Conveying system

Abstract

This provides a novel and improved conveying system that enables more efficient operation of multi-stage sorters. [Solution] The operation control unit assigns digits in ascending order to each of at least some of the multiple sorters in the order of transport, and assigns each of the digit values ​​corresponding to the sorter to at least some of the multiple lanes contained in each sorter. The sorter corresponding to each digit loads multiple transport bodies into the lane for each digit value and holds them there, and then, without changing the order in which the transport bodies are transported within the lane, it sequentially unloads the transport bodies from the lane with the smallest digit value, thereby aligning multiple transport bodies for each digit. The number determination unit can change the number of values ​​for each digit, and the operation control unit controls the multistage sorter so that the sorter corresponding to each digit uses the same number of lanes as the number of values ​​for that digit.

Description

Technical Field

[0001] The present invention relates to a conveying system.

Background Art

[0002] Conventionally, a multi-stage sorter for aligning a plurality of carriers in a desired order has been known (see, for example, Patent Document 1). This type of multi-stage sorter includes a plurality of sorters arranged in series in the conveying direction of the carriers, and each sorter has a plurality of lanes arranged in parallel.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In this type of multi-stage sorter, for example, it would be beneficial if it could be operated more efficiently even when a failure occurs or when the number of carriers conveyed per unit time changes.

[0005] Therefore, one of the problems of the present invention is to provide a novel and improved conveying system that enables, for example, more efficient operation of a multi-stage sorter.

Means for Solving the Problems

[0006] The transport system of the present invention comprises, for example, a number determination unit that assigns to each of the transport bodies included in a virtual column in which a plurality of transport bodies are arranged in a line a multi-digit sequential number in ascending order from the minimum value, as a number indicating the order in the virtual column, where each digit can take a predetermined number of values; a multi-stage sorter that aligns the plurality of transport bodies included in the virtual column in the order described above before they are actually arranged in a line; and an operation control unit that controls the operation of the multi-stage sorter, wherein the multi-stage sorter has a plurality of sorters arranged in series in the order of transport in the column, each sorter having a plurality of lanes arranged in parallel, and the operation control unit assigns the digits in ascending order in the order of transport to at least a portion of each of the plurality of sorters, and assigns each of the digit values ​​corresponding to the sorter to at least a portion of the lanes of the plurality of lanes included in each sorter, and after the sorter corresponding to each of the digits loads and holds the transport bodies included in the column into the lane according to the value of the digit, the transport of the transport bodies within the lane The multistage sorter is controlled to align the multiple conveyed bodies for a given digit by sequentially unloading the conveyed bodies from the lane with the smallest digit value in each lane without changing the order, or the digits are assigned to at least some of the multiple sorters in descending order of the conveying sequence, and each of the digit values ​​corresponding to the sorter is assigned to at least some of the multiple lanes included in each sorter, and the multistage sorter is controlled so that the sorter corresponding to each digit loads and holds the conveyed bodies included in the column into the lane for each digit value, and then sequentially unloads the conveyed bodies from the lane with the largeest digit value in each lane without changing the conveying order of the conveyed bodies within the lane, thereby aligning the multiple conveyed bodies for a given digit, the number determination unit can change the number of digit values ​​for each digit, and the operation control unit controls the multistage sorter so that the same number of lanes as the number of digit values ​​are used in the sorter corresponding to each digit. [Brief explanation of the drawing]

[0007] [Figure 1] Figure 1 is an illustrative and schematic side view showing the rails of the conveying system of the first embodiment and a plurality of conveyed objects being conveyed along the rails. [Figure 2] Figure 2 is an illustrative schematic diagram of the transport system according to the first embodiment. [Figure 3] Figure 3 is an illustrative block diagram of a part of the control device included in the transport system of the first embodiment. [Figure 4] Figure 4 is a table showing an example of sequential numbers assigned to a virtual row of multiple transported objects in the number determination unit included in the transport system of the first embodiment. [Figure 5] Figure 5 is an illustrative schematic diagram of a multi-stage sorter included in the conveying system of the first embodiment. [Figure 6] Figure 6 is an illustrative schematic diagram of a multi-stage sorter included in the conveying system of the first embodiment, showing a state in which the third lane of the first-stage sorter has failed. [Figure 7] Figure 7 is a table showing an example of a sequence number assigned to a virtual row of multiple transported objects in the number determination unit included in the transport system of the first embodiment, which is set in accordance with the state of the multi-stage sorter in Figure 6. [Figure 8] Figure 8 is an illustrative schematic diagram of a multi-stage sorter included in the transport system of the second embodiment. [Figure 9] Figure 9 is an illustrative schematic diagram of a multi-stage sorter included in the conveying system of the third embodiment. [Figure 10] Figure 10 is an illustrative schematic diagram of a multi-stage sorter included in the transport system of the fourth embodiment. [Modes for carrying out the invention]

[0008] The following describes exemplary embodiments of the present invention. The configurations of the embodiments shown below, as well as the operations and results (effects) obtained from such configurations, are examples only. The present invention can also be realized by configurations other than those disclosed in the following embodiments. Furthermore, according to the present invention, it is possible to obtain at least one of the various effects (including derived effects) that can be obtained by the following configurations.

[0009] Furthermore, in the multiple embodiments disclosed below, similar functions and effects are obtained by similar configurations. These similar configurations are given common reference numerals, and redundant explanations may be omitted.

[0010] [First Embodiment] [Basic transport structure] Figure 1 is a side view showing the rail 11 and a plurality of transport bodies 12 of the transport system 10 of the first embodiment. As shown in Figure 1, the transport bodies 12 are supported on the rail 11 so as to be movable along the longitudinal direction of the rail 11. The rail 11 is installed, for example, suspended from the ceiling of a building. Each of the plurality of transport bodies 12 supports an item A suspended from it and moves in a series line along the rail 11. The spacing between the plurality of transport bodies 12 in the direction of alignment varies depending on the location on the rail 11.

