Automated Warehouse System

Abstract

To provide an automatic warehouse system capable of suppressing reduction of operation efficiency even when a recovery operation is performed.SOLUTION: An automatic warehouse system includes: a storage stage of a plurality of steps capable of storing a load; and a conveyance control part for controlling a carriage for conveying the load. When an abnormality occurs at any storage stage of the plurality of steps during automatic driving (step S1), the conveyance control part stops only driving of the storage stage where the abnormality occurs and driving of the designated storage stage (step 7).SELECTED DRAWING: Figure 10

Description

[Technical field]

[0001] The present invention relates to an automated warehouse system, and more particularly to an automated warehouse system having multiple storage shelves. [Background technology]

[0002] There are known automated warehouse systems that can efficiently store and retrieve a large number of items in a small space. Various configurations of the automated warehouse system have been proposed (for example, Patent Document 1).

[0003] In an automated warehouse system such as that described in Patent Document 1, when an abnormality such as cargo collapse occurs within the warehouse, the entire system is stopped to ensure the safety of workers performing recovery work, and then the workers go to the location where the abnormality occurred and perform the recovery work. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2017-160040 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, if the entire automated warehouse system were to be stopped when an abnormality occurred, work would also be stopped at storage shelves where no abnormalities were occurring, which would result in a decrease in the operating efficiency of the automated warehouse system.

[0006] Therefore, the present invention has been made to solve the above-mentioned problems, and aims to provide an automated warehouse system that can suppress a decrease in operating efficiency even when recovery work is being carried out. [Means for solving the problem]

[0007] In order to solve the above problems, one aspect of the present invention is an automated warehouse system comprising a multi-tiered storage stage capable of storing goods, and a transport control unit that controls a transport mechanism that transports the goods, wherein when an abnormality occurs in any of the multi-tiered storage stages during automatic operation, the transport control unit stops operation of only the storage stage in which the abnormality occurred and the operation of only the specified storage stage.

[0008] According to this configuration, the number of storage shelves that need to be shut down when an abnormality occurs can be reduced, and a decrease in operating efficiency can be suppressed.

[0009] Another aspect of the present invention is an automated warehouse system comprising a multiple storage stage capable of storing goods, and a transport control unit that controls a transport mechanism that transports the goods, and when an abnormality occurs in any of the multiple storage stages during automatic operation, the transport control unit stops operation of the storage stage in which the abnormality occurred, and controls the transport mechanism to enable the transport of goods by the transport mechanism in a storage stage other than the storage stage in which the abnormality occurred.

[0010] According to this configuration, the number of storage shelves that need to be shut down when an abnormality occurs can be reduced, and a decrease in operating efficiency can be suppressed. Effect of the Invention

[0011] As described above, according to the present invention, a decrease in operating efficiency can be suppressed even when recovery work is being performed. [Brief description of the drawings]

[0012] [Figure 1] 1 is a plan view illustrating an example of an automated warehouse system according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a plan view showing the arrangement of storage shelves in the automated warehouse system of FIG. [Diagram 3] FIG. 2 is a front view showing a schematic configuration of the automated warehouse system of FIG. [Figure 4]FIG. 2 is a front view showing the arrangement of storage shelves in the automated warehouse system of FIG. [Diagram 5] 2 is a plan view illustrating an example of a first cart in the automated warehouse system of FIG. 1. [Figure 6] FIG. 6 is a side view of the first bogie of FIG. 5. [Figure 7] 2 is a plan view illustrating an example of a second cart in the automated warehouse system of FIG. 1. [Figure 8] FIG. 8 is a side view of the second bogie of FIG. [Figure 9] FIG. 2 is a block diagram of the automated warehouse system of FIG. 1. [Figure 10] FIG. 2 is a flow chart showing the operation of the automated warehouse system of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] The present invention will be described below based on preferred embodiments with reference to the drawings. In the embodiments, comparative examples, and modified examples, the same or equivalent components and members are given the same reference numerals, and duplicated descriptions are omitted as appropriate. The dimensions of the members in each drawing are enlarged or reduced as appropriate for ease of understanding. Some of the members that are not important for explaining the embodiments are omitted in each drawing.

