Picking System

Abstract

To provide a picking system capable of efficiently performing processing for stacking a predetermined number of a plurality of types of articles on pallets using a smaller number of robots.SOLUTION: The picking system has: a diversion candidate addition unit that adds a completed pallet as a diversion candidate when it is determined that the number of articles of predetermined types on the completed pallet is equal to or greater than a predetermined ratio of the number of articles of the predetermined types on a regular pallet; and an order allocation unit that assigns the completed pallet as a diversion candidate immediately after another completed pallet that is constructed by picking a predetermined number of articles from a replenishment pallet having the predetermined types of articles according to a picking order when it is determined that there exists the completed pallet as a diversion candidate among completed pallets where the number of articles of the predetermined types matches the remaining number of articles of the predetermined types on the replenishment pallet after picking a predetermined number of articles according to the picking order.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates to a picking system. [Background technology]

[0002] Conventionally, there has been a picking system that, in response to a shipping order, loads a predetermined number of one or more types of items from one or more types of replenishment pallets, which are stored with the same type of items loaded on the pallets, onto another pallet (a shipping pallet) and ships it as a shipping pallet. Non-patent document 1 discloses a picking system that includes a palletizer (picking robot) that picks items from the required type of replenishment pallet according to a shipping order and loads them onto a shipping pallet, and an unmanned transport device (automated guided vehicle; AGV) that transports the replenishment pallet to the palletizer. [Prior art documents] [Non-patent literature]

[0003] [Non-Patent Document 1] "Special Sale Item Loading Package", [online], Mujin Co., Ltd., [Retrieved August 8, 2022], Internet<URL: https: / / www.mujin.co.jp / solution / distribution / tokubai / > Summary of the Invention [Problem to be solved by the invention]

[0004] In this type of picking system, there is a demand for efficient processing of stacking a predetermined number of multiple types of articles onto a pallet, even if the number of robots such as palletizers and unmanned transport devices is small.

[0005] The present disclosure has been made to solve the above-mentioned problems, and aims to provide a picking system that can efficiently stack a predetermined number of multiple types of items onto a pallet using a fewer number of robots. [Means for solving the problem]

[0006] In order to solve the above problem, the picking system according to the present disclosure includes a completed pallet setting unit that sets a completed pallet loaded with multiple types of items based on an input picking order; an item number comparison and determination unit that determines whether the number of items of a predetermined type on the completed pallet is equal to or greater than a predetermined ratio of the number of items of the predetermined type on a regular pallet loaded with only the items of the predetermined type; a conversion candidate addition unit that adds the completed pallet to a conversion candidate when it is determined that the number of items of the predetermined type on the completed pallet is equal to or greater than a predetermined ratio of the number of items of the predetermined type on the regular pallet; and a conversion candidate addition unit that adds the remaining items on the supplementary pallet after picking a predetermined number of items in accordance with the picking order. a conversion candidate existence determination unit that determines whether the completed pallet having the number of the specified type of items that matches the remaining number of the specified type of items on the replenishment pallet exists in the completed pallet that is a conversion candidate; and, when it is determined that the completed pallet in which the remaining number of the specified type of items on the replenishment pallet and the number of the specified type of items on the completed pallet match exists in the conversion candidate for the completed pallet, an order assignment unit that assigns the completed pallet that is a conversion candidate to immediately after another completed pallet that is formed by picking a specified number of items from a replenishment pallet having the specified type of items in accordance with the picking order. [Effects of the Invention]

[0007] According to the present disclosure, in a picking system, the process of stacking a predetermined number of multiple types of items onto a pallet can be efficiently performed using a smaller number of robots. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a diagram illustrating an example of the arrangement of a picking system according to an embodiment of the present disclosure. [Figure 2] 1 is a block diagram illustrating a configuration example of a control device provided in a picking system according to an embodiment of the present disclosure. FIG. [Figure 3] FIG. 1 is a diagram illustrating an example of a picking order according to an embodiment of the present disclosure. [Figure 4] FIG. 10 is a diagram illustrating a process for updating the order of completed pallets in a picking system according to an embodiment of the present disclosure. [Figure 5] FIG. 5 is a diagram showing an example of a picking order for each completed pallet obtained in the middle of the process shown in FIG. 4. [Figure 6] 10 is a diagram showing a process of updating the stacking order of items on a completed pallet basis in a picking system according to an embodiment of the present disclosure. FIG. [Figure 7] 10A and 10B are diagrams illustrating a process for selecting a destination of a replenishment pallet and a process for assigning tasks to an unmanned transport device in a picking system according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, a picking system according to an embodiment of the present disclosure will be described with reference to FIGS.

[0010] [Picking system configuration] As shown in Figure 1, the picking system 1 of this embodiment is a system for loading a predetermined number of one or more types of items onto another pallet (a shipping pallet) in a warehouse or the like, from multiple replenishment pallets that are stored with the same type of items, in accordance with an input picking order (described below), and shipping the pallet as a shipping pallet. The picking system 1 of this embodiment comprises an unmanned transport device 2 that transports replenishment pallets and shipping pallets, a palletizer 3 that picks items from the replenishment pallet and stacks them on the shipping pallet, and a control device 4 that controls the operation of the unmanned transport device 2 and the palletizer 3.

