Picking system

Abstract

Even when separate transport vehicle systems are used to transport goods in the storage area and the shipping area, this picking system allows for flexible transfer of goods between the storage area and the shipping area depending on the work content. [Solution] The picking system 1 includes a transfer unit 4 for transferring goods C between a first transport vehicle 20A and a second transport vehicle 20B. The sorting unit 3 has a first loading unit 35A and a second loading unit 35B. The first transport vehicle system 2A is configured such that the first transport vehicle 20A is movable between the storage unit 10 and the first loading unit 35A of the sorting unit 3, between the storage unit 10 and the transfer unit 4, and between the first loading unit 35A of the sorting unit 3 and the transfer unit 4. The second transport vehicle system 2B is configured such that the second transport vehicle 20B is movable between the shipping unit 5 and the second loading unit 35B of the sorting unit 3, between the shipping unit 5 and the transfer unit 4, and between the second loading unit 35B of the sorting unit 3 and the transfer unit 4.

Description

Technical Field

[0001] One aspect of the present invention relates to a picking system.

Background Art

[0002] Conventionally, it has been practiced to ship out an item group of the type included in an order from an item box warehouse, pick out items of the type and quantity that match the order from the shipped item group, and aggregate and store these in a delivery box (also referred to as sorting work or picking). For example, Patent Document 1 discloses an item conveyance system that performs such sorting work. Patent Document 1 discloses a picking system (item conveyance system) including a storage space where a conveyance robot conveys shelves, a work space where a worker, an arm robot, or a stacker crane performs sorting work, and a shipping space where the conveyance robot moves a shelf in which sorted items are stored.

Prior Art Document

Patent Document

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the above-described conventional picking system, since dedicated conveyance robots that move shelves are arranged in both the storage space and the shipping space, in order to transfer items from the storage space to the shipping space, it is necessary to go through a worker, an arm robot, or a stacker crane. For this reason, flexible transfer of items according to the work content cannot be achieved.

[0005] Therefore, one aspect of the present invention is to provide a picking system that enables flexible transfer of goods between the storage area and the shipping area according to the work content, even when the transport vehicle systems for transporting goods in the storage area and the shipping area are separate. [Means for solving the problem]

[0006] (1) A picking system according to one aspect of the present invention comprises a storage unit for storing articles, a sorting unit equipped with a terminal device for providing sorting information and where articles are sorted based on the sorting information, a shipping unit where articles sorted in the sorting unit are shipped, a first transport vehicle system for transporting articles on a first transport vehicle in a storage area between the storage unit and the sorting unit, a second transport vehicle system for transporting articles on a second transport vehicle in a shipping area between the sorting unit and the shipping unit, and a controller for controlling the terminal device, the first transport vehicle system and the second transport vehicle system, and is a picking system comprising In this system, the first transport vehicle and the second transport vehicle have a first loading section on which the articles transported by the first transport vehicle or the articles transported by the first transport vehicle are placed, and a second loading section on which the articles transported by the second transport vehicle are placed. The first transport vehicle system is configured so that the first transport vehicle can move between the storage section and the first loading section, between the storage section and the handover section, and between the first loading section and the handover section. The second transport vehicle system is configured so that the second transport vehicle can move between the shipping section and the second loading section, between the shipping section and the handover section, and between the second loading section and the handover section.

[0007] In this picking system configuration, goods can be transferred from a first transport vehicle that transports items in the storage area to a second transport vehicle that transports items in the shipping area without going through the sorting department, and goods can also be transferred from the second transport vehicle that transports items in the shipping area to the first transport vehicle that transports items in the storage area. This allows for flexible transfer of goods between the storage area and the shipping area depending on the work content, even if the transport vehicle systems for transporting goods in the storage area and the shipping area are separate.

[0008] (2) In the picking system described in (1) above, the controller may, in reverse sorting mode, have the second transport vehicle transport items that are not to be shipped and placed on the second loading section to the handover section, and the first transport vehicle transport items that are not to be shipped and received from the handover section to the storage section. In this configuration, if the items placed on the first loading section become items to be shipped by removing items that are not to be shipped rather than removing items that are to be shipped from the first loading section, efficient sorting becomes possible in the sorting section.

[0009] (3) In the picking system described in (2) above, the controller may, in reverse sorting mode, have the second transport vehicle transport the items that are not to be shipped, which are placed in the second loading section, to the handover section, and have the first transport vehicle transport the items that are not to be shipped, which are handed over from the handover section, to the storage section. In this configuration, even if items that are not to be shipped are placed in the second loading section, the items that are not to be shipped can be stored in the storage section.

[0010] (4) In the picking system described in any one of (1) to (3) above, the controller may, based on sorting information, control the first transport vehicle to transport the goods to the handover unit without going through the sorting unit if it determines that the type and quantity of goods to be transported by the first transport vehicle matches the type and quantity of goods to be shipped. In this configuration, goods that do not need to be sorted in the sorting unit can be directly handed over to the second transport vehicle without the goods being transferred in the sorting unit, thereby increasing the efficiency of shipping goods.

[0011] (5) In the picking system described in any one of (1) to (4) above, the transfer unit may have an item support table on which items can be transferred, and the item support table may be configured so that items can be loaded and unloaded by the first transport vehicle entering and exiting from a first direction, and so that items can be loaded and unloaded by the second transport vehicle entering and exiting from a second direction different from the first direction. In this configuration, items can be transferred from the first transport vehicle to the second transport vehicle with a simple configuration.

