Sorting machine system, sorting method, and computer program

Abstract

To optimize unloading order including a post-process performed after loading / unloading of a container into / from a sorting machine.SOLUTION: A sorting machine system comprises: a sorting machine in which a plurality of containers different in destinations are loaded, respectively, and the loaded containers are rearranged by destinations to unload, respectively; an acquisition unit for acquiring loading position information by which a loading position of each container in the sorting machine is determined in the order of unloading of the containers, and information relating to a post-process being a process from when the container is unloaded from the sorting machine until transportation to the destination is completed; an unloading order determination unit for respectively determining an unloading order of a series of containers loaded in the sorting machine so that a time until the post-process is completed is shortened by using the loading position information and the information relating to the post-processing; and a loading position determination unit which, in the loading position information, acquires the loading positions associated with the determined unloading order to determine the loading positions of the series of containers, respectively.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a sorting machine system, a sorting method, and a computer program. [Background technology]

[0002] There is known a technology for optimizing the order in which containers are removed from a sorting machine that receives multiple containers (see, for example, Patent Documents 1 and 2). In the rotary rack described in Patent Document 1, the positions of containers stored on a rotating storage shelf are confirmed, and the direction of rotation is determined so that the distance the containers travel when removed is shortened, and each container is removed.

[0003] Patent Document 2 describes a sorting method for ensuring that when multiple chutes transport containers with different destinations to a shipping area, each chute distributes the same number of containers evenly. In this sorting method, a cut-out unit is determined so that containers are distributed evenly to each chute, and the containers are lined up by destination for shipping. Patent Document 3 describes a storage location management method for plate-like articles organized by lot. This management method uses information on the lot's receiving and shipping plans to prioritize the shipping of each lot, and manages the location of each lot to reduce the amount of rearrangement work required when shipping the lot. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2014-051391 [Patent Document 2] Japanese Patent Application Laid-Open No. 2008-150191 [Patent Document 3] Patent No. 2004-075278 Summary of the Invention [Problem to be solved by the invention]

[0005] The technologies described in Patent Documents 1 and 2 optimize the order in which containers that are randomly input into a sorter are released from the sorter. Therefore, they do not take into consideration the work that occurs after the sorter releases the containers, such as transporting the released containers to their destinations (for example, the loading of containers by workers). Therefore, there has been a demand for an optimization of the release order that takes into consideration not only the process from the input of containers to the sorter to their release, but also the subsequent processes. The management method described in Patent Document 3 is based on the premise that the receiving plan for each lot can be obtained in advance, and does not consider optimizing the release order when lots are randomly received.

[0006] The present invention has been made to solve at least some of the above-mentioned problems, and aims to optimize the order of shipment, including subsequent processes that take place after the containers are loaded into and unloaded from the sorting machine. [Means for solving the problem]

[0007] The present invention has been made to solve at least part of the above-mentioned problems, and can be realized in the following forms.

[0008] (1) According to one aspect of the present invention, there is provided a sorting machine system comprising: a sorter that receives a plurality of containers having different destinations and sorts the received containers by their destinations before discharging them; an acquisition unit that acquires receiving position information that defines the receiving position of each container within the sorter for each order of discharging the containers and information on subsequent processes that are processes from when the containers are discharged from the sorter to when their transportation to their destinations is completed; an outgoing order determination unit that determines the outgoing order of a series of containers that are received into the sorter using the receiving position information and the information on the subsequent processes acquired by the acquisition unit so as to shorten the time until the subsequent processes are completed; and an incoming position determination unit that determines the receiving positions of the series of containers by acquiring, in the receiving position information, the receiving positions that correspond to the outgoing order determined by the outgoing order determination unit.

[0009] According to this configuration, a series of containers entering the sorter system randomly, regardless of the order of their release, are stored at the storage locations associated with the respective release orders determined by the release order determination unit in the storage location information acquired by the acquisition unit. The order of release of containers entered into the sorter is determined taking into account the subsequent processes to be performed on the containers after release. Therefore, with this configuration, the time and cost required to complete the subsequent processes can be reduced compared to when the release order is determined without taking the subsequent processes into account. In other words, this configuration can optimize the order of release of a series of containers, including the subsequent processes that occur after the containers enter and leave the sorter.

[0010] (2) In the sorting machine system of the above aspect, the delivery order determination unit may determine the delivery order of each of the series of containers by minimizing or maximizing an objective function whose work index is the time until the completion of the subsequent process. According to this configuration, by minimizing or maximizing the objective function, it is possible to determine the order in which containers are released so as to shorten the time required to complete the subsequent process.

[0011] (3) In the sorting machine system of the above aspect, the subsequent process may include at least one of a loading operation of loading the containers released from the sorter onto a transport vehicle, an inspection operation of each container released from the sorter, a packaging operation of each container released from the sorter, and a sorting operation of further sorting the containers released from the sorter. According to this configuration, the order in which containers are shipped can be determined by optimizing at least one of the following operations: loading, inspection, packing, and sorting after being shipped from the sorting machine.

[0012] (4) In the sorting machine system of the above aspect, the objective function may include as parameters at least one of the container waiting time of the workers performing the loading work, the number of workers, the location or size of the loading space for the loading work, the departure time of the transport aircraft, and the stopping time of the transport aircraft. According to this configuration, the order in which containers are released can be determined by optimizing at least one of the parameters of the objective function: the container waiting time of workers, the number of workers, the location or size of the loading space, the departure time of the transport aircraft, and the stopping time of the transport aircraft.

[0013] (5) In the sorter system of the above aspect, the outgoing order determination unit may determine the outgoing order of each of the series of containers by using a genetic algorithm for the objective function. According to this configuration, by using a genetic algorithm for the objective function, an optimized order of containers being shipped out can be determined efficiently.

[0014] (6) In the sorting machine system of the above aspect, a prediction unit may further be provided that predicts the delivery time of a container to be delivered from the sorting machine, and the delivery order determination unit may use the predicted delivery time of the container to calculate the time interval at which the container arrives at the subsequent process, and may use the calculated interval to determine the delivery order of the series of containers for each container so as to shorten the time until the subsequent process performed on all containers is completed. According to this configuration, the time intervals between container arrivals are calculated from the container departure times predicted by the prediction unit. The calculated time intervals are used to determine the order in which the containers are to be shipped. This reduces the waiting time that workers have to wait until the containers they are working on are shipped from the sorter. As a result, the time required to complete the post-processing for all containers can be reduced.

