Control System
The control system efficiently manages inventory storage by preventing items from exceeding shelf capacity, minimizing shelf deterioration, and reducing the size and cost of automated warehouses by using a weight information acquisition unit, actual total weight calculation unit, and storing/retrieval control unit to manage inventory storage.
Patent Information
- Application Number
- JP2023039893
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- Filing Date
- 2023-03-14
- Publication Date
- 2025-12-10
- Estimated Expiration
- 2043-03-14
AI Technical Summary
Existing automated warehouse systems fail to efficiently manage inventory storage devices, which can lead to the deterioration of storage shelves over time or even cause damage to the shelves, and the existing automated warehouse systems fail to efficiently manage inventory storage devices.
A control system for controlling an automated warehouse that includes a storage shelf that includes a storage shelf with a plurality of storage sections, each of which can be stored in the storage shelf and an inventory-retrieval device that stores the items in the storage shelf and retrieves the items from the storage shelf and retrieves the items from the storage shelf, a weight information acquisition unit that acquires item weight information, an actual total weight calculation unit that calculates an actual total weight of the items stored on the storage shelf, an actual average load calculation unit that calculates an actual average load of the items stored on the storage shelf, and a storing/retrieval control unit that controls the storing/retrieval device.
The system efficiently manages inventory storage by preventing items from being stored in excess of the shelf's capacity, minimizing shelf deterioration, and reducing the size and cost of the automated warehouse.
Smart Images
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Abstract
Description
[Technical Field]
[0001] The present invention relates to a control system for controlling an automated warehouse that includes a storage shelf having a plurality of storage sections, each capable of storing an item in the storage section, and an inventory / retrieval device that stores the items in the storage shelf and retrieves the items from the storage shelf. [Background technology]
[0002] For example, Japanese Patent Laid-Open No. 2-152803 (Patent Document 1) discloses a technology relating to a control system for controlling an automated warehouse. In the following description of the background art, the reference numerals in parentheses refer to those in Patent Document 1.
[0003] The automated warehouse of Patent Document 1 includes a set of storage shelves (shelves 1) for storing items (loads 6), a stacker crane (loading / unloading device 15) that moves along an aisle (2) formed between the set of storage shelves, loading / unloading conveyors (loading conveyor 8, unloading conveyor 9), a weight measuring device (45), and a control device (29). The weight measuring device (45) is provided in the loading / unloading device (15). When performing management work on the stored loads (6), the control device (29) measures the weight of the loads (6) stored in each storage unit using the weight measuring device (45). The control device (29) then calculates the number of items contained in the loads (6) from the weight and compares the calculation result with management data. This makes it possible to determine the true number of items stored in each storage unit and to correct the management data. [Prior art documents] [Patent documents]
[0004] [Patent Document 1] Japanese Patent Application Publication No. 2-152803 Summary of the Invention [Problem to be solved by the invention]
[0005] Some users may store items in excess of the load capacity of the storage shelves in an automated warehouse. Such use can accelerate the deterioration of the storage shelves over time or even cause damage to the shelves. To prepare for such cases, storage shelves are generally designed with a margin so that they can withstand items stored in excess of the set load capacity. As a result, for users who adhere to the load capacity, this leads to larger shelves and higher costs for the entire automated warehouse.
[0006] Therefore, it is desirable to make it easier to reduce the size and cost of automated warehouses. [Means for solving the problem]
[0007] A control system according to the present disclosure is a control system for controlling an automated warehouse including a storage shelf having a plurality of storage sections, each of which can store an item, and an inventory-retrieval device that stores the items in the storage shelf and retrieves the items from the storage shelf, a weight information acquisition unit that acquires item weight information indicating the weight of the items stored by the storing / retrieving device; an actual total weight calculation unit that calculates an actual total weight indicating the total weight of all the items stored on the storage shelf based on the item weight information; an actual average load calculation unit that calculates an actual average load indicating the average value of the load from the items supported by each storage section by dividing the actual total weight by the total number of storage sections that the storage shelf has; and an storing / retrieving control unit that controls the storing / retrieving device, The upper limit of the total weight of the items that can be stored on the entire storage shelf is defined as an upper limit storage weight, the value obtained by dividing the upper limit storage weight by the total number that can be stored is defined as an upper limit average load, and the items that are to be newly stored by the storage / retrieval device are defined as items to be stored, The actual average load calculation unit calculates a planned average load, which is the actual average load when the planned item is stored, every time the planned item is stored, The inventory control unit uses an average load threshold set to be equal to or less than the upper limit average load, and if the expected average load is equal to or greater than the average load threshold, prohibits the expected item from being stored in the inventory device.
[0008] According to this configuration, if the expected average load is equal to or greater than the average load threshold, items are prohibited from being stored on the storage shelves, which allows for efficient use of the storage shelves and minimizes deterioration of the storage shelves over time. Furthermore, with this configuration, an actual average load indicating the average value of the load from the items supported by each storage section is calculated, and each time an item is scheduled to be stored, a planned average load, which is the actual average load that will be applied if the item is stored, is calculated, and whether or not to prohibit the item from being stored is determined based on whether or not the planned average load is equal to or greater than the average load threshold. As a result, the actual average load calculated from the actual total weight of the items actually stored on the storage shelf will not exceed the average load threshold. This makes it possible to avoid storing items in excess of the shelf's upper limit storage weight, and to design the storage shelf so that there is less room for the weight of items that need to be stored on the shelf. In this way, according to this configuration, it is possible to increase the efficiency with which items can be stored on the storage shelves while also making it easier to reduce the size and cost of the automated warehouse.
