Item replacement device, item replacement system, and item replacement method

Abstract

Provided is an article replacement device comprising: a carriage device that draws out a tray placed on a shelf from the shelf, and pushes the tray onto the shelf; and a movement device that moves the carriage device. The carriage device has a hook part, a transmission device that moves the hook part, and a table. The hook part has a claw part with a tip-end facing upward. After the movement device moves the carriage device to a position on a shelf at which a tray to be drawn out is stored, the transmission device moves the hook part in the upward direction until the claw part is inserted into a downwardly opening recessed part provided on the edge of the tray, and then moves the hook part in the horizontal direction, thereby drawing out the tray from the shelf and placing the tray on the table. After the movement device moves the carriage device to the position on the shelf at which the tray is to be stored, the transmission device brings the hook part into contact with the tray placed on the table, and then moves the hook part in the direction of the tray, thereby pushing the tray into the shelf.

Description

[Technical Field]

[0001] The present invention relates to a technique for replacing stored articles on shelves that are to be loaded by a shelf-type automated guided vehicle in a logistics center. [Background technology]

[0002] In e-commerce distribution centers, product retrieval events occur in response to product orders placed over the Internet. One type of logistics equipment used to retrieve products here is an automated guided vehicle (AGV). Products are loaded onto shelves that can be transported, and the AGV transports the shelves based on the product retrieval event. The shelves are then moved to a work area called a picking station, where a worker who will ultimately retrieve the products is waiting, and the worker retrieves the ordered products.

[0003] Shelves storing popular products are often transported, so they are placed near the picking station. Since multiple items are usually stored on one shelf, the efficiency of product retrieval can be improved by consolidating popular products that are frequently shipped and related products that are frequently shipped together on one shelf or a small number of shelves and placing them near the picking station. In particular, when replenishing products, this provides an opportunity to review the product configuration on each shelf, and it is effective to automatically replace the products based on the ranking of popular products.

[0004] Examples of technologies for automatically replacing products are disclosed in International Publication No. 2016 / 100235 (Patent Document 1) and Japanese Patent Application Laid-Open No. 2020-128266 (Patent Document 2). Patent Document 1 discloses a technology for learning the shape of a product to be replaced and then appropriately grasping the product with a robotic hand and transferring it. Patent Document 2 states, "The warehouse management device of the present invention is characterized by comprising: an aggregation preparation unit that calculates a shipping rate of products stored in a container and determines multiple containers based on the shipping rate; and an aggregation unit that transmits a transport instruction to a transport robot to transport the determined multiple containers to an aggregation station that aggregates the products into one container. The aggregation preparation unit further determines multiple containers to store products with a shipping rate that is high or low enough to meet a predetermined standard, creates an aggregation instruction to move the products from one container to another, and the aggregation unit transmits the aggregation instruction to an aggregation operator located at the aggregation station." [Prior art documents] [Patent documents]

[0005] Patent Document 1: International Publication No. 2016 / 100235

[0006] Patent Document 2: JP 2020-128266 A Summary of the Invention [Problem to be solved by the invention]

[0007] When replacing items by grasping individual items using a robotic hand, the processing accuracy for individual objects is high, but replacing the entire contents of a shelf takes time. Also, directly grasping an item makes it difficult to handle items with low mechanical strength.

[0008] The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a high-speed and efficient article replacement device. [Means for solving the problem]

[0009] A representative example of means for solving at least one of the problems of the present invention is an article replacement device comprising: a carriage device for pulling out trays placed on a shelf from the shelf and pushing the trays onto the shelf; and a moving device for moving the carriage device, wherein the carriage device has a hook portion, a transmission device for moving the hook portion, and a table, and the hook portion has a claw portion with an upwardly facing tip, and after the moving device has moved the carriage device to a position on the shelf where the tray to be pulled out is stored, the transmission device moves the hook portion upward and the claw portion is inserted into a downwardly opening recess provided on the edge of the tray, and then moves the hook portion horizontally, thereby pulling out the tray from the shelf and placing it on the table, and after the moving device has moved the carriage device to a position on the shelf where the tray is to be stored, the transmission device brings the hook portion into contact with the tray placed on the table, and then horizontal The tray is pushed into the shelf by moving the tray in a direction An article exchange device, wherein the transmission device is a wrapping transmission device having a plurality of rotating parts and wrapping parts wrapped around the plurality of rotating parts, the hook part is attached to the wrapping part, and the carriage device has a motor that drives at least one of the plurality of rotating parts, and the motor rotates at least one of the plurality of rotating parts, causing the hook part to move vertically and horizontally along a track formed by the wrapping parts wrapped around the plurality of rotating parts. . [Effects of the Invention]