[0011] The transporter 12 has a movable body 12a and a support member 12b. The movable body 12a is supported on the rail 11 so as to be movable in its longitudinal direction. The movable body 12a has rollers that roll along the rail 11. The rollers are configured to roll, for example, on the bottom wall of the rail 11 which has a C-shaped cross-section. As the rollers roll, the movable body 12a moves along the rail 11. The movable body 12a is also called a trolley.

[0012] The transporter 12 moves along the rail 11 by either press transport or gravity transport.

[0013] In the section of the rail 11 where pressing and conveying is performed, for example, an endless chain is provided in parallel with the rail 11 at a substantially constant interval. A plurality of pressing bodies are provided on the chain at predetermined intervals. In this configuration, by circulating and driving the chain, one of the pressing bodies presses the moving body 12a, and thereby the carrier 12 moves along the rail 11. The pressing body is also referred to as a carrier.

[0014] Further, at least a part of the section of the rail 11 where gravity conveying is performed is provided to incline downward as it goes toward one direction in the longitudinal direction. In this configuration, due to the gravity (self-weight) acting on the carrier 12, the roller of the moving body 12a rolls on the support surface of the rail 11, and along with this rolling, the carrier 12 moves along the rail 11.

[0015] The support member 12b is detachably connected to the moving body 12a and supports the article A in a state of hanging the article A with respect to the moving body 12a. The support member 12b has a bag portion 12b1 for supporting the article A. The bag portion 12b1 has, for example, a belt-like and cloth-like shape with a substantially constant width, extends downward from the upper end, folds back at the lower end, and extends back to the upper end, and supports the article A in a state of wrapping it at least from the front, below, and behind in the conveying direction. Note that, at least in the lower part of the bag portion 12b1, a movement restricting portion such as a gather for restricting the movement of the article A in the lateral direction, that is, the width direction, may be provided. The support member 12b is also referred to as a pouch.

[0016] [Conveying System] FIG. 2 is a schematic configuration diagram of the conveying system 10. As shown in FIG. 2, the conveying system 10 includes a loading processing station 100, a first storage unit 200, a second storage unit 300, a sorting unit 400, an unloading processing station 500, a third storage unit 600, and a control device 700.

[0017] At the receiving processing station 100, item A is placed into the support member 12b of the transporter 12. Between the receiving processing station 100 and the first storage unit 200, between the first storage unit 200 and the second storage unit 300, between the second storage unit 300 and the sorting unit 400, and between the sorting unit 400 and the unloading processing station 500, item A is transported by the transporter 12, which moves along the rail 11, as shown in Figure 1.

[0018] At the unloading processing station 500, item A is unloaded from the support member 12b. Between the unloading processing station 500 and the third storage unit 600, and between the third storage unit 600 and the receiving processing station 100, multiple empty transport bodies 12, which do not support item A, move in a series line along the rail 11.

[0019] [Receiving and Processing Station] At the loading and processing station 100, a worker or robot places item A into the support member 12b of an empty transporter 12 that does not support item A. This results in the supported state of item A shown in Figure 1. In the example in Figure 1, one item A is supported by one support member 12b, but this is not limited to this, and multiple items A may be supported by one support member 12b.

[0020] [First storage department] The first storage unit 200 functions as a storage facility for storing various items A in the state shown in Figure 1. The first storage unit 200 has, for example, one or more loop-shaped rails 11, and dynamically stores multiple transporters 12, each supporting an item A, by moving (circling) along the loop-shaped rails 11.

[0021] In response to a request from an external device (higher-level device) to remove item A, the control device 700 determines which transport body 12 to remove from among the transport bodies 12 supporting item A stored in the first storage unit 200. The control device 700 then controls the operation of the first storage unit 200 so that the determined transport body 12 is removed.

[0022] Here, if we assume that in the first storage unit 200, the article A is stored with multiple transporters 12 stationary, then when unloading, it will take time for the transporters 12 to reach a predetermined speed. In this case, the time it takes for the transporters 12 to reach the exit for transporters 12 in the first storage unit 200 will be longer. In this embodiment, however, as described above, in the first storage unit 200, the article A is stored with multiple transporters 12 moving along the rails 11, so the time required for the transporters 12 to increase in speed is reduced or eliminated. In other words, according to this embodiment, the time required to unload multiple transporters 12 from the first storage unit 200 can be reduced.

[0023] Furthermore, if the control device 700 were to control the operation of the first storage unit 200 in such a way that it repeatedly determines and discharges each transport body 12 one by one, the time required to discharge multiple transport bodies 12 from the first storage unit 200 would be extended. This is because, for example, some transport bodies 12 may be located far from the exit of the first storage unit 200. Therefore, in this embodiment, the control device 700 determines that multiple transport bodies 12 supporting a requested number of articles A are to be discharged from the first storage unit 200, and controls the operation of the first storage unit 200 to discharge these multiple transport bodies 12 from the exit of the first storage unit 200. In this case, since the multiple transport bodies 12 whose discharge has been determined can be discharged sequentially starting from those closest to the exit of the first storage unit 200, the time required to discharge multiple transport bodies 12 can be shortened.

[0024] Furthermore, the control device 700 keeps track of all the transporters 12 included in the first storage unit 200, including the article A that each transporter supports, and their position in the first storage unit 200 or their order in the row of transporters 12. In this case, if there are multiple transporters 12 in the first storage unit 200 that support the article A that is requested to be removed, the control device 700 can select the transporter 12 closest to the exit of the first storage unit 200 from among the multiple transporters 12 to be removed. This processing and operation can further reduce the time required to remove multiple transporters 12 that support the requested article A. However, if there is sufficient time, the control device 700 may decide which transporters 12 to remove from the first storage unit 200 one by one and remove the decided transporters 12 one by one in sequence.