[0011] The unmanned transport device 2 basically transports replenishment pallets between the storage area 5 and the palletizer 3 arranged in the stowage area 6. The unmanned transport device 2 also transports shipping pallets that have been completed by the palletizer 3 loading articles from the palletizer 3 to a shipping location (not shown). The unmanned transport device 2 may, for example, transport pallets that do not carry any articles (empty pallets). The automated guided vehicles 2 of this embodiment include an automated forklift 2A (AGF) that operates in the storage area 5, and an automated guided vehicle 2B (AGV) that operates in the stowage area 6. The number of automated forklifts 2A in the storage area 5 and the number of automated guided vehicles 2B in the stowage area 6 may each be one or more.

[0012] The automated guided vehicle 2B is configured to lift and transport replenishment pallets, shipping pallets, and empty pallets from below. For this reason, a transport platform with legs is used to transport replenishment pallets and the like by the automated guided vehicle 2B. The transport platform with legs is configured so that replenishment pallets and the like can be placed on it and so that the automated guided vehicle 2B can enter under the transport platform. Considering the picking and stacking of items in the palletizer, the automated guided vehicle 2B cannot transport replenishment pallets and the like stacked vertically.

[0013] The stowage area 6 is an area where items are mainly picked from replenishment pallets by the palletizer 3 and loaded onto shipping pallets. A temporary storage area 7 is located in the stowage area 6. The temporary storage area 7 is a place where replenishment pallets placed on transport platforms with legs are temporarily placed.

[0014] The storage area 5 is an area where replenishment pallets and the like are stored. The storage area 5 is located farther away from the palletizer 3 than the temporary storage area 7 described above. In this embodiment, shelves 8 (storage shelves 8) for storing replenishment pallets and the like are arranged in the storage area 5. The storage shelves 8 may be configured, for example, by arranging multiple shelf boards vertically. In this case, multiple replenishment pallets and the like can be lined up vertically by the unmanned forklift 2A.

[0015] At the boundary between the storage area 5 and the stowage area 6, a delivery location 9 is provided where replenishment pallets and the like are handed over between the unmanned forklift 2A and the unmanned guided vehicle 2B. As mentioned above, the unmanned guided vehicle 2B can only transport one replenishment pallet at a time, so at the delivery location 9, replenishment pallets and the like are handed over one by one between the unmanned forklift 2A and the unmanned guided vehicle 2B.

[0016] [Control device configuration] In this embodiment, the control device 4 has a configuration similar to that of a typical computer. That is, as shown in Fig. 2, the control device 4 includes a CPU 10, a memory 11, an input device 12, an output device 13, a recording medium 14, and a communication interface 15.

[0017] The CPU 10 is a processor that controls the operation of the picking system 1 as a computer. The memory 11 is a storage area necessary for the operation of the CPU 10. The input device 12 is, for example, a mouse, a keyboard, a touch panel, or the like. The output device 13 is, for example, a display. The recording medium 14 is a large-capacity storage device such as an HDD, an SSD, etc. In this embodiment, the recording medium 14 can record a picking order T1 (described later). The communication interface 15 transmits and receives various data to and from external devices. In this embodiment, the communication interface 15 receives a picking order T1 from a warehouse management system (not shown) that manages the entire picking system 1.

[0018] As shown in Fig. 3, picking order T1 is a list showing the types of items required by each shipping destination (customer) and the number of items of each type. In picking order T1 in Fig. 3, the types of items and the number of items of each type are shown for each shipping destination.

[0019] As shown in Figure 2, the CPU 10 operates according to a specific program to function as a completed pallet setting unit 100, an item number comparison and determination unit 101, a diversion candidate addition unit 102, a replenishment pallet remaining number confirmation unit 103, a diversion candidate existence determination unit 104, a sequence allocation unit 105, a cargo type determination unit 200, a loading sequence setting unit 201, a first time comparison and determination unit 300, a transport instruction unit 301, a work time estimation unit 302, a second time comparison and determination unit 303, and a task allocation unit 304.

[0020] The completed pallet setting unit 100 sets a completed pallet loaded with multiple types of goods based on the picking order T1 input to the control device 4. The completed pallet is a virtual shipping pallet on which the loading of multiple types of goods has been optimized based on the picking order T1. The completed pallet setting unit 100 sets one or more completed pallets for each shipping destination.

[0021] The item number comparison / determination unit 101 determines whether the number of items of a predetermined type on a completed pallet is equal to or greater than a predetermined ratio of the number of items of the predetermined type on a primary pallet loaded with only items of the predetermined type. A primary pallet is a replenishment pallet that is 100% loaded with items of the same type. The predetermined ratio of the number of items of a predetermined type on a primary pallet is a value that is at least greater than 0 and less than 1. The "predetermined ratio" may be, for example, 1 / 2, 1 / 3, 1 / 4, etc.

[0022] When it is determined that the number of predetermined types of items on a completed pallet is equal to or greater than a predetermined ratio of the number of predetermined types of items on a regular pallet, the diversion candidate adding unit 102 adds the completed pallet to the diversion candidates. A completed pallet that is a diversion candidate is a completed pallet in which the number of predetermined types of items is equal to or greater than a predetermined ratio of the number of predetermined types of items on a regular pallet.

[0023] The replenishment pallet remaining number confirmation unit 103 checks the number of items remaining on the replenishment pallet after a predetermined number of items have been picked in accordance with picking order T1. The "remaining number of items" checked by the replenishment pallet remaining number confirmation unit 103 is the number of items on the replenishment pallet before picking minus the number of items picked from the replenishment pallet by the palletizer 3 in accordance with picking order T1. The number of items on the replenishment pallet before picking may be the number of items on the regular pallet, or may be the number of items on a replenishment pallet that has fewer items loaded than the regular pallet.

