Palletizing System

Abstract

To load so that articles are arranged properly in each section automatically, considering unlikeliness of collapse of articles, in the case where the articles are loaded in the plurality of sections set on a loading surface of one pallet.SOLUTION: In the case where the storage section number N determined by section number determination processing is larger than the empty section number M in loading processing of a second order article group Go, a control device executes pallet switching processing for controlling a pallet carrying-out device 3 and a pallet supply device 2 so as to carry-out a pallet P existing in a palletizing area A2 and supplying a new pallet P to the palletizing area A2.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to a palletizing system. [Background technology]

[0002] For example, Japanese Patent No. 2947834 (Patent Document 1) discloses a technique for stacking articles on pallets, known as palletizing. In the following description of the background art, the reference numerals in parentheses refer to those in Patent Document 1.

[0003] Patent document 1 discloses that a worker (M) stacks items on the stacking surface of a pallet (40) divided into multiple sections according to the type and number of items displayed on a display (30). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 2947834 Summary of the Invention [Problem to be solved by the invention]

[0005] Recently, there has been a demand for automated palletizing. However, when palletizing is performed automatically using a robot or the like, it is more difficult to respond flexibly than when performed by a human worker. Therefore, when loading items into multiple compartments set on the loading surface of a single pallet, it has not been easy to automatically load items in an appropriate arrangement in each compartment, while also taking into consideration the risk of the items shifting.

[0006] In view of the above situation, there is a need for a palletizing system that can automatically load items in multiple compartments set up on the loading surface of a single pallet so that the items are appropriately arranged in each compartment, while also taking into consideration the likelihood of the items falling over. [Means for solving the problem]

[0007] an article group supplying device that supplies a single article group consisting of a plurality of articles of a single type to a picking area; a pallet supply device that supplies pallets to the palletizing area; a pallet carrying-out device that carries out the pallet from the palletizing area; a transfer device that transfers the items between the picking area and the palletizing area; A palletizing system comprising: a control device that controls the article group supply device, the pallet supply device, the pallet carry-out device, and the transfer device, the control device is capable of receiving order information specifying the type and number of items to be loaded onto the pallet in the palletizing area, and performing a loading process in which the items of the type and number specified by the order information are treated as an ordered item group and the ordered item group is loaded onto the pallet; A plurality of compartments are set on the loading surface of the pallet, and a limit height is set, which is an upper limit of the height of the items that can be loaded on the loading surface; The control device, in the stowage processing, an occupation area determination process for determining an item group occupation area, which is an area in a plan view when the ordered item group is stacked on the stowage surface so as to be equal to or less than the limit height; Determine the number of storage compartments N (N is a natural number), which is the number of compartments that can accommodate the item group occupation area. A process of determining the number of partitions to be a loading section determination process for determining a loading section, which is the section into which the group of ordered items will be loaded, according to the number of storage sections N determined by the section number determination process; a transfer process for controlling the transfer device to remove the items related to the ordered item group from the single item group in the picking area and load the ordered item group into the loading section, the control device, after completing the stowage process for the first group of ordered items based on the first order information, if there remains an empty section on the stowage surface, which is the section where no items have been stowed, executes the stowage process for the second group of ordered items based on second order information; In the loading process for the second group of ordered items, if the number of storage compartments N determined by the compartment number determination process is greater than the number of empty compartments, the control device executes a pallet replacement process that controls the pallet unloading device and the pallet supplying device to unload the pallet in the palletizing area and supply a new pallet to the palletizing area.

[0008] According to this configuration, items can be automatically and appropriately stacked in multiple compartments set on the stacking surface of a pallet based on the ordered items related to the order information and the condition of the pallet's stacking surface. Furthermore, the stacking process stacks items within the limit height for stacking items on the stacking surface, making it easier to prevent items from shifting on the pallet after stacking. Furthermore, according to this configuration, it is automatically determined whether ordered items related to one order can be stacked on the same pallet, and if so, the stacking is performed. If not, a pallet swapping process is performed and a new pallet is supplied to the palletizing area. This allows ordered items related to one order to be stacked on the same pallet. As described above, according to this configuration, when items are to be stacked in multiple compartments set on the stacking surface of a single pallet, the items can be automatically stacked so that the items are appropriately arranged in each compartment, taking into account the likelihood of items shifting.

[0009] Further features and advantages of the techniques according to the present disclosure will become more apparent from the following description of exemplary and non-limiting embodiments, which proceeds with reference to the drawings. [Brief explanation of the drawings]

[0010] [Figure 1] Schematic plan view of the palletizing system [Figure 2] An explanatory diagram showing how to create a mixed pallet [Figure 3] Stacking process diagram [Figure 4] Diagram for creating master information [Figure 5] FIG. 10 is an explanatory diagram showing the process when it is determined that the second group of ordered items can be loaded. [Figure 6] FIG. 10 is an explanatory diagram showing the process when it is determined that the second group of ordered items cannot be loaded. [Figure 7] Flowchart showing the stowage processing procedure [Figure 8] Flowchart showing processing procedures depending on whether or not there is an empty section [Figure 9] Flowchart showing the processing procedure of the second stowage process [Figure 10] An explanatory diagram showing the process of redetermining the number of partitions and subsequent processes. [Figure 11] An explanatory diagram showing the process of redetermining the number of partitions and subsequent processes. [Figure 12] FIG. 10 is an explanatory diagram showing a transshipment process in a second embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] A palletizing system is a system for stacking goods onto pallets, or in other words, palletizing. In a palletizing system, palletizing is performed automatically. Below, we will take an example where a palletizing system is applied to an item transport facility that transports goods using pallets. 1 shows an embodiment of a palletizing system.

[0012] [First embodiment] First, a first embodiment of a palletizing system will be described.

