Goods sorting equipment

Abstract

To provide an article sorting facility that facilitates efficient transfer of storage containers by a transfer system when a group of stacked containers is brought into a work area by a transfer system.SOLUTION: The article sorting facility includes a conveying system and a control system. When the control system causes the conveying system to execute a batch carrying-in process for carrying storage containers 1 necessary for sorting work included in each of a plurality of batches into a work area A in the order in which the plurality of batches are processed, the control system causes the conveying system to execute a second carrying-in process for carrying a stacked container group 12, some of which are storage containers 1 belonging to the first batch and the rest are storage containers 1 belonging to the second batch, into the work area A between a first carrying-in process for carrying a stacked container group 11, some or all of which are storage containers belonging to the first batch, into the work area A and a third carrying-in process for carrying a stacked container group 13, some or all of which are storage containers 1 belonging to the second batch, into the work area A.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to an item sorting facility that includes a container storage facility in which multiple storage containers are stored, a work area in which sorting work is carried out to remove items contained in the storage containers and sort them into multiple collection containers, and a conveying system that transports the storage containers from the container storage facility to the work area. [Background technology]

[0002] An example of an article sorting facility for sorting articles is disclosed in Japanese Patent Laid-Open No. 2002-154605 (Patent Document 1). In the following description of this background art, reference numerals from Patent Document 1 will be quoted in parentheses. The facility disclosed in Patent Document 1 is configured so that articles released from an automated warehouse (11) are supplied to an article sorting area (13) where articles are sorted by shipping destination. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2002-154605 Summary of the Invention [Problem to be solved by the invention]

[0004] In an article sorting facility, it is conceivable that a group of stacked containers, in which storage containers required for sorting work are stacked, is carried into a work area where the sorting work is performed (a material handling area in Patent Document 1) by a conveyance system. When carrying a group of stacked containers into the work area in this way by a conveyance system, it is desirable that the conveyance system transport the storage containers with high efficiency. However, Patent Document 1 does not mention this point.

[0005] Therefore, it is desirable to realize a technology that can easily improve the efficiency of transporting storage containers by a transport system when a group of stacked containers is transported to a work area by the transport system. [Means for solving the problem]

[0006] The item sorting equipment according to the present disclosure is an item sorting equipment including: a container storage facility in which a plurality of storage containers are stored; a work area in which a sorting operation is performed in which items contained in the storage containers are removed and sorted into a plurality of collection containers; a transport system that transports the storage containers from the container storage facility to the work area and transports the storage containers from the work area to the container storage facility; and a control system that controls the transport system, wherein the storage containers are configured to be stackable in the vertical direction, and the transport system is configured to create a stacked container group in which a predetermined number of the storage containers are stacked, and transport the stacked container group to the work area, and the control system is configured to group the sorting operation for the predetermined number of collection containers into one batch, and to sort the items contained in the plurality of collection containers into one batch. When the conveying system is caused to execute a batch delivery process in which the storage containers required for the sorting work included in each batch are delivered to the work area in the order in which the multiple batches are processed, one of the batches is designated as a first batch, and the batch processed after the first batch is designated as a second batch, and between a first delivery process in which the stacked container group, some or all of which are storage containers belonging to the first batch, is delivered to the work area, and a third delivery process in which the stacked container group, some or all of which are storage containers belonging to the second batch, is delivered to the work area, the conveying system is caused to execute a second delivery process in which the stacked container group, some of which are storage containers belonging to the first batch and the remainder are storage containers belonging to the second batch, is delivered to the work area.

[0007] According to this configuration, when storage containers required for sorting operations included in each of multiple batches are transported to the work area in a stacked container group with a set number of tiers in the order in which the multiple batches are processed, it is possible to generate stacked container groups that contain a mixture of storage containers belonging to two batches that are processed in different (consecutive) orders, rather than generating only stacked container groups separated by batch. This reduces the need to generate stacked container groups with fewer tiers than the set number, thereby making it easier to improve the efficiency with which the transport system transports storage containers. As described above, according to this configuration, when stacked container groups are transported to the work area by the control system, it is easier to improve the efficiency with which the transport system transports storage containers.

[0008] Further features and advantages of the article sorting installation will become apparent from the following description of an embodiment thereof, which is given with reference to the drawings. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a plan view of a portion of an article sorting facility according to a first embodiment; [Figure 2] 1 is a side view of a transport vehicle according to a first embodiment; [Figure 3] 1 is a plan view of a work area according to a first embodiment; [Figure 4] 1 is a perspective view of a work area according to a first embodiment; [Figure 5] Control block diagram according to the first embodiment [Figure 6] 1 is an explanatory diagram of a batch carry-in process according to a first embodiment; [Figure 7] 1 is an explanatory diagram of a batch carry-in process according to a first embodiment; [Figure 8] 10 is a plan view of a work area according to a second embodiment; [Figure 9] FIG. 10 is a plan view showing a part of a work area according to a third embodiment; [Figure 10] 10 is a plan view of a work area according to a third embodiment; [Figure 11] 10 is a perspective view of a work area according to a third embodiment; [Figure 12]Plan view of a work area according to a fourth embodiment [Figure 13] 10 is a perspective view of a work area according to a fourth embodiment; DETAILED DESCRIPTION OF THE INVENTION

[0010] [First embodiment] A first embodiment of an article sorting facility will be described with reference to the drawings (FIGS. 1 to 7). As shown in FIGS. 1 and 5, the article sorting facility 100 includes a container storage facility 8, a work area A, and a conveying system 40. The article sorting facility 100 further includes a control system 5 (see FIG. 5) that controls the conveying system 40. In the following, two mutually orthogonal horizontal directions are referred to as the X direction and the Y direction. One side in the X direction is referred to as the X direction first side X1, and the other side in the X direction is referred to as the X direction second side X2. One side in the Y direction is referred to as the Y direction first side Y1, and the other side in the Y direction is referred to as the Y direction second side Y2.

[0011] A plurality of storage containers 1 are stored in the container storage facility 8. As shown in FIG. 1, the container storage facility 8 is equipped with a storage shelf 9 for storing the storage containers 1. The storage containers 1 are stored in the storage shelf 9 while being supported on the shelf portion of the storage shelf 9. Details are omitted, but in the example shown in FIG. 1, the storage shelf 9 is configured as follows. The shelf portion is configured to support a plurality of storage containers 1 lined up in the shelf width direction (Y direction in the example shown in FIG. 1). The shelf portions are arranged in multiple levels so as to be lined up in the Z direction, which is the up-down direction (vertical direction), and the storage shelf 9 is configured to be able to store storage containers 1 on each of the multiple levels (tiers).

[0012] The storage container 1 is formed in a box shape (here, a box shape with an open top). As shown in FIG. 4, the storage container 1 is configured to be stackable in the Z direction. A storage container 1 is stacked on another storage container 1 by fitting the bottom of the storage container 1 into the opening at the top of the other storage container 1. The storage containers 1 are configured to be stackable with items 4 stored therein.

[0013] The storage container 1 contains items 4 such as products or parts. Here, the storage container 1 contains multiple items 4 of one or more types. For example, the storage container 1 contains multiple types of items 4, each containing multiple items of each type. The storage container 1 may contain multiple items 4 of a single type, or may contain one item 4 of each of multiple types. The type (category, item) of the item 4 refers to a classification of the items 4 to be handled by the item sorting equipment 100, divided according to predetermined criteria. For example, the type of the item 4 can be classified based on the smallest management unit (SKU) of the item 4, that is, the smallest management unit when managing inventory of the item 4. The type of the item 4 can also be classified based on the identification code of the item 4 (for example, a product identification code such as a JAN code or an EAN code).

[0014] The transport system 40 is configured to transport storage containers 1 from the container storage facility 8 to the work area A, and to transport storage containers 1 from the work area A to the container storage facility 8. As shown in FIG. 1, the transport system 40 includes a conveyor (here, a first conveyor 41) that transports the storage containers 1 within the work area A, and a transport vehicle 90 that transports the storage containers 1 outside the work area A. The transport vehicle 90 transports a stacked container group 10 made up of a plurality of storage containers 1 stacked on top of each other.

[0015] 1, the first conveyor 41 includes an inlet section 50 that receives storage containers 1 (here, stacked container groups 10) that have been carried into the work area A from the container storage facility 8, and an outlet section 60 that carries out storage containers 1 (here, stacked container groups 10) bound for the container storage facility 8 from the work area A. A transport vehicle 90 transports the storage containers 1 (here, stacked container groups 10) from the container storage facility 8 to the inlet section 50, and transports the storage containers 1 (here, stacked container groups 10) from the outlet section 60 to the container storage facility 8.

[0016] The container storage facility 8 (specifically, storage shelves 9) is configured to store a plurality of storage containers 1 in a state where they are separated from one another. A transport vehicle 90 stacks a plurality of storage containers 1 taken out from the storage shelves 9 to form a stacked container group 10, and transports the stacked container group 10 to the loading section 50. The transport vehicle 90 also transports the stacked container group 10 received from the unloading section 60 to the container storage facility 8, and stores the plurality of storage containers 1 that make up the stacked container group 10 in the storage shelves 9 in a state where they are separated from one another.

