Control system for logistics warehouses

Abstract

To provide a control device for logistics warehouses that can improve transport capacity while suppressing the computational load. [Solution] The path calculation unit 13 performs calculations for a first generated path assuming that the lower lane 21A exists and the upper lane 21B does not, and calculates a second generated path assuming that the upper lane 21B exists and the lower lane 21A does not. Furthermore, when calculating the transport path information, the path calculation unit 13 uses both the first generated path and the second generated path. In this case, the path calculation unit 13 can perform the calculation of the first generated path with the computational load of one level, and the calculation of the second generated path with the computational load of one level. Even considering the computational load of using both the first and second generated paths, such calculations can significantly reduce the computational load compared to calculating transport path information for multiple levels at once.

Description

Technical Field

[0001] The present invention relates to a control device for a logistics warehouse.

Background Art

[0002] Conventionally, as a control device for a logistics warehouse, for example, the one described in Patent Document 1 is known. This control device for a logistics warehouse calculates conveyance route information by calculating a reverse operation when it is assumed that the article is moved in the reverse order from the movement completion state to the movement initial state.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Here, in the above-described logistics warehouse, the conveyance lane calculates the route in the case where it is provided for any one layer of the conveyors. However, in order to improve the conveyance capacity, the conveyance lane may be provided for a plurality of layers. For a logistics warehouse having conveyance lanes for a plurality of layers, when calculating conveyance route information based on the reverse operation, there is a problem that the calculation load becomes enormous and the calculation becomes difficult.

[0005] Therefore, an object of the present invention is to provide a control device for a logistics warehouse that can improve the conveyance capacity while suppressing the calculation load.

Means for Solving the Problems

[0006] A control device for a logistics warehouse according to one aspect of the present invention is a control device for a logistics warehouse comprising an automated warehouse for storing goods, a transport lane for transporting a plurality of arranged goods, and a transporter provided between the transport lane and the automated warehouse, wherein the control device includes: an item information acquisition unit that acquires item information indicating the initial state and completed state of movement of an item when the item moves in the order of the transport lane, the transporter, and the automated warehouse, or in the order of the automated warehouse, the transporter, and the transport lane; a route calculation unit that calculates transport route information based on the item information; and an operation control unit that controls the transport operation of the logistics warehouse based on the transport route information, wherein the transport lane has a first lane for a first level of the transporter and a second lane for a second level of the transporter, and the route calculation unit calculates a first generated route assuming that the first lane exists and the second lane does not exist, and calculates a second generated route assuming that the second lane exists and the first lane does not exist, and uses the first generated route and the second generated route when calculating the transport route information.

[0007] In the control system for a logistics warehouse, the transport lanes include a first lane for the first level of the transporter and a second lane for the second level of the transporter. Therefore, goods can be transported to multiple levels, thereby improving transport capacity. The route calculation unit performs calculations for a first generated route assuming that the first lane exists and the second lane does not, and for a second generated route assuming that the second lane exists and the first lane does not. Furthermore, when calculating transport route information, the route calculation unit uses both the first and second generated routes. In this case, the route calculation unit can perform the calculation of the first generated route with the computational load of one level, and the calculation of the second generated route with the computational load of one level. Even considering the computational load of using both the first and second generated routes, such calculations can significantly reduce the computational load compared to calculating transport route information for multiple levels at once. Thus, transport capacity can be improved while suppressing the computational load.

[0008] When calculating transport route information, the route calculation unit calculates the reverse sequence of movement assuming that the items are moved in reverse order from the completed movement state to the initial movement state, based on the item information. The route calculation unit may switch between the first generated route and the second generated route when calculating transport route information. In this case, the computational load can be reduced by the route calculation unit using the reverse sequence of movement to calculate the transport route information. Furthermore, the computational load can be reduced because the route calculation unit only needs to perform calculations for either the first generated route or the second generated route.

[0009] The path calculation unit may switch between the first generated path and the second generated path at the timing when an item enters the conveyor. For example, if the switching timing is too long, both the first and second lanes cannot be used effectively. On the other hand, since the path calculation unit can switch at an appropriate timing, both the first and second lanes can be used effectively.

[0010] When the route calculation unit calculates transport route information, it performs both first and second route generation, and includes one of the generation routes in the transport route information. If the other generation route does not interfere with the first generation route, it may also mix the other generation route into the transport route information. In this case, the route calculation unit can use one generation route as the main route while supplementing it with the other generation route as a subordinate route. This reduces the computational load while effectively utilizing the first and second lanes.

[0011] The route calculation unit may switch between one generation route and the other generation route based on the number of items that can be transported on one generation route and the number of items that can be transported on the other generation route. In this case, the main lane can be switched at an appropriate timing. [Effects of the Invention]

[0012] According to the present invention, it is possible to provide a control device for a logistics warehouse that can improve transport capacity while suppressing the computational load. [Brief explanation of the drawing]

[0013] [Figure 1] It is a schematic side view showing a logistics warehouse equipped with a control device according to an embodiment of the present invention. [Figure 2] It is a schematic configuration diagram showing the configuration of a logistics warehouse according to an embodiment of the present invention. [Figure 3] It is a block configuration diagram of the control device according to the present embodiment. [Figure 4] It is a diagram modeling a logistics warehouse. [Figure 5] It is a conceptual diagram for explaining the processing content of the control device. [Figure 6] It is a conceptual diagram for explaining the processing content of the control device. [Figure 7] It is a conceptual diagram for explaining the processing content of the control device. [Figure 8] It is a flowchart showing the processing content of the control device. [Figure 9] It is a conceptual diagram for explaining the processing content of the control device. [Figure 10] It is a conceptual diagram for explaining the processing content of the control device. [Figure 11] It is a conceptual diagram for explaining the processing content of the control device. [Figure 12] It is a conceptual diagram for explaining the processing content of the control device. [Figure 13] It is a flowchart showing the processing content of the control device. [Figure 14] It is a flowchart showing the processing content of the control device. [Figure 15] It is a flowchart showing the processing content of the control device.

