system

Abstract

To provide a system capable of effectively storing a container in which an article is inputted.SOLUTION: According to an embodiment, a system comprises a sorter and an automatic conveyance device. The sorter includes a first tray and an input mechanism. The first tray loads an article. The input mechanism inputs the article from the first tray to a container. The automatic conveyance device includes a gripping mechanism, a drive mechanism, and a processor. The gripping mechanism grips the container. The drive mechanism moves the gripping mechanism vertically. The processor acquires the container in which the article is inputted from the sorter using the gripping mechanism, and stores the container in which the article is inputted from the sorter in a shelf for storing the container in the height direction using the gripping mechanism and the drive mechanism.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] SUMMARY OF THE INVENTION An embodiment of the present invention relates to a system. [Background technology]

[0002] Systems are provided that use sorters to feed items into each chute, which then sort the items into bins according to the item's destination or other factors.

[0003] Conventionally, systems arrange containers containing items in a two-dimensional manner in a predetermined area in a warehouse, etc. Therefore, the system needs to secure a large space for storing the containers. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2020-132330 Summary of the Invention [Problem to be solved by the invention]

[0005] In order to solve the above problem, a system is provided that can effectively store containers containing items. [Means for solving the problem]

[0006] According to an embodiment, the system includes a sorter and an automatic conveying device. The sorter includes a first tray and an insertion mechanism. The first tray is loaded with items. The insertion mechanism inserts the items from the first tray into a container. The automatic conveying device includes a gripping mechanism, a drive mechanism, and a processor. The gripping mechanism grips the container. The drive mechanism moves the gripping mechanism in an up and down direction. The processor uses the gripping mechanism to obtain the container into which the items have been inserted from the sorter, and uses the gripping mechanism and the drive mechanism to store the container into which the items have been inserted from the sorter vertically on a shelf that stores the containers. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a block diagram showing an example of the configuration of a sorting system according to the first embodiment. [Figure 2] FIG. 2 is a top view showing an example of how the tote according to the first embodiment is installed. [Figure 3] FIG. 3 is a side view showing an example of how the tote according to the first embodiment is installed. [Figure 4] FIG. 4 is a diagram illustrating an example of a shelf according to the first embodiment. [Figure 5] FIG. 5 is a block diagram showing an example of the configuration of a control system of the sorting system according to the first embodiment. [Figure 6] FIG. 6 is a block diagram illustrating an example of the configuration of the division control device according to the first embodiment. [Figure 7] FIG. 7 is a block diagram showing an example of the configuration of the sorter control device according to the first embodiment. [Figure 8] FIG. 8 is a block diagram illustrating an example of the configuration of the CTU control device according to the first embodiment. [Figure 9] FIG. 9 is a side view of the CTU according to the first embodiment. [Figure 10] FIG. 10 is a block diagram showing an example of the configuration of a CTU according to the first embodiment. [Figure 11] FIG. 11 is a diagram illustrating an example of the configuration of sorting destination information according to the first embodiment. [Figure 12] FIG. 12 is a diagram illustrating an example of the operation of the sorting system according to the first embodiment. [Figure 13] FIG. 13 is a diagram illustrating an example of the operation of the sorting system according to the first embodiment. [Figure 14] FIG. 14 is a flowchart illustrating an example of the operation of the division control device according to the first embodiment. [Figure 15] FIG. 15 is a flowchart showing an example of the operation of the sorter control device according to the first embodiment. [Figure 16] FIG. 16 is a flowchart illustrating an example of the operation of the CTU control device according to the first embodiment. [Figure 17] FIG. 17 is a diagram illustrating an example of the operation of the sorting system according to the second embodiment. [Figure 18] FIG. 18 is a flowchart illustrating an example of the operation of the division control device according to the second embodiment. [Figure 19] FIG. 19 is a flowchart showing an example of the operation of the sorter control device according to the second embodiment. [Figure 20] FIG. 20 is a flowchart illustrating an example of the operation of the CTU control device according to the second embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0008] Hereinafter, an embodiment will be described with reference to the drawings. A sorting system according to an embodiment sorts each item into a destination. The sorting system uses a sorter and a high-rise case transport robot (Case Transfer Unit (CTU)) to place the items into a chute corresponding to the destination. The sorting system places the items into a tote through the chute. The sorting system also places the container containing the items on the CTU and stores it on a shelf.

[0009] Fig. 1 shows an example of the configuration of a sorting system 100 according to an embodiment. As shown in Fig. 1, the sorting system 100 includes an induction 3, a scanner 4, a sorter 5, a plurality of CTUs 7, a plurality of totes 8, a plurality of shelves 9, and a plurality of basket cars 200.

[0010] Here, the sorting system 100 transports articles through the induction 3, the scanner 4, and the sorter 5 in this order.

[0011] The induction 3 puts articles into the sorter 5. The induction 3 receives articles put in by an operator, a robot, or the like. The induction 3 transports the put-in articles using a conveyor or the like and puts them into the sorter 5.

[0012] The scanner 4 reads the code attached to the item. For example, the scanner 4 is installed in a position where it can photograph the code on the item being transported to the induction 3. The scanner 4 reads the code from the item being transported.

[0013] The code is obtained by encoding an ID that identifies the item. The scanner 4 may also read the character string of the ID attached to the item by character recognition processing (OCR (Optical Character Recognition) processing) or the like.

[0014] The sorter 5 sorts the articles that are inserted. Here, the sorter 5 is made up of a tray 51 (first tray), a pusher 52, a chute 53, and the like.

[0015] The sorter 5 transports articles by loading them onto trays 51. The trays 51 move in a predetermined direction (to the right in FIG. 1). The sorter 5 uses a pusher 52 to push out articles from the tray 51 into the chute 53 when the tray 51 arrives in front of a predetermined chute 53 .

[0016] Pusher 52 (feeding mechanism) feeds the items loaded on tray 51 into tote 8. Pusher 52 pushes the items into a specific chute 53 depending on the sorting destination of the items. Pusher 52 is located just before induction 3 places the items on tray 51, in the opposite direction to the direction in which the items are pushed out.

[0017] A plurality of chutes 53 are installed in parallel to the direction in which the trays 51 move. The chutes 53 are conveyance paths through which articles pushed out from the trays 51 pass. The chutes 53 are formed in a sloped shape that slopes downward from the trays 51. The sorter 5 puts items into the tote 8 from the chute 53 .

[0018] The sorter 5 may be composed of trays 51 and pushers 52, or may be composed of cross belts, an AGV, or some other mechanism. Here, a sorter 5 having trays 51 and pushers 52 will be described as an example.

[0019] The tote 8 is a container into which items are placed from the sorter 5. Multiple totes 8 are installed adjacent to the chute 53. The tote 8 is installed in a position where it can receive items passing through the chute 53. Here, the tote 8 is formed in the shape of a box with an open top.

[0020] The basket cart 200 is a container that stores the tote bags 8 to be dispensed. For example, the basket cart 200 has a structure that allows it to move while storing the tote bags 8.

[0021] The CTU7 is an automated transport device that loads and transports items. The CTU7 retrieves the tote 8 into which the items have been placed. After retrieving the tote 8, the CTU7 moves to the shelf 9. After moving to the shelf 9, the CTU7 stores the tote 8 on the shelf 9. CTU7 will be discussed in more detail later.

