Goods sorting system

Abstract

In a goods sorting system, the entire process from sorting batch-picked items to delivery is automated, providing a system with a high degree of flexibility in placement and configuration. [Solution] An article sorting system comprising: an article supply unit that supplies articles to be delivered to destinations; an article arrangement unit that arranges the articles supplied from the article supply unit into sections for each destination; an article delivery unit that delivers the articles arranged in the article arrangement unit; a first transfer means for transferring the articles supplied from the article supply unit to sections for each destination in the article arrangement unit; a second transfer means for transferring the articles from the article arrangement unit to the article delivery unit; and an article sorting system control unit that controls the article supply unit, the article arrangement unit, the article delivery unit, the first transfer means, and the second transfer means, characterized in that the first and second transfer means operate unmanned.

Description

Technical Field

[0001] The present invention relates to, for example, an article sorting system for sorting articles, and particularly to an article sorting system that unmanned or automates a system called assorting that sorts articles for each destination.

Background Art

[0002] Conventionally, in mail-order sales and the like, the work of sorting products (articles) for each destination has been widely carried out, and further labor saving of this work has been demanded.

[0003] Particularly, when the same product spans multiple destinations, a method called total picking is effective and widely implemented.

[0004] This method has the following flow. 1) Collect articles to be processed in a predetermined batch. (Batch picking) 2) Supply the articles picked in batch picking. 3) Sort the supplied articles for each destination. (Assortment process) 4) Deliver the sorted articles to the destinations.

[0005] Here, a predetermined batch refers to a group of products that should be processed together under specific conditions such as time zone, direction of destination, shipping origin, etc., and usually, the collection work is performed by workers based on an order picking list.

[0006] Also, the products picked in batch picking are supplied near the workers who perform the sorting using various conveyance means (trolleys, conveyors, etc.), and the workers put (sort) the articles into a predetermined slot of a sorting shelf having a slot for each destination.

[0007] Next, the same or another worker takes out the products from the slot where the sorting is completed and stores them in a delivery container (reusable box, cardboard box, etc.).

[0008] Next, workers load the shipping containers containing the goods onto trucks or other vehicles using various means of transport (cage carts, trolleys, conveyors, etc.), or store them in warehouses or other locations.

[0009] Here, a system known as a "putwall" has been put into practical use, in which sorting shelves are configured to be accessible from both sides, with a sorting opening at the front, and sorted items are retrieved from the back of the shelves and transported to the distribution process.

[0010] In this system, various work support measures are implemented to improve efficiency and reduce work errors.

[0011] For example, Patent Document 1 discloses the following technical concept. (Figure 3 and its explanation) "A sorting rack is installed along one side of each sorting line branching off from the sorting conveyor. This sorting rack has multiple shelves arranged vertically, and each shelf has multiple openings that are assigned as sorting destinations for items along the sorting line. Each opening has an opening on the front side facing the corresponding sorting line and an opening on the back side opposite the sorting line. Sorting containers, such as folding containers for storing items, are placed in each opening. The sorting containers are inserted from the front side of the opening and placed on the shelf, and can be pushed out to the back. An unloading line is installed parallel to the sorting line at the back of the sorting rack, allowing the sorting containers pushed out from each opening to transfer to the unloading line and be unloaded. At the downstream end of these unloading lines, an unloading device is installed to receive the sorting containers from each unloading line and unload them to the next work area, such as a delivery area."

[0012] According to this Patent Document 1, sorting shelves are provided in front of the sorting conveyor that transports the goods, and the sorting work to the sorting shelves is performed manually and is not automated.

[0013] Meanwhile, once the sorting is complete, the containers are pushed to the back of the sorting shelves and then automatically discharged via a conveyor belt.

[0014] In other words, in this Patent Document 1, the sorting process is not automated, and the unloading process is carried out by a fixed conveyor, resulting in limited flexibility and freedom in installation.

[0015] Therefore, conventional technology had the problem that it was not possible to automate everything from sorting of batch-picked items to delivery, and that it was not possible to realize a system with a high degree of flexibility in placement and configuration. [Prior art documents] [Patent Documents]

[0016] [Patent Document 1] Japanese Patent Publication No. 2005-35787 [Overview of the project] [Problems that the invention aims to solve]

[0017] This invention aims to solve the aforementioned problems and aims to achieve unmanned (automated) sorting and delivery of batch-picked goods. [Means for solving the problem]

[0018] To solve the above problems, the article sorting system according to the first aspect of the present invention is: An article supply unit that supplies articles to be delivered to destinations, an article sorting unit that sorts the articles supplied from the article supply unit into compartments for each destination, an article delivery unit that delivers the articles sorted by the article sorting unit, a first transfer means that transfers the articles supplied from the article supply unit to the compartments for each destination of the article sorting unit, a second transfer means that transfers the articles from the article sorting unit to the article delivery unit, and an article sorting system control unit that controls the article supply unit, the article sorting unit, the article delivery unit, the first transfer means, and the second transfer means, wherein the first transfer means and the second transfer means operate unmanned.

[0019] By doing so, the article supply unit, the article sorting unit, the article delivery unit, the first transfer means, and the second transfer means can function unmanned without the intervention of human hands, enabling continuous operation, reducing labor costs, and enjoying many advantages such as reducing processing errors.

[0020] In particular, although automated guided vehicles are often used for each of the above-described units, there are also systems that can be configured without necessarily using automated guided vehicles.

[0021] The automated guided vehicle includes not only an AGV (Automatic Guided Vehicle), but also an AMR (Autonomous Mobile Robot), and any vehicle that can transport articles unmanned may be used.

[0022] Also, "operating unmanned" means that human intervention is not required for the main operations, and human intervention may be allowed for incidental operations (e.g., disposing of empty containers).

[0023] Also, performing operations by remote control is also included in "unmanned operation".

[0024] Next, as a second aspect of the present invention, in the article sorting system according to the first aspect, it may be characterized in that the article supply unit is a single or multiple intermittently driven conveyors.

[0025] That is, articles are placed on a conveyor such as a belt conveyor at intervals, and the conveyor is intermittently driven to send the articles to the first transfer means, which is the next process. In this way, unmanned operation can be realized.

[0026] Next, as a third aspect of the present invention, in the article sorting system according to the first aspect, it may be characterized in that the article supply unit is a flow rack.

[0027] A "flow rack" is an inclined flow rack that can supply articles from the rear and discharge them forward. From this, the first transfer means can take out the articles, and unmanned operation can be realized.

[0028] Note that even if the replenishment of articles to the flow rack is performed manually, it does not deny the unmanned operation after the article supply unit of the present invention.

[0029] Next, as a fourth aspect of the present invention, in the article sorting system according to the third aspect, it may be further characterized in that it has an automatic supply mechanism to the flow rack.

[0030] By doing so, the supply to the flow rack can be further automated (unmanned), and a higher effect can be obtained.

[0031] Next, as a fifth aspect of the present invention, in the article sorting system according to the third aspect, it may be characterized in that the flow rack is formed in multiple stages, and each stage has a shape shifted so that it is easy to access from above at each frontage.

[0032] By doing so, when the first transfer means is a robot (preferably a vertical articulated robot) and picks up articles from above, it is extremely effective.

[0033] Next, as a sixth aspect of the present invention, the article sorting system according to the first aspect may be characterized in that the article supply unit is an automated guided vehicle and a pallet placed on the automated guided vehicle.

[0034] In this way, even heavy items (such as items packaged in cardboard boxes), large items, and long items that are not suitable for supplying by conveyor or flock can be placed on pallets and sorted unattended.

[0035] Next, as a seventh aspect of the present invention, the article sorting system according to the first aspect may be characterized in that the article supply unit further has a vertical automated warehouse for temporarily storing articles before they are sorted.

[0036] Here, "vertical automated warehouse" refers to a place for storing goods vertically, for example, shelves on which goods or cases containing goods (such as folding containers) are placed, which are automatically presented in front of the worker (opening) according to instructions from the control unit. It may also be called an automated warehouse with vertical storage shelves, a vertical storage automated warehouse, or a three-dimensional automated warehouse.

[0037] By using this type of vertical automated warehouse, items can be stored in numerous cases and shelves before being sorted, which is highly effective in facilities with large volumes of goods.

[0038] It should be noted that while several examples have been given to illustrate the concept of a goods supply unit, it is not limited to these. For example, any device that allows goods to be transferred to the next process without human intervention is acceptable, such as a floor surface on which goods are laid flat, a floor surface on which goods are stacked vertically, a pallet support device in the shape of a heated table (kotatsu) for transporting goods on pallets using AGVs / AMRs, or a forklift on which goods are loaded.

[0039] Next, in an eighth aspect of the present invention, the article sorting system according to the first aspect may be characterized in that the article sorting section is a fixed shelf having one or more layers, each with a conveyor on its upper surface and compartments for each destination.

[0040] In other words, if the fixed shelf has one layer, it is preferable that it is configured by arranging multiple compartments for each destination in a straight line, and that each compartment has a horizontal upper surface on which articles fed from the article supply unit by the first transfer means can be placed, and that the upper surface is configured with a conveyor that is driven in the direction of sending out the articles.

[0041] Furthermore, the arrangement is not limited to a straight line; it can be curved, such as in an arc, or in a zigzag pattern, or any other arrangement is acceptable. Depending on the space available at the facility, a particular arrangement may be more advantageous.

[0042] In this way, the sorted and placed items from the goods supply unit by the first transfer means can be sent to the next process (second transfer means), enabling unmanned operation.

[0043] Furthermore, two or more such fixed shelves may be provided in the vertical direction. If the first and second transfer means can accommodate shelves of different heights, the number of compartments can be increased, which is efficient.

[0044] Next, as a ninth aspect of the present invention, in the article sorting system according to the first aspect, the article arranging section may be a multi-layered shelf having sections for each destination with a conveyor on the top surface, and having a lifting mechanism for raising and lowering the shelf.

[0045] In other words, in a multi-layered fixed shelf, the first and second transfer means are arranged to move up and down in a similar manner to the previous embodiment where they correspond in the vertical direction. In this configuration, the first and second transfer means do not correspond in the vertical direction, but can instead correspond only at a position close to the floor.

[0046] Furthermore, both of the above embodiments are examples in which the compartments of the goods sorting area are configured three-dimensionally, thereby enabling the securing of more compartments with a smaller floor area.

[0047] Next, as a tenth aspect of the present invention, the article sorting system according to the first aspect may be characterized in that the article sorting unit is a vertical automated warehouse that has a three-dimensional configuration and has compartments for each of the multiple destinations.

[0048] Vertical automated warehouses have already been explained, and this is another example of a three-dimensional configuration of compartments for the goods sorting section. By using a vertical automated warehouse as the goods sorting section, the number of compartments can be significantly increased, resulting in many advantages, such as being able to store sorted goods until the truck's departure time.

[0049] Next, in an eleventh aspect of the present invention, the article sorting system according to the first aspect may be characterized in that the article arranging section is a conveyor and article storage boxes placed on the conveyor.

[0050] In other words, instead of fixed shelves, a conveyor (a roller conveyor is preferable, but other conveyors such as a belt conveyor may also be used) and a storage box for goods placed on it (folding containers, or "oricon" for short, are preferable, but any box-shaped or dish-shaped container that can store goods will also work) can be used as the destination compartment.

[0051] Furthermore, by using a conveyor belt, it becomes possible to automatically supply empty storage boxes for goods.

[0052] Furthermore, for the transfer to the next process (second transfer means), it is preferable to provide a right-angle branching mechanism on the roller conveyor and configure it to send out the item storage boxes in a direction perpendicular to the direction of travel of the roller conveyor.

[0053] Next, as a twelfth aspect of the present invention, the article sorting system according to the first aspect may be characterized in that the article aligning section is a plurality of unmanned transport vehicles having a conveyor or a flap mechanism on its upper surface.

[0054] In other words, if multiple automated guided vehicles are arranged in a straight line and treated like fixed shelves, and a conveyor capable of transporting goods (a belt conveyor is preferable, but other conveyors may also be used) is provided on the top surface in a direction perpendicular to the direction in which the automated guided vehicles are arranged, then it becomes easy to receive goods from the first transfer means and to send goods to the second transfer means.