[0014] In addition, terms including ordinal numbers such as first, second, etc. are used to describe various components, but these terms are used only for the purpose of distinguishing one component from another component, and the components are not limited by these terms.

[0015] [First embodiment] The configuration of an automated warehouse system according to an embodiment will be described with reference to the drawings. FIG. 1 is a plan view that shows an example of an automated warehouse system according to an embodiment. FIG. 2 is a plan view that shows the arrangement of storage shelves in the automated warehouse system. FIG. 3 is a front view that shows an example of the automated warehouse system. FIG. 4 is a front view that shows the arrangement of storage shelves in the automated warehouse system. In these figures, the illustration of pillars, beams, and the like that are not important for the explanation are omitted, and the same applies to the following figures.

[0016] For convenience of explanation, as shown in the figure, an XYZ orthogonal coordinate system is defined in which a certain horizontal direction is the X direction, a horizontal direction perpendicular to the X direction is the Y direction, and a direction perpendicular to both, i.e., a vertical direction, is the Z direction. Note that, in the following explanation, the XYZ orthogonal coordinate system is used for explanation, but the X direction, Y direction, and Z direction do not necessarily have to be perpendicular to each other, as long as they intersect at approximately 90 degrees. The positive directions of the X axis, Y axis, and Z axis are defined as the directions of the arrows in each figure, and the negative directions are defined as the directions opposite to the arrows. In addition, the positive direction side of the X axis is sometimes called the "right side", and the negative direction side of the X axis is sometimes called the "left side". In addition, the positive direction side of the Y axis is sometimes called the "front side", the negative direction side of the Y axis is sometimes called the "rear side", the positive direction side of the Z axis is sometimes called the "upper side", and the negative direction side of the Z axis is sometimes called the "lower side". Such directional notations do not limit the configuration of the automated warehouse system, and the automated warehouse system can be used in any configuration depending on the application.

[0017] First, the overall configuration of the automated warehouse system 1 will be described. The automated warehouse system 1 is a system including a storage shelf 4 capable of storing a large number of items 2. The automated warehouse system 1 includes the storage shelf 4, a first cart 6, a second cart 8, a first rail 10, a second rail 12, a power supply unit (not shown), and a control unit 14. The storage shelf 4 stores the items 2. In this embodiment, the X-axis direction is exemplified as the first direction. The first rail 10 extends in the X-axis direction. The power supply unit includes a power supply line extending in the Y-axis direction near the second rail 12.

[0018] The first carriage 6 travels in the X-axis direction on the first rail 10. The second carriage 8 travels in the Y-axis direction on the second rail 12. The first carriage 6 and the second carriage 8 are sometimes collectively referred to simply as carriages. Also, the first carriage 6, the second carriage 8, the first rail 10, and the second rail 12 are sometimes collectively referred to simply as the "transport mechanism." The control unit 14 controls the operation of the first carriage 6 and the second carriage 8.

[0019] In the first embodiment, the load 2 is handled while placed on a pallet, but this is not limited thereto, and the load 2 may be handled independently without using a pallet. Transporting the load 2 while placed on a pallet is simply referred to as transporting the load 2.

[0020] The storage and retrieval operations of the automated warehouse system 1 will be described. The automated warehouse system 1 carries the goods 2 from outside the warehouse into the receiving section 18, for example, by a forklift (not shown). The automated warehouse system 1 transports the goods 2 carried into the receiving section 18 to a predetermined storage section 20 by a transport mechanism including a first cart 6 and a second cart 8, and stores the goods. The automated warehouse system 1 also transports the goods 2 stored in the predetermined storage section 20 to an unloading section 22 by the transport mechanism. The automated warehouse system 1 removes the goods 2 transported to the unloading section 22 outside the warehouse, for example, by a forklift.