[0013] As shown in Figure 1, the palletizing system 100 includes an article group supplying device 1 that supplies a single article group Gs consisting of a plurality of articles W of the same type to a picking area A1, a pallet supplying device 2 that supplies a pallet P to the palletizing area A2, a pallet unloading device 3 that unloads the pallet P from the palletizing area A2, a transfer device 4 that transfers the articles W between the picking area A1 and the palletizing area A2, and a control device C that controls the article group supplying device 1, the pallet supplying device 2, the pallet unloading device 3, and the transfer device 4. In this specification, a single article group Gs refers not only to an article consisting of a plurality of articles W of the same type, but also to an article consisting of a single article W. In this embodiment, the article group supplying device 1 supplies a pallet P on which the single article group Gs is placed to the picking area A1. In the palletizing system 100, multiple or single items W are removed (picked) from a single item group Gs in the picking area A1, and the picked multiple or single items W are stacked (palletized) on a pallet P in the palletizing area A2. The palletizing system 100 according to this embodiment further includes a waiting area A3 where the single item group Gs to be supplied to the picking area A1 is kept waiting.

[0014] In this embodiment, the palletizing system 100 includes a first storage section S1 that stores multiple items W together by type, a second storage section S2 that stores multiple types of items W in a mixed state, and an empty pallet storage section S3 that stores empty pallets P on which no items W are placed. In the first storage section S1, items α, β, γ, etc., which are different in shape, size, etc., are stored together by type. In the second storage section S2, items α, β, γ, etc. are stored in a mixed state. In the empty pallet storage section S3, multiple empty pallets P are stored in a stacked state. Note that, hereinafter, when items W are distinguished by type, they may be referred to as items α, β, γ, etc. When no particular distinction is made between types, they may be simply referred to as items W.

[0015] In this embodiment, the item group supplying device 1 is configured using a conveyor. The item group supplying device 1 configures an item group supply path R1, which is a path along which a single item group Gs is supplied to the picking area A1. In this example, the item group supply path R1 configures at least a portion of the path connecting the first storage section S1 to the picking area A1. In the illustrated example, the above-mentioned waiting area A3 is located in a portion of the item group supply path R1.

[0016] In this embodiment, the pallet supply device 2 is configured using a conveyor. The pallet supply device 2 configures a pallet supply path R2, which is a path along which empty pallets P are supplied to the palletizing area A2. In this example, the pallet supply device 2 configures at least a part of the path connecting the empty pallet storage unit S3 to the palletizing area A2.

[0017] In this embodiment, the pallet carry-out device 3 is configured using a conveyor. The pallet carry-out device 3 configures a pallet carry-out path R3, which is a path along which palletized pallets P are carried out. A "palletized pallet P" is a pallet P on which multiple types of items W are placed through palletizing. The palletizing system 100 creates a mixed pallet P on which multiple types of items W are placed on a single pallet P through palletizing. In this example, the mixed pallet P after palletizing is transported to the second storage section S2 via the pallet carry-out path R3.

[0018] In this embodiment, the pallet carrying-out path R3 is a path through which the mixed pallets P after palletization are carried out. In addition to being a path, it also serves as a path for carrying out pallets P after picking. In the illustrated example, the pallet carry-out path R3 is formed to extend from the palletizing area A2, and the picking area A1 is located in a portion of the pallet carry-out path R3. A "pallet P after picking" is a pallet P on which a single type of item W (single item group Gs) has been placed, the number of which has been reduced compared to before picking, or a pallet P on which no items W have been placed. In this example, the pallet P after picking on which the single item group Gs has been placed is transported to the first storage section S1 via the pallet carry-out path R3. Although detailed illustration is omitted, it is preferable that the empty pallet P after picking, which does not have any items W placed on it, be transported to the empty pallet storage section S3 via the pallet carry-out path R3.

[0019] The transfer device 4 is configured to transfer an item W between the picking area A1 and the palletizing area A2. In this embodiment, the transfer device 4 transfers an item W between pallets P. Specifically, the transfer device 4 transfers an item W from a pallet P arranged in the picking area A1 to a pallet P arranged in the palletizing area A2. In this embodiment, the transfer device 4 includes an arm 40 that can rotate freely around a vertical axis, and a holding unit 41 attached to the arm 40.

[0020] In this embodiment, the arm 40 has a multi-joint structure and is configured to allow the holding portion 41 to move three-dimensionally. The holding portion 41 is configured to be able to hold an item W. In this example, the holding portion 41 is configured to hold the item W by adsorbing to the upper surface of the item W. This makes it possible to appropriately hold one item W arbitrarily selected from multiple items W lined up closely on the pallet P. However, the holding portion 41 may also be configured to hold the item W, for example, by clamping the item W.

[0021] In this embodiment, the transfer device 4 includes a recognition unit 42 for recognizing the status of the pallets P in the picking area A1 and the pallets P in the palletizing area A2. The transfer device 4 is configured to recognize the number, shape, or presence or absence of the articles W placed on the pallets P in the picking area A1 using the recognition unit 42. Similarly, the transfer device 4 is configured to recognize the number, shape, or presence or absence of the articles W placed on the pallets P in the palletizing area A2 using the recognition unit 42. In this example, the recognition unit 42 is configured using a camera, and the transfer device 4 recognizes the status of the pallets P in the picking area A1 and the pallets P in the palletizing area A2 based on images captured by the camera, and transfers the articles W between the picking area A1 and the palletizing area A2.

[0022] The control device C is configured to receive order information specifying the type and number of items W to be loaded onto a pallet P in the palletizing area A2, and to perform a loading process in which the type and number of items W specified by the order information are treated as an ordered item group Go and the ordered item group Go is loaded onto the pallet P.