[0017] The guided vehicle 90 may be an automated guided vehicle that travels autonomously or remotely, or may be a manned guided vehicle (e.g., a forklift) that is driven and operated by an operator. In this embodiment, the guided vehicle 90 is an automated guided vehicle that travels autonomously. The guided vehicle 90 may be a rail-guided vehicle (e.g., a stacker crane) that travels along rails installed on the floor or the like, or a non-rail guided vehicle such as an AGV (Automated Guided Vehicle) or an AMR (Autonomous Mobile Robot). When the guided vehicle 90 is a non-rail guided vehicle, the guided vehicle 90 travels along a virtually formed travel path P rather than a physically formed travel path P using rails or the like (see FIG. 1). For example, a plurality of detectable objects such as two-dimensional codes or RF (Radio Frequency) tags are installed on the floor, and the travel path P is virtually formed to connect the plurality of detectable objects. A configuration may also be adopted in which such detectable objects are not installed on the floor, and the travel path P is virtually formed by a route calculated based on the recognition results of the surrounding environment.

[0018] The transport vehicle 90 illustrated in Fig. 2 is configured as follows. The transport vehicle 90 includes a traveling body 93, a support unit 94, a first transfer device 91, and a second transfer device 92. The transport vehicle 90 further includes a lifting device 95. The support unit 94, the first transfer device 91, the second transfer device 92, and the lifting device 95 are all mounted on the travel vehicle 93.

[0019] The running body 93 is configured to run on a floor surface. Although details are omitted, the running body 93 runs by rotating drive wheels using a drive power source such as an electric motor. The running body 93 has a pair of left and right drive wheels, and is configured to turn by rotating the pair of left and right drive wheels in opposite directions.

[0020] The support section 94 supports the stacked container group 10. The support section 94 can also support a single storage container 1. In this example, the conveyor that constitutes the second transfer device 92 constitutes the support section 94. Specifically, the conveying surface of the conveyor that constitutes the second transfer device 92 constitutes the support surface for the stacked container group 10 at the support section 94. The conveying surface of the conveyor is, for example, constituted by a plane (imaginary plane) that includes the upper ends of each of the multiple rollers that constitute the conveyor, or is constituted by the upper surface of the belt that constitutes the conveyor.

[0021] The second transfer device 92 transfers the storage container 1 (here, the stacked container group 10) between the support section 94 and the carry-in section 50. The second transfer device 92 also transfers the storage container 1 (here, the stacked container group 10) between the support section 94 and the carry-out section 60. In FIGS. 1 and 3, the transfer operation of the stacked container group 10 by the second transfer device 92 is indicated by a hollow arrow as the second transfer operation M2. The second transfer operation M2 includes the transfer operation of the stacked container group 10 by the second transfer device 92 from the transport vehicle 90 (in this example, the support section 94) to the carry-in section 50, and the transfer operation of the stacked container group 10 by the second transfer device 92 from the carry-out section 60 to the transport vehicle 90 (in this example, the support section 94).

[0022] In this embodiment, the second transfer device 92 is configured to transfer the stacked container group 10 between the transfer target locations (here, the carry-in section 50 and the carry-out section 60) by moving the stacked container group 10 in the vehicle width direction (a horizontal direction perpendicular to the traveling direction of the transport vehicle 90, and a direction perpendicular to the plane of the paper in FIG. 2). In this example, the second transfer device 92 is equipped with a conveyor (e.g., a roller conveyor or a belt conveyor) that transports the stacked container group 10 in the vehicle width direction. Alternatively, the second transfer device 92 may be a fork-type transfer device equipped with forks that support and move in and out of the stacked container group 10. In this specification, a member that supports a supported object and is moved in and out by a moving in and out device is referred to as a "fork," and the term "fork" is not limited to a specific shape.

[0023] The lifting device 95 is mounted on a running body 93 so as to be able to rise and fall. The lifting device 95 is configured to lift a storage container 1 at any tier (any height) among the multiple storage containers 1 that make up the stacked container group 10 supported by the support part 94. By lifting a storage container 1 at any tier using the lifting device 95 in this way, the storage container 1 at that tier can be separated from the storage container 1 one tier below it. Note that if one or more other storage containers 1 are stacked on top of the storage container 1 that the lifting device 95 is lifting, those other one or more storage containers 1 are also lifted.

[0024] A group of storage containers 1 in multiple tiers lifted by the lifting device 95 is considered a target container group, and in this example, the lifting device 95 is configured to be able to form a space in the Z direction between the storage containers 1 in two adjacent tiers in the target container group (here, between the storage container 1 in the lowest tier and the storage container 1 one tier above it). FIG. 2 shows the lifting device 95 lifting a target container group consisting of a group of two tiers of storage containers 1, and a space in the Z direction is formed between the storage container 1 in the lowest tier that makes up the target container group and the storage container 1 one tier above that (here, the storage container 1 in the top tier that makes up the target container group). As will be described later, FIG. 2 shows the first transfer device 91 moving a storage container 1 (storage container 1 with a circled "2") into the space thus formed.

[0025] The first transfer device 91 transfers the storage container 1 between the storage shelf 9 provided in the container storage facility 8 and the stacked container group 10 supported by the support part 94. In FIG. 1, the transfer operation of the storage container 1 by the first transfer device 91 is indicated by a white arrow as the first transfer operation M1. The first transfer operation M1 includes the operation of transferring the storage container 1 from the storage shelf 9 to the stacked container group 10 supported by the support part 94, and the operation of transferring the storage container 1 from the stacked container group 10 supported by the support part 94 to the storage shelf 9.

[0026] When transferring a storage container 1 from a storage shelf 9 to a stacked container group 10 supported by a support portion 94, a first transfer device 91 removes the storage container 1 from the storage shelf 9 and adds the storage container 1 to one of the tiers of the stacked container group 10 supported by the support portion 94. The first transfer device 91 is mounted on a traveling body 93 so as to be able to move up and down. The first transfer device 91 removes the storage container 1 while being raised and lowered to a height corresponding to the shelf tier on which the storage container 1 to be removed is stored. The first transfer device 91 then removes the storage container 1 while being raised and lowered to a height corresponding to the tier in the stacked container group 10 supported by the support portion 94 to which the storage container 1 will be added, and adds the storage container 1 to that tier. In this example, because the transport vehicle 90 is equipped with a lifting device 95, the first transfer device 91 can add the storage container 1 not only to the top tier of the stacked container group 10 supported by the support portion 94 but also to any tier (specifically, the tier below the storage container 1 lifted by the lifting device 95).

[0027] When transferring a storage container 1 from the stacked container group 10 supported by the support parts 94 to the storage shelf 9, the first transfer device 91 removes the storage container 1 from any one of the levels of the stacked container group 10 supported by the support parts 94, and then stores the storage container 1 on the storage shelf 9. The first transfer device 91 lifts or lowers the storage container 1 to a height corresponding to the level from which the storage container 1 is to be removed in the stacked container group 10 supported by the support parts 94, and then removes the storage container 1 from that level. In this example, because the transport vehicle 90 is equipped with a lifting device 95, the first transfer device 91 can remove the storage container 1 not only from the top level of the stacked container group 10 supported by the support parts 94, but also from any level (specifically, the level below the storage container 1 lifted by the lifting device 95). The first transfer device 91 then lifts or lowers the storage container 1 to a height corresponding to the shelf level on which the storage container 1 is to be stored, and then stores the storage container 1 on that shelf.

[0028] In this embodiment, the first transfer device 91 is a push-pull type transfer device. The first transfer device 91 delivers the storage container 1 to the transfer target location (here, the storage shelf 9 and the stacked container group 10) by pushing the storage container 1, and receives the storage container 1 from the transfer target location by pulling in the storage container 1. Alternatively, the first transfer device 91 may be a fork type transfer device equipped with forks that support the storage container 1 and move forward and backward.

[0029] The first transfer device 91 is mounted on a traveling body 93 so as to be rotatable about an axis along the Z direction. By rotating the first transfer device 91 about an axis along the Z direction, the posture of the first transfer device 91 can be switched between a posture for transferring a storage container 1 between the storage shelf 9 (in this example, a posture facing the width direction of the vehicle body) and a posture for transferring a storage container 1 between the stacked container group 10 supported by the support part 94 (in this example, a posture facing the fore-and-aft direction of the vehicle body). Here, the fore-and-aft direction of the vehicle body is the horizontal direction along the traveling direction of the transport vehicle 90, and is the left-right direction in FIG. 2.

[0030] In this example, the first transfer device 91 is configured to be able to concurrently transfer two storage containers 1. Figure 2 shows a state in which, while the lifting device 95 is lifting two storage containers 1, the first transfer device 91 concurrently removes the storage container 1 one level below these two storage containers 1 (storage container 1 marked with a circled "1") and adds a storage container 1 (storage container 1 marked with a circled "2") between these two storage containers 1.

[0031] The operation of the transport system 40 is controlled by a control system 5 (see FIG. 5). The control system 5 controls the operation of a device to be controlled by controlling the driving of a drive power source (e.g., an electric motor) provided in the device. Each function of the control system 5 is realized by cooperation between hardware such as an arithmetic processing unit and a program executed on the hardware. The control system 5 may be configured not by a single piece of hardware, but by a collection of multiple pieces of hardware (multiple separate pieces of hardware) that can communicate with each other. Furthermore, a device to be controlled by the control system 5 (e.g., a controller provided in the device) may constitute at least a part of the control system 5.

[0032] The various technical features of the control system 5 disclosed in this specification are also applicable to a method for controlling the conveying system 40 and a program for controlling the conveying system 40 (a program for causing a computer to function as the control system 5), and such methods and programs, as well as storage media on which such programs are stored (e.g., computer-readable storage media such as flash memory of an optical disk), are also disclosed by this specification.