[0021] (Storage shelf) The storage shelf 4 is a so-called high-density storage type storage space capable of storing a large number of loads 2. The configuration of the storage shelf 4 is not particularly limited as long as it can accommodate and store a plurality of loads 2. In this example, the storage shelf 4 includes a plurality of storage stages 24 (for example, four stages) stacked in layers in the vertical direction. Each storage stage 24 includes a plurality of storage rows 26 (for example, seven) arranged in the Y-axis direction. Six of the seven storage rows 26 include a plurality of storage sections 20 (for example, twelve) arranged in the X-axis direction. The remaining row of the seven storage rows 26 includes a plurality of storage sections 20 (for example, six) arranged in the X-axis direction. In the illustrated example, six of the seven storage rows 26 have six storage sections 20 on each of the right and left sides of the second rail 12, and the remaining row has six storage sections 20 on the left side of the second rail 12. However, the number of storage rows 26, the number of storage sections 20 in each storage row 26, and the positions of the second rails 12 can be changed as appropriate according to the shape of the warehouse. The storage section 20 is a unit for storing the goods 2.

[0022] Here, each of the multiple storage stages 24 is provided with an entrance section 18 and an exit section 22, and the goods 2 may be entered into or exited from each storage stage 24 by a forklift. Alternatively, a lifting mechanism (not shown) for raising and lowering the goods 2 may be provided separately for each storage stage 24, and the entrance section 18 and the exit section 22 may be provided only for the lowest storage stage 24. In this case, the goods 2 entered from the entrance section 18 are raised by the lifting mechanism and moved to each storage stage 24, and the goods 2 exited from each storage stage 24 are lowered by the lifting mechanism and exited to the exit section 22.

[0023] (rail) The first rail 10 extends in the X-axis direction in the storage row 26. The second rail 12 extends in the Y-axis direction near the end of the storage row 26. The first rail 10 and the second rail 12 are sometimes collectively referred to simply as rails. In this specification, a rail is a member or part having a rolling surface of a wheel configured to run a cart in its extension direction. Therefore, the rail may be a rail having a rolling surface formed on a rod-shaped or band-shaped member, or a rail having a rolling surface formed on a plane.

[0024] (First cart) Next, the first carriage 6 will be described with reference to Fig. 5 and Fig. 6. Fig. 5 is a plan view that shows a schematic diagram of an example of the first carriage. Fig. 6 is a side view of the first carriage. The first carriage 6 travels on the first rail 10 in the X-axis direction in the storage row 26 in order to transport the goods 2. The first carriage 6 takes the goods 2 in and out of the storage section 20. The first carriage 6 travels on the second carriage 8 in the X-axis direction in order to get on and off the second carriage 8.

[0025] The first cart 6 mainly includes a car body 28, a platform 30, a lift mechanism 32, a plurality of (for example, four) wheels 34, and a battery 36. The car body 28 has a contour of a substantially rectangular parallelepiped shape that is flat in the vertical direction. Inside the car body 28, a motor (not shown) that drives the plurality of wheels 34, a control circuit (not shown) that controls the motor, and a battery 36 are mounted. The first cart 6 is configured to drive the motor using power from the battery 36. The battery 36 may be a secondary battery such as a repeatedly rechargeable lithium ion battery.

[0026] The placement section 30 is a section that lifts and holds the load 2. The lift mechanism 32 is a mechanism that raises and lowers the placement section 30. In FIG. 6, the placement section 30 shown by the dashed line is in a raised state, and the placement section 30 shown by the solid line is in a lowered state. The lift mechanism 32 can raise the placement section 30 to lift the load 2 from the storage section 20. The lift mechanism 32 can lower the placement section 30 to unload the load 2 into the storage section 20. The multiple wheels 34 run on the first rail 10 and the second cart 8.

[0027] (Second bogie) Next, the second carriage 8 will be described with reference to Fig. 7 and Fig. 8. Fig. 7 is a plan view that shows a schematic diagram of an example of the second carriage. Fig. 8 is a side view of the second carriage. The second carriage 8 travels on the second rail 12 in the Y-axis direction. The second carriage 8 transports the first carriage 6 in an empty state or in a state in which the load 2 is loaded.