[0023] The order information is information about a single type of item W and is expressed as "item type: quantity." The order information is sent to the control device C by a central control device (not shown) that controls and manages the entire system. For example, when it becomes necessary to replenish mixed pallets P in the second storage section S2, the central control device creates multiple pieces of order information and sends the multiple pieces of order information to the control device C one by one.

[0024] In this embodiment, the multiple types of items W required to create the mixed pallet P for which replenishment is requested are supplied in random order for each of the multiple single item groups Gs by the item group supply device 1. In other words, the order in which the single item groups Gs are supplied to the picking area A1 may be arbitrary, for example, The single item group Gs is supplied to the picking area A1 in the order of removal from the first storage section S1. In this embodiment, when the single item group Gs is in the waiting area A3, the control device C receives order information relating to the single item group Gs in the waiting area A3. Only at this time does the control device C know the type and number of items W (ordered item group Go) to be transferred from the picking area A1 to the palletizing area A2. The single item group Gs in the waiting area A3 is then supplied to the picking area A1. Then, from this single item group Gs, the transfer device 4 transfers the number of items W (ordered item group Go) based on the order information from the picking area A1 to the palletizing area A2. By performing this process for each of the multiple types of items W supplied in random order, a mixed pallet P is created.

[0025] As shown in FIG. 2, for example, if the multiple types of items W required to create a mixed pallet P for which replenishment is requested are items α and β, a single item group Gs consisting of multiple items α and a single item group Gs consisting of multiple items β are supplied to the picking area A1 in no particular order by the item group supplying device 1. Then, the control device C receives order information regarding items α and order information regarding items β at different times. Note that in the following, to distinguish between the multiple pieces of order information that are different from each other, they will be referred to as first order information, second order information, third order information, etc., but this does not indicate the order in which processing is performed.

[0026] In the example shown in Figure 2, the first order information is information indicated as "item α: 5 units," specifying that five units of item α are to be loaded. The second order information is information indicated as "item β: 6 units," specifying that six units of item β are to be loaded. In this example, the control device C executes a stowage process based on the first order information and a stowage process based on the second order information, thereby loading five items α and six items β onto one pallet P to create a mixed pallet P.

[0027] In the palletizing system 100, as shown in Fig. 3, a plurality of sections X are set on the loading surface Pf of the pallet P, and a limit height H is set, which is the upper limit of the height of the articles W that can be loaded on the loading surface Pf. In this embodiment, the plurality of sections X set on the loading surface Pf are all the same size. In this example, the plurality of sections X are arranged in a lattice pattern on the loading surface Pf. In the illustrated example, four sections X, A, B, C, and D, which are all the same size, are set on the loading surface Pf of the pallet P.

[0028] The control device C is configured to execute an occupied area determination process, a section number determination process, a stowage section determination process, and a transfer process in the stowage process.

[0029] In the occupied area determination process, the control device C determines the item group occupied area Ag, which is the area in a plan view when the ordered item group Go is stacked on the stacking surface Pf so that it is below the limit height H. In the illustrated example, the control device C receives order information specifying "item α: 5 pieces" and determines the item group occupied area Ag when five items α are stacked on the stacking surface Pf so that it is below the limit height H.

[0030] In the compartment number determination process, the control device C determines the number of storage compartments N (N is a natural number), which is the number of compartments X that the item group occupation area Ag can fit into. In the illustrated example, the item group occupation area Ag determined based on the ordered item group Go of "item α: 5 pieces" fits into one of the compartments X, so the control device C determines "number of storage compartments N=1" in the compartment number determination process.

[0031] In the stowage section determination process, the control device C determines the stowage section Xt, which is the section X in which the ordered item group Go is to be stowed, in accordance with the number of storage sections N determined in the section number determination process. In the example shown in FIG. 1, the number of storage compartments N determined by the compartment number determination process is "1," and the control device C determines only "A" of the four compartments X, A, B, C, and D, as the loading compartment Xt. In this embodiment, if there is a compartment X (hereinafter referred to as an "existing compartment") in which another ordered item group Go has already been loaded among the multiple compartments X set on the loading surface Pf of the pallet P, the loading compartment determination process determines the loading compartment Xt so as to include the compartment X adjacent to the existing compartment in the arrangement direction of the compartments X (in this example, the vertical or horizontal direction in the figure). For example, if the compartment X indicated by "A" is an existing compartment and the number of storage compartments N determined by the compartment number determination process is "1," the compartment X indicated by "B" or the compartment X indicated by "D" is determined as the loading compartment Xt, rather than the compartment X indicated by "C." By determining the loading compartment Xt in this manner, when performing the loading process for the next ordered item group Go, it becomes easy to determine multiple consecutive compartments X as a single loading compartment Xt, as will be described later.

[0032] In this embodiment, the control device C determines the stowage section Xt to be rectangular in plan view in the stowage section determination process. In the illustrated example, the number of storage sections N determined by the section number determination process is "1", and the control device C determines only one of the multiple sections X as the stowage section Xt, so the stowage section Xt is rectangular in plan view.

[0033] In this embodiment, when the number of storage compartments N determined by the compartment number determination process is 2 or more, the control device C determines N (N≧2) consecutive compartments X from among the multiple compartments X as one stowage compartment Xt. This allows the stowage compartment Xt to be determined to have a rectangular shape in a plan view.

[0034] For example, as shown in FIG. 2, if the order information indicates that six items β, each larger than item α in plan view, are to be loaded ("item β: 6"), the item group occupation area Ag will span two sections X, and the number of storage sections N will be "2." In this case, by determining two adjacent sections X as the loading section Xt among the multiple sections X set on the loading surface Pf, the shape of the loading section Xt will be rectangular in plan view. In the illustrated example, of the four sections X, A, B, C, and D, the adjacent sections "B and C" are determined as one loading section Xt. This simplifies the loading section determination process and the control for executing the subsequent transfer process. Note that in the illustrated example, in order to make the loading section Xt rectangular in plan view, the control device C may determine each combination of "A, B," "C, D," and "A, D" as one loading section Xt. However, in this embodiment, the control device C does not determine a combination of two sections X arranged diagonally, such as "A, C" or "B, D," as one stowage section Xt.