[0015] (7) The sorting machine system of the above aspect may further include a branching conveyor for sending containers released from the sorting machine to different locations where the subsequent processes are carried out depending on the destination. This arrangement allows each container to be automatically sent by conveyor to a different location where subsequent processing takes place, depending on its destination.

[0016] (8) The sorting machine system of the above aspect may further include a conveyor that circulates a container discharged from the sorting machine from the exit of the sorting machine back into the sorting machine when a waiting container occurs in the subsequent process of the container discharged from the sorting machine. According to this configuration, by circulating a container that is waiting in a subsequent process, a container with a different destination that arrives after the circulated container is sent first. As a result, with this configuration, the subsequent process can be carried out without causing the container that was sent first to wait. In other words, by circulating a container that is waiting, this configuration allows the subsequent process to be carried out efficiently for containers that are not waiting.

[0017] The present invention can be realized in various forms, for example, in the form of a sorting machine, a sorting machine system, an entry / exit system, a control method for these devices and systems, a sorting method, an entry / exit method, a computer program executed in these devices and methods, a server device for distributing this computer program, a non-transitory storage medium on which a computer program is stored, etc. [Brief explanation of the drawings]

[0018] [Figure 1] 1 is a schematic block diagram of a sorter system according to an embodiment of the present invention. [Figure 2] FIG. 2 is a schematic block diagram of a control device. [Figure 3] FIG. 2 is an explanatory diagram of an objective function according to the first embodiment. [Figure 4]1 is a flowchart of a sorting method using the sorter system. [Figure 5] FIG. 1 is an explanatory diagram of the order of delivery in the first embodiment. [Figure 6] FIG. 10 is an explanatory diagram of the order of delivery in Comparative Example 1. [Figure 7] FIG. 10 is an explanatory diagram of the order of delivery in Comparative Example 2. [Figure 8] FIG. 10 is an explanatory diagram of the transition of the total waiting time of a worker over time. [Figure 9] FIG. 10 is an explanatory diagram of the maximum number of containers waiting for work in the first embodiment. [Figure 10] FIG. 10 is an explanatory diagram of the maximum number of containers waiting for work in Comparative Example 1. [Figure 11] FIG. 10 is an explanatory diagram of the maximum number of containers waiting for work in Comparative Example 2. [Figure 12] FIG. 10 is an explanatory diagram of the effect of the first embodiment. [Figure 13] FIG. 10 is an explanatory diagram of a remaining task time function according to the second embodiment. [Figure 14] 10 is a flowchart of a modified sorting method. [Figure 15] FIG. 10 is a schematic block diagram of a modified sorting machine system. DETAILED DESCRIPTION OF THE INVENTION

[0019] First Embodiment FIG. 1 is a schematic block diagram of a sorting machine system 400 according to an embodiment of the present invention. The sorting machine system 400 according to this embodiment is installed, for example, in a distribution center of a logistics base, and performs storage and retrieval of multiple containers CT with different destinations. The sorting machine system 400 stores each of the multiple containers with different destinations in a predetermined storage position within the sorter 100, sorts them, and then retrieves them. The sorting machine system 400 determines the order in which a series of containers CT entering the sorter 100 are to be retrieved so as to shorten the total time from the time all the containers CT enter the sorter 100 until the completion of loading onto trucks as a subsequent process after the containers are retrieved from the sorter 100. In other words, the sorting machine system 400 according to this embodiment optimizes the order of retrieval, including the subsequent processes that occur after the entry and retrieval of the containers CT into and from the sorter 100.

[0020] As shown in FIG. 1, the sorting machine system 400 of this embodiment includes a sorting machine 100 into which multiple containers CT with different destinations are respectively loaded and unloaded, a control device 200 that controls each part of the sorting machine 100, and a post-process conveyor 300 (not shown), which will be described later. The multiple containers CT shown in FIG. 1 include containers CT with hatching and containers CT without hatching. In this embodiment, the presence or absence of hatching and the type of hatching applied to the containers CT are distinguished depending on the destination of the container CT. For example, containers CT with the same hatching are transported to the same destination.

[0021] The sorting machine 100 of this embodiment is a multi-story warehouse having four floors of storage shelves 40a to 40d. The sorting machine 100 sorts the received containers CT by destination and then delivers them. The sorting machine 100 includes an identification unit 70 that identifies the containers CT received in the sorting machine 100, an incoming conveyor 10 that transports the multiple containers CT to be received, an incoming elevator 20, a branching device 30, storage shelves 40a to 40d divided into four floors, an outgoing elevator 50, and an outgoing conveyor 60.

[0022] The recognition unit 70 reads the barcode attached to each container CT. The recognition unit 70 can recognize the product number associated with each container from the barcode attached to each container CT. The control device 200, which will be described later, determines the floor number of the storage shelves 40a to 40d as the storage location where each container CT is stored within the sorter 100.

[0023] The receiving-side elevator 20 travels between four floors to transport each container CT to one of the storage shelves 40a to 40d. Each of the receiving-side elevator 20 and the outgoing-side elevator 50 is equipped with two elevator boxes that travel between the first and fourth floors. Under the control of the control device 200, the two elevator boxes operate separately in the vertical direction, and by combining these operations, the container CT is efficiently transported to the destination floor of each of the storage shelves 40a to 40d. The branching device 30 sorts the containers CT transported from the receiving-side elevator 20 into two groups.

[0024] In this embodiment, the storage shelves 40a to 40d each have the same structure. Therefore, only the storage shelf 40d will be described, and descriptions of the other storage shelves 40a to 40c will be omitted. The storage shelf 40d includes a conveyor 41d that transports containers CT from the branching device 30 to the outgoing elevator 50, a right shelf 42d and a left shelf 43d formed on both sides along the transport direction of the conveyor 41d, and a pusher 44d. The right shelf 42d and the left shelf 43d store the containers CT sorted by the branching device 30. Each of the right shelf 42d and the left shelf 43d is composed of multiple conveyors partitioned by solid lines. The control device 200, which will be described later, controls the operation of each conveyor, and the containers CT sorted onto the right shelf 42d and the left shelf 43d are packed and stored from the outgoing elevator 50 side.

