Simulation system and picking station layout design method

Abstract

To verify the layout of a picking station in a simulation system.SOLUTION: A simulation system 1 includes a virtual space creating unit 3, a measuring unit 5, and a calculating unit 7. The virtual space creating unit 3 three-dimensionally expresses a picking station 41 in a virtual space VS. The measuring unit 4 measures, when a worker 61 wearing a head-mount display 21 carries out a work of picking an article W on the basis of a virtual order at the picking station 41 in the virtual space VS, a time needed for the picking work. The calculating unit 7 calculates the processing capacity of the picking station 41 on the basis of the time needed for the picking work.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present invention relates to a simulation system, and more particularly to a system capable of simulating a picking operation at a picking station. [Background technology]

[0002] A picking station is a facility where workers sort items. For example, buckets removed from racks by stacker cranes in an automated warehouse are transported to a picking station. At the picking station, workers sort items by removing them from the buckets and placing them in other containers. A method is known in which a schematic layout of a logistics facility is created and a performance evaluation simulation is performed (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2002-197128 A Summary of the Invention [Problem to be solved by the invention]

[0004] The layout of the picking stations is determined by drawing plans using, for example, CAD. In such cases, however, it is difficult to determine whether the spatial space of the picking station is appropriate, whether the worker's operating position is appropriate, and so on.

[0005] An object of the present invention is to verify the layout of a picking station in a simulation system. [Means for solving the problem]

[0006] In the following, several aspects will be described as means for solving the problems. These aspects can be arbitrarily combined as necessary.

[0007] A simulation system according to one aspect of the present invention includes a virtual space creating unit, a measuring unit, and a calculating unit. The virtual space creation unit represents the picking station in three dimensions within the virtual space. When a worker wearing the head mounted display picks an item based on a virtual order at a picking station in the virtual space, the measurement unit measures the time taken for the picking operation. The calculation unit calculates the processing capacity of the picking station based on the time taken for the picking operation.

[0008] In this simulation system, when a worker picks items based on a virtual order at a picking station in a virtual space, the processing capacity of the picking station is obtained. In this way, it is possible to verify the operability of a specific layout of a picking station without the need to prototype an actual machine. As a result, a picking station with a layout that places less of a burden on workers can be obtained. It should be noted that a "picking station" is a facility where workers sort items. It should be noted that "virtual space" refers to a virtual space in, for example, VR (virtual reality), AR (augmented reality), MR (mixed reality), or a combination thereof.

[0009] A picking completion switch may be provided in the virtual space. The time taken for a picking operation may be the time from when an item arrives at the picking operation location, when a worker picks the item based on a virtual order, until the worker operates the picking completion switch after picking of all items included in the order is completed. In this simulation system, the time actually spent by the worker is obtained as the time required for the picking task. In other words, the time required for the transportation equipment is not included in the time required for the picking task, so the workability at the picking station can be obtained accurately.

[0010] The system may further include a determination unit. The determination unit may determine the picking operation ability of the worker based on the time taken for the picking operation. In this simulation system, the picking work ability of a worker can be determined, so that, for example, the calculation unit can calculate the processing capacity of a picking station by taking into account the picking work ability of the worker.

[0011] A method for designing a layout of a picking station according to another aspect of the present invention includes the following steps. ◎The step of representing the picking station in 3D within the virtual space. A step in which a worker wearing the head mounted display picks items based on a virtual order at a picking station in the virtual space, and the time taken for the picking task is measured. Calculating the processing capacity of the picking station based on the time taken for the picking operation. A step of determining a layout of the picking stations based on the processing capacity of the picking stations. In this method, when a worker performs picking work based on a virtual order at a picking station in a virtual space, the processing capacity of the picking station is obtained. In this way, the operability of a specific layout of a picking station can be verified without the need for a real prototype. As a result, a picking station with a layout that places less of a burden on workers can be obtained. Effect of the Invention

[0012] In the simulation system according to the present invention, the layout of the picking stations is verified. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is a schematic diagram showing a schematic configuration of a simulation system according to a first embodiment. [Diagram 2] FIG. 1 is a block diagram showing a configuration of an information processing device and peripheral devices. [Diagram 3] FIG. [Figure 4] FIG. 13 is a diagram showing an image in a virtual space from the viewpoint of a worker object. [Diagram 5] 11 is a flowchart showing a layout capability calculation control operation. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] 1. First embodiment (1) Simulation System A simulation system 1 will be described with reference to Figures 1 and 2. Figure 1 is a schematic diagram showing a schematic configuration of a simulation system according to a first embodiment. Figure 2 is a block diagram showing the configuration of an information processing device and peripheral devices. The simulation system 1 is a system for designing a picking station by simulating the actions of a worker in a virtual space VS in order to design the picking station. The virtual space VS is a life-size space created using virtual reality technology (VR). The virtual space VS is created based on 3D CAD data. In the simulation system 1, a worker 61 wearing a head mounted display 21 performs a picking task in a virtual space VS.

