioritize storing the surplus items W in the automated warehouse 30 over storing the surplus items W on a buffer conveyor 40 separate from the target conveyor, it becomes easier to have a buffer conveyor 40 on which no items W are stored. A buffer conveyor 40 on which no items W are stored can be used as a transport route for the target type of items when performing the removal process described below.

[0044] In addition, the control system 2 may be configured to perform a different type of item storage process in which the same type item group WG stored in the downstream area A1, which is a continuous area including the downstream end of each of the multiple buffer conveyors 40, is defined as the first item group WG1, and when there is extra space available to store items W in the upstream area A2, which is an area upstream of the downstream area A1, the control system 2 performs a different type of item storage process in which the second item group WG2, which is a same type item group WG of a different type from the first item group WG1, is stored in the upstream area A2. Figure 4 shows how, as a result of the control system 2 performing a different type of item storage process for the fourth conveyor 44, the first item group WG1 consisting of multiple items W[D] is stored in the downstream area A1 of the fourth conveyor 44, and the second item group WG2 consisting of multiple items W[E] is stored in the upstream area A2 of the fourth conveyor 44.

[0045] Furthermore, if there is excess space in the upstream area A2 of any of the buffer conveyors 40 that can store items W, the control system 2 can be configured to prioritize the execution of the different type item group storage process over the process of storing the second item group WG2 in another buffer conveyor 40, making it easier to have a buffer conveyor 40 that does not store any items W. Also, if there is excess space in the upstream area A2 of any of the buffer conveyors 40 that can store items W, the control system 2 does not necessarily have to execute the different type item group storage process, but the control system 2 can also be configured to always execute the different type item group storage process in such cases.

[0046] The items W may be stored in either the automated warehouse 30 or one of the multiple buffer conveyors 40, but in this embodiment, the storage destination of the items W is selected according to set rules. For example, the control system 2 can be configured to control the branch conveying device 20 based on the carry-out frequency of each type of item W so that items W whose carry-out frequency is equal to or greater than a set value are stored in the automated warehouse 30, and items W whose carry-out frequency is less than the set value are stored in one of the multiple buffer conveyors 40. The above set values ​​are changed, for example, by the manager of the item storage facility 1.

[0047] The delivery frequency of items W can be expressed, for example, by the number of items W delivered in a certain period (such as one day). Furthermore, the delivery frequency of items W may be a predicted value based on the delivery schedule of items W to the delivery section 10, or may be an actual value based on past performance. As described above, in this embodiment, items W are stored in the automated warehouse 30 or buffer conveyor 40 until the required number of items W is collected. Therefore, the delivery frequency for each type of item W is determined according to the ease of collecting each type of item W. In general, the easier it is to collect the required number of items W of a type, the higher the delivery frequency of the items W.

[0048] The rules for selecting the storage destination of the items W are not limited to the above. For example, the control system 2 may be configured to control the branch conveying device 20 so that, based on the carry-out frequency of each type of item W, items W whose carry-out frequency is equal to or greater than a set value are stored in one of the multiple buffer conveyors 40, and items W whose carry-out frequency is less than the set value are stored in the automated warehouse 30, as opposed to the above configuration. For example, this configuration may be used when multiple types of items W are stacked on a single support S. When multiple types of items W are stacked on a single support S, for example, the more types of items W specified in the order information, the higher the carry-out frequency and the larger the storage volume in the item storage facility 1. Therefore, by storing items W whose carry-out frequency is equal to or greater than a set value in one of the multiple buffer conveyors 40 rather than in the automated warehouse 30, the possibility of the automated warehouse 30 becoming full is reduced.

[0049] However, there may be cases where it is necessary to transport a target type of item W, which is a type of item that is not stored in either the automated warehouse 30 or the multiple buffer conveyors 40, to the discharge section 61. For example, when an item W of the same type as the type specified by the interrupt order information is not stored in either the automated warehouse 30 or the multiple buffer conveyors 40, it may be necessary to transport the target type of item to the discharge section 61. The interrupt order information may be a transport request per item W or a transport request per support S.