[0055] Furthermore, the arrangement of automated guided vehicles (AGVs) is not limited to a straight line; they can be arranged in any way, such as in a curved shape like an arc or a zigzag pattern. In some cases, a particular arrangement may be more advantageous depending on the space available at the facility.

[0056] Furthermore, if a flip-up mechanism is provided on the top surface, the flip-up mechanism can be operated to enable delivery to the second transfer means.

[0057] By arranging automated guided vehicles in this manner to form a goods sorting area, it is possible to flexibly adjust the location of the goods sorting area and increase or decrease the number of sections.

[0058] Next, as a thirteenth aspect of the present invention, the article sorting system according to the first aspect may be characterized in that the article arranging unit consists of a plurality of automated guided vehicles and article storage boxes placed on the automated guided vehicles.

[0059] In other words, unlike the case described earlier where items are placed directly on the top surface of the automated guided vehicle, this method involves placing item storage boxes on top of the automated guided vehicle.

[0060] This approach offers the advantage of using automated guided vehicles, as explained earlier, plus the benefit of simplifying the next step, since the prepared items are already stored in item storage boxes.

[0061] It should be noted that while several examples have been given to describe the goods sorting area, it is not limited to these. For example, it could be a floor area with partitioned sections for laying sorted goods flat, or a heated table-type pallet support device for placing goods on pallets and transporting those pallets by AGV / AMR. In short, any place or structure where goods can be sorted and handed over to the next process without human intervention is acceptable.

[0062] Next, as a fourteenth aspect of the present invention, the article sorting system according to the first aspect may be characterized in that the article delivery unit comprises a trolley on which article storage boxes containing articles are placed and an automated guided vehicle on which the trolley or pallet is placed or towed.

[0063] Here, the cart should have multiple wheels and be capable of loading cargo on top. A 6-wheel cart or a cage cart (cage cart) is preferable, but it is not limited to these; a dolly or forklift can be selected depending on the application.

[0064] In this way, the automated guided vehicle (AGV) can move the towed or mounted cart or pallet to the desired location, and the delivery process can be largely automated.

[0065] Furthermore, the trolley or pallet and the automated guided vehicle (AGV) may be configured as a single unit. This can reduce the number of system components and potentially offer economic advantages.

[0066] Next, as a fifteenth aspect of the present invention, in the article sorting system according to the fourteenth aspect, the article delivery unit may further be characterized by having an elevator mechanism for transferring the sorted articles or article storage boxes to the trolley or the pallet.

[0067] In other words, an elevator capable of carrying and raising or lowering trolleys or pallets is installed on the floor of the facility. This makes it easier to load items or item storage boxes from a second transfer means onto a trolley with multiple shelves by aligning them to the same height (level).

[0068] Similarly, this method is also effective when stacking goods or storage boxes on pallets.

[0069] Next, as a sixteenth aspect of the present invention, in the article sorting system according to the fourteenth aspect, the article delivery section may further be characterized by having a skip floor with a ramp for transferring sorted articles or article storage boxes to the trolley or the pallet.

[0070] In other words, it involves creating an upward and / or downward ramp on the floor surface of the facility, setting two or more heights as needed, and configuring it as an upward only, downward only, or a combination of both.

[0071] In this way, just like with the elevator explained earlier, you can access it directly from the AGV / AMR This system offers advantages such as the ability to transfer cases onto a six-wheeled trolley, and the fact that, once the ramp is formed, it eliminates the need for power like an elevator.

[0072] It should be noted that while several examples have been given to illustrate the concept of a goods delivery unit, the invention is not limited to these examples. For instance, it could be an autonomous forklift. Furthermore, manned forklifts and small vehicles are also included within the scope of this invention, although the degree of unmanned operation (automation) is limited. Moreover, the goods delivery unit may not have a mobile function and may be directly connected to a mechanism such as a truck loader for directly loading goods onto delivery trucks.

[0073] Next, as a 17th aspect of the present invention, the article sorting system according to the first aspect may be characterized in that the first transfer means is an automated guided vehicle having a flip-up mechanism or conveyor on its upper surface.

[0074] In other words, the automated guided vehicle receives goods from the goods supply unit on its upper surface, then drives itself to the goods sorting unit to deliver the goods. To ensure that the delivery is carried out reliably and unmanned, it is preferable that the automated guided vehicle has a mechanism that allows the upper surface to be raised (hopper type).

[0075] Furthermore, instead of a hopper type, a conveyor (a belt conveyor is preferred but not limited to one) may also be used. In this case, the conveyor can be driven not only when transferring goods to the goods sorting section, but also when receiving goods from the goods supply section, to ensure smooth receiving.

[0076] This approach simplifies system construction because it eliminates the need to install complex transport devices, requiring only the provision of a driving space for automated guided vehicles.

[0077] Furthermore, the automated guided vehicle does not necessarily need to have a special mechanism on its upper surface. For example, the item loading section may have a mechanism (such as a telescope or retractable arm) that can grip and move items, and this mechanism may extend to transfer the items; this is also included within the technical scope of the present invention.

[0078] Next, in an eighteenth aspect of the present invention, the article sorting system according to the first aspect may be characterized in that the first transfer means is a robot capable of transferring articles.

[0079] Here, a vertical articulated robot is preferable in terms of ease of use, but it is not limited to that. Any robot, such as a SCARA type, that can pick up or grasp items from the item supply unit and transfer them to the item sorting unit is acceptable. The robot itself may be fixed or configured to be movable.

[0080] Furthermore, the transfer (sorting) of goods from the goods supply unit to the goods sorting unit is precisely carried out according to instructions from the goods sorting system control unit.

[0081] This approach automates the sorting and transfer of goods from the supply department to the goods preparation department, thereby improving system efficiency and operational accuracy.

[0082] Next, as a 19th aspect of the present invention, in the article sorting system according to the first aspect, the first transfer means may be characterized in that it directly transfers from the article supply unit to the article assembly unit.

[0083] In other words, the first transfer means does not have a special mechanism, but can be configured such that, for example, the goods sorting unit moves compartments to receive goods from the goods supply unit in the appropriate compartment.

[0084] This simplifies the system configuration.

[0085] It should be noted that while several examples have been given to describe the first transfer method, the method is not limited to these. For example, conveyors (belt conveyors, roller conveyors, trolley conveyors, etc.) may be appropriately arranged to carry out transport and transfer, or rail-shaped transport paths or inclined transport paths may be utilized.

[0086] Next, as a 20th aspect of the present invention, the article sorting system according to the first aspect may be characterized in that the second transfer means is an automated guided vehicle having a flip-up mechanism or conveyor on its upper surface.

[0087] In other words, the automated guided vehicle (AGV) receives goods from the goods sorting section on its top surface, then drives itself to the goods delivery section. To ensure that the transfer is carried out reliably and unmanned, it is preferable that the AGV has a mechanism that allows its top surface to be raised (hopper type).

[0088] Furthermore, instead of a hopper type, a conveyor (a belt conveyor is preferred but not limited to one) may also be used. In this case, the conveyor can be driven not only when handing over goods to the goods distribution department but also when receiving goods from the goods sorting department to ensure smooth receiving.

[0089] This approach simplifies system construction because it eliminates the need to install complex transport devices, requiring only the provision of a driving space for automated guided vehicles.

[0090] Furthermore, the automated guided vehicle does not necessarily need to have a special mechanism on its upper surface. For example, the item loading section may have a mechanism for gripping items (such as a pantograph or arm), which extends to transfer the items, and this is also included within the technical scope of the present invention.

[0091] Next, as a 21st aspect of the present invention, in an article sorting system according to the 20th aspect, the second transfer means may further include a conveyor for supplying empty article storage boxes and a right-angle branching mechanism on the conveyor that can move article storage boxes into which articles have been transferred from the automated guided vehicle in a direction perpendicular to the direction of travel of the conveyor.

[0092] In other words, as part of the second transfer means, in addition to the automated guided vehicle, the system includes a conveyor (preferably a roller conveyor) that can automatically supply empty item storage boxes, and a right-angle branching mechanism that, once items are stored in the item storage boxes, can transfer them to a waiting item delivery unit (such as a trolley) in a direction perpendicular to the direction of travel of the conveyor. The system's usefulness is high because it can automatically supply empty item storage boxes.

[0093] The right-angle branching mechanism is also called a right-angle turning mechanism (RAT), and is preferably a conveying unit consisting of a belt or rollers capable of conveying in a right-angle direction between the rollers of a roller conveyor, but other methods may also be used.

[0094] Next, as a 22nd aspect of the present invention, in the article sorting system according to the first aspect, the second transfer means may be a robot, a suspension rail, or a travel rail capable of transferring articles or article storage boxes containing articles.

[0095] Here, a vertical articulated robot is preferable in terms of ease of use, but it is not limited to that. Any robot, such as a SCARA type, that can pick up or grasp items from the item supply unit and transfer them to the item sorting unit is acceptable. The robot itself may be fixed or configured to be movable.

[0096] Alternatively, the item storage boxes may be transferred from the item sorting section by a rail-traveling mechanism (including a suspension mechanism) other than a robot.

[0097] Furthermore, the transfer (stacking) of goods from the goods preparation department to the goods delivery department is precisely executed according to instructions from the goods sorting system control unit.

[0098] This approach ensures that the transfer of goods from the goods sorting department to the goods distribution department is accurate and automated, thereby improving the efficiency of the system.

[0099] Next, as a 23rd aspect of the present invention, in the article sorting system according to the first aspect, the second transfer means may be characterized in that it directly transfers from the article preparation unit to the article delivery unit.

[0100] In other words, the second transfer means does not require a special mechanism, but can be configured to receive the completed item storage boxes by, for example, positioning the item delivery unit, which is composed of a trolley, in close contact with the completed item sorting section of the item sorting unit.

[0101] This simplifies the system configuration.

[0102] It should be noted that while several examples have been given to describe the second transfer method, it is not limited to these. For example, conveyors (belt conveyors, roller conveyors, trolley conveyors, etc.) may be appropriately arranged to carry out transport and transfer, or methods such as utilizing inclined transport paths may also be used.

[0103] Next, as a 24th aspect of the present invention, the article sorting system according to the first aspect may be characterized in that the first transfer means and the second transfer means use a common automated guided vehicle.

[0104] In other words, the transfer of goods from the preceding goods supply unit to the goods sorting unit, and from the subsequent goods sorting unit to the goods delivery unit, is carried out by a common automated guided vehicle (AGV). This allows for mutual cooperation and can address imbalances in workload between the preceding and succeeding units, either quantitatively or temporally, without increasing the number of AGVs.

[0105] Furthermore, by appropriately combining the item supply unit, item sorting unit, item delivery unit, first transfer means, and second transfer means described above, an unmanned item sorting system can be constructed. Several specific examples of these combinations will be described in the section on embodiments for carrying out the invention, but the combinations described therein are not exhaustive, and other combinations not listed therein are also included in the present invention. [Effects of the Invention]

[0106] According to each aspect of the present invention, in an assortment-type goods sorting system, complete unmanned operation (automation) can be achieved from sorting of batch-picked goods to delivery, resulting in an extremely efficient and labor-saving system. [Brief explanation of the drawing]