[0025] [Second storage department] The second storage unit 300 has, for example, multiple lanes arranged in parallel to each other, i.e., linear rails, and temporarily holds multiple transported objects 12 that have been discharged from the first storage unit 200. The provision of the second storage unit 300 makes it possible to discharge the transported objects 12 from the first storage unit 200 and to load the transported objects 12 into the sorting unit 400 in parallel, that is, independently. This makes it possible to suppress the effect of the processing status of one of the first storage unit 200 and the sorting unit 400 on the processing status of the other. The second storage unit 300 may also be called a pre-sorting storage unit.

[0026] [Sorting Department] In the unloading processing station 500, for example, when multiple items A supported by multiple transporters 12 are packed into a single package, it is preferable that the multiple transporters 12 supporting the items A be packed together are grouped in a row of multiple transporters 12 arranged in series. This is because if the multiple transporters 12 supporting the items A be packed together are located far apart in the row, the waiting time until all the items A be packed together are ready at the unloading processing station 500 will be longer, and the processing speed will decrease. In other words, it is preferable that the row of multiple transporters 12 be appropriately aligned according to the work and sequence of the unloading processing at the unloading processing station 500 when they reach the unloading processing station 500.

[0027] However, as described above, when the first storage unit 200 unloads multiple transport bodies 12 prioritizing the reduction of unloading time, the multiple transport bodies 12 are not necessarily arranged appropriately according to the work and order of the unloading process.

[0028] Therefore, the sorting unit 400 rearranges the group of multiple transport bodies 12 that have been unloaded from the first storage unit 200, that is, the row in which multiple transport bodies 12 are lined up in series along the rail 11, and aligns them in a state suitable for the work and order of unloading at the unloading processing station 500. The method of aligning the multiple transport bodies 12 in the sorting unit 400 will be described in detail later.

[0029] [Removal and Processing Station] At the unloading station 500, a worker or robot performs the process of removing item A from the transporter 12 that supports item A, as shown in Figure 1. Furthermore, the worker or robot performs predetermined processing on one or more items A, such as packaging, to achieve a specified unloading configuration. The shipment containing one or more items A that have undergone unloading processing is then unloaded from the unloading station 500.

[0030] [Third Storage Department] The third storage unit 600 stores empty transport bodies 12 that do not support item A. Transport bodies 12 that have been released with item A at the discharge processing station 500 are sent to the third storage unit 600. Empty transport bodies 12 are also sent from the third storage unit 600 to the receiving processing station 100. The third storage unit 600 may also be referred to as the empty transport body storage unit.

[0031] [Control device] Figure 3 is an exemplary block diagram of the control device 700. Note that Figure 3 only shows the functional blocks related to the operation of the sorting unit 400. As shown in Figure 3, the control device 700 is configured as a computer having, for example, an arithmetic processing unit 701, a main memory unit 702, an auxiliary storage unit 703, etc. The arithmetic processing unit 701 is, for example, a processor (circuit) such as a central processing unit (CPU). The main memory unit 702 is, for example, random access memory (RAM) or read-only memory (ROM), and the auxiliary storage unit 703 is, for example, a solid state drive (SSD) or a hard disk drive (HDD).

[0032] The arithmetic processing unit 701 operates according to the installed program, executing processing using a predetermined algorithm defined in the program. The program may be provided as an installable or executable file, recorded on a computer-readable recording medium. The recording medium may also be referred to as a program product. Information such as values, tables, and maps used in the program and processor's arithmetic processing may be pre-stored in the ROM of the main memory unit 702 or in the auxiliary storage unit 703, or they may be stored in the memory of a computer connected to a communication network and downloaded to the auxiliary storage unit 703 via the communication network. The arithmetic processing by the arithmetic processing unit 701 may be performed, at least partially, by hardware. In this case, the arithmetic processing unit 701 may include, for example, an FPGA (field programmable gate array) or an ASIC (application-specific integrated circuit).

[0033] The arithmetic processing unit 701 includes a virtual column determination unit 701a, a number determination unit 701b, an operation control unit 701c, etc., in relation to the operation of the sorting unit 400.

[0034] The virtual column determination unit 701a sets virtual columns for a group of multiple transport bodies 12 that are to be sorted in the sorting unit 400. A virtual column is a virtual column of multiple transport bodies 12 in the calculation performed by the virtual column determination unit 701a, and is the column that serves as the sorting target for the sorting unit 400. A group of multiple transport bodies 12 that are to be sorted in the sorting unit 400 is called a batch. The virtual column determination unit 701a determines virtual columns on a batch basis, in other words, for multiple transport bodies 12 included in a batch. The multiple transport bodies 12 included in a batch may be determined before the multiple transport bodies 12 are discharged from the first storage unit 200, or they may be determined for a group of multiple transport bodies 12 temporarily held in the second storage unit 300. The second storage unit 300 is configured such that multiple transport bodies 12 included in a batch are temporarily held together in one lane or multiple lanes, for example, so that multiple transport bodies 12 can be discharged for each batch.

[0035] Figure 4 is a table showing virtual columns for computer arithmetic processing set up for multiple carriers 12 included in one batch, and the sequential numbers assigned to these virtual columns. In this table, each row corresponds to one carrier 12, and in the virtual columns, the carriers 12 are arranged from top to bottom in the table. Furthermore, the multiple carriers 12 are grouped together, and the numbers assigned to each row in the table indicate temporary numbers assigned to the carriers 12 included in the same group. For example, in the example in Figure 4, group G1 contains three carriers 12 numbered 1 to 3, and group G2 contains five carriers 12 numbered 1 to 5.

[0036] Groups G1 to G21 are, for example, divided into units to be processed at the unloading processing station 500. In this case, items A supported by transporters 12 belonging to the same group are, for example, packaged together at the unloading processing station 500. When the sorting unit 400 arranges multiple transporters 12 included in one batch according to the order of the virtual rows, the multiple transporters 12 are brought into the unloading processing station 500 in groups. That is, multiple transporters 12 included in the same group are brought into the unloading processing station 500 in a connected order. Therefore, the unloading processing station 500 can perform unloading processing more smoothly and quickly. The order of groups G1 to G21 is set, for example, in the order in which the control device 700 receives unloading requests from external devices, but is not limited to this.