Mode for Carrying Out the Invention

[0014] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

[0015] FIG. 1 is a schematic side view showing a logistics warehouse 1 including a control device according to an embodiment of the present invention. As shown in FIG. 1, the logistics warehouse 1 is a system that stores a plurality of articles 150 and can ship the articles 150 to be shipped among the stored articles 150. The logistics warehouse 1 includes an automated warehouse 100, a shipping elevator 104 (conveyor), a receiving elevator 105 (conveyor), a shipping lane 121 (conveyor lane), and a receiving lane 21 (conveyor lane). The automated warehouse 100 is a warehouse for storing the articles 150. The automated warehouse 100 includes a warehouse main body 101, a shipping passage 102, and a receiving passage 103. The warehouse main body 101 has a plurality of shelves 110. The shelves 110 extend from one end to the other end of the warehouse main body 101. In the shelves 110, the transfer device 111 performs the transfer operation of the articles from the receiving path to the shipping path. The receiving passage 103 is provided at one end of the warehouse main body 101 and is a mechanism for receiving the articles 150 for each shelf 110. The shipping passage 102 is provided at the other end of the warehouse main body 101 and is a mechanism for shipping the articles 150 from each shelf 110. The receiving elevator 105 raises and lowers the articles 150 received from the receiving lane 21 and supplies the articles 150 to the receiving passage 103 at the level corresponding to the desired shelf 110. The shipping elevator 104 receives the articles 150 to be shipped from the shelf 110 and the shipping passage 102 and raises and lowers them to a shipping port not shown. The articles 150 shipped from the shipping elevator 104 are carried out to the shipping lane 121.

[0016] Figure 2 is a schematic diagram showing the configuration of a logistics warehouse 1 equipped with a control device 10 according to an embodiment of the present invention. In the following description, the receiving elevator 105 and the outbound elevator 104 may be simply referred to as "conveyor 22". Figure 2 shows the configuration of the receiving side of the logistics warehouse 1. The outbound side of the logistics warehouse 1 has the same configuration as the receiving side, except that the flow of goods 150 is through the automated warehouse 100, conveyor 22 (outbound elevator 104), and outbound lane 121, so the description will be omitted. As shown in Figure 2, the logistics warehouse 1 includes a conveying system 2 for conveying goods 150 and a control device 10 for controlling the conveying system 2. The conveying system 2 includes an receiving lane 21, a conveyor 22, and a conveyor 23 of the automated warehouse 100. Of these, the conveyor 22 is the equipment that constitutes the receiving elevator 105 mentioned above. The receiving lane 21 is a device that horizontally conveys the goods 150 and hands them over to the conveyor 22. The receiving lane 21 is provided for a predetermined level of the conveyor 22. The conveyor 23 is a device that receives goods from the conveyor 22 and transports them horizontally on each floor of the automated warehouse 100. The conveyor 23 is provided on each floor (in this case, the fourth floor) of the receiving passageway 103.

[0017] The conveyor 22 is a device that moves articles 150 in both the vertical and horizontal directions, and is equipped with a horizontal moving means (e.g., a conveyor) and a vertical moving means. Each article 150 being stored is associated with a destination floor. The conveyor 22 then moves each article 150 to its destination floor in the storage passageway 103. In the diagram, articles 150 whose destination is the "n floor" are labeled with the number "n". The same applies to subsequent diagrams. Furthermore, in the following explanation, articles 150 whose destination is the n floor may be referred to as "articles going to the n floor".

[0018] Figure 2 is a schematic diagram showing the configuration of a logistics warehouse 1 according to an embodiment of the present invention. Figure 2 shows the configuration of the receiving side of the automated warehouse 100. As shown in Figure 2, the logistics warehouse 1 comprises a transport system 2 for transporting goods 150 and a control device 10 for controlling the transport system 2. The transport system 2 comprises an receiving lane 21, a transporter 22, and a conveyor 23 of the automated warehouse 100. Of these, the transporter 22 is the equipment that constitutes the aforementioned receiving elevator 105. The receiving lane 21 is a device that receives goods 150 from the transporter 22 and transports them horizontally. The receiving lane 21 is provided at a predetermined level of the transporter 22. The conveyor 23 is a device that transports goods 150 horizontally from the automated warehouse 100 to the transporter 22. The conveyor 23 is provided on each floor (in this case, the fourth floor) of the receiving passageway 103.

[0019] The conveyor 22 is a device that moves the articles 150 in both the vertical and horizontal directions, and is equipped with a horizontal moving means (e.g., a conveyor) and a vertical moving means. This allows the conveyor 22 to receive each article 150 from each floor of the receiving passage 102 and transport it to the receiving lane 21. In the diagram, the article 150 located on the "nth floor" in the storage state of the automated warehouse 100 is labeled with the number "n". The same applies to subsequent diagrams. Furthermore, in the following explanation, the article 150 stored on the nth floor may be referred to as the "article on the nth floor".