[0033] The work area A is an area where a sorting operation is performed in which the items 4 stored in the storage container 1 are removed and sorted into a plurality of collection containers 2. As will be described later, in this embodiment, a worker performs the sorting operation in the work area A. For this reason, an instruction output device 6 (see FIG. 5) that outputs work instructions to the worker is disposed in the work area A. Although the instruction output device 6 is not shown in FIGS. 3 and 4, the instruction output device 6 is, for example, a display (monitor). The control system 5 controls the instruction output device 6 in addition to the conveyance system 40. The instruction output device 6 may be a monitor of a mobile terminal carried by the worker, or may be smart glasses (a display device integrated with eyeglasses) if the worker is wearing such glasses.

[0034] In the work area A, the storage container 1 is transported by a first conveyor 41 (e.g., a roller conveyor or a belt conveyor) provided in the transport system 40. The first conveyor 41 has a transport section 70 that transports the storage container 1 from the loading section 50 to the unloading section 60. The first conveyor 41 transports the storage container 1 in one direction (transport direction T shown in FIG. 3). In this embodiment, the transport section 70 does not branch, and the transport section 70 does not have a branch section 80 or a junction section 81 (see FIGS. 9 and 12) described below.

[0035] 3, the conveying section 70 of the first conveyor 41 includes an inlet section extending from the inlet section 50 toward the second side Y2 in the Y direction, an outlet section extending toward the first side Y1 in the Y direction toward the outlet 60, and an intermediate section connecting the inlet section and the outlet section. In this example, the outlet 60 is disposed on the second side X2 in the X direction relative to the inlet section 50, and the outlet section is disposed on the second side X2 in the X direction relative to the inlet section. In this example, the outlet 60 is disposed at the same position in the Y direction as the inlet section 50. In addition, in this example, the intermediate section includes an upstream section extending from the inlet section toward the second side X2 in the X direction, and a downstream section disposed on the first side Y1 in the Y direction relative to the upstream section and extending toward the first side X1 in the X direction toward the outlet section. Although details are omitted, at the point where the conveying direction T on the first conveyor 41 changes, for example, a conveying mechanism that conveys the storage container 1 in the X direction, a conveying mechanism that conveys the storage container 1 in the Y direction, and a lifting mechanism that raises and lowers these two conveying mechanisms relative to each other are provided.

[0036] As shown in Figures 3 and 4, work area A is equipped with an outgoing container placement section 23 and a collection container placement section 25. In this embodiment, work area A further includes a processing item placement section 20 and an incoming container placement section 24. Note that work area A may be configured to not include either or both of the processing item placement section 20 and the incoming container placement section 24. If work area A does not include the incoming container placement section 24, work area A also does not include the incoming work area A2, which will be described later.

[0037] The outgoing container placement section 23 is where a storage container 1 that has been transported from the container storage facility 8 to the work area A by the conveying system 40 is placed. Hereinafter, the storage container 1 placed in the outgoing container placement section 23 will be referred to as the "first container 1a" to distinguish it from other storage containers 1. The outgoing container placement section 23 is a predetermined area on the first conveyor 41. In this embodiment, the outgoing container placement section 23 is a predetermined area on the above-mentioned intermediate section (specifically, the upstream section) of the first conveyor 41. In this embodiment, this area is set to a size that allows one storage container 1 to be placed therein.

[0038] The work area A includes a take-out work area A1. As will be described later, the work area A further includes a storage work area A2, a processing work area A3, and a sorting work area A4. Each of the areas included in the work area A is at least conceptually defined. Therefore, the multiple areas included in the work area A do not need to be different from each other; multiple areas may partially overlap, or multiple areas may be the same area. For example, the processing work area A3 and the sorting work area A4 may be different from each other, but in this embodiment, the processing work area A3 and the sorting work area A4 are the same area, as shown in Figures 3 and 4.

[0039] In the take-out operation area A1, a take-out operation (picking operation) is performed to take out items 4 from a storage container 1 (first container 1a) placed in the output container placement section 23. Therefore, the output container placement section 23 is a stopping position on the first conveyor 41 where the storage container 1 is stopped for the take-out operation. In the take-out operation, the items 4 stored in the storage container 1 are taken out through an opening in the top surface of the storage container 1. As shown in FIG. 3 , in this embodiment, the take-out operation in the take-out operation area A1 is performed by one or more first workers 31. Therefore, for example, instructions for the take-out operation (e.g., information about the type of items 4 to be taken out and information about the number of items 4 to be taken out) are displayed on an instruction output device 6 that is visible to the first worker 31. Note that the take-out operation may be performed by a robot instead of the first worker 31, or the take-out operation may be performed by a collaboration between the first worker 31 and the robot.

[0040] In this embodiment, the items 4 are stored in a container 3 such as a bag, and are then stored in the storage container 1. For example, the container 3 stores a plurality of items 4 of the same type. In the removal operation, the items 4 are removed from the storage container 1 together with the container 3 in which the items 4 are stored. In other words, in the removal operation, the items 4 are not removed piece by piece (piece picking), but are removed by type (item picking).

[0041] In this embodiment, the carry-in section 50 receives the stacked container group 10 from the transport vehicle 90. For this reason, the work area A is equipped with a de-stacking device 44 that separates the stacked container group 10 received in the carry-in section 50 into individual storage containers 1. The de-stacking device 44 is arranged downstream of the carry-in section 50 and upstream of the outgoing container placement section 23. In this embodiment, the de-stacking device 44 is arranged in the above-mentioned carry-in section side section of the first conveyor 41. The storage containers 1 separated from the stacked container group 10 by the de-stacking device 44 are transported sequentially to the outgoing container placement section 23. The de-stacking device 44 is configured to, for example, sequentially separate and carry out the lowest storage container 1 in the stacked container group 10. Although details are omitted, the de-tiering device 44 includes, for example, a first lifting device that holds and raises and lowers the stacked container group 10, and a second lifting device that holds and raises and lowers the storage container 1 on the lowest level of the stacked container group 10.

[0042] A plurality of collection containers 2 are placed in the collection container placement section 25. The collection container 2 is formed in a box shape (here, a box shape with an open top). In this embodiment, the collection container placement section 25 is a shelf on which a plurality of collection containers 2 can be arranged side by side. As shown in FIG. 4 , in this embodiment, the work area A includes a plurality of collection container placement sections 25. The plurality of collection container placement sections 25 are arranged at different positions (heights) in the Z direction and are arranged so as to overlap each other when viewed in the Z direction (viewed in a direction along the Z direction, i.e., in a plan view). Here, the work area A includes two collection container placement sections 25. Specifically, as shown in FIG. 4 , a shelf section that constitutes one collection container placement section 25 and a shelf section that constitutes another collection container placement section 25 are arranged at different positions in the Z direction and are arranged so as to overlap each other when viewed in the Z direction.

[0043] In this embodiment, the product collection container placement section 25 is configured so that multiple collection containers 2 are lined up in parallel with the conveying direction T of the storage containers 1 in the outgoing container placement section 23. The conveying direction T of the storage containers 1 can also be referred to as the arrangement direction of the storage containers 1. As shown in FIG. 3 , in this embodiment, the conveying direction T of the storage containers 1 in the outgoing container placement section 23 is the X direction. The product collection container placement section 25 is configured so that multiple collection containers 2 are lined up in parallel with the X direction. Here, the product collection container placement section 25 is disposed on the second side Y2 in the Y direction relative to the outgoing container placement section 23. By configuring the product collection container placement section 25 in this manner, the product collection container placement section 25 can be disposed adjacent to and in parallel with a section of the first conveyor 41 that is disposed to extend in the X direction and includes the outgoing container placement section 23 (here, the above-mentioned intermediate section, specifically the upstream section). This makes it possible to reduce the space required to install the outgoing container placement section 23 and the product collection container placement section 25. In this embodiment, the product collection container arrangement section 25 is configured so that the multiple product collection containers 2 are lined up in parallel with the conveyance direction T (here, the X direction) of the storage container 1 in the incoming container arrangement section 24.

[0044] The work area A includes a processing work area A3. In the processing work area A3, the items 4 removed by the removal work are subjected to processing work for shipping (hereinafter simply referred to as "processing work"). The processing work is, for example, the work of processing the items 4, such as merchandise, to suit the shipping form (i.e., the work of carrying out distribution processing). The distribution processing is, for example, packaging, subdivision, replacing the identification tag (shipping label), processing parts, assembling parts, measuring weight, inspection, etc.

[0045] In this embodiment, the items 4 removed by the removal operation are placed in the processing item placement section 20 for the processing operation. In this embodiment, the processing item placement section 20 is a workbench for performing the processing operation. In the example shown in FIG. 3, the items 4 removed by the removal operation are placed on a cart 7 together with the container 3 containing the items 4 and transported from the removal operation area A1 to the processing operation area A3, and then the container 3 is placed in the processing item placement section 20. Then, the processing operation is performed on the items 4 removed from the container 3. In this way, in this embodiment, the items 4 are removed piece by piece (piece picking) in the processing operation.

[0046] 3, in this embodiment, processing work in processing work area A3 is performed by one or more second workers 32. Therefore, for example, instructions for the processing work (for example, specific details of the processing work) are displayed on instruction output device 6 that is visible to second worker 32. Note that it is also possible to configure the processing work to be performed by a robot instead of second worker 32, or to configure the processing work to be performed by second worker 32 and robot in cooperation with each other.