[0050] In this embodiment, when it becomes necessary to transport a target-type item to the discharge section 61, the control system 2 is configured to execute a discharge process in which all items W stored on the target conveyor, which is one of the multiple buffer conveyors 40, are discharged to the discharge path 70, and the target conveyor is passed from the inlet section 10 through the branch conveying device 20 and the target conveyor, and the target-type item is transported to the discharge section 61 via the junction conveying device 50. This discharge process can be called an "emergency discharge process" in that it has a higher priority than the discharge of other items W. This discharge process can also be called a "non-storage discharge process" or a "passing discharge process" in that the items W are passed through the automated warehouse 30 or buffer conveyor 40 without being stored therein. For example, when the first conveyor 41 is selected as the target conveyor, all items W[A] stored on the first conveyor 41 are delivered to the delivery path 70, and the target type of items are transported along a path (delivery processing transport path P, see Figure 2) from the loading section 10 via the branching conveying device 20, the first conveyor 41, and the merging conveying device 50 to the delivery section 61. In this embodiment, the control system 2 is configured to select a buffer conveyor 40 as the target conveyor if there is a buffer conveyor 40 on which no items W are stored. In this case, it is possible to eliminate the need to deliver the items W to the delivery path 70 in order to perform the delivery process.

[0051] As shown in Figures 1 and 2, in this embodiment, the dispensing path 70 is formed so as to branch off from the discharge conveyor 60. That is, the dispensing path 70 is connected to a portion of the conveying path of the article W that is downstream of the junction conveying device 50. In contrast to this configuration, the dispensing path 70 may also be configured to be connected to the junction conveying device 50 so as to dispense the article W from the junction conveying device 50. In this case, the dispensing path 70 is connected to each of the multiple junction conveyors 52 so as to branch off from the junction conveyor 52. Although details are omitted, the article W dispensed from the dispensing path 70 is returned to the loading section 10, for example, by a device such as a conveyor or a transport vehicle, or by an operator.

[0052] Other Embodiments (1) In the above embodiment, an example configuration has been described in which, when it becomes necessary to transport a target-type item to the unloading section 61, the control system 2 performs a carry-out process by discharging all items W stored on a target conveyor, which is one of the multiple buffer conveyors 40, to the unloading path 70, passing the items from the inlet section 10 through the branching conveying device 20 and the target conveyor, and transporting the target-type item to the unloading section 61 via the merging conveying device 50. However, the present disclosure is not limited to such a configuration, and the item storage facility 1 may also be configured to include a connecting conveying device that connects the inlet section 10 and the unloading section 61 without passing through the buffer conveyor 40 and the automated warehouse 30, and when it becomes necessary to transport a target-type item to the unloading section 61, the control system 2 uses the connecting conveying device to perform a carry-out process to transport the target-type item to the unloading section 61.

[0053] For example, in the item storage facility 1 shown in Figure 1, unlike the above embodiment, the first conveyor 41 can be configured to be used as a transport path for the target type of item in the unloading process, rather than as the buffer conveyor 40. In this case, the first conveyor 41 corresponds to the "connecting transport device", and in the unloading process, the target type of item is transported along a path (transport path P for unloading process, see Figure 2) from the loading section 10 via the branching transport device 20, the first conveyor 41, and the merging transport device 50 to the unloading section 61.

[0054] (2) In the above embodiment, a configuration has been described as an example in which the multiple buffer conveyors 40 are arranged separately on both sides of the automated warehouse 30 in the horizontal direction (specifically, the Y direction). However, the present disclosure is not limited to such a configuration, and the multiple buffer conveyors 40 may be arranged on only one side of the automated warehouse 30 in the horizontal direction.

[0055] (3) Note that the configurations disclosed in the above-described embodiments can be applied in combination with configurations disclosed in other embodiments (including combinations of embodiments described as other embodiments) as long as no contradictions arise. Regarding other configurations, the embodiments disclosed in this specification are merely examples in all respects. Therefore, various modifications can be made as appropriate within the scope of the present disclosure.

[0056] [Summary of this embodiment] The embodiment of the item storage facility described above will be summarized below.

[0057] The article storage facility is an article storage facility comprising an inlet section where articles are brought in, a branching conveying device, an automated warehouse, a buffer conveyor, a merging conveying device, an outlet section where the articles are brought out, and a control system, wherein the control system controls the branching conveying device, the automated warehouse, the buffer conveyor, and the merging conveying device so as to transport the plurality of articles to the outlet section in a specified order, the automated warehouse is capable of storing the plurality of articles that have been stored, and is capable of retrieving each of the stored articles in a selected order, and the buffer conveyor The conveyor is configured to be capable of transporting and stopping the transport of the items and to store multiple items on the transport path of the items, the branching conveying device is configured to transport the items transported to the loading section to one selected from the automatic warehouse and the buffer conveyor, the merging conveying device is configured to transport the items transported from the automatic warehouse and the buffer conveyor to the unloading section, and the automatic warehouse and the buffer conveyor are connected in parallel to each other between the branching conveying device and the merging conveying device.

[0058] According to this configuration, since items delivered to the loading section can be stored in both the automated warehouse and the buffer conveyor, a relatively large number of items can be stored. Here, buffer conveyors are generally cheaper than automated warehouses, so storing items using both the automated warehouse and the buffer conveyor in this way makes it easier to reduce the cost of the item storage facility compared to storing items entirely in the automated warehouse. Therefore, according to this configuration, it is possible to ensure a large storage capacity for items while suppressing increases in costs.