[0015] (2) Information processing device The simulation system 1 is executed by an information processing device 3. That is, the information processing device 3 provides a worker interface in the virtual reality VR that the worker 61 experiences through the head mounted display 21.

[0016] The information processing device 3 is a computer system having a processor (e.g., a CPU), a storage device (e.g., a ROM, a RAM, a HDD, an SSD, etc.), and various interfaces (e.g., an A / D converter, a D / A converter, a communication interface, etc.) The information processing device 3 performs various control operations by executing programs stored in a storage unit 19 (corresponding to a part or all of the storage area of ​​the storage device). The information processing device 3 may be configured with a single processor, or may be configured with a plurality of independent processors for each control. A part or all of the functions of each element of the information processing device 3 may be realized as a program executable by a computer system constituting a control unit. In addition, a part of the functions of each element of the information processing device 3 may be configured by a custom IC.

[0017] The information processing device 3 includes an object management unit 5 . The object management unit 5 manages a plurality of objects that hold information by associating them with each other based on the information that each object holds. The object management unit 5 includes an object database in which all objects placed in the virtual space are registered. In this embodiment, the objects are the work station 43, the first conveyor 45, the second conveyor 47, the first bucket 49, the second bucket 51, the article W, the display 53 (FIG. 4), and the picking completion switch 55 (FIG. 4) that configure the picking station 41, as shown in FIG 3. Note that FIG 3 is a schematic perspective view of the virtual space.

[0018] The information processing device 3 includes a virtual space creating unit 7 . The virtual space creation unit 7 uses objects registered in the object database to construct a virtual space VS within a memory section of a memory included in the information processing device 3. In the virtual space VS, the above-mentioned picking station 41 is represented in three dimensions. The virtual space creation unit 7 also places a worker object 63 representing a worker 61 within the constructed virtual space VS, and displays an image of the virtual space VS with the worker object 63 as the viewpoint on a display (described later) of the head-mounted display 21. The virtual space creation unit 7 reflects the posture, hand movements, and position of the worker 61 in the real space to the worker object 63 (described later). In addition, the virtual space creation unit 7 detects the movement of the worker object 63 in the virtual space VS from the reflection result (described later).

[0019] To the information processing device 3, a head mounted display 21 and a position detection device 23 for detecting the position of the worker 61 are connected. The head mounted display 21 is equipped with a motion sensor 27 that detects the movement of the head mounted display 21 itself, and an infrared sensor 29 that detects the movement of the hands of the worker 61 wearing it.

[0020] The motion sensor 27 includes an acceleration sensor (not shown) and an angular velocity sensor (not shown), and outputs a signal that specifies the movement of the head mounted display 21 itself. The infrared sensor 29 includes a light source (not shown) that outputs infrared rays, and an imaging element that receives infrared rays reflected by the hand of the worker 61, and outputs an infrared image as a signal. The head mounted display 21 and the sensors used therein are not particularly limited. In this embodiment, various head mounted displays and sensors that will be developed in the future can be used.

[0021] The head mounted display 21 has a display 25. The display 25 displays a field of view from a worker object 63 in the virtual space VS (described later).

[0022] The information processing device 3 includes a worker action detection unit 9 . The worker motion detection unit 9 detects the motion of the worker 61 in the virtual space VS. Specifically, the worker motion detection unit 9 detects the posture and hand motion of the worker 61 in the real space based on a signal from the motion sensor 27, a signal from the infrared sensor 29, and a signal from the position detection device 23.

[0023] The information processing device 3 includes a measurement unit 11 . When a worker 61 wearing a head mounted display 21 picks an item W based on a virtual order at a picking station 41 in the virtual space VS, the measurement unit 11 measures the time taken for the picking operation. The order is stored in advance in the storage unit 19 of the information processing device 3, and is used in order by being linked to a generated bucket. The "virtual order" can be generated randomly, or can utilize actual performance data.

[0024] The information processing device 3 includes a calculation unit 13 . The calculation unit 13 calculates the processing capacity of the picking station 41 based on the time taken for the picking operation.

[0025] The information processing device 3 includes a layout determination unit 15 . The layout determination unit 15 can compare the processing capacities of a plurality of picking stations 41 and determine the superior one.