[0107] [Figure 1] This is a schematic diagram common to embodiments of the article sorting system of the present invention. [Figure 2]This is an explanatory diagram of a first embodiment of the article sorting system of the present invention. [Figure 3] This is an explanatory diagram of an article sorting rack according to a first embodiment of the system of the present invention. [Figure 4] This is an explanatory diagram of an automated guided vehicle according to a first embodiment of the system of the present invention. [Figure 5] This is an explanatory diagram illustrating the transfer of a first embodiment of the system of the present invention. [Figure 6] This is an explanatory diagram illustrating the transfer of a first embodiment of the system of the present invention. [Figure 7] This is an explanatory diagram illustrating the transfer of a first embodiment of the system of the present invention. [Figure 8] This is an explanatory diagram of a trolley transport system according to a first embodiment of the present invention. [Figure 9] This is an explanatory diagram of a second embodiment of the article sorting system of the present invention. [Figure 10] This is an explanatory diagram of an automated guided vehicle according to a second embodiment of the system of the present invention. [Figure 11] This is an explanatory diagram illustrating the transfer of a second embodiment of the system of the present invention. [Figure 12] This is an explanatory diagram illustrating the transfer of a second embodiment of the system of the present invention. [Figure 13] This is an explanatory diagram of a trolley transport system according to a second embodiment of the present invention. [Figure 14] This is an explanatory diagram of a third embodiment of the article sorting system of the present invention. [Figure 15] This is an explanatory diagram illustrating the transfer of a third embodiment of the system of the present invention. [Figure 16] This is an explanatory diagram of a fourth embodiment of the article sorting system of the present invention. [Figure 17] This is an explanatory diagram of a fifth embodiment of the article sorting system of the present invention. [Figure 18] This is an explanatory diagram of a sixth embodiment of the article sorting system of the present invention. [Figure 19] This is an explanatory diagram of the seventh embodiment of the article sorting system of the present invention. [Figure 20]This is an explanatory diagram of a product sorting rack according to the seventh embodiment of the system of the present invention. [Figure 21] This is an explanatory diagram of the eighth embodiment of the article sorting system of the present invention. [Figure 22] This is a perspective view of a vertical automated warehouse according to the eighth embodiment of the system of the present invention. [Figure 23] This is an explanatory diagram of a vertical automated warehouse according to the eighth embodiment of the system of the present invention. [Figure 24] This is an explanatory diagram of a vertical automated warehouse according to the eighth embodiment of the system of the present invention. [Figure 25] This is an explanatory diagram of the ninth embodiment of the article sorting system of the present invention. [Figure 26] This is an explanatory diagram of the tenth embodiment of the article sorting system of the present invention. [Figure 27] This is an explanatory diagram of the 11th embodiment of the article sorting system of the present invention. [Figure 28] This is an explanatory diagram of the article supply unit of the 11th embodiment of the system of the present invention. [Figure 29] This is an explanatory diagram of the article sorting section of the 11th embodiment of the system of the present invention. [Figure 30] This is an explanatory diagram of an automated guided vehicle according to the eleventh embodiment of the system of the present invention. [Modes for carrying out the invention]

[0108] Embodiments of the present invention will be described below with reference to the attached drawings. These are illustrative examples of apparatuses and methods for realizing the technical idea of ​​the invention, and the technical idea of ​​the present invention is not limited to those described below. The technical idea of ​​the present invention can be modified in various ways within the scope of the claims. In particular, it should be noted that the drawings are schematic and may differ from reality. Parts of the already known technology are omitted from the explanation.

[0109] Figure 1 is a schematic diagram of an article sorting system common to embodiments of the present invention, and is a schematic representation of a plan view from above.

[0110] <Structure> The item sorting system 1 of this embodiment includes an item supply unit 10 that supplies batch-picked items B, an item sorting unit 20 that can temporarily store the items B supplied from the item supply unit 10 in sections for each destination and sort them according to their destination, an item delivery unit 30 that delivers the items B sorted according to their destination in the item sorting unit 20, a first transfer means 40 that transfers items from the item supply unit 10 to the item sorting unit 20, a second transfer means 50 that transfers items from the item sorting unit 20 to the item delivery unit 30, and an item sorting system control unit 60 that controls each unit and each means.

[0111] The goods sorting system control unit 60 includes a CPU, interface unit, memory unit, input / output unit, etc., and may consist of an independent server or PC, or it may utilize cloud computing via the internet, or it may be included in a WMS (Warehouse Management System) that manages the entire warehouse.

[0112] <Operation> In the previous process, items B (in this example, 5 units of item Ba, 3 units of item Bb, 4 units of item Bc, and 2 units of item Bd) that have been pre-selected in a predetermined batch (taking into account shipping time, etc.) are transported by the item supply unit 10 (for example, an intermittently driven belt). Note that the types and quantities of items are illustrative examples and are not limited to these.

[0113] At the exit, the first transfer means 40 (in this case, an automated guided vehicle) transports item B to the item sorting section 20, where it is sorted by transferring it from one of the designated sections 21 to one of the sections 24. Note that the number of sections is an example and is not limited to this.

[0114] The goods sorting section 20 has four sorting compartments 21, 22, 23, and 24 separated on a flat surface, and is configured to receive goods B supplied from the left side and dispense them from the right side in the diagram.

[0115] The second transfer means 50 receives the goods B that have been prepared from each section of the goods preparation section 20, transports them to the goods delivery section 30, and transfers them.

[0116] Furthermore, at any of these stages, the goods B that have been shipped to the same destination may be placed into a goods storage box (a collapsible container is preferred, but a cardboard box, a polystyrene foam container, or other container may also be used).

[0117] The goods delivery unit 30 is preferably a trolley (such as a cage trolley or a 6-wheel trolley), and it is desirable to move them to the next process using an automated guided vehicle (AGV).

[0118] In addition, a trolley, which is an example of the goods delivery unit 30, may have multiple shelves in the vertical direction, and goods B (or goods storage boxes containing goods B) that have been sorted and arranged may be placed on them.

[0119] Furthermore, the goods delivery department is not limited to trolleys 30; various other transport equipment such as cage carts, dollies, forklifts, and conveyors may also be used.

[0120] Next, a first embodiment of the present invention will be described with reference to the attached drawings. These are illustrative examples of apparatus and methods for embodying the technical idea of ​​the invention, and the technical idea of ​​the present invention is not limited to those described below. The technical idea of ​​the present invention can be modified in various ways within the scope of the claims. In particular, it should be noted that the drawings are schematic and may differ from reality. Parts that are already known technology have been omitted from the explanation.

[0121] Figure 2 is an explanatory diagram of the first embodiment of the goods sorting system according to the present invention, and is a plan view seen from above. Some parts are shown in elevation views for easier understanding. (The same applies to subsequent embodiments.)

[0122] <Configuration of the first embodiment> The configuration of the first embodiment of the present invention will now be described.

[0123] The item supply unit 10 is composed of two sets of item supply conveyors 10a. The item supply conveyor 10a is preferably a combination of belt conveyors in series that have a cutting capacity to easily transfer items one by one to the automated guided vehicle 40a, but it is not limited to this, and may also be a roller conveyor that facilitates intermittent operation when loading and unloading items, or other types of conveyors (such as tray conveyors).

[0124] The reason for providing two sets of item supply conveyors 10a is to increase the supply volume, improve efficiency by supplying the same items separately, and provide backup in case of trouble. It is also possible to provide three or more sets, and in some situations, one set may suffice.

[0125] Next, the goods sorting section 20 is composed of goods sorting shelves 20a that are horizontal and have multiple compartments. Figure 3 is an explanatory diagram of the goods sorting shelves 20a used in the first embodiment of the goods sorting system according to the present invention, and is a partial elevation view seen from the left side in Figure 2.

[0126] The goods sorting rack 20a has six compartments 21-26 to accommodate six destinations, and this figure shows compartments 21 and 22.

[0127] The goods sorting rack 20a has legs 201, a rack body 202, a cross belt conveyor 203 stretched across the top of the rack body 202 to each section, which can transport goods from front to back in the diagram, and partitions 204 provided at the parts that separate each section. The partitions 204 are effective in preventing goods from moving across sections.

[0128] In the explanation so far, the item sorting rack 20a has been configured to receive item B on one side and dispense it on the other side, but it may also be configured to receive and dispense from only one side. This can be achieved by providing conveyors in each section of the item sorting rack 20a that can operate in both forward and reverse directions, and this may be advantageous in terms of facility layout.

[0129] Next, the goods delivery unit 30 is comprised of a goods storage box supply unit 30a that supplies empty goods storage boxes 70 for storing goods B destined for the same destination, a goods receiving unit 30b that receives goods from the goods sorting unit 20 in the supplied empty goods storage boxes 70, a goods storage box dispensing unit 30c that dispenses the goods storage boxes 70 containing the received goods, a six-wheeled trolley 30d having three shelves in the vertical direction that receives the dispensed goods storage boxes 70 and transports them to the next process, an elevator 30e to facilitate transfer to the six-wheeled trolley, and an unmanned transport vehicle 30f for trolley towing that tows the six-wheeled trolley 30d and transports it to the next process.

[0130] In Figure 2, the 6-wheeled trolley 30d is shown in an elevation view. (The same applies to subsequent embodiments.)

[0131] In this context, the goods storage box supply section 30a will be explained using a collapsible container (Oricon) as an example of a goods storage box 70 for storing, preserving, and transporting goods.

[0132] When an empty goods storage box 70 is placed inside, it is transported by a chain conveyor in the following order: washing section 31, drying and inspection section 32 which has a blower 321 and a camera 322 for internal inspection, and film inserter 33 for laying film inside for delivery. After that, it is transported by a roller conveyor 34 to a position where goods can be transferred (goods receiving section 30b).

[0133] Next, the first transfer means 40 is composed of a hopper-type unmanned transport vehicle 40a whose top surface can be flipped up.

[0134] Figure 4 is an explanatory diagram of an automated guided vehicle 40a used as the first transfer means 40 in the first embodiment of the goods sorting system according to the present invention. The automated guided vehicle 40a is a so-called hopper type, having a transport vehicle body 402 with wheels 401 that can travel unmanned, and a tray 403 on the upper surface on which goods can be placed and which can be flipped up in a predetermined direction.

[0135] While an AMR that does not require a derivative is preferred for the automated guided vehicle 40a, an AGV may be used with a derivative such as magnetic tape or a QR code (registered trademark) depending on the situation. The same applies to the automated guided vehicles in the subsequent embodiments.

[0136] Next, the second transfer means 50 is composed of a hopper-type automated guided vehicle 50a with a top surface that can be flipped up. The structure is the same as that of the automated guided vehicle 40a, and the vehicle body 502, which has wheels 501 and can move unmanned, has a tray 503 on its top surface on which items can be placed and which can be flipped up in a predetermined direction.

[0137] Furthermore, the system includes an item sorting system control unit 60 that controls this system. This configuration is as described above.

[0138] <Operation of the First Embodiment> The operation of the first embodiment of the article sorting system according to the present invention will be described. First, goods B, which have been batch-picked and whose six destinations (customers) make up one cycle, are supplied to one of the goods supply conveyors 10a.

[0139] Next, the goods are transferred from the goods supply conveyor 10a to the automated guided vehicle 40a, which is the first transfer means 40. Figure 5 is an explanatory diagram of the transfer from the goods supply conveyor 10a to the automated guided vehicle 40a in the first embodiment of the goods sorting system according to the present invention, in which goods B are automatically fed (transferred) from the end of the goods supply conveyor 10a to the tray 403 of the designated automated guided vehicle 40a. In this case, the transfer is performed by the conveying force of the goods supply conveyor 10a.

[0140] Next, the first transfer means 40, the automated guided vehicle 40a, travels autonomously to the item sorting shelf 20a, and the items are transferred (sorted) to the item sorting shelf 20a. Figure 6 is an explanatory diagram of the transfer from the automated guided vehicle 40a to the item sorting shelf 20a in the first embodiment of the item sorting system according to the present invention, showing the situation in which item B is transferred to a designated section 24 within the item sorting shelf 20a by the item sorting system control unit 60.

[0141] Here, the automated guided vehicle 40a approaches the designated section 24 of the goods sorting rack 20a, and by flipping up the tray 413 as shown in the figure, goods B can be transferred onto the cross belt conveyor 203.

[0142] Furthermore, anti-jumping ribs 205 may be provided perpendicular to the direction of travel of the cross-belt conveyor 203, and at the leading and trailing ends when a section is formed. This prevents items from jumping out (falling) during receiving and storage.

[0143] Next, another automated guided vehicle (AGV) 40a loads the goods B supplied from the goods supply conveyor 10a into one of the sections 21-26 according to their destination. This process continues until the goods B are sorted into the goods sorting section 20, i.e., the assortment process is completed.

[0144] Next, the goods are transferred from the item sorting rack 20a to the automated guided vehicle 50a, which is the second transfer means 50. From any section, for example section 24, the cross belt 203 is activated as shown in Figure 6, and the goods are transferred to the tray 503 of the automated guided vehicle 50a by its transport force. In this case, it is preferable to have a step between the floor surfaces on the entrance and exit sides of the item sorting rack 20a, as shown in the figure.

[0145] Next, the automated guided vehicle 50a, which is the second transfer means 50 that has received the goods for the designated destination, travels to the goods delivery section 30 in order to transfer (hand over) the goods.

[0146] Figure 7 is an explanatory diagram showing the transfer process from the automated guided vehicle 50a in the first embodiment of the goods sorting system according to the present invention. Figure 7(a) shows that goods B are transferred from the automated guided vehicle 50a to the goods receiving section 30b on the roller conveyor 34, which is part of the goods delivery section 30, by flipping up the tray 503 onto the goods storage box 70.