[0024] The diversion candidate presence / absence determining unit 104 determines whether or not a completed pallet having a number of predetermined types of articles that matches the remaining number of predetermined types of articles on the replenishment pallet exists among the completed pallets that are diversion candidates.

[0025] When it is determined that a completed pallet in which the remaining number of predetermined types of items on the replenishment pallet matches the number of predetermined types of items on the completed pallet is present among the candidates for conversion of the completed pallet, the sequence assignment unit 105 assigns the sequence of the completed pallet in the conversion candidate to immediately after another completed pallet formed by picking a predetermined number of items from a replenishment pallet having predetermined types of items in accordance with picking order T1. In other words, the sequence assignment unit 105 changes the sequence of the completed pallets to be processed so that the replenishment pallet remaining after the palletizer 3 picks a predetermined number of items from a replenishment pallet having predetermined types of items and stacks them on another completed pallet is converted to the next completed pallet.

[0026] The cargo type determination unit 200 determines whether the types of goods loaded on a predetermined completed pallet include the tail end type of goods loaded at the end of the completed pallet immediately preceding the predetermined completed pallet.

[0027] When it is determined that the item types to be loaded onto a given completed pallet include the last item type to be loaded last on the immediately preceding completed pallet, the stowage order setting unit 201 sets the last item type to the item type to be loaded first on the given completed pallet. In other words, the stowage order setting unit 201 changes the order of the item types to be loaded on the given completed pallet.

[0028] The cargo type determination unit 200 also determines whether the types of goods loaded on a given completed pallet include the leading type of goods that will be loaded first on the completed pallet immediately following the given completed pallet.

[0029] In addition, when the loading order setting unit 201 determines that the item type to be loaded on a specified completed pallet includes the leading item type to be loaded first on the immediately following completed pallet, it sets the leading item type to the item type to be loaded last on the specified completed pallet.

[0030] The first time comparison and determination unit 300 determines whether the estimated time until the same replenishment pallet will be used again in the palletizer 3 is equal to or less than a predetermined first determination threshold. In this embodiment, the first determination threshold is set as a value corresponding to the round-trip time required for the automated guided device 2 to return the replenishment pallet from the palletizer 3 to the storage area 5 and then transport the replenishment pallet from the storage area 5 to the palletizer 3. The first determination threshold may be an actually measured round-trip time, an average of the measured round-trip times, or a time appropriately set by the manager of the picking system 1, for example.

[0031] If the transport instruction unit 301 determines that the estimated time is equal to or less than the first determination threshold, it causes the automated guided device 2 to transport the replenishment pallet from the palletizer 3 to the temporary storage area 7, and if it determines that the estimated time is greater than the first determination threshold, it causes the automated guided device 2 to transport the replenishment pallet from the palletizer 3 to the storage area 5. In this embodiment, the transport of the replenishment pallet from the palletizer 3 to the temporary storage area 7 is performed only by the automated guided vehicle 2B of the automated guided device 2. Furthermore, the transport of the replenishment pallet from the palletizer 3 to the storage area 5 is performed by the automated guided vehicle 2B and the automated forklift 2A of the automated guided device 2.

[0032] The operation time estimation unit 302 estimates the operation time required for the palletizer 3 to pick up items from the same replenishment pallet.

[0033] The second time comparison / determination unit 303 determines whether the estimated operation time for the palletizer 3 to pick an item from a predetermined replenishment pallet is equal to or greater than a predetermined second determination threshold. The estimated operation time is the "operation time" estimated by the operation time estimation unit 302. The second determination threshold is a time set by an administrator of the picking system 1, and may be, for example, a time that allows the automated guided vehicle 2 to sufficiently perform tasks other than transporting replenishment pallets. For example, if the time it takes for the automated guided vehicle 2B to perform one task (task) is 50 seconds, the time that allows the automated guided vehicle 2B to sufficiently perform other tasks may be set to, for example, the time it takes to perform 10 tasks, that is, 500 seconds.

[0034] If the task allocation unit 304 determines that the estimated work time is equal to or greater than the second determination threshold, it assigns to the unmanned guided device 2 the task of transporting the next replenishment pallet to the temporary storage area 7 without transporting it to the palletizer 3, and if it determines that the estimated work time is less than the second determination threshold, it assigns to the unmanned guided device 2 the task of transporting the next replenishment pallet to the palletizer 3. The "next replenishment pallet" transported by the unmanned guided device 2 is a replenishment pallet from which items will be picked by the palletizer 3 after the "current replenishment pallet" from which items have been picked by the palletizer 3.

[0035] [Update process for completed pallet order] Below, with reference to Figures 4 and 5, we will explain the processing of the CPU 10 of the control device 4, in particular the completed pallet setting unit 100, the item number comparison and determination unit 101, the diversion candidate addition unit 102, the replenishment pallet remaining number confirmation unit 103, the diversion candidate existence determination unit 104, and the order allocation unit 105.

[0036] 4, the CPU 10 of the control device 4 receives a picking order T1 from the warehouse management system (step S100). The received picking order T1 is recorded on the recording medium 14.

[0037] Next, the completed pallet setting unit 100 of the control device 4 sets completed pallets loaded with multiple types of items based on the input picking order T1 (step S101). In the processing of step S101, the completed pallet setting unit 100 creates picking order T2 for each completed pallet, as shown in FIG. 5, based on the picking order T1. Specifically, the completed pallet setting unit 100 sets multiple types of items to be shipped to a predetermined destination (e.g., destination A shown in FIGS. 3 and 5) to be appropriately distributed among multiple completed pallets (e.g., multiple completed pallets A1, A2, ... shown in FIG. 5) based on the picking order T1. Note that it is preferable that items of the same type to be shipped to the same destination are placed on the same completed pallet. Items of the same type to be shipped to different destinations are placed on separate completed pallets (e.g., completed pallet A2 and completed pallet B1 shown in FIG. 4).