[0022] The shelf 9 stores a plurality of totes 8. The shelf 9 will be described in detail later.

[0023] Next, an example of how tote 8 is installed will be described. Fig. 2 is a top view showing an example of installation of tote 8. Fig. 3 is a side view showing an example of installation of tote 8.

[0024] As shown in FIGS. 2 and 3, the sorting system 100 includes a loading platform 6 (first loading platform) on which totes 8 are loaded. Loading platform 6 supports tote 8 at a predetermined height at which it can receive articles from chute 53 (at a position at which it can receive articles inserted from pusher 52).

[0025] The loading platform 6 includes a cord 61 and a guide 62 . The code 61 is a code obtained by encoding an identifier that indicates the corresponding chute 53 (or loading platform 6). For example, the code 61 is a barcode or a two-dimensional code. The code 61 is formed on the surface facing the chute 53 and the surface opposite to the surface facing the chute 53.

[0026] Guide 62 is a guide for maintaining the position of tote 8. Guide 62 is formed at a predetermined height. Guide 62 is composed of a first side between chute 53 and tote 8 and two second sides perpendicular to that first side. In other words, guide 62 is formed in the shape of a rectangle with an open side opposite the first side. The loading platform 6 may be structured so that a tote bag 8 can be further stored in the lower part or the like.

[0027] The tote 8 includes a cord 81 and the like. Code 81 is a code obtained by encoding an identifier that identifies tote bag 8. For example, code 81 may be a barcode or a two-dimensional code. Code 81 is formed on the surface facing chute 53 and the surface opposite to it.

[0028] Next, the shelf 9 will be described. FIG. 4 shows an example of the structure of the shelf 9. The shelves 9 are formed at a predetermined height. The shelves 9 are structured so that the CTUs 7 can retrieve or store the totes 8.

[0029] As shown in FIG. 4, the shelf 9 includes a plurality of shelf stages 91 arranged in a vertical direction. The shelf 91 has a depth that allows it to load totes 8. The shelf 91 also has a predetermined width. The shelf 91 loads totes 8 in the width direction. Here, the shelf 91 stores four totes 8 in the width direction. The shelf 91 is also open in the front direction (or rear direction).

[0030] Code 92 is a code obtained by encoding identifiers that indicate the shelf position and the tote position. For example, code 92 may be a barcode or a two-dimensional code. It is affixed to the shelf in accordance with the placement position of the tote.

[0031] The shelf 9 stores the totes 8 arranged vertically on the shelf stages 91.

[0032] Next, the control system of the sorting system 100 will be described. Fig. 5 shows a control system of the sorting system 100. As shown in Fig. 5, the sorting system 100 includes an induction 3, a scanner 4, a sorter 5, a higher-level device 2, a CTU 7, a sorting control device 10, a sorter control device 20, and a CTU control device 30.

[0033] The sorting control device 10 is connected to the induction 3, the scanner 4, the higher-level device 2, the sorter control device 20, and the CTU control device 30. The sorter control device 20 is connected to the sorter 5. The CTU control device 30 is connected to the CTU 7.

[0034] The higher-level device 2 transmits sorting destination information indicating the item and the sorting destination (destination) of the item to the sorting control device 10. The sorting destination information will be described in detail later. For example, the upper device 2 is a WMS (Warehouse Management System), and is configured by a PC or the like.

[0035] The sorting control device 10 controls the sorter 5 and the CTU 7 in accordance with sorting destination information from the higher-level device 2. The sorting control device 10 controls the sorter 5 via a sorter control device 20. The sorting control device 10 also controls the CTU 7 via a CTU control device 30. For example, the sorting control device 10 is a WES (Warehouse Execution System). The sorting control device 10 will be described in detail later.

[0036] The sorter control device 20 controls the sorter 5 in accordance with control signals from the sorting control device 10. The sorter control device 20 functions as a controller for the sorter 5. For example, the sorter control device 20 is a WCS (Warehouse Control System). The sorter control device 20 will be described in detail later.

[0037] The CTU control device 30 controls the CTU 7 in accordance with control signals from the section control device 10. The CTU control device 30 functions as a controller for the CTU 7. For example, the CTU control device 30 is a WCS. The CTU control device 30 will be described in detail later.

[0038] Next, the section control device 10 will be described. Fig. 6 is a block diagram showing an example of the configuration of the section control device 10. As shown in Fig. 6, the section control device 10 includes a processor 11, a ROM 12, a RAM 13, an NVM 14, a communication unit 15, an operation unit 16, a display unit 17, and the like.

[0039] The processor 11, the ROM 12, the RAM 13, the NVM 14, the communication unit 15, the operation unit 16, and the display unit 17 are connected to one another via a data bus or the like. The sectioning control device 10 may include other components as needed in addition to the components shown in FIG. 6, or specific components may be excluded from the sectioning control device 10.

[0040] The processor 11 has the function of controlling the overall operation of the division control device 10. The processor 11 may also include an internal cache and various interfaces. The processor 11 performs various processes by executing programs stored in advance in the internal memory, the ROM 12, or the NVM 14.

[0041] Some of the various functions realized by the processor 11 executing the programs may be realized by hardware circuits. In this case, the processor 11 controls the functions executed by the hardware circuits.

[0042] The ROM 12 is a non-volatile memory that pre-stores control programs, control data, etc. The control programs and control data stored in the ROM 12 are pre-installed in accordance with the specifications of the sectional control device 10.

[0043] RAM 13 is a volatile memory. RAM 13 temporarily stores data being processed by processor 11. RAM 13 stores various application programs based on instructions from processor 11. RAM 13 may also store data necessary for executing application programs and execution results of application programs.

[0044] The NVM 14 is a nonvolatile memory to which data can be written and rewritten. The NVM 14 is configured, for example, with a hard disk drive (HDD), a solid state drive (SSD), or flash memory. The NVM 14 stores control programs, applications, and various data according to the operational use of the section control device 10.

[0045] The communication unit 15 is an interface for communicating with the induction 3, scanner 4, host device 2, sorter control device 20, CTU control device 30, etc. For example, the communication unit 15 is an interface for transmitting and receiving data with the induction 3, scanner 4, host device 2, sorter control device 20, CTU control device 30, etc. via a network. The communication unit 15 connects to the sorter 5 via the sorter control device 20. The communication unit 15 also connects to the CTU 7 via the CTU control device 30. For example, the communication unit 15 is an interface that supports wired or wireless LAN (Local Area Network) connection.

[0046] The communication unit 15 functions as an interface for controlling the sorter 5 and the CTU 7.

[0047] In addition, the communication unit 15 may be composed of an interface for communicating with the induction 3, an interface for communicating with the scanner 4, an interface for communicating with the higher-level device 2, an interface for communicating with the sorter control device 20, and an interface for communicating with the CTU control device 30.

[0048] The operation unit 16 receives input of various operations from an operator. The operation unit 16 transmits a signal indicating the input operation to the processor 11. The operation unit 16 may be configured as a touch panel.

[0049] The display unit 17 displays image data from the processor 11. For example, the display unit 17 is configured with a liquid crystal monitor. When the operation unit 16 is configured with a touch panel, the display unit 17 may be formed integrally with the operation unit 16.