[0147] Next, the items are transferred from the roller conveyor 34 to the 6-wheeled trolley 30d. Figure 7(b) shows the item storage box dispensing section 30c, which dispenses the item storage boxes 70 containing the received items. It has a right-angle branching mechanism with rollers that can transport items in a direction perpendicular to the direction of travel of the roller conveyor 34, and dispenses the item storage boxes 70 on the roller conveyor 34 horizontally.

[0148] The item storage box 70 is received by a six-wheeled trolley 30d having shelves at the dispensing height. The six-wheeled trolley 30d can be raised and lowered by an elevator 30e installed on the facility floor, and in the case of a six-wheeled trolley 30d with three shelves, for example, the height is adjusted so that items can be smoothly transferred to the upper, middle, and lower shelves.

[0149] More specifically, the items are first transferred to the upper shelf. Once this is complete, the six-wheeled trolley 30d is raised by the elevator 30e's lifting mechanism (not shown), and the item storage boxes 70 are transferred to the middle shelf. Subsequently, the lifting mechanism raises the six-wheeled trolley 30d, and the item storage boxes 70 are placed on the lower shelf. This lower placement position becomes the floor level, and the six-wheeled trolley 30d can then depart.

[0150] Furthermore, the number of item storage boxes 70 placed on each level is not limited to one. Figure 2 shows an example in which two item storage boxes 70 are placed on each level of the 6-wheeled trolley 30d, and there may be three or more per level.

[0151] Next, the 6-wheeled trolley 30d is transported to the next process. Figure 8 is an explanatory diagram of the transport of the 6-wheeled trolley 30d in the first embodiment of the goods sorting system according to the present invention.

[0152] Here, the unmanned transport vehicle 30f for towing the trolley has a towing unit 301 for towing the 6-wheel trolley 30d, and by connecting this to the 6-wheel trolley 30d, the 6-wheel trolley 30d can be moved unmanned to a predetermined location (truck, warehouse, etc.).

[0153] More specifically, the unmanned transport vehicle 30f for towing the trolley is waiting at the position shown in Figure 2. Once loading onto the 6-wheel trolley 30d is complete, it moves forward, rotates 90 degrees, reverses to connect with the 6-wheel trolley 30d, and departs, as indicated by the arrows in the figure.

[0154] According to this first embodiment, automated guided vehicles (AGVs) are used as the first transfer means 40, the second transfer means 50, and the AGV 30f for trolley towing. This has advantages such as not requiring fixed equipment, offering a high degree of flexibility in facility layout, and being able to increase or decrease the number of AGVs to accommodate increases or decreases in the volume of goods or destinations.

[0155] Next, a second embodiment of the present invention will be described with reference to the attached drawings. These are illustrative examples of apparatus and methods for embodying the technical idea of ​​the invention, and the technical idea of ​​the present invention is not limited to those described below. The technical idea of ​​the present invention can be modified in various ways within the scope of the claims. In particular, it should be noted that the drawings are schematic and may differ from reality. Parts that are already known technology have been omitted from the explanation.

[0156] Figure 9 is an explanatory diagram of a second embodiment of the goods sorting system according to the present invention, and is a plan view from above.

[0157] <Configuration of the second embodiment> The configuration of a second embodiment of the present invention will now be described.

[0158] The item supply unit 10 is composed of two sets of item supply conveyors 10a. This is the same as in the first embodiment, so the explanation will be omitted.

[0159] Next, the goods sorting unit 20 is comprised of a goods storage box supply unit 20b that supplies empty goods storage boxes 70 for storing goods B destined for the same destination, two goods receiving units 20c that receive goods from the goods supply unit 10 in the supplied empty goods storage boxes 70, and a goods storage box dispensing unit 20d that dispenses the goods storage boxes 70 containing the received goods.

[0160] In other words, unlike the first embodiment, this embodiment uses an article storage box 70 as the article sorting unit 20, so that when sorting is complete, the articles for each destination are already stored in the article storage box 70, which can be advantageous for subsequent transfer and transportation.

[0161] In this section, the goods storage box supply unit 20b will be explained using a collapsible container (Oricon) as an example of a goods storage box 70.

[0162] This section has a configuration similar to the article storage box supply unit 30a of the first embodiment, and is transported in the following order: washing unit 201, drying and inspection unit 202 having a blower 2021 and a camera 2022 for internal inspection, and film inserter 203 for laying film inside. After that, it is transported by roller conveyor 204 to article storage box waiting unit 205 where six article storage boxes 70 can wait. Beyond the article storage box waiting unit 205 is a left and right branching sorter 206, a right-direction roller conveyor 207 after branching, and a left-direction roller conveyor 208.

[0163] Here, the state in which six item storage boxes 70 are lined up on the right conveyor 207 is the item receiving section 20c, and similarly, the state in which six item storage boxes 70 are lined up on the left conveyor 208 is also the item receiving section 20c.

[0164] With this configuration, the goods sorting unit 20 has two goods receiving units 20c, so by using them simultaneously, the number of destinations can be increased, and by using them sequentially, preparations for the next sorting can be made in advance, enabling efficient operation.

[0165] Furthermore, the item storage box standby unit 205 can prepare enough item storage boxes 70 for one cycle, enabling the rapid supply of empty item storage boxes 70.

[0166] The item storage box dispensing unit 20d, which dispenses the item storage boxes 70 containing the received items, is a right-angle branching mechanism (not shown) using rollers that can transport items in a direction perpendicular to the direction of travel of the roller conveyor 207 (or 208) of the item sorting unit 20, and can dispense the item storage boxes 70 on the roller conveyor 207 (or 208) horizontally.

[0167] Next, the goods delivery unit 30 consists of a six-wheeled trolley 30d having three shelves in the vertical direction for receiving goods storage boxes 70 containing the prepared goods and transporting them to the next process, an elevator 30e for facilitating transfer to the six-wheeled trolley, and an automated guided vehicle 30f for towing the trolley 30d and transporting it to the next process.

[0168] Since these individual parts are the same as in the first embodiment, their description will be omitted.

[0169] Next, the first transfer means 40 is composed of a so-called cross-belt type automated guided vehicle 40b, which has a belt conveyor 414 on which articles and other items can be placed and transported in a predetermined direction. Figure 10 is an explanatory diagram of an automated guided vehicle 40b used in a second embodiment of the article sorting system according to the present invention, and has a transport vehicle body 412 that has wheels 411 and can travel unmanned, and a belt conveyor 414 provided on the upper surface of the body.

[0170] Furthermore, as the first transfer means 40, a hopper-type automated guided vehicle 40a described in the first embodiment may be used. Depending on the items to be handled, this may be more reliable than the cross-belt type in terms of preventing items from falling during transport.

[0171] While an AMR that does not require a derivative is preferred for the automated guided vehicle 40b, an AGV may be used with a derivative such as magnetic tape or a QR code (registered trademark) depending on the situation. The same applies to the automated guided vehicles in the subsequent embodiments.

[0172] Next, the second transfer means 50 is configured as a cross-belt type automated guided vehicle 50b, similar to the first transfer means 40. The structure is the same as that of the automated guided vehicle 40b, and includes a transport vehicle body 512 that has wheels 511 and can travel unmanned, and a belt conveyor 514 provided on the upper surface of the body.

[0173] Furthermore, the system includes an item sorting system control unit 60 that controls this system. This configuration is as described above.

[0174] <Operation of the second embodiment> The operation of a second embodiment of the article sorting system according to the present invention will be described. First, goods B, which have been batch-picked and whose six destinations (customers) make up one cycle, are supplied to one of the goods supply conveyors 10a.

[0175] Next, the goods are transferred from the goods supply conveyor 10a to the first transfer means 40, the automated guided vehicle 40b. Although not shown in the illustration, the transfer is carried out as shown in Figure 5 of the first embodiment. However, since the top surface of the automated guided vehicle 40b is a belt conveyor, if the transfer from the goods supply conveyor 10a is difficult due to high friction or other circumstances, smoother transfer may be possible by operating the conveyor on the top surface.

[0176] Next, the first transfer means 40, an automated guided vehicle 40b, travels under its own power to the goods sorting unit 20, and the goods are transferred to the goods sorting unit 20. Figure 11 is an explanatory diagram of the transfer from the first transfer means 40 (automated guided vehicle 40b) to the goods sorting unit 20, and from the goods sorting unit 20 to the second transfer means 50 (automated guided vehicle 50b) in a second embodiment of the goods sorting system according to the present invention.

[0177] In other words, the automated guided vehicle 40b arrives near one of the item storage boxes 70 located at 21 to 26 in the figure, which is designated as the item sorting unit 20 by the item sorting system 1, and activates the belt conveyor 414 on its top surface to load item B into the item storage box 70.

[0178] Next, another automated guided vehicle (AGV) 40b loads the goods B supplied from the goods supply conveyor 10 into one of the goods storage boxes 70 in sections 21-26 according to their destination. This process continues until the goods B are sorted into the goods sorting section 20, i.e., the assortment process is completed.

[0179] As shown in the diagram, it is necessary for the upper surface of the goods storage box 70 to be lower than the conveyor 414 on the upper surface of the automated guided vehicle 40b in order to transfer goods, and the facility's floor is formed in such a manner.

[0180] Next, the goods are transferred from the goods sorting unit 20 to the second transfer means 50. As shown in the figure, the goods storage boxes 70, in which the goods have been sorted and stored, are transferred to the automated guided vehicle 50b, which is the second transfer means 50, waiting on the side opposite to the input side of the goods sorting unit 20.

[0181] The transfer to the second transfer means 50, the automated guided vehicle 50b, is performed by horizontally discharging the item storage boxes 70 from the roller conveyor 207 (or 208) using a right-angle branching mechanism (not shown) with rollers that can transport in a direction perpendicular to the direction of travel of the roller conveyor 207 (or 208) of the item sorting unit 20.

[0182] As shown in the figure, for the transfer of the item storage box 70, it is necessary that the upper surface of the second transfer means 50, the unmanned transport vehicle 50b, be lower than the bottom surface of the item storage box 70, and the facility's floor is formed in such a manner.

[0183] Next, the goods are transferred from the second transfer means 50 to the goods delivery unit 30. Figure 12 is an explanatory diagram of the transfer from the second transfer means 50 to the goods delivery unit 30 in a second embodiment of the goods sorting system according to the present invention.

[0184] In this configuration, a six-wheeled trolley 30d is placed on the elevator 30e, and the item storage boxes 70 are transferred from the automated guided vehicle 50b to the upper, middle, and lower levels of the six-wheeled trolley 30d. The details are the same as in the first embodiment, so the explanation is omitted.

[0185] Next, the 6-wheeled trolley 30d, which has finished transferring the items, is transported. Figure 13 is an explanatory diagram of the transport of the 6-wheeled trolley 30d in the second embodiment of the goods sorting system according to the present invention.

[0186] Here, the unmanned transport vehicle 30f for towing the trolley has a towing unit 301 for towing the 6-wheel trolley 30d, and by connecting this to the 6-wheel trolley 30d, the 6-wheel trolley 30d can be moved unmanned to a predetermined location (truck, warehouse, etc.).

[0187] According to this embodiment, by using an item storage box 70 as the item sorting unit 20, the items for each destination are already stored in the item storage box 70 when sorting is complete, which has advantages such as making subsequent transfer and transportation easy and reliable.

[0188] Next, a third embodiment of the present invention will be described with reference to the attached drawings. These are illustrative examples of apparatus and methods for embodying the technical idea of ​​the invention, and the technical idea of ​​the present invention is not limited to those described below. The technical idea of ​​the present invention can be modified in various ways within the scope of the claims. In particular, it should be noted that the drawings are schematic and may differ from reality. Parts that are already known technology have been omitted from the explanation.

[0189] Figure 14 is an explanatory diagram of a third embodiment of the goods sorting system according to the present invention, and is a plan view from above. Note that in this figure, a perspective view is used for the automated guided vehicle in some parts to facilitate understanding (the same applies to the following embodiments).

[0190] <Configuration of the third embodiment> The configuration of a third embodiment of the present invention will now be described.

[0191] The item supply unit 10 is composed of two sets of item supply conveyors 10a. This is the same as described in the first embodiment, so the explanation will be omitted.

