Automated Warehouse System

Abstract

To provide an automatic warehouse system capable of reducing manpower or space for picking.SOLUTION: An automatic warehouse system 100 comprises a storage shelf 22 having a plurality of storage parts 26 for storing a cargo 10, a picking device 18 for moving a first cargo stored in a first storage part 26p to a second storage part 26s in which a second cargo is stored, and a carrying-out device 28 for carrying the first cargo and the second cargo stored in the second storage part 26s together out of the storage shelf 22.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to an automated warehouse system. [Background technology]

[0002] There is known a picking device for collecting goods in a storage location or goods temporarily stored to a shipping location. For example, Patent Document 1 describes a picking device that picks out goods stacked on a pallet layer by layer. This picking device has a gripping device that grips goods layer by layer from a single-item pallet positioned at a goods removal position and transfers them to each of multiple shipping pallets positioned at a loading position, and a goods transfer device that enables the gripping device to be raised and lowered relative to the shipping pallets. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2002-187618 Summary of the Invention [Problem to be solved by the invention]

[0004] The present inventors have studied automated warehouse systems and have come to the following realization. FIG. 17 is a diagram illustrating the flow from storage to retrieval in an automated warehouse system of a comparative example. FIG. 18 is a plan view showing the layout of the automated warehouse system of the comparative example. First, a single pallet loaded with multiple loads of the same type is transported by a vehicle such as a truck, and the single pallet is unloaded from the vehicle using a transport device such as a forklift (transported into the warehouse). In the automated warehouse system of the comparative example, a single pallet loaded with multiple loads of the same type is stored ( FIG. 17(a)), and a mixed pallet loaded with multiple types of loads and the single pallet are retrieved according to the destination's request ( FIG. 17(e)). To achieve this, the automated warehouse system of the comparative example separates the loads on the single pallet into predetermined units (hereinafter referred to as "cases") ( FIG. 17(b)), and stores the separated cases in a case storage unit ( FIG. 17(c)). Furthermore, when retrieving, different types of cases are stacked on the pallet according to the destination's request to create a mixed pallet ( FIG. 17(d)).

[0005] To achieve this process, as shown in Figure 18, it takes a lot of work to separate the delivered single pallets into cases and to collect the separated and stored cases to create mixed pallets (hereinafter referred to as "picking"). It is also difficult to secure workers to perform the picking. Furthermore, the automated warehouse system of the comparative example requires a case storage section and space for picking in addition to the storage shelves for storing single pallets and mixed pallets, which requires a correspondingly large site area. Furthermore, if the site area is fixed, the storage shelves for storing single pallets must be made smaller by the amount of the case storage section and picking space, which reduces the number of loads that can be stored.

[0006] From these findings, the present inventors have recognized that there is room for improvement in automated warehouse systems in terms of reducing the manpower and space required for picking.

[0007] The present invention has been made in view of the above-mentioned problems, and one of its objects is to provide an automated warehouse system that can reduce the manpower and space required for picking. [Means for solving the problem]

[0008] In order to solve the above problems, one embodiment of the automated warehouse system of the present invention comprises a storage shelf having a plurality of storage sections for storing items, a picking device that moves a first item stored in a first storage section to a second storage section in which a second item is stored, and a carrying-out device that combines the first item and the second item stored in the second storage section and carries them out of the storage shelf.

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

[0010] According to the present invention, an automated warehouse system can be provided that can reduce the manpower and space required for picking. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a plan view schematically illustrating an example of an automated warehouse system according to an embodiment. [Figure 2] FIG. 2 is an enlarged plan view showing the picking device of FIG. 1. [Figure 3] FIG. 2 is a side view schematically showing the automated warehouse system of FIG. 1. [Figure 4] FIG. 4 is an enlarged side view of the picking device of FIG. 3. [Figure 5] 2 is a plan view schematically showing an example of a first carriage of the automated warehouse system of FIG. 1. FIG. [Figure 6] FIG. 6 is a front view of the first bogie of FIG. 5. [Figure 7] 2 is a plan view schematically showing an example of a second carriage of the automated warehouse system of FIG. 1. FIG. [Figure 8] FIG. 8 is a front view of the second carriage of FIG. 7. [Figure 9] 2 is a bottom view showing the holding unit of the picking device of FIG. 1. [Figure 10]FIG. 10 is a diagram illustrating the process of transferring a load from one pallet to another pallet. [Figure 11] FIG. 10 is a diagram illustrating the process of transferring a load from one pallet to another pallet. [Figure 12] FIG. 10 is a diagram illustrating the process of transferring a load from one pallet to another pallet. [Figure 13] FIG. 10 is a diagram illustrating the process of transferring a load from one pallet to another pallet. [Figure 14] FIG. 2 is an explanatory diagram illustrating an example of a picking operation of the automated warehouse system of FIG. [Figure 15] FIG. 10 is a plan view showing the periphery of the storage section and the delivery section of the first modified example. [Figure 16] FIG. 10 is a plan view showing the periphery of the loading section and the unloading section of the second modified example. [Figure 17] FIG. 10 is a diagram illustrating the flow from storage to delivery in an automated warehouse system of a comparative example. [Figure 18] FIG. 18 is a plan view showing the layout of the automated warehouse system of FIG. 17. DETAILED DESCRIPTION OF THE INVENTION

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

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

[0014] [First embodiment] The configuration of an automated warehouse system 100 according to a first embodiment will be described with reference to the drawings. FIG. 1 is a plan view that schematically shows an example of the automated warehouse system 100 according to the first embodiment. FIG. 2 is a plan view that shows an enlarged view of the picking device 18 of FIG. 1. FIG. 3 is a side view that schematically shows the automated warehouse system 100. FIG. 4 is a side view that shows an enlarged view of the picking device 18 of FIG. 3. In these figures, the illustration of some pillars, beams, etc. is omitted.

