Warehouse system, information processing method, and program

Abstract

Reduce the processing time required for rack rearrangement. [Solution] The warehouse system 100 includes an automated warehouse 1. The automated warehouse 1 includes a plurality of racks 4, an inbound / outbound station 12, and a stacker crane 13 that transports goods between the plurality of racks 4 and the inbound / outbound station 12, and is configured to perform inbound and outbound operations automatically. The plurality of racks 4 include a group of outbound racks, each storing goods scheduled to be shipped outside the automated warehouse 1; a group of storage racks, each storing goods not scheduled to be shipped outside the automated warehouse 1; and a group of empty racks, each not storing goods. The warehouse system 100 further includes a server 2 that, during periods when the automated warehouse 1 is not performing inbound or outbound operations, executes at least one of the following: a shipping preparation process for shipping goods outside the automated warehouse 1, and an receiving preparation process for receiving goods from outside the automated warehouse 1.

Description

Technical Field

[0001] The present disclosure relates to a warehouse system, an information processing method, and a program.

Background Art

[0002] The automatic warehouse disclosed in Japanese Patent Application Laid-Open No. 2000-302210 (Patent Document 1) includes shelves, conveying means, a station, and a control unit for managing these. The automatic warehouse is provided with inventory control means for determining a re-storage location of an article after inventory taking and shipping so as to re-arrange the article in the shelf according to a predetermined rule.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] The automatic warehouse of the warehouse system described in Patent Document 1 etc. includes a plurality of racks, an inlet / outlet section, and a conveying section for conveying goods between the plurality of racks and the inlet / outlet section. There is always a demand for efficiently shipping goods outside the automatic warehouse or efficiently receiving goods from outside the automatic warehouse, in other words, minimizing the time required for shipping and / or receiving.

[0005]

[0006] ​This disclosure was made to solve the above-mentioned problems, and one of its objectives is to provide a warehouse system that shortens the processing time for rearranging items in multiple racks. Another objective of this disclosure is to provide an information processing method and program that shortens the processing time for rearranging items in multiple racks. [Means for solving the problem]

[0007] A warehouse system according to one aspect of the present disclosure includes an automated warehouse. The automated warehouse includes a plurality of racks, an inbound / outbound unit, and a transport unit for transporting goods between the plurality of racks and the inbound / outbound unit, and is configured to perform inbound / outbound operations automatically. The plurality of racks include a group of outbound racks, each storing goods scheduled for shipment outside the automated warehouse; a group of storage racks, each storing goods not scheduled for shipment outside the automated warehouse; and a group of empty racks, each not storing goods. The warehouse system further includes a control device that, during periods when the automated warehouse is not performing inbound / outbound operations, performs at least one of the following: a shipment preparation process for shipping goods outside the automated warehouse; and an inbound preparation process for receiving goods from outside the automated warehouse.

[0008] The shipping preparation process includes: obtaining the current arrangement of multiple racks and the predetermined target shipping arrangement of multiple racks; extracting a set of shipping addresses indicating the locations of shipping racks to which multiple shipments will be moved from the shipping rack group to the storage rack group, based on the difference between the current arrangement and the target shipping arrangement, and extracting a set of storage addresses indicating the locations of storage racks to which shipments will be moved from the storage rack group to the shipping rack group; generating multiple swap address sets according to a first optimization algorithm for swapping shipments between the shipping address set and the storage address set; and determining the swap order in the multiple swap address sets according to a second optimization algorithm.

[0009] The receiving preparation process includes: obtaining the current arrangement and the target receiving arrangement of a predetermined number of racks; extracting a set of outbound addresses indicating the locations of outbound or storage racks to be emptied by outbound shipments from the outbound rack group or storage rack group, based on the difference between the current arrangement and the target receiving arrangement, and extracting a set of inbound addresses indicating the locations of racks in the empty rack group that will no longer be emptied by inbound shipments; generating multiple movement address sets for moving goods between the outbound address set and the inbound address set according to a third optimization algorithm; and determining the movement order in the multiple movement address sets according to a fourth optimization algorithm.

[0010] Information processing methods relating to other aspects of this disclosure are performed by a processor to determine the arrangement of goods in an automated warehouse. The automated warehouse is configured to perform receiving and shipping operations automatically by transporting goods between a plurality of racks and a receiving / shipping unit. The plurality of racks include a group of shipping racks, each storing goods scheduled to be shipped outside the automated warehouse; a group of storage racks, each storing goods not scheduled to be shipped outside the automated warehouse; and a group of empty racks, each not storing goods. The information processing method includes the step of performing at least one of the following during a period when the automated warehouse is not performing receiving or shipping operations: a shipping preparation process for shipping goods outside the automated warehouse; and a receiving preparation process for receiving goods from outside the automated warehouse.

[0011] The steps for executing the shipping preparation process include: obtaining the current arrangement of multiple racks and the predetermined target shipping arrangement of multiple racks; extracting a set of shipping addresses indicating the locations of shipping racks to which goods will be moved from the shipping rack group to the storage rack group, and extracting a set of storage addresses indicating the locations of storage racks to which goods will be moved from the storage rack group to the shipping rack group, based on the difference between the current arrangement and the target shipping arrangement; generating multiple swap address sets according to a first optimization algorithm for swapping goods between the shipping address set and the storage address set; and determining the swap order of goods in the multiple swap address sets according to a second optimization algorithm.

[0012] The steps for performing the receiving preparation process include: obtaining the current arrangement and a predetermined target receiving arrangement for a set of racks; extracting a set of outgoing addresses indicating the locations of outgoing racks or storage racks to be emptied by outgoing shipments from a group of outgoing racks or a group of storage racks, and extracting a set of receiving addresses indicating the locations of racks in a group of empty racks that will no longer be emptied by receiving shipments, based on the difference between the current arrangement and the target receiving arrangement; generating a set of movement addresses for moving goods between the set of outgoing addresses and the set of receiving addresses according to a third optimization algorithm; and determining the movement order in the set of movement addresses according to a fourth optimization algorithm.

[0013] In the above warehouse system, information processing method, and program, at least one of the shipping preparation process and the receiving preparation process is executed during a period when no incoming / outgoing operation is being performed. In the shipping preparation process, by executing the processes in the order of acquisition of arrangement, extraction of address, determination of replacement address set, and determination of replacement order, the processing time for rearrangement from the current arrangement to the target shipping arrangement can be shortened. Also, in the receiving preparation process, by executing the processes in the order of acquisition of arrangement, extraction of address, determination of movement address set, and determination of movement order, the processing time for rearrangement from the current arrangement to the target receiving arrangement can be shortened. Therefore, according to the present disclosure, it is possible to determine in a short time how to rearrange the racks.

Advantages of the Invention

[0014] According to the present disclosure, the processing time for rack rearrangement can be shortened.

Brief Description of the Drawings

[0015] [Figure 1] It is a block diagram showing the overall configuration of the warehouse system according to Embodiment 1. [Figure 2] It is a perspective view schematically showing an automated warehouse. [Figure 3] It is a side view schematically showing an automated warehouse. [Figure 4] It is a functional block diagram of the management device. [Figure 5] It is a functional block diagram of the shipping preparation processing unit in the twin fork type. [Figure 6] It is a schematic diagram for explaining an example of the flow of the shipping preparation process regarding the single mode of the twin fork type. [Figure 7] It is a schematic diagram for explaining the first example of pairing. [Figure 8] It is a schematic diagram for explaining the second example of pairing. [Figure 9] It is a schematic diagram for explaining the first example of order determination. [Figure 10] It is a schematic diagram for explaining the second example of order determination. [Figure 11] It is a schematic diagram for explaining an example of the flow of the shipping preparation process related to the twin fork type two-step mode. [Figure 12] It is a functional block diagram of the incoming goods preparation processing unit in the twin fork type. [Figure 13] It is a schematic diagram for explaining an example of the flow of the incoming goods preparation process related to the single mode of the twin fork type. [Figure 14] It is a schematic diagram for explaining an example of the flow of the incoming goods preparation process related to the two-step mode of the twin fork type. [Figure 15] It is a flowchart showing the overall flow of the process in the twin fork type. [Figure 16] It is a flowchart showing the flow of the shipping preparation process in the twin fork type. [Figure 17] It is a flowchart showing the flow of the incoming goods preparation process in the twin fork type. [Figure 18] It is a diagram showing an example of the result of verifying the effect of shortening the processing time for rack rearrangement. [Figure 19] It is a functional block diagram of the shipping preparation processing unit in the single fork type. [Figure 20] It is a schematic diagram for explaining an example of the flow of the shipping preparation process related to the single fork type. [Figure 21] It is a functional block diagram of the incoming goods preparation processing unit in the single fork type. [Figure 22] It is a schematic diagram for explaining an example of the flow of the incoming goods preparation process related to the single fork type. [Figure 23] It is a flowchart showing the flow of the shipping preparation process in the single fork type. [Figure 24] It is a flowchart showing the flow of the incoming goods preparation process in the single fork type. [Figure 25] It is a schematic diagram showing the configuration of an automated warehouse and the flow of the shipping preparation process in a warehouse system according to a modification example of Embodiment 2. [Modes for carrying out the invention]

[0016] This embodiment will be described in detail below with reference to the drawings. In the drawings, the same or corresponding parts are denoted by the same reference numerals, and their descriptions will not be repeated.

[0017] <Explanation of Terms> The following explanation assumes an XYZ coordinate system. The X and Y axes are horizontal. The X and Y axes are orthogonal to each other. The Z axis is vertical. The direction downward along the Z axis is the direction of gravity.

[0018] The act of transporting goods from an automated warehouse to the outside is called "shipping," and the act of transporting goods from the outside to the automated warehouse is called "receiving." The automated warehouse includes storage shelves. The act of moving goods from one part of the storage shelves to another part of the storage shelves (or to the outside) is called "outbound," and the act of moving goods from one part of the storage shelves to another part of the storage shelves (or to the outside) is called "receiving." Therefore, the exchange of goods within the storage shelves is a combination of outbound and receiving. Receiving or outbound may also be written as "inbound / outbound." Note that "goods" may be read as "items."

[0019] [Embodiment 1] <System Configuration> Figure 1 is a block diagram showing the overall configuration of the warehouse system according to Embodiment 1. In this example, the warehouse system 100 includes an automated warehouse, a server 2, and an operation management server 3.

[0020] Automated warehouse 1 stores multiple items. Automated warehouse 1 is configured to be able to store and retrieve a maximum of two items (i.e., one or two items) in a single inbound or outbound operation. Automated warehouse 1 includes a storage unit 11, an inbound / outbound station 12, and a stacker crane 13.