[0020] The conveyor 22 is an alternating lifting device and has a conveyor shelf 22A on the receiving lane 21 side and a conveyor shelf 22B on the conveyor 23 side. In this embodiment, the conveyor shelves 22A and 22B each have a storage area CE with a number of levels equal to "number of floors of the automated warehouse + one floor". They also have a continuous series of conveyor boxes 22a with a number of levels equal to "number of floors of the automated warehouse" (four levels in this case). The continuous conveyor boxes 22a move up and down simultaneously. When the continuous conveyor boxes 22a move downward, each conveyor box 22a is placed in the storage area CE from the first to the fourth level, starting from the bottom. When the continuous conveyor boxes 22a move upward, each conveyor box 22a is placed in the storage area CE from the second to the fifth level, starting from the bottom. In the following description, when the number of levels is mentioned, it refers to the number of levels counted from the bottom unless otherwise specified. Furthermore, the transport boxes 22a of transport rack 22A and transport boxes 22a of transport rack 22B move up and down alternately. That is, when the transport box 22a of transport rack 22A moves upward, the transport box 22a of transport rack 22B moves downward, and when the transport box 22a of transport rack 22A moves downward, the transport box 22a of transport rack 22B moves upward. Also, within the same number of shelves, the goods 150 can be moved horizontally between the transport boxes 22a of transport rack 22A and the transport boxes 22a of transport rack 22B, allowing for the transfer and receipt of goods 150 between them. Note that transport racks 22A and 22B may each have a storage area CE with a number of shelves equal to the "number of floors of the automated warehouse".

[0021] In this embodiment, a lower lane 21A (first lane) is provided for the storage area CE of the second tier from the bottom (first tier), and an upper lane 21B is provided for the storage area CE of the third tier from the bottom (second tier). In addition, four conveyors 23 are provided for the storage areas CE of the first to fourth tiers from the bottom. In Figure 2, the areas indicated as "L" and "R" within the storage area CE are spaces provided for the lifting and lowering of the transport shelves 22A and 22B. However, the positional relationship between the storage area CE, lanes 21A and 21B, and the conveyors 23 is not particularly limited and may be set as appropriate according to the configuration of the logistics warehouse 1.

[0022] Next, the block configuration of the control device 10 will be described with reference to Figure 3. Figure 3 is a block diagram of the control device 10 according to this embodiment. The control device 10 is a unit that controls the transport system 2. The control device 10 is equipped with an ECU (Electronic Control Unit) that comprehensively manages the logistics warehouse 1. The ECU is an electronic control unit that has a CPU (Central Processing Unit), ROM (Read Only Memory), RAM (Random Access Memory), and communication circuits such as CAN (Controller Area Network). In the ECU, for example, various functions are realized by loading a program stored in ROM into RAM and executing the program loaded into RAM with the CPU. The control device 10 includes an operation control unit 11, an item information acquisition unit 12, and a route calculation unit 13.

[0023] The motion control unit 11 is a unit that controls the transport operation of the logistics warehouse 1 so that each item 150 is transported based on the transport path calculated by the path calculation unit 13. The motion control unit 11 controls the transport operation by transmitting control signals to the transport system 2. The motion control unit 11 operates each of the drive units of the receiving lane 21, transporter 22, and conveyor 23 of the transport system 2 by transmitting control signals to each of the drive units.

[0024] The item information acquisition unit 12 acquires item information indicating the initial and completed states of item 150's movement when the item 150 moves in the order of receiving lane 21, conveyor 22, and automated warehouse 100, or when it moves in the order of automated warehouse 100, conveyor 22, and outbound lane 121. The item information includes information such as the destination floor of the item 150 located in receiving lane 21 at the time of receiving, the number of items 150 on each floor, and the receiving order. The item information also includes information such as how many items 150 will be released from which floor of the automated warehouse 100, and the order in which they will be released.

[0025] The path calculation unit 13 is a unit that calculates transport path information from item state information so as to satisfy a standard logical formula based on constraint conditions. The path calculation unit 13 searches for the transport path of each item 150 in the transport system 2. Here, between the initial movement state and the completed movement state, the transport system 2 simultaneously performs horizontal and vertical movement of each item 150, and transports each item 150 to its destination by combining these movements. At this time, the control device 10 moves the items 150 so that multiple items 150 do not interfere with each other and can be sorted quickly. At this time, the path calculation unit 13 calculates what path each item 150 will take within the transport system 2 to reach its destination.

[0026] The route calculation unit 13 calculates transport route information by calculating the reverse sequence of movement assuming that the item 150 is moved in the reverse order from the completed movement state to the initial movement state, based on the item information. The route calculation unit 13 calculates the reverse sequence of movement using, for example, a known method described in Japanese Patent Application Publication No. 2023-044014. The route calculation unit 13 calculates the reverse sequence of movement assuming that the target item is moved in the reverse order from the completed storage state to the position of the storage lane 21. The route calculation unit 13 calculates the reverse sequence of movement by searching for a route for transporting the target item from the completed storage state to the storage start state. That is, the route calculation unit 13 searches for a route that moves the target item, which is located in the storage position, in the reverse direction to the storage lane 21 where the target item originally was located. The route calculation unit 13 searches for multiple reverse sequence route patterns and adopts a reverse sequence route that can be transported efficiently. The path calculation unit 13 employs a reverse motion that allows multiple target items to flow continuously without gaps or stops, reaching the target position in the shortest possible time. However, to determine a reverse motion that allows multiple target items to flow continuously without gaps or stops, reaching the target position in the shortest possible time, the path calculation unit 13 may search for only one reverse motion pattern instead of multiple reverse motion patterns.