[0025] The conveyor 41d transports the placed container CT to the outgoing elevator 50. The pusher 44d pushes a specified container CT out of the containers CT stored on the right shelf 42d or the left shelf 43d toward the conveyor 41d. Note that in FIG. 1, only the pusher 44d that pushes out the container CT stored on the right shelf 42d is shown, and the pusher that pushes out the container CT stored on the left shelf 43d is not shown.

[0026] Fig. 2 is a schematic block diagram of the control device 200. The control device 200 is a personal computer that performs various processes using user operations received by an operation unit 230 and the barcode of the container CT identified by the identification unit 70 of the sorter 100. As shown in Fig. 2, the control device 200 includes a CPU (Central Processing Unit) 210, a memory unit 220 that stores various data, an operation unit 230, and an output unit 240 that outputs various data. The operation unit 230 is composed of a keyboard and a mouse. The output unit 240 is composed of a monitor that displays images and a speaker that outputs audio.

[0027] The storage unit 220 is configured with a hard disk drive (HDD: Hard Disk Drive), etc. The storage unit 220 includes a shipping plan database (shipping plan DB) 221, a storage position table database (storage position table DB) 222, an elevator optimization database (elevator optimization DB) 223, a post-process information database (post-process information DB) 224, an objective function database (objective function DB) 225, and a shipping order database (shipping order DB) 226.

[0028] The outgoing plan DB221 stores an outgoing plan that associates the product number and destination of each container CT with the outgoing order in which the containers are to be outgoing from the sorter 100. The outgoing order of the containers CT included in the outgoing plan is fed back based on the outgoing order changed by the processing performed by the outgoing order determination unit 215 (described later). The storage position table DB222 stores an ingoing position table (storage position information) that is determined by optimizing the outgoing order for each container CT and the storage position of each container CT within the sorter 100 so as to shorten the total time required for the outgoing of all containers CT outgoing from the sorter 100. The storage position table of this embodiment associates the outgoing order of one container CT with one storage position. The elevator optimization DB223 stores an elevator optimization table that indicates the shortest route to the storage position of a container CT that enters the sorter 100 and passes through the ingoing elevator 20.

[0029] The post-process information DB224 stores information on loading work, which is a post-process that is performed on containers CT that have been sorted by destination and released from the sorter 100. The loading work is the work of a work vehicle loading the containers CT sorted by destination onto a truck that will transport them to the destination. The post-process information DB224 stores the time it takes for a worker to load one transported container CT onto a truck (for example, 5 seconds per container), the departure time of the truck, and the stopping time of the truck. The departure time of the truck is the time at which the truck must depart in order to arrive at the destination by a specified time. The stopping time of the truck is the maximum time that the truck can stop for the loading work.

[0030] The objective function DB 225 stores objective functions used to determine the order in which a series of containers entering the sorter 100 are to be released so as to shorten the time required to complete the subsequent process. A method for determining the order of release using objective functions will be described later. The release order DB 226 stores the determined order of release.

[0031] The CPU 210 shown in Figure 2 controls each part of the sorting machine system 400 by expanding and executing a computer program stored in a ROM (Read Only Memory) not shown in the figure into a RAM (Random Access Memory), and also functions as an information acquisition unit (acquisition unit) 211, an entry position determination unit 212, an entry instruction unit 213, a prediction unit 214, and an outgoing order determination unit 215.

[0032] The information acquisition unit 211 acquires various information stored in the memory unit 220 and the product numbers of the containers CT identified by the identification unit 70 of the sorter 100. The storage position determination unit 212 determines the storage position of each container CT scheduled to be stored in the sorter 100 using the outgoing plan stored in the outgoing plan DB221 and the storage position table stored in the storage position table DB222. The storage position determination unit 212 determines the storage positions of each series of containers CT by acquiring the storage positions associated with the outgoing order of each container CT in the storage position table so as to shorten the total outgoing time of all containers CT stored in the sorter 100. In other words, the storage position determination unit 212 determines the storage position of each container CT in the sorter 100 based on the outgoing plan including information on the outgoing order of the series of containers CT to be updated.

[0033] The storage instruction unit 213 transports the identified container CT to a storage position using the product number of the container CT to be stored in the sorter 100 identified by the identification unit 70 and the storage position of each container CT determined by the storage position determination unit 212. The storage instruction unit 213 controls the sorter 100 to instruct the sorter 100 to store the identified container CT at a predetermined storage position within the sorter 100. The storage instruction unit 213 controls the receiving elevator 20 using the elevator optimization table stored in the elevator optimization DB 223 to send the container CT that has been instructed to be stored to the storage position on the storage shelves 40a to 40d via the shortest route.

[0034] The prediction unit 214 predicts the delivery time of the containers CT delivered from the sorter 100, using the delivery order of the containers CT included in the delivery plan and the storage positions of the containers CT. The delivery order determination unit 215 calculates the time intervals at which the containers CT arrive at trucks for each destination, using the predicted delivery time of each container CT and information on loading work as a subsequent process stored in the subsequent process information DB 224.

[0035] The outgoing order determination unit 215 determines the outgoing order of a series of containers CT entering the sorter 100 using the storage position table acquired by the information acquisition unit 211 and information on the loading work as a subsequent process, so as to shorten the time until the loading work is completed. The outgoing order determination unit 215 determines the outgoing order of the containers CT by minimizing an objective function with the time until the completion of the subsequent process as the work index. Specifically, the outgoing order determination unit 215 determines the outgoing order of the containers CT using the time interval between the arrival of the containers CT at trucks with different destinations, so as to shorten the time until the loading work performed on all the containers CT is completed. The outgoing order determination unit 215 determines the outgoing order of the containers CT by minimizing an objective function that includes, as a parameter, the waiting time of the work vehicle that loads the container CT onto the truck. The determined outgoing order is fed back to the outgoing plan. The objective function can take various forms depending on the purpose.

[0036] FIG. 3 is an explanatory diagram of the objective function of Example 1. FIG. 3 shows a schematic diagram of a loading operation in which workers WK1-WK3 load containers CT onto trucks T1-T3 when the containers CT have three destinations. As shown in FIG. 3, the sorting machine system 400 of this embodiment is connected to the outgoing conveyor 60 of the sorter 100 and includes a post-process conveyor (conveyor) 300 that branches into three branches to send the containers CT to different work spaces where the loading operation is performed according to the three destinations. In other words, the post-process conveyor (conveyor) 300 branches to send the containers CT, which have been released from the sorter 100, to different locations where the post-process is performed according to the destinations.