[0050] Next, the sorter control device 20 will be described. Fig. 7 is a block diagram showing an example of the configuration of the sorter control device 20. As shown in Fig. 7, the sorter control device 20 includes a processor 21, a ROM 22, a RAM 23, an NVM 24, a communication unit 25, a sorter interface 26, an operation unit 27, a display unit 28, and the like.

[0051] The processor 21, the ROM 22, the RAM 23, the NVM 24, the sorter interface 26, the communication unit 25, the operation unit 27, and the display unit 28 are connected to one another via a data bus or the like. The sorter control device 20 may include other components as needed in addition to the components shown in FIG. 7, or certain components may be excluded from the sorter control device 20.

[0052] The processor 21 has the function of controlling the overall operation of the sorter control device 20. The processor 21 may also include an internal cache and various interfaces. The processor 21 performs various processes by executing programs stored in advance in the internal memory, the ROM 22, or the NVM 24.

[0053] Note that some of the various functions realized by the processor 21 executing the programs may be realized by hardware circuits. In this case, the processor 21 controls the functions executed by the hardware circuits.

[0054] The ROM 22 is a non-volatile memory that pre-stores control programs, control data, etc. The control programs and control data stored in the ROM 22 are pre-installed in accordance with the specifications of the sorter control device 20.

[0055] The RAM 23 is a volatile memory. The RAM 23 temporarily stores data being processed by the processor 21. The RAM 23 stores various application programs based on instructions from the processor 21. The RAM 23 may also store data necessary for executing the application programs and execution results of the application programs.

[0056] The NVM 24 is a nonvolatile memory to which data can be written and rewritten. The NVM 24 is configured, for example, with an HDD, SSD, flash memory, etc. The NVM 24 stores control programs, applications, various data, etc. depending on the operational use of the sorter control device 20.

[0057] The communication unit 25 is an interface for communicating with the section control device 10 and the like. For example, the communication unit 25 is an interface for sending and receiving data to and from the section control device 10 and the like via a network. For example, the communication unit 25 is an interface that supports wired or wireless LAN connections.

[0058] The sorter interface 26 is an interface for communicating with the sorter 5 .

[0059] The operation unit 27 receives input of various operations from an operator. The operation unit 27 transmits a signal indicating the input operation to the processor 21. The operation unit 27 may be configured as a touch panel.

[0060] Display unit 28 displays image data from processor 21. For example, display unit 28 is configured with a liquid crystal monitor. When operation unit 27 is configured with a touch panel, display unit 28 may be formed integrally with operation unit 27.

[0061] The communication unit 25 and the sorter interface 26 may be integrally formed.

[0062] The processor 21 controls the sorter 5 in accordance with a control signal from the sorting control device 10. For example, the processor 21 causes the sorter 5 to sort a predetermined item into a predetermined chute. For example, the processor 21 pushes the item into the chute when the item reaches the chute.

[0063] Next, the CTU control device 30 will be described. Fig. 8 is a block diagram showing an example configuration of the CTU control device 30. As shown in Fig. 8, the CTU control device 30 includes a processor 31, a ROM 32, a RAM 33, an NVM 34, a communication unit 35, a CTU interface 36, an operation unit 37, a display unit 38, and the like.

[0064] The processor 31, the ROM 32, the RAM 33, the NVM 34, the CTU interface 36, the communication unit 35, the operation unit 37, and the display unit 38 are connected to one another via a data bus or the like. The CTU control device 30 may include components other than those shown in FIG. 8 as needed, or specific components may be excluded from the CTU control device 30.

[0065] The processor 31 has the function of controlling the overall operation of the CTU control device 30. The processor 31 may also include an internal cache and various interfaces. The processor 31 performs various processes by executing programs stored in advance in the internal memory, the ROM 32, or the NVM 34.

[0066] Note that some of the various functions realized by the processor 31 executing the programs may be realized by hardware circuits. In this case, the processor 31 controls the functions executed by the hardware circuits.

[0067] The ROM 32 is a non-volatile memory that pre-stores control programs, control data, etc. The control programs and control data stored in the ROM 32 are pre-installed in accordance with the specifications of the CTU control device 30.

[0068] The RAM 33 is a volatile memory. The RAM 33 temporarily stores data being processed by the processor 31. The RAM 33 stores various application programs based on instructions from the processor 31. The RAM 33 may also store data necessary for executing the application programs and the execution results of the application programs.

[0069] The NVM 34 is a non-volatile memory to which data can be written and rewritten. The NVM 34 may be configured, for example, as an HDD, SSD, or flash memory. The NVM 34 stores control programs, applications, and various data depending on the operational use of the CTU control device 30. For example, the NVM 34 stores a database related to the inventory locations of totes 8.

[0070] The communication unit 35 is an interface for communicating with the section control device 10 and the like. For example, the communication unit 35 is an interface for sending and receiving data to and from the section control device 10 and the like via a network. For example, the communication unit 35 is an interface that supports wired or wireless LAN connections.

[0071] The CTU interface 36 is an interface for communicating with the CTU 7. The CTU interface 36 is connected to the CTU 7 via a wired or wireless connection. For example, the CTU interface 36 may support a wireless LAN connection.

[0072] The operation unit 37 receives input of various operations from an operator. The operation unit 37 transmits a signal indicating the input operation to the processor 31. The operation unit 37 may be configured as a touch panel.

[0073] The display unit 38 displays the image data from the processor 31. For example, the display unit 38 is configured with a liquid crystal monitor. When the operation unit 37 is configured with a touch panel, the display unit 38 may be formed integrally with the operation unit 37.

[0074] The communication unit 35 and the CTU interface 36 may be integrally formed.

[0075] The processor 31 controls the CTU7 in accordance with control signals from the sorting control device 10. For example, the processor 31 causes the CTU7 to move to a predetermined position. The processor 31 also causes the CTU7 to retrieve a tote 8. The processor 31 also causes the CTU7 to set the tote 8.

[0076] Next, the CTU7 will be described. FIG. 9 is a side view of CTU7.

[0077] As shown in Fig. 9, the CTU 7 includes a base 701. The base 701 functions as a movement mechanism for moving the entire CTU 7. The base 701 includes tires 70, which will be described later. The base 701 may also include a camera that reads codes attached to the floor surface.

[0078] Furthermore, member 702 is formed on base 701, extending upward. For example, member 702 is made up of two rod-shaped members extending upward and a rod-shaped member formed between the two members. In other words, member 702 is formed in a ladder shape.

[0079] A plurality of rear trays 703 (second trays) are formed on the member 702. The rear trays 703 are plate-shaped members extending horizontally from the member 702. The rear trays 703 carry totes 8. The rear tray 703 carries one tote 8.

[0080] Here, eight rear trays 703 are formed on the member 702. Note that the number of rear trays 703 formed is not limited to a specific number.

[0081] A shuttle section 704 (gripping mechanism) is formed on the member 702. The shuttle section 704 is formed on the member 702 in the opposite direction to the rear tray 703. The shuttle section 704 can be moved up and down along the member 702 by a drive section 76 (to be described later) or the like.

[0082] The shuttle section 704 grips the tote 8 in front (on the left side in FIG. 9). The shuttle section 704 loads the gripped tote 8 onto one of the rear trays 703. Furthermore, the shuttle section 704 grips a tote 8 that is placed on one of the rear trays 703. The shuttle section 704 releases the gripped tote 8 at the front.