[0027] The path calculation unit 13 calculates the reverse-order movement assuming that the items are moved in the reverse order from the storage position in the automated warehouse 100 to the lower lane 21A. The path calculation unit 13 stores the data table of the pattern obtained in this way in the storage unit 3 as an optimization table for the lower lane 21A. The path calculation unit 13 calculates the reverse-order movement assuming that the items are moved in the reverse order from the storage position in the automated warehouse 100 to the upper lane 21B. The path calculation unit 13 stores the data table of the pattern obtained in this way in the storage unit 3 as an optimization table for the upper lane 21B.

[0028] Next, with reference to Figures 4 to 7, the procedure by which the route calculation unit 13 creates transport route information will be described in detail. In the following examples, as shown in Figure 4(a), in the initial state of movement, items 150 from the 1st to 4th floors are placed on either the lower lane 21A or the upper lane 21B. As shown in Figure 4(b), in the completed state of movement, items 150 from the 1st to 4th floors are placed on the conveyor 23 of the automated warehouse 100 for the corresponding floor.

[0029] The path calculation unit 13 calculates a first generated path assuming that the lower lane 21A exists and the upper lane 21B does not, and calculates a second generated path assuming that the upper lane 21B exists and the lower lane 21A does not. When calculating the first generated path for the lower lane 21A, the path calculation unit 13 reads an optimization table for the lower lane 21A from the storage unit 3. The path calculation unit 13 sets an optimization range OE1 for the lower lane 21A (see Figure 5). The path calculation unit 13 calculates what state is optimal for each item 150 included in the optimization range OE1 in the following operation. The optimization range OE1 includes the lower lane 21A, the conveyor 22, and the conveyors 23 on each floor adjacent to the conveyor 22. When calculating the second generated path for the upper lane 21B, the path calculation unit 13 reads an optimization table for the upper lane 21B from the storage unit 3. The path calculation unit 13 sets an optimization range OE2 for the upper lane 21B (see Figure 5). The path calculation unit 13 calculates what state each item 150 included within the optimization range OE2 should be in for the next operation. The optimization range OE2 includes the upper lane 21B, the conveyor 22, and the conveyors 23 on each floor adjacent to the conveyor 22.

[0030] The route calculation unit 13 uses a first generated route and a second generated route when calculating transport route information. The route calculation unit 13 switches between the first generated route and the second generated route when calculating transport route information. The route calculation unit 13 switches between the first generated route and the second generated route at the timing when the item 150 enters the transporter 22.

[0031] For example, let's consider the case where processing starts from the movement start state shown in the upper left of Figure 5. In this case, as shown in the lower left of Figure 5, the path calculation unit 13 calculates the first generated path assuming that the lower lane 21A exists and the upper lane 21B does not. That is, the path calculation unit 13 calculates the next optimal state based on the arrangement of items 150 in the optimization range OE1 for the lower lane 21A. From the optimization table for the lower lane 21A of the storage unit 3, the path calculation unit 13 selects the optimal arrangement for the arrangement shown in the lower left of Figure 5 as the next optimal state. The path calculation unit 13 adopts the arrangement shown in the upper right of Figure 5 as the next optimal state.

[0032] At this time, the first item 150 in the second row is in the conveyor 22. Therefore, the path calculation unit 13 switches between the first generation path and the second forming path, as shown in the lower right diagram of Figure 5. That is, the path calculation unit 13 switches from the optimization range OE1 for the lower lane 21A to the optimization range OE2 for the upper lane 21B. From the optimization table for the upper lane 21B in the storage unit 3, the path calculation unit 13 selects the optimal arrangement for the arrangement shown in the lower right diagram of Figure 5 as the next optimal state. The path calculation unit 13 adopts the arrangement shown in the upper left diagram of Figure 6 as the next optimal state.

[0033] At this time, the item 150 in the fourth row at the front of the upper lane 21B is in the conveyor 22. Therefore, the path calculation unit 13 switches between the first generation path and the second forming path, as shown in the lower left diagram of Figure 6. That is, the path calculation unit 13 switches from the optimization range OE2 for the upper lane 21B to the optimization range OE1 for the lower lane 21A. From the optimization table for the lower lane 21A in the storage unit 3, the path calculation unit 13 selects the optimal arrangement for the arrangement shown in the lower left diagram of Figure 6 as the next optimal state. The path calculation unit 13 adopts the arrangement shown in the upper left diagram of Figure 6 as the next optimal state.

[0034] At this time, the item 150 in the first row of the lower lane 21B is not in the conveyor 22. Therefore, the path calculation unit 13 does not switch between the first generation path and the second forming path. From the optimization table for the lower lane 21A of the storage unit 3, the path calculation unit 13 selects the optimal arrangement for the arrangement shown in the upper right diagram of Figure 6 as the next optimal state. The path calculation unit 13 adopts the arrangement shown in the upper left diagram of Figure 7 as the next optimal state.

[0035] At this time, the item 150 in the first row of the lower lane 21B is not in the conveyor 22. Therefore, the path calculation unit 13 does not switch between the first generation path and the second forming path. From the optimization table for the lower lane 21A of the storage unit 3, the path calculation unit 13 selects the optimal arrangement for the arrangement shown in the upper left diagram of Figure 7 as the following state. The path calculation unit 13 adopts the arrangement shown in the upper right diagram of Figure 7 as the next optimal state.

[0036] At this time, the first item 150 in the first row of the lower lane 21A is in the conveyor 22. Therefore, the route calculation unit 13 switches between the first generation route and the second forming route, as shown in the lower right diagram of Figure 7. That is, the route calculation unit 13 switches from the optimization range OE1 for the lower lane 21A to the optimization range OE2 for the upper lane 21B. From the optimization table for the upper lane 21B in the storage unit 3, the route calculation unit 13 selects the optimal arrangement for the arrangement shown in the lower right diagram of Figure 7. Here, as shown in the lower right diagram of Figure 7, a new item 150 may be added to the receiving lane 21. If the state in which a new item 150 is added does not exist in the optimization table, the route calculation unit 13 applies a mask process to the new item 150. Items 150 that exist in the mask processing range MK are treated as if they do not exist, and the optimal arrangement is selected. The route calculation unit 13 repeats this process to receive each item 150 and complete the movement.