[0035] As shown in Figure 3, in the transfer process, the control device C controls the transfer device 4 to remove items W related to the ordered item group Go from the single item group Gs in the picking area A1 and load the ordered item group Go in the loading section Xt. In the example shown, five items α related to the ordered item group Go are removed from the single item group Gs composed of multiple items α and loaded in the loading section Xt.

[0036] In this embodiment, the control device C executes the transfer process so that the height of the highest part T of the ordered item group Go is the lowest while satisfying the condition that the item group occupation area Ag is the same. In the illustrated example, the control device C executes the transfer process so that the ordered item group Go of "items α: 5 pieces" is divided into two and three tiers and arranged. As a result, the top end of the items α in the third tier becomes the highest part T. For example, if the transfer process is executed so that the ordered item group Go of "items α: 5 pieces" is divided into one and four tiers and arranged, the top end of the items α in the fourth tier becomes the highest part T, and the height of the highest part T is higher than in the above case. If the transfer process is executed so that the items are arranged in five tiers, the height of the highest part T will be even higher. By executing the transfer process in this way, the palletizing system 100 can widen the item group occupation area Ag. This makes it easier to prevent the load from collapsing on the pallet P after loading.

[0037] Here, the control device C stores master information in which the shape and dimensions of the article W are registered in advance for each type of article W. The control device C stores master information supplied from another device, such as the above-mentioned general control device, or master information generated by the control device C by performing the measurement process described below. In this embodiment, the control device C is configured to execute the occupation area determination process by referring to the master information. In this way, by executing the occupation area determination process by referring to the master information, the processing speed can be increased.

[0038] As shown in FIG. 4, in this embodiment, the control device C performs a measurement process to measure the shape and dimensions of the articles W constituting the single-item group Gs, and creates master information for the shape and dimensions of the articles W constituting the single-item group Gs based on the results of the measurement process. In this example, the control device C performs the measurement process based on information recognized by the recognition unit 42 (see FIG. 1) provided in the transfer device 4. As described above, in this example, the recognition unit 42 is configured using a camera, and the control device C performs the measurement process based on image information captured by the camera. When performing the measurement process, one of the multiple articles W constituting the single-item group Gs is selected as the measurement target, and the transfer device 4 temporarily separates the measurement target article W from the single-item group Gs (specifically, the other articles W constituting the single-item group Gs). This allows the outer shape of the measurement target article W to be clearly grasped, and the shape and dimensions of the measurement target article W can be accurately calculated based on the image information captured by the camera (recognition unit 42). The control device C creates master information for the articles W through this measurement process, and performs an occupation area determination process and the like based on the master information.

[0039] In this embodiment, if predetermined conditions are met, the control device C measures the shape and dimensions of the items W that make up the single item group Gs through a measurement process and updates the master information. The "predetermined conditions" refer to cases where the master information needs to be updated, such as when an error in the master information is discovered or when the master information needs to be confirmed or changed. In these cases, the control device C updates the master information by performing the measurement process again, allowing subsequent processes to be performed appropriately.

[0040] 5 and 6 illustrate an example in which, after the stowage process for the first order group Go is completed based on the first order information, the control device C executes the stowage process for the second order group Go based on the second order information. In the figures, one of the two order group Go already stacked on the pallet P in the palletizing area A2 is the first order group Go related to the first order information. The order information created based on the single item group Gs placed on the pallet P in the waiting area A3 is the second order information. As described above, the control device C receives order information (second order information) related to the single item group Gs in the waiting area A3 while the single item group Gs is in the waiting area A3. In the illustrated example, the second order information is "item γ: 2 pieces." In other words, the second order information specifies that two items γ are to be stacked. In the illustrated example, the item γ alone has a size equivalent to two storage compartments X. In other words, when a single item γ is loaded onto the loading surface Pf of the pallet P, at least two sections X are required.

[0041] After the loading process for the first group of ordered items Go is completed based on the first order information, if there is an empty section Xe, which is a section X where no items W have been loaded, remaining on the loading surface Pf, the control device C executes the loading process for the second group of ordered items Go based on the second order information.

[0042] As shown in FIG. 5, in the stowage process for the second order item group Go, if the number of storage compartments N determined by the compartment number determination process is equal to or less than the number of empty compartments M, which is the number of empty compartments Xe, the control device C executes a stowage compartment determination process according to the number of empty compartments M. In the example shown in FIG. 5, the second order information is "item γ: 2 units," and the number of storage compartments N determined based on this is "2." Two empty compartments Xe remain on the stacking surface Pf of the pallet P in the palletizing area A2, and the number of empty compartments M is "2." That is, in the example shown in FIG. 5, the number of storage compartments N (N = 2) is equal to or less than the number of empty compartments M (M = 2) (more specifically, the number of storage compartments N = the number of empty compartments M). Therefore, the control device C determines that the second order item group Go can be stowed on the pallet P in the palletizing area A2, and executes the stowage compartment determination process and the transfer process. In this example, when the control device C determines that the second order item group Go can be loaded onto the pallet P in the palletizing area A2, it controls the item group supply device 1 to move the single item group Gs containing the second order item group Go from the waiting area A3 to the picking area A1.