[0028] The second bogie 8 mainly includes a car body 38, a recess 40, a plurality of wheels 42, and a current collecting unit 44. The car body 38 has a contour of a substantially rectangular parallelepiped shape that is flat in the vertical direction. Inside the car body 38, a motor (not shown) that drives each wheel 42 and a control circuit (not shown) that controls the motor are mounted. The wheels 42 run on the second rail 12. The current collecting unit 44 is in contact with a power supply line that extends along the second rail and receives a supply of power. The second bogie 8 receives power from the power supply line via the current collecting unit 44. The second bogie 8 is configured to drive the motor with the received power and to supply power to the first bogie 6.

[0029] The second bogie 8 has a concave recess 40 for mounting the first bogie 6. The recess 40 is formed by being recessed downward from the upper surface of the car body 38 in order to mount the first bogie 6. The size of the recess 40 is determined by adding a sufficient margin to the size of the first bogie 6 so that the first bogie 6 can run in the X-axis direction without interfering with the periphery of the recess 40. The first bogie 6 runs on the recess 40.

[0030] (Maintenance area) Each storage stage 24 (see FIG. 1 and FIG. 2) is provided with a maintenance area 48 into which at least the second cart 8 can enter. The maintenance area 48 is disposed at the end of the second rail 12. The maintenance area 48 is provided with a door 50 so that the inside of the maintenance area 48 can be accessed from the outside. The maintenance area 48 has a worker protection structure that can ensure the safety of workers even if a load collapse occurs in the upper storage stage 24. The worker protection structure is a structure having a solid floor and ceiling with no gaps, and is a structure that protects workers from objects falling from above and prevents objects from falling to a lower storage stage. By moving the second cart 8 to the maintenance area 48, the worker can perform maintenance on the second cart 8. In addition, by moving the second cart 8 to the maintenance area 48 with the first cart 6 loaded thereon, the first cart 6 can also be maintained.

[0031] An outer control panel 52a is provided on the outside of the door 50 for accessing the maintenance area 48, and an inner control panel 52b is provided on the inside of the door 50. The outer control panel 52a is provided with a switching means such as a key switch 54 for switching the operation mode of the automated warehouse system 1. A safety plug 52c for stopping the power supply to the transport mechanism and a lamp 52d for indicating that the transport mechanism has been stopped by the operation of the key switch 54 are provided around the outer control panel 52a, i.e., on the outside of the door 50. The door sensor 52e is also capable of detecting the opening and closing of the door 50. The inner control panel 52b is provided with a power supply switch 52f for switching the power supply to the cart on and off. The operation modes of the automated warehouse system 1 include a fully automatic operation mode, a single stage stop mode, and a multiple stage stop mode. In the fully automatic operation mode, the automated warehouse system 1 operates all the storage stages 24 according to a program installed in the automated warehouse system 1. In the self-stage stop mode, the automated warehouse system 1 stops only the operation of the storage stage 24 on which the key switch 54 is provided and allows the operation of the other storage stages 24. In the multi-stage stop mode, the automated warehouse system 1 stops only the operation of the storage stage 24 on which the key switch 54 is provided and the specified storage stage 24, and allows the operation of the other storage stages 24. In other words, the "fully automatic operation mode" is a mode in which all storage stages 24 are operated, and the "self-stage stop mode" and the "multi-stage stop mode" stop only the storage stage on which an abnormality has occurred, and do not stop all or part of the storage stages on which no abnormality has occurred, and allow the transport mechanism to transport goods. In addition, as an operation mode of the automated warehouse system 1, there is a "cycle stop mode" that is used by workers to enter the maintenance area 48 for maintenance of the cart, etc., in addition to when an abnormality occurs. When the cycle stop mode is selected, the transport mechanism that is normally operating is stopped. The storage stage 24 that is stopped at this time may be only the storage stage 24 on which the operated key switch 54 is provided, or the storage stages 24 adjacent to each other above and below may be stopped.

[0032] The key switch 54 is linked to the lock of the door 50, and if the key switch 54 is not set to the "own stage stop mode" or the "multiple stage stop mode", the door 50 cannot be opened, or if the door 50 is opened, the transport mechanism is made to make an emergency stop. Therefore, a worker can enter the maintenance area 48 only when the key switch 54 is switched to the "own stage stop mode" or the "multiple stage stop mode" and the safety of the storage stage 24 on which the key switch 54 is provided is ensured. When a worker enters the maintenance area 48, the worker can access the inner control panel 52b and can stop the power supply to the cart in the storage stage 24 on which the inner control panel 52b is provided.