[0021] Figure 2 is a schematic perspective view of the automated warehouse 1. Figure 3 is a schematic side view of the automated warehouse 1. Referring to Figures 2 and 3, the storage unit 11 in this example includes a pair of storage shelves 111 and 112. Storage shelves 111 and 112 are spaced apart from each other in the X-axis direction. Since storage shelves 111 and 112 have equivalent configurations, Figure 3 shows a representative configuration of storage shelf 111.

[0022] Each of the storage shelves 111 and 112 contains multiple racks 4 arranged two-dimensionally (in the YZ plane) along the Y-axis and Z-axis directions. Each of the multiple racks 4 is configured to store one package L. The number of racks in the Y-axis direction (rows) and the number of racks in the Z-axis direction (tiers) shown in Figures 2 and 3 are illustrative only. Therefore, the number of rows and tiers do not match between Figure 2 and Figure 3. The number of rows and tiers are not particularly limited as long as they are two or more, but are typically between a dozen and several dozen.

[0023] The receiving / shipping station 12 relays incoming or outgoing goods L between the inside and outside of storage shelves 111, 112. The receiving / shipping station 12 corresponds to the "receiving / shipping section" in this disclosure.

[0024] The stacker crane 13 is positioned between storage racks 111 and 112 and transports cargo L between the loading / unloading station 12 and storage racks 111 and 112. More specifically, the stacker crane 13 includes a moving section 14 and a cargo handling section 15. The moving section 14 is configured to move the cargo handling section 15 in the Y-axis and Z-axis directions. The moving section 14 includes a horizontal moving device 141, a plurality of guide members 142, and a lifting device 143. The horizontal moving device 141 is a moving body that travels on the floor surface between storage racks 111 and 112. The plurality of guide members 142 extend upward from the horizontal moving device 141 in the Z-axis direction. The lifting device 143 is configured to move up and down along the plurality of guide members 142. The cargo handling section 15 moves in the Y-axis direction as the horizontal moving device 141 moves, and moves in the Z-axis direction as the lifting device 143 moves. The loading / unloading section 15 is equipped with forks (not shown) that can move in and out of each rack 4.

[0025] When a shipment L arrives, the receiving / discharging station 12 transfers the placed shipment L to the stacker crane 13 once it is positioned at the receiving / discharging station 12. The stacker crane 13 places the shipment L received from the receiving / discharging station 12 into the designated rack 4. Conversely, when a shipment L is dispatched, the stacker crane 13 dispatches the shipment L from the designated rack 4. The receiving / discharging station 12 receives the dispatched shipment L from the stacker crane 13. In this way, the stacker crane 13 is configured to be able to receive (or dispatch) shipment L to and from the corresponding rack 4 (or receiving / discharging station 12). The stacker crane 13 corresponds to the "transportation unit" in this disclosure.

[0026] The multiple racks 4 include a shipping rack group, a storage rack group, and an empty rack group. Each rack belonging to the shipping rack group is a "shipping rack 41" that stores goods scheduled to be shipped when automated warehouse 1 next operates. Each rack belonging to the storage rack group is a "storage rack 42" that stores goods that are not scheduled to be shipped when automated warehouse 1 next operates. Each rack belonging to the empty rack group is an "empty rack 43" that stores neither goods scheduled for shipment nor goods not scheduled for shipment.

[0027] In addition to transferring goods L between the loading / unloading station 12 and the stacker crane 13, the stacker crane 13 can also swap goods L between one rack and another among the multiple racks 4. The stacker crane 13 swaps shipping racks 41 and storage racks 42, or swaps storage racks 42 and empty racks 43, according to the relocation data (described later) generated by the server 2.

[0028] Each of the multiple racks 4 is assigned an address that indicates its location (a combination of X-axis, Y-axis, and Z-axis coordinates). Server 2 uses these addresses to manage the rack placement. Hereafter, the address of shipping rack 41 will be referred to as the "shipping address," the address of storage rack 42 as the "storage address," and the address of empty rack 43 as the "empty address."

[0029] In multiple racks 4, a set of addresses whose elements indicate the locations of two or more racks that are to be replaced or moved from the total address range is referred to as the "address set". Specifically, a set of shipping addresses whose elements are to be replaced or moved is referred to as the "shipping address set", a set of storage addresses whose elements are to be replaced or moved is referred to as the "storage address set", and a set of empty addresses whose elements are to be replaced or moved is referred to as the "empty address set". Furthermore, in the receiving preparation process described later, a set of empty addresses whose elements will become storage racks or shipping racks upon receiving is referred to as the "receiving address set", and a set of storage addresses or shipping addresses whose elements will become empty racks upon shipping is referred to as the "shipping address set".

[0030] The cargo L may be moved and stored while placed in bucket B. The shipping rack 41 and storage rack 42 are not limited to a state in which only cargo L is stored, but may also include a state in which cargo L is stored while placed in bucket B. The empty rack 43 may also include a state in which empty bucket B without cargo L is stored. Whether or not cargo L is placed in bucket B does not affect the arrangement of the shipping rack 41, storage rack 42, and empty rack 43. The stacker crane 13 may load and unload cargo L while it is placed in bucket B. The stacker crane 13 may also load and unload empty bucket B.

[0031] In Embodiment 1, the automated warehouse 1 (inbound / outbound station 12 and stacker crane 13) is configured to be able to inbound and outbound up to two items in a single inbound / outbound operation (it is also possible to inbound and outbound items one at a time). This type of system is called a "twin fork system". In this example, the two racks are adjacent in the Y-axis direction. However, the two racks may also be adjacent in the Z-axis direction.

[0032] In storage racks 111 and 112, the shipping range 16 is pre-set near the receiving / shipping station 12. The shipping range 16 is suitable for shipping because it minimizes the travel time of the stacker crane 13 between the receiving / shipping station 12 and the racks in the shipping range 16. In Figure 3 (and the figures described later), the positions of six racks (two in the Y-axis direction and three in the Z-axis direction) are set as the shipping range 16. The shipping range 16 can be set as appropriate depending on the arrangement of the receiving / shipping station 12.

[0033] Referring again to Figure 1, Server 2 is a management device that manages the automated warehouse 1. When the automated warehouse 1 is not in operation (such as at night, during periods when no receiving or shipping operations are taking place), Server 2 performs a relocation process to rearrange multiple racks 4. By performing this relocation process, it becomes possible to receive and ship goods in a short time when the automated warehouse 1 is next operational. The relocation process will be explained in detail later.

[0034] Server 2 may be a general-purpose computer such as a PC (Personal Computer). Server 2 includes a processor 21, memory 22, storage 23, input device 24, display 25, network controller 26, and bus 27.

[0035] The processor 21 includes processing circuitry such as a CPU (Central Processing Unit) and an MPU (Micro Processing Unit). The memory 22 includes volatile storage devices such as DRAM (Dynamic Random Access Memory) and SRAM (Static Random Access Memory). The storage 23 includes non-volatile storage devices such as an HDD (Hard Disk Drive), an SSD (Solid State Drive), and flash memory. The storage 23 stores a system program (not shown) including an OS (Operating System), a program 231 for executing relocation processing, and management information 232 used in program 231 (information such as current location, target location, movement speed and movement time of the cargo handling unit 15). The processor 21 realizes various relocation processing by reading the system program, program 231, and management information 232, expanding them into memory 22, and executing them.

[0036] Although only one processor is shown in Figure 1, Server 2 may include multiple processors. That is, Server 2 includes one or more processors. The same applies to Memory 22 and Storage 23. In this specification, "processor" is not limited to a processor in the narrow sense that executes processing in a stored-program manner, but may include hardwired circuits such as ASICs (Application Specific Integrated Circuits) and FPGAs (Field-Programmable Gate Arrays). Therefore, the term "processor" can also be read as a processing circuit (circuitry or processing circuitry) whose processing is predefined by computer-readable code and / or hardwired circuits. Server 2 may be divided into multiple units according to function. Server 2 corresponds to the "management device" in this disclosure. The "management device" in this disclosure may be a personal computer, workstation, general-purpose computer, microcomputer, smart device, etc.

[0037] The input device 24 is a keyboard, touch panel, etc., and accepts user input. The display 25 displays the results of the relocation process by the server 2 (racks to be replaced, replacement order, etc.). The network controller 26 is configured to communicate with the outside of the server 2 (operation management server 3) according to the control of the processor 21. The bus 27 connects the components of the server 2 in a way that allows communication between them.

[0038] The operations management server 3 operates at a higher level than server 2 and manages automated warehouse 1 (which may include other automated warehouses not shown in the diagram). The operations management server 3 may have a similar configuration to server 2. Therefore, a detailed explanation of the configuration of the operations management server 3 will not be repeated.

[0039] The operation management server 3 holds various management information. This management information includes, for example, package information, shipping schedule information, and placement information. Package information indicates which package L is placed in which rack 4, showing the correspondence between package L and rack 4. Shipping schedule information indicates which package L will be shipped when the automated warehouse 1 next operates. Placement information indicates which racks belong to the shipping rack group, which racks belong to the storage rack group, and which racks belong to the empty rack group. Placement information includes information showing the current placement of racks (current placement) and information showing the target placement of racks in preparation for the next operation of the automated warehouse 1 (target shipping placement and / or target receiving placement). The operation management server 3 provides management information to the server 2 at the necessary timing. The operation management server 3 also requests the server 2 to execute a relocation process (processing request).

[0040] When Server 2 receives a processing request from Operation Management Server 3, it generates relocation data by executing a relocation process and outputs the generated relocation data to Operation Management Server 3. When Operation Management Server 3 receives the relocation data from Server 2, it provides the relocation data to Automated Warehouse 1 and instructs Automated Warehouse 1 to relocate multiple racks 4 according to the relocation data (operation command). Automated Warehouse 1 relocates multiple racks 4 in response to the operation command from Operation Management Server 3. Note that Automated Warehouse 1 and Server 2 may communicate without going through Operation Management Server 3.

[0041] Figure 4 is a functional block diagram of server 2. Referring to Figures 1, 3, and 4, server 2 includes a target shipping placement acquisition unit 51, a target receiving placement acquisition unit 52, a current placement acquisition unit 53, a shipping preparation processing unit 6, and a receiving preparation processing unit 7.

[0042] The target shipping arrangement acquisition unit 51 acquires the "target shipping arrangement," which is the arrangement of multiple racks (particularly shipping racks 41 and storage racks 42) suitable for shipping during the next operation of the automated warehouse 1, from the operation management server 3. The operation management server 3 may acquire the arrangement specified by the user as the target shipping arrangement, or it may determine the target shipping arrangement by executing calculation processing according to a predetermined algorithm. The same applies to the target receiving arrangement described below. The target shipping arrangement acquisition unit 51 outputs the target shipping arrangement to the shipping preparation processing unit 6.