[0038] Next, the item number comparison / determination unit 101 determines whether the number of items of a predetermined type on the completed pallet is equal to or greater than a predetermined ratio of the number of items of a predetermined type on a primary pallet loaded with only items of the predetermined type (step S102).

[0039] If the item number comparison and determination unit 101 determines that the number of items of a predetermined type on the completed pallet is equal to or greater than a predetermined ratio of the number of items of the predetermined type on the regular pallet, the diversion candidate addition unit 102 adds the completed pallet to the diversion candidates (step S103). On the other hand, if the item number comparison and determination unit 101 determines that the number of items of a predetermined type on the completed pallet is less than a predetermined ratio of the number of items of the predetermined type on the regular pallet, the diversion candidate addition unit 102 does not add the completed pallet to the diversion candidates (step S104). The processes in steps S102 to S104 are carried out for each completed pallet.

[0040] After steps S102 to S104 have been appropriately performed for all completed pallets, the CPU 10 of the control device 4 arranges all completed pallets in order (step S105). The order of the completed pallets arranged in step S105 corresponds to the provisional order in which shipping pallets will be created in the picking system 1.

[0041] After step S105, the replenishment pallet remaining number confirmation unit 103 checks the number of items remaining on the replenishment pallet after a predetermined number of items have been picked in accordance with picking order T1 (step S106). The number of items remaining on the replenishment pallet after picking is checked for each list in picking order T1 (item type in which the type of item corresponds one-to-one to the number of items). The remaining number of items may be checked for all lists (item types), but for example, for item types included in completed pallets that are candidates for conversion, where the number of items is equal to or exceeds a predetermined percentage of the number of items on the original pallet, the remaining number of items on the replenishment pallet does not need to be checked.

[0042] The diversion candidate presence / absence determination unit 104 then determines whether a completed pallet having a number of predetermined items that matches the remaining number of predetermined items on the replenishment pallet is present in the diversion candidate completed pallet (step S107). The remaining number of items on the replenishment pallet selected in step S107 may be limited to a number that is equal to or greater than a predetermined percentage of the number of items on the original pallet. The presence of a completed pallet in which the remaining number of predetermined items on the replenishment pallet matches the number of predetermined items on the completed pallet, among the diversion candidates for the completed pallet, means that the remaining number of predetermined items on a certain replenishment pallet matches the number of predetermined items on the completed pallet that is a diversion candidate, and is equal to or greater than a predetermined percentage of the number of predetermined items on the original pallet.

[0043] If the diversion candidate presence / absence determination unit 104 determines that a completed pallet exists among the diversion candidates for the completed pallet, in which the remaining number of predetermined types of items on the replenishment pallet matches the number of predetermined types of items on the completed pallet, the sequence assignment unit 105 assigns the sequence of the completed pallet of the diversion candidate to immediately after another completed pallet formed by picking a predetermined number of items from a replenishment pallet containing predetermined types of items in accordance with picking order T1 (step S108). On the other hand, if the diversion candidate presence / absence determination unit 104 determines that a completed pallet does not exist among the diversion candidates for the completed pallet, in which the remaining number of predetermined types of items on the replenishment pallet matches the number of predetermined types of items on the completed pallet, the sequence assignment unit 105 does not assign a sequence to the completed pallet of the diversion candidate (step S109). The processes of steps S107 to S109 are performed for each completed pallet of the diversion candidate.

[0044] [Updating the loading order of items on a completed pallet basis] Next, the processing of the cargo type determination unit 200 and the stowage order setting unit 201 of the control device 4 will be described with reference to Fig. 6. The processing described below will be described assuming that it is performed after all the processing shown in Fig. 4.

[0045] As shown in FIG. 6, the cargo type determination unit 200 determines whether the types of goods loaded onto a specified completed pallet include the tail end item type loaded onto the last completed pallet immediately preceding the specified completed pallet (step S200).

[0046] If the cargo type determination unit 200 determines that the item types to be loaded onto a given completed pallet include the tail item type to be loaded last on the immediately preceding completed pallet, the stowage order setting unit 201 sets the tail item type to the item type to be loaded first on the given completed pallet (step S201). That is, the stowage order setting unit 201 updates the order of the item types to be loaded on the given completed pallet. On the other hand, if the cargo type determination unit 200 determines that the item types to be loaded onto a given completed pallet do not include the tail item type to be loaded last on the immediately preceding completed pallet, the stowage order setting unit 201 does not update the order of the item types to be loaded on the given completed pallet (step S202).

[0047] After the above-mentioned step S201 or S202, the cargo type determination unit 200 determines whether the item types loaded on a specified completed pallet include the leading item type that will be loaded first on the completed pallet immediately after the specified completed pallet (step S203).

[0048] If the cargo type determination unit 200 determines that the item types to be loaded on a given completed pallet include the leading item type to be loaded first on the immediately succeeding completed pallet, the stowage order setting unit 201 sets the leading item type to the item type to be loaded last on the given completed pallet (step S204). That is, the stowage order setting unit 201 updates the order of the item types to be loaded on the given completed pallet. On the other hand, if the cargo type determination unit 200 determines that the item types to be loaded on a given completed pallet do not include the leading item type to be loaded first on the immediately succeeding completed pallet, the stowage order setting unit 201 does not update the order of the item types to be loaded on the given completed pallet (step S205). The above steps S200 to S205 are carried out for each completed pallet.

