Automated warehouse

Abstract

We provide an automated warehouse that can improve storage efficiency. [Solution] The automated warehouse 1 comprises a frame 4 arranged vertically with a gap between it and the floor surface F, a rack 3 arranged on the frame 4 and capable of storing cargo T, a horizontal travel rail 10 arranged adjacent to the rack 3 and extending horizontally, a lifting rail 20 extending vertically both within the rack 3 and at least near the floor surface F, and a transport cart 30 that rotates and travels horizontally on the floor surface F, travels horizontally on the horizontal travel rail 10, and rises and falls on the lifting rail 20.

Description

Technical Field

[0001] This disclosure relates to an automated warehouse.

Background Art

[0002] As one type of automated warehouse, a storage and shipping system equipped with a mobile robot that picks and transports articles (totes, containers, etc.) stored at multiple levels is known (see, for example, Patent Document 1). The mobile robot can move between multiple levels without the need for a lift or vertical conveyor. The mobile robot is movable horizontally along a horizontal track of a rack structure. The mobile robot is also movable vertically along a vertical track of the rack structure.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the above-described system, a plurality of workstations for picking products, etc. from totes or containers are provided. A flat transit deck is provided between the rack structure and these workstations so that the mobile robot can travel in two horizontal directions. The flat transit deck connects the rack structure and the plurality of workstations to each other.

[0005] In such a conventional system, a separate installation space for the flat transit deck was required in addition to the installation space of the rack structure. Therefore, there was a limit to the storage efficiency (for example, the number of items stored per unit area) compared to the total installation area of the automated warehouse, and it was difficult to improve the storage efficiency.

[0006] This disclosure describes an automated warehouse that can improve storage efficiency. [Means for solving the problem]

[0007] An automated warehouse according to one aspect of the present disclosure comprises a frame arranged vertically with respect to the floor surface, racks arranged on the frame and capable of storing goods, horizontal rails arranged adjacent to the racks and extending horizontally, lifting rails extending vertically within the racks and at least near the floor surface, and a transport trolley that rotates and travels horizontally on the floor surface, travels horizontally on the horizontal rails, and rises and falls on the lifting rails.

[0008] According to this automated warehouse, the space between the frame and the floor, i.e., the space below the frame, allows the transport cart to travel (or pass) on the floor. Since the lifting rails extend at least to the vicinity of the floor, the transport cart can move between the floor and the horizontal rails within the rack. Within the rack, the transport cart can move in the horizontal direction of travel along the horizontal rails (the direction of travel within the rack), but cannot travel in other horizontal directions. However, in the travel space above the floor, the transport cart can travel not only in the direction of travel within the rack, but also in directions intersecting that direction (for example, perpendicular directions). Because the transport cart can travel in two horizontal directions on the floor, the deck described in the above-mentioned patent document can be omitted or its area can be reduced. As a result, the installation area of ​​the rack can be increased relative to the total installation area of ​​the automated warehouse. In other words, racks capable of storing goods can be installed in the space where a conventional deck was installed. Since the number of lifting rails can be kept to a minimum, sufficient storage volume can be secured within the rack. Therefore, storage efficiency can be improved.

[0009] An automated warehouse may be equipped with a seismic isolation mechanism that supports a frame against the floor and allows for temporary horizontal movement of the frame. In this case, the frame and racks are subject to seismic isolation, while the floor is not. Therefore, the configuration of the seismic isolation mechanism can be kept to the minimum necessary while preventing stored goods from falling.

[0010] In an automated warehouse, the seismic isolation mechanism may include an elastic member that returns the frame to its initial position after a temporary horizontal movement. In this case, after the temporary horizontal movement, the frame is positioned at its initial location. Therefore, the transport cart can enter the rack from the same position (a predetermined position where the lifting rails are installed).

[0011] The automated warehouse may include picking stations located on the floor surface, outside the horizontal frame, from which transport carts can enter and exit. In this case, the floor space can also be used as a travel path (access route) to the picking stations. Therefore, more space is saved compared to when a separate travel path to the picking stations is provided. There are no constraints on the placement of the picking stations relative to the external shape of the frame in plan view, increasing the flexibility of the layout.

[0012] In an automated warehouse, the lifting rails may be installed so that their lower ends are lifted off the floor. In this case, it is not necessary to place a seismic isolation mechanism between the lifting rails and the floor.

[0013] In an automated warehouse, the gap between the lower end of the lifting rail and the floor surface may be smaller than the distance from the contact surface of the drive wheels of the transport trolley to the lifting pinion. In this case, the transport trolley can enter the rack from floor level. It is sufficient to position the lower end of the lifting rail at a predetermined height, and there is no need to install a separate lifter or the like on the floor surface. [Effects of the Invention]

[0014] According to this disclosure, storage efficiency can be improved. [Brief explanation of the drawing]