[0033] In order to simplify the configuration of the control unit, the "own stage stop mode" and the "multiple stage stop mode" may be configured to stop operation of a designated storage stage in addition to the storage stage in which an abnormality has occurred. In this case, in the "own stage stop mode", it is possible not to set a flag indicating the designated storage stage 24. In this case, the "storage stage in which an abnormality has occurred" as referred to in the present invention in the "own stage stop mode" becomes the storage stage 24 in which the abnormality has actually occurred, and since the "designated storage stage" has no value, it becomes the storage stage 24 at stage 0.

[0034] The maintenance area 48 is located on an extension of the foremost storage row 26 along the Y axis when the storage stage 24 is viewed in plan. More specifically, when the second cart 8 is in a position where it can be received from the foremost storage row 26, the second cart 8 will enter the maintenance area. Therefore, when performing maintenance on the second cart 8, etc., the second cart 8 will be moved to a position aligned with the foremost storage row 26.

[0035] The designated storage stage 24 whose operation is stopped in the multi-stage stop mode is preferably any one of the storage stage 24 directly above the storage stage 24 in which the abnormality occurred, all storage stages 24 above the storage stage 24 in which the abnormality occurred, the storage stage 24 directly above and the storage stage 24 directly below the storage stage 24 in which the abnormality occurred, or all storage stages 24 above and the storage stage 24 directly below the storage stage 24 in which the abnormality occurred. By selecting the multi-stage stop mode and performing recovery work in this way, it is possible to stop the storage stage 24 above the storage stage 24 in which the abnormality occurred (one or all of the upper stages) and prevent the load 2 from falling due to further load collapse or the like. In addition, by stopping the storage stage 24 below the storage stage 24 in which the abnormality occurred, it is possible to prevent, for example, a worker from coming into contact with the load 2 being transported in the lower storage stage 24 during recovery work. The storage stage 24 to be stopped in the multi-stage stop mode, i.e., the storage stage 24 designated in the multi-stage stop mode, may be designated in advance when the automated warehouse system 1 is constructed. Also, for example, an input device may be provided near the key switch 54 so that the operator can specify the storage stage 24 to be stopped.

[0036] In addition, in an automated warehouse system 1 having two storage stages 24, two storage stages 24, an upper one and an lower one, are operated when operating in a fully automatic operation mode. Also, for example, if an abnormality occurs in the upper storage stage 24 and the own stage stop mode is selected with the key switch 54 of the upper storage stage 24, only the upper storage stage 24 stops operating, and if the other stage stop mode is selected, the lower storage stage 24 also stops operating. In this case, the "storage stage where the abnormality occurred" according to the present invention is the upper storage stage 24, and the 0th storage stage 24 is the "designated storage stage" that should be stopped.

[0037] Further, an abnormality detection sensor is disposed in each storage stage 24 to detect an abnormality in the storage stage 24. The abnormality detection sensors include a storage section abnormality detection sensor 56 that detects an abnormality in the state of the load in the storage section, such as a load collapse, and a transport mechanism abnormality detection sensor 58 that detects an abnormality in the transport mechanism, such as a failure of the first cart 6 and the second cart 8. The storage section abnormality detection sensor 56 may be a means for detecting whether the load is displaced from a predetermined range in the storage section using an imaging means such as a camera, or an infrared sensor. The transport mechanism abnormality detection sensor 58 may be a means for monitoring the running state of the first cart 6 and the second cart 8, and detecting the occurrence of an abnormality when the first cart 6, etc. are not moving as instructed.