[0049] In the process shown in FIG. 6, the processes of steps S203 to S205 may be performed before the processes of steps S200 to S202, for example. 6 does not necessarily have to be performed after all of the processes shown in FIG. 4, but may be performed immediately after the process of step S101 in FIG.

[0050] [Selection of destination for replenishment pallets] Next, the processing of the first time comparison and determination unit 300 and the transport instruction unit 301 of the control device 4 will be described with reference to Fig. 7. The processing described below will be described as being performed after all the processing shown in Fig. 6.

[0051] 7, the first time comparison and determination unit 300 determines whether the estimated time until the same replenishment pallet is used again in the palletizer 3 is equal to or less than a predetermined first determination threshold (step S301). The determination of the estimated time by the first time comparison and determination unit 300 is performed for each list (item type in which the type of item corresponds one-to-one to the number of items) in the picking order T1.

[0052] If the first time comparing and determining unit 300 determines that the estimated time is equal to or less than the first determination threshold, the transport instructing unit 301 causes the unmanned transport device 2 to transport the replenishment pallet from the palletizer 3 to the temporary storage area 7 (step S302). On the other hand, if the first time comparing and determining unit 300 determines that the estimated time is greater than the first determination threshold, the transport instructing unit 301 causes the unmanned transport device 2 to transport the replenishment pallet from the palletizer 3 to the storage area 5 (step S303). That is, in steps S301 to S303, it is determined for each list in the picking order T1 whether or not to use the temporary storage area 7.

[0053] [Task allocation processing for automated guided vehicles] Next, the processing of the operation time estimation unit 302, the second time comparison and determination unit 303, and the task allocation unit 304 of the control device 4 will be described with reference to Fig. 7. The processing described below will be described as being performed after all the processing shown in Fig. 6.

[0054] The operation time estimation unit 302 estimates the operation time required for the palletizer 3 to pick items from the same replenishment pallet (step S300). The operation time estimation unit 302 estimates the operation time for each "item type" in the picking order T1. In Fig. 7, the processing of step S300 is performed before the processing of steps S301 to S303 described above, but may also be performed after the processing of steps S301 to S303, for example.

[0055] The second time comparison and determination unit 303 determines whether the estimated operation time for the palletizer 3 to pick an item from a predetermined replenishment pallet is equal to or greater than a predetermined second determination threshold (step S304). The estimated operation time used in step S304 is the operation time estimated in the process of step S300 described above.

[0056] If the second time comparing and determining unit 303 determines that the estimated operation time is equal to or greater than the second determination threshold, the task allocating unit 304 assigns to the unmanned guided device 2 the task of transporting the next replenishment pallet to the temporary storage area 7 without transporting it to the palletizer 3 (step S305). On the other hand, if the second time comparing and determining unit 303 determines that the estimated operation time is shorter than the second determination threshold, the task allocating unit 304 assigns to the unmanned guided device 2 the task of transporting the next replenishment pallet to the palletizer 3 (step S306). In this embodiment, the main target to which the task allocating unit 304 assigns a predetermined task in steps S305 and S306 is the unmanned guided vehicle 2B, but the target may also include, for example, the unmanned forklift 2A. In the process of step S305, for example, the task allocation unit 304 may allocate another task to the automatic guided device 2 (particularly the automatic guided vehicle 2B). The other task may include, for example, a task to transport an empty pallet or a transport platform.

[0057] 7, the processes of steps S304 to S306 described above are performed after the processes of steps S301 to S303, but they only need to be performed after the process of at least step S300. Therefore, the processes of steps S304 to S306 may be performed before the processes of steps S301 to S303, for example. All the processes shown in FIG. 7 do not necessarily have to be performed after all the processes shown in FIGS. 4 and 6, but may be performed following the process of step S101 in FIG. 4, for example.

[0058] [Action, effect] In the picking system 1 of this embodiment, if the item number comparison / determination unit 101 determines that the number of items of a predetermined type on a completed pallet is equal to or greater than a predetermined ratio of the number of items of the predetermined type on a primary pallet loaded with only items of the predetermined type, the diversion candidate addition unit 102 adds the completed pallet to the diversion candidates. If the diversion candidate presence / absence determination unit 104 determines that a completed pallet exists among the diversion candidates for the completed pallet, in which the number of items of the predetermined type remaining on the replenishment pallet after a predetermined number of items have been picked in accordance with picking order T1 matches the number of items of the predetermined type on the completed pallet, the sequence assignment unit 105 assigns the sequence of the completed pallet as a diversion candidate immediately after another completed pallet formed by picking a predetermined number of items from a replenishment pallet containing items of the predetermined type in accordance with picking order T1.

[0059] This allows the remaining replenishment pallet after the palletizer 3 has picked a predetermined number of items from a replenishment pallet containing a predetermined type of item and stacked them on another completed pallet to be reused as the next completed pallet. Here, the number of the predetermined type of item on the remaining replenishment pallet is equal to or greater than a predetermined ratio of the number of items on the original pallet and matches the number of the predetermined type of item set on the next completed pallet.

[0060] In this way, by reusing the remaining replenishment pallet as the next completed pallet, it is possible to omit loading a predetermined number of items onto the next completed pallet by the palletizer 3. It is also possible to reduce the number of times that the unmanned guided device 2 supplies (transports) replenishment pallets to the palletizer 3. In other words, it is possible to reduce the workload of the palletizer 3 and the unmanned guided device 2. Therefore, it is possible to efficiently load a predetermined number of multiple types of items onto a pallet using a fewer number of robots (palletizers 3, unmanned guided devices 2).