[0037] The objective function of the first embodiment is the total waiting time t wait The total waiting time t wait is the total waiting time during which workers WK1 to WK3 are unable to load containers CT onto trucks T1 to T3 and wait until the containers CT to be loaded arrive. ij is expressed as the following formula (2). In other words, the objective function of the first embodiment includes, as a parameter, the waiting time (container waiting time) that is the time that the workers WK1 to WK3 performing the loading work wait until the container CT to be worked on is delivered.

[0038]

number

[0039]

number

[0040] The outgoing order determination unit 215 uses random numbers to create multiple solution candidates for the outgoing order when the containers CT outgoing from the sorter 100 are allocated by destination. The outgoing order determination unit 215 calculates the objective function of the first embodiment corresponding to each of the multiple solution candidates using the created solution candidates and the outgoing times of the containers CT predicted by the prediction unit 214. If there is no solution candidate in which the objective function is equal to or less than a predetermined target value and if the calculation has not been performed a predetermined number of times, the outgoing order determination unit 215 searches for a solution candidate for the objective function using a genetic algorithm. When using the genetic algorithm, the outgoing order determination unit 215 selects the top five solution candidates with the smallest objective functions. Using the selected solution candidate and the genetic algorithm, the outgoing order determination unit 215 determines a series of container CT outgoing orders based on the searched solution candidates when the objective function is equal to or less than the target value or when the calculation has been performed a predetermined number of times. The objective function is minimized by searching for solution candidates that minimize the objective function using a genetic algorithm.

[0041] FIG. 4 is a flowchart of a sorting method using the sorter system 400. In the sorting flow shown in FIG. 4, first, the information acquisition unit 211 acquires the retrieval plan stored in the retrieval plan DB 221 and the subsequent process information stored in the subsequent process information DB 224 (step S1). In this embodiment, the information acquisition unit 211 further acquires the storage position table stored in the storage position table DB 222 and the elevator optimization table stored in the elevator optimization DB 223. The storage position determination unit 212 determines a storage position according to the retrieval order of each container CT in the sorter 100 using the retrieval plan and the storage position table (step S2). Note that the storage positions of each container CT determined in the processing of step S2 change according to the retrieval order of the containers CT updated in the processing of step S10 by the processing of step S11 described below.

[0042] The prediction unit 214 predicts the delivery time of the container CT when it is delivered from the sorter 100, using the storage position of the container CT and the delivery order of the container CT included in the delivery plan (step S3). The delivery order determination unit 215 uses the predicted delivery time of each container CT and information on the loading work as a subsequent process to determine the time interval ta until the containers CT sorted according to destination arrive at the loading work space of the trucks T1 to T3. ij Calculate.

[0043] The shipping order determination unit 215 uses random numbers to create multiple solution candidates for the shipping order of the containers CT allocated by destination (step S4). The shipping order determination unit 215 calculates an objective function using the created multiple solution candidates and the shipping times of the containers CT (step S5). The shipping order determination unit 215 determines whether there is a solution candidate that is equal to or less than a target value among the multiple objective functions calculated corresponding to the multiple solution candidates (step S6).

[0044] In the process of step S7, if it is determined that there is no solution candidate that is equal to or less than the target value (step S6: NO), the shipping order determination unit 215 determines whether the number of calculations of the objective function has reached a predetermined number (step S7). If it is determined that the predetermined number of calculations has not been reached (step S7: NO), the shipping order determination unit 215 selects the top five solution candidates with the smallest objective functions (step S8). Using the selected solution candidates and a genetic algorithm, the shipping order determination unit 215 searches for a solution candidate that minimizes the objective function (step S9), and the processes from step S6 onwards are repeated.

[0045] If it is determined in the processing of step S6 that a solution candidate that is equal to or less than the target value exists (step S6: YES), or if it is determined in the processing of step S7 that the number of calculations has reached a predetermined number (step S7: YES), the shipping order determination unit 215 updates and determines the shipping order using the solution candidate (step S10). The determined shipping order is fed back to the shipping plan. The storage position determination unit 212 determines the storage positions of the series of containers CT by acquiring the storage positions of the containers CT associated with the shipping order determined by the shipping order determination unit 215 in the storage position table (step S11), and the sorting flow ends. That is, the shipping order determined by the shipping order determination unit 215 is fed back to the shipping plan, and the storage position determination unit 212 determines the storage positions of the containers CT using the fed back shipping plan. The sorting machine system 400 loads and unloads containers CT into and from the sorting machine 100 using the loading position of each container CT determined by the loading position determination unit 212 and the unloading order of each container CT determined by the unloading order determination unit 215.

[0046] FIG. 5 is an explanatory diagram of the outgoing order of Example 1. FIG. 5 shows, in a table, the outgoing plan for 12 containers CT determined by the sorter system 400 of this embodiment and the outgoing order of the containers CT. The stores to which the 12 containers CT shown in FIG. 5 are transported are either A1, A2, B1 to B4, or C1. The containers CT for stores A1 and A2 are transported by truck T1. The containers CT for stores B1 to B4 are transported by truck T2. The container CT for store C1 is transported by truck T3. The group is an outgoing priority associated with the destination store. Specifically, group G01 loaded onto truck T1 is transported from the sorter 100 with priority over group G02. Groups G03 to G06 loaded onto truck T2 are transported from the sorter 100 with priority in the order of groups G03, G04, G05, and G06. The group of four containers CT loaded onto truck T3 is all group G07. Therefore, there is no priority in the order of delivery of containers CT with product numbers 1009 to 1012 in group G07.

[0047] FIG. 6 is an explanatory diagram of the shipping order in Comparative Example 1. FIG. 7 is an explanatory diagram of the shipping order in Comparative Example 2. Each of FIGS. 6 and 7 shows, in the form of a table, the shipping plans and shipping orders for containers CT in Comparative Examples 1 and 2, which correspond to FIG. 5 in Example 1. In Comparative Example 1 shown in FIG. 6, the containers CT are shipped together by truck. Therefore, in Comparative Example 1, after the containers CT with product numbers 1001 to 1004 loaded onto truck T1 are shipped, the containers CT with product numbers 1005 to 1008 loaded onto truck T2 are shipped, and the containers CT with product numbers 1009 to 1012 loaded onto truck T3 are shipped last.