[0009] Further features and advantages of the control system will become apparent from the following description of exemplary, non-limiting embodiments which are given with reference to the drawings. [Brief explanation of the drawings]
[0010] [Figure 1] Perspective view of an automated warehouse [Figure 2] Control Block Diagram [Figure 3] 1 is a flowchart illustrating an example of a control system. [Figure 4] 1 is a flowchart illustrating an example of a control system. [Figure 5] 1 is a flowchart illustrating an example of a control system. [Figure 6] A diagram showing an example of a storage list for a group of items of the same type. [Figure 7] A diagram showing an example of a storage list for a group of combined items. [Figure 8] A diagram showing an example of delivery schedule information [Figure 9] A diagram showing an example of a list of recommended items for shipping DETAILED DESCRIPTION OF THE INVENTION
[0011] An embodiment of an automated warehouse will be described with reference to the drawings. As shown in Fig. 1, the automated warehouse 1 is equipped with a storage shelf 2 having a plurality of storage sections 20, each capable of storing an item W, and an inventory-retrieval device 3 that stores and retrieves the item W from the storage shelf 2. In this embodiment, the automated warehouse 1 further includes a control device 10 (see Fig. 2).
[0012] In this embodiment, as shown in FIG. 1 , an automated warehouse 1 includes a plurality of storage shelves 2 and a common storage / retrieval device 3 shared by the plurality of storage shelves 2. The common storage / retrieval device 3 stores and retrieves items W from the plurality of storage shelves 2. In this example, the plurality of storage shelves 2 (here, a set of storage shelves 2) are arranged to face each other with the storage / retrieval device 3 in between. A specific direction along the horizontal direction is defined as a specific horizontal direction, and each of the plurality of storage shelves 2 is arranged so that a plurality of storage sections 20 are lined up in the vertical direction and the specific horizontal direction. The specific horizontal direction is the direction in which a travel path 5, which will be described later, extends, and a conveying device 31, which will be described later and which is included in the storage / retrieval device 3, travels along the specific horizontal direction to convey the items W.
[0013] In this embodiment, as shown in FIG. 1 , the storing / retrieving device 3 includes a transport device 31 and a storing / retrieving conveyor 32. The transport device 31 transports items W between the storing / retrieving conveyor 32 and the storage shelves 2. In this example, the transport device 31 is a stacker crane. A set of storage shelves 2 is arranged on either side of the travel path 5 of the transport device 31, and the transport device 31 delivers items W to each storage shelf 2. The storing / retrieving conveyor 32 includes an storing conveyor 32a and an delivering conveyor 32b. The transport device 31 receives items W to be stored from the storing conveyor 32a and delivers them to the storage section 20, which is the destination. The transport device 31 also receives items W to be delivered from the storage section 20 and delivers them to the delivering conveyor 32b, which is the destination. Note that the storing / retrieving device 3 may be configured such that the transport device 31 is an item transport vehicle with a configuration different from a stacker crane. In this case, it is preferable to arrange a plurality of travel paths 5 along which the article transport vehicles can travel so as to correspond to the respective storage sections 20 arranged in a plurality of stages in the vertical direction.
[0014] As shown in FIGS. 6 and 7, there are multiple types of items W with different weights. A predetermined combination of multiple types of items W is called a combined item group Ws, and the combined item group Ws includes multiple types with different weights. In this example, the combined item group Ws (FIG. 7) and a same-type item group Wk (FIG. 6) consisting of multiple items W of the same type are stored in the storage section 20. In the example of FIG. 1, such items W are stored in the storage section 20 while placed on a pallet (not shown). Furthermore, the items W are stored in and out of the storage shelf 2 by the storage / retrieval device 3 while placed on the pallet. Note that one item W may be stored in the storage section 20 while placed on one pallet. While this example illustrates a configuration using a pallet, a configuration without a pallet is also possible. Furthermore, the item W may be a combination of a container and the contents contained in the container. The example of FIG. 6 shows a storage list of the same-type item group Wk already stored in the storage shelf 2. The second line from the top of this storage list indicates that 10 items W with item code "A" are stored on a pallet registered with pallet ID "1." It also indicates that each item W weighs "6 kg." The example in FIG. 7 shows a storage list of a combined item group Ws already stored on storage shelf 2. The second line from the top of this storage list indicates that two items W each with item code "A," "B," and "C" are stored on a pallet with pallet ID "1." It also indicates that each item W with item code "A" weighs "6 kg," each item W with item code "B" weighs "4 kg," each item W with item code "C" weighs "2 kg," and that a total of "24 kg" of items W are stored on this pallet.
[0015] 2, a control system 100 that controls the automated warehouse 1 as described above includes a control device 10 provided in the automated warehouse 1, and a higher-level control device (hereinafter referred to as a higher-level controller C) that is configured to be able to communicate with the control device 10. The control device 10 acquires item weight information D1 and shipping schedule information D2, which will be described later, from the higher-level controller C.
[0016] The control device 10 includes a processing unit such as a CPU and peripheral circuits such as a memory, and each function of the control device 10 is realized by cooperation between these pieces of hardware and programs executed on the hardware such as the processing unit. The control device 10 may be configured not as a single piece of hardware, but as a collection of multiple pieces of hardware (multiple separate pieces of hardware) that can communicate with each other.
[0017] 2, the control system 100 includes a weight information acquisition unit 81 that acquires item weight information D1 indicating the weight of items W stored by the storing / retrieving device 3, an actual total weight calculation unit 82 that calculates an actual total weight A1 indicating the total weight of all items W stored on the storage shelf 2 based on the item weight information D1, an actual average load calculation unit 83 that calculates an actual average load A2 indicating the average value of the load from the items W supported by each storage section 20 by dividing the actual total weight A1 by the total number of storage sections 20 provided on the storage shelf 2, and an storing / retrieving control unit 80 that controls the storing / retrieving device 3. In this embodiment, the control device 10 includes the weight information acquisition unit 81, the actual total weight calculation unit 82, the actual average load calculation unit 83, and the storing / retrieving control unit 80 (see FIG. 2).