[0047] The work area A includes a sorting work area A4. In the sorting work area A4, a sorting work is performed in which the items 4 after processing are placed into collection containers 2. The sorting work involves placing the items 4 of the type specified in the order into each of the multiple collection containers 2 placed in the collection container placement unit 25, in the number specified in the order. That is, an order specifying the number of items 4 of each type is assigned to each of the multiple collection containers 2. For example, the control system 5 or another control system that can communicate with the control system 5 (e.g., a higher-level control system) generates an order based on an order from a shipping destination of the items 4, and manages the generated order by correlating it with the shipping destination. The control system 5 then controls the transport system 40 to transport the storage containers 1 containing the items 4 of the type specified in the order (i.e., the storage containers 1 required for the sorting work) to the output container placement unit 23.

[0048] 3, in this embodiment, the sorting work in the sorting work area A4 is performed by one or more second workers 32. Therefore, for example, instructions for the sorting work (for example, information on the type and number of items 4 specified in the order for each collection container 2) are displayed on an instruction output device 6 that is visible to the second workers 32. Note that the sorting work may be performed by a robot instead of the second workers 32, or the sorting work may be performed by the second workers 32 and the robot in cooperation with each other.

[0049] In this embodiment, both the processing work and the sorting work are performed by the same worker (worker or robot). In the example shown in Fig. 3, a second worker 32 performs both the processing work and the sorting work. That is, the second worker 32 performs the processing work on the items 4, and then performs the sorting work of placing the items 4 into the collection container 2. Alternatively, the processing work and the sorting work may be performed by different workers.

[0050] As shown in FIG. 4, in this embodiment, the collection container placement section 25 is disposed on the upper side Z1 of the processing item placement section 20. The processing item placement section 20 and the collection container placement section 25 are disposed so as to overlap when viewed in the Z direction. In the example shown in FIGS. 3 and 4, the direction perpendicular to the arrangement direction of the multiple storage containers 1 in the collection container placement section 25 when viewed in the Z direction is defined as the target direction (the Y direction in this example), and the processing item placement section 20 is formed with a larger dimension in the target direction than the collection container placement section 25. The processing item placement section 20 is disposed so as to protrude on both sides of the target direction relative to the collection container placement section 25 when viewed in the Z direction. This allows multiple second workers 32 to be separated on both sides of the target direction relative to the processing item placement section 20 and the collection container placement section 25, making it easier to perform processing and sorting work, as shown in FIG.

[0051] In the incoming container placement section 24, a storage container 1 to be transported from the work area A to the container storage facility 8 by the conveyance system 40 is placed. Hereinafter, the storage container 1 placed in the incoming container placement section 24 will be referred to as the "second container 1b" to distinguish it from other storage containers 1. The incoming container placement section 24 is a predetermined area on the first conveyor 41. The incoming container placement section 24 is a predetermined area downstream of the outgoing container placement section 23 in the conveyance section 70 (specifically, the intermediate section described above, more specifically, the upstream section described above). In this embodiment, this area is set to a size that allows one storage container 1 to be placed therein. In the example shown in FIGS. 3 and 4, between the first container 1a placed in the outgoing container placement section 23 and the second container 1b placed in the incoming container placement section 24, storage containers 1 other than the first container 1a and the second container 1b (here, four storage containers 1) can be placed.

[0052] The work area A includes an incoming work area A2. In the incoming work area A2, incoming work is carried out. The incoming work is the work of placing the items 4 to be stored into a storage container 1 (second container 1b) placed in the incoming container placement section 24, or the work of placing the storage container 1 containing the items 4 to be stored in the incoming container placement section 24. Therefore, the incoming container placement section 24 is a stop / placement position on the first conveyor 41 where the storage container 1 is stopped or placed for the incoming work.

[0053] In this embodiment, the storing operation of placing the items 4 to be stored into the second container 1b involves placing the container 3 from which the items 4 have been removed by the processing operation (the container 3 from which the items 4 remain) into the second container 1b. In the example shown in FIG. 3, the container 3 from which the items 4 have been removed by the processing operation is placed on a cart 7 and transported from the processing operation area A3 to the receiving operation area A2, and then placed into the second container 1b. Note that the second container 1b into which the container 3 is placed may be the same storage container 1 as the storage container 1 from which the container 3 was removed by the removal operation, or a different storage container 1. In this embodiment, the storing operation of placing the items 4 to be stored into the second container 1b also involves placing the container 3 containing replenishment items 4 or the container 3 containing new items 4 to be stored (the container 3 shown by the two-dot chain line in FIG. 3) into the second container 1b.

[0054] In addition, in this embodiment, the receiving work of placing the storage container 1 containing the items 4 to be stored in the incoming container placement section 24 involves loading the storage container 1 containing the items 4 to be replenished or the items 4 newly to be stored in the container 3 onto the incoming container placement section 24 from outside the first conveyor 41.

[0055] As shown in FIG. 3, in this embodiment, the storing operation in the storing operation area A2 is performed by one or more third workers 33. Note that it is also possible to configure the system so that a robot performs the storing operation instead of the third worker 33, or so that the third worker 33 and a robot work together to perform the storing operation. In the example shown in FIG. 3, the processing operation and the sorting operation are performed by the same worker (worker or robot), but any two or more of the removal operation, processing operation, sorting operation, and storing operation may be performed by the same worker. For example, it is possible to configure the removal operation and storing operation to be performed by the same worker.

[0056] In this embodiment, the unloading section 60 delivers the stacked container group 10 to the transport vehicle 90. For this reason, the work area A is equipped with a stacking device 45 that stacks multiple storage containers 1 (in this embodiment, a set number of storage containers 1, described below) to create the stacked container group 10. The stacking device 45 is located downstream of the outgoing container placement section 23 and the incoming container placement section 24 and upstream of the unloading section 60. In this embodiment, the stacking device 45 is located in the unloading section side section of the first conveyor 41. The stacked container group 10, created by sequentially stacking multiple storage containers 1 in the stacking device 45, is transported to the unloading section 60. The stacking device 45 is configured, for example, to sequentially add storage containers 1 to be stacked to the stacked container group 10 as the lowest storage container 1. For example, the destacking device 44 and the stacking device 45 may have a common configuration.

[0057] Although not limited to this configuration, in this embodiment, the control system 5 is configured to cause the conveyance system 40 to execute batch carry-in processing. The sorting operations for a predetermined number of collection containers 2 are grouped together as one batch, and the batch carry-in processing involves carrying in the storage containers 1 required for the sorting operations contained in each of the multiple batches to the work area A in the order in which the multiple batches are processed. As described above, in this embodiment, the work area A includes multiple collection container placement units 25 in which collection containers 2 are placed. Furthermore, each of the multiple collection container placement units 25 holds collection containers 2 belonging to different batches. Therefore, sorting operations contained in multiple batches (specifically, batches equal in number to the number of installed collection container placement units 25) can be performed in parallel. The maximum number of collection containers 2 that can be placed in each collection container placement unit 25 (six in the example shown in FIGS. 3 and 4 ) is set to the same number as the maximum number of collection containers 2 belonging to a single batch. It should be noted that "collection container 2 belonging to a batch" refers to the collection container 2 into which items 4 are sorted by the sorting work included in the batch.

[0058] 3 and 4, the sorting operations for six collection containers 2 placed in one collection container placement section 25 are collectively considered to be one batch. Then, collection containers 2 belonging to two different batches (specifically, one batch and the batch to be processed after the first batch) are placed in each of the two collection container placement sections 25. When the sorting operation included in one of the two batches is completed, the collection containers 2 belonging to that batch (six collection containers 2 in this example) are carried out from the collection container placement section 25, and collection containers 2 belonging to the batch to be processed after the first batch are placed in that collection container placement section 25.

[0059] In this embodiment, the conveying system 40 is configured to create a stacked container group 10 by stacking a predetermined number of storage containers 1 (eight in the example shown in FIG. 4 ), and to carry the stacked container group 10 into the work area A. When carrying the stacked container group 10 into the work area A in this way, it is also possible to create one stacked container group 10 only from storage containers 1 belonging to the same batch, and not create a stacked container group 10 containing a mixture of storage containers 1 belonging to different batches (i.e., to create only stacked container groups 10 separated by batch). In this case, however, it becomes necessary to create stacked container groups 10 with fewer layers than the set number, which may reduce the efficiency with which the conveying system 40 transports the storage containers 1. Note that "storage containers 1 belonging to a batch" refers to storage containers 1 required for the sorting work included in that batch.

[0060] In consideration of the above, in this embodiment, instead of carrying in only stacked container groups 10 divided into batches into work area A, as described below, stacked container groups 10 containing a mixture of storage containers 1 belonging to multiple batches whose processing orders are different (consecutive) are also carried into work area A. This reduces the need to create stacked container groups 10 with fewer tiers than the set number, making it easier to improve the efficiency of transporting storage containers 1 by the transport system 40. Note that, although this embodiment assumes that the "set number" is always a fixed number, the set number may also be configured to be changeable depending on the situation.