[0048] In Comparative Example 2 shown in Figure 7, containers CT are alternately delivered to each of trucks T1 to T3. Therefore, in Comparative Example 2, the containers are delivered in the order of container CT with product number 1001 loaded onto truck T1, container CT with product number 1005 loaded onto truck T2, and container CT with product number 1009 loaded onto truck T3. Thereafter, the containers CT are delivered in the order of truck T1, truck T2, and truck T3. On the other hand, the delivery order in Example 1 shown in Figure 5 is more irregular than in Comparative Examples 1 and 2, while respecting the priority of the delivery order for each truck represented by a group.

[0049] Figure 8 shows the total waiting time t wait 8 is an explanatory diagram of the time transition of the total waiting time t which is also the objective function of Example 1 shown in the above formula (1) in Example 1 and Comparative Examples 1 and 2 when 50 containers CT are loaded on each of three trucks T1 to T3, unlike the examples shown in FIGS. wait The transition of the total waiting time t wait The transition of the loading time t working 8, the time course of Example 1 is shown by a solid curve C01, the time course of Comparative Example 1 is shown by a dashed straight line C11, and the time course of Comparative Example 2 is shown by a dashed curve C12.

[0050] As shown in FIG. 8, the loading work time t working The longer the time, the more the containers CT to be delivered accumulate in the cargo space. Therefore, the total waiting time t wait When Example 1 is compared with Comparative Example 1, Example 1 has a shorter total waiting time t wait On the other hand, in Comparative Example 1, where the container CT is delivered by truck, the total waiting time t wait is the loading operation time t working That is, between Example 1 and Comparative Examples 1 and 2, Example 1 completes the loading operation the fastest.

[0051] FIG. 9 is an explanatory diagram of the maximum number of containers waiting for work in Example 1. In the example shown in FIG. 8, the transition of the number of containers waiting for work occurring in each of trucks T1 to T3 is shown as the containers being unloaded from the sorter 100 progress. The transition of the number of containers waiting for work occurring in truck T1 is shown by solid polygonal line L011. The number of containers waiting for work occurring in truck T2 is shown by dashed polygonal line L012. The number of containers waiting for work occurring in truck T3 is shown by dashed polygonal line L013. In Example 1, the number of containers waiting for work in truck T2 is the maximum of five. In other words, the maximum number of containers waiting for work in Example 1 is five (pieces).

[0052] FIG. 10 is an explanatory diagram of the maximum number of containers waiting for work in Comparative Example 1. FIG. 11 is an explanatory diagram of the maximum number of containers waiting for work in Comparative Example 2. FIGS. 10 and 11 each show the transitions in the number of containers waiting for work in Comparative Examples 1 and 2, which correspond to FIG. 9 of Example 1. For Comparative Examples 1 and 2, the transitions in the number of containers waiting for work occurring on truck T1 are shown by solid polygonal lines L111 (FIG. 10) and L121 (FIG. 11). The transitions in the number of containers waiting for work occurring on truck T2 are shown by dashed polygonal lines L112 (FIG. 10) and L122 (FIG. 11). The transitions in the number of containers waiting for work occurring on truck T3 are shown by dashed polygonal lines L113 (FIG. 10) and L123 (FIG. 11).

[0053] As shown in Fig. 10, the maximum number of containers waiting for work in Comparative Example 1, in which containers CT are delivered by each truck, is 26 (units), which is the maximum number for each of trucks T1 to T3. As shown in Fig. 11, the maximum number of containers waiting for work, in which containers CT loaded onto each truck are delivered alternately, is 2 (units), which is the maximum number for each of trucks T1 to T3.

[0054] Fig. 12 is an explanatory diagram of the effect of Example 1. In Fig. 12, the horizontal axis represents the maximum number of containers waiting for work, and the vertical axis represents the total waiting time t wait 12, Example 1 and Comparative Examples 1 and 2 are plotted when the objective function of Example 1 is taken as t wait is shorter than both Comparative Examples 1 and 2. The maximum number of containers waiting for work in Example 1 is slightly higher than the maximum number in Comparative Example 2, but is far lower than the maximum number in Comparative Example 1. The total waiting time t wait Since the time is the shortest, the loading operation of the containers CT onto the trucks T1 to T3 in the first embodiment as the subsequent process is completed most quickly.

[0055] As described above, in the sorter system 400 of this embodiment, the outgoing order determination unit 215 determines the outgoing order of a series of containers CT entering the sorter 100 so as to shorten the time until the loading operation is completed, using the receiving position table acquired by the information acquisition unit 211 and information on the loading operation as a subsequent process. The receiving position determination unit 212 determines the receiving positions of each of the series of containers CT by acquiring the receiving positions associated with the outgoing order of each container CT so as to shorten the total outgoing time of all containers CT entering the sorter 100. Therefore, in this embodiment, a series of containers CT entering the sorter system 400 regardless of the outgoing order are stored at the receiving positions associated with the respective outgoing orders determined by the outgoing order determination unit 215 in the receiving position table acquired by the information acquisition unit 211. The outgoing order of the containers CT entering the sorter 100 is determined taking into account the subsequent processes to be performed on the containers CT after they are released. As a result, the sorter system 400 of this embodiment can reduce the time and cost required to complete the subsequent processes compared to when the outgoing order is determined without taking the subsequent processes into consideration. In other words, the sorter system 400 can optimize the outgoing order of a series of containers CT, including the subsequent processes that are performed after the containers CT enter and leave the sorter 100.

[0056] Furthermore, the outgoing order determination unit 215 of this embodiment determines the outgoing order of a series of containers CT by minimizing an objective function in which the time until the completion of the subsequent process is used as the work index. Therefore, by minimizing or maximizing the objective function shown in the above formula (1), it is possible to determine the outgoing order of the containers CT that shortens the time until the completion of the loading work as the subsequent process.

[0057] Furthermore, in this embodiment, the subsequent process performed after the sorting machine 100 leaves the warehouse is the loading work of loading the containers CT onto trucks T1 to T3, so the order of leaving the warehouse for the containers CT for which the loading work has been optimized can be determined.

[0058] In addition, the objective function of this embodiment includes the waiting time (container waiting time) of the workers WK1 to WK3 who perform the loading work as a parameter. Therefore, the total waiting time t wait The order of delivery of the optimized containers CT can be determined.