[0012] (6) In the picking system described in (5) above, the handover section may have multiple item support stands. This configuration allows for adjustment of the time it takes to ship the items to be shipped.

[0013] (7) In the picking system described in any one of (1) to (6) above, the first transport vehicle and the second transport vehicle may have the same configuration. In this configuration, the transport capacity can be adjusted by changing the number of transport vehicles.

[0014] (8) In the picking system described in any one of (1) to (7) above, the controller may control the first and second transport vehicles so that the items to be shipped are transported to the shipping department in accordance with the shipping time at the shipping department, and may also distribute sorting information to the terminal device. In this configuration, there is no need to store the sorted items to be shipped anywhere, so the amount of storage space that needs to be secured can be reduced. [Effects of the Invention]

[0015] According to one aspect of the present invention, even when the transport vehicle systems for transporting goods in the storage area and the shipping area are separate, it becomes possible to flexibly transfer goods between the storage area and the shipping area according to the nature of the work. [Brief explanation of the drawing]

[0016] [Figure 1] Figure 1 is a plan view showing a schematic configuration of a picking system according to one embodiment. [Figure 2] Figure 2(A) is a perspective view of the first and second transport vehicles. Figure 2(B) is a perspective view of the first and second transport vehicles with pallets loaded on them. [Figure 3] Figure 3(A) is a perspective view showing the sorting station. Figure 3(B) is a magnified perspective view showing the vicinity of the first loading section of the sorting station. [Figure 4]FIG. 4(A) is a perspective view showing the delivery station. FIG. 4(B) is a perspective view showing the delivery station with a pallet placed thereon. [Figure 5] FIG. 5(A) is a perspective view showing a handcart and a first transporter entering the shipping station. [Figure 6] FIG. 6(A) is a perspective view showing the handcart. FIG. 6(B) is a perspective view showing the handcart with a pallet placed thereon. [Figure 7] FIG. 7 is a block diagram of the picking system.

Embodiments for Carrying out the Invention

[0017] Hereinafter, a picking system 1 according to an embodiment will be described with reference to the drawings. In the description of the drawings, the same reference numerals are given to the same elements, and redundant descriptions are omitted.

[0018] As shown in FIG. 1, the picking system 1 takes out a pallet P (see FIG. 3) on which articles C included in an order are placed from the automated warehouse 10, performs a sorting operation of taking out the articles C in the order quantity at the sorting station 3, and conveys the articles C sorted at the sorting station 3 to a loading position (shipping station 5) where the articles C are loaded onto a truck T for shipping. In the picking system 1 of the present embodiment, at the shipping station 5, the articles C are transferred from the second transporter 20B to the handcart 60, and the articles C are carried into the truck T by the handcart 60. The picking system 1 is configured inside the building B.

[0019] The picking system 1 includes an automated warehouse (storage section) 10, a first transfer vehicle system 2A, a second transfer vehicle system 2B, a sorting station (sorting section) 3, a delivery station (delivery section) 4, a shipping station (shipping section) 5, a first buffer 6, a second buffer 7, and an access passage R. Inside the building B, there are a storage area A1 (the area to the right of the dashed line shown in FIG. 1) between the automated warehouse 10, the sorting station 3, and the delivery station 4, and a shipping area A2 (the area to the left of the dashed line shown in FIG. 1) between the sorting station 3, the delivery station 4, and the shipping station 5.

[0020] The automated warehouse 10 stores the articles C (see FIG. 3) placed on the pallet P. In the automated warehouse 10 of the present embodiment, articles C of the same type are placed on one pallet P. In other words, a plurality of types of articles C are not placed on one pallet P. The automated warehouse 10 has a rack 11, a stacker crane 13, and an in / out section 14. The operation of the automated warehouse 10 is controlled by a main controller (controller) 80 (see FIG. 7).

[0021] The rack 11 stores the pallet P with the articles C placed thereon. The rack 11 has a plurality of storage sections arranged along the traveling direction (hereinafter, also referred to as the "longitudinal direction") and the vertical direction of the stacker crane 13. The storage section is constituted by a member that supports both ends of the pallet P in the longitudinal direction from below.

[0022] The stacker crane 13 mainly comprises a traveling section, a mast, a lifting section, and a transfer section. The traveling section travels along a rail 12 that extends in the longitudinal direction, supporting the mast, the lifting section, and the transfer section. The traveling section is driven by a drive unit. The mast is a columnar member that is erected from the traveling section and extends in the vertical direction. The lifting section is provided so as to be movable up and down along the extending direction of the mast. The lifting section is driven by a drive unit. The transfer section is provided on the lifting section. The transfer section is provided so as to be extendable in the width direction perpendicular to both the longitudinal and vertical directions. The transfer section transfers pallets P to the rack and the loading / unloading section by extending and retracting. The loading / unloading section 14 transfers pallets P with goods C on them between the stacker crane 13 and the first transport vehicle 20A that constitutes the first transport vehicle system 2A.

[0023] The first transport vehicle system 2A comprises a plurality of first transport vehicles 20A and a first system controller 27A (see Figure 7). The first transport vehicle system 2A is a system that transports pallets P on which goods C are placed, or pallets P on which goods C are not placed, in the storage area A1 between the automated warehouse 10 and the sorting station 3 using the first transport vehicles 20A.