[0015] [Figure 1] Figure 1 is a side view of an automated warehouse according to one embodiment of the present disclosure. [Figure 2] Figure 2 is a plan view of the frame and picking station, and is a cross-sectional view along line II-II in Figure 1. [Figure 3] Figure 3 is a side view of the transport cart. [Figure 4] Figure 4 is a perspective view showing the transport cart located on the horizontal travel rail. [Figure 5] Figure 5 is a cross-sectional view of the lifting rail cut in a horizontal cross-section. [Figure 6] Figure 6 is a perspective view showing the intersection of the lifting rail and the horizontal travel rail. [Figure 7] Figure 7 is a perspective view showing the transport cart ascending on the lifting rail. [Figure 8] Figure 8 is a diagram showing the transfer device of the transport cart. [Figure 9] Figure 9 is a diagram showing the state of pulling in a load from the storage section of the rack by the transfer device. [Figure 10] Figure 10(a) is a diagram for explaining the position of the lower end of the lifting rail in the travel space on the floor surface, and Figure 10(b) is a diagram for explaining the positioning effect by the seismic isolation mechanism having an elastic member. [Figure 11] Figure 11 is a perspective view showing the lifting rail attached to the gantry. [[ID=二十七]] [Figure 12] Figure 12 is a plan view showing an example of the advancing / retreating path of the transport cart with respect to the picking station. [Figure 13] Figure 13(a) is a side view conceptually showing the automated warehouse according to the present disclosure, and Figure 13(b) is a side view conceptually showing the automated warehouse according to the comparative example.

Mode for Carrying Out the Invention

[0016] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. In the description of the drawings, the same reference numerals are assigned to the same elements, and duplicate descriptions are omitted. In the drawings, for convenience of explanation, the respective configurations according to the embodiments are represented with appropriately changed scales. The XYZ orthogonal coordinate system is shown in some of the drawings. In the following description, this coordinate system is referred to for ease of explanation. Hereinafter, one direction along the horizontal plane is defined as the X direction, the direction orthogonal to the X direction and along the horizontal plane is defined as the Y direction, and the vertical direction is defined as the Z direction for explanation.

[0017] First, referring to FIGS. 1 and 2, the overall configuration of the automated warehouse 1 will be described. As shown in FIGS. 1 and 2, the automated warehouse 1 includes a rack structure 2 having a plurality of racks 3, and a plurality of carrier trucks 30 that respectively convey the goods T stored in the storage shelves of the plurality of racks 3. The rack structure 2 is formed by connecting long steel materials or the like extending in the X, Y, and Z directions to each other. As shown in FIG. 2, the automated warehouse 1 includes, for example, four racks 3 arranged in the Y direction. Each rack 3 has a left rack 3A and a right rack 3B that face each other in the Y direction and extend in the X direction. A horizontal travel space Sh in which a plurality of carrier trucks 30 travel is formed between the pair of racks 3A and 3B. Each of the left rack 3A and the right rack 3B has a large number of storage shelves (or storage racks) provided over a plurality of layers. The rack 3 can store (or hold) the goods T in each storage shelf.

[0018] The configurations of the rack structure 2 and the rack 3 can be appropriately changed according to the required storage capacity, volume, and size of the available installation space of the goods T, etc. The automated warehouse 1 may include four or more racks 3 (that is, four or more pairs of racks 3A and 3B) in order to store a larger quantity of goods T. When a large number of racks 3 are provided, those racks 3 are arranged in the Y direction. Note that the automated warehouse 1 may include only one rack 3 (that is, only one pair of racks 3A and 3B). Also, a carrier truck 30 that travels in two horizontally adjacent travel spaces Sh in the Y direction may share the racks and storage shelves arranged therebetween. In the example shown in FIG. 1, the number of vertical layers of each rack 3 is six, but the number of layers (number of levels) may also be appropriately changed and set.

[0019] The automated warehouse 1 is installed, for example, on the floor surface F inside a building. As shown in Figure 2, the automated warehouse 1 comprises a plurality of (e.g., six) picking stations 100 located outside the rack structure 2 (a plurality of racks 3). For example, three picking stations 100 are arranged adjacent to either end of the rack structure 2 in the X direction, and three picking stations 100 are arranged adjacent to either end of the rack structure 2 in the Y direction. At each picking station 100, predetermined picking is performed by a worker or a picking robot (work robot), etc.

[0020] The automated warehouse 1 is equipped with a controller 6 that comprehensively controls the transport of goods T by each transport cart 30. The controller 6 can communicate with terminals (operation units, operation panels, etc.) provided at all transport carts 30 and each picking station 100 via wired or wireless communication means. The controller 6 is a computer that includes, for example, a processor such as a CPU (Central Processing Unit), ROM (Read-Only Memory), and RAM (Random Access Memory).

[0021] The automated warehouse 1 includes an receiving station (not shown). For example, the receiving station is located outside the rack structure 2 (multiple racks 3) and in a different area from the picking station 100. In the automated warehouse 1, a package T is, for example, a container (also called a tote bag, etc.) that holds multiple goods. Packages T stored in the racks 3 via the receiving station are transported and released by a transport cart 30 in response to requests from each picking station 100, or under the control of a controller 6. Packages T that have been picked at each picking station 100 are transported and stored by the transport cart 30, or (if the container is empty) are transported to the receiving station as an empty container.