[0192] Next, the goods sorting unit 20 is composed of a group of goods storage boxes 70 placed on automated guided vehicles. Specifically, it consists of a goods storage box supply unit 20a that supplies empty goods storage boxes 70 for storing goods B destined for the same destination, and a self-propelled goods sorting unit 20e which is formed by aligning the supplied empty goods storage boxes 70 on the top surface of self-propelled automated guided vehicles and the automated guided vehicles with goods storage boxes 70 on them in a vertical line.

[0193] Here, the item storage box supply unit 20a is the same as that described in the second embodiment, but it does not have the elements from the item storage box waiting unit onwards, and the ready item storage boxes 70 are transferred to the upper surface of the unmanned transport vehicle that constitutes the self-propelled item sorting unit 20e.

[0194] Here, the unmanned transport vehicle (AGV) serving as the self-propelled goods sorting unit 20e is preferably a so-called cross-belt type AGV 40b, which has a belt conveyor 414 on which goods can be placed on its upper surface and which can be transported in a predetermined direction. This is explained in Figure 10 and related embodiments.

[0195] Next, the goods delivery unit 30 consists of a goods storage box transfer conveyor 30g that moves the goods storage boxes 70 received from the second transfer means 50 (described later) in the horizontal direction, a six-wheeled trolley 30d having three shelves in the vertical direction that receives the goods storage boxes 70 containing the assembled goods and transports them to the next process, an elevator 30e to facilitate transfer to the six-wheeled trolley, and an unmanned transport vehicle 30f for trolley towing that pulls the six-wheeled trolley 30d and transports it to the next process.

[0196] Here, any parts of these individual components that are not explained are the same as in previous embodiments, so their explanation will be omitted.

[0197] Next, the first transfer means 40 is configured as a hopper-type automated guided vehicle 40a with a top surface that can be flipped up. This is the same as the one described in the first embodiment, so the explanation will be omitted.

[0198] Next, the second transfer means 50 is configured to be used by the self-propelled item sorting unit 20e, which is part of the item sorting unit 20. The self-propelled item sorting unit 20e is as described above.

[0199] Furthermore, the system includes an item sorting system control unit 60 that controls this system. This configuration is as described above.

[0200] <Operation of the third embodiment> The operation of the first embodiment of the article sorting system according to the present invention will be described. The process from the item supply conveyor 10a, which is the item supply unit 10, to the hopper-type unmanned transport vehicle 40a, which is the first transfer means 40, is the same as in the first embodiment, and therefore the explanation will be omitted.

[0201] Next, the first transfer means 40, the automated guided vehicle 40a, moves and arrives at an item storage box 70 placed on one of the automated guided vehicles of the self-propelled item sorting unit 20e.

[0202] Therefore, the items are transferred (sorted) into the item storage box 70.

[0203] Figure 15 is an explanatory diagram of the transfer from the unmanned transport vehicle 40a to the item storage box 70 of the self-propelled item sorting unit 20e in a third embodiment of the item sorting system according to the present invention, showing the situation in which item B is transferred to the item storage box 70 designated by the item sorting system control unit 60 within the self-propelled item sorting unit 20e.

[0204] Here, by flipping up the tray 413 of the automated guided vehicle 40a as shown in the figure, item B can be transferred onto the cross-belt conveyor 203.

[0205] On the other hand, the self-propelled item sorting unit 20e, on which the item storage boxes 70, which constitute the item sorting unit 20, are placed, is positioned lower than the automated guided vehicle 40a, so that it can receive items that fall.

[0206] Next, another automated guided vehicle 40a sorts the items into the same or different item storage boxes 70. Once sorting is complete, the self-propelled item sorting unit 20e, which also serves as the second transfer means 50, moves to the item delivery unit 30.

[0207] In the goods delivery unit 30, first, the goods storage boxes 70 on the unmanned transport vehicle of the self-propelled goods sorting unit 20e, which is the second transfer means 50, are transferred using the belt conveyor of the unmanned transport vehicle to the goods storage box transfer conveyor 30g, which moves the goods storage boxes 70 received from the second transfer means 50 (described later) in a horizontal direction.

[0208] The transferred item storage boxes 70 are then moved to the upper level of the three shelves provided on the six-wheeled trolley 30d, after the trolley 30d has arrived.

[0209] Next, the item storage boxes 70 are sequentially transferred to the middle and lower levels using the elevator 30e. Once the designated item storage boxes 70 have been transferred, the 6-wheeled trolley 30d is transported to the next process using the trolley-towing automated guided vehicle 30f.

[0210] Furthermore, while the item storage box transfer conveyor 30g is effective in releasing the self-propelled item sorting unit 20e early, it can be omitted depending on the operational situation.

[0211] According to this third embodiment, since the self-propelled goods sorting unit 20e and the second transfer means 50 are used interchangeably, there are advantages such as requiring fewer fixed facilities and enabling a flexible facility layout.

[0212] Next, a fourth embodiment of the present invention will be described with reference to the attached drawings. These are illustrative examples of apparatus and methods for embodying the technical idea of ​​the invention, and the technical idea of ​​the present invention is not limited to those described below. The technical idea of ​​the present invention can be modified in various ways within the scope of the claims. In particular, it should be noted that the drawings are schematic and may differ from reality. Parts that are already known technology have been omitted from the explanation.

[0213] Figure 16 is an explanatory diagram of a fourth embodiment of the goods sorting system according to the present invention, where Figure 16(a) is a top view and Figure 16(b) is a side view.

[0214] <Configuration of the fourth embodiment> The configuration of a fourth embodiment of the present invention will now be described.

[0215] The goods supply unit 10 is comprised of goods supply conveyors 10a. This is almost the same as the second embodiment, but here, four goods supply conveyors 10a are provided.

[0216] Next, the goods sorting unit 20 is comprised of a goods storage box supply unit 20a that supplies empty goods storage boxes 70 for storing goods B destined for the same destination, a first goods receiving unit 20b and a second goods receiving unit 20c that receive goods from the goods supply unit 10 in the supplied empty goods storage boxes 70, and a goods storage box dispensing unit 20d that dispenses the goods storage boxes 70 containing the received goods. This configuration is the same as in the second embodiment, and further details will be omitted.

[0217] Next, the goods delivery unit 30 consists of a six-wheeled trolley 30d having three shelves in the vertical direction for receiving goods storage boxes 70 containing the prepared goods and transporting them to the next process, a skip floor 30h to facilitate transfer to the six-wheeled trolley 30d, and an unmanned transport vehicle 30f for towing the trolley tow the six-wheeled trolley 30d and transporting it to the next process.

[0218] In other words, the elevator 30e in the second embodiment is replaced with a skip floor 30h.

[0219] Here, the skip floor 30h is configured as follows: A ramp (slope) Su is provided rising from the base floor so that the unmanned transport vehicle 50b, which will be described later as the second transfer means 50, can rise. A first transfer area T1 is provided on the flat part at the top, and then a descending ramp Sd is provided to return the unmanned transport vehicle 50b to the base floor.

[0220] The height of the first transfer location T1 is set to facilitate transfer to the upper level of the six-wheeled trolley 30d, which has three shelves. (See Figure 16(b). The same applies below.)

[0221] Similarly, a ramp Sd descending from the floor surface is provided to allow the automated guided vehicle 50b to descend, a third transfer area T3 is provided on the flat bottom, and at this location the vehicle can be transferred to a 6-wheeled trolley 30d. After that, an ascending ramp Su is provided to return the automated guided vehicle 50b to the base floor surface.

[0222] Furthermore, the height of the third transfer location T3 is set to facilitate transfer to the lower level of the 6-wheeled trolley 30d, which has three shelves.

[0223] Furthermore, a second transfer area T2 is provided in a location where a ramp is not provided on the standard floor surface. The height of this second transfer area is such that it is easy to transfer to the middle level of the 6-wheeled trolley 30d, which has three shelves.

[0224] Furthermore, it is preferable to provide fall prevention walls F on both or one side of the extending direction of the ascending slope Su and the descending slope Sd, except in the area where the vehicle is transferred to the 6-wheeled trolley 30d, for safety reasons.

[0225] Next, the first transfer means 40 is composed of a hopper-type automated guided vehicle 40a with a top surface that can be flipped up. Details have been explained in the previous embodiment, so they will be omitted here.

[0226] Next, the second transfer means 50 is composed of a cross-belt type automated guided vehicle 50b. Details have been explained in the previous embodiment and will be omitted here.

[0227] Furthermore, the system includes an item sorting system control unit 60 that controls this system. This configuration is as described above.

[0228] <Operation of the fourth embodiment> The operation of a fourth embodiment of the article sorting system according to the present invention will be described. First, goods B, which have been batch-picked and whose six destinations (customers) make up one cycle, are supplied to one of the goods supply conveyors 10a.

[0229] In this embodiment, four item supply conveyors 10a are provided, which can be effectively used when there is a large volume of goods or when there are many destinations.

[0230] Furthermore, by providing space below the conveyor of the item storage box supply section 20a of the item sorting section 20, an automated guided vehicle 40a can pass through, allowing the four item supply conveyors 10a to be used freely.

[0231] Next, the goods are transferred from the goods supply conveyor 10a to the first transfer means 40, which is the automated guided vehicle 40a. Since the automated guided vehicle 40a is a hopper type, the transfer is carried out by the conveying force of the goods supply conveyor 10a. Details have been explained in the previous embodiment, so they will be omitted here.

[0232] Next, the first transfer means 40, the automated guided vehicle 40a, travels under its own power to the goods sorting unit 20, where the goods are transferred to one of the goods storage boxes 70 in the goods sorting unit 20. The transfer is performed by flipping up the hopper section of the hopper-type automated guided vehicle 40a and loading the goods into the goods storage boxes 70 of the goods sorting unit 20. Details have been explained in the previous embodiment and will be omitted here.

[0233] Next, the goods are transferred from the goods sorting unit 20 to the second transfer means 50. The goods storage boxes 70, in which the goods have been sorted and stored, are transferred to the automated guided vehicle 50b, which serves as the second transfer means 50 and is waiting on the opposite side of the goods sorting unit 20 from the input side.

[0234] The transfer to the second transfer means 50, the automated guided vehicle 50b, is performed by a right-angle branching mechanism using rollers that can transport in a direction perpendicular to the direction of travel of the roller conveyor of the goods alignment unit 20. Details were described in the previous embodiment.

[0235] Next, the goods are transferred from the second transfer means 50 to the goods delivery unit 30. Here, the automated guided vehicle 50b, on which the prepared goods storage boxes 70 are placed, moves to the first transfer location T1 if the goods storage boxes 70 are to be transferred to the upper level of the six-wheeled trolley 30d, to the second transfer location T2 if the goods are to be transferred to the middle level of the six-wheeled trolley 30d, and to the third transfer location if the goods are to be transferred to the lower level of the six-wheeled trolley 30d.

[0236] Once the designated item storage boxes 70 have been transferred to each level, the 6-wheeled trolley 30d is towed by the trolley-towing automated guided vehicle 30f and transported to the next process.

[0237] In the previous explanation, we assumed the trolley had three shelves, but this is not limited to that; any two or more shelves will suffice.

[0238] According to this embodiment, since a skip floor is prepared in advance for loading onto the 6-wheeled trolley 30d, there is no need to install power-operated equipment such as an elevator, which reduces running costs and shortens processing time.

[0239] Next, a fifth embodiment of the present invention will be described with reference to the attached drawings. These are illustrative examples of apparatus and methods for embodying the technical idea of ​​the invention, and the technical idea of ​​the present invention is not limited to those described below. The technical idea of ​​the present invention can be modified in various ways within the scope of the claims. In particular, it should be noted that the drawings are schematic and may differ from reality. Parts that are already known technology have been omitted from the explanation.

[0240] Figure 17 is an explanatory diagram of a fifth embodiment of the goods sorting system according to the present invention, and is a plan view seen from above.

[0241] <Configuration of the Fifth Embodiment> The configuration of the fifth embodiment of the present invention will now be described.

[0242] The item supply unit 10 is composed of one set of item supply conveyors 10a. This is the same as in the previous embodiment, so the explanation will be omitted.