[0043] The target receiving arrangement acquisition unit 52 acquires the "target receiving arrangement," which is the arrangement of multiple racks (especially empty racks 43) suitable for receiving goods during the next operation of the automated warehouse 1, from the operation management server 3. The target receiving arrangement acquisition unit 52 outputs the target receiving arrangement to the receiving preparation processing unit 7.

[0044] The current placement acquisition unit 53 acquires the "current placement," which is the current arrangement of multiple racks (shipping racks 41, storage racks 42, and empty racks 43), from the operation management server 3. The current placement acquisition unit 53 may acquire the current placement from the automated warehouse 1 instead of the operation management server 3. The current placement acquisition unit 53 acquires the current placement immediately before the shipping preparation processing unit 6 and the receiving preparation processing unit 7 generate the shipping re-allocation data or receiving re-allocation data described later. The current placement acquisition unit 53 outputs the current placement to the shipping preparation processing unit 6 and the receiving preparation processing unit 7.

[0045] The shipping preparation processing unit 6 generates "shipping reconfiguration data" by executing shipping preparation processing based on the target shipping configuration and the current configuration. Shipping reconfiguration data indicates which shipping racks 41 and which storage racks 42 should be swapped, and in what order, for shipping during the next operation of the automated warehouse 1. The shipping preparation processing unit 6 outputs the shipping reconfiguration data to the operation management server 3.

[0046] The receiving preparation processing unit 7 generates "receiving rearrangement data" by executing receiving preparation processing based on the target receiving arrangement and the current arrangement. Receiving rearrangement data indicates which shipping racks 41 or storage racks 42 and which empty racks 43 should be swapped, and in what order, for receiving goods when the automated warehouse 1 is next operational. The receiving preparation processing unit 7 outputs the receiving rearrangement data to the operation management server 3.

[0047] <Preparation for shipment> Figure 5 is a functional block diagram of the shipping preparation processing unit 6 in the twin-fork system. Here, the flow of the shipping preparation processing is briefly explained, and each process will be explained in detail in Figure 6 and subsequent figures. The shipping preparation processing unit 6 includes an address extraction unit 61, a combination determination unit 62, and a sequence determination unit 63.

[0048] The address extraction unit 61 extracts the addresses (address sets) of two or more racks that are to be replaced from among multiple racks. More specifically, the address extraction unit 61 calculates the difference between the current arrangement and the target shipping arrangement. The address extraction unit 61 outputs the shipping address set and storage address set obtained from the difference to the combination determination unit 62. In the two-step mode, as will be explained later in Figure 11, the address extraction unit 61 also extracts an empty address set from the current arrangement and outputs it to the combination determination unit 62.

[0049] The combination determination unit 62 determines the combination of addresses between the shipping address set and the storage address set extracted by the address extraction unit 61. As described above, the automated warehouse 1 in Embodiment 1 is a twin-fork type capable of handling up to two packages simultaneously. Therefore, in this example, the automated warehouse 1 can select either a "one-step mode" in which the exchange of packages between two racks is performed in one step, or a "two-step mode" in which the exchange of packages between two racks is performed in two steps. The combination determination unit 62 includes a one-step exchange unit 621 corresponding to the one-step mode and a two-step exchange unit 622 corresponding to the two-step mode.

[0050] The one-step replacement unit 621 includes a pairing unit 621A. The pairing unit 621A generates a pair of addresses between the shipping address set and the storage address set (pairing).

[0051] The two-step swapping unit 622 includes a first pairing unit 622A, a second pairing unit 622B, and a relay unit 622C. The first pairing unit 622A performs pairing within the shipping address set or the storage address set. The second pairing unit 622B performs pairing between pairs in the shipping address set and pairs in the storage address set generated by the first pairing unit 622A. The relay unit 622C determines addresses (relay address set, described later) that indicate the location of empty racks to be relayed when moving goods from storage racks to shipping racks. The combination determination unit 62 determines the combination of addresses and outputs the determined combination to the sequence determination unit 63.

[0052] The sequence determination unit 63 determines the order in which the packages will be swapped based on the address combinations determined by the combination determination unit 62 (swap order). The sequence determination unit 63 outputs the determined swap order, along with the address combinations determined by the combination determination unit 62, as shipment redistribution data to the operation management server 3 (see Figure 1).

[0053] <<Shipping preparation processing: Twin fork type + 1 step mode>> Figure 6 is a schematic diagram illustrating an example of the shipping preparation process flow for a twin-fork type 1-step mode. In this example, as shown in Figure 6(A), in the current configuration, two shipping racks 41 are located inside the shipping range 16, while four shipping racks 41 are located outside the shipping range 16. In contrast, in the target shipping configuration, all six shipping racks 41 are located inside the shipping range 16.

[0054] Referring to Figures 5 and 6, first, the address extraction unit 61 calculates the shipping address set and the storage address set based on the difference between the current arrangement and the target shipping arrangement (see Figure 6(B)). In this example, the shipping address set includes 4 shipping addresses, and the storage address set includes 4 storage addresses.

[0055] Next, the pairing unit 621A of the one-step replacement unit 621 generates "address pairs" between the shipping address set and the storage address set (see Figure 6(C)). In this example, since each address set contains four addresses, four address pairs are generated, each consisting of one shipping address and one storage address. As a pairing method, for example, the following method can be used.

[0056] Figure 7 is a schematic diagram illustrating the first example of pairing. In the first example of pairing, a greedy method is used. The greedy method in pairing is a method of generating address pairs from among multiple possible address pairs in order of shortest to longest movement time for the stacker crane 13. When the horizontal movement device 141 and the lifting device 143 of the stacker crane 13 operate simultaneously, the movement time of the stacker crane 13 is the longer of the movement time of the horizontal movement device 141 and the movement time of the lifting device 143 (see Figure 2). When the horizontal movement device 141 and the lifting device 143 do not operate simultaneously, the movement time of the stacker crane 13 is the sum of the movement time of the horizontal movement device 141 and the movement time of the lifting device 143. First, the address pair with the shortest movement time for the stacker crane 13 is selected from all address pairs. Subsequently, the address pair with the shortest movement time for the stacker crane 13 is selected from the remaining address pairs, excluding the first selected address pair. The same process is repeated until no more address pairs can be generated.

[0057] Similar to Figure 6, we will describe an example where the shipping address set contains 4 shipping addresses (addresses 1-4) and the storage address set contains 4 storage addresses (addresses 5-8). In this case, 4 x 4 = 16 possible address pairs can be generated (see Figure 7(A)). Of the 16 possible address pairs, we assume that the address pair of address 1 and address 7 results in the shortest travel time for the stacker crane 13. Therefore, the pairing unit 621A first selects the address pair of address 1 and address 7.

[0058] Next, nine possible address pairs can be generated, each consisting of one of the remaining addresses 2-4 and one of the addresses 5, 6, or 8 (see Figure 7(B)). Among these nine address pairs, the address pair of address 3 and address 6 results in the shortest travel time for the stacker crane 13. Therefore, the pairing unit 621A selects the address pair of address 3 and address 6.

[0059] Next, four possible address pairs can be generated, each consisting of one of the remaining addresses 2 or 4 and one of the addresses 5 or 8 (see Figure 7(C)). Of the four possible address pairs, the address pair of address 2 and address 8 results in the shortest travel time for the stacker crane 13. Therefore, the pairing unit 621A selects the address pair of address 2 and address 8. Finally, the pairing unit 621A selects the address pair of the remaining address 4 and address 5 (see Figure 7(D)).

[0060] Figure 8 is a schematic diagram illustrating the second example of pairing. In this second example of pairing, the matching method is used. The matching method in pairing is an optimization technique that calculates address pairs such that the total travel time, calculated by adding up the travel times of the stacker crane 13 for each address pair, is the shortest. This method is also called the weighted maximum matching problem.

[0061] The travel time of the stacker crane 13 for address pairs between address i (i=1~4) belonging to the shipping address set and address j (j=5~8) belonging to the storage address set (equivalent to the cost in the weighted maximum matching problem) is C. ij The pairing unit 621A solves the weighted maximum matching problem by applying a known algorithm, thereby reducing the travel time of four steps C. ij Identify the four address pairs whose sum (total travel time) is minimized. In this example, the total travel time C 17 +C 28 +C 35 +C 46 This minimizes the value. Therefore, the pairing unit 621A selects the address pair between address 1 and address 7, the address pair between address 2 and address 8, the address pair between address 3 and address 5, and the address pair between address 4 and address 6.

[0062] In this example, the algorithm (greedy or matching method) used in the pairing method described in Figures 7 and 8 corresponds to the "first optimization algorithm" in this disclosure. The address pairs generated by combining the shipping addresses from the shipping address set and the storage addresses from the storage address set correspond to the "replacement address set" in this disclosure.

[0063] Returning to Figures 5 and 6, the sequence determination unit 63 then determines the swapping order for the two or more address pairs generated by the pairing (see Figure 6(D)). In this example, the swapping order from 1 to 4 is determined for four pairs of address pairs. Specifically, as indicated by arrows A1 to A11, the order of repositioning is determined such that the stacker crane 13 moves in the following order: starting point - 1st storage address (outbound) - 1st shipping address (outbound + inbound of goods from the 1st storage address) - 1st storage address (inbound of goods from the 1st shipping address) - 2nd storage address (outbound) - 2nd shipping address (outbound + inbound of goods from the 2nd storage address) - 2nd storage address (inbound of goods from the 2nd shipping address) - 3rd storage address (outbound) - 3rd shipping address (outbound + inbound of goods from the 3rd storage address) - 3rd storage address (inbound of goods from the 3rd shipping address) - 4th storage address (outbound) - 4th shipping address (outbound + inbound of goods from the 4th storage address) - 4th storage address (inbound of goods from the 4th shipping address) - ending point. In this example, outbound goods from storage addresses occur first, but outbound goods from shipping addresses may also occur first (not shown). The order in which the storage address and the shipping address are processed may be changed during the exchange. For example, the first exchange might be from the first storage address to the first shipping address and then to the first storage address, followed by the second shipping address, the second storage address, and the second shipping address. The following methods may be used to determine the exchange order.

[0064] Figure 9 is a schematic diagram illustrating the first example of order determination. In this first example of order determination, a greedy algorithm is used. The greedy algorithm is a method of determining which address pairs to move (replace loads) from among two or more address pairs, in order of shortest movement time for the stacker crane 13.

