Picking equipment for automated warehouses, automated warehouse systems

Abstract

To provide a picking device for an automated warehouse which is capable of stably holding a plurality of loads.SOLUTION: A picking device 3 for an automated warehouse in an embodiment is a picking device to move a plurality of loads 10 held by a holding mechanism 32 capable of holding the loads 10. The holding mechanism 32 includes a plurality of holding parts 34 to suck the loads 10. The plurality of holding parts 34 carry out a holding operation of the load 10 as a picking object on the basis of a surface state of the load that is the picking objects.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a picking device for an automated warehouse and an automated warehouse system. [Background technology]

[0002] There is known a picking device for an automated warehouse that collects products in a storage area or temporarily placed products to a shipping location. For example, Patent Document 1 describes an article transfer device that suctions the top surface of an article, suspends the article, and moves it to a transfer destination. This device includes a suction unit including multiple suction blocks with suction pads, and a suction control unit. The suction control unit moves the suction block horizontally in accordance with dimensional information of the target article, weight information of the target article, coordinate data related to the center of gravity of the target article, etc. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2015-40130 Summary of the Invention [Problem to be solved by the invention]

[0004] The present inventors have recognized the following. In order to efficiently pick items in an automated warehouse picking device, it is desirable to be able to pick multiple items simultaneously. Furthermore, when handling items wrapped in cases such as cardboard boxes, if the case has perforations, a sticker attached to the case, or anti-slip rubber or the like on its surface, causing unevenness, sufficient suction force cannot be obtained in areas that are not suitable for suction, resulting in unstable holding of the items. In particular, when picking multiple items simultaneously, the influence of areas that are not suitable for suction becomes more pronounced, making holding of the items even more unstable.

[0005] The picking device described in Patent Document 1 does not provide sufficient support from the viewpoint of stably holding a plurality of loads while avoiding areas that are not suitable for pickup.

[0006] The present invention has been made in view of the above-mentioned problems, and one of its objects is to provide a picking device for an automated warehouse that can stably hold multiple items. [Means for solving the problem]

[0007] In order to solve the above problems, a picking device for an automated warehouse according to one aspect of the present invention is a picking device that moves loads held by a holding mechanism capable of holding multiple loads, the holding mechanism having multiple holding parts that adsorb the loads, and the multiple holding parts perform a holding operation for the load to be picked based on the surface condition of the load to be picked.

[0008] Another aspect of the present invention is an automated warehouse system. The automated warehouse system includes a shelf unit having a plurality of storage sections capable of storing loads, a moving means for moving loads to or from the shelf unit for storage or retrieval, and a picking device for moving the loads using a holding mechanism capable of holding the plurality of loads. The holding mechanism has a plurality of holding sections for holding the loads. The plurality of holding sections perform a holding operation based on the surface condition of the load to be picked.

[0009] Any combination of the above components, or mutual substitution of the components or expressions of the present invention between methods, systems, etc., are also valid aspects of the present invention. [Effects of the Invention]

[0010] According to the present invention, a picking device for an automated warehouse that can stably hold multiple items can be provided. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a plan view schematically illustrating an automated warehouse system according to a first embodiment. [Figure 2]FIG. 1 is a perspective view showing an example of a package in which multiple packages are stacked. [Figure 3] 2 is a front view schematically showing an example of a first moving means of the automated warehouse system of FIG. 1. FIG. [Figure 4] 2 is a front view schematically showing an example of a second moving means of the automated warehouse system of FIG. 1. FIG. [Figure 5] FIG. 2 is a diagram illustrating an example of the picking device of FIG. 1. [Figure 6] 2 is a front view showing a holding mechanism of the picking device of FIG. 1. [Figure 7] FIG. 2 is a plan view showing a suction mechanism of the picking device of FIG. [Figure 8] 8 is a plan view showing a first example of the suction region of the suction mechanism of FIG. 7. FIG. [Figure 9] 8 is a plan view showing a second example of the suction region of the suction mechanism of FIG. 7. FIG. [Figure 10] 2 is an explanatory diagram illustrating an example of a picking operation of the picking device of FIG. 1. FIG. [Figure 11] 2 is a flowchart illustrating a depalletizing operation of the picking device of FIG. 1. [Figure 12] FIG. 10 is a plan view showing a suction mechanism of the picking device of the second embodiment. [Figure 13] 13 is a diagram showing a holding part of the suction mechanism of FIG. 12. FIG. [Figure 14] 13 is a diagram showing a holding part of the suction mechanism of FIG. 12. FIG. [Figure 15] 13 is a diagram showing a holding part of the suction mechanism of FIG. 12. FIG. [Figure 16] 13 is a flowchart illustrating the depalletizing operation of the picking device of FIG. 12. DETAILED DESCRIPTION OF THE INVENTION

[0012] The present invention will be described below based on preferred embodiments with reference to the drawings. In the embodiments and modifications, identical or equivalent components and members are designated by the same reference numerals, and redundant explanations will be omitted where appropriate. The dimensions of the members in the drawings are enlarged or reduced as appropriate to facilitate understanding. Some members that are not important for explaining the embodiments will be omitted from the drawings.

[0013] Furthermore, terms including ordinal numbers such as first and second are used to describe various components, but these terms are used only to distinguish one component from another and do not limit the components.

[0014] [First embodiment] The configuration of an automated warehouse system 1 equipped with a picking device 3 according to a first embodiment will be described with reference to the drawings. Fig. 1 is a plan view schematically showing the automated warehouse system 1 according to the first embodiment.

[0015] For ease of explanation, an XYZ Cartesian coordinate system is defined as shown in the figure, with a certain horizontal direction being the X-axis direction, a horizontal direction perpendicular to the X-axis direction being the Y-axis direction, and a direction perpendicular to both, i.e., the vertical direction, being the Z-axis direction. The positive directions of the X-axis, Y-axis, and Z-axis are defined as the directions indicated by the arrows in each figure, and the negative directions are defined as the directions opposite to the arrows. Furthermore, the direction along the X-axis is sometimes referred to as the column direction, the direction along the Y-axis as the row direction, and the direction along the Z-axis as the row direction (up and down direction). These directional notations do not limit the configuration of the automated warehouse system 1, and the automated warehouse system 1 can be used in any configuration depending on the application.