[0059] Furthermore, according to this configuration, the automated warehouse and the buffer conveyor are connected in parallel to each other between the branching conveying device and the merging conveying device. Therefore, an item carried into the carrying-in section can be transported from the branching conveying device to either the automated warehouse or the buffer conveyor, and an item stored in either the automated warehouse or the buffer conveyor can be transported from the merging conveying device to the carrying-out section. Therefore, according to this configuration, it is easy to appropriately select a storage destination for an item carried into the carrying-in section, taking into account the differences in characteristics between the automated warehouse and the buffer conveyor, and it is also easy to transport items stored in the automated warehouse and the buffer conveyor to the carrying-out section in a specified order.

[0060] Here, it is preferable that a plurality of buffer conveyors are provided, and the plurality of buffer conveyors are connected in parallel to each other between the branching conveying device and the merging conveying device, and that there are a plurality of types of items, and that a plurality of items of one type are grouped together as a group of items of the same type, and that each of the plurality of buffer conveyors is configured to store a plurality of items as a unit of the group of items of the same type.

[0061] According to this configuration, since multiple buffer conveyors are provided, it is easy to ensure a large storage capacity for items. Also, since multiple items are stored in units of groups of items of the same type on each of the multiple buffer conveyors, when the required number of items are stored on the buffer conveyors and then the required number of items of the same type are collectively transported to the transport section, it is easy to efficiently transport the multiple items to the transport section.

[0062] In the above configuration, it is preferable that the control system is configured to perform a different type of item group storage process in which the group of items of the same type stored in a downstream area, which is a continuous area including the downstream end of each of the multiple buffer conveyors, is defined as a first group of items, and when there is remaining space in an upstream area, which is an area upstream of the downstream area, in which the items can be stored, a second group of items of the same type that is a different type from the first group of items is stored in the upstream area.

[0063] According to this configuration, if there is any extra space available for storing items in the upstream region of the buffer conveyor, this space can be used to store items of a different type than the items stored in the downstream region, thereby making it possible to effectively utilize the storage space for items on the limited number of buffer conveyors.

[0064] It is also preferable that a plurality of buffer conveyors are provided, and the plurality of buffer conveyors are connected in parallel between the branch conveying device and the merging conveying device, and that there are a plurality of types of items, and that when it becomes necessary to transport a target type item, which is an item of a type that is not stored in either the automated warehouse or the plurality of buffer conveyors, to the discharge section, the control system is configured to discharge all of the items stored on the target conveyor, which is one of the plurality of buffer conveyors, to a discharge path, pass the branch conveying device and the target conveyor from the discharge section, and execute a discharge process to transport the target type item to the discharge section via the merging conveying device.

[0065] According to this configuration, even if an item of the target type that is not stored in either the automated warehouse or multiple buffer conveyors needs to be urgently transported to the unloading section due to an interrupt order or the like, the item of the target type can be quickly transported from the loading section to the unloading section along a route from the loading section via the branching conveying device, the target conveyor, and the merging conveying device to the unloading section.

[0066] It is also preferable that the system further includes a connecting conveying device that connects the loading section and the unloading section without going through the buffer conveyor and the automated warehouse, and that when there is a need to transport a target type of item, which is a type of item that is not stored in either the automated warehouse or the buffer conveyor, to the unloading section, the control system is configured to use the connecting conveying device to perform an unloading process to transport the target type of item to the unloading section.

[0067] According to this configuration, even if an item of the target type that is not stored in either the automated warehouse or multiple buffer conveyors needs to be urgently transported to the unloading section due to an interrupt order or the like, the connected transport device can be used to quickly transport the item of the target type from the loading section to the unloading section.

[0068] It is also preferable that a plurality of buffer conveyors are provided, and the plurality of buffer conveyors are connected in parallel to each other between the branching conveying device and the merging conveying device, and that there are a plurality of types of items, and a plurality of items of one type are grouped together to form a same-type item group, and that each of the plurality of buffer conveyors stores a plurality of items as a unit of the same-type item group, and that the control system is configured to execute a process of storing, in the automated warehouse, surplus items of the same-type item group that cannot be stored on the target conveyor, among the items that make up the same-type item group, when the number of items of the same-type item group to be stored on a target conveyor that is one of the plurality of buffer conveyors, is greater than the maximum number of items that can be stored on the target conveyor.

[0069] This configuration allows for more effective use of the buffer conveyors than storing excess items on a separate buffer conveyor, making it easier to store a greater variety and number of items on a limited number of buffer conveyors.