[0018] 1, the storage / retrieval control unit 80 controls the storage conveyor 32a, the delivery conveyor 32b, and the transport device 31. In the illustrated example, the storage / retrieval control unit 80 controls the storage conveyor 32a, the delivery conveyor 32b, and a stacker crane serving as the transport device 31.
[0019] In the following description, the upper limit of the total weight of the items W that can be stored on the entire storage shelf 2 is defined as the upper limit storage weight, the value obtained by dividing the upper limit storage weight by the total number that can be stored is defined as the upper limit average load, and the items W that are about to be newly stored by the storage / retrieval device 3 are defined as the items Wt to be stored. In this embodiment, an upper limit storage weight is set for each of the multiple storage shelves 2, and therefore the upper limit average load for each storage shelf 2 is also set in advance.
[0020] In this example, the weight information acquisition unit 81 acquires item weight information D1 of either the combined item group Ws or the same-type item group Wk to be stored. More specifically, the weight information acquisition unit 81 acquires item weight information D1 of either the combined item group Ws or the same-type item group Wk placed on the storage conveyor 32a. The item weight information D1 of the item W to be stored on the storage shelf 2 is stored in advance in the upper controller C. Note that in this example, each calculation is performed based on the item weight information D1 acquired from the upper controller C, but, for example, a weight measuring device may be provided in the storage / retrieval device 3, and the control device 10 may measure the weight of the item W each time it is stored, and each calculation may be performed based on the measurement results.
[0021] 3, the actual total weight calculation unit 82 calculates the actual total weight A1 for each of a plurality of storage shelves 2. In this example, the actual total weight calculation unit 82 calculates the actual total weight A1 of all items W (here, including the combined item group Ws and the same type item group Wk) stored on each storage shelf 2. The actual total weight calculation unit 82 calculates the actual total weight A1 of each storage shelf 2 from the item weight information D1 of all items W stored on each storage shelf 2. In the example shown, the actual total weight calculation unit 82 calculates the actual total weight A1 of each of a set of storage shelves 2.
[0022] In this embodiment, the actual average load calculation unit 83 calculates the actual average load A2 for each of the multiple storage shelves 2. More specifically, the actual average load calculation unit 83 calculates the actual average load A2 for each set of storage shelves 2 by dividing the actual total weight A1 by the total number of items that can be stored. Furthermore, each time an item Wt is scheduled to be stored, the actual average load calculation unit 83 calculates a planned average load A5, which is the actual average load A2 when the item Wt is stored. In this embodiment, the actual average load calculation unit 83 calculates the planned average load A5 of a storage shelf 2 among the multiple storage shelves 2 that is assigned to store the item Wt (here, including the combined item group Ws and the same-type item group Wk that are scheduled to be stored). In this way, in this embodiment, the actual average load calculation unit 83 calculates the actual average load A2 and the planned average load A5 for each of the multiple storage shelves 2.
[0023] The storing / retrieving control unit 80 uses an average load threshold A6 set equal to or less than the upper limit average load, and prohibits the storing / retrieving device 3 from storing the items Wt scheduled to be stored if the expected average load A5 is equal to or greater than the average load threshold A6. In this embodiment, the average load threshold A6 is set to be the same as the upper limit average load. Furthermore, the upper limit average load and the average load threshold A6 are set to be the same for each of the multiple storage shelves 2. If there is an excess expected storage shelf 12 among the multiple storage shelves 2, which is a storage shelf 2 whose expected average load A5 is equal to or greater than the average load threshold A6, the storing / retrieving control unit 80 prohibits the storing / retrieving device 3 from storing the items Wt scheduled to be stored to the excess expected storage shelf 12. In this case, the storing / retrieving control unit 80 controls the storing / retrieving device 3 as follows. When prohibiting the storing / retrieving device 3 from storing the items Wt scheduled to be stored, the storing / retrieving control unit 80 stops the storing / retrieving device 3 from storing the items Wt scheduled to be stored, or causes the storing / retrieving device 3 to retrieve the items Wt. 1 and 3, when prohibiting storage on the planned excess storage shelf 12, the storage / retrieval control unit 80 causes the storage-scheduled item Wt to be retrieved by the storage / retrieval device 3. Specifically, the storage / retrieval control unit 80 controls the transport device 31 to transfer the storage-scheduled item Wt placed on the storage conveyor 32a to the retrieval conveyor 32b. Note that in this control system 100, the average load threshold A6 can also be set to a value less than the upper limit average load. For example, it is preferable to set the average load threshold A6 to 0.9 times the preset upper limit average load, but it may be set to a multiplier other than 0.9 times as long as it is less than the upper limit average load.
[0024] In this embodiment, the control system 100 further includes a notification unit 84 that notifies the manager of the automated warehouse 1. The inventory control unit 80 controls the notification unit 84 to issue a notification. Specifically, the inventory control unit 80 uses a notification threshold A8 that is set to be less than the average load threshold A6, and issues a notification via the notification unit 84 when the expected average load A5 is equal to or greater than the notification threshold A8. In this example, the notification unit 84 issues a notification when the expected average load A5 for the storage shelf 2 assigned to the item Wt to be stored is equal to or greater than the notification threshold A8. The notification unit 84 is a monitor of a management terminal (computer) of the automated warehouse 1, and the notification content is displayed on the monitor. The notification unit 84 can also be an indicator light, a buzzer, or the like. For example, the notification threshold A8 is preferably 0.9 times the average load threshold A6, but may be set to a multiplier other than 0.9 as long as it is less than the average load threshold A6.