[0016] In this specification, the following terms are used for loads: A "load" refers to a case such as a cardboard box containing contents. A load may contain multiple items.

[0017] Additionally, an empty pallet is simply referred to as a "pallet 12j." A pallet 12j with one or more loads 10 placed on it is referred to as a "loaded pallet 12." The loaded pallet 12 exemplifies a collection of loads containing multiple loads 10. The loaded pallet 12 refers to the combination of the pallet 12j and the loads 10 on the pallet 12j. The loaded pallet 12 may be composed of multiple stacked layers, and each layer may contain multiple loads 10. For example, the loaded pallet 12 includes three layers each containing six loads 10. The loaded pallet 12 may be the smallest unit of goods received, stored, and shipped from the automated warehouse system 1. The loads 10 may also be the smallest unit handled when picking.

[0018] FIG. 2 is a perspective view showing an example of a package in which multiple packages 10 are stacked. The side that is expected to be opened to remove the contents is called the "counter-bottom side," which refers to the bottom side opposite the counter-bottom side. The example in FIG. 2 shows package 10 in an uninverted state, with the counter-bottom side facing upward and the bottom side facing downward. Package 10 may be inverted by an inverting device (not shown), and may be handled, such as for picking, in an inverted state with the bottom side facing upward and the counter-bottom side facing downward. The counter-bottom side may be easier to open than the bottom side, or the bottom side may be stronger than the counter-bottom side. As an example of an indication method, the inverted state may be indicated by characters printed on the side of the case being inverted.

[0019] As shown in Figure 1, the automated warehouse system 1 mainly comprises a shelf section 22 having multiple storage sections 26 capable of storing goods 10, moving means 14, 16, 18 for moving goods 10 to or from the shelf section 22, a picking device 3 for moving goods 10 using a holding mechanism 32 capable of holding multiple goods 10, and a control unit 50.

[0020] The moving means 14, 16, 18 include a first moving means 14 (e.g., a first carriage), a second moving means 16 (e.g., a second carriage), and a third moving means 18 (e.g., a lifting device). The first moving means 14, the second moving means 16, and the third moving means 18 constitute a conveying means 8 that moves the loading pallet 12 in the row direction, the column direction, and the tier direction. The first moving means 14 can move the loading pallet 12 along the row direction. The second moving means 16 can move the loading pallet 12 along the column direction. The third moving means 18 can move the loading pallet 12 in the tier direction.

[0021] For example, the transport means 8 can remove the loaded pallet 12 from the storage section 26 of the shelf section 22. For example, the transport means 8 can carry the loaded pallet 12 into the storage section 26 of the shelf section 22. For example, the transport means 8 can transport the loaded pallet 12 from one storage section 26 of the shelf section 22 to another storage section 26 of the shelf section 22.

[0022] The shelf section 22 is a storage space capable of storing a large number of loads 10, and is sometimes referred to as a storage shelf. The shelf section 22 in this embodiment includes two shelf sections 22a and 22b separated by the second traveling path 44. The configuration of the shelf section 22 is not particularly limited as long as it is capable of accommodating and storing a plurality of loads 10. The shelf section 22 includes a plurality of storage sections 26 arranged along the X-axis direction (column direction), the Y-axis direction (row direction), and the Z-axis direction (tier direction). Each storage section 26 is configured to be able to accommodate a load pallet 12.

[0023] The shelf unit 22 is provided with a first running path 40 (e.g., a first rail) along which the first moving means 14 runs, and a second running path 44 (e.g., a second rail) along which the second moving means 16 runs. The first running path 40 extends in the Y-axis direction between the shelf units 22a, 22b and the picking space 302. The first moving means 14 can run below each storage unit 26. The second running path 44 extends in the X-axis direction adjacent to the shelf units 22a, 22b and the picking space 302.

[0024] (1st means of transportation) FIG. 3 is a front view schematically illustrating an example of the first moving means 14. The first moving means 14 drives multiple wheels 14f using a motor (not shown) and moves along the first running path 40 in the Y-axis direction either empty or with a loaded pallet 12. The first moving means 14 raises and lowers the loaded pallet 12 on the platform 14c using a lift mechanism 14d. In FIG. 3, the platform 14c in the raised state is shown by a dashed line, and the platform 14c in the lowered state is shown by a solid line. The first moving means 14 can lower the loaded pallet 12 into the storage section 26. The first moving means 14 can lift and support the loaded pallet 12 from the storage section 26. The first moving means 14 can get on and off the second moving means 16 and the third moving means 18.

[0025] (Second means of transportation) 4 is a front view schematically illustrating an example of the second moving means 16, showing the state in which the first moving means 14 is mounted. The second moving means 16 drives a plurality of wheels 16f by a motor (not shown) and travels in the X-axis direction on the second travel path 44. The second moving means 16 transports the first moving means 14 in an empty state or when a loading pallet 12 is mounted thereon.

[0026] (Third means of transportation) As shown in Fig. 1, the third moving means 18 is provided adjacent to the second travel path 44. The third moving means 18 can raise and lower the first moving means 14 and the loaded pallet 12 from any storage tier to another storage tier. In the example of Fig. 1, a single loading / unloading section 52 is provided for all tiers, and the third moving means 18 is connected to the loading / unloading section 52.

[0027] In this example, the loaded pallet 12 to be stored is carried into the loading / unloading section 52 by external transport means 54 (e.g., a forklift), and is transferred to the desired shelf by third moving means 18. In addition, the loaded pallet 12 to be unloaded is raised or lowered from the shelf where it was stored to the shelf of the loading / unloading section 52 by third moving means 18, transferred to the loading / unloading section 52, and then carried out from the loading / unloading section 52 by external transport means 54.