[0061] Furthermore, in the picking system 1 of this embodiment, if the item type determination unit 200 determines that the item type to be loaded onto a given completed pallet includes the last item type to be loaded at the end of the immediately preceding completed pallet, the loading order setting unit 201 sets the last item type to the item type to be loaded first on the given completed pallet. Therefore, the palletizer 3 can load the same type of items loaded on a replenishment pallet at the end of one completed pallet and then at the beginning of the next completed pallet. In other words, items loaded on the same replenishment pallet can be loaded onto two consecutive completed pallets. This reduces the number of times the automated guided vehicle 2 supplies (transports) the same type of replenishment pallet to the palletizer 3. In other words, the workload of the automated guided vehicle 2 can be reduced. Therefore, it becomes possible to efficiently load a predetermined number of multiple types of items onto pallets using a smaller number of automated guided vehicle devices 2.

[0062] Furthermore, in the picking system 1 of this embodiment, if the item type determination unit 200 determines that the item type to be loaded on a given completed pallet includes the leading item type to be loaded first on the immediately succeeding completed pallet, the loading order setting unit 201 sets the leading item type to the item type to be loaded last on the given completed pallet. Therefore, the palletizer 3 can load the same type of items loaded on a replenishment pallet at the end of the given completed pallet, and then at the beginning of the immediately succeeding completed pallet. In other words, items loaded on the same replenishment pallet can be loaded onto two consecutive completed pallets. This reduces the number of times the automated guided device 2 supplies (transports) the same type of replenishment pallet to the palletizer 3. In other words, the workload of the automated guided device 2 can be reduced. Therefore, it becomes possible to efficiently load a predetermined number of multiple types of items onto a pallet using a smaller number of automated guided devices 2.

[0063] Furthermore, in the picking system 1 of this embodiment, if the first time comparison and determination unit 300 determines that the estimated time until the same replenishment pallet will be used again in the palletizer 3 is equal to or less than the first determination threshold, the unmanned guided device 2 does not return the replenishment pallet to the storage area 5, but instead transports it to the temporary storage area 7 that is closer to the palletizer 3 than the storage area 5. This reduces the workload of the unmanned guided device 2. Therefore, it becomes possible to efficiently stack a predetermined number of multiple types of articles on a pallet using a smaller number of unmanned guided devices 2.

[0064] Furthermore, in the picking system 1 of this embodiment, the first determination threshold is set to a value equivalent to the round trip time required for the unmanned guided device 2 to return a replenishment pallet from the palletizer 3 to the storage area 5, and then transport the replenishment pallet from the storage area 5 to the palletizer 3. This makes it possible to efficiently reduce the workload of the unmanned guided device 2.

[0065] Furthermore, in the picking system 1 of this embodiment, if the second time comparison and determination unit 303 determines that the estimated operation time for the palletizer 3 to pick items from a predetermined replenishment pallet is equal to or longer than the second determination threshold, the unmanned guided device 2 transports the next replenishment pallet to the temporary storage area 7 without transporting it to the palletizer 3. This allows the next replenishment pallet to remain at the temporary storage area 7. Therefore, the task allocation unit 304 can assign other tasks (for example, a task to transport an empty pallet or a transport platform) to the unmanned guided device 2. In other words, the standby time of the unmanned guided device 2 can be reduced. Therefore, it is possible to efficiently stack a predetermined number of multiple types of items on a pallet using a smaller number of unmanned guided devices 2.

[0066] The embodiments of the present disclosure have been described above in detail with reference to the drawings, but the specific configurations are not limited to these embodiments and include design changes and the like within the scope of the gist of the present disclosure.

[0067] For example, in the above embodiment, the CPU 10 of the control device 4 is equipped with all of the completed pallet setting unit 100, item number comparison and determination unit 101, diversion candidate addition unit 102, replenishment pallet remaining number confirmation unit 103, diversion candidate existence determination unit 104, sequence allocation unit 105, cargo type determination unit 200, stowage sequence setting unit 201, first time comparison and determination unit 300, transport instruction unit 301, work time estimation unit 302, second time comparison and determination unit 303, and task allocation unit 304, but this is not limited to this.

[0068] The CPU 10 may include, for example, only the completed pallet setting unit 100, the item number comparison and determination unit 101, the diversion candidate addition unit 102, the replenishment pallet remaining number confirmation unit 103, the diversion candidate existence determination unit 104, and the sequence allocation unit 105. Furthermore, the CPU 10 may include only the cargo type determination unit 200 and the stowage order setting unit 201, for example. Furthermore, the CPU 10 may include only the first time comparison and determination unit 300 and the transport instruction unit 301, for example. Furthermore, the CPU 10 may include only the task time estimation unit 302, the second time comparison and determination unit 303, and the task allocation unit 304, for example.

[0069] In the present disclosure, the various processes executed by the control device 4 of the picking system 1 are stored in the form of a program on a computer-readable recording medium 14, and the various processes are performed by the computer reading and executing the program. The computer-readable recording medium 14 refers to a magnetic disk, a magneto-optical disk, a CD-ROM, a DVD-ROM, a semiconductor memory, etc. Alternatively, the computer program may be distributed to a computer via a communication line, and the computer that receives the program may execute the program.

[0070] The program may be a program for realizing some of the above-mentioned functions, or may be a so-called differential file (differential program) that can realize the above-mentioned functions in combination with a program already recorded in the computer system.