[0061] When the control system 5 causes the transport system 40 to execute the batch loading process, the control system 5 controls the transport system 40 as follows: One of the batches is designated as the first batch, and the batch processed after the first batch is designated as the second batch. Between the first loading process in which a stacked container group 10, some or all of which are storage containers 1 belonging to the first batch, is loaded into the work area A, and the third loading process in which a stacked container group 10, some or all of which are storage containers 1 belonging to the second batch, is loaded into the work area A, the control system 5 causes the transport system 40 to execute a second loading process in which a stacked container group 10, some of which are storage containers 1 belonging to the first batch and the remainder of which are storage containers 1 belonging to the second batch, is loaded into the work area A.

[0062] Note that if the stacked container group 10 carried into the work area A in the first carrying-in process is a stacked container group 10 in which some of the storage containers 1 belong to the first batch, the remaining storage containers 1 are, for example, storage containers 1 that belong to the batch that will be processed before the first batch. That is, the remaining storage containers 1 in this case are not basically storage containers 1 that belong to the second batch. Also, if the stacked container group 10 carried into the work area A in the third carrying-in process is a stacked container group 10 in which some of the storage containers 1 belong to the second batch, the remaining storage containers 1 are, for example, storage containers 1 that belong to the batch that will be processed next after the second batch. That is, the remaining storage containers 1 in this case are not basically storage containers 1 that belong to the first batch.

[0063] 6 is an explanatory diagram of the first, second, and third carry-in processes. As shown in FIG. 6(a), a situation is assumed in which there are 13 storage containers 1 (storage containers 1 marked with a circled "1") belonging to the first batch and 11 storage containers 1 (storage containers 1 marked with a circled "2") belonging to the second batch. In FIG. 6(b), a first stacked container group 11 is a stacked container group 10 carried into work area A by the first carry-in process, a second stacked container group 12 is a stacked container group 10 carried into work area A by the second carry-in process, and a third stacked container group 13 is a stacked container group 10 carried into work area A by the third carry-in process. Here, an example is shown in which all of the storage containers 1 belonging to the first batch are lined up consecutively in the Z direction in the second stacked container group 12, and all of the storage containers 1 belonging to the second batch are lined up consecutively in the Z direction, but as described above, in this embodiment, sorting operations included in multiple batches (two batches in the example shown in FIG. 4) can be performed in parallel. Therefore, in the second stacked container group 12, one or more storage containers 1 belonging to the first batch and one or more storage containers 1 belonging to the second batch may be lined up alternately in the Z direction.

[0064] 6(b) , if the system were configured to generate only stacked container groups 10 divided into batches, two stacked container groups 10 with fewer tiers than the set number would be generated instead of the second stacked container group 12: one stacked with five storage containers 1 belonging to the first batch, and one stacked with three storage containers 1 belonging to the second batch. In this case, the stacked container groups 10 would need to be transferred from the transport vehicle 90 to the loading section 50 four times, one more than the three times required in the case shown in FIG. 6(b), which could reduce the efficiency of transporting the storage containers 1 by the transport system 40. In contrast, by generating not only stacked container groups 10 divided into batches, but also stacked container groups 10 containing a mixture of storage containers 1 belonging to different batches, the number of times the stacked container groups 10 need to be transferred from the transport vehicle 90 to the loading section 50 can be reduced, improving the efficiency of transporting the storage containers 1 by the transport system 40.

[0065] When the control system 5 causes the transport system 40 to execute the batch loading process, it is not necessary for the control system 5 to cause the transport system 40 to execute the first loading process, the second loading process, and the third loading process in that order, but the control system 5 may cause the transport system 40 to execute other loading processes. For example, if one of the batches is the third batch, the batch processed after the third batch is the fourth batch, and the batch processed after the fourth batch is the fifth batch, the control system 5 can be configured to control the transport system 40 as follows when the number of storage containers 1 belonging to the fourth batch is equal to or less than the set number minus 2. Between a fourth delivery process in which a stacked container group 10, some or all of which are storage containers 1 belonging to the third batch, is delivered to the work area A, and a sixth delivery process in which a stacked container group 10, some of which are storage containers 1 belonging to the fifth batch, is delivered to the work area A, the control system 5 causes the conveying system 40 to execute a fifth delivery process in which a stacked container group 10, some of which are storage containers 1 belonging to the third batch, some of which are storage containers 1 belonging to the fourth batch, and the remainder of which are storage containers 1 belonging to the fifth batch, is delivered to the work area A.

[0066] Note that if the stacked container group 10 carried into work area A in the fourth carrying-in process is a stacked container group 10 in which some of the storage containers 1 belong to the third batch, the remaining storage containers 1 will be considered to be storage containers 1 that belong to the batch that will be processed before the third batch, for example. That is, the remaining storage containers 1 in this case will not basically be considered to be storage containers 1 that belong to the fourth or fifth batch. Also, if the stacked container group 10 carried into work area A in the sixth carrying-in process is a stacked container group 10 in which some of the storage containers 1 belong to the fifth batch, the remaining storage containers 1 will be considered to be storage containers 1 that belong to the batch that will be processed next after the fifth batch, for example. That is, the remaining storage containers 1 in this case will not basically be considered to be storage containers 1 that belong to the third or fourth batch.

[0067] 7 is an explanatory diagram of the above-mentioned fourth, fifth, and sixth carry-in processes. As shown in FIG. 7(a), a situation is assumed in which there are 10 storage containers 1 (storage containers 1 marked with a circled "3") belonging to the third batch, 5 storage containers 1 (storage containers 1 marked with a circled "4") belonging to the fourth batch, and 9 storage containers 1 (storage containers 1 marked with a circled "5") belonging to the fifth batch. That is, in FIG. 7, the number of storage containers 1 belonging to the fourth batch is 5, and the number obtained by subtracting 2 from the set number is 6, which satisfies the condition that the number of storage containers 1 belonging to the fourth batch is equal to or less than the number obtained by subtracting 2 from the set number. In Figure 7(b), the fourth stacked container group 14 is a stacked container group 10 that is transported into the work area A by the fourth loading process, the fifth stacked container group 15 is a stacked container group 10 that is transported into the work area A by the fifth loading process, and the sixth stacked container group 16 is a stacked container group 10 that is transported into the work area A by the sixth loading process.

[0068] 7(b), if only stacked container groups 10 divided into batches were to be generated, three stacked container groups 10 with fewer tiers than the set number would be generated: a stacked container group 10 consisting of two storage containers 1 belonging to the third batch, a stacked container group 10 consisting of five storage containers 1 belonging to the fourth batch, and a stacked container group 10 consisting of one storage container 1 belonging to the fifth batch. Note that a single storage container 1 is also referred to as a stacked container group 10. In this case, the stacked container group 10 would need to be transferred five times from the transport vehicle 90 to the loading section 50, two more than the three times in the case shown in FIG. 7(b), which could reduce the efficiency of transporting the storage containers 1 by the transport system 40. In contrast, by configuring the system to generate not only stacked container groups 10 divided by batch, but also stacked container groups 10 containing a mixture of storage containers 1 belonging to different batches, the number of times the stacked container groups 10 are transferred from the transport vehicle 90 to the loading section 50 can be reduced, thereby improving the efficiency of transporting storage containers 1 by the transport system 40.

[0069] When the number of storage containers 1 belonging to the fourth batch is equal to or less than the set number minus two, the control system 5 does not necessarily cause the transport system 40 to execute the fourth carry-in process, the fifth carry-in process, and the sixth carry-in process in sequence, as described above. Specifically, when not all of the storage containers 1 belonging to the third batch can be carried into the work area A in the fourth carry-in process, and further, when the sum of the remaining number of storage containers 1 belonging to the third batch and the number of storage containers 1 belonging to the fourth batch is less than the set number, the control system 5 causes the transport system 40 to execute the fourth carry-in process, the fifth carry-in process, and the sixth carry-in process in sequence, as described above. On the other hand, when the sum of the remaining number of storage containers 1 belonging to the third batch and the number of storage containers 1 belonging to the fourth batch is equal to or greater than the set number, instead of the fifth carry-in process, a carry-in process is executed to carry into the work area A a stacked container group 10, some of which are storage containers 1 belonging to the third batch and the remainder are storage containers 1 belonging to the fourth batch. Furthermore, if all of the storage containers 1 belonging to the third batch can be transported into work area A in the fourth transport process, instead of the fifth transport process, a transport process is performed in which a stacked container group 10, some of which are storage containers 1 belonging to the fourth batch and some or the remainder are storage containers 1 belonging to the fifth batch, is transported into work area A.

[0070] Second Embodiment A second embodiment of the article sorting equipment will be described with reference to the drawing (FIG. 8). The following description will focus on the differences from the first embodiment. Points that are not specifically mentioned are the same as those in the first embodiment, and the same reference numerals will be used to omit detailed descriptions.

[0071] 8, in this embodiment, the transport system 40 includes a first conveyor 41 and a second conveyor 42 as conveyors for transporting the storage container 1 within the work area A. In the example shown in FIG. 8, the second conveyor 42 is disposed adjacent to the first conveyor 41 on the second side X2 in the X direction.

[0072] The first conveyor 41 includes a first loading section 51 that receives storage containers 1 (here, stacked container group 10) that have been loaded into the work area A from the container storage facility 8, a first unloading section 61 that unloads storage containers 1 (here, stacked container group 10) bound for the container storage facility 8 from the work area A, and a first transport section 71 that transports the storage containers 1 from the first loading section 51 to the first unloading section 61. The first loading section 51, the first unloading section 61, and the first transport section 71 correspond to the loading section 50, the unloading section 60, and the transport section 70 in the first embodiment, respectively. In this example, the first transport section 71 includes a first input section extending from the first input section 51 to the second side Y2 in the Y direction, a first output section extending to the first side Y1 in the Y direction toward the first output section 61, and a first intermediate section extending from the first input section to the second side X2 in the X direction and connecting the first input section and the first output section. Unlike the intermediate section in the first embodiment, the first intermediate section is arranged in a straight line along the X direction.