[0028] The third moving means 18 can transport the first moving means 14 carrying the loaded pallet 12 to each storage tier, including the top storage tier. After being transported to each storage tier, the first moving means 14 moves to the second moving means 16 of each storage tier, carrying the loaded pallet 12. The third moving means 18 may be one that raises and lowers the loaded pallet 12 while it is still mounted on the first moving means 14, or one that raises and lowers the loaded pallet 12 alone.

[0029] Returning to FIG. 1, the control unit 50 is configured to include an MPU (Micro Processing Unit) and controls the movement of the loading pallet 12 for storing, retrieving, carrying out, transporting, etc. based on the results of operations from the user. As an example, the control unit 50 controls the operation of the first moving means 14, second moving means 16, and third moving means 18 so as to transport the loading pallet 12 between a storing / retrieving area and a storage unit, or between multiple storage units. The control unit 50 also controls the operation of the picking device 3 to pick the load 10.

[0030] The control unit 50 also acquires the surface condition of the load to be picked from a storage device in which the surface condition of the load to be picked is stored in advance. In this example, the storage device is a database DB provided in the information management center 90. The control unit 50 acquires data regarding the surface condition of the load to be picked from the database DB via the network NW. Data on specific areas suitable for pickup for the load to be picked is pre-registered in the database DB, and the control unit 50 can acquire the registered data of the specific areas from the database DB. Hereinafter, in this specification, a specific area suitable for pickup is an example of a specific area suitable for holding, and a non-specific area unsuitable for pickup is an example of a non-specific area unsuitable for holding.

[0031] The configuration of the picking device 3 will be described with reference to FIGS. 1 and 5. First, the picking space 302 will be described. In the example of FIG. 1, the picking space 302 includes a picking space 302a provided in shelf 22a and a picking space 302b provided in shelf 22b. The picking space 302 may be provided in one shelf, or in a part of a shelf. FIG. 5(A) is a plan view showing an enlarged view of the picking device 3. FIG. 5(B) is a side view showing an enlarged view of the picking device 3. In these figures, some pillars, beams, etc. are omitted. The picking space 302 is a space for picking using the picking device 3, and in this embodiment, it is provided within the shelf 22 (see also FIG. 1). The picking space 302 is provided with a first loading section 26p for placing the loading pallet 12 before picking (hereinafter referred to as the "first loading pallet 12S"), and a second loading section 26s for placing the loading pallet 12 after picking (hereinafter referred to as the "second loading pallet 12M").

[0032] The first placement unit 26p and the second placement unit 26s do not refer to specific locations within the picking space 302, but rather to spaces for temporarily storing the loading pallets 12. Therefore, the positions and ranges of the first placement unit 26p and the second placement unit 26s in the picking space 302 may change for each picking operation. The first placement unit 26p and the second placement unit 26s in this embodiment have the same configuration as the storage unit 26.

[0033] In the picking space 302 of this embodiment, a first running path 40 extends in the Y-axis direction. The first placement section 26p and the second placement section 26s are provided on the first running path 40. The first moving means 14 can travel below the first placement section 26p and the second placement section 26s. The first loading pallet 12S before picking is carried into the first placement section 26p by the first moving means 14. The second loading pallet 12M after picking is carried out from the second placement section 26s by the first moving means 14.

[0034] The configuration of the picking device 3 will be described. As shown in FIG. 5(B), the picking device 3 picks up loads 10 from a first load pallet 12S before picking and transfers them to a second load pallet 12M. The picking device 3 of this embodiment includes a so-called gantry-type crane mechanism 30 and a holding mechanism 32. The crane mechanism 30 includes a pair of cross beams 30e, a cross girder 30k, a crane cart 30d, and a hanging unit 30j. The pair of cross beams 30e are provided spaced apart on both sides in the Y-axis direction in the upper space of the picking space 302. Both ends of the cross beam 30e are supported by the upper ends of the vertical columns 30g.

[0035] The cross beam 30k is a rail-like structure extending in the Y-axis direction and is spanned between a pair of cross beams 30e. The cross beam 30k is configured to be self-moving on the cross beam 30e in the X-axis direction. The cross beam 30k is sometimes called a crane girder. The crane cart 30d is a cart that is self-moving on the cross beam 30k in the Y-axis direction. The crane cart 30d is sometimes called a trolley cart. The suspending unit 30j suspends the holding mechanism 32 from the crane cart 30d and can move the holding mechanism 32 up and down in the Z-axis direction. The suspending unit 30j can also rotate the holding mechanism 32 horizontally. The holding mechanism 32 is provided at the tip of the suspending unit 30j and is configured to be able to lift the load 10.

[0036] The crane mechanism 30 supports the holding mechanism 32 so that it can move freely in the horizontal column and row directions (X-axis direction, Y-axis direction).The crane mechanism 30 also supports the holding mechanism 32 so that it can move in the row direction (Z-axis direction).

[0037] The holding mechanism 32 will be described with reference to Fig. 6. Fig. 6 is a front view showing the holding mechanism 32. As described above, the holding mechanism 32 has a plurality of holding portions 34 that adsorb and hold the load 10. The plurality of holding portions 34 constitute the adsorption mechanism 33.

[0038] As shown in FIG. 6 , the picking device 3 of this embodiment is also equipped with cameras 391 and 392 for acquiring images. The cameras 391 and 392 are positioned so as to be able to acquire images of the lower side from the holding mechanism 32. In this example, the cameras 391 and 392 include two first cameras 391 capable of capturing images of the load 10 on the load pallet 12 held by the holding mechanism 32, and two second cameras 392 capable of capturing images of the load pallet 12 positioned below the holding mechanism 32. The second cameras 392 can detect the relative positions of the load pallet 12 and the holding mechanism 32. The two first cameras 391 are provided on both sides of the holding mechanism 32 in the width direction. The two second cameras 392 are provided on both sides of the holding mechanism 32 in the width direction. The camera 391 may be fixed in a fixed position without being provided in the holding mechanism 32. The camera 392 may use a sensor.