[0022] Each transport cart 30 is an autonomous mobile robot. In the automated warehouse 1, each transport cart 30 can travel horizontally and vertically (up and down) independently within the rack 3. This eliminates the need for conveyors and lifts to deliver goods T to each picking station 100 in the automated warehouse 1 (of course, these auxiliary facilities are not necessarily excluded). The functions of the transport carts 30 enable the storage, transport, sorting, and picking of goods T in the automated warehouse 1. Furthermore, since the rack 3 and picking stations 100 are modularized, they can be expanded (added) according to the required capacity. The number of transport carts 30 operating in the automated warehouse 1 can also be expanded (added) in the same way. The transport carts 30 are compatible with, for example, refrigerated and frozen environments, and can realize storage environments with multiple temperature zones such as ambient temperature, chilled, and frozen on each level of the rack 3.

[0023] As shown in Figures 1 and 2, the rack structure 2 (automated warehouse 1) comprises a plurality of horizontal travel rails 10 arranged adjacent to the rack 3, and a plurality of lifting rails 20 extending vertically within the rack 3. The horizontal travel rails 10 extend in the X direction at each level of the rack 3. A pair of horizontal travel rails 10 extend parallel to each other and spaced apart in the Y direction, corresponding to a pair of drive wheels 32 of a transport trolley 30, which will be described later (see Figure 4). Within the rack 3, a horizontal travel space Sh extends in the X direction, having the area between the pair of horizontal travel rails 10 as its bottom surface and having a predetermined height (cross-sectional area) that allows the transport trolley 30 to pass through. Each transport trolley 30 travels horizontally on the horizontal travel rails 10 in the horizontal travel direction Dh1. The horizontal travel direction Dh1 is parallel to the X direction.

[0024] The lifting rails 20 are provided, for example, at multiple locations in the X direction within the rack 3. In the example shown in Figure 1, for example, two lifting rails 20 are incorporated into the rack 3. Each lifting rail 20 includes, for example, a first lifting rail 21 and a second lifting rail 22 spaced a predetermined distance apart in the X direction. Each of the first lifting rail 21 and the second lifting rail 22 extends in the Z direction so as to penetrate all levels of the rack 3. Each transport cart 30 moves up and down (up and down) in the vertical travel direction Dv on the first lifting rail 21 or the second lifting rail 22. The vertical travel direction Dv is parallel to the Z direction. Furthermore, in the explanation that "each transport cart 30 rises and falls on the lifting rail," "on the lifting rail" does not mean that each transport cart 30 is positioned "on" the lifting rail relative to gravity (or the vertical direction), but rather that at least a part of the transport cart 30 is in contact with the lifting rail as it rises and falls. "Each transport cart 30 rises and falls on the lifting rail" is synonymous with "each transport cart 30 rises and falls along the lifting rail."

[0025] Either the first lifting rail 21 or the second lifting rail 22 may be dedicated to upward movement, and the other to downward movement. As shown in Figure 1, for example, the orientation of a transport trolley 30 moving on the second lifting rail 22 is the same as the orientation of a transport trolley 30 moving on the first lifting rail 21. Between the first lifting rail 21 and the second lifting rail 22, there is a space large enough in the X direction to allow one transport trolley 30 to move on the first lifting rail 21. On the side of the second lifting rail 22 opposite to the first lifting rail 21 in the X direction, there is a space large enough to allow one transport trolley 30 to move on the second lifting rail 22. With this configuration, two transport trolleys 30 moving simultaneously on each lifting rail 21, 22 can pass each other. Also, one transport trolley 30 can overtake the other transport trolley 30. Within the rack 3, a rectangular prism-shaped lifting space Sv extends in the Z direction, including a first lifting rail 21 and a second lifting rail 22, and having a predetermined cross-sectional area that allows the passage of two transport carts 30. Both the first lifting rail 21 and the second lifting rail 22 may be used for both upward and downward movement. In the automated warehouse 1, contact between transport carts 30 during horizontal movement and contact between transport carts 30 during upward and downward movement are avoided based on the detection results of distance sensors provided on the transport carts 30.

[0026] Note that in Figure 1, a portion of the rack 3 is omitted from the illustration in order to easily identify the pair of lifting rails 21 and 22. In Figure 2, each pair of racks 3A and 3B and the horizontal travel space Sh within the rack 3 are partially shown with dashed lines, and the cross-section of the lifting rail 20 is partially shown.

[0027] As shown in Figure 1, in this embodiment, the automated warehouse 1 includes a frame 4 arranged at intervals in the Z direction (vertical direction) relative to the floor surface F. As shown in Figure 2, the frame 4 is, for example, a frame structure having approximately the same size and shape as the racks 3 (rack structure 2) in a plan view. The rack structure 2, consisting of multiple racks 3, multiple horizontal rails 10, and multiple lifting rails 20, is supported by the frame 4. In other words, the multiple racks 3 are arranged on the frame 4.

[0028] The frame 4 includes, for example, a pair of first main members 4a extending in the X direction and a pair of second main members 4b extending in the Y direction. These first main members 4a and second main members 4b form a rectangular frame extending along the XY plane. The frame 4 may also include a plurality of sub-members 4c spanning between the pair of first main members 4a. Steel materials having the desired strength are used for these first main members 4a, second main members 4b, and sub-members 4c. H-shaped steel or C-shaped steel may be used as the steel material. The configuration of the frame 4 (shape, size, and structural members used, etc.) can be designed as appropriate.