[0073] The second conveyor 42 includes a second carry-in section 52 that receives storage containers 1 (here, stacked container group 10) that have been carried into the work area A from the container storage facility 8, a second carry-out section 62 that carries out storage containers 1 (here, stacked container group 10) heading from the work area A to the container storage facility 8, and a second transport section 72 that transports the storage containers 1 from the second carry-in section 52 to the second carry-out section 62. The second carry-in section 52 receives, for example, empty storage containers 1 that do not contain any items 4. In this example, the second transport section 72 includes a second input section extending from the second input section 52 toward the second side Y2 in the Y direction, a second output section extending toward the first side Y1 in the Y direction toward the second output section 62, and a second intermediate section extending from the second input section toward the second side X2 in the X direction and connecting the second input section and the second output section. In the example shown in FIG. 8 , the second conveyor 42 has the same configuration as the first conveyor 41. Therefore, the second input section 52, the second output section 62, the second transport section 72, the second input section, the second output section, and the second intermediate section correspond to the first input section 51, the first output section 61, the first transport section 71, the first input section, the first output section, and the first intermediate section, respectively.

[0074] In this embodiment, the outgoing container placement section 23 is a predetermined section in the first conveying section 71 (here, the first intermediate section), and the incoming container placement section 24 is a predetermined section in the second conveying section 72 (here, the second intermediate section). In the example shown in Figure 8, the work area A is equipped with a de-stacking device 44 downstream of the first carrying-in section 51 and upstream of the outgoing container placement section 23 (here, in the first carrying-in section side section), and is equipped with a stacking device 45 downstream of the outgoing container placement section 23 and upstream of the first unloading section 61 (here, in the first unloading section side section). In addition, in the example shown in Figure 8, the work area A is equipped with a de-stacking device 44 downstream of the second loading section 52 and upstream of the incoming container placement section 24 (here, in the second loading section side section), and is equipped with a stacking device 45 downstream of the incoming container placement section 24 and upstream of the second unloading section 62 (here, in the second unloading section side section).

[0075] Third Embodiment A third embodiment of the article sorting equipment will be described with reference to the drawings (FIGS. 9 to 11). FIG. 9 is a plan view of the work area A, omitting the third conveyor 43 shown in FIG. 10. The following description will focus on differences from the first embodiment. Points that are not specifically mentioned are the same as those in the first embodiment, and the same reference numerals will be used to omit detailed description thereof.

[0076] 9, the conveying section 70 of the first conveyor 41 includes a branching section 80 located downstream of the inlet section 50, a plurality of branch sections 82 branching off at the branching section 80, and a junction section 81 located upstream of the outlet section 60 and where the plurality of branch sections 82 join together. The number of branching sections 80 and junction sections 81 is not limited to one, and the number of branch sections 82 is not limited to two, but in the present embodiment, the conveying section 70 includes one branching section 80, two branch sections 82, and one junction section 81.

[0077] 9 to 11, the transport section 70 of the first conveyor 41 includes an inlet section extending from the inlet 50 toward the second side Y2 in the Y direction, an outlet section extending toward the first side Y1 in the Y direction toward the outlet 60, and an intermediate section extending from the inlet section toward the second side X2 in the X direction to connect the inlet section and the outlet section. The section of the intermediate section on the first side X1 in the X direction is made up of two branch sections 82 that are parallel to each other in the X direction, and the section of the intermediate section on the second side X2 in the X direction is made up of a single section formed after the two branch sections 82 join at a junction 81.

[0078] As shown in FIG. 9, in this embodiment, an output container placement section 23 where removal work is performed is set in each of the multiple branch line sections 82. Then, as shown in FIG. 10, work area A has the same number of removal work areas A1 as the number of branch line sections 82. Note that the multiple removal work areas A1 may be grouped together as a single area, but in this example, two removal work areas A1, the same number as the number of branch line sections 82, are set on opposite sides in the Y direction, sandwiching the two branch line sections 82 between them. Removal work in the removal work area A1 is performed on a storage container 1 (first container 1a) placed in the output container placement section 23 corresponding to the removal work area A1. In the example shown in Figures 9 and 10, a first worker 31 positioned in the removal work area A1 on the first side Y1 of the Y direction performs removal work on a first container 1a placed in the output container placement section 23 on the first side Y1 of the Y direction, and a first worker 31 positioned in the removal work area A1 on the second side Y2 of the Y direction performs removal work on a first container 1a placed in the output container placement section 23 on the second side Y2 of the Y direction.

[0079] In this embodiment, the removal work involves removing items 4 piece by piece (piece picking). Therefore, in this embodiment, unlike the first embodiment, piece picking is not performed in the processing work. The removal work is, for example, a work in which a container 3 is removed from a storage container 1, an item 4 is removed from the container 3, and then the container 3 (the container 3 with the item 4 remaining) is placed into the same storage container 1. In the removal work, the item 4 may be removed from the container 3 without removing the container 3 from the storage container 1.

[0080] 9 and 10, a first worker 31 performing a removal operation places the items 4 removed by the removal operation in the processing item placement section 20. Then, a second worker 32 performing a processing operation and a sorting operation performs a processing operation on the items 4 placed in the processing item placement section 20, and then places the items 4 in a collection container 2. In this example, two processing work areas A3 (in other words, two sorting work areas A4), the same number as the number of branch sections 82, are set on opposite sides in the Y direction, with a transport section 70 of the first conveyor 41 (specifically, the above-mentioned intermediate section) in between. In addition, two processing item placement sections 20 are set on opposite sides in the Y direction, with a transport section 70 of the first conveyor 41 (specifically, the above-mentioned intermediate section) in between.

[0081] In this embodiment, the product collection container placement section 25 is also configured so that multiple product collection containers 2 are lined up in parallel with the conveying direction T of the storage container 1 in the outgoing container placement section 23. As shown in FIG. 9, in this embodiment, the direction in which the storage container 1 is carried into the outgoing container placement section 23 is toward the second side X2 in the X direction, and the direction in which the storage container 1 is carried out from the outgoing container placement section 23 is toward the first side Y1 in the Y direction or the second side Y2 in the Y direction. Therefore, the conveying direction T of the storage container 1 in the outgoing container placement section 23 includes both the X direction and the Y direction. As shown in FIG. 10, in this embodiment, the product collection container placement section 25 is configured so that the conveying direction T of the storage container 1 in the outgoing container placement section 23 is the X direction, and multiple product collection containers 2 are lined up in parallel with the X direction. By configuring the collection container placement section 25 in this manner, it becomes easier to place the collection container placement section 25 adjacent to the section that is arranged to extend in the X direction on the first conveyor 41 and includes the output container placement section 23 (here, the section on the first side X1 in the X direction in the intermediate section described above, specifically the section that transports the storage container 1 to the second side X2 in the X direction toward the output container placement section 23).

[0082] As shown in FIGS. 10 and 11 , in this embodiment, the article sorting equipment 100 (specifically, the conveying system 40) includes a third conveyor 43. The third conveyor 43 is a conveyor (e.g., a roller conveyor or a belt conveyor) that carries empty collection containers 2 into the collection container placement section 25 and carries collection containers 2 for which sorting has been completed out of the collection container placement section 25. The third conveyor 43 is configured, for example, to continuously transport a plurality of collection containers 2. The collection container placement section 25 is a predetermined area on the third conveyor 43. In the example shown in FIGS. 10 and 11 , this area is set to a size that allows four collection containers 2 to be arranged side by side. In the example shown in FIG. 11 , the article sorting equipment 100 includes two third conveyors 43 at different positions in the Z direction, and these two third conveyors 43 are arranged to overlap each other when viewed in the Z direction. As a result, similarly to the first embodiment, the two collection container arrangement sections 25 are arranged at different positions in the Z direction and are arranged so as to overlap each other when viewed in the Z direction.

[0083] In this embodiment, the processing article placement section 20 and the collection container placement section 25 are arranged at horizontally offset positions so as not to overlap when viewed in the Z direction. In this embodiment, as shown in Fig. 11, the collection container placement section 25 is arranged on the upper side Z1 of the transport section 70 of the first conveyor 41. Then, as shown in Figs. 9 and 10, the transport section 70 (specifically, the intermediate section described above) and the collection container placement section 25 are arranged so as to overlap when viewed in the Z direction.

[0084] In this embodiment, unlike the first embodiment, the work area A does not have an incoming container placement section 24 and an incoming work area A2, but in order to make it easier to replenish items 4 and add new items 4 to be stored, the work area A in this embodiment may also be configured to have an incoming container placement section 24 and an incoming work area A2.

[0085] [Fourth embodiment] A fourth embodiment of the article sorting equipment will be described with reference to the drawings (FIGS. 12 and 13). The following description will focus on differences from the first embodiment. Points that are not specifically mentioned are the same as those in the first embodiment, and the same reference numerals will be used to omit detailed description.