[0039] The suction mechanism 33 will be described with reference to FIG. 7. FIG. 7 is a diagram illustrating the suction mechanism 33 in a plan view. The suction mechanism 33 has a substantially rectangular shape in a horizontal view. The suction mechanism 33 has a plurality of holders 34 arranged in a matrix in the X-axis and Y-axis directions. In the example of FIG. 7, the suction mechanism 33 has 238 holders 34 arranged in 17 rows in the X-axis direction and 14 columns in the Y-axis direction. In this description, the plurality of holders 34 are distinguished by assigning row symbols 1 to 17 and column symbols A to M. Each of the plurality of holders 34 has adjustable holding force. In this example, the holders 34 generate a suction force by negative pressure by drawing in air. That is, the holding force in this example is a suction force. Each holder 34 can increase or decrease its suction force by adjusting the negative pressure. Each holder 34 can turn off its suction force by adjusting the negative pressure. The shape of the holders 34 may be rectangular or circular.

[0040] Each holding unit 34 can be switched between an ON state in which it generates an adhesive force capable of holding the load 10 and an OFF state in which it does not substantially generate any adhesive force. Generating an adhesive force capable of adsorbing the load 10 in the holding unit 34 is referred to as "turning on the holding unit 34," and not substantially generating any adhesive force is referred to as "turning off the holding unit 34." The adsorption mechanism 33 can change the pattern of adsorption areas (hereinafter referred to as the "adsorption pattern") by controlling the on-off of the multiple holding units 34. The adsorption mechanism 33 can also adjust the adsorption pattern to adsorb and hold all loads 10 on a single layer, some of the loads 10, or a single load 10. The adsorption pattern is a planar pattern in which the planar positions of the multiple holding units 34 that are turned on and the holding units 34 that are turned off are plotted.

[0041] A first example of the suction pattern of the suction mechanism 33 will be described with reference to FIG. 8. FIG. 8 is a plan view showing the first example of the suction pattern of the suction mechanism 33. This figure shows 12 loads 10 stacked in one layer of a loading pallet, with 13 columns and 17 rows of holding units 34 superimposed on them. In this first example, the suction mechanism 33 suctions six loads 10 (10-A to 10-F) indicated by bold lines. In this example, the areas on both sides of the upper surface of the load 10, excluding the central one-third in the Y-axis direction, are areas determined by the control unit 50 to be suitable for suction (hereinafter referred to as "specific areas P"). Furthermore, the central one-third in the Y-axis direction of the upper surface of the load 10, excluding the specific area P, is referred to as a non-specific area Q. In FIG. 8, the specific area P is indicated by hatching, and the non-specific area Q is indicated by white.

[0042] In the example of FIG. 8, the holding mechanism 32 turns on the holding units 34 corresponding to the specific region P of six loads 10-A to 10-F. Specifically, for load 10-A, the holding units 34 for A2, A5, B2, B5, C2, and C5 are turned on; for load 10-B, the holding units 34 for A7, A10, B7, B10, C7, and C10 are turned on; for load 10-C, the holding units 34 for D2, D5, E2, E5, F2, and F5 are turned on; for load 10-D, the holding units 34 for D7, D10, E7, E10, F7, and F10 are turned on; and for loads 10-E and 10-F, the holding units 34 for G2 to G7 and J2 to J7, which are connected in the Y-axis direction, are turned on. Note that the holding units 34 adjacent to the turned-on holding units 34 may also be turned on. In addition, the holding mechanism 32 may determine non-specific areas on the surface of the load 10 that are judged to be unsuitable for holding based on the surface condition, and turn on the holding parts 34 that do not correspond to the non-specific areas among the multiple holding parts 34.

[0043] A second example of the suction pattern of the suction mechanism 33 will be described with reference to Fig. 9. Fig. 9 is a plan view showing the second example of the suction pattern of the suction mechanism 33. This figure shows 13 columns and 17 rows of holding units 34 superimposed on eight loads 10 stacked in one layer of a loading pallet. In the second example, the suction mechanism 33 suctions five loads 10 (10-A to 10-E) indicated by thick lines.

[0044] 8, the holding mechanism 32 turns on the holding units 34 corresponding to the specific regions P of the five loads 10-A to 10-E. Specifically, for loads 10-A, 10-B, and 10-C, the holding units 34 for A1 to M1, A2 to M2, A5 to M5, and A6 to M6 that are connected in the X-axis direction are turned on, and for loads 10-D and 10-E, the holding units 34 for A7 to A11, B7 to B11, E7 to E11, H7 to H11, I7 to I11, L7 to L11, and M7 to M11 that are connected in the Y-axis direction are turned on.

[0045] (Picking operation) Next, the picking operation of the picking device 3 will be described with reference to FIG. 10. FIG. 10 is an explanatory diagram illustrating an example of the picking operation of the picking device. The picking operation includes the depalletizing operation and palletizing operation, which will be described later. In this description, to distinguish between different types of loads and pallets, the reference numerals will be suffixed with "-A," "-B," or "-C." In FIG. 10, load 10-A is shown in white, load 10-B is shown with straight hatching, and load 10-C is shown with dashed hatching.

[0046] In this example, the picking operation involves removing loads 10 from a first loading pallet 12S based on a shipping plan and creating a second loading pallet 12M for shipping to a destination such as a retail store. Different types of loads 10-A, 10-B, and 10-C are loaded on the first loading pallets 12S-A, 12S-B, and 12S-C. In this operation, the loading pallets 12 are moved by moving means 14, 16, and 18.

[0047] In the example of Figure 10, first loading pallets 12S-A, 12S-B, and 12S-C are placed on the first placement sections 26p-A, 26p-B, and 26p-C of the picking space 302, and a second loading pallet 12M is placed on the second placement section 26s.