[0015] For ease of explanation, an XYZ Cartesian coordinate system is defined as shown in the figure, with a horizontal direction being the X-axis direction, a horizontal direction perpendicular to the X-axis direction being the Y-axis direction, and a direction perpendicular to both, i.e., the vertical direction, being the Z-axis direction. The positive directions of the X-axis, Y-axis, and Z-axis are defined as the directions of the arrows in each figure, and the negative directions are defined as the directions opposite to the arrows. These directional notations do not limit the configuration of the automated warehouse system 100, and the automated warehouse system 100 can be used in any configuration depending on the application.

[0016] In this specification, one or more items contained in a cardboard case or other container is referred to as a load 10. An empty pallet is simply referred to as a "pallet." A single pallet 12S is a single load 10 containing one or more loads of the same type, and a mixed pallet 12M is a pallet containing multiple loads 10 of different types. For convenience, a mixed pallet 12M is also referred to as a pallet 12M when some of the loads to be loaded are not yet loaded. The single pallet 12S and the mixed pallet 12M refer to the pallet and the loads on it. Hereinafter, the single pallet 12S and the mixed pallet 12M are collectively referred to as a "load pallet 12." A load pallet 12 may be composed of multiple stacked layers, and each layer may contain multiple loads 10. A load pallet 12 may be the smallest unit of items to be received, stored, and removed from the automated warehouse system 100. A load 10 may be the smallest unit handled during picking.

[0017] First, we will explain the overall configuration of the automated warehouse system 100. The automated warehouse system 100 is a system that includes storage shelves 22 that can store a large number of items 10. As shown in Fig. 1, the automated warehouse system 100 includes the storage shelves 22, an item sorting unit 20, a first cart 14, a second cart 16, a picking device 18, a carry-out device 28, a transfer mechanism 32, and a control unit 30.

[0018] The storage shelf 22 has multiple storage sections 26 for storing loaded pallets 12. The goods sorting section 20 uses a picking device 18 to pick goods from the single pallets 12S before picking within the storage shelf 22, and creates a mixed pallet 12M (see Figure 3). The picking device 18 moves goods 10 stored in one storage section 26 to another storage section 26 to create a mixed pallet 12M. The first cart 14 is a cart that can carry the loaded pallet 12 and travel in the Y-axis direction on the storage shelf 22. The second cart 16 is a cart that can carry the loaded pallet 12 and the first cart 14 and travel in the X-axis direction on the storage shelf 22.

[0019] The carry-out device 28 is a device for carrying out the mixed pallet 12M created by picking from the storage shelf 22. The transfer mechanism 32 includes a lifting device 34 for raising and lowering the loaded pallet 12, and transfers the load 10 from one storage section 26 to another storage section 26. The control unit 30 controls the operations of the first cart 14, the second cart 16, the picking device 18, the carry-out device 28, the transfer mechanism 32, and the lifting device 34. These elements will be described in detail below.

[0020] (storage shelf) A plurality of storage shelves 22 are installed on the floor Lg and are capable of storing a large number of loads 10, providing a so-called high-density storage space. As shown in FIG. 1 , the storage shelf 22 of this embodiment includes three storage shelves 22a, 22b, and 22c. The storage shelves 22a, 22b, and 22c are separated by a second rail 44 and are arranged in this order from the negative side to the positive side in the Y-axis direction. The configuration of the storage shelves 22a, 22b, and 22c is not particularly limited as long as they can accommodate and store a plurality of loads 10. The storage shelves 22a, 22b, and 22c each have a plurality of storage tiers 24 (e.g., three tiers) stacked vertically. Each storage tier 24 includes a plurality of storage sections 26 arranged in the X-axis and Y-axis directions. Each storage section 26 is configured to accommodate a load pallet 12.

[0021] The uppermost storage shelf of storage shelf 22a will be referred to as uppermost storage shelf 24a1, and the storage shelves other than uppermost storage shelf 24a1 will be referred to as storage shelves 24a2. The uppermost storage shelf of storage shelf 22b will be referred to as uppermost storage shelf 24b1, and the storage shelves other than uppermost storage shelf 24b1 will be referred to as storage shelves 24b2. The uppermost storage shelf of storage shelf 22c will be referred to as uppermost storage shelf 24c1, and the storage shelves other than uppermost storage shelf 24c1 will be referred to as storage shelves 24c2. Hereinafter, the uppermost storage shelves 24a1, 24b1, and 24c1 will be collectively referred to as uppermost storage shelf 24p, and the storage shelves 24a2, 24b2, and 24c2 will be collectively referred to as storage shelf 24s.

[0022] The product sorting section 20 will now be described. As described above, the product sorting section 20 functions as a picking space within the storage shelf 22 for picking using the picking device 18. The product sorting section 20 is provided with a first storage section 26p and a second storage section 26s for picking. The first storage section 26p is provided for placing the single pallet 12S before picking, and the second storage section 26s is provided for placing the mixed pallet 12M after picking. Note that the first storage section 26p and the second storage section 26s do not refer to specific locations within the picking space, but rather refer to spaces for temporarily storing the loaded pallets 12. Therefore, the positions and ranges of the first storage section 26p and the second storage section 26s in the product sorting section 20 may change for each picking operation.

[0023] Although there is no limitation on the location of the arranging section 20, in this embodiment, the arranging section 20 is provided on the top storage tier 24b1 of the storage shelf 22b. The entire area of ​​the top storage tier 24b1 may be used as the arranging section 20, but in this example, only a portion of the top storage tier 24b1 is used as the arranging section 20, and the remaining area is used for storing the loading pallets 12. In other words, based on the shipping plan, the area used as the arranging section 20 may be expanded when the shipping frequency is high, and may be reduced when the shipping frequency is low. Flexible expansion and contraction allows the storage shelf 22b to be used effectively, improving space efficiency. The arranging section 20 is provided with a first storage section 26p and a second storage section 26s.