[0065] When determining the sequence, it is assumed that the "starting point," which is the position where the stacker crane 13 begins to move, and the "ending point," which is the position where the stacker crane 13 ends its movement, are predetermined. The stacker crane 13 starts from the starting point, sequentially performs swaps in two or more address pairs, and finally reaches the ending point. The starting point is preferably set within the shipping range 16, as shown in Figure 6(D), because it shortens the time required for swapping goods. However, the starting point may also be set at either the shipping rack 41 or the storage rack 42 outside the shipping range 16.

[0066] As shown in Figure 9(A), let's explain using an example where four address pairs (pairs 1-4) are generated by the aforementioned pairing. In this example, we assume that the travel time from the starting point to pair 1 is the shortest among pairs 1-4. In this case, the first movement from the starting point to pair 1 is determined (see Figure 9(B)). Next, among the remaining pairs 2-4, the travel time from pair 1 to pair 3 is the shortest. Therefore, the movement from pair 1 to pair 3 is determined (see Figure 9(C)). Similarly, among the remaining pairs 2 and 4 from pair 3, the travel time from pair 3 to pair 2 is shorter, so the movement from pair 3 to pair 2 is determined (see Figure 9(D)). This leaves pair 4, so the movement from pair 2 to pair 4 is determined (see Figure 9(E)). As a result, the sequence determination unit 63 determines the movement in the order of starting point-pair 1-pair 3-pair 2-pair 4-end point (see Figure 9(F)).

[0067] Figure 10 is a schematic diagram illustrating a second example of sequence determination. In this second example of sequence determination, the matching method is used. The matching method in sequence determination is an optimization technique that determines the sequence such that the total travel time, calculated by summing the travel time (corresponding to cost) of the stacker crane 13 for all paths, is minimized when passing through one or more address pairs between the start and end points. This method is also called the minimum cost flow problem.

[0068] D is the time it takes for the stacker crane 13 to move from one of the address pairs 1-4 to the other, with the starting point s and ending point g. kl(k=s,1~4, l=g,1~4) is used to denote the order determination unit 63 by applying a known algorithm for solving the minimum cost flow problem, thereby determining the five travel times D kl Determine the order that minimizes the sum (total travel time).

[0069] The algorithms used for order determination (greedy algorithm or matching algorithm) described in Figures 9 and 10 correspond to the "second optimization algorithm" in this disclosure.

[0070] Thus, in the twin-fork type shipping preparation process, in this example, by swapping the shipping racks 41 and storage racks 42 according to the 1-step mode, an arrangement in which the shipping racks 41 are concentrated in the shipping range 16 is achieved. In the example in Figure 6, initially, four shipping racks 41 were located outside the shipping range 16, but by swapping these four shipping racks 41 with four storage racks 42, these four shipping racks 41 move inside the shipping range 16 (see Figure 6(E)). As a result, a total of six shipping racks 41 are concentrated in the shipping range 16. This allows for the rapid shipment of the six packages in the shipping racks 41 concentrated in the shipping range 16 during the next shipment from the automated warehouse 1. Therefore, the time required for shipment from the automated warehouse 1 can be reduced.

[0071] By using the matching method, the total movement time of the stacker crane 13 during movement within or between address pairs can be reduced. On the other hand, generally, the computational complexity required to solve a problem using the matching method increases exponentially as the number of parameters to be matched increases. A typical automated warehouse 1 contains many more racks (addresses) than the simplified example described in Figures 6 to 10, so the computational complexity may be greater. In other words, the matching method may place an excessive computational load on the processor 21 of server 2. In contrast, the greedy method, while potentially resulting in a relatively longer total movement time for the stacker crane 13 compared to the matching method, does not require complex calculations. Therefore, it can reduce the computational load on the processor 21.

[0072] The pairing method and the ordering method can be combined in any way. For example, a greedy algorithm may be used for both pairing and ordering, or a matching algorithm may be used for both pairing and ordering. Alternatively, a greedy algorithm may be used for one of pairing or ordering, and a matching algorithm for the other.

[0073] <<Shipping preparation processing: Twin fork type + 2-step mode>> In the two-step mode, the empty rack 43 is used as a "transit" for goods to be exchanged between the shipping rack 41 and the storage rack 42. Therefore, the location of the empty rack 43 is also shown in Figure 11.

[0074] Figure 11 is a schematic diagram illustrating an example of the flow of the shipping preparation process in the twin-fork type 2-step mode. Referring to Figures 5 and 11, first, the address extraction unit 61 calculates the shipping address set and the storage address set based on the difference between the current placement and the target shipping placement (see Figures 11(A) and 11(B)). This process is the same as the process in the 1-step mode (see Figures 6(A) and 6(B)). In addition, in the 2-step mode, the address extraction unit 61 calculates the current empty address set.

[0075] In one-step mode, the pairing unit 621A of the one-step replacement unit 621 generates address pairs between the shipping address set and the storage address set, that is, between different address sets (see Figure 6(C)). In contrast, in two-step mode, as shown in Figure 11(C), the first pairing unit 622A of the two-step replacement unit 622 generates the same number of address pairs within the shipping address set and the storage address set, that is, within the same address set. In the example shown in Figure 11, each of the shipping address set and the storage address set contains four addresses. Therefore, two pairs P1 and P2 are generated within the storage address set, and two pairs P3 and P4 are generated within the shipping address set (first pairing). Pairs P1 and P2 correspond to the "storage address set" as per this disclosure, and pairs P3 and P4 correspond to the "shipping address set" as per this disclosure. A greedy method or a matching method may be used as the first pairing method. These methods have already been described in detail, so they will not be repeated here.

[0076] In this embodiment, since the stacker crane 13 is a twin-fork type capable of loading and unloading up to two items at once, an "address pair" containing two addresses is generated. However, if the stacker crane is capable of loading and unloading up to N items (where N is a natural number greater than or equal to 3) at once, a "storage address set" or "shipping address set" containing N addresses may be generated.

[0077] Furthermore, the second pairing unit 622B of the two-step replacement unit 622 generates additional pairs between address pairs belonging to the shipping address set and address pairs belonging to the storage address set, that is, between different address sets. What is generated is, so to speak, a pair of address pairs. In the example shown in Figure 11, a pair is generated between address pair P1 belonging to the storage address set and address pair P3 belonging to the shipping address set. In addition, a pair is generated between address pair P2 belonging to the storage address set and address pair P4 belonging to the shipping address set (second pairing).

[0078] Each of the address pairs P1, P2, P3, and P4 generated by the first pairing contains two addresses. The second pairing unit 622B preferably determines which of these two addresses to process first by considering the addresses of the other pair in the second pairing, in order to minimize the total travel time (total travel distance) of the stacker crane 13. For example, the decision of which of the two storage addresses in address pair P1 to process first is made by considering the two shipping addresses in address pair P3. A greedy method or a matching method can also be used as the second pairing method.

[0079] In this example, the pair of address pair P1 and address pair P3, and the pair of address pair P2 and address pair P4, each correspond to the "replacement address set" as defined in this disclosure. Furthermore, the pairing algorithm (greedy or matching method) used in the first and second pairings corresponds to the "first optimization algorithm" as defined in this disclosure.

[0080] In the 2-step mode, when exchanging packages between the shipping address set and the storage address set, two packages corresponding to a storage address pair released from the storage address set are relayed to an empty address set, and two packages corresponding to a shipping address pair released from the shipping address set are moved to the storage address set that became available through this relay. The relay unit 622C determines the empty addresses for relaying. These empty addresses for relaying are referred to as "relay addresses." Relay addresses may be located near the source storage address. Relay addresses may be located near the destination shipping address. Relay addresses may be located between the source storage address and the destination shipping address. That is, if a set whose elements are relay addresses is referred to as the "relay address set," it is desirable that the relay address set consists of empty addresses between a shipping address pair and a storage address pair, or empty addresses that are closer to the shipping address pair than a predetermined distance. This is to shorten the travel distance of the stacker crane 13.

[0081] Subsequently, the order determination unit 63 determines the swapping order for the paired address combinations (address pairs) and relay address sets shown in Figure 11(C) (see Figure 11(E)). A greedy algorithm is preferably used as the method for determining the swapping order.

[0082] In this example, we assume that the first address pair selected for replacement is the pair of address pairs P1 and P3. Consequently, two empty addresses E1 that are close to address pair P3 (the address closest to address pair P3 and the second closest address) are determined to be relay addresses.

[0083] It is assumed that the next address to be replaced will be the pair of address P2 and address P4 (a pair of address pairs). Consequently, for example, two empty addresses E2 that are close to address pair P4 will be determined as relay addresses.

[0084] As a result of this process, the following order is determined: address pair P1 - 2 empty addresses E1 - address pair P3 - address pair P2 - 2 empty addresses E2 - address pair P4. By moving the rack according to this order, the contents are rearranged as follows.

[0085] (1) Two packages that are not scheduled for shipment and are stored at address pair P1 are moved to two empty addresses E1. (2) The two packages scheduled for shipment that were stored at address pair P3 are moved to address pair P1, which became available as a result of (1) above. (3) Two packages that are not scheduled for shipment and are stored at address pair P2 are moved to two empty addresses E2. (4) The two shipments scheduled for delivery that were stored at address pair P2 are moved to address pair P4, which became available as a result of (3) above.

[0086] The algorithm used to determine the order of replacement (greedy algorithm) corresponds to the "second optimization algorithm" in this disclosure.

[0087] In this example, it was explained that the sequence determination unit 63 selects the swapping order—which of the two swapped address pairs (address pair P1, P3 and address pair P2, P4) to process first—and then determines the relay address. However, it can also be said that the relay address is ultimately determined by the positional relationship of the swapped address pairs (the storage address of the source and / or the shipping address of the destination). Therefore, after the second pairing is performed, the relay unit 622C may determine the relay address first, and then the sequence determination unit 63 may determine the swapping order.

[0088] Thus, in the twin-fork type shipping preparation process, in this example, the shipping rack 41 and storage rack 42 are swapped using the empty rack 43 as an intermediary according to the two-step mode, thereby achieving an arrangement where the shipping rack 41 is concentrated in the shipping range 16 (see Figure 11(F)). As a result, similar to the one-step mode (see Figure 6), the six packages in the shipping rack 41 that have been gathered in the shipping range 16 can be quickly shipped when shipping from the automated warehouse 1 next time. Therefore, the time required for shipping from the automated warehouse 1 can be reduced.

[0089] In this embodiment, an example of using empty racks as relay points has been described. However, other relay points may be provided instead of or in addition to empty racks. For example, dedicated relay shelves may be provided outside of storage shelves 111 and 112, or dedicated relay shelves may be provided inside storage shelves 111 and 112. Alternatively, the inbound / outbound station 12 may be used as a relay point.