[0048] By the picking operation of the picking device 3, the required number of loads 10-A are taken out from the first loading pallet 12S-A and stacked onto the second loading pallet 12M. Similarly, the required number of loads 10-B are taken out from the first loading pallet 12S-B and stacked onto the second loading pallet 12M, and the required number of loads 10-C are taken out from the first loading pallet 12S-C and stacked onto the second loading pallet 12M.

[0049] During the picking operation, the holding mechanism 32 may be rotated horizontally to change the posture of the load 10. After loading, the second loading pallet 12M may be transferred to the shelf section 22 for temporary storage, or may be transferred to the loading / unloading section 52 for removal from the warehouse. These operations complete the picking operation.

[0050] (Depalletizing operation) Next, referring to Figures 10 and 11, a process S110 will be described as an example of the depalletizing operation of the picking device 3. Figure 11 is a flowchart of process S110. Here, a process of picking a plurality (N units) of loads 10-B from a first loading pallet 12S-B placed at a target position will be described. In this description, the N units 10-B are the loads to be picked, and may be simply referred to as "loads 10-B."

[0051] When the process S110 starts, the picking device 3 receives a depalletizing instruction from the control unit 50 (step S111). As an example, this instruction includes the position of the first loading pallet 12S-B and the arrangement and quantity of the loads to be picked.

[0052] After executing step S111, the picking device 3 moves the crane mechanism 30 in the X-axis direction or the Y-axis direction to move the holding mechanism 32 toward the target position (step S112).

[0053] After executing step S112, the picking device 3 determines whether the holding mechanism 32 has reached the target position (step S113). In this step, whether the target position has been reached can be determined based on images acquired by one or both of the first camera 391 and the second camera 392. For example, this determination may be made by recognizing the relative positional relationship between the first loading pallet 12S-B and the holding mechanism 32 based on the acquired images, and determining whether the positional deviation from the target position is equal to or less than a predetermined reference value. If it is determined that the target position has not been reached (N in step S113), the picking device 3 returns the process to step S112 and repeats steps S112 to S113.

[0054] If it is determined that the target position has been reached (Y in step S113), the picking device 3 acquires the surface condition of the load to be picked from the detection means 39, which detects the surface condition of the load. In this example, the detection means 39 is one or both of the first camera 391 and the second camera 392. Therefore, the picking device 3 acquires a surface image of the load to be picked (step S114). In this step, the picking device 3 determines areas (non-specific areas) that are not suitable for pickup from the load surface image. As an example, non-specific areas may be areas that have external factors that cause pickup disturbance, such as the four corners of the case or areas near the folded portions of the case. Examples of areas that have external factors that cause pickup disturbance include areas where hot melt adhesive adheres, areas with perforations, and areas that are subject to large deformation due to external forces. After determining the non-specific areas, the picking device 3 avoids the non-specific areas and determines specific areas on the load surface that are determined to be suitable for pickup.

[0055] Furthermore, the picking device 3 acquires registered data of a specific area related to the load to be picked from the database DB via the control unit 50 (step S115). The picking device 3 determines the specific area of ​​the load to be picked based on the registered data.

[0056] After determining the specific area in steps S114 and S115, the picking device 3 determines a pickup pattern corresponding to the specific area (step S116). In this step, the picking device 3 determines which of the multiple holders 34 to turn on and which to turn off, depending on the specific area.

[0057] After the pickup pattern is determined in step S116, the picking device 3 executes on / off control to control the plurality of holders 34 to be on and off based on the pickup pattern (step S117).

[0058] After generating the suction force in step S117, the picking device 3 lowers the holding mechanism 32 (step S118).

[0059] After executing step S118, the picking device 3 sucks the load 10-B on the first loading pallet 12S-B with the suction mechanism 33 (step S119), and raises the holding mechanism 32 (step S120).

[0060] After executing step S120, the picking device 3 determines whether or not the pickup has been successful (step S121). In this step, whether or not the pickup has been successful can be determined based on the images acquired by one or both of the first camera 391 and the second camera 392.

[0061] If it is determined that the pickup has not been successful (N in step S121), the process returns to step S118, and steps S118 to S121 are repeated, causing the picking device 3 to lower the holding mechanism 32 again and perform the pickup operation again.

[0062] In this step, the picking device 3 may change the suction position (holding position) depending on the suction state (holding state) of the picked load 10. The holding state of the load 10 includes the suction state of the picked load 10. In other words, the picking device 3 may change which of the multiple holders 34 to turn on and which to turn off.

[0063] If it is determined that the pickup was successful (Y in step S121), the process S110 ends. The load 10 removed in the above-described depalletizing operation is stacked on another pallet by a palletizing operation. Various modifications are possible to each of the above-described steps.

[0064] (Palletizing operation) During the palletizing operation, the picking device 3 uses the crane mechanism 30 to move the holding mechanism 32 to the loading position based on the loading instruction for the load 10-B obtained from the control unit 50, and loads the load 10-B onto the second loading pallet 12M.

[0065] (warehousing and unloading operations) The storage and retrieval operations of the automated warehouse system 1 will be described with reference to Figure 1. These operations are controlled by the control unit 50. In the storage operation, a loading pallet 12 produced in a manufacturing plant is transported to the automated warehouse system 1 by a truck or the like, and is carried into the loading / unloading section 52 by external transport means 54. The loading pallet 12 carried into the loading / unloading section 52 is transferred to a shelf at the storage destination by the third moving means 18, and then transferred to the storage section 26 at the storage destination by the first moving means 14 and the second moving means 16, and stored in that storage section 26. Storing is performed through these operations.

[0066] In the retrieval operation, the loaded pallet 12 in the storage section 26 from which it is transported is transferred to the third transfer means 18 by the first transfer means 14 and the second transfer means 16, and then transferred to the loading / unloading section 52 by the third transfer means 18. The loaded pallet 12 transferred to the loading / unloading section 52 is loaded onto a truck (not shown) or the like by the external transport means 54. By these operations, retrieval is performed. The picking operation may be performed after the retrieval operation or before the retrieval operation.