[0243] Next, the goods sorting unit 20 is composed of a goods storage box supply unit 20b that supplies empty goods storage boxes 70 for storing goods B destined for the same destination, a mobile goods receiving unit 20f that receives goods from the goods supply unit 10 in the supplied empty goods storage boxes 70, and a goods storage box dispensing unit 20d that dispenses the goods storage boxes 70 containing the received goods.

[0244] Here, the item storage box supply unit 20a prepares empty item storage boxes 70, as described in the second embodiment, and also has an item storage box waiting unit 205 that holds ready item storage boxes 70 for one cycle (6 boxes in this case).

[0245] Furthermore, the item storage box 70 is transported to the mobile item receiving unit 20f via the right-angle direction conversion unit 20g. Note that known technology can be used for the right-angle direction conversion unit 20g.

[0246] In this example, the mobile goods receiving unit 20f sorts goods to six destinations, but it is designed to accommodate 11 goods storage boxes 70. As will be described later, goods from the fixed goods supply conveyor 10a are received by moving the goods storage boxes 70 to be received, and for this reason, there are more places to put the goods storage boxes 70 than there are sorting destinations.

[0247] The item storage box dispensing section 20d is a right-angle branching mechanism (not shown) using rollers that can transport items in a direction perpendicular to the direction of travel of the roller conveyor of the mobile item receiving section 20f, and can dispense the item storage boxes 70 on the roller conveyor horizontally.

[0248] Next, the goods delivery unit 30 consists of a six-wheeled trolley 30d having three shelves in the vertical direction for receiving goods storage boxes 70 containing the prepared goods and transporting them to the next process, an elevator 30e for facilitating transfer to the six-wheeled trolley, and an automated guided vehicle 30f for towing the trolley 30d and transporting it to the next process.

[0249] Since these individual parts are the same as in the first embodiment, their description will be omitted.

[0250] Next, the first transfer means from the goods supply unit 10 to the goods sorting unit 20 will be described. In this embodiment, since the transfer is performed directly from the goods supply unit 10 to the goods sorting unit 20 without using any special mechanism, the first transfer means 40 is "direct".

[0251] Next, a second transfer means from the goods sorting unit 20 to the goods delivery unit 30 will be described. In this embodiment, since the transfer is performed directly from the goods sorting unit 20 to the goods delivery unit 30 without using any special mechanism, the second transfer means is "direct".

[0252] Furthermore, the system includes an item sorting system control unit 60 that controls this system. This configuration is as described above.

[0253] <Operation of the Fifth Embodiment> The operation of a fifth embodiment of the article sorting system according to the present invention will be described. First, goods B, which have been batch-picked and comprise six destinations (customers) per cycle, are supplied to the goods supply conveyor 10a.

[0254] A mobile item receiving unit 20f, which is part of the item sorting unit 20, is closely attached to the end of the item supply conveyor 10a.

[0255] The item storage box 70, which is the destination for the first supplied items, is moved to the end (exit) of the item supply conveyor 10a by operating the mobile item receiving unit 20f at the instruction of the item sorting system control unit 60.

[0256] The item supply conveyor 10a is operated to directly load items into the item storage box 70 that has been moved.

[0257] Next, the item storage box 70, which will be the destination for the incoming items, is aligned with the exit of the item supply conveyor 10a by the mobile item receiving unit 20f, and the items are loaded into it.

[0258] This process is repeated until sorting by destination (assortment process) is complete, at which point the item storage boxes 70 are transferred to a 6-wheeled trolley 30d that is waiting in close proximity to the dispensing side of the item storage box dispensing unit 20d.

[0259] Furthermore, the 6-wheeled trolley 30d is mounted on the elevator 30e, and as described in the previous embodiments, it can be easily transferred to multiple levels of the 6-wheeled trolley 30d.

[0260] Next, the 6-wheeled trolley 30d, having completed the transfer, is transported to the next process using an automated guided vehicle 30f for trolley towing. Details have been explained in previous embodiments.

[0261] According to this embodiment, since both the transfer from the goods supply unit 10 to the goods sorting unit 20 (first transfer means) and the transfer from the goods sorting unit 20 to the goods delivery unit 30 (second transfer means) are "direct," there are advantages such as a simplified configuration.

[0262] Next, a sixth embodiment of the present invention will be described with reference to the attached drawings. These are illustrative examples of apparatus and methods for embodying the technical idea of ​​the invention, and the technical idea of ​​the present invention is not limited to those described below. The technical idea of ​​the present invention can be modified in various ways within the scope of the claims. In particular, it should be noted that the drawings are schematic and may differ from reality. Parts that are already known technology have been omitted from the explanation.

[0263] Figure 18 is an explanatory diagram of a fifth embodiment of the goods sorting system according to the present invention, and is a plan view seen from above.

[0264] <Configuration of the 6th Embodiment> The configuration of the sixth embodiment of the present invention will now be described.

[0265] The article supply section 10 is composed of two sets of article supply conveyors 10a. Since this is the same as in the previous embodiment, the description thereof will be omitted.

[0266] Next, the article alignment section 20 is composed of a group of article storage boxes 70 placed on an automated guided vehicle. Specifically, it consists of a self-propelled article alignment section 20e on which empty article storage boxes 70 for storing articles B with the same destination are placed.

[0267] Here, as the self-propelled article alignment section 20e, an automated guided vehicle of the so-called cross-belt type 40b having a belt conveyor 414 on the upper surface on which articles and the like can be placed and which can be conveyed in a predetermined direction is suitable. There is an explanation about this in FIG. 10 and related embodiments.

[0268] Note that, unlike the previous embodiment, the self-propelled article alignment section 20e does not require alignment and can receive transfer from the first transfer means 40 described later at a free position.

[0269] Next, the article delivery section 30 is composed of a six-wheeled cart 30d having three shelves in the vertical direction for receiving the article storage box 70 received from the self-propelled article alignment section 20e and transporting it to the next process, a skip floor 30h for facilitating transfer to the six-wheeled cart, and an automated guided vehicle 30f for towing the six-wheeled cart 30d and transporting it to the next process.

[0270] Here, parts for which there is no explanation regarding these individual parts are the same as in the previous embodiments, so the description thereof will be omitted.

[0271] Next, the first transfer means 40 is composed of a moving path 40c formed in an arc shape and a hopper-type automated guided vehicle 40a that can move in the forward and reverse directions on the moving path 40c and whose upper surface can be flipped up.

[0272] Next, the second transfer means 50 is configured to also be used by the self-propelled goods sorting unit 20e. That is, the self-propelled goods sorting unit 20e directly transports the sorted goods storage boxes 70 to the goods delivery unit 30 and transfers them to the goods delivery unit 30.

[0273] <Operation of the 6th Embodiment> The operation of a sixth embodiment of the article sorting system according to the present invention will be described. First, goods B, which have been batch-picked and whose six destinations (customers) make up one cycle, are supplied to one of the two goods supply conveyors 10a.

[0274] A hopper-type automated guided vehicle 40a, which is the first transfer means 40, is closely attached to the end of the item supply conveyor 10a, and the supplied items B are transferred onto it. The transfer method is as described in the previous embodiment.

[0275] The automated guided vehicle 40a moves in both forward and reverse directions along the travel path 40c until it arrives at a position directly opposite the self-propelled item sorting unit 20e, which is equipped with a designated item storage box 70 that is the destination for the supplied items. There, it transfers the supplied items to the destination item storage box 70.

[0276] This process is repeated until sorting by destination (assortment process) is complete. Then, the self-propelled goods sorting unit 20e, which also serves as a second transfer means, loads (transfers) the goods onto the 6-wheeled trolley 30d via the skip floor 30h.

[0277] Details of this procedure have been described in previous embodiments.

[0278] According to this embodiment, by using an automated guided vehicle 40a in which the first transfer means 40 is arranged in an arc shape, the degree of freedom in arranging the goods sorting unit 20 is increased, and the system is simplified by having the self-propelled goods sorting unit 20e also serve as the second transfer means.

[0279] Next, a seventh embodiment of the present invention will be described with reference to the attached drawings. These are illustrative examples of apparatus and methods for embodying the technical idea of ​​the invention, and the technical idea of ​​the present invention is not limited to those described below. The technical idea of ​​the present invention can be modified in various ways within the scope of the claims. In particular, it should be noted that the drawings are schematic and may differ from reality. Parts that are already known technology have been omitted from the explanation.

[0280] Figure 19 is an explanatory diagram of the seventh embodiment of the goods sorting system according to the present invention, and is a plan view seen from above.

[0281] <Configuration of the 7th embodiment> The configuration of the seventh embodiment of the present invention will now be described. This embodiment is the same as the first embodiment except for the article sorting unit 20, and the description of that part will be simplified.

[0282] The goods supply unit 10 is composed of two sets of goods supply conveyors 10a.

[0283] Next, the goods sorting section 20 is composed of a three-dimensional goods sorting shelf 20h having multiple three-dimensional compartments that can be raised and lowered. Figure 20 is an explanatory diagram of the three-dimensional goods sorting shelf 20h used in the seventh embodiment of the goods sorting system according to the present invention, and is an elevation view taken from the left side in Figure 20.

[0284] The three-dimensional goods sorting rack 20h consists of six rows of vertical shelves 251, each having three shelves (storage spaces) in the vertical direction, resulting in a total of 18 compartments (openings). These vertical shelves 251 are installed by cutting out sections of the facility's floor L.

[0285] The lower part of the vertical shelf 251 has a holding part 252 that holds the vertical shelf 251, and a lifting mechanism 253 that moves the holding part 252 up and down.

[0286] Each vertical shelf 251 can be individually lifted and lowered by a lifting mechanism 253, and can be stopped at any of the three levels of shelves at a height where it can receive transfer from the hopper-type automated guided vehicle 40a, which is the first transfer means 40 described later.

[0287] Next, the article delivery section 30 is composed of an article storage box supply section 30a that supplies an empty article storage box 70 for storing articles B with the same destination, an article receiving section 30b that receives articles from the article sorting section 20 in the supplied empty article storage box 70, an article storage box dispensing section 30c that dispenses the article storage box 70 in which the received articles are stored, a six-wheeled cart 30d having three shelves in the vertical direction that receives the dispensed article storage box 70 and transports it to the next process, an elevator 30e for facilitating transfer to the six-wheeled cart, and an automated guided vehicle 30f for towing the six-wheeled cart 30d and transporting it to the next process. Details of each part have been described in the first embodiment.

[0288] Next, the first transfer means 40 is composed of a hopper-type automated guided vehicle 40a whose upper surface can be flipped up. Details have been described in the first embodiment.

[0289] Next, the second transfer means 50 is composed of a hopper-type automated guided vehicle 50a whose upper surface can be flipped up. Details have been described in the first embodiment.

[0290] Also, it is equipped with an article sorting system control section 60 for controlling this system. This configuration is as described above.

[0291] <Operation of the Seventh Embodiment> The operation of the seventh embodiment of the article sorting system according to the present invention will be described. First, articles B that have been batch-picked and have six destinations (orderers) per tact are supplied to any one of the article supply conveyors 10a.

[0292] Next, the goods are transferred from the goods supply conveyor 10a to the first transfer means 40, which is the automated guided vehicle 40a. The details of this transfer method have already been explained in the first embodiment.

[0293] Next, the first transfer means 40, the automated guided vehicle 40a, moves autonomously to the three-dimensional item sorting shelf 20h, where the items are transferred (sorted) to the three-dimensional item sorting shelf 20h. Specifically, the items B placed on the automated guided vehicle 40a are moved by raising and lowering the three-dimensional item sorting shelf 20h to one of the three sections of the shelves in one of the six rows of vertical shelves 251, i.e., one of the 18 sections. The transfer method is the same as in the first embodiment, and in Figure 20, the hopper of the automated guided vehicle 40a is raised to face the opening when transferring items.

[0294] Next, another automated guided vehicle (AGV) 40a loads the goods B supplied from the goods supply conveyor 10a into one of 18 designated sections, each corresponding to its destination. This process continues until the goods B are sorted into the goods sorting section 20, i.e., the assortment process is completed.

[0295] Next, the items are transferred from the item sorting rack 20a to the second transfer means 50, which is the automated guided vehicle 50a. The three-dimensional item sorting rack 20h is raised and lowered to position the designated section at a height where it can be transferred, and, as in the first embodiment, the cross belts provided at each opening are activated, and the items are transferred to the trays of the automated guided vehicle 50a by their transport force.