[0025] The control system 100 also includes an information presentation unit 85 that presents information to the manager of the automated warehouse 1. The inventory control unit 80 controls the information presentation unit 85 to present information via the information presentation unit 85. The information presentation unit 85 is a monitor of a management terminal (computer) of the automated warehouse 1. That is, in this example, the information presentation unit 85 is a monitor of the same management terminal as the notification unit 84. The information presentation unit 85 may also be a monitor of a management terminal different from the notification unit 84, and may be, for example, a speaker that outputs audio information.
[0026] 4, the storing / retrieving control unit 80 calculates at least one of the number of items that can be stored per type M2, which is the number of items W that can be stored on the storage shelf 2 for each type of item W, and the number of combined item groups that can be stored M1, which is the number of combined item groups Ws that can be stored on the storage shelf 2 for each type of combined item group Ws, based on the difference between the average load threshold value A6 and the actual average load A2, and presents the calculation result to the information presentation unit 85. In this example, the storing / retrieving control unit 80 calculates both the number of items that can be stored per type M2 and the number of combined item groups that can be stored M1 for each type of storage shelf 2, and presents the calculation result to the information presentation unit 85. This allows the manager of the automated warehouse 1 to easily know how many remaining items W can be stored on each storage shelf 2. In addition, the number of items that can be stored by type M2 and the number of combined item groups that can be stored M1 are calculated based on the total load margin value obtained by multiplying the difference ΔT between the average load threshold value A6 and the actual average load A2 by the total number of items that can be stored on the target storage shelf 2.
[0027] As shown in FIGS. 2 and 5, the weight information acquisition unit 81 acquires item weight information D1 of all items W that are scheduled to be newly stored within a specific period, which is a predetermined period. In this example, the control system 100 can set various specific periods. For example, the control system 100 can change the specific period as needed, such as by hour, day, week, or month. The control system 100 can also set different specific periods for each of multiple storage shelves 2 (here, a set of storage shelves 2). Here, the weight information acquisition unit 81 acquires item weight information D1 of all items W that are scheduled to be newly stored within the specific period for each of the multiple storage shelves 2. The weight information acquisition unit 81 also acquires item weight information D1 of all items W that are scheduled to be removed within the specific period. The weight information acquisition unit 81 acquires the item weight information D1 of all items W that are scheduled to be removed within the specific period for each of the multiple storage shelves 2 at a specified time. For example, if the specific period is set to one week, the weight information acquisition unit 81 can be set to acquire, at 7:00 a.m. on Monday, from the upper controller C, item weight information D1 of all items W scheduled to be stored and retrieved within one week from each storage shelf 2. In this way, the timing for acquiring item weight information D1 within the specific period can be changed as appropriate.
[0028] Then, the actual average load calculation unit 83 calculates the after-specific-period average load A7, which is the actual average load A2 when all the items W scheduled to be newly stored within the specific period are stored (CL5). More specifically, the actual average load calculation unit 83 calculates the after-specific-period average load A7 as the actual average load A2 when all the items W scheduled to be newly stored within the specific period are stored and all the items W scheduled to be removed within the same specific period are removed. In this example, the actual average load calculation unit 83 calculates the after-specific-period average load A7 for each of the multiple storage shelves 2. Specifically, the actual total weight calculation unit 82 calculates the actual total weight A1 after the specific period based on the item weight information D1 of all the items W scheduled to be stored and removed from each storage shelf 2 within the specific period. Then, the actual average load calculation unit 83 calculates the after-specific-period average load A7 for each storage shelf 2 by dividing the actual total weight A1 after the specific period by the total number of items that can be stored.
[0029] Then, when the average load A7 after the specific period is equal to or greater than the average load threshold value A6, the inventory control unit 80 issues a notification via the notification unit 84. In this example, the system can be configured so that when the average load A7 after the specific period is equal to or greater than the average load threshold value A6 for all storage shelves 2 in the automated warehouse 1, the notification unit 84 issues a notification. It is also possible to configure the system so that the above-mentioned notification is issued for some of the multiple storage shelves 2. For example, if the specific period is set to one week, the system can be configured so that such a notification is issued at 7:00 a.m. on Monday. In this way, the timing of notification by the notification unit 84 can be changed as appropriate.
[0030] In this embodiment, as shown in FIG. 2 , the control system 100 further includes an outgoing schedule information acquisition unit 86 that acquires outgoing schedule information D2, which is information indicating the scheduled outgoing times of all items W stored on the storage shelf 2. In this example, the control device 10 includes the outgoing schedule information acquisition unit 86. As shown in FIGS. 5 , 8 , and 9 , when the average load A7 after a specific period is equal to or greater than the average load threshold A6, the incoming / outgoing control unit 80 creates a list L of items W recommended for outgoing so that the average load A7 after a specific period is less than the average load threshold A6 by preferentially selecting items W whose outgoing schedule is approaching based on the outgoing schedule information D2, and presents the created list L to the information presentation unit 85. In this example, the incoming / outgoing control unit 80 creates the list L for the storage shelves 2 of which the average load A7 after a specific period is equal to or greater than the average load threshold A6, among the multiple storage shelves 2, and presents the list L to the information presentation unit 85. The example in FIG. 8 illustrates the outgoing schedule information D2 acquired by the outgoing schedule information acquisition unit 86. In this example, the outgoing schedule information D2 includes an outgoing list R of the same-type item group Wk for each pallet to be outgoing from the storage shelf 2. This outgoing list R is created by arranging the items W in order of earliest scheduled outgoing. The second line from the top of this outgoing list R indicates that five items W with product code "B" (each weighing 4 kg) are stored on a pallet registered with pallet ID "1," and that this pallet is scheduled to be outgoing on a certain date. This outgoing list R is also created in the same way when the items W are a combined item group Ws. The incoming / outgoing control unit 80 then creates the list L based on the outgoing list R. If an outgoing schedule for each pallet is predetermined, as shown in FIG. 8, the outgoing time included in the outgoing schedule information D2 is preferably set based on information about that schedule. For items W with expiration dates or best-before dates, the outgoing time may be set based on information about such dates. In this case, the delivery time can be set to be a certain period (for example, several months) before the deadline.