[0037] The number determination unit 701b assigns sequential numbers C1 and C2 as sequential numbers indicating the order in the virtual column. In the example in Figure 4, a decimal sequential number C1 and a three-digit quaternary sequential number C2 are assigned to the virtual column of multiple carriers 12 included in multiple groups G1 to G21. Both sequential numbers C1 and C2 are integers greater than or equal to 0. The three-digit quaternary sequential number C2 can be described as a three-digit (multiple-digit) sequential number where each digit can take on one of four values ​​(a predetermined number): 0, 1, 2, or 3. The sorting unit 400 operates based on the sequential number C2. The operation of the sorting unit 400 according to the sequential number C2 will be described later. Note that the sequential number C1 corresponds to the sequential number C2 converted to decimal notation. In both sequential numbers C1 and C2, the value increases by 1 from the minimum value as you move from the top row to the bottom row, with the maximum value being in the bottom row. For sequential number C1, the minimum value is 0, the maximum value is 63, and the number of occurrences is 64. For sequential number C2, the minimum value is 000, the maximum value is 333, and the number of occurrences is 4 × 4 × 4 = 64.

[0038] The operation control unit 701c controls the operation of the sorting unit 400 to rearrange the multiple unaligned transport bodies 12 included in one batch discharged from the second storage unit 300 according to the sorting order (sequence number C2) set for the virtual column in Figure 4. Note that "unaligned" means that they are not arranged in the sorting order of sequence number C2.

[0039] The group ID, the ID of the transporter 12, the serial numbers C1 and C2, the group's supplementary information, the ID of the item A supported by the transporter 12, and the supplementary information of the item A are all stored in a manner that is linked to each other, for example, in the RAM of the auxiliary storage unit 703 or the main storage unit 702. The group's supplementary information includes, for example, information such as the destination (delivery address) and packaging form of one or more items A corresponding to the group, while the supplementary information of item A includes, for example, information indicating the specifications of item A, such as its size and weight.

[0040] [Configuration and operation of the sorting unit] Figure 5 is a configuration diagram of the sorting unit 400A (400) of the first embodiment. The sorting unit 400A shown in Figure 5 has a configuration that can correspond to the serial number C2 exemplified in Figure 4. Below, the operation of the sorting unit 400A when applied to multiple transport bodies 12 included in one batch assigned the serial number C2 in Figure 4 will be described.

[0041] The sorting unit 400A has multiple sorters (410-1, 410-2, 410-3) 410 arranged in series according to the order in which the multiple transported bodies 12 are transported. Each sorter 410 also has multiple lanes L1 to L4 arranged in parallel. The entrance to each lane L1 to L4 is a turnout 21, and the exit is a merger 22. Each lane L1 to L4 has rails 11b from the turnout 21 to the merger 22. The sorting unit 400A is an example of a multi-stage sorter.

[0042] Multiple conveyors 12, each comprising a batch, are sequentially fed into the sorting unit 400 from the inlet IN. After passing through multiple sorters 410 arranged in series, the multiple conveyors 12, each comprising a batch, are sequentially discharged from the outlet OUT.

[0043] In each sorter 410, multiple conveyors 12 are brought in one by one from the entrance rail 11i, branched at the turnout 21 and brought into one of the lanes L1 to L4, where they are temporarily held. After multiple conveyors 12 included in one batch have been brought in, the conveyors 12 held in each lane L1 to L4 are sequentially brought out from the merger 22 to the exit rail 11o for each lane L1 to L4, and are transported in a line to the entrance rail 11i or exit OUT of the next sorter 410.

[0044] The operation control unit 701c controls the destination of the multiple transport bodies 12 by controlling the operation of the turnout 21. The operation control unit 701c also controls the transport order of the multiple transport bodies 12 by controlling the operation of the merging device 22. Each of the lanes L1 to L4 has a single rail 11b in the shape of a line segment, and the transport direction is limited to one direction. Therefore, there is no change in the transport order (arrangement) of the transport bodies 12 in each lane L1 to L4.

[0045] The operation control unit 701c assigns each digit of the serial number C2 in ascending order to each of the multiple sorters 410. Specifically, in the example in Figure 5, the operation control unit 701c assigns the first digit to sorter 410-1 and controls the operation of sorter 410-1 to sort according to the value of the first digit of the serial number C2. The operation control unit 701c also assigns the second digit to sorter 410-2 and controls the operation of sorter 410-2 to sort according to the value of the second digit of the serial number C2. Then, the operation control unit 701c assigns the third digit to sorter 410-3 and controls the operation of sorter 410-3 to sort according to the value of the third digit of the serial number C2.

[0046] Furthermore, the operation control unit 701c assigns the digit values ​​assigned to each sorter 410 to the multiple lanes L1 to L4 of each sorter 410. For example, the operation control unit 701c assigns the digit value 0 to lane L1, the digit value 1 to lane L2, the digit value 2 to lane L3, and the digit value 3 to lane L4 in each sorter 410.

[0047] The turnout 21 operates based on the detection result of the identifier of the transport body 12 that has arrived before the turnout 21. A sensor is provided before the turnout 21 to read the identifier provided on the transport body 12. The identifier is, for example, a one-dimensional code or a two-dimensional code, and the sensor is, for example, a code reader, but is not limited to these.