[0024] (rail) The storage shelf 22 is provided with a first rail 40 along which the first carriage 14 travels and a second rail 44 along which the second carriage 16 travels. The first rail 40 extends in the Y-axis direction on the storage shelves 22a, 22b, and 22c. The first rail 40 is provided below each storage section 26 on each storage level. The first carriage 14 can travel below each storage section 26 on each storage level. The second rail 44 extends in the X-axis direction on each storage level between the storage shelves 22a and 22b and between the storage shelves 22b and 22c. On each storage level, a power supply unit (not shown) for supplying power to the second carriage 16 is provided along the second rail 44.

[0025] An entry section 50 and an exit section 52 are provided adjacent to one end of the second rail 44. In this embodiment, the entry section 50 and the exit section 52 are provided on each storage tier 24. The entry section 50 functions as the entrance of the storage shelf 22 from which the loading pallets 12 to be stored are stored. The exit section 52 functions as the exit of the storage shelf 22 from which the loading pallets 12 to be shipped are shipped. A lifting device 34 is connected adjacent to one end of the second rail 44. The lifting device 34 can raise and lower the first cart 14 and loading pallet 12 from any storage tier 24 to another storage tier 24.

[0026] (First bogie) Next, the first carriage 14 will be described with reference to Figures 5 and 6. Figure 5 is a plan view that schematically shows an example of the first carriage 14. Figure 6 is a front view of the first carriage 14. As described above, the first carriage 14 carries a loading pallet 12 and travels in the Y-axis direction on the first rails 40 of each storage level of the storage shelves 22a, 22b, and 22c. The first carriage 14 takes the loading pallet 12 in and out of the storage section 26. The first carriage 14 travels in the Y-axis direction on the second carriage 16 to get on and off the second carriage 16.

[0027] The first bogie 14 mainly includes a vehicle body 14b, a platform 14c, a lift mechanism 14d, and a plurality of (for example, four) wheels 14f. The vehicle body 14b has a generally rectangular parallelepiped shape that is flat in the vertical direction. Inside the vehicle body 14b, there are mounted a motor (not shown) that drives the plurality of wheels 14f, a control circuit (not shown) that controls the motor, and a battery (not shown). The first bogie 14 is configured to drive the motor using power from the battery. The battery is a secondary battery such as a rechargeable lithium-ion battery.

[0028] The loading platform 14c is a portion that lifts and holds the loading pallet 12. The lift mechanism 14d is a mechanism that raises and lowers the loading platform 14c. In FIG. 6, the loading platform 14c in the raised state is shown by a dashed line, and the loading platform 14c in the lowered state is shown by a solid line. The lift mechanism 14d can raise the loading platform 14c and lift the loading pallet 12 from the loading surface of the storage section 26. The lift mechanism 14d can lower the loading platform 14c and lower the loading pallet 12 onto the loading surface of the storage section 26. The multiple wheels 14f can roll on the first rail 40 and the second cart 16.

[0029] (Second bogie) Next, the second carriage 16 will be described with reference to Figures 7 and 8. Figure 7 is a plan view that schematically shows an example of the second carriage 16. Figure 8 is a front view of the second carriage 16, showing the state in which the first carriage 14 is mounted. The second carriage 16 travels on the second rail 44 in the X-axis direction. The second carriage 16 transports the first carriage 14 in an empty state or when a loading pallet 12 is mounted thereon.

[0030] The second bogie 16 mainly includes a bogie mounting portion 16c, a housing portion 16d, a cover portion 16e, a plurality of (for example, four) wheels 16f, and a current collecting unit 38. The bogie mounting portion 16c is provided in the center of the second bogie 16 in the X-axis direction. The bogie mounting portion 16c is a portion for mounting the first bogie 14, and has a pair of guide portions 16j that guide the first bogie 14. The cross section of each guide portion 16j in a front view has an angular, sideways U-shape. When viewed from the front, the bogie mounting portion 16c of the second bogie 16 has a generally concave shape that is concave on both the left and right sides.

[0031] The housing 16d and the cover 16e are provided on either side of the carriage mounting portion 16c in the X-axis direction, spaced apart from each other. The housing 16d and the cover 16e each cover a portion of the plurality of wheels 16f from above. The housing 16d functions as a casing that houses a motor (not shown) for driving the wheels 16f and a control circuit (not shown) that controls the motor.

[0032] The second bogie 16 receives power from the power supply unit via the power collection unit 38. The second bogie 16 is configured to be able to rotate a motor (not shown) using the received power to drive the wheels 16f. The second bogie 16 is configured to be able to charge the battery of the first bogie 14 using the received power.

[0033] (Picking device) The picking device 18 will now be described. As shown in FIG. 4, the picking device 18 moves the load 10 stored in the first storage section 26p to the second storage section 26s where another load 10 is stored. Hereinafter, the load 10 stored in the first storage section 26p and moved by the picking device 18 will be referred to as the "first load 10a" or "load 10a," and the load 10 that was already stored in the second storage section 26s before the load 10a was moved will be referred to as the "second load 10b" or "load 10b." In other words, load 10b refers to the load that was stored in the second storage section 26s before load 10a, and load 10a refers to the load that was stored in the second storage section 26s after load 10b. It does not matter whether load 10a and load 10b are the same type of load 10 or different types of loads 10.