[0086] 12, the conveying section 70 of the first conveyor 41 includes a branching section 80 located downstream of the inlet section 50, a plurality of branch sections 82 branching off at the branching section 80, and a junction section 81 located upstream of the outlet section 60 and where the plurality of branch sections 82 join together. In this embodiment, the conveying section 70 includes three branching sections 80, four branch sections 82, and three junction sections 81.

[0087] 12 and 13, the transport section 70 of the first conveyor 41 includes an inlet section extending from the inlet 50 toward the second side Y2 in the Y direction, an outlet section extending toward the first side Y1 in the Y direction toward the outlet 60, and an intermediate section extending from the inlet section toward the second side X2 in the X direction to connect the inlet section and the outlet section. The intermediate section is made up of four branch sections 82 that are parallel to each other in the X direction.

[0088] As shown in Fig. 12, in this embodiment, an outgoing container placement section 23 where removal work is performed is set in each of the multiple branch line sections 82. As shown in Fig. 12, the work area A has the same number of removal work areas A1 as the number of branch line sections 82. In the example shown in Figs. 12 and 13, of the four removal work areas A1 set to be lined up in the Y direction, the two removal work areas A1 on the first side Y1 in the Y direction are grouped together as one area, and the two removal work areas A1 on the second side Y2 in the Y direction are grouped together as one area.

[0089] The removal work in the removal work area A1 is performed on the storage container 1 (first container 1a) placed in the output container placement section 23 corresponding to the removal work area A1. In this example, the first worker 31 placed in the removal work area A1 closest to the first side Y1 in the Y direction performs the removal work on the first container 1a placed in the output container placement section 23 closest to the first side Y1 in the Y direction, and the first worker 31 placed in the removal work area A1 second from the first side Y1 in the Y direction performs the removal work on the first container 1a placed in the output container placement section 23 second from the first side Y1 in the Y direction. In addition, the first worker 31 positioned in the removal work area A1 closest to the second side Y2 in the Y direction performs removal work on the first container 1a positioned in the output container placement section 23 closest to the second side Y2 in the Y direction, and the first worker 31 positioned in the removal work area A1 second from the second side Y2 in the Y direction performs removal work on the first container 1a positioned in the output container placement section 23 second from the second side Y2 in the Y direction.

[0090] 12 and 13, the processing item placement section 20 includes a first item placement section 21 and a second item placement section 22. The first item placement section 21 is disposed above the transport section 70 of the first conveyor 41 (specifically, the aforementioned inlet section side section) so as to overlap with the transport section 70 as viewed in the Z direction. The collection container placement section 25 is disposed on the first side X1 in the X direction relative to the first conveyor 41, and the second item placement section 22 is disposed adjacent to the collection container placement section 25 on the second side X2 in the X direction. In the example shown in FIGS. 12 and 13, a first worker 31 performing the removal operation places the items 4 removed by the removal operation in the first item placement section 21. Then, a second worker 32 who performs processing and sorting work performs processing work on the items 4 placed in the first item placement section 21 in the first item placement section 21 or the second item placement section 22, and then places the items 4 into the collection container 2.

[0091] In the first to third embodiments, the product collection container placement section 25 was configured so that multiple collection containers 2 were lined up in parallel with the conveying direction T of the storage container 1 in the outgoing container placement section 23. However, in this embodiment, the product collection container placement section 25 is configured so that multiple outgoing container placement sections 23 are set up and multiple collection containers 2 are lined up in parallel with the arrangement direction of the multiple outgoing container placement sections 23. Specifically, as shown in FIGS. 12 and 13 , in this embodiment, four outgoing container placement sections 23 are set up, and the arrangement direction of these four outgoing container placement sections 23 is the Y direction. The product collection container placement section 25 is configured so that multiple collection containers 2 are lined up in parallel with the Y direction. Here, the product collection container placement section 25 is arranged on the first side X1 in the X direction with respect to the four outgoing container placement sections 23. By configuring the collection container placement section 25 in this manner, the collection container placement section 25 can be placed in parallel adjacent to a section (here, the above-mentioned loading section side section) that is arranged to extend in the Y direction on the first conveyor 41 and connects multiple output container placement sections 23 (in other words, multiple branch section 82), thereby reducing the space required to install the output container placement section 23 and the collection container placement section 25.

[0092] 12 and 13, the collection container arrangement section 25 may be configured so that multiple collection containers 2 are lined up in parallel in the Y direction on the second side X2 in the X direction relative to the four outgoing container arrangement sections 23. In this case, the collection container arrangement section 25 can be arranged adjacent to and in parallel with the section of the first conveyor 41 that is arranged to extend in the Y direction and connects the multiple outgoing container arrangement sections 23 (here, the above-mentioned carry-out section side section).

[0093] In this embodiment, unlike the first embodiment, the work area A does not have an incoming container placement section 24 and an incoming work area A2, but in order to make it easier to replenish items 4 and add new items 4 to be stored, the work area A in this embodiment may also be configured to have an incoming container placement section 24 and an incoming work area A2.

[0094] Other Embodiments (1) In each of the above embodiments, an example has been described in which the items 4 are stored in a container 3 such as a bag and then stored in the storage container 1. However, the present disclosure is not limited to such a configuration, and the items 4 may also be stored in the storage container 1 without being stored in a container 3. When such a configuration is used in the first and second embodiments, the items 4 are removed piece by piece (piece picking) in the removal operation, and the storage operation of placing the container 3 after the items 4 have been removed in the processing operation into the second container 1b is not performed. Therefore, in this case, the work area A may be configured not to include the receiving container placement unit 24 and the receiving work area A2.

[0095] (2) In each of the above embodiments, an example has been described in which the container storage facility 8 stores a plurality of storage containers 1 in a mutually separated state. However, the present disclosure is not limited to such a configuration, and the container storage facility 8 may also be configured to store a stacked container group 10. Furthermore, the container storage facility 8 may also be configured to include both an area for storing a plurality of storage containers 1 in a mutually separated state and an area for storing a stacked container group 10.

[0096] (3) In each of the above embodiments, an example has been described in which the container storage facility 8 includes a storage shelf 9 for storing the storage containers 1. However, the present disclosure is not limited to such a configuration, and the container storage facility 8 may not include a storage shelf 9, and the storage containers 1 may be stored in the container storage facility 8 by being placed on the floor or the like.

[0097] (4) In the above embodiments, the transport system 40 includes a transport vehicle 90 that transports a storage container 1 outside the work area A. However, the present disclosure is not limited to such a configuration. The transport system 40 may include a container transport device different from the transport vehicle 90 instead of or in addition to the transport vehicle 90. In this case, the container transport device may be configured to carry out at least one of the following: loading the storage container 1 or the stacked container group 10 into the loading section 50; and unloading the storage container 1 or the stacked container group 10 from the unloading section 60. For example, a container transport device different from the transport vehicle 90 may include a gripping unit that grips the storage container 1 or the stacked container group 10, an elevating unit that raises and lowers the gripping unit, and a horizontal moving unit that moves the gripping unit in two horizontal directions that are perpendicular to each other. Preferably, the container transport device is configured to allow the combination of storage containers 1 that make up the stacked container group 10 to be changed.

[0098] (5) In each of the above embodiments, a configuration has been described in which work area A is equipped with a destacking device 44 and a stacking device 45. However, the present disclosure is not limited to such a configuration, and a configuration is also possible in which work area A does not include a destacking device 44, and the task of separating the stacked container group 10 into individual storage containers 1 is performed manually by a worker or the like. Also, a configuration is possible in which work area A does not include a stacking device 45, and the task of stacking multiple storage containers 1 to create the stacked container group 10 is performed manually by a worker or the like. If work area A does not include a stacking device 45, a configuration in which the storage containers 1 are carried out one by one from the carrying-out section 60 may also be used.

[0099] (6) In the above embodiments, the configuration in which the collection container placement section 25 is arranged on the upper side Z1 of the processing item placement section 20 has been described as an example. However, the present disclosure is not limited to such a configuration, and the collection container placement section 25 may also be arranged on the lower side Z2 of the processing item placement section 20. Furthermore, in the first and second embodiments, the configuration in which the processing item placement section 20 and the collection container placement section 25 are arranged to overlap when viewed in the Z direction has been described as an example. However, in the first and second embodiments, the processing item placement section 20 and the collection container placement section 25 may also be arranged at horizontally offset positions so as not to overlap when viewed in the Z direction, as in the third and fourth embodiments.

[0100] (7) In the above embodiments, the working area A is provided with a plurality of collection container placement sections 25, and the plurality of collection container placement sections 25 are arranged at different positions (heights) in the Z direction and are arranged so as to overlap one another when viewed in the Z direction. However, the present disclosure is not limited to such a configuration, and the plurality of collection container placement sections 25 may also be arranged at positions offset in the horizontal direction so as not to overlap one another when viewed in the Z direction. In this case, the plurality of collection container placement sections 25 may also be arranged at the same position in the Z direction. The working area A may also be arranged with only one collection container placement section 25.

[0101] (8) In the first to third embodiments, an example was described in which the product collection container placement section 25 is configured so that multiple product collection containers 2 are lined up in parallel with the conveying direction T of the storage container 1 in the outgoing container placement section 23, and in the fourth embodiment, an example was described in which the product collection container placement section 25 is configured so that multiple outgoing container placement sections 23 are set and multiple product collection containers 2 are lined up in parallel with the arrangement direction of the multiple outgoing container placement sections 23. However, the present disclosure is not limited to such a configuration, and the configuration of the product collection container placement section 25 may be different from either of these two cases.