[0048] The operation control unit 701c determines the destination of the transport body 12 to which the identifier has been assigned based on the identifier detection result, and controls the operation of the turnout 21 so that the transport body 12 is transported to the predetermined destination. Specifically, taking sorter 410-1 corresponding to the first digit as an example, if the first digit of the serial number C2 corresponding to the transport body 12 that has reached the turnout 21 at the entrance of lane L1 of sorter 410-1 is 0, the operation control unit 701c controls the operation of the turnout 21 so that the transport body 12 is brought into lane L1. On the other hand, if the first digit of the serial number C2 corresponding to the transport body 12 is 1, 2, or 3, the operation control unit 701c controls the operation of the turnout 21 so that the transport body 12 is not brought into lane L1 and continues to be transported on the entrance rail 11i. Similarly, for a transport body 12 that has reached the point before the turnout 21 at the entrance of lane L2 of sorter 410-1, if the first digit of the serial number C2 corresponding to the transport body 12 is 1, the operation control unit 701c controls the operation of the turnout 21 so that the transport body 12 is brought into lane L2. On the other hand, if the first digit of the serial number C2 corresponding to the transport body 12 is (0), 2, or 3, the operation control unit 701c controls the operation of the turnout 21 so that the transport body 12 is not brought into lane L2 and continues to be transported on the entrance rail 11i. Note that in the example of Figure 5, lane L2 is located downstream of lane L1, and if the intended operation is performed at the turnout 21 at the entrance of lane L1, a transport body 12 with a first digit of serial number C2 of 0 should not arrive at the turnout 21 at the entrance of lane L2.

[0049] In other words, in the sorting unit 400 of Figure 5, the operation control unit 701c controls the operation of the turnout 21 located at the entrance of lane Lj corresponding to the value J of the first digit of the sequence number C2 of the sorter 410, as follows: If the value of the first digit of the sequence number C2 assigned to the transport body 12 that has arrived before the turnout 21 is J, the operation control unit 701c controls the operation of the turnout 21 to transport the transport body 12 into lane Lj. On the other hand, if the value of the first digit of the sequence number C2 assigned to the transport body 12 that has arrived before the turnout 21 is not J, the operation control unit 701c controls the operation of the turnout 21 to not transport the transport body 12 into lane Lj. Here, I is an integer greater than or equal to 1, J is an integer from 0 to Jmax-1, j is an integer from 1 to Jmax, and Jmax is the number of values ​​in the first digit of the sequence number C2.

[0050] With this configuration and operation, the sorter 410 corresponding to each digit of the serial number C2 can classify multiple transport bodies 12 according to the value of that digit (J=0~3). Specifically, taking sorter 410-1 corresponding to the first digit as an example, transport bodies 12 assigned to serial number C2 with a first digit value of 0 (e.g., 000, 010, 020, ...) are brought into and held in lane L1. Transport bodies 12 assigned to serial number C2 with a first digit value of 1 (e.g., 001, 011, 021, ...) are brought into and held in lane L2. Transport bodies 12 assigned to serial number C2 with a first digit value of 2 (e.g., 002, 012, 022, ...) are brought into and held in lane L3. Additionally, transport bodies 12, each assigned a sequential number C2 (for example, 003, 013, 023, ...) with the first digit being 3, are brought into and held in lane L4.

[0051] After all the transport objects 12 in a batch are sorted by the sorter 410 corresponding to each digit of the serial number C2, the operation control unit 701c controls the merger 22, etc., to sequentially discharge multiple transport objects 12 in each lane Lj, ​​starting from the lane Lj with the smallest value of the corresponding digit, without changing the order of the transport objects 12. As a result, in each sorter 410, first all the transport objects 12 held in lane L1 are discharged, then all the transport objects 12 held in lane L2 are discharged, then all the transport objects 12 held in lane L3 are discharged, and finally all the transport objects 12 held in lane L4 are discharged. The sorter 410 corresponding to a predetermined digit of the serial number C2 sorts all the rows of transport objects 12 in a batch in ascending order of the value of the corresponding digit of the serial number C2.

[0052] As described above, the multiple sorters 410 are arranged in series in the direction of transport of the transported bodies 12, and are arranged to process sequentially from the smallest digit. Therefore, for a row of multiple transported bodies 12 included in one batch, sorter 410-1 first sorts the transported bodies 12 based on the value of the first digit, then sorter 410-2 sorts the transported bodies 12 based on the value of the second digit, and finally sorter 410-3 sorts the transported bodies 12 based on the value of the third digit. In addition, each sorter 410 performs classification and sorting based on the value of the relevant digit, but does not sort based on the values ​​of digits other than the relevant digit. Thus, by sorting sequentially in ascending order from the sorter 410 corresponding to the smallest digit using the multiple sorters 410 arranged in series, the multiple transported bodies 12 included in one batch discharged from the sorting unit 400 are arranged in ascending order of the serial number C2.

[0053] However, if each sorter 410 sequentially discharges the transport bodies 12 from the lane with the smallest assigned digit, then if the digit assignments for multiple sorters 410 are not in ascending order, sorting will become impossible. As an example, consider a case where the third digit is assigned to the first sorter 410 and the second sorter 410 is assigned to the second digit, and multiple unsorted transport bodies 12 with sequential numbers C2 of 310, 300, 010, 000, ... are delivered to the sorting unit 400 in this order. First, in the first sorter 410, conveyor bodies 12 with serial numbers C2 of 010, 000, ... are loaded into lane L1, which is for conveyor bodies 12 with the third digit value being 0, in that order. Then, conveyor bodies 12 with serial numbers C2 of 310, 300, ... are loaded into lane L4, which is for conveyor bodies 12 with the third digit value being 3, in that order. Since conveyor bodies 12 are discharged from the first sorter 410 in the order of lanes L1, L2, L3, L4, conveyor bodies 12 with serial numbers C2 of 010, 000, ..., 310, 300, ... are discharged in that order. Next, in the second sorter 410, conveyor bodies 12 with serial numbers C2 of 000,...,300,... are loaded into lane L1, which is used to load conveyor bodies 12 with a second digit value of 0, and conveyor bodies 12 with serial numbers C2 of 010,...,310,... are loaded into lane L2, which is used to load conveyor bodies 12 with a second digit value of 1, and conveyor bodies 12 with serial numbers C2 of 010,...,310,... are loaded into lane L2, which is used to load conveyor bodies 12 with a second digit value of 1, and conveyor bodies 12 with serial numbers C2 of 010,...,310,... are loaded into lane L1, L2, L3, L4, in which order. In this case, conveyor bodies 12 with serial numbers C2 of 000,...,300,...,010,...,310,... are loaded into lane L1, which is used to load conveyor bodies 12 with a second digit value of 0, and At this point, the transporter 12 with serial number C2 of 300 is positioned before the transporter 12 with serial number C2 of 010, and sorting by the third digit has already been completed by the first sorter 410. Therefore, the sorting unit 400 cannot sort that column.