[0031] FIG. 9 shows an example of list L. This list L indicates that the actual total weight A1 after the specified period will be 200 kg greater (i.e., exceeding 200 kg) than the total load threshold value obtained by multiplying the average load threshold A6 by the total number of items that can be accommodated. Items W whose release date is approaching are preferentially included in list L. In this example, list L includes items W scheduled for release on a certain month and a certain date. The third line from the top of list L indicates that five items W (each weighing 6 kg) with product code "A" are stored on a pallet with pallet ID "5." The weight of this pallet alone is 25 kg, and the total weight of the items W is 6 kg x 5 = 30 kg. In other words, if the pallet with pallet ID "5" is released based on list L, the actual total weight A1 after the specified period will be reduced by the total weight of the pallet, which is 30 kg + 25 kg = 55 kg. In this example, while items W with upcoming shipping dates are prioritized in list L so that the actual total weight A1 after the specific period is less than the total load threshold and as close as possible to the total load threshold. In the example of FIG. 9 , a pallet with pallet ID "9" is included in list L (sixth line from the top of list L in FIG. 9 ). This pallet is scheduled to be shipped on a certain date, which differs from the scheduled shipping dates (a certain date) of the other pallets included in list L. However, by including pallet ID "9" in list L, it can be seen that the actual total weight A1 after the specific period will be reduced by "203 kg" if all pallets on list L are shipped (seventh line from the top of list L in FIG. 9 ). In this way, list L of items W recommended for shipping prioritizes items W with upcoming shipping dates, but may prioritize weight over shipping date for some items W so that the average load A7 after the specific period is less than the average load threshold A6 and close to the average load threshold A6.
[0032] The following describes the control by the control system 100 based on the flowcharts of Figures 3 to 5. Here, the control system 100 executes storage / retrieval control (Figure 3), command calculation control (Figure 4), and specific period control (Figure 5). Each control will be described below.
[0033] In the warehousing / receiving control, as shown in FIG. 3, the control device 10 determines whether or not there are any items Wt scheduled to be stored (S1). Specifically, when an item Wt scheduled to be stored is placed on the storage conveyor 32a, the control device 10 determines that there are any items Wt scheduled to be stored. If the control device 10 determines that there are no items Wt scheduled to be stored (S1: No), it again determines whether or not there are any items Wt scheduled to be stored. If the control device 10 determines that there are any items Wt scheduled to be stored (S1: Yes), the weight information acquisition unit 81 acquires item weight information D1 from the upper controller C (S2). Thereafter, the control device 10 calculates an actual total weight A1 based on the item weight information D1 using the actual total weight calculation unit 82 (S3). Thereafter, the control device 10 calculates an actual average load A2 based on the actual total weight A1 using the actual average load calculation unit 83 (S4). Next, the control device 10 calculates the planned average load A5 based on the actual average load A2 and the item weight information D1 of the item Wt to be stored using the actual average load calculation unit 83 (S5). The control device 10 then determines whether the planned average load A5 is equal to or greater than the notification threshold A8 (S6). If the control device 10 determines that the planned average load A5 is equal to or greater than the notification threshold A8 (S6: Yes), the storage / retrieval control unit 80 of the control device 10 issues a notification using the notification unit 84 (S7). On the other hand, if the control device 10 determines that the planned average load A5 is not equal to or greater than the notification threshold A8 (S6: No), the notification unit 84 does not issue a notification. Thereafter, the control device 10 determines whether the planned average load A5 is less than the average load threshold A6. If the control device 10 determines that the planned average load A5 is less than the average load threshold A6 (S9: Yes), the control device 10 controls the storage / retrieval device 3 to store the item Wt to be stored. When the control device 10 determines that the expected average load A5 is not less than the average load threshold value A6 (S9: No), the control device 10 causes the goods Wt to be stored to be removed from the automated warehouse 1 (S10).
[0034] In command calculation control, as shown in FIG. 4, the control device 10 determines whether or not a calculation command has been issued (S11). For example, when an operator or the like inputs a calculation command into the management terminal of the automated warehouse 1, the control device 10 determines whether or not a calculation command has been issued. If the control device 10 determines that a calculation command has been issued (S11: Yes), it calculates the number of items that can be stored per type M2 or the number of combined item groups that can be stored M1. The operator or the like can select, on the management terminal, whether to calculate the number of items that can be stored per type M2 or the number of combined item groups that can be stored M1. Then, the inventory control unit 80 of the control device 10 presents the calculation result of the number of items that can be stored per type M2 or the number of combined item groups that can be stored M1 to the information presentation unit 85 (S13). Furthermore, if the control device 10 determines that a calculation command has not been issued (S11: No), it again determines whether or not a calculation command has been issued (S11).