[0037] Next, with reference to Figure 8, the specific processing details of the control device 10 will be described. However, the processing details are not limited to those shown in Figure 8. As shown in Figure 8, the path calculation unit 13 initializes the data (step S10). Next, the path calculation unit 13 reads the optimization table for the first layer (lower lane 21A) and the optimization table for the second layer (upper lane 21B) from the storage unit 3 (step S20). Next, the path calculation unit 13 sets the target layer that is assumed to exist as the first layer (step S30). Here, the path calculation unit 13 assumes that the lower lane 21A exists and the upper lane 21B does not exist.

[0038] Next, the path calculation unit 13 determines whether or not all items have completed their movement (step S40). If they are not in a completed movement state, it repeats the processing contents of "Loop 1" from steps S40 to S70. If they are in a completed movement state, it exits "Loop 1" and completes the processing shown in Figure 8. When repeating "Loop 1", the path calculation unit 13 determines whether or not the movement of all items within the optimization range has been completed (step S50). If it is determined in step S50 that the movement has not been completed, the path calculation unit 13 performs the operation according to the operation instructions (step S60).

[0039] If it is determined that the process is complete in step S50, the route calculation unit 13 resets the data of the masked items 150 (step S80). The route calculation unit 13 determines whether or not the masking process is complete (step S90), and if it is not complete, it repeats the processing contents of "loop 2" from steps S90 to S130. The route calculation unit 13 determines whether or not the current state exists in the optimization table (step S100). If it is determined in step S100 that it does not exist, the route calculation unit 13 considers the upstream item among the items 150 within the optimization range as not existing and performs the masking process (step S110). For example, a masking range MK as shown in the lower right of Figure 7 is set, recorded, and retained. Note that when step S110 is performed for the second time or later, the route calculation unit 13 performs the masking process on the upstream item among the items that have not been masked. The route calculation unit 13 records and retains the masked items 150 (step S120). For example, set the mask processing range MK as shown in the lower right of Figure 7, and record and retain it.

[0040] In step S100, if it is determined that the item exists, the path calculation unit 13 refers to the optimization table and calculates the next optimal state (step S140). Next, the path calculation unit 13 issues operation instructions to the items within the optimization range (step S160). The path calculation unit 13 also issues operation instructions to the masked items (step S170). Next, the path calculation unit 13 determines whether or not there was a forward instruction for the item 150 immediately preceding the conveyor 22 within the optimization range (step S180). If it is determined in step S180 that there was a forward instruction, the item has entered the conveyor 22 from the receiving lane 21, so the path calculation unit 13 performs a target layer switch (switching shown in Figures 5 to 7) (step S190). If it is determined in step S180 that there was no forward instruction, step S90 is not performed. After that, the process proceeds to step S60 in "Loop 1".

[0041] Next, the operation and effects of the control device 10 according to this embodiment will be described.

[0042] In the control device 10 of the logistics warehouse 1, the transport lanes include a lower lane 21A (first lane) for the first level of the transporter 22, and an upper lane 21B (second lane) for the second level of the transporter 22. Therefore, goods 150 can be transported to multiple levels, thereby improving transport capacity. In response, the route calculation unit 13 calculates a first generated route assuming that the lower lane 21A exists and the upper lane 21B does not, and calculates a second generated route assuming that the upper lane 21B exists and the lower lane 21A does not. Furthermore, when calculating transport route information, the route calculation unit 13 uses the first generated route and the second generated route. In this case, the route calculation unit 13 can perform the calculation of the first generated route with the computation load of one level, and perform the calculation of the second generated route with the computation load of one level. Even considering the computational load of using both the first and second generation paths, this type of calculation significantly reduces the computational load compared to calculating multiple layers of transport path information at once. Therefore, transport capacity can be improved while suppressing the computational load.

[0043] When creating an optimization table, it is sufficient to create one table for each level. Therefore, the size of the optimization table can be reduced. Furthermore, when adding transport lanes to an existing logistics warehouse that only has one level of transport lanes, the existing optimization table can be effectively used and extended to accommodate multiple levels. In addition, the reverse operation algorithm can be applied to other embodiments without modification.

[0044] The route calculation unit 13 calculates the transport route information by calculating the reverse sequence of movement, assuming that the items are moved in the reverse order from the completed movement state to the initial movement state, based on the item information. By calculating the transport route information using the reverse sequence of movement in this way, the computational load can be reduced. Furthermore, the route calculation unit 13 may switch between the first generated route and the second generated route when calculating the transport route information. In this case, the route calculation unit 13 only needs to perform calculations for either the first generated route or the second generated route, thus reducing the computational load. Note that the calculation of the reverse sequence of movement by the route calculation unit 13 is not necessarily required; the route calculation unit 13 can simply calculate the transport route information based on the item information.

[0045] The path calculation unit 13 may switch between the first generated path and the second generated path at the timing when an item enters the conveyor 22. For example, if the switching timing is too long, both the lower lane 21A and the upper lane 21B cannot be used effectively. On the other hand, since the path calculation unit 13 can switch at an appropriate timing, both the lower lane 21A and the upper lane 21B can be used effectively.

[0046] The present invention is not limited to the embodiments described above.