[0029] In the flat space extending in the X and Y directions formed between the frame 4 and the floor surface F, i.e., the space below the frame 4 (the travel space Sa described later), multiple transport trolleys 30 can travel in any direction. More specifically, as shown in Figures 1 and 2, the frame 4 is supported by multiple (12 in the illustrated example) seismic isolation mechanisms 50. These seismic isolation mechanisms 50 are support parts or legs that support the frame 4. The seismic isolation mechanisms 50 allow horizontal movement of the frame 4 by including known seismic isolation devices or seismic isolation members. As shown in Figure 10(a), the distance H between the lower end of the frame 4 and the floor surface F is greater than the height of the transport trolley 30 located on the floor surface F (i.e., the total height of the transport trolley 30). Even when a load T is held on the transport trolley 30, the upper end of the load T is at approximately the same height as the top surface of the transport trolley 30 (the upper end surface of the housing 35 shown in Figure 3), or lower than the top surface. Therefore, the spacing H is greater than the height of the transport cart 30, which is located on the floor surface F and holds the load T. Each transport cart 30 can travel in the horizontal travel direction X and the horizontal travel direction Dh2 in the travel space Sa formed between the frame 4 and the floor surface F. If the top surface of the transport cart 30 is lower than the upper end of the load T when the load T is held by the transport cart 30, the spacing H between the lower end of the frame 4 and the floor surface F may be made greater than the height of the upper end of the load T held by the transport cart 30. The horizontal travel direction Dh2 is parallel to the Y direction. That is, the horizontal travel direction Dh2 is perpendicular to the horizontal travel direction Dh1.

[0030] Next, referring to Figure 3, the configuration of the transport trolley 30 will be explained, and referring to Figures 4 to 6, the structure related to the movement of the transport trolley 30 will be explained. Figure 3 is a side view of the transport trolley 30. The transport trolley 30 can travel in any direction by forward and reverse rotation of the drive wheels 32, so there is no particular concept of front and rear. In the following explanation, the side on which the housing 35 and the information and communication unit 39 are provided will be referred to as the rear, and the opposite side will be referred to as the front. The transport trolley 30 includes a flat base portion 31 and a housing 35 provided on the base portion 31. A trolley controller (not shown) that controls the movement of the transport trolley 30 is provided inside the housing 35. The trolley controller communicates information with the controller 6 to cause the transport trolley 30 to transport the cargo T.

[0031] The transport trolley 30 includes a pair of drive wheels 32 mounted slightly rearward of the base 31 and, for example, two pairs of support wheels 33 mounted in front of the base 31. The transport trolley 30 includes four guide rollers 34 located at the four corners of the base 31 and rotatable around a vertical axis. The transport trolley 30 further includes a pair of lower counter wheels 36 and a pair of lifting pinions 38 mounted coaxially with the drive shafts 32a of the drive wheels 32, and a pair of upper counter wheels 37 having an upper counter shaft 37a located above the drive shafts 32a. The drive shafts 32a of the drive wheels 32, the rotation axes of the support wheels 33, and the upper counter shafts 37a of the upper counter wheels 37 are parallel to each other and extend horizontally in the width direction of the base 31.

[0032] The drive wheels 32 are driven by a drive motor (not shown) and rotate in either forward or reverse direction. The left and right drive wheels 32 may be driven by a single common drive motor, or by two separate drive motors. On the other hand, the lifting pinion 38 is driven by the drive motor of the drive wheels 32 and rotates in either forward or reverse direction. The lower counter wheel 36 and the lifting pinion 38 are movable axially relative to the drive shaft 32a via splines or the like. The lifting pinion 38 rotates with the drive motor of the drive wheels 32, but its axial position is controlled by another motor (not shown) (for example, the drive motor 30M shown in Figure 8). The lower counter wheel 36 also moves axially with the lifting pinion 38, but the lower counter wheel 36 is mounted to the drive shaft 32a via a bearing and rotates freely independently of the rotation of the drive wheels 32 and the lifting pinion 38. The upper counter wheel 37 (upper counter shaft 37a), like the lower counter wheel 36, has its axial position controlled by another motor (not shown, for example, the drive motor 30M shown in Figure 8). The lower counter wheel 36, the lifting pinion 38, and the upper counter wheel 37 move axially in synchronous motion. The mechanical interlocking of these components is achieved using known mechanical elements.

[0033] The drive mechanism in the transport trolley 30 may be configured with a different known configuration than that described above.

[0034] A retaining frame 31a is provided in front of the base section 31. In the transport trolley 30, both sides of the retaining frame 31a in the width direction are open so that the load T can pass through in the width direction (horizontal direction perpendicular to the direction of travel, i.e., left-right direction) (see Figure 9). This allows the load T to be transferred (moved) by sliding it between the retaining space C of the retaining frame 31a and both the left rack 3A and the right rack 3B.

[0035] Figure 4 is a perspective view showing a transport trolley 30 positioned on a horizontal rail 10. As shown in Figure 4, the transport trolley 30 travels in the horizontal direction Dh1 with a pair of drive wheels 32 and two pairs of support wheels 33 resting on a pair of running surfaces 10a of the horizontal rail 10. The horizontal rail 10 has an L-shaped cross-section. The four guide rollers 34 of the transport trolley 30 contact the vertical walls of the horizontal rail 10, thereby maintaining the correct position of the transport trolley 30 in the width direction.