[0024] As shown in Figures 2(A) and 2(B), the first transport vehicle 20A is an unmanned transport trolley. The first transport vehicle 20A travels along a predetermined route. The first transport vehicle 20A has a vehicle body 21 that is guided along the route, a lifter 22 provided on the vehicle body 21 as a transfer device for raising and lowering pallets P, and a mounting plate 23 on which pallets P are placed. The first transport vehicle 20A is also equipped with a detection sensor 24 for detecting objects. If the detection sensor 24 detects that an object is within a predetermined range while the first transport vehicle 20A is traveling, it stops traveling. The first transport vehicle 20A is configured to be movable between the automated warehouse 10 and the first mounting section 35A of the sorting station 3, between the automated warehouse 10 and the item support base 40 of the handover station 4, and between the first mounting section 35A and the item support base 40 of the handover station 4.

[0025] The first transport vehicle 20A uses an AGV (Automatic Guided Vehicle). The guidance method used in the first transport vehicle 20A is not particularly limited and may be any of the following: magnetic guidance, laser guidance, or tracked guidance. The route may be composed of, for example, magnetic tape (magnetic markers), laser reflectors, two-dimensional codes, or rails. The first transport vehicle 20A travels to the position specified by the main controller 80 using these guidance methods. Alternatively, the first transport vehicle 20A may use an AMR (Autonomous Mobile Robot) that autonomously travels to the position specified by the main controller 80 using known technologies such as SLAM.

[0026] As shown in Figure 7, the operation of the first transport vehicle 20A is controlled by the first system controller 27A. The first system controller 27A includes a CPU (Central Processing Unit), ROM (Read Only Memory), RAM (Random Access Memory), etc. The first system controller 27A is configured to communicate with the main controller 80 and is controlled by the main controller 80. As shown in Figure 1, the first transport vehicle 20A is controlled so that it does not move beyond the boundary between storage area A1 and shipping area A2 from storage area A1.

[0027] The second transport vehicle system 2B comprises a plurality of second transport vehicles 20B and a second system controller 27B. The second transport vehicle system 2B is a system that causes the second transport vehicles 20B to transport pallets P on which goods C are placed, or pallets P on which goods C are not placed.

[0028] As shown in Figures 2(A) and 2(B), the second transport vehicle 20B is a transport trolley having the same configuration as the first transport vehicle 20A. The second transport vehicle 20B travels along a predetermined route, just like the first transport vehicle 20A. The second transport vehicle 20B also has a vehicle body 21 that is guided along the route, a lifter 22 provided on the vehicle body 21 as a transfer device for raising and lowering the pallet P, and a mounting plate 23 on which the pallet P is placed. The second transport vehicle 20B is also equipped with a detection sensor 24 for detecting objects. If the detection sensor 24 detects that an object is within a predetermined range while the second transport vehicle 20B is traveling, it stops traveling. The second transport vehicle 20B is configured to be movable between the shipping station 5 and the second loading section 35B of the sorting station 3, between the shipping station 5 and the item support base 40 of the handover station 4, and between the second loading section 35B and the item support base 40 of the handover station 4.

[0029] The second transport vehicle 20B uses an AGV (Automatic Guided Vehicle) similar to the first transport vehicle 20A. The guidance method used in the second transport vehicle 20B is not particularly limited and may be any of the following: magnetic guidance, laser guidance, or tracked guidance. The route may be composed of, for example, magnetic tape (magnetic markers), laser reflectors, two-dimensional codes, or rails. The second transport vehicle 20B travels to the position specified by the main controller 80 using these guidance methods. Alternatively, the second transport vehicle 20B may use an AMR (Autonomous Mobile Robot) that autonomously travels to the position specified by the main controller 80 using known technologies such as SLAM.

[0030] As shown in Figure 7, the operation of the second transport vehicle 20B is controlled by the second system controller 27B. The second system controller 27B includes a CPU, ROM, RAM, etc. The second system controller 27B is configured to communicate with the main controller 80 and is controlled by the main controller 80. As shown in Figure 1, the second transport vehicle 20B is controlled so that it does not move from the shipping area A2 beyond the boundary between the storage area A1 and the shipping area A2.

[0031] Sorting station 3 is where workers sort items C based on sorting information transmitted to terminal device 37. Sorting station 3 is composed of multiple (two in this embodiment) picking racks 30. As shown in Figures 3(A) and 3(B), the picking rack 30 includes a column section 31, a work step 33, a first placement section 35A, a second placement section 35B, and a terminal device 37.

[0032] The column 31 supports the work step 33 from below. The work step 33 is a flat plate-shaped member. The work step 33 forms a walking surface on which workers performing sorting work at the sorting station 3 walk. The column 31 positions the walking surface of the work step 33 above the running surface on which the first transport vehicle 20A and the second transport vehicle 20B travel. In plan view, the work step 33 has a recessed portion and a convex portion. The recessed portion of the work step 33 has a first mounting portion 35A and a second mounting portion 35B formed therein.