[0070] Furthermore, it is preferable that the control system is configured to control the branch conveying device so that, based on the removal frequency for each type of item, the items whose removal frequency is equal to or greater than a set value are stored in the automated warehouse, and the items whose removal frequency is less than the set value are stored in the buffer conveyor.

[0071] According to this configuration, the frequency with which items stored in the automated warehouse are removed is higher than the frequency with which items stored on the buffer conveyor, which reduces the possibility of the automated warehouse becoming full. This makes it easier to make effective use of the limited storage capacity of the automated warehouse.

[0072] It is sufficient for the item storage facility according to the present disclosure to achieve at least one of the above-described effects. [Explanation of symbols]

[0073] 1: Goods storage equipment 2: Control system 10: Loading section 20: Branching conveyor 30: Automated warehouse 40: Buffer conveyor 41: First conveyor (connection conveying device) 50: Merging conveying device 61: Unloading section 70: Payment route A1: Downstream area A2:Upstream area W:Goods WG: Same type of goods group WG1: 1st article group WG2: 2nd article group

Claims

1. An article storage facility comprising: an inlet section into which articles are carried in; a branching conveying device; an automated warehouse; a buffer conveyor; a merging conveying device; an outlet section from which the articles are carried out; and a control system, the control system controls the branching conveying device, the automated warehouse, the buffer conveyor, and the merging conveying device so as to convey the plurality of articles to the discharge section in a specified order; the automated warehouse is capable of storing the plurality of received items and of retrieving each of the stored items in a selected order, the buffer conveyor is configured to be capable of conveying and stopping the conveyance of the article and to store a plurality of the articles on a conveyance path of the article; the branch conveying device is configured to convey the article carried into the carrying-in section to one selected from the automated warehouse and the buffer conveyor, the junction conveying device is configured to convey the articles conveyed from the automated warehouse and the buffer conveyor to the discharge section, The automated warehouse and the buffer conveyor are connected in parallel to each other between the branching conveying device and the merging conveying device.

2. A plurality of the buffer conveyors are provided, the plurality of buffer conveyors are connected in parallel to one another between the branching conveying device and the merging conveying device; There are multiple types of the article, A plurality of the items of one type are grouped into a same-type item group, 2. The article storage facility according to claim 1, wherein each of the plurality of buffer conveyors stores a plurality of articles in units of the same type of article group.

3. The control system performs a different type of item storage process in which the group of items of the same type stored in a downstream area, which is a continuous area including the downstream end of each of the multiple buffer conveyors, is designated as a first group of items, and when there is excess space in an upstream area, which is an area upstream of the downstream area, in which the items can be stored, a second group of items of the same type, which is a different type from the first group of items, is stored in the upstream area.

4. A plurality of the buffer conveyors are provided, the plurality of buffer conveyors are connected in parallel to one another between the branching conveying device and the merging conveying device; There are multiple types of the article, 2. The item storage facility of claim 1, wherein when it becomes necessary to transport a target type item, which is an item of a type that is not stored in either the automated warehouse or the multiple buffer conveyors, to the discharge section, the control system discharges all of the items stored on the target conveyor, which is one of the multiple buffer conveyors, to a discharge path, passes the items from the input section through the branch conveying device and the target conveyor, and performs a discharge process to transport the target type item to the discharge section via the merging conveying device.

5. The automated warehouse further includes a connecting conveyance device that connects the loading section and the unloading section without passing through the buffer conveyor and the automated warehouse, There are multiple types of the article, The item storage facility described in claim 1, wherein when it becomes necessary to transport a target type item, which is an item of a type that is not stored in either the automated warehouse or the buffer conveyor, to the discharge section, the control system uses the connecting conveying device to perform a discharge process to transport the target type item to the discharge section.

6. A plurality of the buffer conveyors are provided, the plurality of buffer conveyors are connected in parallel to one another between the branching conveying device and the merging conveying device; There are multiple types of the article, A plurality of the items of one type are grouped into a same-type item group, Each of the plurality of buffer conveyors stores a plurality of the articles in units of the same type of article group, The item storage facility described in claim 1, wherein the control system executes a process to store surplus items that cannot be stored on the target conveyor among the items that make up the same type of item group in the automated warehouse when the number of items of the same type that are to be stored on the target conveyor, which is one of the multiple buffer conveyors, is greater than the maximum number of items that can be stored on the target conveyor.

7. 7. The item storage facility according to claim 1, wherein the control system controls the branch conveying device to store items whose removal frequency is equal to or greater than a set value in the automated warehouse and store items whose removal frequency is less than the set value in the buffer conveyor, based on the removal frequency for each type of item.

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