[0071] Furthermore, in the present disclosure, the control device 4 of the picking system 1 may have an internal CPU 10, and the CPU 10 may execute the above processing according to a program, or may be realized using hardware alone, or may be realized using a custom LSI such as an FPGA (Field Programmable Gate Array).

[0072] <Additional Notes> The picking system 1 described in the above embodiment can be understood, for example, as follows.

[0073] (1) A picking system 1 according to a first aspect includes a completed pallet setting unit 100 that sets a completed pallet loaded with multiple types of items based on an input picking order T1; an item number comparison and determination unit 101 that determines whether the number of items of a predetermined type on the completed pallet is equal to or greater than a predetermined ratio of the number of items of the predetermined type on a regular pallet loaded with only the items of the predetermined type; a diversion candidate addition unit 102 that adds the completed pallet to a diversion candidate when it is determined that the number of items of the predetermined type on the completed pallet is equal to or greater than the predetermined ratio of the number of items of the predetermined type on the regular pallet; and a replenishment unit that checks the remaining number of items on a replenishment pallet after picking a predetermined number of items according to the picking order T1. The picking system 1 includes a refill pallet remaining number confirmation unit 103, a conversion candidate presence / absence determination unit 104 that determines whether the completed pallet having the number of items of the specified type that matches the remaining number of items of the specified type on the refill pallet is present in the completed pallet that is a conversion candidate, and a sequence assignment unit 105 that, when it is determined that the completed pallet in which the remaining number of items of the specified type on the refill pallet and the number of items of the specified type on the completed pallet match is present in the conversion candidate for the completed pallet, assigns the sequence of the completed pallet that is a conversion candidate to immediately after another completed pallet that is formed by picking a specified number of items from a refill pallet having the specified type of items in accordance with the picking order T1.

[0074] In the above configuration, the palletizer 3 can repurpose the remaining replenishment pallet after picking a predetermined number of items from a replenishment pallet containing a predetermined type of item and stacking them on another completed pallet as the next completed pallet. Here, the number of the predetermined type of item on the remaining replenishment pallet is equal to or greater than a predetermined ratio of the number of items on the primary pallet and matches the number of the predetermined type of item set on the next completed pallet. In this way, by reusing the remaining replenishment pallet as the next completed pallet, it is possible to omit loading a predetermined number of items onto the next completed pallet by the palletizer 3. It is also possible to reduce the number of times that the unmanned guided device 2 supplies (transports) replenishment pallets to the palletizer 3. In other words, it is possible to reduce the workload of the palletizer 3 and the unmanned guided device 2. Therefore, it is possible to efficiently load a predetermined number of multiple types of items onto a pallet using a fewer number of robots (palletizers 3, unmanned guided devices 2).

[0075] (2) The picking system 1 according to the second aspect is the picking system 1 described in (1), which has a cargo type determination unit 200 that determines whether the item types to be loaded onto the specified completed pallet include the last item type to be loaded at the end of the completed pallet immediately preceding the specified completed pallet, and a loading order setting unit 201 that, when it is determined that the item types to be loaded onto the specified completed pallet include the last item type to be loaded at the end of the completed pallet immediately preceding the specified completed pallet, sets the last item type to the item type to be loaded first on the specified completed pallet.

[0076] In the above configuration, if the item type determination unit 200 determines that the item type to be loaded onto a given completed pallet includes the last item type to be loaded at the end of the immediately preceding completed pallet, the loading order setting unit 201 sets the last item type as the item type to be loaded first on the given completed pallet. Therefore, the palletizer 3 can load the same type of items loaded on a replenishment pallet at the end of one completed pallet and then at the beginning of the next completed pallet. In other words, items loaded on the same replenishment pallet can be loaded onto two consecutive completed pallets. This reduces the number of times the automated guided transport device 2 supplies (transports) the same type of replenishment pallet to the palletizer 3. In other words, the workload of the automated guided transport device 2 can be reduced. Therefore, it becomes possible to efficiently load a predetermined number of multiple types of items onto a pallet using a fewer number of automated guided transport devices 2.

[0077] (3) The picking system 1 according to the third aspect is the picking system 1 described in (1) or (2), which has a first time comparison and judgment unit 300 that judges whether the estimated time until the same replenishment pallet is used again in the palletizer 3 is equal to or less than a predetermined first judgment threshold, and a transport instruction unit 301 that, if it is judged that the estimated time is equal to or less than the first judgment threshold, causes the unmanned transport device 2 to transport the replenishment pallet from the palletizer 3 to a temporary storage area 7, and, if it is judged that the estimated time is greater than the first judgment threshold, causes the unmanned transport device 2 to transport the replenishment pallet from the palletizer 3 to a storage area 5.

[0078] In the above configuration, if the first time comparison and determination unit 300 determines that the estimated time until the same replenishment pallet will be used again in the palletizer 3 is equal to or less than the first determination threshold, the unmanned guided device 2 does not return the replenishment pallet to the storage area 5, but instead transports it to the temporary storage area 7 that is closer to the palletizer 3 than the storage area 5. This reduces the workload of the unmanned guided device 2. Therefore, it becomes possible to efficiently stack a predetermined number of multiple types of articles on a pallet using a fewer number of unmanned guided devices 2.

[0079] (4) A picking system 1 according to a fourth aspect is a picking system 1 as described in (3), in which the first judgment threshold is defined as a value equivalent to the round-trip time required for the unmanned transport device 2 to return the replenishment pallet from the palletizer 3 to the storage area 5, and then transport the replenishment pallet from the storage area 5 to the palletizer 3.