[0043] As shown in FIG. 6, in the stowage process for the second group of ordered items Go, if the number of storage sections N determined by the section number determination process is greater than the number of empty sections M, which is the number of empty sections Xe, the control device C executes a pallet replacement process that controls the pallet unloading device 3 and the pallet supplying device 2 to unload the pallet P in the palletizing area A2 and supply a new pallet P to the palletizing area A2. In the example shown in FIG. 6, the second order information is "item γ: 2 pieces," and the number of storage sections N determined based on this is "2." Furthermore, one empty section Xe remains on the loading surface Pf of the pallet P in the palletizing area A2, and the number of empty sections M is "1." That is, in the example shown in FIG. 6, the number of storage sections N (N = 2) is greater than the number of empty sections M (M = 1). Therefore, the control device C determines that the second group of ordered items Go cannot be loaded onto the pallet P in the palletizing area A2, and executes a pallet replacement process, removing the pallet P in the palletizing area A2 and supplying a new pallet P to the palletizing area A2. The control device C then executes a stowage process to load the second group of ordered items Go onto the new pallet P.

[0044] As described above, in this embodiment, the pallet discharge path R3 not only serves as a path for discharging pallets P after palletizing, but also as a path for discharging pallets P after picking. The picking area A1 is located in part of the pallet discharge path R3. That is, pallets P discharged from the palletizing area A2 pass through the picking area A1. In this embodiment, a single item group Gs to be supplied to the picking area A1 waits in the waiting area A3 before being supplied to the picking area A1. This prevents the pallet P carrying the single item group Gs from interfering with a pallet P (mixed pallet P) passing through the picking area A1 on its way out of the palletizing area A2.

[0045] Next, the procedure of the process executed by the control device C will be described with reference to the flowcharts of FIGS.

[0046] As shown in FIG. 7, when the control device C executes a stowage process, it first executes an occupied area determination process (#1). In the occupied area determination process, it determines an item group occupied area Ag, which is an area in a plan view when the ordered item group Go is stacked on the stowage surface Pf so that it is equal to or less than the limit height H (see FIG. 3). After executing the occupied area determination process, the control device C executes a section number determination process (#2). In the section number determination process, it determines the number of storage sections N, which is the number of sections X that can accommodate the item group occupied area Ag (see FIG. 3). After executing the section number determination process, the control device C executes a loading section determination process (#3). In the loading section determination process, it determines a loading section Xt, which is the section X where the ordered item group Go will be loaded, according to the number of storage sections N determined by the section number determination process (see FIG. 3). After executing the loading section determination process, the control device C does not execute a transfer process. In the transfer process, the group of ordered items Go is loaded into the loading section Xt determined by the loading section determination process. The control device C is configured to execute the stowage process by sequentially executing each of the processes described above.

[0047] 8 shows the processing steps of the control device C when executing stowage processing based on each of multiple order information. For ease of explanation, the stowage processing for stowage of the first group of ordered items Go related to the first order information will be referred to as the "first stowage processing," and the stowage processing for stowage of the second group of ordered items Go related to the second order information will be referred to as the "second stowage processing."

[0048] As shown in FIG. 8, after the first stowage process for a pallet P in the palletizing area A2 is completed (#10), the control device C determines whether or not an empty section Xe exists on the stacking surface Pf of the pallet P in the palletizing area A2 (#20). This determination may be made, for example, based on information recognized by the recognition unit 42 of the transfer device 4. In this example, the control device C determines whether or not an empty section Xe exists on the stacking surface Pf based on image information captured by a camera serving as the recognition unit 42. If the control device C determines that an empty section Xe exists on the stacking surface Pf (#20: Yes), it executes the second stowage process (#30). On the other hand, if the control device C determines that an empty section Xe does not exist on the stacking surface Pf (#20: No), it executes the pallet replacement process (#40).

[0049] FIG. 9 shows the processing procedure of step #30 in FIG. 8, that is, the detailed processing procedure of the second stowage processing.

[0050] As shown in Figure 9, when executing the second stowage process, the control device C first executes an occupied area determination process based on the second ordered item group Go related to the second order information (#31). After executing the occupied area determination process, the control device C executes a compartment number determination process (#32). This determines the number of storage compartments N based on the second ordered item group Go.

[0051] Next, the control device C determines whether the number of storage sections N is greater than the number of empty sections M, which is the number of empty sections Xe present on the pallet P (#33). If the control device C determines that the number of storage sections N is less than or equal to the number of empty sections M on the pallet P (#33: No), it determines that the second group of ordered items Go can be loaded onto the pallet P, and executes a loading section determination process according to the number of empty sections M (#34) and a transfer process (#35). On the other hand, if the control device C determines that the number of storage sections N is greater than the number of empty sections M on the pallet P (#33: Yes), it determines that the second group of ordered items Go cannot be loaded onto the pallet P, and executes a pallet replacement process (#36) and supplies a new pallet P (empty pallet P) to the palletizing area A2. The control device C then executes the loading section determination process (#34) and the transfer process (#35) to load the second group of ordered items Go onto the new pallet P.

[0052] Here, as shown in Figure 10, there may be cases where the group of ordered items Go related to one piece of order information cannot be loaded into the initially determined loading section Xt due to incomplete master information indicating the shape and dimensions of the items W, or due to a collapse of the load during the loading work of the items W. In the example shown in Figure 10, the order information is "item α: 5 pieces", and a collapse occurs while the group of ordered items Go related to that order information is being loaded, resulting in a situation where the fourth and subsequent items W cannot be loaded into the initially determined loading section Xt.

[0053] In this embodiment, when the ordered goods group Go cannot be loaded in the loading section Xt in the transfer process, the control device C After executing an occupation area redetermination process to determine the item group occupation area Ag for the item W that could not be loaded into the loading section Xt, the control device C executes a section number redetermination process to determine the number of storage sections N that can accommodate the item group occupation area Ag determined by the occupation area redetermination process. If the number of storage sections N determined by the section number redetermination process is equal to or less than the number of empty sections M, which is the number of empty sections Xe on the pallet P in the palletizing area A2, the control device C executes a stowage section determination process and a transfer process in accordance with the number of storage sections N determined by the section number redetermination process.