[0038] (Control system) FIG. 9 is a block diagram of the automated warehouse system. The automated warehouse system 1 has a system control unit 64 including a load management unit 60 that manages the loads managed in the storage unit 20, the above-mentioned key switch 54, and a transport control unit 62 for controlling the transport mechanism. The automated warehouse system 1 further has an abnormality detection unit 66 that includes the above-mentioned storage unit abnormality detection sensor 56 and the transport mechanism abnormality detection sensor 58, and carts A, B, ... arranged in each storage stage 24. The transport and management of the load 2 in the automated warehouse system 1 is performed by simultaneously operating the corresponding multiple carts A, B, ... by the cart control units 68A, 68B, ... of the system control unit 64. Then, when an abnormality is detected by the abnormality detection unit 66 or when the key switch 54 is operated, a process for abnormality recovery is executed as described below.

[0039] (Cart maintenance) Although no abnormality occurs in the operation of the automated warehouse system, a worker may access the cart to perform maintenance, etc. In this case, the worker accesses the key switch 54 of the storage stage 24 where the cart to be maintained is located and switches the operation mode to "cycle stop mode". This stops the cart that is normally operating. Next, the worker removes the key switch 54 from the outer control panel 52a. The worker also removes the safety plug 52c. This stops the power supply to the transport mechanism. Next, the worker visually checks the lamp 52d to confirm that the cart has stopped, then opens the door 50, enters the maintenance area 48, and closes the door 50. When the door 50 is closed, the door sensor 52e turns on, and the transport mechanism becomes capable of being supplied with power. Next, the worker operates the power supply switch 52f of the inner control panel 52b to turn on the power supply to the cart. Next, the worker inserts the key switch 54 into the cart and switches it to manual mode. This allows the cart to be operated manually. After the maintenance of the dolly, the worker operates the key switch 54 to switch the dolly to the automatic mode. Then, he turns off the power supply switch 52f on the inside control panel 52b and goes outside the door 50. This turns on the door sensor 52e. Then, the worker inserts the safety plug 52c, inserts the key switch 54 into the outside control panel 52a, and switches the key switch to the fully automatic operation mode.

[0040] (Abnormal recovery action) Next, we will explain the abnormality recovery operation of the automated warehouse system 1. Note that the control of the automated warehouse system 1 described below is executed by hardware such as a micro processing unit (MPU) of a computer using software stored in advance in a storage unit.

[0041] 10 is a flow diagram showing the operation of the automated warehouse system. When a series of processes starts, first, in step S1, the automated warehouse system 1 waits until an abnormality is detected in the storage stage 24. In this process, a judgment is made based on the detection result of the abnormality detection unit 66.

[0042] When an abnormality is detected in step S1, in step S2 the automated warehouse system 1 stops operation of the storage stage 24 in which the abnormality has occurred. Stopping the operation of the storage stage 24 means stopping the first cart 6 and the second cart 8 traveling within the corresponding storage stage 24 on the spot. By stopping the traveling of the carts within the storage stage 24 in which the abnormality has occurred, safety can be ensured when workers enter the storage stage 24 for recovery work.

[0043] Next, in step S3, the automated warehouse system 1 determines whether the detected abnormality is an abnormality relating to the cart or an abnormality relating to the inside of the storage stage 24. This process is performed by the system control unit 64 determining the detection result of the abnormality detection unit 66, i.e., which sensor, the storage unit abnormality detection sensor 56 or the transport mechanism abnormality detection sensor 58, has detected the abnormality.

[0044] If the abnormality is not with the cart but with the inside of the storage stage 24, in step S4 the automated warehouse system 1 notifies an operator of the abnormality. In this process, the system control unit 64 displays on a monitor (not shown) or the like that an abnormality has occurred inside a specific storage stage 24. This allows the operator to know that an abnormality has occurred in the specific storage stage 24, and he or she can begin preparations for recovery work. To perform the recovery work, the operator moves to outside the maintenance area 48 of the storage stage 24 where the abnormality has occurred, and operates the key switch 54.

[0045] In step S5, the automated warehouse system 1 determines whether or not the key switch 54 has been operated. When the automated warehouse system 1 is operating normally, the key switch 54 is set to "fully automatic operation mode." Depending on the type of abnormality notified by the automated warehouse system 1, an operator operates the key switch 54 to select either the "single-tier stop mode" or the "multiple-tier stop mode."