[0026] (3) Operation (3-1) Premise The virtual space creation unit 7 uses objects registered in the object database to construct a virtual space VS within a memory section of a memory provided in the information processing device 3. A picking station 41 and a worker object 63 are placed within the virtual space VS. The virtual space creation unit 7 displays an image of the virtual space VS from the viewpoint of a worker object 63 on the display 25 of the head mounted display 21, as shown in Fig. 4. This allows the worker 61 to experience virtual reality. Fig. 4 is a diagram showing an image of the virtual space from the viewpoint of the worker object.

[0027] (3-2) Basic operation The worker movement detection unit 9 detects the posture, hand movements, and position of the worker 61 in real space based on signals from the motion sensor 27 and infrared sensor 29 of the head mounted display 21 and image data from the position detection device 23. The virtual space creation unit 7 reflects the posture, hand movements, and position of the worker 61 in the real space in the worker object 63.

[0028] The virtual space creation unit 7 detects the motion of the worker object 63 in the virtual space VS from the reflection result. If the motion of the worker object 63 moves another object, the virtual space creation unit 7 reflects the motion on the other object. For example, when the worker object 63 picks up, moves, or puts down an item W in the virtual space VS, the motion is realized as the movement of the item W in the virtual space VS. The movements of the worker object 63 and the object W in the virtual space VS described below are based on the above basic movements.

[0029] (3-3) Layout capacity calculation control operation In this simulation system 1, a worker object 63 performs picking work based on a virtual order at a picking station 41 in a virtual space VS. A picking operation in the virtual space VS will be described with reference to Fig. 5. Fig. 5 is a flow chart showing the layout ability calculation control operation.

[0030] In step S1, a virtual space VS is constructed and displayed as shown in Fig. 3. At this time, a worker object 63 is standing in front of the work station 43 of the picking station 41. In addition, the number of items W to be picked from each first bucket 49 is displayed on the display 53 (Fig. 4).

[0031] In step S2, transportation of the items W is started in the virtual space VS. Specifically, the first conveyor 45 supplies the first bucket 49 containing a plurality of items W to the work station 43. The worker object 63 can pick up the items W in the first bucket 49 that has arrived and place them in the second bucket 51. When the picking completion switch 55 is operated, the first bucket 49 that has been picked is carried out by the second conveyor 47, and then a new first bucket 49 is carried into the work station 43. In the above work, the worker 61 can enter the virtual space VS and get a feel for the space and check the height and other positions of various devices.

[0032] In step S3, it is determined whether the picking completion switch 55 (FIG. 4) is pressed after picking of all the items W included in one order has been completed in the virtual space VS. If pressed, the process proceeds to step S4.

[0033] In step S4, the measurement unit 11 measures the time taken for one picking operation. The time taken for the picking operation is the time from when the first first bucket 49 arrives at the work station 43, when the worker object 63 picks based on the virtual order (grabs each item W and replaces it), and when picking of all items W included in the order is completed, until the worker object 63 operates the picking completion switch 55. Therefore, the time taken for the worker object 63 to actually perform the work is obtained as the time taken for the picking operation. In other words, the time taken for the first conveyor 45 and the second conveyor 47 is not included in the time taken for the picking operation.

[0034] In step S5, the calculation unit 13 calculates the processing capacity of the picking station 41. Specifically, the calculation unit 13 calculates the number of items to be processed per unit time. In this way, the operability of a particular layout of picking station 41 can be verified without the need for a prototype.

[0035] The above explanation is about calculating the processing capacity of one picking station 41, but the design of the picking station is determined by calculating the processing capacities for multiple picking stations with different layouts and dimensions and then comparing them with each other. Specifically, after the processing capacities of a plurality of mutually different picking stations 41 are calculated, the layout determination unit 15 determines the layout of the picking stations based on the processing capacities of the picking stations 41. Note that the differences between the picking stations 41 include the direction of entry and exit of the items W, the location of the empty bucket, the position and height of the items W to be taken out, and the position and height of the items W to be put in. By using the above-described method for designing the layout of a picking station, it is possible to obtain a picking station with a layout that places less strain on the worker 61 when he or she operates the actual machine.

[0036] The information processing device 3 further includes a determination unit 17. The determination unit 17 determines the picking operation ability of the worker 61 based on the time taken for the picking operation. Since the picking operation capability of the worker 61 can be determined in this manner, for example, the calculation unit 13 can calculate the processing capability of the picking station 41 by taking into account the picking operation capability of the worker 61. Specifically, by having a plurality of workers 61 perform the same work using picking stations 41 with the same layout and shape, the picking work ability of the workers 61 can be determined based on the length of work time. Then, the calculation unit 13 can calculate the processing ability of the picking station 41 by taking into account the work ability of the workers 61 who belong to a specific group (for example, a group by region, age, or gender), for example.