[0036] Next, the lifting rail 20 will be described. Figure 5 is a cross-sectional view of the lifting rail 20 cut in a horizontal cross-section. Figure 6 is a perspective view showing the intersection of the lifting rail 20 and the horizontal running rail 10. In the following description of the detailed structure of the lifting rail 20, only the first lifting rail 21 will be described. The structure of the second lifting rail 22 is the same as that of the first lifting rail 21, so redundant descriptions of the second lifting rail 22 will be omitted. As shown in Figures 5 and 6, the first lifting rail 21 has a lifting frame 23 having a U-shaped cross-section fixed to the vertical wall of the horizontal running rail 10, and a pair of holding guide members 24 fixed within the lifting frame 23 and facing each other in the X direction. The lifting frame 23 is open in the Y direction toward the horizontal running space Sh. A rail gap 11 is formed in the horizontal running rail 10 so as to coincide with the position of the open part of the lifting frame 23. In other words, from a broad perspective, the horizontal running rail 10 and the lifting rail 20 intersect at a right angle, but from a more detailed perspective, the horizontal running rail 10 is interrupted at the intersection with the first lifting rail 21 (lifting rail 20). This rail gap 11 allows the drive shaft 32a and the upper counter shaft 37a to pass through when the transport trolley 30 is raised or lowered.

[0037] On the surface of one of the retaining guide members 24, there is a rack gear portion 26 extending in the Z direction and a groove portion 24a adjacent to the rack gear portion 26 in the Y direction. The rack gear portion 26 includes a linear gear that meshes with the lifting pinion 38. The position of the rack gear portion 26 corresponds to the position of the advanced lifting pinion 38 in the width direction (Y direction) of the transport trolley 30. At that time, the position of the groove portion 24a corresponds to the positions of the advanced lower counter wheel 36 and upper counter wheel 37, respectively, in the width direction (Y direction) of the transport trolley 30.

[0038] Figure 7 is a perspective view showing a transport trolley 30 rising on a lifting rail. The transport trolley 30 can always know its own position while traveling on the horizontal travel rail 10. The trolley controller of the transport trolley 30 sequentially acquires detection values ​​from encoders provided on, for example, the drive motors of the drive wheels 32, and based on the acquired detection values, it determines its own position within the rack 3 (on the horizontal travel rail 10). When the transport trolley 30 moves to another floor, for example to an upper floor, it stops at the position of the first lifting rail 21 (lifting rail 20). Then, the lifting pinion 38, lower counter wheel 36, and upper counter wheel 37 are advanced, and the drive wheels 32 etc. are retracted by another motor etc. The lower counter wheel 36 and upper counter wheel 37 pass through the notches 23a (see Figure 6) formed in the lifting frame 23. The lifting pinion 38 engages with the rack gear section 26, and the lower counter wheel 36 and upper counter wheel 37 fit into the grooves 24a. The drive wheels 32 retract to a position inward in the width direction from the running surface 10a of the horizontal running rail 10. In this state, the transport trolley 30 rises along the first lifting rail 21 by rotating the lifting pinion 38. When the transport trolley 30 moves to a lower level, it descends along the first lifting rail 21 by rotating the lifting pinion 38 in the reverse direction.

[0039] The position of the center of gravity of the transport trolley 30 differs depending on whether the transport trolley 30 is holding a load T on the holding frame 31a or not. The position of the center of gravity of the transport trolley 30 also differs depending on the weight of the load T. The lower counter wheels 36 and upper counter wheels 37, which are arranged in the vertical direction, support the transport trolley 30 on a pair of first lifting rails 21 in a cantilevered state as shown in Figure 7, and the lifting pinion 38 and the rack gear section 26 mesh securely. This generates the propulsive force for raising and lowering the transport trolley 30.

[0040] The transport trolley 30 can rotate and travel horizontally on a flat surface such as a floor surface F. For example, the left and right pair of drive wheels 32 can be driven independently, and the direction of the transport trolley 30 can be changed by rotating one of the drive wheels 32 in the forward direction and the other drive wheel 32 in the reverse direction. Furthermore, by creating a speed difference between the left and right drive wheels 32, the transport trolley 30 can also change direction while moving.

[0041] Next, with reference to Figure 8, the transfer device 40 of the transport trolley 30 will be described. As shown in Figure 8, a pair of transfer devices 40 are provided on both outer sides of the holding frame 31a in the X direction. Each transfer device 40 rotates a belt 45 and a plurality of engaging arms 44 provided on the belt 45 in a first rotational direction 46 or a second rotational direction 47 via a drive shaft 41 rotated by a motor (not shown) and a belt 43 and two pulleys 42. The cargo T is supported and stored, for example, by a pair of L-shaped support members 3c spanning between a pair of horizontal rails 10. The pair of support members 3c constitute a storage shelf in the rack 3. The support surfaces of the support members 3c are flat and allow the cargo T to slide in the Y direction. As shown in Figure 9, by rotating the engaging arms 44 in the first rotational direction 46, the pair of engaging arms 44 catch on projections Ta protruding from both sides of the cargo T in the X direction, and the cargo T is pulled into the holding space C. When the load T is fully retracted, the engagement between the engaging arm 44 and the projection Ta is released, and the transport trolley 30 begins to move in accordance with the transport request. When transferring the load T to the storage shelf, the engaging arm 44 is moved in the second rotation direction 47, and the load T is transferred onto the support member 3c in the reverse operation of the above.