[0035] In the specific period control, as shown in FIG. 5, the control device 10 determines whether it is a specified timing (period) (S14). For example, the specific period can be one day, and the specified period can be set to 7:00 AM. If the control device 10 determines that it is not the specified period (S14: No), it again determines whether it is the specified period (S14). If the control device 10 determines that it is the specified period (S14: Yes), it acquires from the upper controller C the item weight information D1 of all items W scheduled to be stored and shipped within the specific period (S15). Thereafter, the control device 10 calculates the average load A7 after the specific period using the actual average load calculation unit 83 (S16). The control device 10 determines whether the average load A7 after the specific period is equal to or greater than the average load threshold value A6 (S17). When the control device 10 determines that the average load A7 after the specific period is equal to or greater than the average load threshold value A6 (S17: Yes), the inventory control unit 80 of the control device 10 issues a notification via the notification unit 84 (S18). Thereafter, the control device 10 acquires the shipping schedule information D2 from the upper controller C (S19). Then, the inventory control unit 80 of the control device 10 creates a list L of items W that are recommended to be shipped (S20). Thereafter, the inventory control unit 80 presents the created list L to the information presentation unit 85 (S21). When the control device 10 determines that the average load A7 after the specific period is not equal to or greater than the average load threshold value A6 (S17: No), the control device 10 does not perform such control.
[0036] Other Embodiments Next, other embodiments of the control system will be described.
[0037] (1) In the above embodiment, the control system 100 has been described as including a control device 10 provided in the automated warehouse 1 and a host controller C configured to be able to communicate with the control device 10, but this is not limited thereto. For example, the control system 100 may be configured only with the control device 10 provided in the automated warehouse 1.
[0038] (2) In the above embodiment, the storage / retrieval control unit 80 is configured to cause the storage / retrieval device 3 to retrieve the items Wt to be stored when the storage of the items Wt is prohibited. However, the present invention is not limited to this. In this case, the storage / retrieval control unit 80 may be configured to stop the storage of the items Wt to be stored by the storage / retrieval device 3. The storage / retrieval control unit 80 may also be configured to allow a worker or the like to directly remove the items Wt to be stored from the storage conveyor 32a without transferring the items Wt placed on the storage conveyor 32a to the transport device 31.
[0039] (3) In the above embodiment, the storage / retrieval control unit 80 uses a notification threshold value set to a value less than the average load threshold value A6, and when the expected average load A5 is equal to or greater than the notification threshold value, a notification is issued by the notification unit 84. However, the present invention is not limited to this configuration, and the control system 100 may be configured without the notification unit 84.
[0040] (4) In the above embodiment, the inventory control unit 80 is described as being configured to be able to calculate both the number of items that can be stored per type M2 and the number of combined item groups that can be stored M1, but this is not limited to this. In this case, the inventory control unit 80 can also be configured to calculate only either the number of items that can be stored per type M2 or the number of combined item groups that can be stored M1. Also, in this example, the inventory control unit 80 performs the above calculation in response to a calculation command from a worker, etc., but the above calculation can also be performed automatically at a specific time (for example, a time, a day of the week, etc.).
[0041] (5) In the above embodiment, the actual average load calculation unit 83 is configured to calculate the average load A7 after a specific period, which is the actual average load A2 when all of the items W scheduled to be newly stored within a specific period are stored. However, without being limited to this configuration, the actual average load calculation unit 83 may be configured to calculate the actual average load A2 when only some of the items W are stored among all of the items W scheduled to be newly stored within a specific period.
[0042] (6) In the above embodiment, the actual average load calculation unit 83 is configured to calculate the average load after a specific period A7, which is the actual average load A2 when all items W scheduled to be newly stored within a specific period are stored and all items W scheduled to be destined for the same specific period are destined for the same specific period. However, without being limited to this configuration, the actual average load calculation unit 83 may be configured to separately calculate the average load after a specific period A7, which is the actual average load A2 when all items W scheduled to be destined for the same specific period are destined for the same specific period.
[0043] (7) In the above embodiment, the outgoing schedule information D2 includes an outgoing list, and the outgoing list is created by arranging the items W in order of earliest scheduled outgoing. However, the outgoing schedule information D2 is not limited to this configuration, and in addition to the outgoing list, it can also include information such as the expiration date of each item W stored on the storage shelf 2. For example, the outgoing list can be created in order of earliest expiration date of the items W.
[0044] (8) In the above embodiment, the automated warehouse 1 is provided with a plurality of storage shelves 2, and the actual total weight A1, actual average load A2, and planned average load A5 are calculated for each of the plurality of storage shelves 2. However, this is not limiting. For example, the automated warehouse 1 may be provided with a single storage shelf 2 that is divided into a plurality of sections, and the actual total weight A1, actual average load A2, and planned average load A5 are calculated for each section. In this case, each of the plurality of sections corresponds to a "storage shelf."
[0045] [Summary of the above embodiment] The control system described above will now be outlined.
[0046] A control system according to the present disclosure is a control system for controlling an automated warehouse including a storage shelf having a plurality of storage sections, each of which can store an item, and an inventory-retrieval device that stores the items in the storage shelf and retrieves the items from the storage shelf, a weight information acquisition unit that acquires item weight information indicating the weight of the items stored by the storing / retrieving device; an actual total weight calculation unit that calculates an actual total weight indicating the total weight of all the items stored on the storage shelf based on the item weight information; an actual average load calculation unit that calculates an actual average load indicating the average value of the load from the items supported by each storage section by dividing the actual total weight by the total number of storage sections that the storage shelf has; and an storing / retrieving control unit that controls the storing / retrieving device, The upper limit of the total weight of the items that can be stored on the entire storage shelf is defined as an upper limit storage weight, the value obtained by dividing the upper limit storage weight by the total number that can be stored is defined as an upper limit average load, and the items that are to be newly stored by the storage / retrieval device are defined as items to be stored, The actual average load calculation unit calculates a planned average load, which is the actual average load when the planned item is stored, every time the planned item is stored, The inventory control unit uses an average load threshold set to be equal to or less than the upper limit average load, and if the expected average load is equal to or greater than the average load threshold, prohibits the expected item from being stored in the inventory device.