[0090] <Preparation for incoming goods> In the receiving preparation process, automated warehouse 1 can select either "single mode," which moves packages one at a time, or "twin mode," which moves packages two at a time.

[0091] Figure 12 is a functional block diagram of the receiving preparation processing unit 7 in a twin-fork system. The receiving preparation processing unit 7, like the shipping preparation processing unit 6 (see Figure 5), includes an address extraction unit 71, a combination determination unit 72, and a sequence determination unit 73.

[0092] The address extraction unit 71 calculates a storage address set (which may also be a shipping address set) based on the difference between the current arrangement and the target receiving arrangement, and also calculates an empty address set in preparation for receiving goods when the automated warehouse 1 is next operational. The address extraction unit 71 outputs the calculated multiple address sets to the combination determination unit 72.

[0093] The combination determination unit 72 determines the combination of the stored address set (which may be the shipping address set) extracted by the address extraction unit 71 and the empty address set. The combination determination unit 72 includes a single mobile unit 721 corresponding to single mode and a twin mobile unit 722 corresponding to twin mode. Single mode and twin mode will be explained in detail in Figures 13 and 14, respectively. The combination determination unit 72 determines the address combination and outputs the determined combination to the sequence determination unit 73.

[0094] The sequence determination unit 73 determines the order in which the packages will be moved (movement order) based on the address combinations determined by the combination determination unit 72. The sequence determination unit 73 outputs the determined movement order, along with the address combinations determined by the combination determination unit 72, as incoming redistribution data to the operation management server 3 (see Figure 1).

[0095] <<Preparation for incoming shipment: Twin fork type + single mode>> Figure 13 is a schematic diagram illustrating an example of the flow of the receiving preparation process for a twin-fork single-mode system. In the receiving preparation process, only some of the empty racks belonging to the empty rack group are moved, not all of them. The movement of the empty racks is achieved by swapping empty rack 43 with either shipping rack 41 or storage rack 42 (only storage rack 42 in this example). In other words, by taking goods out of storage rack 42 and placing those goods into empty rack 43, a new empty rack is created in the original location of storage rack 42, and the original empty rack 43 becomes either shipping rack 41 or storage rack 42.

[0096] For more details, refer to Figures 12 and 13. First, the address extraction unit 71 determines which empty racks will remain in place based on the difference between the current arrangement and the target receiving arrangement, and then determines which other empty racks will be moved to be near the racks that will remain in place. The positions of the empty racks in the target receiving arrangement are determined according to predetermined criteria. For example, the positions of the empty racks may be determined so that they are distributed as evenly as possible among multiple racks (not concentrated in one place). Alternatively, the positions of the empty racks may be determined so that they are located as far away from the shipping arrangement 16 as possible.

[0097] Furthermore, the address extraction unit 71 calculates the "outbound address set" and the "inbound address set" based on the difference between the current arrangement and the target incoming arrangement (see Figures 13(A) and 13(B)). The outbound address set is the address set that indicates the location of all racks that are currently shipping racks 41 or storage racks 42 but will be emptied by outbound shipping. The inbound address set is the address set that indicates the location of all racks that are currently empty racks 43 but will no longer be empty (will become shipping racks 41 or storage racks 42) by inbound shipping. In this example, the outbound address set includes two storage addresses, and the inbound address set includes two empty addresses. Note that, in order to make the purpose of the incoming preparation process easier to understand, Figure 13(B) also shows the location of empty racks that will remain without moving (i.e., will not be inbound).

[0098] Next, the pairing 721A of the single mobile unit 721 generates address pairs between the outgoing address set and the incoming address set. If each address set contains two addresses, two address pairs (pairs P1, P2) are generated, each consisting of one stored address and one empty address (see Figure 13(C)). These two address pairs correspond to the "mobile address set" as described in this disclosure. A greedy algorithm or a matching algorithm may be used as the pairing method. The algorithm used for this pairing corresponds to the "third optimization algorithm" as described in this disclosure.

[0099] Subsequently, the order determination unit 73 determines the movement order for two or more address pairs generated by pairing (see Figure 13(D)). In this example, as indicated by arrows A1 to A3, the movement order is determined such that the stacker crane 13 moves in the following order: storage address (outbound) of pair P1 - empty address of pair P1 (inbound of goods from the storage address of pair P1) - storage address (outbound) of pair P2 - empty address of pair P2 (inbound of goods from the storage address of pair P2). A greedy method or a matching method may be used as the method for determining the movement order. The algorithm used for determining the movement order corresponds to the "fourth optimization algorithm" in this disclosure.

[0100] Thus, in the twin-fork receiving preparation process, in this example, by moving the goods stored in storage rack 42 one by one to empty rack 43 according to the single mode, a configuration is achieved where two empty racks 43 are adjacent to each other. In this example, three sets of two adjacent empty racks are realized (see Figure 13(E)). As a result, when receiving goods into the automated warehouse 1 next time, two goods can be placed into two adjacent empty racks in a single receiving operation. Therefore, the time required for receiving goods into the automated warehouse 1 can be reduced.

[0101] <<Preparation for incoming shipment: Twin fork type + twin mode>> Figure 14 is a schematic diagram illustrating an example of the flow of the receiving preparation process for a twin-fork type twin mode. Referring to Figures 12 and 14, first, the address extraction unit 71 calculates the outbound address set and the incoming address set by the difference between the current arrangement and the target receiving arrangement, similar to the single mode (see Figures 14(A) and 14(B)).

[0102] In single mode, the pairing unit 721A of the single mobile unit 721 generates address pairs between the outgoing address set and the incoming address set, that is, between different address sets (see Figure 13(C)). In contrast, in twin mode, the first pairing unit 722A of the twin mobile unit 722 generates the same number of address pairs within the outgoing address set and the incoming address set, that is, within the same address set, as shown in Figure 14(C) (first pairing). In this example, each of the outgoing address set and the incoming address set contains 4 addresses. Therefore, 2 pairs of address pairs are generated within the outgoing address set, and 2 pairs of address pairs are generated within the incoming address set. The 2 pairs of address pairs in the outgoing address set correspond to the "outgoing address set" according to this disclosure, and the 2 pairs of address pairs in the incoming address set correspond to the "incoming address set" according to this disclosure. A greedy method or a matching method may be used as the pairing method. The algorithm used for this pairing corresponds to the "third optimization algorithm" described in this disclosure.

[0103] Next, the second pairing unit 722B of the twin moving unit 722 generates further pairs between address pairs belonging to the outgoing address set and address pairs belonging to the incoming address set, that is, between different address sets (second pairing). In this example, two pairs (pairs of address pairs) are generated. These two pairs correspond to the "moving address set" as described in this disclosure. A greedy method or a matching method may be used as the pairing method. The algorithm used for this pairing also corresponds to the "third optimization algorithm" as described in this disclosure.

[0104] Subsequently, the sequence determination unit 73 determines the movement order for one or more pairs generated in the second pairing (see Figure 14(D)). In this example, the movement order is determined so that the stacker crane 13 moves in the order of arrows A1 to A7, specifically, in the order of starting point - 1st outbound address (outbound) - 2nd outbound address (outbound) - 1st inbound address (inbound) - 2nd inbound address (inbound) - 3rd outbound address (outbound) - 4th outbound address (outbound) - 3rd inbound address (inbound) - 4th inbound address (inbound) - ending point. Regarding which of the two addresses in the first pairing is processed first, the second pairing unit 622B preferably makes a decision considering the address of the other pair in the second pairing so as to minimize the total movement time (total movement distance) of the stacker crane 13. The second pairing unit 622B may determine the processing order for each pair of first paired addresses in order of decreasing total movement time for the stacker crane 13. A greedy algorithm or a matching algorithm may be used as the method for determining the movement order. The algorithm used for determining the movement order corresponds to the "fourth optimization algorithm" in this disclosure.

[0105] Thus, in the twin-fork receiving preparation process, in this example, by moving two items at a time from the storage rack 42 to the empty rack 43 according to the twin mode, a configuration is achieved where the two empty racks are adjacent to each other. As a result, similar to the single mode (see Figure 13), when receiving goods into the automated warehouse 1 next time, two items can be placed into two adjacent empty racks in a single receiving operation. Therefore, the time required for receiving goods into the automated warehouse 1 can be reduced.

[0106] <Processing Flow> ≪Overall Flow≫ Figure 15 is a flowchart showing the overall processing flow in a twin-fork system. The processing shown in this flowchart is called and executed from a main routine (not shown) when predetermined conditions are met (for example, at predetermined intervals). Each step is implemented by software processing by Server 2 (Processor 21), but may also be implemented by hardware (electrical circuits) located within Server 2. Hereinafter, steps will be abbreviated as S.

[0107] In S1, Server 2 determines whether the rack replacement condition has been met. The rack replacement condition is met, for example, when a predetermined time (typically a specified time during the late-night period) arrives. If the rack replacement condition has not been met (NO in S1), Server 2 returns processing to the main routine. If the rack replacement condition has been met (YES in S1), Server 2 proceeds processing to S2.

[0108] In S2, Server 2 determines the result of the selection of the process to be executed. For example, the process to be executed is selected based on user operation to Server 2 (input device 24). If the user selects only the shipping preparation process (first operation in S2), Server 2 executes only the shipping preparation process (S3). If the user selects only the receiving preparation process (second operation in S2), Server 2 executes only the receiving preparation process (S4). If the user selects both the shipping preparation process and the receiving preparation process (third operation in S2), Server 2 executes the shipping preparation process (S3), followed by the receiving preparation process (S4).

[0109] Thus, Server 2 only needs to be configured to be able to perform at least one of the shipping preparation process and the receiving preparation process. Server 2 may also be configured to be able to perform only one of the shipping preparation process and the receiving preparation process, and not be able to perform the other.

[0110] Server 2 can also execute the receiving preparation process (S4) before the shipping preparation process (S3). However, in the shipping preparation process, as explained in the two-step mode (see Figure 11), the arrangement of empty racks may change as shipping racks and storage racks are swapped. Therefore, if the receiving preparation process is executed first, the subsequent shipping preparation process may disrupt the arrangement of adjacent empty racks. In that case, it may be necessary to execute the receiving preparation process again. By executing the shipping preparation process (S3) first, and then executing the receiving preparation process (S4) after the arrangement of empty racks has been determined, the process is simplified. Therefore, the processing time for rack rearrangement can be shortened.

[0111] <<Shipping preparation processing: Twin fork type>> Figure 16 is a flowchart showing the flow of the shipping preparation process (S3) in a twin-fork system. In S301, Server 2 obtains the current arrangement (the current arrangement of shipping racks 41, storage racks 42, and empty racks 43) from the automated warehouse 1 or the operation management server 3.