[0067] The features of the automated warehouse picking device 3 configured as above will be described below. The picking device 3 is a picking device that moves loads 10 held by a holding mechanism 32 that can hold multiple loads 10. The holding mechanism 32 has multiple holding units 34 that adsorb the loads 10, and the multiple holding units 34 perform a holding operation for the load 10 to be picked based on the surface condition of the load to be picked.

[0068] According to this configuration, the suction area of ​​the suction mechanism 33 is changed depending on the surface condition of the load to be picked, thereby reducing the influence of areas unsuitable for suction and enabling multiple loads to be held stably.

[0069] In this embodiment, the holding mechanism 32 determines a specific area on the surface of the load 10 that is deemed suitable for adsorption based on the surface condition, and turns on the holding unit 34 corresponding to that specific area from among the multiple holding units 34. In this case, since the specific area suitable for adsorption can be adsorbed, multiple loads can be stably held. Selectively turning on / off the multiple holding units 34 reduces the burden on the compressor that supplies negative pressure to the holding units 34, which is advantageous in terms of compressor size and energy conservation.

[0070] In this embodiment, a detection means 39 is provided for detecting the surface condition of the load to be picked, and the surface condition is acquired from the detection means 39. In this case, it is possible to detect disturbance factors specific to the load to be picked.

[0071] In this embodiment, the surface condition of the load to be picked is acquired from a storage device that has previously stored the surface condition of the load to be picked. In this case, the registered data is used, so the influence of areas that are not suitable for pickup can be further reduced.

[0072] In this embodiment, the holding mechanism 32 changes the suction position depending on the holding state (suction state) of the sucked load 10. In this case, it is possible to reduce the influence of disturbance factors specific to the load to be picked.

[0073] The following describes the features of the automated warehouse system 1. The automated warehouse system 1 includes a shelf section 22 having a plurality of storage sections 26 capable of storing the loads 10, moving means 14, 16, 18 for moving the loads 10 to the shelf section 22 for storage or retrieval, and a picking device 3 for moving the loads 10 using a holding mechanism 32 capable of holding the plurality of loads 10. The holding mechanism 32 has a suction mechanism 33 having a plurality of holding sections 34 that are movably provided and that suction the loads 10, and acquires the surface condition of the load to be picked and changes the suction area of ​​the suction mechanism 33 based on the surface condition.

[0074] This configuration changes the suction area of ​​the suction mechanism 33 depending on the surface condition of the load to be picked, reducing the influence of areas unsuitable for suction and enabling stable holding of multiple loads. When multiple loads are held in contact with each other, the adjacent loads interact with each other, making the holding unstable. However, this configuration allows multiple loads to be held stably. Furthermore, because multiple loads can be stably supported, the movement speed of the holding mechanism 32 can be increased, shortening the picking time. For example, when the contents stored in the case are heavy, such as bottled drinks or canned drinks, when the force exerted by the holding mechanism 32 on the surface of the load 10 when the suction mechanism 32 picks the load 10 is large, or when the case is thin due to environmental considerations, stable support is possible even when bent loads 10 are in contact with each other and interacting with each other.

[0075] [Second embodiment] Next, a picking device 3 according to a second embodiment will be described. In this embodiment, multiple holding units 34 are arranged side by side within a suction mechanism 33 so as to be movable in two mutually perpendicular directions, and the holding mechanism 32 selects a specific area on the surface of the load 10 that is determined to be suitable for suction based on the surface condition, and moves the holding units 34 so as to suction the specific area, which is different from the first embodiment; other configurations are the same. Duplicate explanations will be omitted, and the following description will focus on the configuration that differs from the first embodiment.

[0076] FIG. 12 is a plan view showing the suction mechanism 33 of the picking device 3 according to the second embodiment. The suction mechanism 33 has a substantially rectangular shape in a plan view. The suction mechanism 33 has a plurality of holders 34 arranged in a matrix in the X-axis direction and the Y-axis direction. In the example of FIG. 12, the suction mechanism 33 has 20 holders 34 arranged in five rows in the X-axis direction and four columns in the Y-axis direction. In this description, the plurality of holders 34 will be distinguished by assigning row symbols 1 to 5 and column symbols A to D, and will be denoted, for example, as "A1."

[0077] The multiple holders 34 are driven by a driving means (not shown) and move horizontally in the X-axis and Y-axis directions within the suction mechanism 33. In the example of Fig. 12, the multiple holders 34 are supported at the intersections of first supports 331, 332, 333, 334, and 335 and second supports 336, 337, 338, and 339. The first supports 331, 332, 333, 334, and 335 are movable stages that extend in the X-axis direction and are movable in the Y-axis direction. The second supports 336, 337, 338, and 339 are movable stages that extend in the Y-axis direction and are movable in the X-axis direction.

[0078] Each holding section 34 has a plurality of (for example, four) suction cells 36. The four suction cells 36 are arranged in a matrix so as to be movable in the X-axis and Y-axis directions within the holding section 34. Each suction cell 36 has a plurality of (for example, four) suction pads 37. In this example, the suction pads 37 generate suction force by drawing in air through negative pressure. The suction pads 37 can increase or decrease suction force by adjusting the negative pressure. The suction pads 37 can turn off suction force by adjusting the negative pressure.

[0079] 13 to 15 are diagrams showing the holding unit 34 of the adsorption mechanism 33. FIGS. 13(A), 14(A), and 15(A) show the holding unit 34 in a side view, and FIGS. 13(B), 14(B), and 15(B) show the holding unit 34 in a plan view. As shown in these figures, the adsorption cells 36 are supported by support links 382 and 383 of the drive mechanism 38. FIG. 13 shows the holding unit 34 in an intermediate state where the spacing between the four adsorption cells 36 is intermediate. FIG. 14 shows the holding unit 34 in a wide state where the spacing between the four adsorption cells 36 is widened. FIG. 15 shows the holding unit 34 in a narrow state where the spacing between the four adsorption cells 36 is narrowed.