[0296] Next, the automated guided vehicle 50a, which is the second transfer means 50 that has received the goods for the designated destination, travels to the goods delivery section 30 in order to transfer (hand over) the goods.

[0297] The subsequent operations, such as transferring the goods to the goods delivery unit 30 and towing the 6-wheeled trolley 30d as the goods delivery unit 30, are as described in the first embodiment, so the explanation will be omitted.

[0298] According to this embodiment, the goods sorting section 20 is a three-dimensional goods sorting shelf 20h, which allows for more destination compartments (openings) compared to a two-dimensional goods sorting shelf. This is extremely advantageous for operations with many destinations.

[0299] Next, an eighth embodiment of the present invention will be described with reference to the attached drawings. These are illustrative examples of apparatus and methods for embodying the technical idea of ​​the invention, and the technical idea of ​​the present invention is not limited to those described below. The technical idea of ​​the present invention can be modified in various ways within the scope of the claims. In particular, it should be noted that the drawings are schematic and may differ from reality. Parts that are already known technology have been omitted from the explanation.

[0300] Figure 21 is an explanatory diagram of the eighth embodiment of the goods sorting system according to the present invention, and is a plan view seen from above.

[0301] <Configuration of the 8th embodiment> The configuration of the eighth embodiment of the present invention will now be described.

[0302] The goods supply unit 10 consists of five sets of goods supply conveyors 10a and a vertical automated warehouse 10b (or 10c) for temporarily storing the goods supplied by the goods supply conveyors 10a.

[0303] Figure 22 is a perspective view of a vertical automated warehouse 10b used in the eighth embodiment of the goods sorting system according to the present invention, and Figure 23 is a schematic diagram of the interior of the vertical automated warehouse as seen from the left side.

[0304] The vertical automated warehouse 10b is provided with two openings 111a and 111b on the receiving and shipping sides. A tray-shaped component called a tray 112 is provided horizontally in the opening 111, and five item storage boxes 70 capable of holding items can be placed on top of it.

[0305] Although details are omitted here, as shown in the diagram, the tray 112 is structured to protrude out of the vertical automated warehouse 10b at the opening 111.

[0306] This vertical automated warehouse 10b has a first storage section 113 on the receiving side, an elevator section 114 in the center, and a second storage section 115 on the outbound side.

[0307] Here, the tray 112 is transferred to the elevator section 114 using the transfer mechanism 116 while maintaining a horizontal position, and is moved vertically and horizontally to be stored in the first storage section 113 or the second storage section 115 in the warehouse.

[0308] The transfer mechanism 116 can use known technology, such as a telescopic mechanism, and the elevator section 114 can also use various known linear movement technologies. A vertical automated warehouse 10b of this type is called an elevator system.

[0309] In addition, there are other types of vertical automated warehouses, such as the rotating shelf system or the carousel system. Figure 25 is a schematic diagram of a vertical automated warehouse 10c used in the eighth embodiment of the goods sorting system according to the present invention.

[0310] The vertical automated warehouse 10c is provided with two openings 111a and 111b, and a tray 112 is presented horizontally through opening 111.

[0311] The tray 112 is held in place by fasteners (attachments) on an endless chain 117 provided on either the left or right end when viewed from the front.

[0312] This chain 117 has a rounded rectangular shape (like a running track) when viewed from the side, and has sprockets (not shown) at the top and bottom. By rotating either or both of these, it is possible to rotate the tray 112 in both forward and reverse directions (in the direction of the arrows in the figure).

[0313] In this embodiment, the vertical automated warehouse can be selected from an elevator system, a carousel system, or another system, depending on the requirements of the goods sorting system.

[0314] Next, the goods sorting unit 20 is composed of a self-propelled goods sorting unit 20e formed by aligning unmanned transport vehicles carrying goods storage boxes 70 in a vertical line. This self-propelled goods sorting unit 20e is the same as that of the third embodiment. If necessary, a goods storage box supply unit (not shown) for supplying empty goods storage boxes 70 may be provided.

[0315] Here, the unmanned transport vehicle (AGV) serving as the self-propelled goods sorting unit 20e is preferably a so-called cross-belt type AGV 40b, which has a belt conveyor 414 on which goods can be placed on its upper surface and which can be transported in a predetermined direction. This has also been explained in the third embodiment.

[0316] Alternatively, instead of using a tandem arrangement of automated guided vehicles (AGVs) as the self-propelled goods sorting unit 20e, the AGVs could be driven sequentially to receive the goods storage boxes 70 as they are sorted. This would eliminate the need to reserve space in advance.

[0317] Next, the goods delivery unit 30 consists of a six-wheeled trolley 30d having three shelves in the vertical direction for receiving goods storage boxes 70 containing the prepared goods and transporting them to the next process, a skip floor 30h to facilitate transfer to the six-wheeled trolley 30d, and an unmanned transport vehicle 30f for towing the trolley tow the six-wheeled trolley 30d and transporting it to the next process.

[0318] This configuration is the same as that described in the fourth embodiment, so its explanation will be omitted.

[0319] Next, the first transfer means 40 is composed of a fixed robot 40d capable of transferring articles. Here, a vertical articulated robot is preferable in terms of ease of use, but it is not limited to that; any robot that can pick up or grasp articles from the article supply unit 10 and transfer them to the self-propelled article sorting unit 20e is acceptable.

[0320] Next, the transfer (sorting) of items from the goods supply unit to the goods sorting unit is precisely carried out according to instructions from the goods sorting system control unit 60.

[0321] Next, the second transfer means 50 is configured to be used by the self-propelled item sorting unit 20e, which is part of the item sorting unit 20. The self-propelled item sorting unit 20e is as described above.

[0322] Furthermore, the system includes an item sorting system control unit 60 that controls this system. This configuration is as described above.

[0323] <Operation of the 8th Embodiment> The operation of an eighth embodiment of the article sorting system according to the present invention will be described. First, goods B, which have been batch-picked and whose six destinations (customers) make up one cycle, are supplied to one of the five goods supply conveyors 10a.

[0324] Next, the supplied items are placed into item storage boxes 70 which are placed on trays 112 of vertical automated warehouses 10b located at the end of each item supply conveyor 10a.

[0325] Once a predetermined amount of goods has been supplied to all the item storage boxes 70 on tray 112, tray 112 is temporarily stored inside the vertical automated warehouse 10b by the elevator unit 114 or the like.

[0326] When it is time to prepare the goods, a tray 112 containing the item storage boxes 70 to be prepared is presented from the vertical automated warehouse 10b to the exit side opening 111b.

[0327] Here, the robot 40d, which is the first transfer means 40, is transferred to the self-propelled item sorting unit 20e on which the item storage box 70, which is the item sorting unit 20, is placed.

[0328] Here, five self-propelled item sorting units 20e are lined up as destinations for item sorting. Items are sorted into one of these units, completing the sorting process.

[0329] Furthermore, if the types or quantities of items to be packed are insufficient using only the item storage boxes 70 on one tray 112, the elevator unit 114 may be activated to present another tray 112.

[0330] Next, the items are transferred from the item sorting rack 20a to the second transfer means 50, which is the automated guided vehicle 50a. The three-dimensional item sorting rack 20h is raised and lowered to position the designated section at a height where it can be transferred, and, as in the first embodiment, the cross belts provided at each opening are activated, and the items are transferred to the trays of the automated guided vehicle 50a by their transport force.

[0331] Next, the automated guided vehicle 50a, which is the second transfer means 50 that has received the goods for the designated destination, travels to the goods delivery section 30 in order to transfer (hand over) the goods.

[0332] The subsequent operations, such as transferring goods to the goods delivery unit 30 using the skip floor and towing the 6-wheeled trolley 30d as the goods delivery unit 30, are as described in the fourth embodiment, so the explanation will be omitted here.

[0333] According to this embodiment, since the goods supply unit 10 is equipped with a vertical automated warehouse 10b, a wide variety and large quantity of goods to be sorted can be temporarily stored. Furthermore, since sorting is performed by a robot, the sorting process can be carried out quickly and unattended for a long period of time, thereby improving productivity.

[0334] Next, a ninth embodiment of the present invention will be described with reference to the attached drawings. These are illustrative examples of apparatus and methods for embodying the technical idea of ​​the invention, and the technical idea of ​​the present invention is not limited to those described below. The technical idea of ​​the present invention can be modified in various ways within the scope of the claims. In particular, it should be noted that the drawings are schematic and may differ from reality. Parts that are already known technology have been omitted from the explanation.

[0335] Figure 25 is an explanatory diagram of the ninth embodiment of the goods sorting system according to the present invention, and is a plan view seen from above.

[0336] <Configuration of the 9th embodiment> The configuration of the ninth embodiment of the present invention will now be described.

[0337] The goods supply unit 10 is composed of flow racks 10d. Each of the multiple levels of the flow rack 10d may have an automatic replenishment mechanism 10e for automatically replenishing items to be sorted (or cardboard boxes or collapsible containers for storing items).

[0338] Furthermore, it is preferable that the flow rack 10d be arranged in a stepped configuration, with multiple levels offset from each other, to facilitate suction or gripping by the robot 40d, which is the first transfer means described later, and to be accessible from above, thus resembling terraced fields.

[0339] Next, the goods sorting unit 20 is composed of a goods storage box supply unit 20b that supplies empty goods storage boxes, a goods receiving unit 20c that receives goods sorted into goods storage boxes 70, a goods storage box dispensing unit 20d that dispenses the goods storage boxes 70 containing the received goods, and a vertical automated warehouse 20m that temporarily stores the dispensed goods storage boxes 70.

[0340] Here, the item storage box supply unit 20b, the item receiving unit 20c, and the item storage box dispensing unit 20d are the same as those described in the second embodiment, and their description will be omitted.

[0341] Furthermore, the vertical automated warehouse 20m is the same as the vertical automated warehouse 10b of the eighth embodiment, and the explanation is omitted by substituting the first storage section 113 with 213, the elevator section 114 with 214, and the second storage section 115 with 215.

[0342] Next, the goods delivery unit 30 is composed of a six-wheeled trolley 30d having three shelves in the vertical direction, a skip floor 30h to facilitate transfer to the six-wheeled trolley 30d, and an unmanned transport vehicle 30f for towing the trolley to transport the six-wheeled trolley 30d to the next process.

[0343] This configuration is the same as that described in the fourth embodiment, so its explanation will be omitted.

[0344] Next, the first transfer means 40 is composed of a fixed robot 40d capable of transferring articles. This robot 40d is the same as in the eighth embodiment, so its description will be omitted.

[0345] Next, the second transfer means 50 consists of a crane 50f and a cross-belt type unmanned transport vehicle 50b that carries the goods storage boxes 70 from the crane 50f to the goods delivery section 30.

[0346] The cross-belt type automated guided vehicle 50b has already been described in previous embodiments.

[0347] Here, the crane 50f is preferably an overhead-mounted crane, but other types of cranes may also be used.

[0348] Furthermore, the system includes an item sorting system control unit 60 that controls this system. This configuration is as described above.

[0349] <Operation of the 9th Embodiment> The operation of the ninth embodiment of the article sorting system according to the present invention will be described. First, items B, which are batch-picked and have six destinations (customers) per cycle, are supplied by an automatic replenishment mechanism 10e that automatically replenishes multi-tiered flow racks 10d.

[0350] Meanwhile, in the goods sorting section 20, empty goods storage boxes 70 are transported by a conveyor in the goods storage box supply section 20b and arrive at the goods receiving section 20c.

[0351] Therefore, the robot 40d, which is the first transfer means 40, picks up the items to be sorted by methods such as suction or gripping, and places them into the designated item storage box 70 in the item receiving unit 20c.

[0352] Afterward, the item storage boxes 70 in which the items have been sorted are dispensed from the item storage box dispensing unit 20d and placed on trays 212 in the vertical automated warehouse 20m. Once the desired item storage boxes 70 are placed on trays 212, they are temporarily stored in the first storage unit 213 or the second storage unit 214 of the vertical automated warehouse 20m.

[0353] When it's time for delivery, the item storage box 70 to be delivered is placed on tray example 212 on the outbound side of the 20m vertical automated warehouse.

[0354] This item storage box 70 is moved from the vertical automated warehouse 20m to the outside by a crane 50f, which is a second transfer means 50, and placed on a waiting cross-belt type unmanned transport vehicle 50b.