[0047] For example, in the control device 10 according to another embodiment, the route calculation unit 13 may perform both a first generated route and a second generated route when calculating transport route information. The route calculation unit 13 includes one of the first generated route and the second generated route in the transport route information, and if the other generated route does not interfere with the first generated route, it mixes the other generated route into the transport route information. As shown in the bottom diagrams of Figures 9 to 12, the optimization range for one of the generated routes is called the "main area ME". The optimization range for the other generated route is called the "secondary area SM".

[0048] The route calculation unit 13 executes optimization processing after confirming that the item 150 has stopped in all areas, including the main area ME and the secondary area SM. The route calculation unit 13 refers to the optimization table for the item 150 in the main area ME and obtains the next destination candidate in the main area ME. The route calculation unit 13 refers to the optimization table for the item 150 in the secondary area SE and obtains the next destination candidate in the secondary area SE. The route calculation unit 13 makes an adoption decision for the acquired destination candidates. For the item 150 in the main area ME, the route calculation unit 13 adopts all destination candidates as the next destination. For the item 150 in the secondary area SM, the route calculation unit 13 adopts a destination candidate if it does not interfere with the operation of the main area ME. However, this is limited to the number of items that can be transported simultaneously. For destination candidates where the item 150 in the main area ME does not flow and only the items in the secondary area SM flow, the route calculation unit 13 prevents the items in the secondary area SM from being transported.

[0049] The route calculation unit 13 may switch between one generation route and the other generation route based on the number of items 150 that can be transported by one generation route and the number of items 150 that can be transported by the other generation route. That is, the route calculation unit 13 may switch between the main area ME and the secondary area SM based on the number of items 150 that can be transported by the main area ME and the number of items 150 that can be transported by the secondary area SE. For example, the route calculation unit 13 may switch areas if the number of items transported in the main area ME is greater than the number of items transported in the secondary area SM, and maintain the areas otherwise.

[0050] The initial state of receiving goods is shown in the bottom diagram of Figure 9. The optimization range corresponding to the lower lane 21A is designated as the main area ME, and the optimization range for the upper lane 21B is designated as the secondary area SE. The calculation area CME shows a model of the calculations performed in the main area ME. In the model of the calculation area CME, the receiving lane 21 related to the secondary area SE and the goods 150 present therein are omitted. The calculation area CSE shows a model of the calculations performed in the secondary area SE. In the model of the calculation area CSE, the receiving lane 21 related to the main area ME and the goods 150 present therein are omitted.

[0051] As shown in the calculation area CME of Figure 9, the path calculation unit 13 selects the optimal arrangement from the optimization table for the lower lane 21A of the storage unit 3, for the arrangement shown in the left diagram of the calculation area CME, as the next optimal state. The path calculation unit 13 adopts the arrangement shown in the right diagram of the calculation area CME as the next optimal state. As shown in the calculation area CSE of Figure 9, the path calculation unit 13 selects the optimal arrangement from the optimization table for the upper lane 21B of the storage unit 3, for the arrangement shown in the left diagram of the calculation area CSE, as the next optimal state. The path calculation unit 13 adopts the arrangement shown in the right diagram of the calculation area CSE as a destination candidate as the next optimal state. The path calculation unit 13 determines that all destination candidates for items 150 do not interfere with the optimal state of items 150 in the main area ME, and adopts them as destinations. The state of items 150 after being moved by these processes is shown in the bottom row of Figure 10. In the diagram, items 150 that can be used as destinations are marked with a "○", and items 150 that cannot be used are marked with a "×".

[0052] As shown in the calculation area CME of Figure 10, the path calculation unit 13 selects the optimal arrangement from the optimization table for the lower lane 21A of the storage unit 3, for the arrangement shown in the left diagram of the calculation area CME, as the next state. The path calculation unit 13 adopts the arrangement shown in the right diagram of the calculation area CME as the next optimal state. As shown in the calculation area CSE of Figure 10, the path calculation unit 13 selects the optimal arrangement from the optimization table for the upper lane 21B of the storage unit 3, for the arrangement shown in the left diagram of the calculation area CSE, as the next state. The path calculation unit 13 adopts the arrangement shown in the right diagram of the calculation area CSE as a destination candidate as the next optimal state. Here, one of the destination candidates interferes with the next destination in the main area ME (item 150 marked with "×"). Therefore, the path calculation unit 13 determines that the destination candidates for all items 150 other than the one determined to interfere do not interfere with the optimal state item 150 in the main area ME, and adopts them as destinations. The candidate destinations for item 150 that are determined to cause interference are not selected as destinations. The state of item 150 after these processes are shown in the bottom row of Figure 11.

[0053] As shown in the bottom row of Figure 11, when an existing item 150 moves in the receiving lane 21, a new item 150 (in this case, an item on the second floor) is added to the receiving lane 21. Assuming there is no optimization table for the new item 150, a masking process is performed on the new item 150. As shown in the calculation area CME of Figure 11, the path calculation unit 13 selects the optimal arrangement from the optimization table for the lower lane 21A of the storage unit 3, for the arrangement shown in the left diagram of the calculation area CME, as the next optimal state. The path calculation unit 13 adopts the arrangement shown in the right diagram of the calculation area CME as the next optimal state. As shown in the calculation area CSE of Figure 11, the path calculation unit 13 selects the optimal arrangement from the optimization table for the upper lane 21B of the storage unit 3, for the arrangement shown in the left diagram of the calculation area CSE, as the next optimal state. The path calculation unit 13 adopts the arrangement shown in the right diagram of the calculation area CSE as a destination candidate. Here, three of the candidate destinations interfere with the next destination in the main area ME (items marked with "×" - 150). Note that in the right-hand diagram of the calculation area CSE in Figure 11, the rightmost item 150 marked with "×" that goes to the first floor is not accepted because it contradicts the placement in the main area ME. The middle item 150 marked with "×" that goes to the fourth floor is not accepted because it is placed in the same position as the item 150 on the first floor in the main area ME. The leftmost item 150 marked with "×" that goes to the fourth floor is not accepted because the middle item 150 marked with "×" that goes to the fourth floor cannot move. Therefore, the path calculation unit 13 determines that the candidate destinations for all items 150 that were determined to interfere do not interfere with the optimal state of item 150 in the main area ME and accepts them as destinations. The candidate destinations for the items 150 that were determined to interfere are not accepted as destinations. The state of item 150 after these processes have been performed is shown in the bottom row of Figure 12.