[0102] (9) Note that the configurations disclosed in the above-described embodiments can be applied in combination with configurations disclosed in other embodiments (including combinations of embodiments described as other embodiments) as long as no contradictions arise. Regarding other configurations, the embodiments disclosed in this specification are merely examples in all respects. Therefore, various modifications can be made as appropriate within the scope of the present disclosure.

[0103] [Summary of this embodiment] The embodiment of the article sorting equipment described above will be summarized below.

[0104] The article sorting equipment includes a container storage facility in which a plurality of storage containers are stored, a work area in which a sorting operation is performed in which the items contained in the storage containers are removed and sorted into a plurality of collection containers, a transport system that transports the storage containers from the container storage facility to the work area and transports the storage containers from the work area to the container storage facility, and a control system that controls the transport system, wherein the storage containers are configured to be stackable in the vertical direction, and the transport system is configured to create a stacked container group in which a predetermined set number of the storage containers are stacked, and transport the stacked container group to the work area, and the control system groups the sorting operation for the predetermined number of collection containers into one batch, and controls the sorting operation for the plurality of batches When the conveyance system is caused to execute a batch delivery process in which the storage containers required for the sorting operation included in each of the batches are delivered to the work area in the order in which the multiple batches are processed, one of the batches is designated as a first batch, and the batch to be processed after the first batch is designated as a second batch, the conveyance system is caused to execute a second delivery process in which the stacked container group, some of which are storage containers belonging to the first batch and the remainder are storage containers belonging to the second batch, delivered to the work area between a first delivery process in which the stacked container group, some of which are storage containers belonging to the first batch and the remainder are storage containers belonging to the second batch, is delivered to the work area, and a third delivery process in which the stacked container group, some of which are storage containers belonging to the first batch and the remainder are storage containers belonging to the second batch, is delivered to the work area.

[0105] According to this configuration, when storage containers required for sorting operations included in each of multiple batches are transported to the work area in a stacked container group with a set number of tiers in the order in which the multiple batches are processed, it is possible to generate stacked container groups that contain a mixture of storage containers belonging to two batches that are processed in different (consecutive) orders, rather than generating only stacked container groups separated by batch. This reduces the need to generate stacked container groups with fewer tiers than the set number, thereby making it easier to improve the efficiency with which the transport system transports storage containers. As described above, according to this configuration, when stacked container groups are transported to the work area by the control system, it is easier to improve the efficiency with which the transport system transports storage containers.

[0106] Here, it is preferable that one of the batches is the third batch, the batch to be processed after the third batch is the fourth batch, and the batch to be processed after the fourth batch is the fifth batch, and when the number of storage containers belonging to the fourth batch is equal to or less than the set number minus 2, the control system causes the conveying system to execute a fifth delivery process to deliver the stacked container group, some of which are storage containers belonging to the third batch, some of which are storage containers belonging to the fourth batch, and the remainder of which are storage containers belonging to the fifth batch, into the work area between a fourth delivery process to deliver the stacked container group, some of which are storage containers belonging to the third batch, and a sixth delivery process to deliver the stacked container group, some of which are storage containers belonging to the fifth batch, into the work area.

[0107] According to this configuration, when the storage containers required for sorting work included in each of multiple batches are brought into the work area in the order in which the multiple batches are processed in a stacked container group with a set number of tiers, if the number of storage containers belonging to a certain batch is small, a stacked container group containing a mixture of storage containers belonging to three batches that are processed in different orders can be created. Therefore, it is easy to improve the efficiency of transporting storage containers by the transport system regardless of the number of storage containers belonging to each batch.

[0108] It is also preferable that the work area includes a plurality of collection container placement sections in which the collection containers are placed, and that each of the plurality of collection container placement sections has placed therein a collection container belonging to a different batch.

[0109] According to this configuration, sorting operations included in multiple batches can be performed in parallel in the work area, which makes it easier to improve the efficiency of the sorting operations.

[0110] Furthermore, it is preferable that the transport system comprises a conveyor that transports the storage containers within the work area and a transport vehicle that transports the storage containers outside the work area, the conveyor having an entrance section that receives the stacked container group that has been transported from the container storage facility to the work area, the work area having a de-stacking device that separates the stacked container group received at the entrance section into individual storage containers, and the transport vehicle having a traveling vehicle, a support section mounted on the traveling vehicle and supporting the stacked container group, a first transfer device mounted on the traveling vehicle and transferring the storage containers between a storage shelf provided in the container storage facility and the stacked container group supported by the support section, and a second transfer device mounted on the traveling body and transferring the stacked container group between the support section and the entrance section.

[0111] According to this configuration, the transport vehicle can retrieve the necessary storage containers from the storage shelves of the container storage facility, create a stacked container group, and transport them to the work area. Then, in the work area, the stacked container group can be separated into individual storage containers for sorting. Therefore, multiple storage containers can be efficiently transported by the transport vehicle, and sorting can be performed appropriately in the work area.

[0112] In the above configuration, the conveyor further includes an unloading section from which the stacked container group is transported from the work area to the container storage facility, the second transfer device transfers the stacked container group between the support section and the unloading section, and the work area is preferably arranged upstream of the unloading section and further includes a stacking device that stacks the set number of storage containers to generate the stacked container group.

[0113] With this configuration, after the sorting work is completed, the storage containers can be handed over to the transport vehicle as a stacked container group again. Therefore, when the sorted storage containers are returned to the storage shelves of the container storage facility, the multiple storage containers can be efficiently transported by the transport vehicle.

[0114] It is sufficient for the article sorting equipment according to the present disclosure to achieve at least one of the above-mentioned effects. [Explanation of symbols]

[0115] 1: Storage container 2: Collection container 4: Goods 5: Control system 8: Container storage equipment 9: Storage shelf 10: Stacked containers 25:Collection container arrangement section 40:Transportation system 41: First conveyor (conveyor) 42: Second conveyor (conveyor) 44: De-stacking device 45: Stacking device 50: Loading section 60: Unloading section 90: Transport vehicle 91: 1st transfer device 92:Second transfer device 93: Running body 94: Support part 100: Goods sorting equipment A: Work area Z: Z direction (vertical direction)

Claims

1. An item sorting facility comprising: a container storage facility in which a plurality of storage containers are stored; a work area in which sorting work is performed in which items contained in the storage containers are removed and sorted into a plurality of collection containers; a transport system that transports the storage containers from the container storage facility to the work area and transports the storage containers from the work area to the container storage facility; and a control system that controls the transport system, The storage container is configured to be stackable in the vertical direction, the transport system is configured to create a stacked container group in which a predetermined number of the storage containers are stacked, and transport the stacked container group to the work area; The control system includes: When the sorting work for a predetermined number of the collection containers is grouped into one batch and the transport system is caused to execute a batch carrying-in process in which the storage containers necessary for the sorting work included in each of the plurality of batches are carried into the work area in the processing order of the plurality of batches, An item sorting facility in which, between a first delivery process in which a group of stacked containers, some or all of which are storage containers belonging to the first batch, are delivered to the work area, with one of the batches designated as a first batch and the batch processed next after the first batch designated as a second batch, and a third delivery process in which a group of stacked containers, some of which are storage containers belonging to the second batch, are delivered to the work area, a second delivery process in which a group of stacked containers, some of which are storage containers belonging to the first batch and the remainder are storage containers belonging to the second batch, is carried out by the conveying system.

2. one of the batches is designated as a third batch, the batch processed next after the third batch is designated as a fourth batch, and the batch processed next after the fourth batch is designated as a fifth batch; 2. The item sorting equipment of claim 1, wherein the control system causes the conveying system to execute a fifth delivery process to deliver to the work area a group of stacked containers, some of which are storage containers belonging to the third batch, some of which are storage containers belonging to the fourth batch, and the remainder of which are storage containers belonging to the fifth batch, between a fourth delivery process to deliver to the work area a group of stacked containers, some of which are storage containers belonging to the third batch, and a sixth delivery process to deliver to the work area a group of stacked containers, some of which are storage containers belonging to the fifth batch, when the number of storage containers belonging to the fourth batch is equal to or less than the set number minus 2.

3. the work area includes a plurality of collection container placement units in which the collection containers are placed, The article sorting facility according to claim 1 or 2, wherein the collection containers belonging to different batches are placed in each of the plurality of collection container placement sections.

4. the transport system includes a conveyor that transports the storage container within the work area and a transport vehicle that transports the storage container outside the work area; the conveyor includes a loading section that receives the stacked container group that has been carried into the work area from the container storage facility, the work area is equipped with a de-stacking device that separates the stacked container group received in the loading section into individual storage containers, The transport vehicle is A traveling vehicle; a support portion mounted on the traveling body and supporting the stacked container group; a first transfer device mounted on the traveling body and configured to transfer the storage container between a storage shelf provided in the container storage facility and the stacked container group supported by the support section; a second transfer device mounted on the traveling body and configured to transfer the stacked container group between the support section and the loading section; The article sorting equipment according to claim 1 or 2, comprising:

5. The conveyor further includes a discharge section through which the stacked container group is transported from the work area to the container storage facility, the second transfer device transfers the stacked container group between the support unit and the unloading unit, 5. The article sorting equipment according to claim 4, wherein the work area is arranged upstream of the discharge section, and further comprises a stacking device that stacks the set number of storage containers to generate the stacked container group.

Images