[0083] The shuttle unit 704 can retrieve totes 8 from each shelf level 91 of the shelf 9 and the loading platform 6. The shuttle unit 704 can also set totes 8 on each shelf level 91 of the shelf 9 and the loading platform 6.

[0084] The shuttle unit 704 is equipped with a camera 705. The camera 705 is installed so as to capture images of what is in front of it. The camera 705 captures images of the cord 61 of the loading platform 6, the cord 81 of the tote 8, or the cord 92 of the shelf 9. The camera 705 may also be equipped with lighting, etc.

[0085] Next, the control system of the CTU 7 will be described. 10 is a block diagram showing an example of the configuration of the CTU 7. The CTU 7 includes a processor 71, a ROM 72, a RAM 73, an NVM 74, a communication unit 75, a drive unit 76 (drive mechanism), a battery 78, a charging mechanism 79, tires 70, a shuttle unit 704, a camera 705, and the like.

[0086] The processor 71 has the function of controlling the overall operation of the CTU 7. The processor 71 may also include an internal cache and various interfaces. The processor 71 performs various processes by executing programs stored in advance in the internal memory, the ROM 72, or the NVM 74.

[0087] For example, the processor 71 is a central processing unit (CPU). The processor 71 may be realized by hardware such as a large scale integration (LSI), an application specific integrated circuit (ASIC), or a field-programmable gate array (FPGA).

[0088] The ROM 72 is a non-transitory computer-readable storage medium that stores the above-mentioned programs. The ROM 72 also stores data and various setting values ​​used by the processor 71 when performing various processes. The RAM 73 is a memory used for reading and writing data. The RAM 73 is used as a so-called work area for storing data that is temporarily used by the processor 71 when performing various processes.

[0089] The NVM 74 is a non-transitory computer-readable storage medium that may store the above-mentioned programs. The NVM 74 also stores data used by the processor 71 when performing various processes, data generated by the processes of the processor 71, various setting values, and the like.

[0090] The communication unit 75 is an interface that transmits and receives data to and from the CTU control device 30, etc. via a wireless LAN access point, etc. For example, the communication unit 75 supports wireless LAN connection.

[0091] The drive unit 76 drives the tire 70. The drive unit 76 is a motor or the like that rotates the tire 70, and rotates or stops the motor based on a drive signal output from the processor 71. The power of the motor is transmitted to the tire 70. The CTU 7 moves to a target position using the power from the motor.

[0092] The drive unit 76 also drives the shuttle unit 704. For example, the drive unit 76 moves the shuttle unit 704 in the up and down direction. The drive unit 76 also causes the shuttle unit 704 to perform a gripping operation. The drive unit 76 is a motor or the like that drives the shuttle unit 704.

[0093] The drive unit 76 may be configured from a mechanism for driving the tire 70 and a mechanism for driving the shuttle unit 704 .

[0094] The battery 78 supplies the necessary power to the drive unit 76 etc. The charging mechanism 79 is a mechanism that connects the charging station and the battery 78, and the battery 78 is charged with power supplied from the charging station etc. via the charging mechanism 79.

[0095] The tires 70 are rotated by power from the drive unit 76. The rotation of the tires 70 allows the CTU 7 to move forward, backward, change direction, etc.

[0096] It should be noted that the CTU 7 may be provided with other components as required in addition to the components shown in FIGS. 9 and 10, and certain components may be excluded from the CTU 7.

[0097] The processor 71 performs processes such as calculations and controls required for acceleration, deceleration, stopping, direction changes, and the operation of the shuttle unit 704. Based on control signals from the CTU control device 30 or the like, the processor 71 executes programs stored in the ROM 72 or NVM 74 or the like to generate drive signals and output them to each unit.

[0098] The processor 71 of the CTU 7 outputs a drive signal in response to a control signal sent from the CTU control device 30. As a result, the CTU 7 moves from its current position to a predetermined position, and performs operations such as gripping, opening, and loading the tote 8.

[0099] Next, a description will be given of functions realized by the section control device 10. The functions realized by the section control device 10 are realized by the processor 11 executing a program stored in the internal memory, the ROM 12, the NVM 14, or the like.

[0100] First, the processor 11 has a function of acquiring sorting destination information. As described above, the sorting destination information indicates the sorting destination of the item.

[0101] Fig. 11 shows an example of the configuration of sorting destination information. As shown in Fig. 11, the sorting destination information stores records that associate "ID" and "destination".

[0102] "ID" is an identifier that identifies the item to be sorted. Here, "ID" is a numeric value. "Destination" is the destination of the corresponding item. "Destination" corresponds to the tote 8 in which the item is stored and the shelf 9 on which the tote 8 is stored. In other words, "destination" is information that enables the processor 11 of the sorting control device 10 to identify the tote 8 into which the item is to be placed and the shelf 9 on which the tote 8 is stored.

[0103] For example, the "destination" may be information indicating an address (or part of an address). The configuration of the sorting destination information is not limited to a specific configuration.

[0104] The processor 11 receives sorting destination information from the higher-level device 2 through the communication unit 15. The processor 11 may also transmit a request to the higher-level device 2 through the communication unit 15 to request sorting destination information.

[0105] The processor 11 also has a function of generating one-path sorting information and one-path allocation plan information based on sorting destination information.

[0106] Here, the processor 11 causes the sorter 5 to put the items into the chute 53, and causes the CTU 7 to store the tote 8 with the items put into it on the shelf 9. That is, the processor 11 puts the items into the sorter 5 once and sorts them (one-pass sorting).

[0107] The one-pass classification information is information that specifies the chute 53 into which an item is to be dropped. For example, the one-pass classification information stores an item identifier and the chute 53 into which the item is to be dropped in association with each other.

[0108] The one-path layout plan information is information that identifies the shelf 9 that stores the tote 8 that has received the items from the chute 53. For example, the one-path layout plan information stores the identifier of the tote 8, the identifier of the loading platform 6 that carries the tote 8, and the shelf 9 that stores the tote 8, in association with each other.

[0109] After generating the one-pass sorting information, the processor 11 transmits it to the sorter control device 20 via the communication unit 15. Furthermore, when the processor 11 generates the one-path allocation plan information, it transmits it to the CTU control device 30 via the communication unit 15. Here, the processor 11 uses the induction 3 to start putting the articles into the sorter 5.

[0110] Next, a description will be given of functions realized by the sorter control device 20. The functions realized by the sorter control device 20 are realized by the processor 21 executing a program stored in the internal memory, the ROM 22, the NVM 24, or the like.

[0111] The processor 21 has a function of putting the articles into the chute 53 based on the one-pass sorting information.

[0112] First, the processor 21 receives one-pass sorting information from the sorting control device 10 via the communication unit 25. Upon receiving the one-pass sorting information, the processor 21 generates sorting designation information that designates the chute 53 into which each item is to be dropped, based on the one-pass sorting information.

[0113] After generating the sorting designation information, the processor 21 causes the sorter 5 to load the items inserted from the induction 3 onto the tray 51. When the sorter 5 loads the items onto the tray 51, the processor 21 acquires the ID read by the scanner 4 from the items.

[0114] For example, the processor 21 obtains the ID read from the item by the scanner 4 from the sorting control device 10 via the communication unit 25. The processor 21 may obtain the ID from the scanner 4. The processor 21 may also obtain an image from the scanner 4 and decode a code appearing in the image to obtain the ID.