[0034] As shown in FIG. 1, the picking device 18 is provided at a position overlapping with the storage shelf 22 in a plan view. The picking device 18 can pick up a target load 10 from a loading pallet 12 on the top storage shelf 24b1 of the storage shelf 22b and transfer it to another pallet. The picking device 18 may include a so-called gantry-type crane mechanism. As shown in FIG. 4, the picking device 18 of this embodiment includes a pair of cross beams 18e, a cross girder 18k, a crane cart 18d, a hanging portion 18j, and a holding portion 18h. The pair of cross beams 18e are provided spaced apart on both sides in the Y-axis direction in the upper space above the top storage shelf 24b1. Both ends of the cross beam 18e are supported by the upper ends of the vertical columns 18g.

[0035] Cross beam 18k is a rail-like structure extending in the Y-axis direction and is spanned between a pair of cross beams 18e. Cross beam 18k is configured to be self-moving on cross beam 18e in the X-axis direction. Cross beam 18k is sometimes referred to as a crane girder. Crane cart 18d is a cart that is self-moving on cross beam 18k in the Y-axis direction. Crane cart 18d is sometimes referred to as a trolley cart. Hanging portion 18j suspends holding portion 18h from crane cart 18d and can move it up and down in the Z-axis direction. Hanging portion 18j can also rotate holding portion 18h horizontally. Holding portion 18h is provided at the tip of hanging portion 18j and is configured to be able to lift load 10.

[0036] The picking device 18 can freely move the holder 18h in the X-axis direction, Y-axis direction, and Z-axis direction in the space above the top storage tier 24b1. By moving the holder 18h, the picking device 18 can pick up the target item 10 from above one storage section of the top storage tier 24b1, move it horizontally, and unload the target item 10 from above onto a pallet in another storage section 26 of the top storage tier 24b1.

[0037] The holder 18h will be described. FIG. 9 is a bottom view showing the holder 18h of the picking device 18. The holder 18h has a substantially rectangular shape when viewed from the bottom. A plurality of suction units 18s are arranged in a matrix in the X-axis and Y-axis directions on the bottom surface of the holder 18h. Each suction unit 18s can independently generate a suction force. That is, by selecting a suction unit 18s that generates a suction force, the holder 18h can suction and hold the load 10 in the area corresponding to that suction unit 18s. The suction unit 18s may be configured to generate a suction force by sucking in air.

[0038] 10 to 13 are top views illustrating the process of transferring a load 10 from a source pallet to a destination pallet. For example, the source pallet may be a single-load pallet 12S stored in the first storage section 26p. In this example, the source pallet has eight loads 10 stacked on each layer. For example, the destination pallet may be an empty pallet stored in the second storage section 26s. In explaining these figures, the loads 10 are identified by adding "(1)", "(2)", or "(3)" to the end of their reference numerals.

[0039] 10, the holding unit 18h generates a suction force on the suction unit 18s among the multiple suction units 18s that corresponds to the single load 10(1) so that the holding unit 18h picks up only the load 10(1). In this example, the picking device 18 picks up only the load 10(1) from the source pallet, moves it horizontally, and drops it onto the destination pallet.

[0040] 11, the holding unit 18h generates suction forces in the suction units 18s corresponding to the plurality of loads 10(2) among the plurality of suction units 18s so as to suction only the plurality of loads 10(2) (for example, five loads). In this example, the picking device 18 picks up only the plurality of loads 10(2) from the source pallet, moves them horizontally, and drops them onto the destination pallet.

[0041] 12, the holding unit 18h generates an attraction force in the attraction units 18s corresponding to the loads 10(3) on one layer among the plurality of attraction units 18s so as to attract all the loads 10(3) on one layer. In this case, the holding unit 18h may generate an attraction force in all the attraction units 18s.

[0042] 13, the holding unit 18h generates an attraction force on the attraction unit 18s among the plurality of attraction units 18s that corresponds to the single load 10(1) so as to attract only this load 10(1). In this example, the picking device 18 picks up only the load 10(1) from the source pallet, moves it horizontally, rotates it horizontally, and drops the load 10(1) onto the destination pallet in a changed position.

[0043] In this way, the picking device 18 of this embodiment can transfer a desired number of loads 10 from a plurality of loads 10 on one layer in one picking operation.

[0044] (Unloading device) The carry-out device 28 will be described with reference to Figures 1 to 4 and 14. The carry-out device 28 is a device for carrying out the mixed pallet 12M in the second storage section 26s from the storage shelf 22. There are no limitations on the configuration of the carry-out device 28, but in this embodiment, the carry-out device 28 is realized by the first cart 14 and the second cart 16. The carry-out device 28 may include a lifting device 34.

[0045] An example of the operation of the carry-out device 28 will now be described. (1) In this example, the first carriage 14 moves to the bottom of the second storage section 26s, loads the mixed pallet 12M, and travels in the Y-axis direction on the first rail 40 of the storage shelf 22b1 to move onto the second carriage 16. (2) The second carriage 16 travels on the second rail 44 and transports the first carriage 14 carrying the mixed pallet 12M to the unloading section 52. This transfer completes the operation of the carry-out device 28. The mixed pallet 12M transported to the unloading section 52 is then carried out, for example, by a forklift 54 ​​and loaded onto external transport means 56 such as a truck. In this case, the forklift 54 ​​loads the mixed pallet 12M from the unloading section 52 of the desired level onto the external transport means 56.

[0046] The discharge device 28 may be used to transfer the mixed pallet 12M stored in the second storage section 26s to another storage shelf. For example, the discharge device 28 may be controlled to transfer the mixed pallet 12M stored in the second storage section 26s of the storage shelf 22b to the storage shelves 22c and 22a.