[0059] In addition, the shipping order determination unit 215 of this embodiment uses a genetic algorithm to search for solution candidates for the objective function and determine the shipping order, so that an efficiently optimized shipping order for each container CT can be determined.

[0060] Further, the prediction unit 214 of this embodiment predicts the delivery time of the container CT delivered from the sorter 100. The delivery order determination unit 215 determines the interval ta between the arrival of the container CT at the trucks T1 to T3 for different destinations. ij The shipping order of a series of containers CT is determined by using the time ta calculated by using the predicted shipping time of the container CT so as to shorten the time until the loading work performed on all the containers CT is completed. ij In this embodiment, the order in which the containers CT are to be released is determined by using the above formula. As a result, in this embodiment, the total waiting time t wait As a result, the time required to complete loading operations for all containers CT can be shortened.

[0061] 3, the downstream process conveyor 300 of this embodiment branches to send the containers CT delivered from the sorter 100 to different locations where loading work as a downstream process is performed, depending on their destinations. Therefore, the downstream process conveyor 300 can automatically send each container CT to a different location where loading work is performed, depending on its destination.

[0062] Second Embodiment In the second embodiment, the outgoing order determination unit 215 determines the outgoing order of the containers CT by minimizing the objective function I of the second embodiment shown in the following formula (3), which is different from that of the first embodiment. The objective function I of the second embodiment is wait and the remaining work time function C max and a weight α (0<α<1).

[0063]

number

[0064] Work time remaining function C max is the remaining work time t of each work vehicle WK1 to WK3 at an arbitrary time. remain and the work time t used in the objective function of Example 1. working The remaining work time t is calculated using the following formula (4). remain is the time until processing of the container CT waiting for work is completed.

[0065]

number

[0066] FIG. 13 shows the remaining work time function C max This is an explanatory diagram of the remaining work time function C max is the remaining work time t remain and working time t working , it can be said that it is a function of the number of containers waiting for work shown in Figs. 9 to 11 of the first embodiment. For example, the remaining work time function C max When is "1", "2", or "3", it means that the number of containers waiting for work is 1, 2, or 3, respectively. On the other hand, the remaining work time function C max is the working time t working Since this is a value obtained by dividing by , it can take a decimal value, unlike the number of containers waiting for work, which is expressed as an integer and is shown in Figures 9 to 11.

[0067] 13, as in FIGS. 9 to 11 of the first embodiment, the remaining operation time function C changes depending on the order of delivery when 50 containers CT are loaded onto each of three trucks T1 to T3. max In Fig. 13, the time transition of the remaining work time function C max The time transition of is shown by the solid broken line L021. The remaining work time function C of truck T2 max The time transition of is shown by the broken line L022. The remaining work time function C of truck T3 max The time transition of is shown by the dashed line L023. In the second embodiment, the remaining work time function C max The maximum value of is "3". In other words, the maximum number of containers waiting for work in Example 2 is 3 (units), which is less than 5 (units) in Example 1. That is, Example 2 is optimized to shuffle the containers CT loaded onto each truck T1 to T3 more frequently than Example 1. In this way, the objective function defined to optimize the outgoing order of the containers CT can be modified.

[0068] <Modifications of the embodiment> The present invention is not limited to the above-described embodiment, and can be implemented in various forms without departing from the spirit of the present invention, including, for example, the following modifications: In the above-described embodiment, part of the configuration realized by hardware may be replaced by software, and conversely, part of the configuration realized by software may be replaced by hardware.

[0069] <Variation 1> The sorter system 400 of the first embodiment is an example, and the configuration of the sorter system 400 and the control it executes can be modified. The sorter system 400 can be modified to the extent that it determines the order of unloading a series of containers CT using the storage position table and information on the subsequent process so as to shorten the time until the subsequent process is completed. For example, the unloading order determination unit 215 may determine the order of unloading the containers CT without using an objective function. The unloading order determination unit 215 determines the order of unloading the containers CT by using the total waiting time t wait The storage position table can be modified within a range in which the storage position of each container CT in the sorter 100 is determined for each storage order of the containers CT, and may be in a form other than a table.

[0070] In addition, the outgoing order determination unit 215 may determine the outgoing order of the containers CT by maximizing an objective function different from the objective function defined by equation (1) in the first embodiment or the objective function I defined by equation (3) in the second embodiment. For example, the outgoing order determination unit 215 may determine the outgoing order of the containers CT by maximizing an objective function I different from the objective function defined by equation (1) in the first embodiment or the objective function I defined by equation (3) in the second embodiment. wait The order of unloading the containers CT may be determined by maximizing an objective function that represents work efficiency, the objective function including, as parameters, the number of workers performing the loading work and the location or size of the loading space for the loading work. The objective function may include, as a parameter, at least one of the departure times of the trucks T1 to T3 and the stopping times of the trucks T1 to T3. The objective function may also include, as a parameter, the total waiting time t wait The objective function may not necessarily include parameters such as the number of containers waiting to be worked on or the number of containers waiting to be worked on. The parameters included in the objective function may be selected within the scope of well-known techniques. Methods other than the genetic algorithm may be used to search for a solution to the objective function.

[0071] In addition, the subsequent processes performed on the containers CT released from the sorting machine 100 may include at least one of loading work, inspection work for each container CT, packaging work for each container CT, and sorting work to further sort the containers CT.

[0072] The shipping order determination unit 215 determines the interval ta between the arrival times of the containers CT predicted by the prediction unit 214. ij However, the shipping order may be determined without using the prediction result of the prediction unit 214. The shipping order determination unit 215 uses the prediction result of the prediction unit 214 to determine the interval ta between the arrival times of the containers CT. ij The control device 200 may not function as the prediction unit 214.

[0073] <Variation 2> In the first embodiment, the storage position determination unit 212 determines the storage position of each container CT stored in the sorter 100, but the sorter system 400 does not need to determine the storage position. For example, information about the storage position may be obtained from another device, and the storage instruction unit 213 may issue a storage instruction.