[0112] In S302, Server 2 obtains a predetermined target shipping arrangement (the arrangement of shipping racks 41 and storage racks 42 suitable for shipping during the next operation of automated warehouse 1) from the operation management server 3. Note that the order of S301 and S302 can be changed.

[0113] In S303, Server 2 extracts an address set (shipping address set, storage address set, and empty address set) that indicates the location of the racks that need to be replaced in order to change from the current configuration to the target shipping configuration, based on the difference between the current configuration and the target shipping configuration.

[0114] In S304, Server 2 determines which mode, 1-step mode or 2-step mode, has been selected by the user. Either mode may always be selected regardless of user selection. Alternatively, only one mode may exist.

[0115] If one-step mode is selected (one-step mode in S304), server 2 proceeds to S305 to generate one or more address pairs between the shipping address set and the storage address set. Either a greedy algorithm or a matching algorithm can be used for this process.

[0116] In S306, Server 2 determines the swapping order based on one or more address pairs generated in S305, such that one shipping address and one storage address alternate. Both greedy and matching algorithms can be used for this process. After that, Server 2 proceeds to S311.

[0117] On the other hand, if the two-step mode is selected (two-step mode in S304), Server 2 proceeds to S307, generating one or more pairs within the shipping address set and the same number of pairs within the storage address set. Then, Server 2 further generates pairs of address pairs belonging to the shipping address set and address pairs belonging to the storage address set (S308). Both greedy and matching algorithms can be used for this process.

[0118] In S309, Server 2 determines a set of relay addresses (two or more relay addresses) to be used for relaying between the storage address set and the shipping address set.

[0119] In S310, Server 2 determines the swapping order such that two relay addresses are placed between two storage addresses and two shipping addresses. It is preferable to use a greedy algorithm for this process. After that, Server 2 proceeds to S311.

[0120] In S311, Server 2 outputs shipment relocation data to Operation Management Server 3, which shows two or more pairs determined in S306 or S310, and the replacement order within those pairs. As a result, the shipment relocation data is output from Operation Management Server 3 to Automated Warehouse 1 at the appropriate time, and rack relocation is performed in Automated Warehouse 1 based on the shipment relocation data.

[0121] <<Preparation for incoming shipment: Twin fork type>> Figure 17 is a flowchart showing the flow of the receiving preparation process (S4) in a twin-fork system. The processes in S401 and S402 are basically the same as the processes in S301 and S302 in the shipping preparation process.

[0122] In S403, Server 2 calculates the difference between the current arrangement and the target shipping arrangement, and determines the locations of empty racks to be maintained without moving, according to predetermined criteria. Server 2 then extracts a set of addresses (outbound address set, inbound address set, and empty address set) indicating the locations of racks that need to be moved in order to change from the current arrangement to the target receiving arrangement.

[0123] In S404, Server 2 determines which mode, single mode or twin mode, has been selected by the user. Either mode may always be selected regardless of user choice. Alternatively, only one mode may exist.

[0124] If single mode is selected (single mode in S404), server 2 proceeds to S405, generating one or more address pairs between the outgoing address set (shipping address set and / or storage address set) and the incoming address set (empty address set). Both greedy and matching algorithms can be used for this process.

[0125] In S406, Server 2 determines the order of movement based on one or more address pairs generated in S405, such that one outgoing address and one incoming address alternate. Server 2 then proceeds to S410. Both greedy and matching algorithms can be used in this process.

[0126] On the other hand, if twin mode is selected (twin mode in S404), server 2 proceeds to S407, generating one or more address pairs in the outgoing address set and the same number of pairs in the incoming address set. Then, server 2 further generates pairs of address pairs belonging to the outgoing address set and address pairs belonging to the incoming address set (S408). Both greedy and matching algorithms can be used for these processes.

[0127] In S409, Server 2 determines the replacement order based on the address pairs generated in S408, such that two stored addresses and two empty addresses alternate. After that, Server 2 proceeds to S410.

[0128] In S410, Server 2 outputs incoming goods relocation data to Operation Management Server 3, which shows two or more pairs determined in S406 or S409, and the movement order of those pairs. As a result, the incoming goods relocation data is output from Operation Management Server 3 to Automated Warehouse 1 at the appropriate time, and rack relocation is performed in Automated Warehouse 1 based on the incoming goods relocation data.

[0129] <Effectiveness Verification> Figure 18 shows an example of the results of verifying the effect of reducing processing time for rack rearrangement. The processing time for rack rearrangement (hereinafter abbreviated as "rearrangement processing time") is the total processing time by Server 2 required to perform the shipping preparation process (2-step mode) followed by the receiving preparation process (twin mode) (see the third operation in the flowchart of Figure 15).

[0130] The rearrangement processing time was measured using either a greedy method or a matching method, and for comparison, the rearrangement processing time was also measured using a sequential method. More specifically, the greedy method in Figure 18 is one in which a greedy method is used for pairing and ordering in the shipping preparation process, and also for pairing and ordering in the receiving preparation process. The matching method in Figure 18 is one in which a greedy method is used for pairing and ordering in the shipping preparation process, while the matching method is used for pairing and ordering in the receiving preparation process. The sequential method in Figure 18 is a method that simply searches for items to be replaced and moved sequentially from the ends of storage shelves 111 and 112 and moves the racks.

[0131] In the sequential method, the shipping preparation process is a one-step mode process that does not involve optimal pairing or order determination, and specifically consists of the following processes (1) to (3). (1) Repeatedly perform a rack search starting from the bottom left of the storage shelf. A rack search involves (a) moving the leftmost row from bottom to top in the row direction (Z direction), (b) moving one row to the right (the second row from the left) in the row direction (Y direction), and (c) moving the second row from the left from bottom to top in the row direction. (2) Generate pairs of shipping addresses and storage addresses within the shipping range in the order they are found by the rack search in (1). (3) The shipping address and storage address are swapped in the order in which the pairs were generated.

[0132] In the sequential method, the incoming preparation process is a twin-mode process that does not involve optimal pairing or order determination, and more specifically, it is the following processes (4) to (6). (4) Repeat the rack search in the same manner as in (1) above. (5)(4) In the order found by the search, pairs are generated of storage addresses to be taken out and made into empty racks (outbound addresses) and empty addresses to be received and made into storage racks (receiving addresses). (6) Swap the outgoing address and incoming address in the order in which the pairs were generated.

[0133] The left vertical axis represents the relocation processing time. The right vertical axis represents the improvement rate relative to the sequential method (the ratio of the relocation processing time shortened by each method compared to the sequential method). In this verification, the improvement rate compared to the sequential method was approximately 26% regardless of whether the greedy algorithm or the matching algorithm was used. In other words, a time reduction effect of approximately 26% was confirmed.

[0134] As described above, in Embodiment 1, shipping preparation processing and / or receiving preparation processing are performed. In the shipping preparation processing, rack rearrangement is performed from the current arrangement to a given target shipping arrangement by swapping two or more shipping racks 41 with two or more storage racks 42. In the target shipping arrangement, since the shipping racks 41 are gathered in the shipping range 16, goods can be shipped quickly when shipping from the automated warehouse 1 next time. In addition, in the receiving preparation processing, rack rearrangement is performed from the current arrangement to a given target receiving arrangement by swapping two or more storage racks with two or more empty racks. In the target receiving arrangement, since two empty racks 43 are arranged next to each other, goods can be received quickly when receiving goods from the automated warehouse 1 next time.

[0135] In the shipping preparation process, the following steps are performed: acquisition of the layout, extraction of addresses, determination of replacement address pairs, and determination of the replacement order. This reduces the processing time required for rearranging racks from the current layout to the target shipping layout. Similarly, in the receiving preparation process, the following steps are performed: acquisition of the layout, extraction of addresses, determination of move address pairs, and determination of the move order. This also reduces the processing time required for rearranging racks from the current layout to the target receiving layout. Therefore, according to Embodiment 1, the processing time required for rack rearrangement can be reduced.

[0136] Depending on the stacker crane 13, a misalignment may occur in the stopping position of the stacker crane 13 relative to the storage racks 111 and 112. As a result of this misalignment, when the cargo handling unit 15 places the cargo into the first rack, an error occurs in the position of the cargo. Furthermore, when the cargo handling unit 15 takes the cargo out of the first rack and places it into the second rack, an error occurs in the position of the cargo as well. As these errors accumulate, there is a possibility that the cargo will be placed in the second rack at a position significantly off from the appropriate position (in the worst case, the cargo may not be able to be placed in the second rack at all).

[0137] In contrast, the loading / unloading station 12 has a position correction function. More specifically, the loading / unloading station 12 includes a positioning mechanism (not shown) for the stopping position of the stacker crane 13. In addition, the loading / unloading station 12 includes a mechanism (not shown) for placing the cargo at the correct position on the cargo handling section 15 when moving from the loading / unloading station 12 to the cargo handling section 15.

[0138] Therefore, although not shown in the diagram, it is preferable that the server 2 determines the movement path of the cargo handling unit 15 so that it passes through the loading / unloading station 12 between the time a load is unloaded from one rack to another during the rack rearrangement process in the shipping preparation and receiving preparation processes. This is because by unloading the load from the cargo handling unit 15 to the loading / unloading station 12 and then loading the load back onto the cargo handling unit 15 from the loading / unloading station 12, the position correction function of the loading / unloading station 12 is activated, reducing (canceling) the position error of the load relative to the cargo handling unit 15. Note that components other than the loading / unloading station 12 in the automated warehouse unit 1 (position correction unit not shown) may also have a position correction function. In that case, the server 2 only needs to determine the movement path of the cargo handling unit 15 so that it passes through the position correction unit.

[0139] [Embodiment 2] Embodiment 1 described a configuration in which the stacker crane 13 is of the twin-fork type. Embodiment 2 describes a configuration in which the stacker crane 13 is of the single-fork type, which loads and unloads goods one by one. The overall configuration of the warehouse system according to Embodiment 2 is equivalent to the overall configuration of the warehouse system 100 according to Embodiment 1 (see Figures 1 to 3), so the explanation will not be repeated.

[0140] <Preparation for shipment> Figure 19 is a functional block diagram of the shipping preparation processing unit in a single-fork system. The shipping preparation processing unit 8 shown in Figure 19 includes an address extraction unit 81, a combination determination unit 82, and a sequence determination unit 83, similar to the shipping preparation processing unit 6 in a twin-fork system (see Figure 5). The address extraction unit 81 has the same function as the address extraction unit 61 in a twin-fork system.