[0047] (transfer mechanism) The transfer mechanism 32 will now be described. The transfer mechanism 32 is a mechanism for transferring the object 10 from the storage section 26 of one storage tier to the storage section 26 of another storage tier. In this embodiment, the transfer mechanism 32 transfers the object 10 from the storage section 26 (transfer source) of a storage tier 24s other than the top storage tier 24p to the first storage section 26p (transfer destination) of the object sorting unit 20. Here, the object 10 transferred to the first storage section 26p by the transfer mechanism 32 is referred to as the "third object 10c" or "object 10c." It does not matter whether the object 10c is the same type of object 10 as the object 10a or object 10b or a different type of object 10. The source storage section 26 may be the storage section of any of the storage shelves 22a, 22b, or 22c. There are no limitations on the configuration of the transfer mechanism 32, but in this embodiment, the transfer mechanism 32 is realized by the first carriage 14, the second carriage 16, and the lifting device 34.

[0048] A description will be given of an example of the operation of the transfer mechanism 32. In this example, a single-loading pallet 12S containing a third load 10c is transferred from the storage section 26 (transfer source) of the second storage stage 24a2 of the storage shelf 22a to the transfer destination. (1) The first carriage 14 moves to the bottom of the storage section 26 from which it was transferred, loads the single-loading pallet 12S, and travels on the first rail 40 of the storage shelf 22a1 in the Y-axis direction to move onto the second carriage 16. (2) The second carriage 16 travels on the second rail 44 and transfers the first carriage 14 carrying the single pallet 12S to the lifting device 34.

[0049] (3) The lifting device 34 transfers the first carriage 14 carrying the single pallet 12S to the uppermost storage tier 24b1. The first carriage 14, which has been transferred to the uppermost storage tier 24b1, moves onto the second carriage 16 on the uppermost storage tier 24b1 together with the single pallet 12S. (4) The second carriage 16 travels on the second rail 44 and transports the first carriage 14 carrying the single pallet 12S to the entrance of the storage row to which the first storage section 26p belongs. (5) The transferred first carriage 14 travels on the first rail 40 with the single pallet 12S, and transfers the single pallet 12S to the first storage section 26p, which is the transfer destination. (6) The first carriage 14 lowers the single pallet 12S into the first storage section 26p, and the operation of the transfer mechanism 32 ends.

[0050] (Control unit) The control unit 30 will now be described. The control unit 30 is configured to include an MPU (Micro Processing Unit) and controls the movement of the loading pallet 12 for storing, retrieving, carrying out, transporting, etc. based on the results of user operations. As an example, the control unit 30 controls the first cart 14 and the second cart 16 to transport the loading pallet 12 between a predetermined storage unit and the storage unit 50 or the delivery unit 52, or between multiple storage units. The control unit 30 also controls the operation of the picking device 18 to pick the load 10. The control unit 30 also controls the lifting device 34 to raise and lower the first cart 14 and the loading pallet 12 from one storage tier 24 to another storage tier 24.

[0051] (warehousing operation) 1 to 4, an example of the storage operation of the automated warehouse system 100 will be described. In this example, a process will be described in which a single pallet 12S, which has been transported and received by external transport means 56 such as a truck, is stored in the storage section 26 of the storage shelf 22a. (1) The single pallet 12S produced in the manufacturing factory is loaded onto the external transport means 56, and transported to the automated warehouse system 100 for delivery. (2) The single pallet 12S received by the external transport means 56 is carried into the receiving section 50 by a forklift 54 ​​or the like. In this case, the forklift 54 ​​carries the single pallet 12S from the external transport means 56 into the receiving section 50 at the desired level. (3) The single pallet 12S carried into the receiving section 50 is transported by the first cart 14 and the second cart 16 to a predetermined storage section 26 of the storage shelf 22a and stored therein.

[0052] The warehousing operation is completed by these operations. During the warehousing operation, the first carriage 14 and the second carriage 16 are controlled by the control unit 30.

[0053] (Picking operation) Next, an example of the picking operation of the automated warehouse system 100 will be described with reference to FIG. 14. FIG. 14 is an explanatory diagram illustrating an example of the picking operation. In this example, the picking operation involves removing loads 10 from a single pallet 12S based on a shipping plan and creating a mixed pallet 12M for shipping to a destination such as a retailer. In this example, the single pallet 12S is stored on storage shelf 22a, and picking is performed by the load sorting unit 20 set on the top storage shelf 24b1 of storage shelf 22b, while the mixed pallet 12M is stored on storage shelf 22c. In this description, to distinguish between loads, pallets, and the first storage unit, the symbols are suffixed with "-A," "-B," and "-C." In FIG. 14, load 10-A is shown in white, load 10-B is shown with straight hatching, and load 10-C is shown with dashed hatching.

[0054] (1) The first cart 14 and the second cart 16 transport the single-cart pallet 12S from the storage section 26 of the storage shelf 22a to the first storage section 26p of the goods sorting section 20. In this example, the single-carts 12S-A, 12S-B, and 12S-C loaded with different types of goods 10-A, 10-B, and 10-C are transported to the first storage sections 26p-A, 26p-B, and 26p-C. (2) An empty pallet for forming the mixed pallet 12M is placed in the second storage section 26s of the product sorting section 20.

[0055] (3) The picking device 18 removes the required number of loads 10-A from the single-loading pallet 12S-A and places them on an empty pallet to create a mixed-loading pallet 12M. At this time, the picking device 18 may change the position of the loads 10-A, for example by rotating them horizontally. (4) The picking device 18 removes the required number of loads 10-B from the single-loading pallet 12S-B and places them on the mixed-loading pallet 12M on which the loads 10-A are placed. At this time, the picking device 18 may change the position of the loads 10-B.

[0056] (5) The picking device 18 removes the required number of loads 10-C from the single-loading pallet 12S-C and places them on the mixed-loading pallet 12M on which the loads 10-A and 10-B are placed. At this time, the picking device 18 may change the position of the loads 10-C. (6) The mixed pallet 12M loaded with the loads 10-A, 10-B, and 10-C is transported from the second storage section 26s to the storage section 26 of the storage shelf 22c by the first cart 14 and the second cart 16. At this time, the lifting device 34 may also be used to transport the mixed pallet 12M to another level of the storage shelf 22c.