[0033] The first loading section 35A is where items C that are transported by the first transport vehicle 20A while placed on a pallet P, or items C that are transported by the first transport vehicle 20A while placed on a pallet P, are loaded. A single picking stand 30 has multiple (two in this embodiment) first loading sections 35A. An item support base 40 on which a pallet P can be loaded is provided in the first loading section 35A. The second loading section 35B is where items C that are transported by the second transport vehicle 20B while placed on a pallet P are loaded. A single picking stand 30 has multiple (three in this embodiment) second loading sections 35B. Similar to the first loading section 35A, an item support base 40 on which a pallet P can be loaded is provided in the second loading section 35B.

[0034] As shown in Figure 4(A), the article support stand 40 comprises four columnar sections 41 and four support sections 43 supported by each of the columnar sections 41. The columnar sections 41 are columnar members extending in the vertical direction. The columnar sections 41 support the support sections 43. The support sections 43 have a lower support section 43A and a lateral support section 43B. The lower support section 43A has a mounting surface on which the pallet P is placed and is the part that supports the pallet P from below. The lateral support section 43B is the part that protrudes upward from the lower support section 43A and is the part that supports the pallet P from the side. The lateral support section 43B positions the planar position of the pallet P. The lower support section 43A and the lateral support section 43B are formed in an L-shape in plan view. The columnar sections 41 and the support sections 43 are arranged to support the four corners of the pallet P according to the size of the pallet P.

[0035] The item support stand 40 is configured so that the first transport vehicle 20A and the second transport vehicle 20B can pass underneath the pallet P when the pallet P is placed on it. That is, the height of the column section 41 is adjusted so that the first transport vehicle 20A and the second transport vehicle 20B can pass underneath the pallet P placed on the item support stand 40. The first transport vehicle 20A and the second transport vehicle 20B move under the pallet P placed on the item support stand 40, and when the lifter 22 is raised inside the item support stand 40 (inside the imaginary lines that virtually connect the four column sections 41), the pallet P without an item C on it (hereinafter also referred to as "empty pallet P") or the pallet P with an item C on it is lifted by the loading plate 23. Then, by moving the first transport vehicle 20A and the second transport vehicle 20B, the empty pallet P or the pallet P with an item C on it can be transported.

[0036] On the other hand, by moving the first transport vehicle 20A and the second transport vehicle 20B to the inside of the item support base 40 while the empty pallet P or the pallet P with the item C placed on it is lifted by the loading plate 23, and then lowering the lifter 22, the empty pallet P or the pallet P with the item C placed on it can be placed on the item support base 40. The first transport vehicle 20A and the second transport vehicle 20B can exit from below the pallet P placed on the item support base 40 and move to another location.

[0037] The terminal device 37 shown in Figures 3(A) and 3(B) provides sorting information to the worker. The terminal device 37 provides sorting information to the worker by displaying the sorting information on its display unit. The sorting information is transmitted from the main controller 80. The terminal device 37 is provided in correspondence with the first mounting section 35A. That is, one terminal device 37 is provided for each first mounting section 35A. The terminal device 37 is provided on the mounting base 37A which is placed on the work step 33.

[0038] The transfer station 4 is a location for transferring empty pallets P or items C placed on pallets P, which are transported by the first transport vehicle 20A, to the second transport vehicle 20B. The transfer station 4 is also a location for transferring empty pallets P or items C placed on pallets P, which are transported by the second transport vehicle 20B, to the first transport vehicle 20A. Multiple (three in this embodiment) item support stands 40 are arranged at the transfer station 4. The multiple item support stands 40 are located on the boundary between the storage area A1 and the shipping area A2. The item support stands 40 at the transfer station 4 have the same configuration as the item support stands 40 arranged on the picking rack 30 as described above.

[0039] At the transfer station 4, the empty pallet P or the item C placed on the pallet P by the first transport vehicle 20A is placed on the item support stand 40. The method of placing the empty pallet P or the item C placed on the pallet P onto the item support stand 40 is as described above. At the transfer station 4, the empty pallet P or the item C placed on the pallet P, which has been placed in this manner, is transported by the second transport vehicle 20B. The method of transporting the empty pallet P or the item C placed on the pallet P, which has been placed on the item support stand 40, is as described above. Through these operations, the transfer of the empty pallet P or the item C placed on the pallet P from the first transport vehicle 20A to the second transport vehicle 20B via the transfer station 4 is completed. Similarly, the transfer of the empty pallet P or the item C placed on the pallet P from the second transport vehicle 20B to the first transport vehicle 20A is carried out in the same manner.

[0040] The item support platform 40 at the transfer station 4 is configured such that the first transport vehicle 20A can move in and out from one of the directions in which the storage area A1 and the shipping area A2 face each other (hereinafter also referred to as the "first direction"), thereby enabling the loading and unloading of empty pallets P or items C placed on pallets P, and the second transport vehicle 20B can move in and out from the other direction in which the storage area A1 and the shipping area A2 face each other (hereinafter also referred to as the "second direction"), thereby enabling the loading and unloading of empty pallets P or items C placed on pallets P.

[0041] The shipping station 5 is a location for transferring empty pallets P or goods C placed on pallets P, which are transported by the second transport vehicle 20B, to the hand truck 60. The shipping station 5 is also a location for transferring empty pallets P or goods C placed on pallets P, which are transported by the hand truck 60, to the second transport vehicle 20B. The shipping station 5 is composed of a plurality (11 in this embodiment) of shipping racks 50. The shipping racks 50 position the hand trucks 60, which will be described in detail later. As shown in Figure 5, the shipping racks 50 are composed of a first positioning section 51 and a second positioning section 53.