[0141] The combination determination unit 82 differs from the combination determination unit 62 in the twin-fork type (see Figure 5) in that it does not include a one-step swapping unit and includes only a two-step swapping unit 822. The two-step swapping unit 822 includes a pairing unit 822A and a relay unit 822B. The pairing unit 822A generates address pairs between the shipping address set and the storage address set. The relay unit 822B determines a relay address set (two or more empty addresses) to be used for relaying between the storage address set and the shipping address set. The combination determination unit 82 determines the address combinations and outputs the determined combinations to the sequence determination unit 63.

[0142] The sequence determination unit 83 determines the replacement order for the address combinations (address pairs) determined by the combination determination unit 82. The sequence determination unit 83 outputs the determined replacement order, along with the address combinations determined by the combination determination unit 82, to the operation management server 3 (see Figure 1) as shipment relocation data.

[0143] Figure 20 is a schematic diagram illustrating an example of the flow of the shipping preparation process for a single-fork system. Figure 20 is shown in comparison with Figure 11, which illustrates the twin-fork system. Referring to Figures 19 and 20, the address extraction unit 81 first calculates the shipping address set and the storage address set based on the difference between the current arrangement and the target shipping arrangement (see Figures 20(A) and 20(B)). This process is the same as the process in the twin-fork system (see Figures 11(A) and 11(B)).

[0144] The pairing method differs between the single-fork (two-step mode) and the twin-fork two-step mode. In the twin-fork two-step mode, as explained in Figure 11(C), address pairs are generated between the same address sets, and then pairs of address pairs are generated between different address sets. In contrast, in the single-fork two-step mode, address pairs are generated between different address sets from the beginning (see Figure 20(C)). In this example, the pairing unit 822A of the two-step replacement unit 822 generates four pairs of address pairs between the shipping address set and the storage address set. A greedy method or a matching method may be used as the pairing method. This pairing method corresponds to the "first optimization algorithm" in this disclosure. In this example, each of the address pairs generated here corresponds to the "replacement address set" in this disclosure.

[0145] Next, the relay unit 822B of the two-step replacement unit 822 determines a set of relay addresses indicating the location of the empty rack 43 at the relay destination (see Figure 20(D)). Each relay address belonging to the relay address set may be located near the storage address set (address of the storage rack 42 from which the item was moved) or near the shipping address set (address of the shipping rack 41 to which the item was moved). Each relay address may be located between the storage address set and the shipping address set. In addition, as any shipping rack 41 moves to the shipping range 16, that shipping rack 41 becomes a new empty rack 43. Therefore, the address of the original shipping rack 41 may be determined as the relay address.

[0146] Subsequently, the sequence determination unit 83 determines the swapping order for the paired address pairs shown in Figure 20(C) (see Figure 20(E)). In this example, the swapping order is in the order of arrows A1 to A8. Note that, to avoid making the diagrams complicated, the movement of the cargo handling unit 15 when no cargo is being moved is not shown. It is preferable to use a greedy method for determining the swapping order. This method for determining the swapping order corresponds to the "second optimization algorithm" in this disclosure.

[0147] Thus, in the single-fork type (2-step mode) shipping preparation process, similar to the twin-fork type 2-step mode, one shipping rack 41 and one storage rack 42 are swapped with one empty rack 43 as an intermediary, thereby achieving an arrangement where the shipping racks 41 are concentrated in the shipping range 16 (see Figure 20(F)). As a result, similar to the twin-fork type, the six packages in the shipping racks 41 that have been gathered in the shipping range 16 can be quickly shipped when shipping from the automated warehouse 1 next time. Therefore, the time required for shipping from the automated warehouse 1 can be reduced.

[0148] <Preparation for incoming goods> Figure 21 is a functional block diagram of the receiving preparation processing unit 9 in a single-fork system. The receiving preparation processing unit 9 includes an address extraction unit 91, a combination determination unit 92, and a sequence determination unit 93, similar to the receiving preparation processing unit 7 in a twin-fork system (see Figure 12). The address extraction unit 91 has the same function as the address extraction unit 71 in a twin-fork system.

[0149] The combination determination unit 92 differs from the combination determination unit 72 in the twin-fork type (see Figure 12) in that it does not include a twin-movement unit and includes only a single-movement unit 921. The single-movement unit 921 includes a pairing unit 921A. The pairing unit 921A generates address pairs between an outbound address set indicating the location of all racks to be emptied by outbound shipment (shipping racks 41 or storage racks 42) and an inbound address set indicating the location of all racks to be no longer emptied by inbound shipment (to become storage racks) (empty racks 43). In this example, each of the address pairs generated here corresponds to a "movement address set" according to this disclosure. The combination determination unit 92 determines the address combinations (address pairs) and outputs the determined combinations to the sequence determination unit 93.

[0150] The sequence determination unit 93 determines the replacement order for the address combinations (address pairs) determined by the combination determination unit 92. The sequence determination unit 93 outputs the determined replacement order, along with the address combinations determined by the combination determination unit 92, as incoming redistribution data to the operation management server 3 (see Figure 1).

[0151] Figure 22 is a schematic diagram illustrating an example of the receiving preparation process for a single-fork type system. This process is similar to the receiving preparation process for a twin-fork type system in single mode (see Figure 13), so a detailed explanation will not be repeated. In the target receiving arrangement shown in Figure 22, two empty racks 43 are adjacent to each other, but the empty racks 43 may be arranged separately. This is because, since only one package can be received at a time in a single-fork type system, whether the empty racks 43 are adjacent or scattered does not significantly affect receiving efficiency (receiving time reduction efficiency).

[0152] <Processing Flow> The flowchart showing the overall processing flow in a single-fork system is the same as the flowchart showing the overall processing flow in a twin-fork system (see Figure 15). Below, we will explain each process in the single-fork system: the shipping preparation process (1-step mode) and the receiving preparation process (single mode).

[0153] <<Preparing for shipment: Single forklift type>> Figure 23 is a flowchart showing the flow of the shipping preparation process in a single-forklift system. Referring to Figures 1 and 23, the processes from S501 to S503 are the same as the processes from S301 to S303 in the shipping preparation process in a single-forklift system (see Figure 16).

[0154] In S304, Server 2 determines whether the user has selected one-step mode or two-step mode. However, since only two-step mode is available in a single-fork configuration, one-step mode may be unavailable to the user. Server 2 may also automatically select two-step mode.

[0155] If two-step mode is selected (two-step mode in S504), server 2 proceeds to S505 to generate one or more address pairs between the shipping address set and the storage address set. Either a greedy algorithm or a matching algorithm can be used for this process.

[0156] In S506, Server 2 determines one or more empty addresses (a set of relay addresses) to be used as relays between the storage address and the shipping address.

[0157] In S507, Server 2 determines the swapping order such that one relay address is placed between one storage address and one shipping address. It is preferable to use a greedy algorithm for this process.

[0158] In S508, Server 2 outputs shipment relocation data to Operation Management Server 3, which indicates two or more address pairs and the swapping order within those two or more address pairs. As a result, the shipment relocation data is output from Operation Management Server 3 to Automated Warehouse 1 at the appropriate time, and rack relocation is performed in Automated Warehouse 1 based on the shipment relocation data.

[0159] <<Preparing for shipment: Single fork type>> Figure 24 is a flowchart showing the flow of the receiving preparation process in a single-forklift system. The processes from S601 to S607 are the same as the processes when single mode is selected for receiving preparation in a single-forklift system (see S401 to S406 and S410 in Figure 17), so a detailed explanation will not be repeated.

[0160] As described above, in Embodiment 2 relating to the single-fork type, the shipping preparation process and / or receiving preparation process are performed, similar to Embodiment 1 relating to the twin-fork type. In the shipping preparation process, one or more shipping racks 41 and one or more storage racks 42 are swapped to rearrange the racks from the current configuration to a given target shipping configuration. In the target shipping configuration, the shipping racks 41 are gathered in the shipping range 16, so that goods can be shipped quickly the next time they are shipped from the automated warehouse 1. In addition, in the receiving preparation process, one or more storage racks 42 and one or more empty racks 43 are swapped to rearrange the racks from the current configuration to a given target receiving configuration. Since the shipping preparation process or receiving preparation process is also performed in Embodiment 2, the processing time for rearranging racks from the current configuration to a target shipping configuration or target receiving configuration can be shortened, similar to Embodiment 1.

[0161] [Modified version of Embodiment 2] Embodiments 1 and 2 described a configuration in which goods are loaded and unloaded into a three-dimensional automated warehouse 1 (storage section 11) using a stacker crane 13. However, the "automated warehouse" in this disclosure is not limited to a three-dimensional one. A modified example of Embodiment 2 describes a configuration in which goods are loaded and unloaded into a two-dimensional automated warehouse. The overall configuration of the warehouse system in this modified example is equivalent to the overall configuration of the warehouse system 100 in Embodiments 1 and 2 (see Figure 1).

[0162] Figure 25 is a schematic diagram showing the configuration of an automated warehouse and the flow of the shipping preparation process in a modified warehouse system according to Embodiment 2. In this modified version, instead of the stacker crane 13 (see Figure 2), for example, two flat conveyors 17 (indicated as A and B in the figure) are used. The two flat conveyors 17 travel in the aisles of the automated warehouse, avoiding collisions with each other, and in this example, they transport goods to one of the three exit ports 18. Each flat conveyor 17 may be an automated guided forklift (AGF) or a shuttle cart.

[0163] The flat conveyor 17 corresponds to the "conveying unit" in this disclosure. As shown in Figure 25, the automated warehouse may be a warehouse in which the movement path of the "conveying unit" is limited. The outlet 18 corresponds to the "inbound / outbound unit" in this disclosure.

[0164] The flat conveyor 17 handles items one by one. Therefore, the server 2 can perform the shipping preparation process in the same way as the single-fork type stacker crane 13. The single-fork type shipping preparation processing unit has been explained in detail in Figures 19, 20, and 23, so it will not be explained again here. The time required for shipping from the automated warehouse can also be reduced by modifications of Embodiment 2. In addition, the processing time for rearranging racks from the current arrangement to the target shipping arrangement can be reduced.