[0074] FIG. 14 is a flowchart of a modified sorting method. In the modified sorting method, the sorter system 400 determines the order of unloading of containers CT that have already been stored in the sorter 100 so as to shorten the time until the subsequent process is completed. In the modified sorting flow, as shown in FIG. 14, first, an acquisition process is performed in which the information acquisition unit 211 acquires a storage position table and information about the subsequent process (step S21). The unloading order determination unit 215 performs an unloading order determination process using the acquired storage position table and information about the subsequent process (step S22). In the unloading order determination process, the unloading order of a series of containers CT that are stored in the sorter 100 is determined so as to shorten the time until the subsequent process is completed. In the unloading order determination process, the unloading order of a series of containers CT may be optimized using an objective function or the like so as to shorten the time until the subsequent process is completed. After the outgoing order determination process, the storage position determination unit 212 performs an incoming position determination process to determine the incoming positions of each of a series of containers CT by obtaining the incoming positions in the storage position table that correspond to the outgoing order determined by the outgoing order determination process (step S23), and the sorting flow ends.

[0075] The control device 200 may not include the operation unit 230 and the output unit 240. The CPU 210 of the control device 200 may not function as the storage instruction unit 213 and the prediction unit 214. The control device 200 may not include the memory unit 220. In this case, the information acquisition unit 211 may acquire information regarding the storage position of the container CT and the subsequent process from a server or other device different from the configuration of the sorter system 400.

[0076] The sorter system 400 may include multiple sorters 100. When the sorter system 400 includes multiple sorters, the sorters may have different structures and capacities. For example, one sorter 100 may have four storage shelves 40a-40d, while a different sorter may have only one storage shelf. The number of containers that can be stored in the storage shelf 40a on the first floor of the sorter 100 may be different from the number of containers that can be stored in the storage shelf on the first floor of a different sorter. The storage location of the container CT does not necessarily have to be the floor number of the storage shelves 40a-40d within the sorter 100. For example, a specific location may be specified as the storage location. Furthermore, depending on the container CT, the storage location may be the floor number of the storage shelves 40a-40d or a specific location.

[0077] <Variation 3> 15 is a schematic block diagram of a modified sorter system 400a. The modified sorter system 400a differs from the sorter system 400 of the first embodiment only in the post-process conveyor 300a. Therefore, only the post-process conveyor 300a will be described, and descriptions of other components will be omitted.

[0078] In the modified example shown in Fig. 15, the downstream process conveyor 300a includes a main conveyor 310 that circulates from the exit to the entrance of the sorter 100, and sub-conveyors 301-303 that send containers to trucks T1-T3 with different destinations. As shown in Fig. 15, in the modified example, when a predetermined number of containers CT are waiting for loading work in a downstream process, such as truck T2, the main conveyor 310 of the downstream process conveyor 300a circulates the containers CT to be loaded onto truck T2. The main conveyor 310 sends the containers CT that have been unloaded from the sorter 100 from the exit to the entrance of the sorter 100, and then circulates them again into the sorter 100.

[0079] Therefore, in the sorter system 400a of the modified example, the container CT that is waiting in the loading operation of the subsequent process is circulated, and the container CT that follows the circulated container CT is sent first to the truck corresponding to its destination. This prevents the sorter system 400a from causing the container CT that is being sent to the subsequent process conveyor 300a to wait. In other words, by circulating the container CT that is waiting, the sorter system 400a can efficiently load the container CT that is not waiting.

[0080] This aspect has been described above based on embodiments and modifications. However, the above-described embodiments are intended to facilitate understanding of this aspect and are not intended to limit this aspect. This aspect may be modified or improved without departing from the spirit and scope of the claims, and equivalents thereof are included in this aspect. Furthermore, if a technical feature is not described as essential in this specification, it may be deleted as appropriate.

[0081] The present invention can also be realized in the following forms. [Application example 1] 1. A sorter system comprising: a sorting machine into which a plurality of containers having different destinations are stored, and which sorts the stored containers by their destinations and then discharges the containers; an acquisition unit that acquires storage position information that defines the storage position of each container within the sorter for each container's order of release, and information regarding subsequent processes that are processes from when the container is released from the sorter until transportation to the destination is completed; a shipping order determination unit that determines a shipping order for a series of containers that are to be stored in the sorter, using the storage position information and information related to the subsequent process acquired by the acquisition unit, so as to shorten the time until the subsequent process is completed; a storage position determination unit that determines a storage position of each of the series of containers by acquiring the storage positions associated with the outgoing order determined by the outgoing order determination unit in the storage position information; A sorting machine system comprising: [Application example 2] The sorter system according to Application Example 1, The sorting machine system, wherein the outgoing order determination unit determines the outgoing order of the series of containers by minimizing or maximizing an objective function having the time until the subsequent process is completed as a work index. [Application example 3] The sorter system according to Application Example 1 or Application Example 2, The post-process is a loading operation of loading the containers delivered from the sorter onto a transport aircraft; Inspection of each container delivered from the sorting machine; Packing each container delivered from the sorting machine; a sorting operation for further sorting the containers delivered by the sorting machine; A sorting machine system comprising at least one of: [Application example 4] The sorter system according to any one of Application Examples 1 to 3, The objective function is: The container waiting time of the worker performing the loading work; The number of workers; The location or size of the loading space for the loading operation; The departure time of the transport aircraft; The stop time of the transport aircraft; A sorting machine system including at least one of the following as a parameter. [Application example 5] The sorter system according to any one of Application Examples 1 to 4, The sorting machine system, wherein the outgoing order determination unit determines the outgoing order of each of the series of containers by using a genetic algorithm for the objective function. [Application Example 6] The sorter system according to any one of Application Examples 1 to 5, further comprising: a prediction unit that predicts the delivery time of a container that will be delivered from the sorter, The outgoing order determination unit calculates the time intervals at which containers arrive at the subsequent process using the predicted outgoing times of the containers, and determines the outgoing order of the series of containers using the calculated intervals so as to shorten the time it takes for the subsequent process to be completed for all containers. [Application Example 7] The sorter system according to any one of Application Examples 1 to 6, further comprising: A sorting machine system comprising a conveyor that branches off to send containers discharged from the sorting machine to different locations where the subsequent processes are carried out depending on the destination. [Application Example 8] The sorter system according to any one of Application Examples 1 to 7, further comprising: A sorting machine system comprising a conveyor that circulates a container discharged from the sorting machine from the exit of the sorting machine back into the sorting machine when a container is waiting in the subsequent process. [Application Example 9] A sorting method, comprising: an acquiring process for acquiring, in a sorting machine into which a plurality of containers with different destinations are stored and which sorts the stored containers by destination and then stores them out, storage position information in which the storage position of each container is determined according to the order in which the containers are stored out, and information on subsequent processes which are processes from when the containers are stored out of the sorting machine until transportation to the destinations is completed; a shipping order determination process for determining a shipping order for a series of containers entering the sorting machine using the acquired storage position information and information related to the subsequent process so as to shorten the time required to complete the subsequent process; a storing position determining step of determining storing positions of the series of containers by acquiring the storing positions associated with the outgoing order determined by the outgoing order determining step from the storing position information; A sorting method to perform. [Application Example 10] A computer program comprising: an acquisition function for acquiring, in a sorting machine into which a plurality of containers with different destinations are stored and which sorts the stored containers by destination and then stores them out, storage position information in which the storage position of each container is determined according to the order in which the containers are stored out, and information on subsequent processes which are processes from when the containers are stored out of the sorting machine until transportation to the destinations is completed; a shipping order determination function that determines the shipping order of a series of containers that are to be stored in the sorter by using the acquired storage position information and information related to the subsequent process so as to shorten the time until the subsequent process is completed; a storage position determination function that determines a storage position of each of the series of containers by acquiring the storage positions associated with the outgoing order determined by the outgoing order determination function in the storage position information; A computer program that causes a computer to execute the following. [Explanation of symbols]