[0054] As shown in the bottom row of Figure 12, the path calculation unit 13 switches between the main area ME and the secondary area SM, making the upper lane 21B the main area ME and the lower lane 21A the secondary area SE. As shown in the calculation area CME of Figure 12, the path calculation unit 13 selects the optimal arrangement from the optimization table for the upper lane 21B of the storage unit 3, for the arrangement shown in the left diagram of the calculation area CME, as the next state. The path calculation unit 13 adopts the arrangement shown in the right diagram of the calculation area CME as the next optimal state. As shown in the calculation area CSE of Figure 12, the path calculation unit 13 selects the optimal arrangement from the optimization table for the lower lane 21A of the storage unit 3, for the arrangement shown in the left diagram of the calculation area CSE, as the next state. The path calculation unit 13 adopts the arrangement shown in the right diagram of the calculation area CSE as a destination candidate as the next optimal state. The path calculation unit 13 determines that all destination candidates for items 150 do not interfere with the optimal state of items 150 in the main area ME, and adopts them as destinations. The route calculation unit 13 repeats the same process until the receiving of goods is complete.

[0055] Next, the specific processing details of the control device 10 will be explained with reference to Figures 13 to 15. However, the processing details are not limited to those shown in Figures 13 to 15. As shown in Figure 13, the path calculation unit 13 initializes the data (step S200). Next, the path calculation unit 13 reads the optimization table for the first layer (lower lane 21A) and the optimization table for the second layer (upper lane 21B) from the storage unit 3 (step S210). Next, the path calculation unit 13 sets the optimization range for the first layer to the main area and the optimization range for the second layer to the secondary area (step S220). Here, the path calculation unit 13 sets the optimization range for the lower lane 21A to the main area and the optimization range for the upper lane 21B to the secondary area. The path calculation unit 13 sets the count for the main area to "mainCount=0" and the count for the secondary area to "secondaryCount=0" (step S230).

[0056] Next, the path calculation unit 13 determines whether or not all items have completed their movement (step S40). If they are not in a completed movement state, it repeats the processing contents of "loop 3" from steps S240 to S280. If they are in a completed movement state, it exits "loop 3" and completes the processing shown in Figure 13. When repeating "loop 3", the path calculation unit 13 sets the flag indicating that items 150 enter the conveyor 22 in the main area to "main IN=false" and the flag indicating that items 150 enter the conveyor 22 in the secondary area to "secondary IN=false" (step S250). The path calculation unit 13 determines whether or not the operation of all items 150 within the optimization range has been completed (step S260). If it is determined in step S260 that the operation has not been completed, the path calculation unit 13 performs the operation according to the operation instructions (step S280).

[0057] If it is determined that step S50 is complete, the route calculation unit 13 performs the next optimal state calculation process for the main area (step S300). If the route calculation unit 13 receives a forward instruction for the item 150 immediately preceding the conveyor 22 in the main area, it sets a flag to "main IN=true" (step S310). The route calculation unit 13 performs the next optimal state calculation process for the subordinate area (step S320). The route calculation unit 13 obtains candidate destinations for each item 150 in the subordinate area. As shown in Figure 15, the processing of the next optimal state calculation process in steps S300 and S320 is the same as the processing in steps S90 to S170 in Figure 8.

[0058] The route calculation unit 13 registers the arrangements identified as candidates for the next destination by the processing in step S300 as destinations for the items in the main area (step S330). Meanwhile, the route calculation unit 13 extracts items 150 that exist only in the secondary areas (step S340). For example, in the example shown in Figure 11, the items 150 shown in P1 and P2 are items 150 that exist only in the secondary areas. If we indicate items 150 that exist only in the secondary areas as "Secondary Only (i=1:N)", then in the example in Figure 11, there are two items 150 that exist only in the secondary areas, so "N=2". For example, item 150 at P1 may be designated as "Secondary Only (1)" and item 150 at P2 as "Secondary Only (2)".

[0059] As shown in Figure 14, the route calculation unit 13 determines whether all adoption determination processes for items 150 that exist only in the subordinate area have been completed (step S350). If not, it repeats the processing contents of "loop 4" from steps S35 to S420. The route calculation unit 13 refers to the destination candidate in step S320 and obtains the position in the next optimal state of "subordinate Only (i)" (step S360). Next, the route calculation unit 13 determines whether the "subordinate Only (i)" item 150 interferes with a registered operation (step S380). The state in which the "subordinate Only (i)" item 150 does not interfere is either a state in which it does not match the destination of a registered item in the main area, or a state in which an item currently exists and its destination is not registered.

[0060] If it is determined in step S370 that there is no interference, the path calculation unit 13 determines whether or not "Subordinate Only(i)" is the root item (step S380). The root item is item 150, indicated as "PR" in the lower part of Figure 11. If it is determined in step S380 that "Subordinate Only(i)" is not the root item, the path calculation unit 13 registers a candidate destination for "Subordinate Only(i)" as the destination (step S410).