[0042] The first positioning section 51 is a columnar member extending in the vertical direction. Two first positioning sections 51 are provided and are arranged at a predetermined distance apart in the width direction perpendicular to the entry direction of the hand truck 60 (white arrow in Figure 6). This predetermined distance is set to be approximately the same as the width of the hand truck 60. The first positioning section 51 positions the hand truck 60 in the width direction.

[0043] The second positioning section 53 has a column section 53A, a first guide section 53B, and a second guide section 53C. The column section 53A supports the first guide section 53B and the second guide section 53C. The column section 53A is a columnar member that extends vertically, similar to the first positioning section 51. Two column sections 53A are provided and are arranged at a predetermined distance from each other in the width direction of the hand truck 60. This predetermined distance is set to be approximately the same as the width direction of the hand truck 60, similar to the first positioning section 51.

[0044] The first guide section 53B is a columnar member that extends along the transport direction of the hand truck 60 (white arrow in Figure 6). Two first guide sections 53B are provided and are arranged at a predetermined distance apart in the width direction of the hand truck 60. This predetermined distance is set to be approximately the same as the width of the hand truck 60, similar to the first positioning section 51. The first guide section 53B positions the hand truck 60 in the width direction. The first guide section 53B may also be a member that connects the first positioning section 51 and the columnar section 53A.

[0045] The second guide section 53C is a columnar member that extends along the width direction of the hand truck 60 (the direction perpendicular to the white arrow in Figure 6). Two second guide sections 53C are provided and are arranged at a predetermined interval in the width direction of the hand truck 60 (for example, an interval that allows the second transport vehicle 20B to pass through). The second guide section 53C contacts the front end of the hand truck 60 as it enters in the direction of the white arrow, and positions the hand truck 60 in the direction of entry (white arrow in Figure 6). The first guide section 53B and the second guide section 53C may be formed as a single L-shaped member or as separate members.

[0046] Furthermore, the shipping station 5 may be equipped with fixing means for securing the hand truck 60, which is positioned in a predetermined location relative to the shipping rack 50, or the hand truck 60 may be equipped with fixing means such as wheel stoppers.

[0047] Here, the hand truck 60 will be described. The hand truck 60 is a trolley on which an empty pallet P or a pallet P with goods C placed on it can be placed and transported by a worker pushing it by hand. In this embodiment, it is used at the shipping station 5 to transport an empty pallet P or a pallet P with goods C placed on it, received from the second transport vehicle 20B, to the loading position 5A of the truck T.

[0048] As shown in Figures 6(A) and 6(B), the hand truck 60 comprises a mounting frame 61, a positioning block 63, wheels 65, and a push handle 67. The mounting frame 61 is a member formed in a U-shape in plan view. The mounting frame 61 supports an empty pallet P or a pallet P on which an item C is placed from below. In this embodiment, the hand truck 60 is configured so that a second transport vehicle 20B can pass under the pallet P when the pallet P is placed on it. That is, the height of the mounting frame 61 is adjusted so that the second transport vehicle 20B can pass under the pallet P placed on the hand truck 60.

[0049] The positioning block 63 is positioned on the mounting surface of the pallet P on the mounting frame 61. The positioning block 63 positions the pallet P placed on the mounting frame 61. The positioning block 63 positions three sides of the mounting frame 61. The wheels 65 roll on the floor surface of the building. The wheels 65 are positioned at the four corners of the mounting frame 61. The wheels 65 facilitate the movement of the hand truck 60. The push section 67 is the part of the hand truck 60 that is pushed by the worker.

[0050] Next, the transfer of an empty pallet P or a pallet P with goods C placed on it between the second transport vehicle 20B and the hand truck 60 at the shipping station 5 will be described. First, the hand truck 60 is positioned in a predetermined location on the shipping stand 50. With the empty pallet P or the pallet P with goods C placed on it lifted by the loading plate 23, the second transport vehicle 20B is moved to the inside of the hand truck 60 located in a predetermined location on the shipping stand 50 (inside the imaginary line that virtually connects the four wheels 65), and then the lifter 22 is lowered. This allows the empty pallet P or the pallet P with goods C placed on it to be placed on the hand truck 60. The second transport vehicle 20B can then exit from below the pallet P placed on the hand truck 60 and move to another location.

[0051] Meanwhile, the second transport vehicle 20B moves under the pallet P placed on the hand truck 60 positioned in a predetermined location on the shipping stand 50. By raising the lifter 22 inside the hand truck 60, the empty pallet P or the pallet P with the item C placed on it is lifted by the loading plate 23. Then, by moving the second transport vehicle 20B, the empty pallet P or the pallet P with the item C placed on it can be transported.

[0052] At the shipping station 5, when a pallet P with goods C on it is placed on a hand truck 60, the worker moves the hand truck 60 to the loading position 5A of the truck T. At the loading position 5A, the worker loads goods C onto the truck T.

[0053] The first buffer 6 is a place in storage area A1 where empty pallets P or pallets P on which goods C are placed are temporarily moved. Multiple (eight in this embodiment) item support stands 40 are arranged in the first buffer 6. When the first transport vehicle 20A moves empty pallets P or pallets P on which goods C are placed between the automated warehouse 10 and the first loading unit 35A, between the automated warehouse 10 and the transfer station 4, and between the first loading unit 35A and the transfer station 4, these empty pallets P or pallets P on which goods C are placed can be temporarily moved to the first buffer 6.