[0080] In this way, the suction mechanism 33 of this embodiment can obtain a desired suction pattern by moving the multiple holding units 34 in the X-axis and Y-axis directions, changing the spacing between the four suction cells 36, and further controlling the on / off of the suction force of each suction pad 37. In other words, the suction mechanism 33 selects a specific area of ​​the load to be picked, and moves the multiple holding units 34, changes the spacing between the suction cells 36, and controls the on / off of the suction force of the suction pads 37 to achieve a suction pattern corresponding to that specific area.

[0081] Next, process S210 will be described as an example of the depalletizing operation of this embodiment with reference to Fig. 16. Fig. 16 is a flowchart of process S210. Here, explanations that overlap with those in the first embodiment will be omitted. Furthermore, the palletizing operation is the same as in the first embodiment, so explanations will be omitted.

[0082] When the process S210 starts, the picking device 3 receives a depalletizing instruction from the control unit 50 (step S211). As an example, this instruction includes the position of the first loading pallet 12S-B and the arrangement and quantity of the loads to be picked.

[0083] After executing step S211, the picking device 3 moves the crane mechanism 30 in the X-axis direction or the Y-axis direction to move the holding mechanism 32 toward the target position (step S212).

[0084] After executing step S212, the picking device 3 determines whether the holding mechanism 32 has reached the target position (step S213). In this step, whether the target position has been reached can be determined based on images acquired by one or both of the first camera 391 and the second camera 392. For example, this determination may be made by recognizing the relative positional relationship between the first loading pallet 12S-B and the holding mechanism 32 based on the acquired images, and determining whether the positional deviation from the target position is equal to or less than a predetermined reference value. If it is determined that the target position has not been reached (N in step S213), the picking device 3 returns the process to step S212 and repeats steps S212 to S213.

[0085] If it is determined that the target position has been reached (Y in step S213), the picking device 3 acquires the surface condition of the load to be picked from the detection means 39, which detects the surface condition of the load. In this example, the detection means 39 is one or both of the first camera 391 and the second camera 392. Therefore, the picking device 3 acquires a surface image of the load to be picked (step S214). In this step, the picking device 3 determines areas (non-specific areas) that are not suitable for pickup from the load surface image. As an example, non-specific areas may be areas that have external factors that cause pickup disturbance, such as the four corners of the case or areas near the folded portions of the case. Examples of areas that have external factors that cause pickup disturbance include areas where hot melt adhesive adheres, areas with perforations, and areas that are subject to large deformation due to external forces. After determining the non-specific areas, the picking device 3 avoids the non-specific areas and determines specific areas on the load surface that are determined to be suitable for pickup.

[0086] Furthermore, the picking device 3 acquires the registered data of the specific area from the database DB through the control unit 50 (step S215). The picking device 3 determines the specific area based on the registered data.

[0087] After determining the specific area in steps S214 and S215, the picking device 3 determines a suction pattern corresponding to the specific area (step S216). In this step, the picking device 3 determines the positions of the multiple holders 34, the positions of the four suction cells 36, and which of the suction pads 37 to turn on and which to turn off, according to the specific area.

[0088] After determining the suction pattern in step S216, the picking device 3 moves the multiple holding units 34 based on the suction pattern (step S217), changes the spacing between the four suction cells 36 (step S218), and performs on / off control of the suction pads 37 (step S219).

[0089] After executing step S219, the picking device 3 lowers the holding mechanism 32 (step S220), adsorbs the load 10-B on the first loading pallet 12S-B with the suction mechanism 33 (step S221), and raises the holding mechanism 32 (step S222).

[0090] After executing step S222, the picking device 3 determines whether or not the pickup has been successful (step S223). In this step, whether or not the pickup has been successful can be determined based on the images acquired by one or both of the first camera 391 and the second camera 392.

[0091] If it is determined that the pickup has not been successful (N in step S223), the process returns to step S220 and steps S220 to S223 are repeated, causing the picking device 3 to lower the holding mechanism 32 again and perform the pickup operation again.

[0092] In this step, the picking device 3 may change the suction pattern depending on the holding state (suction state) of the picked-up load 10.

[0093] If it is determined that the pickup was successful (Y in step S223), the process S210 ends. The load 10 removed in the above-mentioned depalletizing operation is stacked on another pallet by the palletizing operation. Various modifications are possible to each of the above-mentioned steps.

[0094] This embodiment provides the same functions and effects as the first embodiment.

[0095] The above describes in detail exemplary embodiments of the present invention. The above-described embodiments merely illustrate specific examples of implementing the present invention. The content of the embodiments does not limit the technical scope of the present invention, and many design modifications, such as changes, additions, and deletions of components, are possible within the scope of the inventive concept defined in the claims. In the above-described embodiments, content that allows such design modifications is described using notations such as "in the embodiment" or "in the embodiment," but this does not mean that design modifications are not permitted in content that does not have such notations. Furthermore, hatching in the drawings does not limit the material of the hatched object.

[0096] (Variation) The following describes the modified examples. In the drawings and descriptions of the modified examples, the same or equivalent components and members as those in the embodiment are denoted by the same reference numerals. Explanations that overlap with the embodiment will be omitted as appropriate, and the description will focus on the configurations that differ from the embodiment.

[0097] In the description of the embodiment, the holding mechanism 32 generates an adhesive force by negative air pressure, but the present invention is not limited to this. The holding mechanism 32 may include a holding portion that can apply a force to the upper surface of the load 10 to move the load 10 upward. In the embodiment, the holding portion 34 is shown as an example of the holding portion. For example, instead of negative air pressure, the holding mechanism 32 may use magnetic attraction force from a magnet or other type of attraction force based on other physical principles. For example, if the contents are steel cans, the holding mechanism 32 may hold the cases by magnetically attracting the steel cans using an electromagnet provided in the holding mechanism 32 instead of the suction pad 37.

[0098] In the description of the embodiment, an example has been shown in which the picking space 302 is provided integrally with the shelf unit 22, but the present invention is not limited to this, and the picking space 302 may be provided outside the shelf unit 22. In this case, the loading pallet 12 may be transported between the shelf unit 22 and the picking space 302 by a transport mechanism such as a forklift.