[0054] In other words, in the sorting unit 400, each digit of the serial number C2 is assigned in ascending order to a plurality of sorters 410 arranged in series in the order of transport of the transported bodies 12, and each of the corresponding digit values ​​is assigned to a plurality of lanes Lj in each sorter 410, so that the transported bodies 12 are unloaded sequentially from the lane Lj with the smallest digit value, without changing the order of the transported bodies 12 within each lane Lj. Note that as long as the transported bodies 12 are unloaded sequentially from the lane Lj with the smallest value, the arrangement of lanes Lj in each sorter 410 can be set arbitrarily.

[0055] Furthermore, as an example of how similar sorting is possible, in the sorting unit 400, each digit of the serial number C2 may be assigned in descending order to a plurality of sorters 410 arranged in series in the order of transport of the transport bodies 12, and each of the corresponding digit values ​​may be assigned to a plurality of lanes Lj in each sorter 410, and the transport bodies 12 may be sequentially discharged from each lane Lj, ​​starting with the lane Lj with the largest digit value, without changing the order of the transport bodies 12 within each lane Lj. In this case as well, as long as the transport bodies 12 are sequentially discharged from each lane Lj, ​​starting with the lane Lj with the largest value, the arrangement of lanes Lj in each sorter 410 can be set arbitrarily.

[0056] Furthermore, any transported objects 12 that were not transported into lane Lj at any of the turnouts 21 of each sorter 410 (hereinafter referred to as error transported objects) are transported on the error rail 11e and discharged from the error exit EOUT. The error rail 11e is an example of a discharge lane.

[0057] [Handling changes in the number of lanes] Figure 6 shows a state in the sorting unit 400A of this embodiment where the third lane Ln of the first-digit sorter 410 has failed and become unusable. In this case, the number of lanes Lj decreases, so the sequential number setting C2 in Figure 4 becomes unusable. Therefore, the number determination unit 701b sets the sequential number C2 for the virtual columns of the multiple transport bodies 12 as shown in Figure 7.

[0058] Figure 7 shows an example of a sequence number assigned to a virtual column of multiple transporters 12. In the example in Figure 7, the number of usable lanes Lj of the sorter 410 for the first digit has decreased from 4 to 3. In this case, the number determination unit 701b changes the number of values ​​in the first digit of the sequence number C2 from 4 (values ​​are 0, 1, 2, 3) to 3 (values ​​are 0, 1, 2) so that it matches the number of usable lanes Lj of the sorter 410 for the first digit. The number determination unit 701b does not change the number of values ​​in the other digits of the sequence number C2. In this case, the sequential numbers C2 assigned to the 48 carriers 12 in one batch are 000, 001, 002, 010, ..., 030, 031, 032, 100, ..., 130, 131, 132, 200, ..., 230, 231, 232, 300, ..., 320, 321, 322, 330, 331, 332. Here, the value of the first digit is 0, 1, or 2. In the ascending sequential number C2, when representing the number following a number whose first digit is 2, the second digit is increased by 1 to make the first digit 0. Also, the values ​​of the second and third digits are both 0, 1, 2, or 3. For sequential number C1, the minimum value is 0, the maximum value is 47, and the number of occurrences is 48. For sequential number C2, the minimum value is 000, the maximum value is 332, and the number of occurrences is 3 × 4 × 4 = 48.

[0059] The relationship between sequential number C1 and sequential number C2 can be expressed as shown in equation (1) below. Sequential number C2 can be said to be a number that has the relationship shown in equation (1) with sequential number C1.

number

[0060] Furthermore, in the case of Figure 6, the fourth lane from the top (the fourth lane) of the sorter 410-1 in Figure 6 is designated as lane L3, which holds a transporter 12 whose corresponding serial number C2 has a value of 3 in the last digit. As shown in Figure 5, when all lanes Lj are in a normal state, this fourth lane was lane L4, which holds a transporter 12 whose corresponding serial number C2 has a value of 4 in the last digit. In this way, the operation control unit 701c can flexibly operate the sorting unit 400 for both the state shown in Figure 5 and the state shown in Figure 6 by changing the assignment of digit values ​​to lanes Lj. This flexible assignment and control by the operation control unit 701c has the advantage of enabling efficient operation of the sorting unit 400.

[0061] As described above, in this embodiment, the number determination unit 701b can change the number of values ​​for each digit in a multi-digit sequential number C2 in which each digit can take a predetermined number of values. Furthermore, the operation control unit 701c controls each sorter 410 of the sorting unit 400 so that the same number of lanes Lj as the number of values ​​for that digit are used in the sorter 410 corresponding to each digit. With this configuration, for example, even if one of the lanes Lj included in the sorting unit 400 becomes unusable, the sorting unit 400 can be operated more efficiently by utilizing the lanes Lj other than the unusable lane Lj. In particular, by making the number of usable lanes Lj in any sorter 410 the same as the number of values ​​for the digit corresponding to that sorter 410 in the sequential number C2, the sorting unit 400 can be operated more efficiently by making maximum use of lanes Lj that are not malfunctioning and are normally usable. Furthermore, it is possible to, for example, designate a lane Lj to be temporarily closed and perform maintenance such as inspection, repair, and parts replacement on that closed lane Lj.

[0062] [Example 1] As shown in the example in Figure 6, if one lane Ln becomes unusable in sorter 410-1, in the sequence number C2, not only is the number of digit values ​​corresponding to sorter 410-1 reduced from 4 to 3, but the number of digit values ​​corresponding to all sorters 410 (410-1 to 410-3) may also be reduced from 4 to 3, and the number of lanes Lj used may also be reduced. In other words, the number of digit values ​​for multiple digits may be kept the same. In this case, the advantage is that the processing load related to the assignment of sequence numbers C2 in the number determination unit 701b can be reduced.