[0042] In the automated warehouse 1 of this embodiment, as shown in Figures 1 and 10(a), the transport cart 30 rotates and travels horizontally in the travel space Sa on the floor surface F. Multiple horizontal travel spaces Sh and multiple lifting spaces Sv intersect and communicate with each other, and multiple lifting spaces Sv reach and communicate with the travel space Sa on the floor surface F. All transport carts 30 operating in the automated warehouse 1 can move back and forth between the rack 3 and the travel space Sa. The configuration that enables the transport carts 30 to move back and forth between the rack 3 and the travel space Sa will be described below. The lifting rail 20 extends vertically between the inside of the rack 3 and the vicinity of the floor surface F. The first lifting rail 21 and the second lifting rail 22 are installed so that their lower ends 21b and 22b are away from the floor surface F. More specifically, the gap G between the lower ends 21b, 22b and the floor surface F is smaller than the distance h from the contact surface of the drive wheels 32 of the transport trolley 30 to the rotation center of the lifting pinion 38 (center of the drive shaft 32a).

[0043] As shown in Figures 2 and 4, the lifting rail 20 is positioned offset to the outside of the pair of horizontal running rails 10. The lifting rail 20 is also positioned offset in the Y direction from the first main member 4a of the frame 4. To position the lifting rail 20 in the running space Sa while maintaining this positional relationship, for example, the lifting rail lower end structure 20X shown in Figure 11 is applied. In the lifting rail lower end structure 20X, the distance between the first lifting rail 21 and the second lifting rail 22 is maintained by a spacing member 25 provided between their lower ends 21b and 22b. The first lifting rail 21 and the second lifting rail 22 are also supported by a pair of support members 27 to a pair of rack columns 3E erected on the upper surface of the first main member 4a. The lower ends 21b and 22b of the first lifting rail 21 and the second lifting rail 22 are supported by a pair of diagonal members 28 connected to the lower surface of the first main member 4a. Two intersecting braces 29 may be attached between the lower ends 21b, 22b and the lower surface of the first main member 4a. Note that the gap G (see Figure 10(a)) described above is determined not by the lower ends 21b, 22b as members of the first lifting rail 21 and the second lifting rail 22, but by the position where the rack gear section 26 terminates (the lower end position of the structure that can mesh with the lifting pinion 38).

[0044] Multiple two-dimensional codes, such as barcodes, are fixed to the floor surface F, arranged in the X and Y directions at predetermined intervals, so that the transport trolley 30 can determine its own position. The transport trolley 30 determines its own position by reading these two-dimensional codes with a reader device (not shown) facing the floor surface F. The transport trolley 30 has pre-stored map information of the floor surface F, including the arrangement of the lifting rails 20. When moving from the floor surface F to the rack 3, it stops at the position of the lifting rails 20 and rises into the rack 3 in the same manner as the lifting operation described above.

[0045] According to the above configuration, the transport cart 30, having descended further from the lowest level of rack 3, lands on the floor surface F with the lifting pinion 38 and the rack gear section 26 engaged between a pair of lifting rails 20. Afterward, the transport cart 30 disengages from the rack gear section 26 and travels on the floor surface F. The transport cart 30 rotates and travels horizontally within the travel space Sa on the floor surface F. By traveling on the floor surface F, each transport cart 30 can access any of the picking stations 100. As shown in Figure 12, each transport cart 30 receives picking at any of the picking stations 100 and then returns to the travel space Sa, for example, by traveling along a U-shaped path in plan view. The configuration of the picking station 100 is not particularly limited. The transport cart 30 may remain on the floor surface F even when receiving picking, or it may be lifted by a lifter or the like only when receiving picking. The transport cart 30 then travels along the floor surface F and stops at the position of the lifting rail 20. At that position, the lifting pinion 38 engages with the rack gear section 26, and the cart rises into the rack 3. Alternatively, the transport cart 30 may be raised using the lifting pinion 38 or by traveling along an upward slope only when receiving picking.

[0046] Next, the seismic isolation mechanism 50 will be described. As shown in Figure 10(b), the seismic isolation mechanism 50 includes a support base 51 provided on the floor surface F, and an elastic member 52 provided on the support base 51 and between the support base 51 and the frame 4, which returns the frame 4 to its initial position P after a temporary horizontal movement of the frame 4. The elastic member 52 is a known seismic isolation member, such as laminated rubber. Alternatively, a ball bearing type seismic isolation mechanism may be arranged as the elastic member 52, and then elastic members such as dampers or springs may be arranged in the horizontal direction. As a result, the position of the lifting rail 20 in the travel space Sa is less affected by shaking caused by earthquakes.