[0054] The second buffer 7 is a place in the shipping area A2 where empty pallets P or pallets P on which goods C are placed are temporarily moved. Multiple (eight in this embodiment) item support stands 40 are arranged in the second buffer 7. When the second transport vehicle 20B moves empty pallets P or pallets P on which goods C are placed between the shipping station 5 and the second loading section 35B, between the shipping station 5 and the handover station 4, and between the second loading section 35B and the handover station 4, these empty pallets P or pallets P on which goods C are placed can be temporarily moved to the second buffer 7.

[0055] Access passage R is the passage through which workers move to the picking platform 30. Multiple first transport vehicles 20A move in storage area A1, and multiple second transport vehicles 20B move in shipping area A2. Therefore, workers need to move in a way that avoids contact with the first transport vehicles 20A and second transport vehicles 20B. As mentioned above, the first transport vehicles 20A and second transport vehicles 20B have a function to stop when they detect an object (worker), but it is desirable to be able to move more safely.

[0056] For example, the access passage R is preferably provided in a location where the first transport vehicle 20A and the second transport vehicle 20B travel infrequently (for example, the route between the second loading section 35B of the second transport vehicle 20B and the transfer station 4). Also, if the access passage R is provided so as to cross the travel paths of the first transport vehicle 20A and the second transport vehicle 20B, a barrier or the like may be set up to prevent workers from entering the travel path when the first transport vehicle 20A and the second transport vehicle 20B are approaching. Also, when workers are crossing the travel path, an entry prohibition button may be provided to stop the first transport vehicle 20A and the second transport vehicle 20B from entering that position. Furthermore, if the first transport vehicle 20A and the second transport vehicle 20B travel infrequently, an access passage R with an overbridge configuration that avoids the travel path in three dimensions may be provided.

[0057] The main controller 80 includes a CPU (Central Processing Unit), ROM (Read Only Memory), RAM (Random Access Memory), etc. The main controller 80 is configured to communicate with the stacker crane 13, the first system controller 27A, the second system controller 27B, and the terminal device 37. The main controller 80 controls the operation of the picking system 1. The main controller 80 can be configured as software, for example, in which a program stored in ROM is loaded onto RAM and executed by the CPU. The main controller 80 may also be configured as hardware, such as an electronic circuit.

[0058] The main controller 80 is configured to switch between a normal sorting mode and a reverse sorting mode. The normal sorting mode is a mode in which sorting information is displayed on the terminal device 37 indicating that items C to be shipped will be sorted from the items C on the pallet P placed on the first loading section 35A onto the pallet P placed on the second loading section 35B. The reverse sorting mode is a mode in which sorting information is displayed on the terminal device 37 indicating that items C not to be shipped will be removed from the items C on the pallet P placed on the first loading section 35A, and the items C to be shipped will be sorted onto the pallet P placed on the first loading section 35A.

[0059] In normal sorting mode, the main controller 80 causes the pallet P on which the items C to be shipped are placed (the group of items including the items C to be shipped) to be transported to the first loading section 35A by the first transport vehicle 20A, and the pallet P on which the items C to be shipped that have been sorted to the second loading section 35B are placed to be transported to the shipping station 5 by the second transport vehicle 20B.

[0060] In reverse sorting mode, the main controller 80 causes pallets P on which goods C to be shipped are placed to be transported to the first loading section 35A by the first transport vehicle 20A, and then causes pallets P on which goods C to be shipped are placed, sorted in the first loading section 35A, to be transported to the handover station 4 by the first transport vehicle 20A, and then causes pallets P on which goods C to be shipped are placed, which are handed over from the handover station 4, to be transported to the shipping station 5 by the second transport vehicle 20B. In reverse sorting mode, the main controller 80 also causes pallets P on which goods C not to be shipped are placed in the second loading section 35B to be transported to the handover station 4 by the second transport vehicle 20B, and then causes pallets P on which goods C not to be shipped are placed, which are handed over from the handover station 4, to be transported to the automated warehouse 10 by the first transport vehicle 20A.

[0061] Based on sorting information, the main controller 80 determines that the type and quantity of goods C placed on the pallet P being transported by the first transport vehicle 20A match the type and quantity of goods C to be shipped. The main controller then controls the first transport vehicle 20A to transport the pallet P containing the goods C to the handover station 4 without passing through the sorting station 3. The main controller 80 moves the second transport vehicle 20B to the handover station 4 at the same time as the first transport vehicle 20A arrives at the handover station 4. At the handover station 4, the main controller 80 controls the second transport vehicle 20B to receive the pallet P containing the goods C from the first transport vehicle 20A and then moves it to the shipping station 5.

[0062] The main controller 80 controls the first transport vehicle 20A, the second transport vehicle 20B, and the stacker crane 13 so that the item C to be shipped is transported to the shipping station 5 in accordance with the shipping time of the item C at the shipping station 5, and also distributes sorting information to the terminal device 37. For example, the main controller 80 may synchronize the picking source and the picking destination at the picking stand 30, that is, the arrival time of the first transport vehicle 20A, which transports the pallet P on which the item C to be shipped is placed, to the first loading section 35A, and the arrival time of the second transport vehicle 20B, which transports the pallet P on which the item C to be shipped has been transferred, to the second loading section 35B.