[0099] In the description of the embodiment, an example was shown in which the second moving means 16 and the third moving means 18 are provided separately, but this is not limiting. As the second moving means, a moving means (for example, a stacker crane) capable of moving the loading pallet 12 in the row and column directions may be used. In this case, the stacker crane may not be capable of mounting the first moving means, or may be capable of mounting the first moving means together with the loading pallet 12.

[0100] In the description of the embodiment, an example has been shown in which a single loading / unloading section 52 is provided for all shelves and the third moving means 18 is connected to the loading / unloading section 52, but this is not limiting. Each shelf may be provided with its own loading / unloading section, and goods to be loaded and unloaded may be loaded into and unloaded from the loading / unloading section of each shelf by a forklift. Also, the loading / unloading section may be divided into an loading section and an unloading section.

[0101] In the description of the embodiment, an example has been shown in which the picking device 3 transfers the load 10 removed from the first loading pallet 12S to the second loading pallet 12M, but the destination to which the load 10 is transferred by the picking device 3 is not limited to a pallet. For example, the picking device 3 may transfer the removed load 10 onto a belt conveyor or the like, or onto the bed of a forklift or truck, or onto a self-propelled cart such as the first moving means 14.

[0102] In the description of the embodiment, an example has been shown in which the picking space 302 is provided on the same plane as the shelf section 22, but the present invention is not limited to this, and the picking space 302 may be provided on a different plane from the shelf section 22.

[0103] The holding mechanism 32 may hold the sides of the load using arms and hands.

[0104] In the description of the embodiment, an example was shown in which the picking device 3 is supported from the ceiling side by a gantry-type crane mechanism 30, but the present invention is not limited to this. For example, the picking device may be supported by an articulated robot or a support means with a different configuration. Furthermore, the picking device may be attached to a side wall on the side and supported from the side.

[0105] In the description of the embodiment, an example has been shown in which the loads 10 removed from a loading pallet 12 containing the same type of loads 10 are stacked onto a loading pallet 12 containing multiple types of loads 10 in the picking operation, but the present invention is not limited to this. The picking operation may include removing loads 10 from a loading pallet 12 containing multiple types of loads 10, or may involve creating a loading pallet 12 containing the same type of loads 10 using the removed loads 10. In addition, the loading pallet 12 containing the same type of loads 10 created by picking may be shipped out.

[0106] In the description of the embodiment, an example in which items are picked from the multiple first receivers 26p-A, 26p-B, and 26p-C to the single second receiver 26s has been shown, but the present invention is not limited to this. Items may be picked from the multiple first receivers 26p to the multiple second receivers 26s.

[0107] In the description of the embodiment, an example in which the multiple first mounting portions 26p-A, 26p-B, and 26p-C are arranged in a line in the Y-axis direction is shown in Fig. 10, but the present invention is not limited to this. It is not essential to arrange the multiple first mounting portions in a line, and they may be arranged spaced apart from each other.

[0108] In the description of the embodiment, an example has been shown in which the entire picking device 3 is included within the planar range of the shelf section 22, but the present invention is not limited to this. Part or all of the picking device 3 may extend outside the planar range of the shelf section 22.

[0109] Each of these modifications provides the same functions and effects as the embodiment.

[0110] 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 combined embodiments and modifications. [Explanation of symbols]

[0111] 1 automated warehouse system, 3 automated warehouse picking device, 10 load, 22 shelf section, 26 storage section, 32 holding mechanism, 33 suction mechanism, 34 holding section, 36 suction cell, 37 suction pad, 39 detection means.

Claims

1. A picking device that moves loads held by a holding mechanism that can hold multiple loads, the holding mechanism has a plurality of holding portions that adsorb a load, a detection means for detecting a surface condition of the load before the holding unit adsorbs the load to be picked, The plurality of holding units are configured to hold the object to be picked based on the surface condition of the object to be picked detected by the detection means, The detection means is capable of detecting perforations or attachments on the surface of the load, The holding mechanism determines an area on the surface of the load that has perforations or attachments as a non-specific area based on the detected surface condition, and turns on a holding unit among the plurality of holding units that does not correspond to the non-specific area. Picking device for automated warehouses.

2. A picking device that moves loads held by a holding mechanism capable of holding multiple loads, the holding mechanism has a plurality of holding portions that adsorb a load, a detection means for detecting a surface condition of the load before the holding unit adsorbs the load to be picked, The plurality of holding units are configured to hold the object to be picked based on the surface condition of the object to be picked detected by the detection means, The detection means is capable of detecting perforations or attachments on the surface of the load, The holding mechanism determines a specific area on the surface of the load that is free of perforations and attachments and is judged to be suitable for holding based on the surface condition, and turns on a holding unit among the plurality of holding units that corresponds to the specific area. Picking device for automated warehouses.

3. The surface condition of the load to be picked is acquired from a storage device in which the condition of the perforations or attachments on the surface of the load to be picked is stored in advance. The picking device for an automated warehouse according to claim 1 or 2.

4. The holding mechanism changes the suction position depending on the holding state of the held load. The picking device for an automated warehouse according to any one of claims 1 to 3.

5. a shelf unit having a plurality of storage units capable of storing loads; a moving means for moving an article to be stored or removed from the shelf; a picking device that moves loads using a holding mechanism that can hold multiple loads; Equipped with The holding mechanism has a plurality of holding portions that hold a load, a detection means for detecting a surface condition of the load before the holding unit adsorbs the load to be picked, The plurality of holding units are configured to perform holding operations based on the surface condition of the load to be picked detected by the detection means, The detection means is capable of detecting perforations or attachments on the surface of the load, The holding mechanism determines an area on the surface of the load that has perforations or attachments as a non-specific area based on the detected surface condition, and turns on a holding unit among the plurality of holding units that does not correspond to the non-specific area. Automated warehouse system.

Images