[0054] In the example shown in FIG. 10, the control device C executes the occupied area redetermining process and the section number redetermining process for the (5-3) items α that could not be loaded. The number of storage sections N determined by this section number redetermining process is "1." Furthermore, the number of empty sections M, which is the number of empty sections Xe present on the pallet P, is "1," calculated by subtracting the number of loaded empty sections Xe from the number before loading ("2"). In this case, the number of storage sections N (N = 1) determined by the section number redetermining process is less than or equal to the current number of empty sections M (M = 1) (specifically, the number of storage sections N = the number of empty sections M). Therefore, the control device C executes the loading section determination process and the transfer process to load the remaining two items α that could not be loaded into the current empty sections Xe, among the items α that make up the ordered item group Go. This allows the ordered item group Go to be loaded onto a single pallet P, even if a load shift or other problem occurs during the loading operation of the ordered item group Go.

[0055] On the other hand, as shown in FIG. 11 , the number of storage sections N determined by the section number re-determination process may be greater than the number of empty sections Xe on the pallet P in the palletizing area A2. In the example shown in FIG. 11 , the number of empty sections M, which is the number of empty sections Xe on the pallet P, is “0,” calculated by subtracting the number of empty sections Xe that have been loaded from the number “1” before loading. In this case, there are no empty sections Xe on the pallet P for loading the remaining two items α that constitute the ordered item group Go and therefore loading of further items α onto this pallet P is impossible. In this embodiment, the control device C issues an error message if the number of storage sections N (N=1 in the illustrated example) determined by the section number re-determination process is greater than the number of empty sections M (M=0 in the illustrated example), which is the number of empty sections Xe on the pallet P in the palletizing area A2. In this way, by issuing an error message when loading is impossible, the situation can be notified to an operator, and the operator can perform the subsequent work. The control device C can notify the worker of the error information by means of visual or auditory means. For example, the control device C may display an error message on the screen of a terminal operated by the worker, or may blink or light a light. The control device C may also emit an alarm sound, or output an error message by voice.

[0056] According to the palletizing system 100 described above, when items W are loaded into multiple sections X set on the loading surface Pf of one pallet P, the items W can be loaded automatically so that they are appropriately arranged in each section X, taking into consideration the likelihood of the items W falling over.

[0057] Second Embodiment Next, a second embodiment of the palletizing system will be described. The following mainly describes the differences from the first embodiment. Points that are not particularly described are the same as those in the first embodiment.

[0058] As shown in the left diagram of FIG. 12, there are cases where the number of storage compartments N (N=1 in the illustrated example) determined by the compartment number re-determination process is greater than the number of empty compartments M (M=0 in the illustrated example), which is the number of empty compartments Xe of the pallet P in the palletizing area A2. In this case, in the first embodiment described above, In the conventional example, the control device C is configured to notify error information. However, in this embodiment, the control device C executes a process different from notifying an error.

[0059] As shown in Figure 12, in this embodiment, if the number of storage compartments N determined by the compartment number re-determination process is greater than the number of empty compartments M, which is the number of empty compartments Xe on the pallet P in the palletizing area A2, the control device C removes from the stowage section Xt those items W that make up the ordered item group Go that have already been loaded in the stowage section Xt, and then performs a pallet replacement process and a reloading process to load all items W that make up the ordered item group Go, including the items W removed from the stowage section Xt, onto a new pallet P supplied to the palletizing area A2 by the pallet replacement process.

[0060] In the example shown in Figure 12, the control device C executes an occupied area re-determination process and a section number re-determination process for the (5-3) items α that could not be loaded. The number of storage sections N determined by the section number re-determination process is "1" (N = 1). The number of empty sections M on the pallet P in the palletizing area A2 is "0" (M = 1 - 1 = 0). In this case, there are no empty sections Xe on the pallet P to load the remaining two items α that could not be loaded among the items α that make up the ordered item group Go, so it is not possible to load any more items α onto this pallet P.

[0061] Therefore, the control device C controls the transfer device 4 to remove the three items α already stacked in the stacking section Xt from the pallet P (see the center diagram in Figure 12). At this time, the control device C may control the transfer device 4 to temporarily return the three removed items α to the pallet P in the picking area A1, or may temporarily move them to a separately provided temporary storage table. Then, the control device C executes a pallet replacement process to replace the pallet P and supply a new pallet P to the palletizing area A2. After that, the control device C loads all of the items α that make up the group of ordered items Go, including the three removed items α, i.e., five items α in this case, onto the new pallet P. This series of processes is the reloading process. With this configuration, even if the group of ordered items Go cannot be loaded within the initially determined stacking section Xt, it is possible to avoid the group of ordered items Go related to one order information being loaded onto two pallets P.

[0062] Other Embodiments Next, other embodiments of the palletizing system will be described.

[0063] (1) In the above second embodiment, an example was described in which the control device C replaces the pallet P by executing a pallet replacement process in the transshipment process, supplies a new pallet P to the palletizing area A2, and then stacks all of the items W that make up the ordered item group Go, including the removed item W, onto the new pallet P. However, without being limited to this example, the control device C does not need to execute the pallet replacement process in the transshipment process. In this case, after removing the item W that was loaded in the stowage section Xt from the stowage section Xt, the control device C may again load all of the items W that make up the ordered item group Go, including the removed item W, into the stowage section Xt.

[0064] (2) In the above embodiment, the control device C performs the transfer process so that the height of the highest part T of the ordered item group Go is the lowest while satisfying the condition that the item group occupation area Ag is the same. However, the present invention is not limited to this example, and it is sufficient that the height of the highest part T is equal to or less than the limit height H (see FIG. 3).