[0063] [Differentiation 2] Furthermore, as shown in the example in Figure 6, if one lane Ln becomes unusable in sorter 410-1, sorter 410-1 may be operated in a way that it is not used for sorting. In this case, the number determination unit 701b sets the number of digits of the sequential number C2 to be the same as the number of sorters 410 being used. That is, the number determination unit 701b changes the number of digits of the sequential number C2 from the normal 3 to 2 and assigns the digits of the sequential number C2 only to the other sorters 410-2 and 410-3, respectively. In this case, the maximum number of sequential numbers C2, i.e., the maximum number of transported objects 12 included in one batch, is 4 × 4 = 16. Note that in the example in Figure 6, one of the multiple lanes Lj that sorter 410-1 has, for example, lane L1, which is not malfunctioning, is reserved as a lane for transporting multiple transported objects 12.

[0064] This operation of stopping the use of sorters 410 in this manner is not limited to cases where a sorter 410 fails. For example, sorters 410 may be designated for temporary shutdown, and inspections, repairs, parts replacements, and other maintenance may be performed on those shut-down sorters 410. For example, this operation may be temporarily implemented during periods when the number of processes per unit time decreases.

[0065] When changing the number of sorters 410 used as described above, the number determination unit 701b can change the number of digits in the sequential number C2 within a range less than or equal to the number of sorters 410 that the sorting unit 400 has. Also, when changing the number of sorters 410 used, the operation control unit 701c can cause the sorting unit 400 to perform the desired operation by changing the correspondence between the sorters 410 and the digits of the sequential number C2.

[0066] [Second Embodiment] Figure 8 is a configuration diagram of the sorting unit 400B (400) of the second embodiment. The sorting unit 400B in Figure 8 has the same configuration as the sorting unit 400A of the first embodiment, and the same operation and effects based on that configuration can be obtained. However, in this embodiment, each sorter 410 has a lane Ls in addition to the normally used lanes L1 to L4. Lane Ls has the same configuration as the other lanes L1 to L4. According to this embodiment, if any of the lanes Lj cannot be used, lane Ls can be used as a substitute, and the same processing as when lane Lj can be used can be performed. Lane Ls is an example of a spare lane.

[0067] Furthermore, in the configuration shown in Figure 8, without distinguishing between the normally used lanes L1 to L4 and lane Ls, the number determination unit 701b sets the number of digit values ​​to be the same as a number less than the number of lanes Lj in each sorter 410 (5 in the example in Figure 8) (for example, 4), and the operation control unit 701c variably sets the correspondence between the lane Lj and the corresponding digit value of the sequential number C2, thereby enabling the operation of each sorter 410 while variably setting which lanes Lj are paused. Specifically, the number determination unit 701b sets the digit value of the sequential number C2 corresponding to sorter 410-1 to 4. In this case, the operation control unit 701c controls sorter 410-1 to use lanes L1 to L4 and pause lane Ls during a predetermined period, for example, and controls sorter 410-1 to use lanes L2 to L4 and Ls and pause lane L1 during another predetermined period. According to this embodiment, the advantage is that maintenance such as inspection, repair, and parts replacement can be performed on the idled lane Lj while changing the idled lane Lj.

[0068] In the configuration shown in Figure 8, it is also possible to use all five lanes L1 to L4 and Ls of each sorter 410, as long as the processing capacity of other parts of the transport system 10, such as the second storage unit 300 or the unloading processing station 500, is not exceeded. In this case, the number determination unit 701b sets the number of values ​​for each digit to 5, which is the same as the number of lanes Lj of each sorter 410, i.e., 5 in the example of Figure 8, and the operation control unit 701c sets the correspondence between each lane Lj and the value of the digit corresponding to that lane Lj in the sequential number C2. For example, this type of operation may be temporarily implemented during periods or times when the processing rate per unit time increases.

[0069] [Third Embodiment] Figure 9 is a configuration diagram of the sorting unit 400C (400) of the third embodiment. The sorting unit 400C in Figure 9 has the same configuration as the sorting unit 400B of the second embodiment, and the same operation and effects based on that configuration can be obtained. However, in this embodiment, a part of the error rail 11e is used as lane Ls. In this case, a turnout 21 is provided at the exit of the common rail 11es which becomes lane Ls in each sorter 410, and the arriving transport body 12 can be distributed to the error rail 11e and the exit rail 11o by the turnout 21. Furthermore, in sorters 410-2 and 410-3 which are downstream from sorter 410-1, a merger 22 is provided at the inlet of the common rail 11es, so that the source of connection to the common rail 11es can be switched between the error rail 11e and the inlet rail 11i. In this configuration, when the shared rail 11es is used as lane Ls, the operation control unit 701c switches the confluencer 22 located at the entrance of the shared rail 11es so that the transported objects 12 from the entrance rail 11i are transported into the shared rail 11es. Furthermore, when the shared rail 11es is used as part of the error rail of another sorter 410, the operation control unit 701c controls the confluencer 22 located at the entrance of the shared rail 11es so that the transported objects 12 from the error rail 11e are transported into the shared rail 11es, and controls the turnout 21 located at the exit of the shared rail 11es so that the transported objects 12 from the shared rail 11es are discharged onto the error rail 11e. According to this embodiment, the sorting unit 400 can be made more compact because a part of the error rail 11e can be shared with lane Ls.

[0070] [Fourth Embodiment] Figure 10 is a diagram of the sorting unit 400D (400) of the fourth embodiment. The sorting unit 400D in Figure 10 has the same configuration as the sorting unit 400B of the second embodiment, and the same operation and effects based on that configuration can be obtained. However, in this embodiment, the lanes Ls are configured to be connectable to each sorter 410, and are shared by multiple sorters 410. Specifically, a loop-shaped rail 11c is formed, and turnouts 21a to 21c and merging devices 22a to 22c are provided on the rail 11c, and a part of the rail 11c is used as lane Ls.