[0057] The picking operation is completed by these operations. In the picking operation, the first cart 14, the second cart 16 and the picking device 18 are controlled by the control unit 30.

[0058] (Removal operation) 1 to 4, an example of a retrieval operation of the automated warehouse system 100 will be described. In this example, a process of loading a mixed pallet 12M stored in the storage section 26 of the storage shelf 22c onto an external transport means 56 will be described. (1) The mixed pallet 12M stored in the storage section 26 of the storage shelf 22c is transported to the outgoing section 52 by the first cart 14 and the second cart 16. At this time, the first cart 14 and the second cart 16 are controlled by the control section 30. (2) The mixed pallet 12M transported to the delivery section 52 is loaded onto the external transport means 56 by a forklift 54 ​​or the like. In this case, the forklift 54 ​​loads the mixed pallet 12M onto the external transport means 56 from the delivery section 52 of the desired level. (3) The mixed pallet 12M loaded onto the external transport means 56 is transported to the destination and shipped.

[0059] The first carriage 14 and the second carriage 16 are controlled by the control unit 30 during the leaving operation.

[0060] The features of the automated warehouse system 100 configured as described above will be described. The automated warehouse system 100 includes a storage shelf 22 having a plurality of storage sections 26 for storing items 10, a picking device 18 that moves a first item 10a stored in a first storage section 26p to a second storage section 26s in which a second item 10b is stored, and a carrying-out device 28 that carries out the first item 10a and the second item 10b stored in the second storage section 26s together from the storage shelf 22. This configuration reduces the space required for case storage and picking compared to the automated warehouse system of the comparative example, thereby increasing the ratio of storage shelves to the site area and improving storage efficiency. It also reduces the amount of manpower required for picking.

[0061] The storage shelf 22 has a plurality of storage tiers 24 in which storage sections 26 are arranged horizontally, and the storage tiers 24 are arranged vertically, with the first storage section 26p and the second storage section 26s being provided on the top storage tier 24p, the highest of the plurality of storage tiers 24. In this case, the relatively ample space above the top storage tier 24p can be effectively utilized, thereby improving the space efficiency of the automated warehouse system 100.

[0062] The picking device 18 picks up the first item 10a from above the first storage section 26p and loads the first item 10a into the second storage section 26s from above. In this case, the work space in a plan view can be reduced compared to when picking up or loading from the side, thereby improving the space efficiency of the site.

[0063] The system includes a transfer mechanism 32 that transfers the third item 10c from a storage stage 24s other than the top storage stage 24p among the multiple storage stages 24 to the first storage section 26p, and the picking device 18 moves the third item to the second storage section 26s. In this case, the item 10 from the storage stage 24s other than the top storage stage 24p can be picked.

[0064] The picking device 18 is provided at a position that overlaps with the storage shelf 22 in a plan view. In this case, the picking space in a plan view can be reduced, thereby improving the space efficiency of the site.

[0065] Second and third embodiments of the present invention will be described below. In the drawings and descriptions of the second and third embodiments, components and members that are the same as or equivalent to those in the first embodiment will be designated by the same reference numerals. Explanations that overlap with the first embodiment will be omitted as appropriate, and the description will focus on the configurations that differ from the first embodiment.

[0066] [Second embodiment] A second embodiment of the present invention is an operation method S80 of the automated warehouse system 100. This operation method S80 is an operation method for an automated warehouse system equipped with storage shelves 22 having a plurality of storage sections 26 for storing items 10, and includes the steps of moving a first item 10a stored in a first storage section 26p to a second storage section 26s in which a second item 10b is stored and picking the item, and removing the first item 10a and the second item 10b stored in the second storage section 26s together from the storage shelf 22. According to the operation method S80, picking is performed within the storage shelf 22, thereby reducing the space required for picking.

[0067] In the operation method S80, the storage shelf 22 has a plurality of storage tiers 24 in which storage sections 26 are arranged horizontally, and the storage tiers 24 are arranged vertically, and the above-mentioned picking may be performed on the top storage tier 24p, the topmost of the plurality of storage tiers 24. In this case, the relatively ample space above the top storage tier 24p can be effectively used, thereby improving the space efficiency of the automated warehouse system 100.

[0068] The operation method S80 further includes transferring a third load 10c from a storage tier 24s other than the top storage tier 24p among the plurality of storage tiers 24 to the top storage tier 24p, and performing the above-mentioned picking may include moving the third load 10c transferred to the top storage tier 24p to the second storage section 26s. In this case, the load 10 from the storage tier 24s other than the top storage tier 24p can be picked.

[0069] In the operation method S80, while the above-mentioned picking is being performed within the storage shelf 22, another load 10 other than the first load 10a and the second load 10b may be carried into or out of the storage shelf 22. In this case, since warehousing and retrieval can be performed even while picking is being performed, the operating efficiency of the automated warehouse system 100 can be improved.

[0070] [Third embodiment] A third embodiment of the present invention is a method S90 for receiving and shipping goods using an automated warehouse system 100. This method S90 receives a single pallet 12S on which a plurality of goods of the same type are loaded, receives the received single pallet 12S into the automated warehouse system 100 for storage, removes the goods to be shipped from the single pallet 12S and places them on one pallet within the automated warehouse system 100, creates a mixed pallet 12M on which a plurality of types of goods are loaded on the one pallet, and then takes the mixed pallet 12M out of the automated warehouse system 100 for shipping.

[0071] The receiving / shipping method S90 can be realized by combining the receiving operation, picking operation, and shipping operation described in the first embodiment.