[0065] (3) In the above embodiment, the control device C determines whether the shape and dimensions of the article W are registered in advance. In the above example, the control device C is configured to execute the occupied area determination process by referring to the master information. However, the present invention is not limited to this example, and the control device C may execute the occupied area determination process without referring to the master information. In this case, the control device C may recognize the shape and dimensions of the item W placed on the pallet P in the picking area A1 using the recognition unit 42 each time the control device C executes the stowage process.

[0066] (4) In the above embodiment, an example has been described in which four sections X, A, B, C, and D, are set on the loading surface Pf of the pallet P. However, the present invention is not limited to this example, and any number of sections X may be set on the loading surface Pf of the pallet P.

[0067] (5) In the above embodiment, an example has been described in which the control device C determines N (N≧2) consecutive sections X among the multiple sections X as one stowage section Xt when the number of storage sections N determined by the section number determination process is 2 or more. However, without being limited to this example, the control device C may also determine N (N≧2) non-consecutive sections X among the multiple sections X as one stowage section Xt. When N (N≧2) non-consecutive sections X are determined as one stowage section Xt, the stowage section Xt will not be rectangular in plan view.

[0068] (6) In the above embodiment, an example has been described in which the pallet discharge path R3 serves not only as a path for discharging palletized mixed pallets P but also as a path for discharging pallets P after picking. However, the present invention is not limited to this example, and the path for discharging palletized mixed pallets P and the path for discharging pallets P after picking may be provided separately.

[0069] (7) The configurations disclosed in the above-described embodiments may be combined with configurations disclosed in other embodiments as long as no contradictions arise. Regarding other configurations, the embodiments disclosed in this specification are merely examples in all respects. Therefore, various modifications may be made as appropriate within the scope of the present disclosure.

[0070] [Summary of the above embodiment] The above-described palletizing system will now be described.

[0071] an article group supplying device that supplies a single article group consisting of a plurality of articles of a single type to a picking area; a pallet supply device that supplies pallets to the palletizing area; a pallet carrying-out device that carries out the pallet from the palletizing area; a transfer device that transfers the items between the picking area and the palletizing area; A palletizing system comprising: a control device that controls the article group supply device, the pallet supply device, the pallet carry-out device, and the transfer device, the control device is capable of receiving order information specifying the type and number of items to be loaded onto the pallet in the palletizing area, and performing a loading process in which the items of the type and number specified by the order information are treated as an ordered item group and the ordered item group is loaded onto the pallet; A plurality of compartments are set on the loading surface of the pallet, and a limit height is set, which is an upper limit of the height of the items that can be loaded on the loading surface; The control device, in the stowage processing, an occupation area determination process for determining an item group occupation area, which is an area in a plan view when the ordered item group is stacked on the stowage surface so as to be equal to or less than the limit height; a compartment number determination process for determining the number of storage compartments N (N is a natural number), which is the number of compartments that can accommodate the item group occupation area; a loading section determination process for determining a loading section, which is the section into which the group of ordered items will be loaded, according to the number of storage sections N determined by the section number determination process; a transfer process for controlling the transfer device to remove the items related to the ordered item group from the single item group in the picking area and load the ordered item group into the loading section, the control device, after completing the stowage process for the first group of ordered items based on the first order information, if there remains an empty section on the stowage surface, which is the section where no items have been stowed, executes the stowage process for the second group of ordered items based on second order information; In the loading process for the second group of ordered items, if the number of storage compartments N determined by the compartment number determination process is greater than the number of empty compartments, the control device executes a pallet replacement process that controls the pallet unloading device and the pallet supplying device to unload the pallet in the palletizing area and supply a new pallet to the palletizing area.

[0072] According to this configuration, items can be automatically and appropriately stacked in multiple compartments set on the stacking surface of a pallet based on the ordered items related to the order information and the condition of the pallet's stacking surface. Furthermore, the stacking process stacks items within the limit height for stacking items on the stacking surface, making it easier to prevent items from shifting on the pallet after stacking. Furthermore, according to this configuration, it is automatically determined whether ordered items related to one order can be stacked on the same pallet, and if so, the stacking is performed. If not, a pallet swapping process is performed and a new pallet is supplied to the palletizing area. This allows ordered items related to one order to be stacked on the same pallet. As described above, according to this configuration, when items are to be stacked in multiple compartments set on the stacking surface of a single pallet, the items can be automatically stacked so that the items are appropriately arranged in each compartment, taking into account the likelihood of items shifting.

[0073] If the ordered item group cannot be loaded into the loading section in the transfer process, the control device executes an occupation area redetermination process to determine the item group occupation area for the items that cannot be loaded into the loading section among the items that make up the ordered item group, and then executes a compartment number redetermination process to determine the number of storage compartments N that can accommodate the item group occupation area determined by the occupation area redetermination process, The control device If the number of storage compartments N determined by the compartment number re-determination process is equal to or less than the number of empty compartments on the pallet in the palletizing area, the stowage compartment determination process is executed and the transfer process is executed according to the number of storage compartments N determined by the compartment number re-determination process, It is preferable that error information is notified when the number of storage compartments N determined by the compartment number re-determination process is greater than the number of empty compartments on the pallet in the palletizing area.

[0074] There may be cases where a group of ordered items related to one piece of order information cannot be loaded into the initially determined loading section due to incomplete master information indicating the shape and dimensions of the items, or due to the collapse of the cargo during the loading work of the items. With this configuration, even in such cases, the situation is taken into consideration and it is automatically determined whether or not the group of ordered items related to the order information can be loaded onto the same pallet. If loading is possible, loading is then carried out. If loading is not possible, an error message is issued to notify the worker or the like of the situation, allowing the worker to carry out the subsequent work. As described above, with this configuration, the group of ordered items can be loaded into the initially determined loading section. Even if this is not possible, it is possible to avoid a group of ordered items related to one piece of order information being split and loaded onto two pallets.