[0115] When the ID is acquired, the processor 21 refers to the sorting specification information and identifies the chute 53 corresponding to the acquired ID. When the chute 53 is identified, the processor 21 causes the sorter 5 to feed the articles loaded on the tray 51 into the chute 53 via the sorter interface 26.

[0116] For example, the processor 21 causes the sorter 5 to use the pusher 52 to put the items from the tray 51 into the chute 53 when the tray 51 reaches the chute 53. The items pass through the chute 53 and are put into the tote 8.

[0117] Processor 21 similarly causes sorter 5 to place articles into chute 53 until one pass of sorting is completed.

[0118] The processor 21 also detects when the tote 8 has reached a predetermined volume. For example, if there is volume information associated with the code of the item, the processor 21 adds up the volume of each item placed in the tote 8, and when the sum of the added volumes is equal to or greater than a volume threshold preset based on the internal volume of the tote 8, the processor 21 determines / detects that the tote 8 has reached the predetermined volume. If there is no volume information, or if there is volume information but the processor 21 uses that information in conjunction with sensor information to make the determination, the processor 21 determines / detects that the tote 8 has reached the predetermined volume by combining information from a reflection sensor 54 attached to each chute as shown in FIG. 21 with the volume information when items are piled up above a certain set height position. When the processor 21 detects that the tote 8 has reached the predetermined volume, the processor 21 transmits a control signal (predetermined volume detection signal) to the sorting control device 10 indicating that the tote 8 has reached the predetermined volume. The predetermined volume detection signal is transmitted to the CTU control device 30 via the sorting control device 10.

[0119] Next, we will explain the functions realized by the CTU control device 30. The functions realized by the CTU control device 30 are realized by the processor 31 executing a program stored in the internal memory, the ROM 32, the NVM 34, or the like.

[0120] The processor 31 has a function of storing the tote 8 containing the article on the shelf 9 based on the one-path arrangement plan information.

[0121] First, the processor 31 receives one-path arrangement plan information from the sorting control device 10 via the communication unit 35. Upon receiving the one-path arrangement plan information, the processor 31 formulates an operation plan for each CTU 7 based on the one-path arrangement plan information. Also, here, it is assumed that the CTU 7 does not have any totes 8 loaded on the rear tray 703.

[0122] After formulating the operation plan, the processor 31 causes one of the CTUs 7 to move to the shelf 9. After causing the CTU 7 to move to the shelf 9, the processor 31 causes the CTU 7 to retrieve an empty tote 8 from the shelf 9. Here, the processor 31 causes the CTU 7 to load an empty tote 8 onto each rear tray 703.

[0123] The processor 71 of the CTU 7 uses the drive unit 76 to move the shuttle unit 704 to the height of the shelf 91 on which the empty tote 8 is stored. After moving the shuttle unit 704, the processor 71 uses the shuttle unit 704 to grasp the empty tote 8 and load it onto the rear tray 703. The processor 71 similarly loads empty totes 8 from the shelf 9 onto each rear tray 703.

[0124] After the CTU 7 acquires the empty tote 8, the processor 31 waits until it receives a signal indicating that the predetermined amount has been detected.

[0125] When a predetermined amount detection signal is received, the processor 31 causes the CTU 7 to move to the position of the tote 8 that has reached the predetermined amount. For example, the processor 71 of the CTU 7 uses the camera 705 to read the code 61 of the loading platform 6 or the code 81 of the tote 8, and moves to the front of the tote 8 that has reached the predetermined amount.

[0126] When the CTU 7 is moved to the position, the processor 31 causes the CTU 7 to retrieve the tote bags 8 that have reached a predetermined amount and set the empty tote bags 8 therein.

[0127] The processor 31 may also cause the CTU 7 to place an empty tote 8 placed below the loading platform 6 onto the loading platform 6.

[0128] 12 shows an example of the operation in which the CTU 7 retrieves totes 8 that have reached a predetermined level and places an empty tote 8 in place. As shown in FIG. 12, it is assumed that a predetermined tote 8 has reached a predetermined level with items P. In addition, it is assumed here that the loading platform 6 stores empty totes 8 in its lower portion.

[0129] The processor 71 of the CTU 7, under control of the CTU control device 30, uses the shuttle unit 704 and drive unit 76 to retrieve a predetermined number of totes 8. Once the predetermined number of totes 8 has been retrieved, the processor 71 uses the shuttle unit 704 and drive unit 76 to load the predetermined number of totes 8 onto one of the rear trays 703. Once the predetermined number of totes 8 has been loaded onto one of the rear trays 703, the processor 71 uses the shuttle unit 704 and drive unit 76 to set the empty tote 8 loaded on one of the rear trays 703 onto the loading platform 6.

[0130] The processor 31 of the CTU control device 30 repeats the above operation until a predetermined number of totes 8 are loaded on each rear tray 703 of the CTU 7 .

[0131] When a predetermined number of totes 8 have been loaded onto each rear tray 703 of the CTU7, the processor 31 causes the CTU7 to move to a predetermined shelf 9. Once the CTU7 has moved to the predetermined shelf 9, the processor 31 causes the CTU7 to store the predetermined number of totes 8 on the predetermined shelf 9. For example, the predetermined shelf 9 is a shelf 9 that can store totes 8.

[0132] 13 shows an example of the operation of the CTU 7 moving to a predetermined shelf 9 and storing a predetermined number of totes 8 on the shelf 9. As shown in FIG. 13, the processor 71 of the CTU 7 loads the predetermined number of totes 8 onto the rear tray 703, and then drives the drive unit 76 and other components to move the CTU 7 to the predetermined shelf 9. Once the CTU 7 has reached the predetermined shelf 9, the processor 71 uses the shuttle unit 704 to grab the predetermined number of totes 8 from the rear tray 703.

[0133] When a predetermined amount of totes 8 has been gripped, processor 71, while shuttle unit 704 is gripping the totes 8, uses drive unit 76 to move shuttle unit 704 to the height of shelf 91 at which the totes 8 can be loaded. After moving shuttle unit 704, processor 71 uses shuttle unit 704 to load the totes 8 onto shelf 91.

[0134] Similarly, the processor 71 uses the shuttle unit 704 and the drive unit 76 to store each tote 8 loaded on the rear tray 703 on a predetermined shelf 9.

[0135] If the tote 8 cannot fit on one shelf 9, the processor 71 may store the tote 8 on multiple shelves 9 under control of the CTU control device 30. Furthermore, the processor 31 of the CTU control device 30 operates each CTU 7 in the same manner.

[0136] The processor 31 of the CTU control device 30 similarly causes the CTU 7 to store a predetermined number of totes 8 on the shelves 9 until one pass segment is completed.

[0137] Next, an example of the operation of the sorting system 100 will be described. First, an example of operation of the sorting control device 10 will be described. FIG. 14 is a flowchart for explaining an example of operation of the sorting control device 10.

[0138] First, the processor 11 of the sorting control device 10 receives sorting destination information from the upper device 2 via the communication unit 15 (S11). Upon receiving the sorting destination information, the processor 11 generates one-path sorting information based on the sorting destination information (S12).