[0061] If it is determined in step S380 that "Subordinate Only(i)" is the root item, the route calculation unit 13 determines whether "Main IN = true" is true (step S390). If it is determined in step S390 that "Main IN = true", the route calculation unit 13 determines whether the number of items 150 in the conveyor 22 is less than or equal to a limit value (step S400). If it is determined in step S400 that it is less than or equal to a limit value, the route calculation unit 13 registers a candidate destination for "Subordinate Only(i)" as the destination (step S410). If it is determined to be No in steps S370, S390, and S400, the route calculation unit 13 does not adopt a candidate destination for "Subordinate Only(i)".

[0062] When Loop 4 is completed, the route calculation unit 13 sets a flag to "Subordinate IN = true" if there is a forward instruction for the item 150 immediately preceding the transporter 22 in the subordinate area (step S430). If "Main IN = true", the route calculation unit 13 increments the count of the main area by 1 to "Main Count += 1" (step S440). If "Subordinate IN = true", the route calculation unit 13 increments the count of the subordinate area by 1 to "Subordinate Count += 1" (step S440). The route calculation unit 13 determines whether the count of the main area is greater than the count of the subordinate area (step S460). If step S460 is Yes, the route calculation unit 13 swaps the main area and the subordinate area (step S470). If step S460 is No, no swap is performed. The route calculation unit 13 determines whether the count in the main area is greater than or equal to the number of items in the main area, and whether the count in the secondary area is less than the number of items in the secondary area (step S480). If step S480 is Yes, the route calculation unit 13 swaps the main area and the secondary area (step S470). If step S460 is No, no swap is performed. If a swap is performed in step S470, the swap in step S490 may or may not be performed. Once step S490 is completed, the process returns to step S270 in Figure 13.

[0063] When calculating transport path information, the path calculation unit 13 performs both first and second generation path generation, and includes one of the first and second generation paths in the transport path information. If the other generation path does not interfere with the first generation path, it may also mix the other generation path into the transport path information. In this case, the path calculation unit 13 can use one generation path as the main path while supplementing the other generation path as a subordinate path. This reduces the computational load and allows for effective use of the lower lane 21A and the upper lane 21B.

[0064] The route calculation unit 13 may switch between one generation route and the other generation route based on the number of items that can be transported on one generation route and the number of items that can be transported on the other generation route. In this case, the main lane can be switched at an appropriate timing.

[0065] In the configurations shown in Figures 4 to 8, the timing for switching between the first and second generation paths is not limited to the timing when the item 150 enters the conveyor 22, but can be changed as appropriate. For example, the switching may occur when the item 150 has entered the conveyor 22 a predetermined number of times. In the configurations shown in Figures 9 to 15, the conditions for switching between the main area and the secondary area are not limited to those described above.

[0066] In the above-described embodiment, the transport lanes were provided for two and three levels, but the level to which they are provided is not particularly limited. Also, the levels of the lower lane 21A and the upper lane 21B do not have to be adjacent; for example, the lower lane 21A may be provided for one level and the upper lane 21B for three levels. Furthermore, although the transport lanes were provided for two levels, they may also be provided for three levels. In addition, the number of levels in the logistics warehouse may exceed four, in which case the transport lanes may be provided for three or more levels.

[0067] In the above embodiment, the scenario of receiving goods into storage was used as an example, but it may also be used for route calculation for goods being shipped out. [Explanation of symbols]

[0068] 1...Logistics warehouse, 10...Control device, 13...Route calculation unit, 21...Conveyor lane, 21A...Lower lane (1st lane), 21B...Upper lane (2nd lane), 150...Items.

Claims

1. An automated warehouse for storing goods, A transport lane for transporting multiple items arranged in a line, A control device for a logistics warehouse, comprising a conveyor installed between the conveyor lane and the automated warehouse, When the article moves in the order of the transport lane, the transporter, and the automated warehouse, or when it moves in the order of the automated warehouse, the transporter, and the transport lane, an article information acquisition unit acquires article information indicating the initial state and completed state of the article's movement. A route calculation unit calculates transport route information based on the aforementioned item information, The system includes an operation control unit that controls the transport operation of the logistics warehouse based on the transport route information, The transport lane includes a first lane for the first level of the transport machine and a second lane for the second level of the transport machine. The aforementioned path calculation unit, The calculation of the first generation path is performed assuming that the first lane exists and the second lane does not, and the calculation of the second generation path is performed assuming that the second lane exists and the first lane does not. A control device for a logistics warehouse that uses the first generated path and the second generated path when calculating the transport path information.

2. When calculating the transport route information, the route calculation unit calculates the reverse sequence of movement based on the item information, assuming that the item is moved in the reverse order from the completed movement state to the initial movement state. The control device for a logistics warehouse according to claim 1, wherein the route calculation unit switches between the first generated route and the second generated route when calculating the transport route information.

3. The control device for a logistics warehouse according to claim 2, wherein the path calculation unit switches between the first generated path and the second generated path at the timing when an item enters the conveyor.

4. When the route calculation unit calculates the transport route information, it performs both the first generated route and the second generated route. A control device for a logistics warehouse according to claim 1, wherein one of the first generation path and the second generation path is included in the transport path information, and if the other generation path does not interfere with the first generation path, the other generation path is mixed into the transport path information.

5. The control device for a logistics warehouse according to claim 4, wherein the route calculation unit switches between the one generation route and the other generation route based on the number of items that can be transported by the one generation route and the number of items that can be transported by the other generation route.

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