[0072] According to the receiving / shipping method S90, it is possible to reduce the manpower and space required from the time when the single-loading pallet 12S arrives until the time when the mixed-loading pallet 12M is shipped.

[0073] The above describes in detail exemplary embodiments of the present invention. The above-described embodiments merely illustrate specific examples of implementing the present invention. The content of the embodiments does not limit the technical scope of the present invention, and many design modifications, such as changes, additions, and deletions of components, are possible within the scope of the inventive concept defined in the claims. In the above-described embodiments, content that allows such design modifications is described using notations such as "in the embodiment" or "in the embodiment," but this does not mean that design modifications are not permitted in content that does not have such notations. Furthermore, hatching in the drawings does not limit the material of the hatched object.

[0074] (Variation) The following describes the modified examples. In the drawings and descriptions of the modified examples, the same or equivalent components and members as those in the embodiment are denoted by the same reference numerals. Explanations that overlap with the embodiment will be omitted as appropriate, and the description will focus on the configurations that differ from the embodiment.

[0075] [First Modification] In the first embodiment, an example in which a receiving section 50 and an unloading section 52 are provided for each tier has been described, but the present invention is not limited thereto. For example, a single receiving section 50 and unloading section 52 may be provided for all tiers, with a lifting device 34 connected to each receiving section 50 and unloading section 52. FIG. 15 is a plan view showing the periphery of the receiving section 50 and unloading section 52 of the first modified example. This figure shows a configuration in which a lifting device 34 is connected to each receiving section 50 and unloading section 52. In this case, a loading pallet 12 to be stored is carried into the receiving section 50 from an external transport means 56 by a forklift 54 ​​and then transferred to the target tier by the lifting device 34. Furthermore, a loading pallet 12 to be unloaded is transferred from the tier where it was stored to the unloading section 52 by the lifting device 34, and then unloaded from the unloading section 52 onto the transport means 56.

[0076] In the first modified example, the lifting device 34 is disposed between the storage section 50 / outgoing section 52 and the second rail 44, but the lifting device 34 may be disposed on the opposite side of the storage section 50 or the outgoing section 52 from the second rail 44. The lifting device 34 may also be disposed on the positive or negative side of the X-axis direction of the storage section 50 or the outgoing section 52. In this case, an arrangement that is advantageous for storage and retrieval operations can be selected.

[0077] [Second Modification] In the description of the first embodiment, an example was shown in which the lifting device 34 was disposed in the Y-axis direction at the end of the second rail 44, but the present invention is not limited to this. For example, another lifting device 36 may be provided on the positive side of the end of the second rail 44 in the X-axis direction. FIG. 16 is a plan view showing the periphery of the loading section 50 and the unloading section 52 of the second modified example. This figure shows a configuration in which another lifting device 36 is provided at the end of the second rail 44. In the second modified example, the lifting device 36 can raise and lower the second cart 16 carrying the first cart 14 from one stage to another.

[0078] [Other variations] In the description of the first embodiment, an example was shown in which the storage shelves 22a, 22b, and 22c have the same number of tiers, but the present invention is not limited to this. The storage shelf 22 may include a portion with a different number of tiers. For example, the portion of the storage shelf 22 where the picking device 18 is installed may have a portion with a different number of tiers to ensure space for installing the picking device 18.

[0079] In the description of the first embodiment, an example was shown in which the holding unit 18h of the picking device 18 holds the load 10 by suction force, but the present invention is not limited to this. For example, the holding unit of the picking device may be configured to hold the load by an arm and a hand.

[0080] In the first embodiment, an example was shown in which the picking device 18 was supported from the ceiling by a gantry-type crane mechanism, but the present invention is not limited to this. For example, the picking device may be attached to a side wall on the side and supported from the side.

[0081] In the explanation of the first embodiment, examples of the operation of the carry-out device 28, the operation of the transfer mechanism 32, the storing operation, the picking operation, and the retrieving operation are shown, but the present invention is not limited to these. These operations are merely examples, and other operations may be added, some operations may be deleted or changed, or the order of operations may be changed.

[0082] In the description of the first embodiment, an example was shown in which the picking operation removes the load 10 from the single pallet 12S to create a mixed pallet 12M, but the present invention is not limited to this. The picking operation may include the operation of removing the load 10 from the mixed pallet 12M, or the operation of creating a single pallet 12S from the removed load 10. Furthermore, the single pallet 12S created by picking may be shipped out.

[0083] In the description of the first embodiment, an example was shown in which items are picked from the multiple first storage units 26p-A, 26p-B, and 26p-C to the single second storage unit 26s in the picking operation, but the present invention is not limited to this. Items may be picked from the multiple first storage units 26p to the multiple second storage units 26s.

[0084] In the description of the first embodiment, an example in which the multiple first housing sections 26p-A, 26p-B, and 26p-C are arranged in a line in the Y-axis direction is shown in Fig. 14, but the present invention is not limited to this. Arranging the multiple first housing sections in a line is not essential, and they may be arranged spaced apart from each other.

[0085] In the first embodiment, an example was shown in which the picking device 18 is provided with a movable range that covers a portion of a storage shelf divided into multiple sections, but the present invention is not limited to this. For example, a picking device 18 with a movable range that covers the entire storage shelf may be provided in a non-divided storage shelf.

[0086] In the description of the first embodiment, an example was shown in which the entire picking device 18 overlaps with the storage shelf 22 in a plan view, but the present invention is not limited to this. A part of the picking device 18 may extend outward from the planar range of the storage shelf 22.

[0087] Instead of the forklift 54, the loading pallet 12 may be carried in and out by another type of transfer device, such as a transfer device equipped with a crane.

[0088] These modifications each provide the same effects as the first embodiment.