[0139] After generating the one-path classification information, the processor 11 generates one-path layout plan information (S13). After generating the one-path layout plan information, the processor 11 transmits the one-path classification information to the sorter control device 20 via the communication unit 15 (S14).

[0140] After transmitting the one-path sorting information to the sorter control device 20, the processor 11 transmits the one-path allocation plan information to the CTU control device 30 via the communication unit 15 (S15). After transmitting the one-path allocation plan information to the CTU control device 30, the processor 11 ends its operation.

[0141] Next, an example of the operation of the sorter control device 20 will be described. FIG. 15 is a flowchart for explaining an example of the operation of the sorter control device 20.

[0142] First, the processor 21 of the sorter control device 20 receives one-pass sorting information from the sorting control device 10 via the communication unit 25 (S21). Upon receiving the one-pass sorting information, the processor 21 generates sorting designation information based on the one-pass sorting information (S22).

[0143] When the sorting designation information is generated, the processor 21 causes the sorter 5 to receive the item from the induction 3 (S23). When the processor 21 receives the item, it acquires the ID of the item (S24).

[0144] When the ID of the item is acquired, processor 21 causes sorter 5 to put the item into chute 53 corresponding to the ID (S25). After putting the item into chute 53 corresponding to the ID, processor 21 determines whether one pass of sorting is completed (S26).

[0145] If it is determined that one pass segment is not complete (S26, NO), the processor 21 returns to S23. When it is determined that one pass segment has been completed (S26, YES), the processor 21 ends the operation.

[0146] Next, an example of the operation of the CTU control device 30 will be described. FIG. 16 is a flowchart for explaining an example of the operation of the CTU control device 30.

[0147] First, the processor 31 of the CTU control device 30 receives one-path allocation plan information through the communication unit 35 (S31). Upon receiving the one-path allocation plan information, the processor 31 formulates an operation plan based on the one-path allocation plan information (S32).

[0148] After formulating the operation plan, processor 31 causes CTU 7 to move to shelf 9 and load empty totes 8 from shelf 9 onto rear tray 703 (S33). After loading the empty totes 8 onto CTU 7, processor 31 waits until it receives a signal that a predetermined amount has been detected.

[0149] When the predetermined amount detection signal is received (S34), the processor 31 moves the CTU 7 to the front of the tote 8 whose amount has reached the predetermined amount, and causes the tote 8 whose amount has reached the predetermined amount to be loaded onto the rear tray 703 (S35).

[0150] When a predetermined amount of totes 8 have been loaded, the processor 31 causes the CTU 7 to set the empty totes 8 loaded on the rear tray 703 onto the loading platform 6 (S36).

[0151] The processor 31 repeats steps S34 to S36 until a predetermined number of totes 8 are loaded on each rear tray 703.

[0152] When a predetermined number of totes 8 have been loaded onto each rear tray 703, the processor 31 causes the CTU 7 to move the totes 8 to the shelf 9 (S37). After the totes 8 have been moved to the shelf 9, the processor 31 causes the CTU 7 to store the predetermined number of totes 8 on the shelf 9 (S38).

[0153] When the predetermined number of totes 8 have been stored on the shelves 9, the processor 31 determines whether one pass of sorting has been completed (S39).

[0154] If it is determined that one pass segment is not complete (S39, NO), the processor 31 returns to S33. When it is determined that one pass segment is complete (S39, YES), the processor 21 ends the operation. The processor 31 executes steps S33 to S38 simultaneously for each CTU.

[0155] The processor 31 may also cause the CTU 7 to store on the shelf 9 a tote 8 that has articles in it but does not contain the predetermined amount of articles. Furthermore, empty totes 8 may be pre-loaded on rear tray 703.

[0156] Also, the sorting system 100 does not necessarily have to include the chute 53. For example, the articles may be directly placed into the totes 8 from the sorter 5.

[0157] Additionally, the sorting system 100 may cause the CTU 7 to transport a predetermined number of totes 8 from the shelf 9 to the cart 200. For example, the sorting system 100 causes the CTU 7 to transport a predetermined number of totes 8 from the shelf 9 to the cart 200 during the discharge process.

[0158] The sorting system configured as described above uses a sorter to load items into totes. The sorting system also uses CTUs to store empty totes and totes filled to a predetermined amount on shelves that can store totes vertically. This allows the sorting system to arrange totes three-dimensionally. This allows the sorting system to store totes effectively. (Second embodiment) Next, a second embodiment will be described. The sorting system 100 according to the second embodiment differs from that of the first embodiment in that after one-pass sorting, the items sorted into totes 8 are again put into the sorter 5 for sorting (two-pass sorting). Therefore, the other aspects are given the same reference numerals and detailed explanations are omitted. The sorting system 100 according to the second embodiment includes a conveyor 101 (second loading platform) which will be described later. The conveyor 101 will be described in detail later.

[0159] Next, we will explain the functions realized by the sorting control device 10. The functions realized by the sorting control device 10 are realized by the processor 11 executing programs stored in the internal memory, ROM 12, NVM 14, etc. The sorting control device 10 according to the second embodiment realizes the following functions in addition to the functions executed by the sorting control device 10 according to the first embodiment.

[0160] The processor 11 has a function of generating two-path sorting information and two-path allocation plan information based on sorting destination information.

[0161] Here, after performing one-pass sorting, processor 11 causes CTU 7 to put items from totes 8 on shelf 9 into chute 53 and into sorter 5, and then causes sorter 5 to store the totes 8 with the items put into them back on shelf 9. In other words, processor 11 sorts items by putting them into sorter 5 twice (two-pass sorting).

[0162] The 2-pass sorting information is information that specifies the chute 53 into which the item is to be dropped in the 2nd pass. For example, the 2-pass sorting information stores an item identifier and the chute 53 into which the item is to be dropped in association with each other.

[0163] The two-path layout plan information is information that identifies the shelf 9 that will store the tote 8 that has received the items from the chute 53 in the second path. For example, the two-path layout plan information stores the identifier of the tote 8, the identifier of the loading platform 6 that carries the tote 8, and the shelf 9 that stores the tote 8, in association with each other.

[0164] For example, processor 11 generates second-pass sorting information and second-pass layout plan information to sort items in more detail than in the first pass. Processor 11 may also generate second-pass sorting information and second-pass layout plan information so that items are re-input into sorter 5 in the order of the first pass while maintaining the order of the sorting results in the first pass.

[0165] After generating the two-path sorting information, the processor 11 transmits it to the sorter control device 20 via the communication unit 15. Furthermore, after generating the two-path allocation plan information, the processor 11 transmits it to the CTU control device 30 via the communication unit 15.

[0166] Next, we will explain the functions realized by the sorter control device 20. The functions realized by the sorter control device 20 are realized by the processor 21 executing programs stored in the internal memory, ROM 22, NVM 24, etc. The sorter control device 20 according to the second embodiment realizes the following functions in addition to the functions executed by the sorter control device 20 according to the first embodiment.

[0167] The processor 21 has the function of putting the articles into the chute 53 based on the two-pass sorting information.

[0168] First, processor 21 receives two-pass sorting information from sorting control device 10 via communication unit 25. Upon receiving the two-pass sorting information, processor 21 generates sorting designation information that designates the chute 53 into which each item is to be dropped, based on the two-pass sorting information.