[0075] If the ordered item group cannot be loaded into the loading section in the transfer process, the control device executes an occupation area redetermination process to determine the item group occupation area for the items that cannot be loaded into the loading section among the items that make up the ordered item group, and then executes a compartment number redetermination process to determine the number of storage compartments N that can accommodate the item group occupation area determined by the occupation area redetermination process, The control device If the number of storage compartments N determined by the compartment number re-determination process is equal to or less than the number of empty compartments on the pallet in the palletizing area, the stowage compartment determination process is executed and the transfer process is executed according to the number of storage compartments N determined by the compartment number re-determination process, If the number of storage compartments N determined by the compartment number re-determination process is greater than the number of empty compartments on the pallet in the pallet in the palletizing area, it is preferable to remove from the stowage section those items that make up the group of ordered items that have already been loaded in the stowage section, and then perform the pallet replacement process, and also perform a reloading process to load all of the items that make up the group of ordered items, including the items removed from the stowage section, onto a new pallet supplied to the palletizing area by the pallet replacement process.

[0076] There may be cases where a group of ordered items related to a single order cannot be loaded onto the initially determined loading section due to incomplete master information indicating the shape and dimensions of the items or due to the collapse of the items during loading. According to this configuration, even in such cases, the system automatically determines whether the group of ordered items related to the order information can be loaded onto the same pallet, taking the situation into consideration. If loading is possible, the loading is then carried out. If loading is not possible, the items already loaded into the loading section are removed from the loading section, and then all of the items comprising the group of ordered items, including the items removed from the loading section, are loaded onto a pallet newly supplied to the palletizing area. Thus, according to this configuration, even if the group of ordered items cannot be loaded into the initially determined loading section, it is possible to avoid the group of ordered items related to a single order being loaded onto two pallets. Note that after the items loaded into the loading section are removed from the loading section, all of the items comprising the group of ordered items, including the removed items, may be loaded onto the same loading section again.

[0077] Preferably, in the stowage section determination process, the control device determines the stowage sections to have a rectangular shape in a plan view.

[0078] According to this configuration, it is easy to simplify the control for executing the stowage section determination process and the subsequent transfer process.

[0079] Preferably, the control device executes the transfer process so that the height of the highest part of the ordered item group is the lowest while satisfying the condition that the item group occupation area is the same.

[0080] According to this configuration, it is possible to easily prevent the load from collapsing on the pallet after loading without expanding the area occupied by the group of items.

[0081] the control device is configured to execute the occupation area determination process by referring to master information in which the shape and dimensions of the article are registered in advance; Preferably, when a predetermined condition is met, the control device performs a measurement process to measure the shape and dimensions of the items that make up the single item group, and updates the master information.

[0082] According to this configuration, the occupied area determination process is performed by referring to the master information, which increases the processing speed. Furthermore, if the master information needs to be updated, for example, if an error in the master information is discovered or if the master information needs to be confirmed or changed, the shape and dimensions of the item can be measured on the item conveyance line and the master information can be updated. [Industrial Applicability]

[0083] The technology disclosed herein can be used in a palletizing system. [Explanation of symbols]

[0084] 100: Palletizing system 1: Goods group supply device 2: Pallet supply device 3: Pallet removal device 4:Transfer device C: Control device A1: Picking area A2: Palletizing area P: Palette Pf: Loading surface X: Parcel Xe: Empty compartment Xt: Loading section Ag: Goods group occupied area H: Height limit N: Number of storage compartments Gs: Single item group Go: Order items W:Goods T:Top part α :Goods β :Goods γ :Goods

Claims

1. A pallet supply device that supplies pallets to a palletizing area; a pallet carrying-out device that carries out the pallet from the palletizing area; a transfer device that transfers articles onto the pallets in the palletizing area; A palletizing system including a control device that controls the pallet supply device, the pallet carry-out device, and the transfer device, the control device is capable of executing a stowage process in which the type and number of the items specified by the order information are treated as an ordered item group and the ordered item group is stowed on the pallet in the palletizing area; A plurality of compartments are set on the loading surface of the pallet, and a limit height is set, which is an upper limit of the height of the items that can be loaded on the loading surface; The control device, in the stowage processing, an occupation area determination process for determining an item group occupation area, which is an area in a plan view when the ordered item group is stacked on the stowage surface so as to be equal to or less than the limit height; a compartment number determination process for determining the number of storage compartments N (N is a natural number), which is the number of compartments that can accommodate the item group occupation area; a stowage section determination process for determining a stowage section, which is the section into which the group of ordered items is to be stowed, according to the number of storage sections N determined by the section number determination process; a transfer process for controlling the transfer device so as to stow the group of ordered items in the stowage section.

2. The control device, after completing the stowage process for the first group of ordered items based on the first order information, if there remains an empty section on the stowage surface, which is the section where no items have been stowed, executes the stowage process for the second group of ordered items based on the second order information; 2. The palletizing system of claim 1, wherein, in the loading process for the second group of ordered items, if the number of storage compartments N determined by the compartment number determination process is greater than the number of empty compartments, the control device executes a pallet replacement process that controls the pallet unloading device and the pallet supplying device to unload the pallet in the palletizing area and supply a new pallet to the palletizing area.

3. The palletizing system according to claim 1 or 2, wherein the control device determines the stowage sections so that the stowage sections have a rectangular shape in a plan view in the stowage section determination process.

4. The palletizing system according to any one of claims 1 to 3, wherein the control device executes the transfer process so that the height of the highest part of the ordered item group is the lowest while satisfying the condition that the item group occupation area is the same.

Images