[0063] Furthermore, the main controller 80 may calculate the arrival time of the second transport vehicle 20B at the second loading section 35B by working backward from the arrival time of the truck T at the loading position 5A, and control the second transport vehicle 20B. Alternatively, the main controller 80 may calculate the departure time of the stacker crane 13 for the target item C to the loading / unloading section 14 by working backward from the arrival time of the first transport vehicle 20A at the first loading section 35A, and control the stacker crane 13. Since the calculation of such times depends on the load conditions of each transport device (stacker crane 13, first transport vehicle 20A, and second transport vehicle 20B), it is preferable to perform the allocation to each transport device while running a simulation in real time.

[0064] The effects and advantages of the picking system 1 of the above embodiment will now be explained. In the picking system 1 of the above embodiment, an empty pallet P or a pallet P with goods C placed on it can be transferred from the first transport vehicle 20A in the storage area A1 to the second transport vehicle 20B in the shipping area A2 without going through the sorting station 3, and an empty pallet P or a pallet P with goods C placed on it can be transferred from the second transport vehicle 20B in the shipping area A2 to the first transport vehicle 20A in the storage area A1. As a result, even if the transport vehicle systems (first transport vehicle system 2A and second transport vehicle system 2B) that transport goods C are separate in the storage area A1 and the shipping area A2, it becomes possible to flexibly transfer empty pallets P or pallets P with goods C placed on them between the storage area A1 and the shipping area A2 according to the work content.

[0065] In the above embodiment of the picking system, the main controller 80, in reverse sorting mode, transports items C that are not to be shipped from the pallet P placed on the second loading section 35B to the handover station 4 by the second transport vehicle 20B, and transports the pallet P on which the items C that are not to be shipped are placed, which are received from the handover station 4, to the automated warehouse 10 by the first transport vehicle 20A. As a result, if removing the items C that are not to be shipped makes the items C on the pallet P placed on the first loading section 35A the same as the items C that are to be shipped, then sorting can be done efficiently at the sorting station 3.

[0066] In the above embodiment, the main controller 80 of the picking system 1, in reverse sorting mode, causes items C that are not to be shipped, which are placed on the pallet P on the second loading section 35B, to be transported to the handover station 4 by the second transport vehicle 20B, and the pallet P on which the items C that are not to be shipped are placed, which are then handed over from the handover station 4, to be transported to the automated warehouse 10 by the first transport vehicle 20A. As a result, even if items C that are not to be shipped are placed on the pallet P on the second loading section 35B, the pallet P on which the items C that are not to be shipped are to be stored in the automated warehouse 10.

[0067] In the above embodiment of the picking system 1, the main controller 80 determines, based on sorting information, that the type and quantity of goods C on the pallet P being transported by the first transport vehicle 20A matches the type and quantity of goods C to be shipped. The controller then controls the first transport vehicle 20A to transport the pallet P on which the goods C are placed to be shipped to the transfer station 4 without passing through the sorting station 3. This allows goods C that do not need to be sorted at the sorting station 3 to be transferred to the second transport vehicle 20B without the goods C being repackaged at the sorting station 3, thereby increasing the shipping efficiency of the goods C.

[0068] The item support table 40 of the picking system 1 in the above embodiment is configured such that the pallet P on which the item C is placed can be loaded and unloaded by the first transport vehicle 20A entering and exiting from a first direction, and the pallet P on which the item C is placed can be loaded and unloaded by the second transport vehicle 20B entering and exiting from a second direction different from the first direction. This makes it possible to transfer the pallet P on which the item C is placed from the first transport vehicle 20A to the second transport vehicle 20B with a simple configuration.

[0069] The picking system 1 in the above embodiment has a handover station 4 with multiple item support tables 40. This allows for adjustment of the time it takes to transport the pallet P on which the items C to be shipped are placed to the shipping station 5.

[0070] The first transport vehicle 20A and the second transport vehicle 20B of the picking system 1 in the above embodiment have the same configuration. This allows the transport capacity to be adjusted by changing the number of transport vehicles that make up the first transport vehicle system 2A and the second transport vehicle system 2B.

[0071] The main controller 80 of the picking system 1 in the above embodiment controls the first transport car 20A and the second transport car 20B so that the items C to be shipped are transported to the shipping station 5 in accordance with the shipping time at the shipping station 5, and also distributes sorting information to the terminal device 37. As a result, there is no need to leave the pallets P on which the sorted items C to be shipped are placed anywhere, so the amount of storage space that needs to be secured (the space for installing the first buffer 6 and the second buffer 7) can be reduced.

[0072] Although one embodiment has been described above, one aspect of the present invention is not limited to the above embodiment. Various modifications are possible without departing from the spirit of the invention.

[0073] In the above embodiment of the picking system 1, an example was described in which items C placed on pallets P are stored in an automated warehouse 10 and transported by a stacker crane 13, a first transport vehicle 20A, and a second transport vehicle 20B. However, the system is not limited to this. For example, the picking system 1 may store and transport items C contained in returnable boxes, cardboard boxes, containers, etc.