[0080] In the above configuration, the workload of the automatic guided device 2 can be reduced efficiently.

[0081] (5) A picking system 1 according to a fifth aspect is a picking system 1 described in any one of (1) to (4), which includes an operation time estimation unit 302 that estimates the operation time for the palletizer 3 to pick items from the same replenishment pallet; a second time comparison and judgment unit 303 that judges whether the estimated operation time for the palletizer 3 to pick items from a predetermined replenishment pallet is equal to or greater than a predetermined second judgment threshold; and a task allocation unit 304 that, when it is judged that the estimated operation time is equal to or greater than the second judgment threshold, assigns to the unmanned transport device 2 the task of transporting the next replenishment pallet to a temporary storage area 7 without transporting it to the palletizer 3, and, when it is judged that the estimated operation time is less than the second judgment threshold, assigns to the unmanned transport device 2 the task of transporting the next replenishment pallet to the palletizer 3.

[0082] In the above configuration, when the second time comparison and determination unit 303 determines that the estimated operation time for the palletizer 3 to pick items from a predetermined replenishment pallet is equal to or longer than the second determination threshold, the unmanned guided device 2 transports the next replenishment pallet to the temporary storage area 7 without transporting it to the palletizer 3. This allows the next replenishment pallet to remain at the temporary storage area 7. Therefore, the task allocation unit 304 can assign other tasks (for example, a task to transport an empty pallet or a transport platform) to the unmanned guided device 2. In other words, the standby time of the unmanned guided device 2 can be reduced. Therefore, it is possible to efficiently stack a predetermined number of multiple types of items on a pallet using a smaller number of unmanned guided devices 2. [Explanation of symbols]

[0083] 1. Picking system 2. Unmanned transport devices 3 Palletizer 5. Storage Area 6. Loading area 7 Temporary storage area 100 Completed Palette Setting Section 101 Comparison and Judgment Department of Number of Articles 102 Additional diversion candidates 103 Replenishment pallet remaining quantity check section 104 Diversion candidate presence / absence determination unit 105 Order assignment section 200 Cargo type determination section 201 Loading order setting unit 300 First time comparison judgment section 301 Transport Instruction Department 302 Work Time Estimation Unit 303 Second time comparison and judgment section 304 Task Allocation Unit T1 Picking Order

Claims

1. a completed pallet setting unit that sets completed pallets loaded with multiple types of items based on an input picking order; an item number comparison / determination unit that determines whether the number of items of a predetermined type on the completed pallet is equal to or greater than a predetermined ratio of the number of items of the predetermined type on a primary pallet loaded with only the items of the predetermined type; a diversion candidate addition unit that adds the completed pallet to a diversion candidate when it is determined that the number of the predetermined type of items on the completed pallet is equal to or greater than a predetermined ratio of the number of the predetermined type of items on the original pallet; a replenishment pallet remaining number confirmation unit that checks the remaining number of items on the replenishment pallet after a predetermined number of items have been picked in accordance with the picking order; a diversion candidate presence / absence determination unit that determines whether the completed pallet having the number of the predetermined type of items that matches the remaining number of the predetermined type of items on the refill pallet is present in the diversion candidate completed pallet; a sequence allocation unit that, when it is determined that the completed pallet, in which the remaining number of the predetermined type of items on the replenishment pallet matches the number of the predetermined type of items on the completed pallet, is present in the conversion candidate for the completed pallet, assigns the sequence of the completed pallet, which is the conversion candidate, immediately after another completed pallet that is formed by picking a predetermined number of items from a replenishment pallet having the predetermined type of items in accordance with the picking order; A picking system having:

2. a cargo type determination unit that determines whether the cargo types loaded onto a predetermined completed pallet include a tail cargo type to be loaded onto the last completed pallet immediately before the predetermined completed pallet; a loading order setting unit that, when it is determined that the item types loaded on a given completed pallet include the last item type loaded last on the immediately preceding completed pallet, sets the last item type to the item type loaded first on the given completed pallet; The picking system according to claim 1 , comprising:

3. a first time comparison and determination unit that determines whether an estimated time until the same replenishment pallet is used again in the palletizer is equal to or less than a predetermined first determination threshold; a transport instruction unit that, when it is determined that the estimated time is equal to or less than the first determination threshold, causes an unmanned transport device to transport the replenishment pallet from the palletizer to a temporary storage area, and, when it is determined that the estimated time is greater than the first determination threshold, causes the unmanned transport device to transport the replenishment pallet from the palletizer to a storage area; The picking system according to claim 1 or 2, comprising:

4. The picking system described in claim 3, wherein the first judgment threshold is defined as a value corresponding to the round-trip time required for the unmanned transport device to return the replenishment pallet from the palletizer to the storage area and then transport the replenishment pallet from the storage area to the palletizer.

5. an operation time estimation unit that estimates an operation time required for the palletizer to pick up items from the same replenishment pallet; a second time comparison and determination unit that determines whether an estimated operation time required for the palletizer to pick an item from a predetermined replenishment pallet is equal to or greater than a predetermined second determination threshold; a task allocation unit that, when it is determined that the estimated operation time is equal to or greater than the second determination threshold, assigns to the unmanned transport device a task of transporting the next replenishment pallet to a temporary storage area without transporting it to the palletizer, and, when it is determined that the estimated operation time is shorter than the second determination threshold, assigns to the unmanned transport device a task of transporting the next replenishment pallet to the palletizer; The picking system according to claim 1 or 2, comprising:

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