[0047] According to the automated warehouse 1 of this embodiment, the transport cart 30 can travel (or pass through) on the floor surface F by utilizing the space H between the frame 4 and the floor surface F, that is, the space below the frame 4. Since the lifting rail 20 extends to the vicinity of the floor surface F, the transport cart 30 can move back and forth between the floor surface F and the horizontal travel rail 10 inside the rack 3. Inside the rack 3, the transport cart 30 can move in the horizontal travel direction Dh1 along the horizontal travel rail 10, but cannot travel in the other horizontal travel direction Dh2. However, in the travel space Sa on the floor surface F, the transport cart 30 can travel not only in the horizontal travel direction Dh1 inside the rack 3, but also in the horizontal travel direction Dh2 which is a direction intersecting it (for example, a direction perpendicular to it). Because the transport cart 30 can travel in two (or three or more) horizontal directions on the floor surface F, the deck described in Patent Document 1 can be omitted or its area can be reduced. This allows for a larger rack installation area relative to the overall installation area of ​​the automated warehouse. In other words, racks 3 capable of storing cargo T can be installed in the space where conventional decks were installed. Since the number of lifting rails 20 is kept to a minimum, sufficient storage volume can be secured within racks 3. Therefore, storage efficiency can be improved. In addition, since multiple lifting rails 20 extend to the vicinity of the floor surface F, the floor surface F can be used as a shortcut passage, allowing the transport carts 30 to move to the adjacent lane more quickly.

[0048] An example of the above effect will be explained with reference to Figure 13. Figure 13(a) is a conceptual side view of automated warehouse 1 according to this disclosure, and Figure 13(b) is a conceptual side view of automated warehouse 200 according to a comparative example. In automated warehouse 200, a rack structure 202 consisting of racks 203 is installed directly on the floor surface F. A deck 210 consisting of one or more layers is provided between the rack structure 202 and the picking station 100. Transport carts move horizontally between the racks 203 and the deck 210. On the deck 210, transport carts can travel in horizontal travel directions Dh1 and Dh2. However, in automated warehouse 200 with such a configuration, the capacity (size) of rack 203 in the X direction is smaller than that of rack 3 in automated warehouse 1. The area in which a lifting space (lifting rail) can be installed within rack 203 is also limited. Furthermore, the picking station 100 can only be installed in an area accessible via the deck 210 (in the example in Figure 13(b), the picking stations 100 are adjacent only in the X direction). Moreover, the rack 203 (rack structure 202) does not have any earthquake countermeasures.

[0049] In the automated warehouse 1 of this embodiment, the entire rack 3 (rack structure 2) is lifted onto the frame 4 (a travel space Sa exists below the frame 4), so the capacity (size) of the rack 3 in the X direction is sufficiently secured, resulting in excellent storage capacity. In addition, the area in which the lifting space Sv (lifting rail 20) can be installed within the rack 3 is also wide. Furthermore, since the function of the deck 210 in the automated warehouse 200 is provided on the floor surface F, the picking station 100 can be installed in any location outside the rack 3 in both the X and Y directions. Depending on the warehouse layout, a deck may be provided only on the upper level, and the movement of the transport cart 30 between the rack 3 and the deck may be permitted only on the upper level. Thus, automated warehouse 1 has many advantages over automated warehouse 200. In addition, unlike automated warehouse 200, an automated warehouse of the type in which the cart can only move up and down within the rack and the cart can only travel horizontally on the floor surface is also conceivable. In terms of this type of automated warehouse, automated warehouse 1 is superior in all respects, including the degree of freedom in the operating area, the space-saving aspect of the area required for the trolleys to operate, the arrangement of the picking stations 100, and seismic resistance.

[0050] The automated warehouse 1 is equipped with a seismic isolation mechanism 50 that supports the frame 4 against the floor surface F and allows for temporary horizontal movement of the frame 4. The frame 4 and rack 3 are subject to seismic isolation, while the floor surface F is not. Therefore, the configuration of the seismic isolation mechanism 50 can be kept to the minimum necessary while preventing the stored goods T from falling.

[0051] In the automated warehouse 1, the seismic isolation mechanism 50 has an elastic member 52 that returns the frame 4 to its initial position P after a temporary horizontal movement. As a result, after a temporary horizontal movement, the frame 4 is positioned at its initial position P. Therefore, the transport trolley 30 can enter the rack 3 from the same position (a predetermined position where the lifting rail 20 is installed). In particular, the positional accuracy of the pair of lifting frames 23 and rack gear section 26 facing each other in the Y direction is important in the lifting rail 20. With the seismic isolation mechanism 50 having the elastic member 52, the lifting rail 20 is positioned at its initial position P in both the Y direction and the X direction.

[0052] The automated warehouse 1 is located on the floor surface F, outside the horizontal frame 4, and includes a picking station 100 from which a transport cart 30 can enter and exit. As a result, the travel space Sa on the floor surface F can also be used as a travel path (access route) to the picking station 100. Therefore, more space is saved compared to the case where a separate travel path to the picking station 100 is provided. There are no constraints on the placement of the picking station 100 in relation to the outer shape of the frame 4 in plan view (see Figure 12), and the degree of layout flexibility is increased.

[0053] In the automated warehouse 1, the lifting rails 20 are installed so that their lower ends 21b and 22b are away from the floor surface F. This eliminates the need to place a seismic isolation mechanism between the lifting rails 20 (first lifting rail 21 and second lifting rail 22) and the floor surface F.