[0165] The embodiments disclosed herein should be considered in all respects to be illustrative and not restrictive. The scope of this disclosure is indicated by the claims rather than by the description of the embodiments above, and all modifications within the meaning and scope equivalent to the claims are intended to be included. [Explanation of Symbols]

[0166] 100 Warehouse system, 1 Automated warehouse, 2 Server, 3 Operation management server, 6 Shipping preparation processing unit, 7 Receiving preparation processing unit, 8 Shipping preparation processing unit, 9 Receiving preparation processing unit, 11 Storage unit, 12 Inbound / Outbound station, 13 Stacker crane, 14 Mobile unit, 15 Cargo handling unit, 16 Shipping range, 17 Flat conveyor, 18 Outbound port, 21 Processor, 22 Memory, 23 Storage, 24 Input device, 25 Display, 26 Network controller, 27 Bus, 41 Shipping rack, 42 ​​Storage rack, 43 Empty rack, 51 Target shipping placement acquisition unit, 52 Target receiving placement acquisition unit, 53 Current placement acquisition unit, 61 Address extraction unit, 62 Combination determination unit, 63 Sequence determination unit, 71 Address extraction unit, 72 Combination determination unit, 73 Sequence determination unit, 81 Address extraction unit, 82 Combination determination unit, 83 Sequence determination unit, 91 Address extraction unit, 92 93 Combination determination unit, 111 Order determination unit, 112 Storage shelf, 141 Horizontal movement device, 142 Guide member, 143 Lifting device, 231 Program, 232 Management information, 621 1-step swapping unit, 621A Pairing unit, 622 2-step swapping unit, 622A First pairing unit, 622B Second pairing unit, 622C Relay unit, 721 Single movement unit, 722 Twin movement unit, 822 2-step swapping unit, 822A Pairing unit, 822B Relay unit, 921 Single movement unit, 921A Pairing unit.

Claims

1. It is a warehouse system, The automated warehouse includes multiple racks, an inbound / outbound section, and a transport section for transporting goods between the multiple racks and the inbound / outbound section, and is configured to perform inbound / outbound operations automatically. The aforementioned multiple racks are The aforementioned automated warehouse consists of a group of shipping racks, each storing goods scheduled for shipment to the outside, The aforementioned automated warehouse consists of a group of storage racks, each containing goods that are not scheduled for shipment outside the warehouse, This includes empty racks where no luggage is stored, The warehouse system further includes a management device that, during periods when the automated warehouse is not performing pre-entry and dispatch operations, performs at least one of the following: a dispatch preparation process for dispatching goods to the outside of the automated warehouse, and an inbound preparation process for receiving goods from the outside of the automated warehouse. The aforementioned shipping preparation process is: A process for obtaining the current arrangement of the aforementioned multiple racks and a predetermined target shipping arrangement, Based on the difference between the current arrangement and the target shipping arrangement, the process extracts a set of shipping addresses indicating the location of shipping racks to which goods will be moved from the shipping rack group to the storage rack group, and also extracts a set of storage addresses indicating the location of storage racks to which goods will be moved from the storage rack group to the shipping rack group. A process for generating multiple swap address sets according to a first optimization algorithm for swapping packages between the aforementioned shipping address set and the aforementioned storage address set, The process includes determining the order in which packages are swapped in the aforementioned set of swapped address sets according to a second optimization algorithm. The aforementioned preparation process for receiving goods is as follows: The process involves obtaining the current arrangement and a predetermined target arrival arrangement. Based on the difference between the current arrangement and the target receiving arrangement, the process extracts a set of outbound addresses indicating the locations of the outbound racks or storage racks in the outbound rack group or storage rack group that will be emptied by outbound shipments, and extracts a set of inbound addresses indicating the locations of the racks in the empty rack group that will no longer be emptied by inbound shipments. A process for generating multiple movement address sets for moving goods between the outbound address set and the inbound address set according to a third optimization algorithm, A warehouse system comprising a process for determining the order of movement in the plurality of movement address sets according to a fourth optimization algorithm.

2. The aforementioned loading / unloading unit is configured to handle a maximum of N (where N is a natural number of 2 or more) packages for each loading / unloading operation. The aforementioned target shipping arrangement is an arrangement for gathering multiple packages scheduled for shipment into a predetermined shipping area. The warehouse system according to claim 1, wherein the target receiving arrangement is an arrangement in which N racks belonging to the empty rack group are adjacent to each other.

3. The warehouse system according to claim 2, wherein the process of determining the order of goods to be changed in the shipping preparation process includes a process of determining the order of goods to be changed so that the starting point for starting the change of goods to be changed is set within the predetermined shipping range.

4. The warehouse system according to claim 2, wherein the generation process in the shipping preparation process includes a process for generating the plurality of replacement address sets by combining one or more shipping addresses belonging to the shipping address set and one or more storage addresses belonging to the storage address set.

5. The first optimization algorithm is a greedy algorithm or a matching algorithm, The warehouse system according to claim 4, wherein the second optimization algorithm is a greedy algorithm or a matching algorithm.

6. The process to be generated in the aforementioned shipping preparation process is: A process to generate a shipping address set within the aforementioned shipping address set, and a process to generate a storage address set within the aforementioned storage address set, The process includes generating a plurality of replacement address sets by further generating sets between the shipping address set and the storage address set, The warehouse system according to claim 2, wherein the shipping preparation process further includes a process of determining a relay address set indicating the location of racks in the empty rack group to be used for relaying, so as to relay two or more packages released from the storage address set to the empty rack group when exchanging packages between the shipping address set and the storage address set, and move two or more packages released from the shipping address set to the storage address set that have become vacant as a result of the relay.

7. The warehouse system according to claim 6, wherein the process for determining the relay address set includes determining the relay address set such that it includes addresses between the shipping address set and the storage address set in the plurality of replacement address sets, or addresses within the plurality of replacement address sets that are closer to the shipping address set than a predetermined distance.

8. The warehouse system according to claim 6, wherein the management device performs the shipping preparation process, and subsequently performs the receiving preparation process.

9. The first optimization algorithm is a greedy algorithm or a matching algorithm, The warehouse system according to any one of claims 6 to 8, wherein the second optimization algorithm is a greedy algorithm.

10. The warehouse system according to claim 2, wherein the generation process in the incoming preparation process includes a process for generating a plurality of moving address sets by combining one or more outgoing addresses belonging to the outgoing address set and the same number of incoming addresses belonging to the incoming address set.

11. The third optimization algorithm is a greedy algorithm or a matching algorithm. The warehouse system according to claim 10, wherein the fourth optimization algorithm is a greedy algorithm or a matching algorithm.

12. The process to be generated in the aforementioned preparation process for incoming goods is: The process involves generating an outgoing address set within the outgoing address set and generating an incoming address set within the incoming address set, The warehouse system according to claim 2, further comprising the process of generating a plurality of movement address sets by generating sets between the outbound address set and the inbound address set.

13. The third optimization algorithm is a greedy algorithm or a matching algorithm. The warehouse system according to claim 12, wherein the fourth optimization algorithm is a greedy algorithm or a matching algorithm.

14. The aforementioned loading and unloading section is a single-fork type that loads and unloads packages one at a time. The warehouse system according to claim 1, wherein the target shipping arrangement is an arrangement for gathering multiple packages scheduled for shipment into a predetermined shipping range.

15. The warehouse system according to claim 14, wherein the process of determining the order of shipments in the shipment preparation process includes a process of determining the order of shipments such that the starting point for starting the shipment exchange is included in the predetermined shipment range.

16. The process to be generated in the aforementioned shipping preparation process is: A process to generate a shipping address set within the aforementioned shipping address set, and a process to generate a storage address set within the aforementioned storage address set, The process includes generating a plurality of replacement address sets by further generating sets between the aforementioned shipping address set and the aforementioned storage address set, The warehouse system according to claim 14, wherein the shipping preparation process further includes a process of determining a relay address set indicating the location of racks among the empty rack group to be used for relaying, so as to relay goods dispatched from the storage address set to the empty rack group and move goods dispatched from the shipping address set to the storage address set that have become available as a result of the relay.

17. The warehouse system according to claim 16, wherein the process for determining the relay address set includes determining the relay address set such that it includes addresses between the shipping address set and the storage address set in the plurality of replacement address sets, or addresses within the plurality of replacement address sets that are closer to the shipping address set than a predetermined distance.

18. The warehouse system according to claim 16, wherein the management device performs the shipping preparation process, and subsequently performs the receiving preparation process.

19. The first optimization algorithm is a greedy algorithm, The warehouse system according to any one of claims 16 to 18, wherein the second optimization algorithm is a greedy algorithm.

20. The warehouse system according to claim 14, wherein the generation process in the incoming preparation process includes a process for generating a plurality of moving address sets by combining one or more outgoing addresses belonging to the outgoing address set and the same number of incoming addresses belonging to the incoming address set.

21. The third optimization algorithm is a greedy algorithm or a matching algorithm. The warehouse system according to claim 20, wherein the fourth optimization algorithm is a greedy algorithm or a matching algorithm.

22. An information processing method performed by a processor to determine the arrangement of goods in an automated warehouse, The aforementioned automated warehouse is configured to automatically perform loading and unloading operations by using a transport unit that transports goods between multiple racks and loading / unloading units. The aforementioned multiple racks are A group of shipping racks, each containing shipments scheduled for external delivery to the aforementioned automated warehouse, The aforementioned automated warehouse consists of a group of storage racks, each containing goods that are not scheduled for shipment outside the warehouse, This includes empty racks where no luggage is stored, The information processing method includes the step of performing at least one of the following during a period when the automated warehouse is not performing pre-entry and dispatch operations: a dispatch preparation process for dispatching goods to the outside of the automated warehouse and a receiving preparation process for receiving goods from the outside of the automated warehouse. The step of performing the aforementioned shipping preparation process is: The steps include obtaining the current arrangement of the aforementioned multiple racks and a predetermined target shipping arrangement, Based on the difference between the current arrangement and the target shipping arrangement, the steps include: extracting a set of shipping addresses indicating the location of shipping racks to which goods will be moved from the shipping rack group to the storage rack group, and extracting a set of storage addresses indicating the location of storage racks to which goods will be moved from the storage rack group to the shipping rack group; The steps include generating a plurality of swap address sets according to a first optimization algorithm for swapping packages between the aforementioned shipping address set and the aforementioned storage address set, The step includes determining the order in which packages are swapped in the plurality of swap address sets according to a second optimization algorithm, The step of performing the aforementioned preparation process for incoming goods is: The steps include obtaining the current arrangement and a predetermined target arrival arrangement, Based on the difference between the current arrangement and the target receiving arrangement, the steps include: extracting a set of outbound addresses indicating the locations of the outbound racks or storage racks in the outbound rack group or storage rack group that will be emptied by outbound shipments, and extracting a set of inbound addresses indicating the locations of the racks in the empty rack group that will no longer be emptied by inbound shipments; The steps include generating a plurality of movement address sets for moving goods between the outbound address set and the inbound address set according to a third optimization algorithm, An information processing method comprising the step of determining the order of movement in the plurality of move address sets according to a fourth optimization algorithm.

23. A program for causing the processor to execute the information processing method described in claim 22.

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