[0169] When the sorting designation information is generated, the processor 21 causes the sorter 5 to put the items into the chute 53. An example of the operation in which the processor 21 causes the sorter 5 to put the items into the chute 53 is similar to that in the first embodiment, and therefore a description thereof will be omitted.

[0170] Next, we will explain the functions realized by the CTU control device 30. The functions realized by the CTU control device 30 are realized by the processor 31 executing programs stored in the internal memory, ROM 32, NVM 34, etc. The CTU control device 30 according to the second embodiment realizes the following functions in addition to the functions executed by the CTU control device 30 according to the first embodiment.

[0171] The processor 31 has a function of storing the tote 8 containing the items on the shelf 9 based on the two-path arrangement plan information.

[0172] The processor 31 has a function of transporting the tote 8 containing the items from the shelf 9 to the conveyor 101 based on the two-path layout plan information.

[0173] First, the processor 31 receives two-path allocation plan information from the section control device 10 via the communication unit 35. Upon receiving the two-path allocation plan information, the processor 31 formulates an operation plan for each CTU 7 based on the one-path allocation plan information.

[0174] After formulating the operation plan, processor 31 causes one of the CTUs 7 to move to a shelf 9 in accordance with the operation plan. After moving to the shelf 9, processor 31 causes the CTU 7 to retrieve the tote 8 containing the items from the shelf 9. After retrieving the tote 8 from the shelf 9, processor 31 causes the CTU 7 to move to the conveyor 101. After moving to the conveyor 101, processor 31 causes the CTU 7 to place the tote 8 on the conveyor 101.

[0175] 17 shows an example of an operation in which the CTU 7 sets the tote 8 from the shelf 9 onto the conveyor 101. As described above, the sorting system 100 includes the conveyor 101.

[0176] The conveyor 101 is disposed near the induction 3. Here, two conveyors 101 are disposed with the induction 3 sandwiched between them.

[0177] The conveyor 101 receives the tote 8 containing the items from the CTU 7. The conveyor 101 transports the received tote 8 in a predetermined direction. The conveyor 101 loads the tote 8 containing the items to be reloaded into the sorter 5. The items in the tote 8 loaded by the conveyor 101 are sequentially loaded into the induction 3 by a robot, an operator, or the like. Here, it is assumed that CTU7 does not have tote 8 loaded on it.

[0178] First, the processor 71 of the CTU 7 moves to the shelf 9. Once at the shelf 9, the processor 71 uses the drive unit 76 to move the shuttle unit 704 to the height of the shelf level 91 on which a specific tote 8 is loaded. Once the shuttle unit 704 has been moved, the processor 71 uses the shuttle unit 704 to grasp the tote 8 on the shelf level 91. Once the tote 8 has been grasped, the processor 71 uses the shuttle unit 704 to load the tote 8 onto the rear tray 703. The processor 71 similarly loads the totes 8 onto each rear tray 703 .

[0179] Once the tote 8 is loaded onto each rear tray 703, the processor 71 uses the drive unit 76 to move to a position where the tote 8 can be inserted into one end (starting end) of one of the conveyors 101. Once moved to that position, the processor 71 uses the shuttle unit 704 to grasp the tote 8 on the rear tray 703.

[0180] Once the tote 8 is grasped, the processor 71 uses the shuttle unit 704 to place the grasped tote 8 at one end of the conveyor 101 . Similarly, the processor 71 sets the totes 8 in each rear tray 703 at one end of the conveyor 101 .

[0181] After placing the tote 8 on each rear tray 703, the processor 71 uses the drive unit 76 to move the tote 8 from the other end (terminal end) of the conveyor 101 to a position where it can be picked up.

[0182] Once in this position, the processor 71 uses the shuttle unit 704 to pick up an empty tote 8 from the other end of the conveyor 101 and place it on the rear tray 703 . The processor 71 similarly loads empty totes 8 onto each rear tray 703 .

[0183] When empty totes 8 are loaded onto each rear tray 703, similar to the first embodiment, the processor 31 causes the CTU 7 to retrieve the predetermined number of totes 8 from the loading platform 6 and set the empty totes 8 on the loading platform 6. The processor 31 also causes the CTU 7 to store the predetermined number of totes 8 on the shelf 9.

[0184] The processor 31 of the CTU controller 30 operates each CTU 7 in the same manner until the two-pass section is complete.

[0185] Next, an example of the operation of the sorting system 100 will be described. First, an example of operation of the sorting control device 10 will be described. FIG. 18 is a flowchart for explaining an example of operation of the sorting control device 10.

[0186] First, processor 11 of sorting control device 10 receives sorting destination information from host device 2 via communication unit 15 (S41). Upon receiving the sorting destination information, processor 11 generates two-path sorting information based on the sorting destination information (S42).

[0187] After generating the two-path sorting information, the processor 11 generates two-path layout plan information (S43). After generating the two-path layout plan information, the processor 11 transmits the two-path sorting information to the sorter control device 20 via the communication unit 15 (S44).

[0188] After transmitting the two-path sorting information to the sorter control device 20, the processor 11 transmits the two-path layout plan information to the CTU control device 30 via the communication unit 15 (S45). After transmitting the two-path layout plan information to the CTU control device 30, the processor 11 ends its operation.

[0189] Next, an example of the operation of the sorter control device 20 will be described. FIG. 19 is a flowchart for explaining an example of the operation of the sorter control device 20.

[0190] First, the processor 21 of the sorter control device 20 receives two-path sorting information from the sorting control device 10 via the communication unit 25 (S51). Upon receiving the two-path sorting information, the processor 21 generates sorting designation information based on the two-path sorting information (S52).

[0191] When the sorting designation information is generated, the processor 21 causes the sorter 5 to receive the item from the induction 3 (S53). When the processor 21 receives the item, it acquires the ID of the item (S54).

[0192] When the ID of the item is acquired, processor 21 causes sorter 5 to put the item into chute 53 corresponding to the ID (S55). After putting the item into chute 53 corresponding to the ID, processor 21 determines whether two-pass sorting is complete (S56).

[0193] If it is determined that the two-pass division is not complete (S56, NO), the processor 21 returns to S53. When it is determined that the two-pass division is complete (S56, YES), the processor 21 ends the operation.

[0194] Next, an example of the operation of the CTU control device 30 will be described. FIG. 20 is a flowchart for explaining an example of the operation of the CTU control device 30.

[0195] First, the processor 31 of the CTU control device 30 receives two-path layout plan information through the communication unit 35 (S61). Upon receiving the two-path layout plan information, the processor 31 formulates an operation plan based on the two-path layout plan information (S62).

[0196] When the operation plan is formulated, the processor 31 causes the CTU 7 to move to the shelf 9 and load the totes 8 containing items from the shelf 9 onto each rear tray 703 (S63). After the totes 8 have been loaded onto the CTU 7, the processor 31 causes the CTU 7 to move to the conveyor 101 (S64).

[0197] Once moved to the conveyor 101, the processor 31 causes the CTU 7 to set each tote 8 at one end of the conveyor 101 (S65). Once each tote 8 has been set, the processor 31 causes the CTU 7 to load the empty totes 8 onto each rear tray 703 from the other end of the conveyor 101 (S66).

[0198] When an empty tote 8 is loaded, the processor 31 waits until it receives a signal indicating that a predetermined amount has been detected.