[0089] Any combination of the above-described embodiments and modifications is also useful as an embodiment of the present invention. A new embodiment resulting from the combination has the combined effects of the combined embodiments and modifications.

[0090] The present invention can also be defined by the following features. (Item 1) a storage shelf having a plurality of storage sections for storing cargo; a picking device that moves a first item stored in a first storage unit to a second storage unit in which a second item is stored; a carrying-out device that combines the first load and the second load stored in the second storage unit and carries them out of the storage shelf; An automated warehouse system comprising:

[0091] (Item 2) The storage shelf has a storage stage in which a plurality of the storage sections are arranged horizontally, The storage stage is provided in a plurality of rows in a vertical direction, 2. The automated warehouse system according to item 1, wherein the first storage section and the second storage section are provided on the uppermost storage shelf of the plurality of storage shelves.

[0092] (Item 3) 3. The automated warehouse system according to item 2, wherein the picking device removes the first item from above the first storage section and loads the first item into the second storage section from above the second storage section.

[0093] (Item 4) a transfer mechanism that transfers a third load in a storage stage other than the uppermost storage stage among the plurality of storage stages to the first storage section; 4. The automated warehouse system according to item 2 or 3, wherein the picking device moves the third load to the second storage section.

[0094] (Item 5) 5. The automated warehouse system according to any one of items 1 to 4, wherein the picking device is provided at a position that overlaps with the storage shelf in a plan view.

[0095] (Item 6) An operation method of an automated warehouse system equipped with storage shelves having a plurality of storage sections for storing loads, comprising: moving a first load stored in a first storage unit to a second storage unit in which a second load is stored, and picking the first load; removing the first load and the second load stored in the second storage unit together from the storage shelf; An operating method for an automated warehouse system, comprising:

[0096] (Item 7) The storage shelf has a storage stage in which a plurality of the storage sections are arranged horizontally, The storage stage is provided in a plurality of rows in a vertical direction, The picking is performed on the uppermost storage shelf among the plurality of storage shelves. 7. The method for operating an automated warehouse system according to item 6.

[0097] (Item 8) further comprising transferring a third load from a storage stage other than the top storage stage among the plurality of storage stages to the top storage stage; The picking includes moving the third item transferred to the uppermost storage stage to the second storage section. 8. The method for operating an automated warehouse system according to item 7.

[0098] (Item 9) While the picking is being performed in the storage shelf, a load other than the first load and the second load is carried into or out of the storage shelf. 9. A method for operating an automated warehouse system according to any one of items 6 to 8.

[0099] (Item 10) We receive a single pallet containing multiple items of the same type, The received single-loading pallets are stored in an automated warehouse system, In the automated warehouse system, the load to be shipped is removed from the single pallet and placed on a single pallet, and a mixed pallet on which multiple types of loads are loaded is created. The mixed pallet is removed from the automated warehouse system and shipped. A method for receiving and shipping goods, characterized by: [Explanation of symbols]

[0100] 10···Load, 12···Loaded pallet, 12M···Mixed pallet, 12S···Single pallet, 18···Picking device, 20···Load sorting section, 24p···Top storage shelf, 24, 24s···Storage shelf, 26···Storage section, 26p···First storage section, 26s···Second storage section, 28···Carry-out device, 32···Transfer mechanism, 100···Automated warehouse system.

Claims

1. a storage shelf having a plurality of storage sections capable of storing single pallets on which a plurality of loads of the same kind are loaded and mixed pallets on which a plurality of loads of the same kind are loaded; a picking device that can access a picking space for picking and places multiple types of cargo to be shipped from the single pallets stored on the storage shelf onto an outgoing pallet to create the mixed pallet; a transfer mechanism that moves the single-loading pallet to the picking space; a carrying-out device that carries out the mixed pallet from the picking space; Equipped with The storage shelf has a storage stage in which a plurality of the storage sections are arranged horizontally, The storage stage is provided in a plurality of rows in a vertical direction, the storage shelf has the plurality of storage stages arranged side by side, and includes a non-picking storage shelf on which the picking device is not provided in a plan view, the picking space is provided outside the non-picking storage shelf among the storage shelves and adjacent to the non-picking storage shelf, the storage unit is not disposed above the picking space, the transfer mechanism is configured to be able to move the single-loading pallet from the non-picking storage shelf to the picking space, The automated warehouse system is characterized in that the carrying-out device is configured to be able to move the mixed pallet from the picking space to the non-picking storage shelf.

2. 2. The automated warehouse system according to claim 1, wherein the picking device comprises a crane cart that moves in a predetermined horizontal direction above the picking space, and a holding unit that is provided on the crane cart and is capable of lifting a load.

3. The picking device includes a pair of cross beams and a cross girder that is bridged between the pair of cross beams and is capable of moving along the cross beams, The automated warehouse system according to claim 2 , wherein the crane cart is self-propelled on the cross beam.

4. The automated warehouse system according to claim 2 or 3, wherein the holding unit is capable of simultaneously lifting a plurality of selected loads from the plurality of loads on the single pallet.

5. The automated warehouse system according to any one of claims 2 to 4, wherein the holding unit lifts one or more loads from the single-loading pallet, rotates them horizontally, and lowers them onto the outgoing pallet in a different position than before the lifting.

6. The automated warehouse system according to any one of claims 2 to 5, wherein the picking device removes a load from above the single pallet that has been moved to the picking space and loads the load onto the outgoing pallet from above the picking space.

7. The transfer mechanism and the discharge device are a first carriage that is capable of moving in a first direction through the non-picking storage shelf and the picking space with the single pallet or the mixed pallet loaded thereon; a second carriage that can be loaded onto the first carriage with the single pallet or the mixed pallet loaded thereon and that is movable in a second direction perpendicular to the first direction; The automated warehouse system according to any one of claims 1 to 6, comprising:

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