[0355] The subsequent operations, such as transferring goods to the goods delivery unit 30 using the skip floor and towing the 6-wheeled trolley 30d as the goods delivery unit 30, are as described in the fourth embodiment, so the explanation will be omitted here.

[0356] According to this embodiment, the completed item storage boxes 70 can be temporarily stored in a vertical automated warehouse 20m, which has significant advantages, such as allowing work to be completed with ample time before delivery.

[0357] Next, a tenth embodiment of the present invention will be described with reference to the attached drawings. These are illustrative examples of apparatus and methods for embodying the technical idea of ​​the invention, and the technical idea of ​​the present invention is not limited to those described below. The technical idea of ​​the present invention can be modified in various ways within the scope of the claims. In particular, it should be noted that the drawings are schematic and may differ from reality. Parts of the already known technology have been omitted from the explanation.

[0358] This embodiment is a modified version of the ninth embodiment, and the plan view in Figure 25 is the same in this embodiment as well.

[0359] Figure 26 is an explanatory diagram of the tenth embodiment of the goods sorting system according to the present invention, and is a cross-sectional view of the vertical automated warehouse from 20m onwards in Figure 25.

[0360] <Configuration and Operation of the 10th Embodiment> The configuration and operation of the tenth embodiment of the present invention will be described.

[0361] The article supply unit 10, the article storage box supply unit 20b of the article sorting unit 20, the article receiving unit 20c that receives the articles sorted into the article storage boxes 70, and the article storage box dispensing unit 20d that dispenses the article storage boxes 70 containing the received articles are the same as in the ninth embodiment, so their description will be omitted.

[0362] In the vertical automated warehouse 20m for temporarily storing the dispensed item storage boxes 70, the first storage section 213, elevator section 214, and second storage section 215 are similar, but three openings 211b on the exit side are provided.

[0363] Here, three cranes 50f, which are the second transfer means 50, are provided to match the three openings 211b.

[0364] Furthermore, the cross-belt type automated guided vehicle 50b that receives the goods storage boxes 70 suspended by the crane 50f will also travel on floor surfaces L1, L2, and L3 of different heights to accommodate the three openings 211b.

[0365] Next, the goods delivery unit 30 may, without any particular limitations, transfer goods from the automated guided vehicle 50b to the six-wheeled trolley 30d via an elevator or skip floor, and then tow the six-wheeled trolley 30d with a towing trolley 30f.

[0366] Furthermore, by setting the height of the three-tiered floor on which the automated guided vehicle 50b travels to match the height of the shelves on the six-wheeled trolley 30d by adding a slight slope, it becomes possible to transfer items to the six-wheeled trolley 30d without the need for elevators or skip floors.

[0367] According to this embodiment, by providing multiple exit-side openings for the vertical automated warehouse, there are advantages such as the ability to operate it flexibly.

[0368] Next, an eleventh embodiment of the present invention will be described with reference to the attached drawings. These are illustrative examples of apparatus and methods for embodying the technical idea of ​​the invention, and the technical idea of ​​the present invention is not limited to those described below. The technical idea of ​​the present invention can be modified in various ways within the scope of the claims. In particular, it should be noted that the drawings are schematic and may differ from reality. Parts that are already known technology have been omitted from the explanation.

[0369] Figure 27 is an explanatory diagram of the 11th embodiment of the goods sorting system according to the present invention, and is a plan view seen from above.

[0370] <Configuration of the 11th embodiment> The configuration of the 11th embodiment of the present invention will now be described.

[0371] The goods supply unit 10 consists of multiple pallets 10g and an automated guided vehicle 10h for pallet transport with pallets 10g placed on its upper surface.

[0372] Figure 28 is an explanatory diagram of the article supply section of this embodiment of the article sorting system according to the present invention, where Figure 28(a) is a perspective view and Figure 28(b) is a plan view used in Figure 27.

[0373] The perspective view shows a pallet 10g placed on the automated guided vehicle 10h for pallet transport, while the plan view shows only the automated guided vehicle 10h for pallet transport.

[0374] The pallet transport automated guided vehicle 10h can lift (lift) a pallet 10g and move under its own power, and can also be fixed in place by its legs 151 once it arrives at a designated location.

[0375] Next, the goods stacking section 20 is composed of a goods stacking trolley 20h having one or more tiers. If necessary, each tier of the goods stacking trolley 20h may be equipped with a component capable of holding the stacked goods, such as a goods storage box 70 or a small pallet.

[0376] Figure 29 is an explanatory diagram of the goods sorting section of this embodiment of the goods sorting system according to the present invention, where Figure 29(a) is a perspective view and Figure 29(b) is a plan view used in Figure 27.

[0377] While a cage cart is preferable for this trolley, other types of trolleys may be used, and even shelves without wheels may be used. Furthermore, each tier of the goods arrangement trolley 20h may be equipped with a component capable of holding the arranged goods, such as a goods storage box 70 or a small pallet, as needed.

[0378] Next, the goods delivery unit 30 is configured to also serve as the goods loading cart 20h. In other words, the cart in which the goods have been loaded is used as the goods delivery cart 30h.

[0379] The goods delivery unit 30 may further include a mechanism (not shown) for loading goods onto a delivery truck 80.

[0380] Next, the first transfer means 40 is composed of an automated guided vehicle 40h with a telescope. Figure 30 is an explanatory diagram of the goods sorting section of this embodiment of the goods sorting system according to the present invention, where Figure 30(a) is a perspective view and Figure 30(b) is a plan view used in Figure 27.

[0381] The telescopic automated guided vehicle 40h is capable of grasping items in front of it by extending its arm 451 (which can also be called a telescope) horizontally. Furthermore, the arm 451 can move up and down by a lifting mechanism 452, allowing it to transfer items to each level of the multi-tiered item loading trolley 20h.

[0382] Next, the second transfer means 50 is configured as an automated guided vehicle 50h for transporting goods on a trolley. Specifically, it is an automated guided vehicle whose upper surface can be raised and lowered, which enters below the goods arranging trolley 20h, lifts its upper surface, and then moves under its own power to transport the goods. It has a similar structure to the automated guided vehicle 10h for transporting pallets and can be used for both purposes.

[0383] In this case, since the goods loading cart 20h also serves as the goods delivery cart 30h, it is more of a movement of location than a means of transfer, so it can be called a means of transportation. Furthermore, the automated guided vehicle 50h for transporting carts may tow the goods loading cart 20h instead of transporting it with it on top.

[0384] Furthermore, the system includes an item sorting system control unit 60 that controls this system. This configuration is as described above.

[0385] <Operation of the 11th Embodiment> The operation of this embodiment of the article sorting system according to the present invention will be described. First, four different types of items, each representing one cycle of five destinations (customers) after batch picking, are placed on four pallets (10g) and transported by an automated guided vehicle (AGV) (10h) for pallet transport, stopping at a designated location.

[0386] Next, the telescopic automated guided vehicle 40h approaches the pallet 10g, extends its horizontal arm 451 to grasp the items to be sorted, and either lifts them up as they are or using the lifting mechanism 452 to transfer them to one of the item sorting trolleys 20h using the telescopic function.

[0387] Subsequently, the items are repeatedly transferred from pallet 10g to one of the item sorting carts 20h. Once the sorting is complete, the automated guided vehicle 50h lifts up item sorting cart 20h and moves it under its own power to the delivery location (for example, the loading area for delivery truck 80). At this point, item sorting cart 20h becomes item delivery cart 30h.

[0388] Subsequently, using a loading mechanism (not shown) for the delivery truck 80, the items on the pallet 10g (or the item storage boxes 70 containing the items, or the pallet 10g with the items on it) are loaded onto the truck, completing the delivery process.

[0389] According to this embodiment, since the goods are supplied on pallets, it is possible to handle heavy or long items, and since the pallets can be transported by an automated guided vehicle for pallet transport, there are advantages such as not needing large-scale equipment as a goods supply unit. [Industrial applicability]

[0390] This invention enables significant automation of the supply, sorting, and delivery of goods in the logistics industry, resulting in extremely high efficiency in terms of cost reduction, time savings, and error reduction. Furthermore, since this technology can be applied to the receiving, storage, and dispatching of parts in assembly plants and other facilities, it has broad industrial applicability. [Explanation of symbols]

[0391] 1. Item sorting system 10 Goods supply department 20. Goods Packing Department 30. Goods Shipping Department 40 First transfer means 50 Second transfer means 60. Item sorting system control unit 70 Storage boxes for items

Claims

1. The goods supply department supplies goods to be delivered to destinations, The article sorting unit sorts the articles supplied from the article supply unit into sections according to their destination, The goods delivery unit delivers the goods that have been prepared in the goods preparation unit, A first transfer means for transferring articles supplied from the article supply unit to sections for each destination in the article sorting unit, A second transfer means for transferring items from the item preparation unit to the item delivery unit, The article supply unit, the article sorting unit, the article delivery unit, the first transfer means, and the article sorting system control unit that controls the second transfer means, An article sorting system having the first transfer means and the second transfer means operating unmanned.

2. The article sorting system according to claim 1, characterized in that the article supply unit is one or more intermittently driven conveyors.

3. The article sorting system according to claim 1, characterized in that the article supply unit is a flow rack.

4. The article sorting system according to claim 3, characterized by having an automatic supply mechanism to the flow rack.

5. The article sorting system according to claim 3, characterized in that the flow rack is formed in multiple tiers, and each tier has an offset shape that allows easy access from above to the opening of each tier.

6. The article sorting system according to claim 1, characterized in that the article supply unit is an automated guided vehicle and a pallet placed on the automated guided vehicle.

7. The article sorting system according to claim 1, characterized in that the article supply unit further has a vertical automated warehouse for temporarily storing articles before they are sorted.

8. The article sorting system according to claim 1, characterized in that the article sorting section is a fixed shelf having one or more layers, each with a conveyor on its upper surface and compartments for each destination.

9. The article sorting system according to claim 1, characterized in that the article sorting section is a multi-layered shelf with a conveyor on the top surface and compartments for each destination, and has a lifting mechanism for raising and lowering the shelf.

10. The goods sorting system according to claim 1, characterized in that the goods sorting section is a vertical automated warehouse configured vertically, having sections for each of several destinations.

11. The article sorting system according to claim 1, characterized in that the article sorting section comprises a conveyor and article storage boxes placed on the conveyor.

12. The article sorting system according to claim 1, characterized in that the article sorting section is a plurality of automated guided vehicles having a conveyor or a lifting mechanism on their upper surfaces.

13. The article sorting system according to claim 1, characterized in that the article sorting unit comprises a plurality of automated guided vehicles and article storage boxes placed on the automated guided vehicles.

14. The article sorting system according to claim 1, characterized in that the article delivery section comprises a trolley on which article storage boxes containing articles are placed, and an automated guided vehicle on which the trolley or pallet is placed or towed.

15. The article sorting system according to claim 14, further characterized in that the article delivery unit has an elevator mechanism for transferring sorted articles or article storage boxes to the trolley or the pallet.

16. The article sorting system according to claim 14, further characterized in that the article delivery section has a skip floor with a ramp for transferring sorted articles or article storage boxes to the trolley or the pallet.

17. The article sorting system according to claim 1, characterized in that the first transfer means is an automated guided vehicle having a flip-up mechanism or conveyor on its upper surface.

18. The article sorting system according to claim 1, characterized in that the first transfer means is a robot capable of transferring articles.

19. The article sorting system according to claim 1, characterized in that the first transfer means directly transfers from the article supply unit to the article sorting unit.

20. The article sorting system according to claim 1, characterized in that the second transfer means is an automated guided vehicle having a flip-up mechanism or conveyor on its upper surface.

21. The article sorting system according to claim 20, characterized in that the second transfer means further comprises a conveyor for supplying empty article storage boxes, and a right-angle branching mechanism on the conveyor that can move article storage boxes into which articles have been transferred from the automated guided vehicle in a direction perpendicular to the direction of travel of the conveyor.

22. The article sorting system according to claim 1, characterized in that the second transfer means is a robot, suspension rail, or travel rail capable of transferring articles or article storage boxes containing articles.

23. The article sorting system according to claim 1, characterized in that the second transfer means directly transfers the articles from the article preparation section to the article delivery section.

24. The article sorting system according to claim 1, characterized in that the first transfer means and the second transfer means use a common automated guided vehicle.

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