[0037] 2. Features of the embodiment The above first embodiment can also be explained as follows. The simulation system 1 (an example of a simulation system) includes a virtual space creating unit 7, a measuring unit 11, and a calculating unit 13. The virtual space creation unit 7 (an example of a virtual space creation unit) three-dimensionally represents a picking station 41 (an example of a picking station) within a virtual space VS (an example of a virtual space). When a worker 61 wearing a head-mounted display 21 (an example of a head-mounted display) picks an item W (an example of an item) based on a virtual order at a picking station 41 in the virtual space VS, the measurement unit 11 (an example of a measurement unit) measures the time taken for the picking operation. The calculation unit 13 (an example of a calculation unit) calculates the processing capacity of the picking station 41 based on the time taken for the picking operation.

[0038] In this simulation system 1, when a worker 61 performs picking work based on a virtual order at a picking station 41 in a virtual space VS, the processing capacity of the picking station 41 is obtained. In this way, it is possible to verify the operability in a specific layout of a picking station without the need to prototype an actual machine. As a result, a picking station with a layout that places less of a burden on the worker 61 can be obtained.

[0039] 3. Other embodiments Although one embodiment of the present invention has been described above, the present invention is not limited to the above embodiment, and various modifications are possible without departing from the spirit of the invention. In particular, the multiple embodiments and modifications described in this specification can be arbitrarily combined as necessary.

[0040] In the above embodiment, VR (Virtual Reality) technology is used as a technology for realizing the "virtual space." However, the "virtual space" may be realized by VR, AR (Augmented Reality), MR (Mixed Reality), SR (Replacement Reality), or a combination thereof.

[0041] The types of hardware and software for realizing the virtual space are not particularly limited. The position detection device may be, for example, a camera-type sensor. In addition to or separately from the position detection device, a glove or a controller may be used to detect the movement of the worker's hands. The type of picking station, the type and number of conveyors, and the actual work of the worker are not limited to those in the first embodiment. Picking may be an operation of carrying an article from a bucket to a placement location other than the bucket. The layout determination section and the determination section may be omitted. [Industrial Applicability]

[0042] The present invention can be widely applied to systems capable of simulating picking operations at a picking station. [Explanation of symbols]

[0043] 1: Simulation system 3: Information processing equipment 5: Object Management Section 7: Virtual space creation section 9: Worker movement detection unit 11: Measurement section 13: Calculation section 15: Layout determination section 17: Judgment section 19: Storage section 21: Head-mounted display 23: Position detection device 25: Display 27: Motion sensor 29: Infrared sensor 41: Picking station 43:Work station 45: First conveyor 47: Second conveyor 49: First bucket 51: Second bucket 53:Display unit 55: Picking completion switch 61: Worker 63: Worker object VS: Virtual Space W:Goods

Claims

1. a virtual space creation unit that represents the picking station in three dimensions within a virtual space; a measuring unit that measures a time taken for a picking operation in which an operator wearing a head mounted display picks an item from one container to another container based on a virtual order at the picking station in the virtual space; and A calculation unit that calculates a processing capacity of the picking station based on a time taken for the picking operation; a layout determination unit that, after the calculation unit calculates the processing capacities for a plurality of picking stations having different layouts and / or dimensions in a virtual space, compares the processing capacities of the respective picking stations with each other; Equipped with a picking completion switch is provided in the virtual space, The time taken for the picking operation is the time from when the item arrives at the picking operation location, until the worker picks the item based on a virtual order, until the worker operates the picking completion switch after picking all items included in the order is completed.

2. The simulation system according to claim 1 , further comprising a determination unit that determines a picking operation ability of the worker based on a time taken for the picking operation.

3. Representing the picking station in three dimensions in a virtual space; a step of measuring a time taken for a picking operation in which an operator wearing a head mounted display picks an item from one container to another container based on a virtual order at the picking station in the virtual space; Calculating a processing capacity of the picking station based on a time taken for the picking operation; A step of three-dimensionally representing a layout and / or a plurality of picking stations having different dimensions in the virtual space, a step of measuring a time taken for a picking operation, and a step of calculating a processing capacity of the picking station, and a step of comparing the calculated processing capacities of the plurality of picking stations to determine a layout of the picking stations; A method for designing a layout of a picking station, comprising: a picking completion switch is provided in the virtual space, The picking station layout design method, wherein the time taken for the picking operation is the time from when the item arrives at the picking operation position, when the worker picks the item based on a virtual order, and when picking of all items included in the order is completed, until the worker operates the picking completion switch.

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