[0082] 10...Incoming conveyor 20...Entry elevator 30...Branching device 40a~40d...Storage shelves 41d...Conveyor 42d…Right shelf 43d…Left shelf 44d...Pusher 50...Exit elevator 60...Outlet conveyor 70...Identification section 100...Sorting machine 200...Control device 210...CPU 211…Information acquisition unit (acquisition unit) 212…Archive position determination unit 213... Warehousing instruction section 214…Prediction Department 215...Delivery order determination section 220...Storage section 221...Shipping plan database 222...Inventory location table database 223...Elevator Optimization Database 224...Post-process information database 225...Objective function database 226...Return order database 230...Operation unit 240...Output section 300, 300a...Post-process conveyor (conveyor) 301~303...Sub-conveyor 310...Main conveyor 400, 400a...Sorting machine system CT: Container C max … remaining work time function I...Objective function T1~T3...Truck WK1~WK3...Workers ta ij …the interval between container arrivals t remain … remaining work time t working …Loading operation time tw ij …Work waiting time

Claims

1. 1. A sorter system comprising: a sorting machine into which a plurality of containers having different destinations are stored, and which sorts the stored containers by their destinations and then discharges the containers; an acquisition unit that acquires storage position information that defines the storage position of each container within the sorter for each container's order of release, and information regarding subsequent processes that are processes from when the container is released from the sorter until transportation to the destination is completed; a shipping order determination unit that determines a shipping order for a series of containers that are to be stored in the sorter, using the storage position information and information related to the subsequent process acquired by the acquisition unit, so as to shorten the time until the subsequent process is completed; a storage position determination unit that determines a storage position of each of the series of containers by acquiring the storage positions associated with the outgoing order determined by the outgoing order determination unit in the storage position information; A sorting machine system comprising:

2. 10. The sorter system of claim 1, The sorting machine system, wherein the outgoing order determination unit determines the outgoing order of the series of containers by minimizing or maximizing an objective function having the time until the subsequent process is completed as a work index.

3. 3. The sorter system of claim 2, The post-process is a loading operation of loading the containers delivered from the sorter onto a transport aircraft; Inspection of each container delivered from the sorting machine; Packing each container delivered from the sorting machine; a sorting operation for further sorting the containers delivered by the sorting machine; A sorter system comprising at least one of:

4. 4. The sorter system of claim 3, The objective function is: The container waiting time of the worker performing the loading work; The number of workers; The location or size of the loading space for the loading operation; The departure time of the transport aircraft; The stop time of the transport aircraft; A sorting machine system including at least one of the following as a parameter.

5. 5. The sorter system of claim 4, The sorting machine system, wherein the outgoing order determination unit determines the outgoing order of each of the series of containers by using a genetic algorithm for the objective function.

6. 6. The sorter system of claim 5, further comprising: a prediction unit that predicts the delivery time of a container that will be delivered from the sorter, The outgoing order determination unit calculates the time intervals at which containers arrive at the subsequent process using the predicted outgoing times of the containers, and determines the outgoing order of the series of containers using the calculated intervals so as to shorten the time it takes for the subsequent process to be completed for all containers.

7. The sorter system according to any one of claims 1 to 6, further comprising: A sorting machine system comprising a conveyor that branches off to send containers discharged from the sorting machine to different locations where the subsequent processes are carried out depending on the destination.

8. The sorter system according to any one of claims 1 to 6, further comprising: A sorting machine system comprising a conveyor that circulates a container discharged from the sorting machine from the exit of the sorting machine back into the sorting machine when a container is waiting in the subsequent process.

9. A sorting method, comprising: an acquiring process for acquiring, in a sorting machine into which a plurality of containers with different destinations are stored and which sorts the stored containers by destination and then stores them out, storage position information in which the storage position of each container is determined according to the order in which the containers are stored out, and information on subsequent processes which are processes from when the containers are stored out of the sorting machine until transportation to the destinations is completed; a shipping order determination process for determining a shipping order for a series of containers entering the sorting machine using the acquired storage position information and information related to the subsequent process so as to shorten the time required to complete the subsequent process; a storing position determining step of determining storing positions of the series of containers by acquiring the storing positions associated with the outgoing order determined by the outgoing order determining step from the storing position information; A sorting method to perform.

10. A computer program comprising: an acquisition function for acquiring, in a sorting machine into which a plurality of containers with different destinations are stored and which sorts the stored containers by destination and then stores them out, storage position information in which the storage position of each container is determined according to the order in which the containers are stored out, and information on subsequent processes which are processes from when the containers are stored out of the sorting machine until transportation to the destinations is completed; a shipping order determination function that determines the shipping order of a series of containers that are to be stored in the sorter by using the acquired storage position information and information related to the subsequent process so as to shorten the time until the subsequent process is completed; a storage position determination function that determines a storage position of each of the series of containers by acquiring the storage positions associated with the outgoing order determined by the outgoing order determination function in the storage position information; A computer program that causes a computer to execute the following.

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