[0047] According to this configuration, if the expected average load is equal to or greater than the average load threshold, items are prohibited from being stored on the storage shelves, which allows for efficient use of the storage shelves and minimizes deterioration of the storage shelves over time. Furthermore, with this configuration, an actual average load indicating the average value of the load from the items supported by each storage section is calculated, and each time an item is scheduled to be stored, a planned average load, which is the actual average load that will be applied if the item is stored, is calculated, and whether or not to prohibit the item from being stored is determined based on whether or not the planned average load is equal to or greater than the average load threshold. As a result, the actual average load calculated from the actual total weight of the items actually stored on the storage shelf will not exceed the average load threshold. This makes it possible to avoid storing items in excess of the shelf's upper limit storage weight, and to design the storage shelf so that there is less room for the weight of items that need to be stored on the shelf. In this way, according to this configuration, it is possible to increase the efficiency with which items can be stored on the storage shelves while also making it easier to reduce the size and cost of the automated warehouse.
[0048] Here, when the inventory control unit prohibits the entry of the item to be stored, it is preferable that the inventory control unit stops the entry of the item to be stored by the inventory control device, or causes the item to be stored to be released by the inventory control device.
[0049] According to this configuration, it is possible to appropriately prevent items from being stored in the storage shelf in excess of the upper limit storage weight of the storage shelf.
[0050] The automated warehouse further includes a notification unit that notifies a manager of the automated warehouse. It is preferable that the storage / retrieval control unit uses a notification threshold value set to be less than the average load threshold value, and when the expected average load becomes equal to or greater than the notification threshold value, a notification is issued by the notification unit.
[0051] According to this configuration, the notification unit notifies the manager that the expected average load is approaching the average load threshold value, which makes it easier to take measures such as changing the schedule for items entering and leaving the automated warehouse.
[0052] The automated warehouse further includes an information presentation unit that presents information to a manager of the automated warehouse, There are multiple types of the article with different weights, A combination of a plurality of types of the items set in advance is defined as a combined item group, and the combined item group includes a plurality of types of items with different weights, It is preferable that the inventory control unit calculates at least one of the number of items that can be stored per type, which is the number of items that can be stored on the storage shelf for each type of item, and the number of combined item groups that can be stored, which is the number of combined item groups that can be stored on the storage shelf for each type of combined item group, based on the difference between the average load threshold value and the actual average load, and presents the calculation result to the information presentation unit.
[0053] According to this configuration, based on the information presented by the information presentation unit, the manager can know at least one of the number of items that can be stored per type, which is the number of items that can be stored on a storage shelf for each type of item, and the number of combined item groups that can be stored, which is the number of combined item groups that can be stored on a storage shelf for each preset combined item group. Therefore, the manager can easily know how many more items can be stored in the automated warehouse.
[0054] The automated warehouse further includes a notification unit that notifies a manager of the automated warehouse. the weight information acquisition unit acquires the item weight information of all the items that are scheduled to be newly stored within a specific period that is a predetermined period, the actual average load calculation unit calculates an average load after a specific period, which is the actual average load when all of the items scheduled to be newly stored within the specific period are stored; It is preferable that the storage / retrieval control unit issues a notification by the notification unit when the average load after the specific period is equal to or greater than the average load threshold value.
[0055] According to this configuration, the manager can know in advance that the average load after the specific period, which is the actual average load when all items scheduled to be stored within the specific period, will be equal to or greater than the average load threshold value. Therefore, it becomes easy for the manager to take measures such as changing the schedule of items to be stored in and out of the automated warehouse.
[0056] Further, the weight information acquisition unit acquires the item weight information of all the items scheduled to be released within the specific period, It is preferable that the actual average load calculation unit calculates, as the average load after the specified period, the actual average load when all of the items scheduled to be newly stored within the specified period have been stored and all of the items scheduled to be destined for the same specified period have been destined for the same specified period.
[0057] According to this configuration, the average load after a specific period is calculated taking into account not only all items scheduled to be stored within a specific period, but also all items scheduled to be shipped out within the same specific period, thereby improving the accuracy of the average load after a specific period.
[0058] The automated warehouse further includes an information presentation unit that presents information to a manager of the automated warehouse, and an outgoing schedule information acquisition unit that acquires outgoing schedule information that is information indicating the scheduled outgoing dates of all the items stored on the storage shelves, When the average load after the specified period is equal to or greater than the average load threshold, the inventory control unit preferably creates a list of items that are recommended to be shipped in order to make the average load after the specified period less than the average load threshold by preferentially selecting items whose shipping date is approaching based on the shipping schedule information, and presents the created list to the information presentation unit.
[0059] According to this configuration, when the average load after the specific period, taking into account all items scheduled to be newly received within the specific period and all items scheduled to be destined for the specific period, is equal to or greater than the average load threshold, a list of items that are recommended to be destined for the specific period so as to make the average load after the specific period less than the average load threshold can be presented to the manager. Therefore, since the manager can use the list of items, it becomes easy to take measures to make the average load after the specific period equal to or less than the average load threshold.
[0060] The automated warehouse includes a plurality of the storage shelves and the loading / unloading device common to the plurality of storage shelves, the actual total weight calculation unit calculates the actual total weight for each of the plurality of storage shelves, the actual average load calculation unit calculates the actual average load and the planned average load for each of the plurality of storage shelves, It is preferable that the inventory control unit prohibits the inventory device from storing the items scheduled to be stored on the excess storage shelf if there is an excess storage shelf among the multiple storage shelves, which is a storage shelf where the scheduled average load is equal to or greater than the average load threshold value.