[0054] In the automated warehouse 1, the gap G between the lower ends 21b, 22b of the lifting rails 20 and the floor surface F is smaller than the distance h from the contact surface of the drive wheels 32 of the transport trolley 30 to the center of the lifting pinion 38. As a result, the transport trolley 30 can enter the rack 3 from the height of the floor surface F. It is only necessary to position the lower ends 21b, 22b of the lifting rails 20 at a predetermined height, and there is no need to install a separate lifter or the like on the floor surface F to raise the position of the transport trolley 30.

[0055] Although embodiments of the present disclosure have been described above, the present invention is not limited to the above embodiments. For example, the lifting rail 20 only needs to extend vertically at least over the vicinity of the floor surface F. The lower end of the lifting rail may reach or be connected to the floor surface F. In this case, the lifting rail can be made subject to seismic isolation by arranging a seismic isolation mechanism or the like between the lower end of the lifting rail and the floor surface.

[0056] The gap between the lower end of the lifting rail and the floor surface may be greater than the distance from the contact surface of the drive wheels of the transport trolley to the lifting pinion. In that case, the lifting pinion 38 can engage with the lifting rail 20 by either raising a portion of the floor surface F in a trapezoidal shape, or by providing a lifter or the like on the floor surface F.

[0057] The seismic isolation mechanism 50 may have sliding bearings or rolling bearings, etc., instead of elastic members. The seismic isolation mechanism may be omitted.

[0058] The frame 4 may be fixed to the floor surface F via legs instead of the seismic isolation mechanism 50. In this case, the legs have the same height as the seismic isolation mechanism 50, ensuring a travel space Sa. The frame 4 may be fixed to a foundation or the like below the floor surface F. The frame 4 may not be a flat frame but may have an inclined part or a part that protrudes downward. That is, the distance H between the lower end of the frame 4 and the floor surface F does not have to be constant. Even in that case, a travel space Sa is formed in at least a portion of the area on the floor surface F.

[0059] One or more picking stations 100 may be arranged on the frame 4.

[0060] The constituent elements of one aspect of this disclosure are described below. [1] A frame is positioned with vertical spacing relative to the floor, A rack, which is placed on the aforementioned frame and capable of storing luggage, A horizontal rail is positioned adjacent to the aforementioned rack and extends horizontally, A lifting rail extending vertically within the rack and at least near the floor surface, A transport trolley that rotates and travels horizontally on the floor surface, travels horizontally on the horizontal travel rail, and rises and falls on the lifting rail, An automated warehouse equipped with [unclear / unclear]. [2] The automated warehouse according to [1], comprising a seismic isolation mechanism that supports the frame with respect to the floor surface and allows temporary horizontal movement of the frame. [3] The seismic isolation mechanism comprises an elastic member that returns the frame to its initial position after the temporary horizontal movement, as described in [2]. [4] An automated warehouse according to any one of [1] to [3], comprising a picking station located on the floor surface and outside the frame in the horizontal direction, from which the transport cart can move in and out. [5] The lifting rail is installed such that the lower end of the lifting rail is lifted away from the floor surface, as described in any one of [1] to [4]. [6] The automated warehouse according to [5], wherein the gap between the lower end of the lifting rail and the floor surface is smaller than the distance from the contact surface of the drive wheel of the transport trolley to the lifting pinion. [Explanation of Symbols]

[0061] 1...Automated warehouse, 2...Rack structure, 3...Rack, 3A...Left rack, 3B...Right rack, 4...Frame, 6...Controller, 10...Horizontal travel rail, 20...Lifting rail, 21...First lifting rail, 21b...Lower end, 22...Second lifting rail, 22b...Lower end, 26...Rack gear section, 30...Transport trolley, 32...Drive wheels, 36...Lower counter wheel, 37...Upper counter wheel, 38...Lifting pinion, 40...Transfer device, 44...Engaging arm, 50...Seismic isolation mechanism (support part), 51...Support base, 52...Elastic member, Dh1, Dh2...Horizontal travel direction, Dv...Vertical travel direction, F...Floor surface, H...Spacing, h...Distance, Sa...Travel space, Sh...Horizontal travel space, Sv...Lifting space, T...Cargo.

Claims

1. A frame is positioned with vertical spacing relative to the floor, A rack, which is placed on the aforementioned frame and capable of storing luggage, A horizontal rail is positioned adjacent to the aforementioned rack and extends horizontally, A lifting rail extending vertically within the rack and at least near the floor surface, A transport trolley that rotates and travels horizontally on the floor surface, travels horizontally on the horizontal travel rail, and rises and falls on the lifting rail, An automated warehouse equipped with [unclear / unclear].

2. The automated warehouse according to claim 1, further comprising a seismic isolation mechanism that supports the frame with respect to the floor surface and allows for temporary horizontal movement of the frame.

3. The automated warehouse according to claim 2, wherein the seismic isolation mechanism has an elastic member that returns the frame to its initial position after the temporary horizontal movement.

4. The automated warehouse according to any one of claims 1 to 3, comprising a picking station located on the floor surface and outside the frame in the horizontal direction, from which the transport cart can move in and out.

5. The automated warehouse according to any one of claims 1 to 3, wherein the lifting rail is installed such that the lower end of the lifting rail is lifted away from the floor surface.

6. The automated warehouse according to claim 5, wherein the gap between the lower end of the lifting rail and the floor surface is smaller than the distance from the contact surface of the drive wheel of the transport trolley to the lifting pinion.

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