[0074] In the above embodiment and the modified picking system 1, an example was given in which a pallet P on which the goods C to be shipped are placed is transferred between the second transport vehicle 20B and the hand truck 60, but the system is not limited to this. For example, the second transport vehicle 20B may be configured to move directly from the sorting station 3 or the handover station 4 to the loading position 5A of the truck T. In other words, the second transport vehicle 20B may be transported directly to the loading position 5A of the truck T without the provision of a shipping rack 50.

[0075] In the above embodiment and the above modified example, an item support stand 40 was described as being placed at the transfer station 4 of the picking system 1. However, a conveying device such as a belt conveyor, chain conveyor, or roller conveyor may be provided, and instead of or in addition to the item support stand 40, empty pallets P or pallets P on which items C are placed may be transferred between the first transport car 20A and the second transport car 20B.

[0076] In the above embodiments and modifications, examples were given in which the system is configured to allow switching between a normal sorting mode and a reverse sorting mode. However, a picking system 1 that only performs the normal sorting mode may also be used.

[0077] In the above embodiment and the modified picking system 1, an example was given in which items C of the same type are placed on one pallet P, but multiple types of items C may be placed on one pallet P. [Explanation of Symbols]

[0078] 1...Picking system, 2A...First transport vehicle system, 2B...Second transport vehicle system, 3...Sorting station (sorting department), 4...Delivery station (delivery department), 5...Shipping station (shipping department), 5A...Loading position, 6...First buffer, 7...Second buffer, 10...Automated warehouse (storage department), 13...Stacker crane, 20A...First transport vehicle, 20B...Second transport vehicle, 30...Picking stand, 35A...First loading area, 35B...Second loading area, 37...Terminal device, 40...Item support stand, 50...Shipping stand, 60...Hand truck, 80...Main controller (controller), A1...Storage area, A2...Shipping area, B...Building, C...Items, P...Pallet, R...Access passage.

Claims

1. A storage area for storing goods, A terminal device is provided to provide sorting information, and a sorting unit is provided in which the sorting of the items is performed based on the sorting information, The sorting section and the shipping section are used to ship the sorted items. A first transport vehicle system that transports the items to the first transport vehicle in the storage area between the storage unit and the sorting unit, A second transport vehicle system that transports the goods to a second transport vehicle in the shipping area between the sorting department and the shipping department, A picking system comprising the terminal device, the first transport vehicle system, and a controller for controlling the second transport vehicle system, A transfer unit is provided for transferring the articles being transported by one of the first transport vehicle and the second transport vehicle to the other of the first transport vehicle and the second transport vehicle. The aforementioned sorting unit is, A first mounting section on which the article transported by the first transport vehicle or the article to be transported by the first transport vehicle is placed, It has a second mounting section on which the article to be transported by the second transport vehicle is placed, The first transport vehicle system is configured such that the first transport vehicle can move between the storage unit and the first loading unit, between the storage unit and the transfer unit, and between the first loading unit and the transfer unit. The second transport vehicle system is a picking system configured such that the second transport vehicle is movable between the shipping unit and the second loading unit, between the shipping unit and the handover unit, and between the second loading unit and the handover unit.

2. The aforementioned controller, A normal sorting mode in which sorting information indicating that the items to be shipped are sorted from the items placed on the first placement unit to the second placement unit is displayed on the terminal device, The system is configured to allow switching between a reverse sorting mode, in which sorting information indicating that items not to be shipped are removed from the items placed on the first placement unit and the items to be shipped are sorted to the first placement unit, and a reverse sorting mode, in which sorting information is displayed on the terminal device. The aforementioned controller, In the normal sorting mode, the group of items including the items to be shipped is transported to the first loading area by the first transport vehicle, and the items to be shipped that have been sorted to the second loading area are transported to the shipping area by the second transport vehicle. The picking system according to claim 1, wherein in the reverse sorting mode, the group of items including the items to be shipped is transported to the first loading area by the first transport vehicle, the items to be shipped that have been sorted in the first loading area are transported to the handover area by the first transport vehicle, and the items to be shipped that are handed over from the handover area are transported to the shipping area by the second transport vehicle.

3. The picking system according to claim 2, wherein in the reverse sorting mode, the controller causes the items not to be shipped, which are placed on the second placement section, to be transported to the handover section by the second transport vehicle, and the items not to be shipped, which are handed over from the handover section, to be transported to the storage section by the first transport vehicle.

4. The picking system according to any one of claims 1 to 3, wherein the controller, based on the sorting information, determines that the type and quantity of the items to be transported by the first transport vehicle matches the type and quantity of the items to be shipped, and controls the first transport vehicle to transport the items to the delivery unit without going through the sorting unit.

5. The transfer unit has an article support stand on which the article can be transferred, The picking system according to any one of claims 1 to 3, wherein the article support stand is configured such that the article can be loaded and unloaded by the first transport vehicle entering and exiting from a first direction, and the article can be loaded and unloaded by the second transport vehicle entering and exiting from a second direction different from the first direction.

6. The picking system according to claim 5, wherein the transfer section has a plurality of article support bases.

7. The picking system according to any one of claims 1 to 3, wherein the first transport vehicle and the second transport vehicle have the same configuration.

8. The picking system according to any one of claims 1 to 3, wherein the controller controls the first transport vehicle and the second transport vehicle so that the items to be shipped are transported to the shipping department in accordance with the shipping time at the shipping department, and also distributes the sorting information to the terminal device.

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