[0071] In this configuration, when rail 11c is used as lane Ls of sorter 410-1, the operation control unit 701c controls the transport body 12 from the inlet rail 11i of sorter 410-1 to be transported to rail 11c via confluencer 22a, and then transported out from turnout 21a to the outlet rail 11o of sorter 410-1 via turnout 21c, turnout 21b, and confluencer 22c. Error transport bodies are discharged from turnout 21c to error rail 11e.

[0072] When rail 11c is used as lane Ls of sorter 410-2, the operation control unit 701c controls the transport body 12 from the inlet rail 11i of sorter 410-2 to be transported to rail 11c via merger 22b, and then transported out to the outlet rail 11o of sorter 410-2 via merger 22a and turnout 21c from turnout 21b. Error transport bodies are discharged from turnout 21c to error rail 11e.

[0073] Furthermore, when rail 11c is used as lane Ls of sorter 410-3, the operation control unit 701c controls the transport body 12 from the entrance rail 11i of sorter 410-3 to be transported to rail 11c via confluencer 22c, and then transported via turnout 21a, confluencer 22b, confluencer 22a, turnout 21c, and further via exit rail 11o which is partially shared with error rail 11e, to be transported from turnout 21e to the exit rail 11o of sorter 410-3. Error transport bodies are discharged from turnout 21e to error rail 11e. According to this embodiment, since lane Ls can be shared by multiple sorters 410, the sorting unit 400 can be configured more compactly, which is an advantage.

[0074] Although embodiments of the present invention have been illustrated above, these embodiments are merely examples and are not intended to limit the scope of the invention. The above embodiments can be implemented in various other forms, and various omissions, substitutions, combinations, and modifications can be made without departing from the spirit of the invention. Furthermore, each configuration and specification (structure, type, orientation, model, size, length, width, thickness, height, number, arrangement, position, material, etc.) can be modified as appropriate.

[0075] For example, the number of sorters in the sorting unit, the number of lanes each sorter has, the number of sorters used in operation, the number of lanes used in operation, the number of digits in the sequential number, the number of values ​​in each digit of the sequential number, etc., are not limited to the above embodiment. [Explanation of Symbols]

[0076] 10…Conveyor system 11e…Error rail (discharge lane) 12... Carrier 400,400A~400D…Sorting section (multistage sorter) 410, 410-1, 410-2, 410-3… Sota L1~L4, Lj, Ln... lanes Ls... Lane (reserve lane) 701b...Number determination unit 701c...Operation Control Unit A… item C2…repeatedly

Claims

1. A number determination unit assigns to each of the multiple transporters included in a virtual column in which multiple transporters are lined up in a row a multi-digit sequential number, in ascending order from the smallest value, which indicates the order in the virtual column, where each digit can take a predetermined number of values. A multi-stage sorter that sorts the multiple transporters included in the virtual row into the order in which they are actually arranged in a line, before alignment. An operation control unit that controls the operation of the multi-stage sorter, Equipped with, The multi-stage sorter has a plurality of sorters arranged in series in the order in which the plurality of conveyed bodies are conveyed, and each sorter rearranges the plurality of conveyed bodies. The sorter has multiple lanes arranged in parallel, The aforementioned operation control unit, The multi-stage sorters are controlled such that, for at least a portion of the plurality of sorters, the digits are assigned in ascending order according to the transport order, and each of the digit values ​​corresponding to the sorter is assigned to at least a portion of the plurality of lanes contained in each of the sorters, and the sorter corresponding to each of the digits loads the plurality of transport bodies into the lane for each digit value and holds them there, and then, without changing the transport order of the transport bodies within the lane, the transport bodies are sequentially unloaded from the lane with the smallest digit value, thereby aligning the plurality of transport bodies for each digit, or The multi-stage sorters are controlled such that the digits are assigned in descending order to each of at least some of the plurality of sorters in the conveying order, and each of the digit values ​​corresponding to the sorter is assigned to at least some of the plurality of lanes contained in each of the sorters, and the sorter corresponding to each of the digits loads the plurality of conveyed bodies into the lane for each digit value and holds them there, and then loads the conveyed bodies sequentially from the lane with the largest digit value into the lane without changing the conveying order of the conveyed bodies within the lane, thereby aligning the plurality of conveyed bodies for each digit. The number determination unit can change the number of values ​​for each of the digits, A transport system in which the operation control unit controls the multi-stage sorter so that the same number of lanes as the number of values ​​in the corresponding digit are used in the sorter corresponding to that digit.

2. The transport system according to claim 1, wherein the number determination unit can set the number of digit values ​​corresponding to the sorter so that it is the same as the number of lanes available for use in the sorter.

3. The transport system according to claim 2, wherein the number determination unit can set the number of values ​​for each of the multiple digits to be the same.

4. The conveying system according to claim 1, wherein the number determination unit can set the number of digit values ​​corresponding to the sorter so as to be the same as a number less than the number of lanes the sorter has.

5. The transport system according to claim 1, wherein the multi-stage sorter has a spare lane that can be temporarily used as the lane of any of the sorters, and the plurality of sorters have a spare lane that can be shared.

6. The multi-stage sorter has a discharge lane for discharging the conveyed objects that could not be classified by any of the sorters. The transport system according to claim 5, wherein the discharge lane can be used as the reserve lane.

7. The transport system according to any one of claims 1 to 6, wherein the operation control unit can change the correspondence between the lanes of the sorter and the digit values ​​corresponding to the sorter.

8. The transport system according to claim 1, wherein the number determination unit can change the number of digits in the sequential number within a range less than or equal to the number of sorters.

9. The transport system according to claim 8, wherein the number determination unit can set the number of digits of the sequential number to be the same as the number of sorters that can be used in the multi-stage sorter.

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