[0061] According to this configuration, even if the automated warehouse has multiple storage shelves, storing items in the excess storage shelves among the multiple storage shelves is prohibited. Therefore, each storage shelf can be used efficiently and deterioration over time can be minimized. Furthermore, with this configuration, it is possible to prevent each storage shelf from storing items exceeding its upper limit storage weight, and it is possible to design all storage shelves so that there is little margin for the weight of items that need to be stored on the storage shelf. Therefore, even when multiple storage shelves are installed, it is possible to easily achieve size and cost reduction for the entire automated warehouse.
[0062] It is sufficient for the control system according to the present disclosure to achieve at least one of the above-described effects. [Explanation of symbols]
[0063] 1: Automated warehouse 2: Storage shelf 3: Storage and retrieval equipment 12: Overstock shelf 20: Storage section 80: Storage and retrieval control unit 81: Weight information acquisition section 82:Actual total weight calculation section 83: Actual average load calculation section 84:Notification Department 85: Information presentation section 86: Delivery schedule information acquisition unit 100: Control System A1: Actual total weight A2: Actual average load A5: Planned average load A6: Average load threshold A7: Average load after specific period A8: Notification threshold D1: Goods weight information D2: Scheduled delivery information L : list M1: Number of combinations of items that can be stocked M2: Number of items that can be stored by type W:Goods Ws: Combination item group Wt: Items to be stocked
Claims
1. A control system for controlling an automated warehouse including a storage shelf having a plurality of storage sections, each of which can store an item, and an inventory-retrieval device that stores the items in the storage shelf and retrieves the items from the storage shelf, a weight information acquisition unit that acquires item weight information indicating the weight of the items stored by the storing / retrieving device; an actual total weight calculation unit that calculates an actual total weight indicating the total weight of all the items stored on the storage shelf based on the item weight information; an actual average load calculation unit that calculates an actual average load indicating the average value of the load from the items supported by each storage section by dividing the actual total weight by the total number of storage sections that the storage shelf has; and an storing / retrieving control unit that controls the storing / retrieving device, The upper limit of the total weight of the items that can be stored on the entire storage shelf is defined as an upper limit storage weight, the value obtained by dividing the upper limit storage weight by the total number that can be stored is defined as an upper limit average load, and the items that are to be newly stored by the storage / retrieval device are defined as items to be stored, The actual average load calculation unit calculates a planned average load, which is the actual average load when the planned item is stored, every time the planned item is stored, The inventory control unit uses an average load threshold set to be equal to or less than the upper limit average load, and if the planned average load is equal to or greater than the average load threshold, prohibits the item to be stored from being stored in the inventory control device.
2. The control system of claim 1, wherein the inventory control unit, when prohibiting the entry of the item scheduled to be stored, stops the entry of the item scheduled to be stored by the inventory device, or causes the item scheduled to be stored to be released by the inventory device.
3. A notification unit that notifies a manager of the automated warehouse is further provided, The control system according to claim 1 or 2, wherein the inventory control unit uses a notification threshold set to be less than the average load threshold, and when the planned average load becomes equal to or greater than the notification threshold, a notification is issued by the notification unit.
4. An information presentation unit that presents information to a manager of the automated warehouse is further provided, There are multiple types of the article with different weights, A combination of a plurality of types of the items set in advance is defined as a combined item group, and the combined item group includes a plurality of types of items with different weights, The control system described in claim 1 or 2, wherein the inventory control unit calculates at least one of the number of items that can be stored per type, which is the number of items that can be stored on the storage shelf for each type of item, and the number of combined item groups that can be stored, which is the number of combined item groups that can be stored on the storage shelf for each type of combined item group, based on the difference between the average load threshold value and the actual average load, and presents the calculation result to the information presentation unit.
5. A notification unit that notifies a manager of the automated warehouse is further provided, the weight information acquisition unit acquires the item weight information of all the items that are scheduled to be newly stored within a specific period that is a predetermined period, the actual average load calculation unit calculates an average load after a specific period, which is the actual average load when all of the items scheduled to be newly stored within the specific period are stored; The control system according to claim 1 or 2, wherein the storage / retrieval control unit issues a notification by the notification unit when the average load after the specific period is equal to or greater than the average load threshold value.
6. the weight information acquisition unit acquires the item weight information of all the items scheduled to be released within the specific period, 6. The control system according to claim 5, wherein the actual average load calculation unit calculates, as the average load after the specific period, the actual average load when all of the items scheduled to be newly stored within the specific period have been stored and all of the items scheduled to be despatched within the same specific period have been despatched.
7. an information presentation unit that presents information to a manager of the automated warehouse; and an outgoing schedule information acquisition unit that acquires outgoing schedule information that is information indicating the scheduled outgoing dates of all the items stored on the storage shelves, 7. The control system of claim 6, wherein the inventory control unit creates a list of items that are recommended to be shipped in order to make the average load after the specific period less than the average load threshold value by preferentially selecting items whose shipping date is approaching based on the shipping schedule information, when the average load after the specific period is greater than or equal to the average load threshold value, and presents the created list to the information presentation unit.
8. the automated warehouse includes a plurality of the storage shelves and the loading / unloading device common to the plurality of storage shelves, the actual total weight calculation unit calculates the actual total weight for each of the plurality of storage shelves, the actual average load calculation unit calculates the actual average load and the planned average load for each of the plurality of storage shelves, 3. The control system according to claim 1, wherein the inventory control unit prohibits the inventory device from storing the items scheduled to be stored on the excess storage shelf if there is an excess storage shelf among the plurality of storage shelves, the excess storage shelf being a storage shelf where the scheduled average load is equal to or greater than the average load threshold value.
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