[0046] If it is determined in step S6 that the automated storage system 1 has been set to the multi-stage stop mode, in step S7 the automated storage system 1 stops or sets the designated storage stage 24 to not be allowed to operate, in addition to the storage stage 24 that is already stopped or in which the abnormality occurred. As a result, operation of the designated storage stage 24, such as the upper storage stage 24 and the lower storage stage 24, in addition to the storage stage 24 in which the abnormality occurred, is prevented. On the other hand, operation is enabled under the control of the transport control unit 62 in the storage stage 24 in which the abnormality occurred and storage stages 24 other than the designated storage stage 24.

[0047] When operation within a given storage stage 24 has stopped, the worker unplugs the safety plug 52c, passes through the door 50 of the maintenance area 48, enters the maintenance area 48, and turns off the power supply switch 52f on the inside control panel 52b to stop power supply to the cart. The worker then performs recovery work for any abnormalities, such as cargo collapse, within the storage unit 20. After the recovery work, the worker turns on the power supply switch 52f, passes through the maintenance area again, and exits the storage unit 20. Next, the worker inserts the safety plug 52c and operates the key switch 54 to set the mode to "fully automatic operation mode."

[0048] If the automated warehouse system 1 determines in step S8 that the key switch 54 is set to "fully automatic operation mode", then in step S9 the automated warehouse system resumes operation of all storage stages 24 that were stopped.

[0049] Furthermore, if it is determined in step S6 that the multi-stage stop mode has not been selected, the automated warehouse system 1 determines that the local stage stop mode has been selected. In this case as well, the operator recovers from the abnormality in the storage stage 24, and then operates the key switch 54 to set the "fully automatic operation mode."

[0050] Furthermore, if the automated warehouse system 1 determines in step S3 that the detected abnormality is related to the cart, then in step S10 the automated warehouse system 1 checks the position of the cart. The cart here means the cart in which the abnormality has occurred, and for example, if the transport mechanism abnormality detection sensor 58 detects that an abnormality has occurred in the first cart 6, the automated warehouse system 1 checks the position of the first cart 6 in which the abnormality has occurred. Furthermore, if the transport mechanism abnormality detection sensor 58 detects that an abnormality has occurred in the second cart 8, the automated warehouse system 1 checks the position of the second cart 8.

[0051] Next, in step S11, the automated warehouse system 1 notifies the worker of the abnormality. In this process, the system control unit 64 displays on a monitor (not shown) or the like that an abnormality has occurred in either the first cart 6 or the second cart 8, or both, inside the specific storage stage 24. This allows the worker to know that an abnormality has occurred in the specific cart, and starts preparations for recovery work. In carrying out the recovery work, the worker moves to the outside of the maintenance area 48 of the storage stage 24 in which the abnormal cart is located, and operates the key switch 54. In this case, the worker checks the position of the cart in which the abnormality has occurred, and if the corresponding cart is stopped within the maintenance area 48, which is a worker protection structure, sets the key switch 54 to "self-stage stop mode". If the cart is stopped within the maintenance area 48, the worker does not need to enter the storage unit 20 to perform the recovery work of the cart, and can safely perform the recovery work within the maintenance area 48. In this embodiment, the trolley stops in the maintenance area 48 when the first trolley 6 and the second trolley 8 arrive at the storage row 26 located at the front side along the Y axis, or when, for example, the first trolley 6 enters the maintenance area 48 for charging or maintenance. In such a case, the key switch 54 is set to the "own stage stop mode", and only the storage stage 24 in which the abnormal trolley is located is stopped, and the other storage stages 24 are allowed to operate, thereby suppressing a decrease in the work efficiency of the automated warehouse system 1. Next, the worker removes the key switch 54, pulls out the safety plug 52c, and enters the maintenance area 48 through the door 50. Next, the worker closes the door 50 and operates the power supply switch 52f of the inner control panel 52b to turn on the power supply to the trolley. Next, the worker inserts the key switch 54 into the trolley and switches it to manual mode. This allows the trolley to be operated manually. After maintenance of the trolley, the worker operates the key switch 54 and switches the trolley to automatic mode. Next, the worker turns off the power supply switch 52f on the inside control panel 52b and goes outside the door 50. This turns on the door sensor 52e. Next, the worker inserts the safety plug 52c, inserts the key switch 54 into the outside control panel 52a, and switches the key switch to the fully automatic operation mode.