[0199] When the predetermined amount detection signal is received (S67), the processor 31 moves the CTU 7 to the front of the tote 8 that has reached the predetermined amount on the loading platform 6, and loads the tote 8 that has reached the predetermined amount onto the rear tray 703 (S68).

[0200] When a predetermined amount of totes 8 have been loaded, the processor 31 causes the CTU 7 to set the empty totes 8 loaded on the rear tray 703 onto the loading platform 6 (S69).

[0201] The processor 31 repeats steps S67 to S69 until a predetermined number of totes 8 are loaded on each rear tray 703.

[0202] When a predetermined number of totes 8 have been loaded onto each rear tray 703, the processor 31 causes the CTU 7 to move the totes 8 to the shelf 9 (S70). After the CTU 7 has moved the totes 8 to the shelf 9, the processor 31 causes the CTU 7 to store the predetermined number of totes 8 on the shelf 9 (S71).

[0203] When the predetermined number of totes 8 have been stored on the shelves 9, the processor 31 determines whether the two-pass sorting is complete (S72).

[0204] If it is determined that the two-pass division is not complete (S72, NO), the processor 31 returns to S63. When it is determined that one pass segment has been completed (S69, YES), the processor 21 ends the operation.

[0205] The processor 31 executes steps S63 to S71 simultaneously for each CTU.

[0206] Furthermore, after two-pass sorting is completed, the sorting system 100 may have the CTU 7 transport a predetermined number of totes 8 from the shelf 9 to the cart 200. For example, the sorting system 100 transports a predetermined number of totes 8 from the shelf 9 to the cart 200 during the discharge process.

[0207] Furthermore, the CTU 7 may set the tote 8 containing the articles from the shelf 9 onto a predetermined table or floor surface. In this case, the sorting system 100 does not need to include the conveyor 101.

[0208] In addition, the sorting system 100 may sort the items again after completing the two-pass sorting (three-pass sorting). The number of times sorting is performed by the sorting system 100 is not limited to a specific number of times.

[0209] The sorting system configured as described above re-sorts the items sorted in one pass by feeding them into the sorter. As a result, the sorting system can sort the items in more detail. For example, if the sorting system has n chutes, it can sort the items into n x n destinations.

[0210] Although several embodiments of the present invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be embodied in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included within the scope and spirit of the invention, and are also included in the scope of the invention and its equivalents as defined in the claims. The invention as set forth in the claims of the present application as originally filed is set forth below. [Appendix 1] A system including a sorter and an automatic conveying device, The sorter is a first tray for carrying an item; a loading mechanism that loads the items from the first tray into a container; Equipped with The automatic conveying device is a gripping mechanism that grips the container; a drive mechanism that moves the gripping mechanism in the up and down direction; Using the gripping mechanism, the container into which the article has been placed is acquired from the sorter; using the gripping mechanism and the drive mechanism, the container into which the articles have been put from the sorter is stored in a shelf for storing the containers in a vertical direction; a processor; Equipped with system. [Appendix 2] a first loading platform that supports the container at a position where the article is to be loaded by the loading mechanism; the automatic conveying device includes a second tray for loading the containers; the processor retrieves the container into which the article has been placed from the sorter, from the first loading tray, and then uses the gripping mechanism to set the empty container to be loaded by the second tray onto the first loading tray; 10. The system of claim 1. [Appendix 3] The system described in Appendix 1 or 2, wherein the processor uses the gripping mechanism to retrieve the container containing the items from the sorter when the container contains a predetermined amount of items inserted by the insertion mechanism. [Appendix 4] the processor uses the gripping mechanism and the drive mechanism to retrieve the empty container from the shelf and load it onto the second tray; 1. The system described in Appendix 2. [Appendix 5] the first loading platform includes a guide for maintaining the position of the container; 1. The system described in Appendix 2. [Appendix 6] a second loading platform for loading the containers for storing the items to be reloaded into the sorter; The processor: using the gripping mechanism and the drive mechanism to obtain the container into which the article has been placed from the sorter, from the shelf; Using the gripping mechanism, the container is loaded onto the second loading platform. 6. The system of any one of claims 1 to 5. [Appendix 7] the processor uses the gripping mechanism to obtain the empty container from the second loading platform; 10. The system described in Appendix 6. [Appendix 8] The second loading platform is a conveyor. 8. The system of claim 6 or 7. [Appendix 9] The shelf comprises a plurality of shelves. 9. The system of any one of appendices 1 to 8. [Explanation of symbols]

[0211] 2...Host device, 3...Induction, 4...Scanner, 5...Sorter, 6...Loading platform, 7...CTU, 8...Tote, 9...Shelf, 10...Sorting control device, 11...Processor, 12...ROM, 13...RAM, 14...NVM, 15...Communication unit, 16...Operation unit, 17...Display unit, 20...Sorter control device, 21...Processor, 22...ROM, 23...RAM, 24...NVM, 25...Communication unit, 26...Sorter interface, 27...Operation unit, 28...Display unit, 30...CTU control device, 31...Processor, 32...ROM, 33...RAM, 34...NVM, 35 ...Communication unit, 36...CTU interface, 37...Operation unit, 38...Display unit, 51...Tray, 52...Pusher, 53...Chute, 54...Reflective sensor, 61...Cord, 62...Guide, 70...Tire, 71...Processor, 72...ROM, 73...RAM, 74...NVM, 75...Communication unit, 76...Drive unit, 78...Battery, 79...Charging mechanism, 81...Cord, 91...Shelf, 100...Sorting system, 101...Conveyor, 200...Cage, 701...Base, 702...Component, 703...Rear tray, 704...Shuttle unit, 705...Camera.

Claims

1. A system including a sorter and an automatic conveying device, The sorter is a first tray for carrying an article; a loading mechanism for loading the items from the first tray into a container; Equipped with The automatic conveying device is a gripping mechanism that grips the container; a drive mechanism that moves the gripping mechanism in the up and down direction; Using the gripping mechanism, the container into which the article has been placed is acquired from the sorter; using the gripping mechanism and the drive mechanism, storing the container into which the articles have been put from the sorter in a height direction on a shelf for storing the container; using the gripping mechanism and the drive mechanism to retrieve the container from the shelf; using the gripping mechanism to load the container storing the items to be reloaded into the sorter onto a loading location; a processor; Equipped with system.

2. The automatic conveying device includes a second tray for loading the container, the processor, after retrieving the container into which the articles have been put from the sorter, uses the gripping mechanism to set the empty container to be loaded onto the second tray; The system of claim 1 .

3. After the processor retrieves the container into which the item has been placed from the sorter from the first loading platform, it uses the gripping mechanism to set the empty container to be loaded by the second tray onto the first loading platform. The system of claim 2 .

4. The system of claim 1 , wherein the processor uses the gripping mechanism to retrieve the container containing the items from the sorter when the container contains a predetermined amount of the items inserted by the insertion mechanism.

5. the processor uses the gripping mechanism and the drive mechanism to retrieve the empty container from the shelf and load it onto the second tray; The system of claim 2 .

6. a second loading platform; the loading location is the second loading platform; A system according to any one of claims 1 to 5.

7. the processor uses the gripping mechanism to obtain the empty container from the loading location. The system of claim 1 .

8. The loading location is a conveyor. The system of claim 1 .

9. The shelf comprises a plurality of shelves. A system according to any one of claims 1 to 8.

Images