[0052] After the maintenance of the cart is completed, the worker leaves the maintenance area and sets the key switch 54 to "fully automatic operation mode," which causes the automated warehouse system 1 to resume operation of the storage stage 24 that had been stopped in step S8.

[0053] As described above, according to this embodiment, when an abnormality occurs in the automated warehouse system 1, only the storage stage 24 in which the abnormality occurred and a designated storage stage 24 as necessary are stopped, and the remaining storage stages 24 are allowed to operate, thereby minimizing the decrease in work efficiency when an abnormality occurs. In addition, the designated storage stage 24 can be any of the storage stage 24 directly above the storage stage 24 in which the abnormality occurred, all storage stages 24 above the storage stage 24 in which the abnormality occurred, the storage stage 24 directly above and the storage stage 24 directly below the storage stage 24 in which the abnormality occurred, or all storage stages 24 above the storage stage 24 in which the abnormality occurred and the storage stage 24 directly below, thereby ensuring the safety of workers.

[0054] The present invention has been described above based on the embodiments. These embodiments are merely examples, and it is understood by those skilled in the art that various modifications and changes are possible within the scope of the claims of the present invention, and that such modifications and changes are also within the scope of the claims of the present invention. Therefore, the descriptions and drawings in this specification should be treated as illustrative rather than restrictive.

[0055] (Modification) Modifications will be described below. It is not essential to provide a first carriage 6 in each row of each stage, and the first carriage 6 does not have to be provided in each stage.

[0056] The storage stage 24 may consist of one column of storage rows 26 .

[0057] It is not essential that the number of storage sections 20 in the storage row 26 is uniform. Depending on the irregularities of the walls of the building that houses the storage shelves 4, some storage rows 26 may have a larger number of storage sections 20 than others.

[0058] It is not essential that the number of stages of the storage stages 24 stacked vertically is uniform. The number of stages of the storage stages 24 may be increased or decreased depending on the ceiling height of the building that houses the storage shelves 4.

[0059] It is not essential that the load 2 includes a pallet. The present automated warehouse system may be configured to handle loads 2 that do not include a pallet.

[0060] Instead of a forklift, the load 2 may be stored or removed by another type of transfer device, such as a transfer device equipped with a crane.

[0061] Each of these modified examples provides the same effects as the embodiment.

[0062] Any combination of the above-described embodiments and modifications is also useful as an embodiment of the present invention. A new embodiment resulting from the combination has the combined effects of the respective embodiments and modifications. [Explanation of symbols]

[0063] 1 automated warehouse system, 2 load, 6 first cart, 8 second cart, 10 first rail, 12 second rail, 24 storage stage, 48 maintenance area, 62 transport control unit

Claims

1. An automated warehouse system, a plurality of storage stages each including a storage section capable of storing cargo; A transport control unit that controls a transport mechanism that transports the load, The storage stages of each tier are each formed by arranging a plurality of the storage sections in a first direction, and a plurality of storage rows are arranged in parallel in a second direction intersecting the first direction, The automated warehouse system is configured such that, when an abnormality occurs in any one of the multiple storage stages during automatic operation, the transport control unit stops operation of all of the multiple storage rows within the storage stage in which the abnormality occurred, as well as all of the multiple storage rows within at least one of the storage stages immediately above and immediately below the storage stage in which the abnormality occurred.

2. An automated warehouse system, A storage stage with multiple levels for storing cargo; A transport control unit that controls a transport mechanism that transports the load, The automated warehouse system is configured such that, when an abnormality occurs in any of the multiple storage stages during automatic operation, the transport control unit stops operation of the storage stage in which the abnormality occurred and all storage stages above the storage stage in which the abnormality occurred.

3. The automated warehouse system according to claim 1 or 2, wherein the transport control unit controls the transport mechanism to enable the transport mechanism to transport goods in a storage stage among the plurality of storage stages other than the storage stage that was stopped when the abnormality occurred.

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