[0010] According to one aspect of the present invention, stored items in a shelf can be moved all at once, and damage to the stored items can be reduced. This invention makes it possible to realize a high-speed and efficient item replacement device. Note that problems, configurations, and effects other than those described above will become clear from the description of the following embodiments. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a block diagram showing an example of a configuration of an information processing system according to an embodiment of the present invention. [Figure 2] FIG. 1 is a perspective view showing an example of a warehouse layout of a logistics center according to an embodiment of the present invention. [Figure 3] FIG. 1 is an explanatory diagram showing an example of an arrangement of items in a warehouse according to an embodiment of the present invention. [Figure 4]FIG. 1 is a perspective view showing an example of a configuration of a shelf in an embodiment of the present invention. [Figure 5] 1 is a perspective view showing an example of the configuration of a work station for replacing an item according to an embodiment of the present invention; [Figure 6] 1 is a perspective view showing an example of a configuration of an article replacement device according to an embodiment of the present invention. [Figure 7A] FIG. 2 is a front view showing an example of the configuration of a carriage device according to an embodiment of the present invention. [Figure 7B] 7 is an enlarged view of a hook portion 703 in a front view showing an example of the configuration of a carriage device according to an embodiment of the present invention. FIG. [Figure 7C] FIG. 2 is a plan view showing an example of the configuration of a carriage device according to an embodiment of the present invention. [Figure 7D] FIG. 2 is a left side view showing an example of the configuration of a carriage device according to the embodiment of the present invention. [Figure 8A] 10A and 10B are explanatory diagrams showing an example of the operation of pulling out and pushing in a tray by a carriage device in an embodiment of the present invention. [Figure 8B] 10A and 10B are explanatory diagrams showing an example of the operation of pulling out and pushing in a tray by a carriage device in an embodiment of the present invention. [Figure 8C] 10A and 10B are explanatory diagrams showing an example of the operation of pulling out and pushing in a tray by a carriage device in an embodiment of the present invention. [Figure 8D] 10A and 10B are explanatory diagrams showing an example of the operation of pulling out and pushing in a tray by a carriage device in an embodiment of the present invention. [Figure 8E] 10A and 10B are explanatory diagrams showing an example of the operation of pulling out and pushing in a tray by a carriage device in an embodiment of the present invention. [Figure 8F] 10A and 10B are explanatory diagrams showing an example of the operation of pulling out and pushing in a tray by a carriage device in an embodiment of the present invention. [Figure 9] 10A and 10B are explanatory diagrams showing examples of the shapes of the shelf boards and trays in an embodiment of the present invention. [Figure 10] FIG. 10 is an explanatory diagram illustrating an example of order information according to an embodiment of the present invention. [Figure 11] FIG. 10 is an explanatory diagram illustrating an example of inventory information according to an embodiment of the present invention. [Figure 12] FIG. 10 is an explanatory diagram illustrating an example of shelf information according to an embodiment of the present invention. [Figure 13] 1 is a flowchart illustrating an example of a process related to picking of an item, which is executed by an information processing system according to an embodiment of the present invention. [Figure 14] 10 is a flowchart illustrating an example of a process related to replacement and replenishment of items executed by the information processing system according to the embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, embodiments of the present invention will be described with reference to the drawings. The examples are illustrative for explaining the present invention, and for clarity of explanation, appropriate omissions and simplifications have been made. The present invention can also be implemented in various other forms. Unless otherwise specified, each component may be singular or plural.

[0013] In order to facilitate understanding of the invention, the position, size, shape, range, etc. of each component shown in the drawings may not represent the actual position, size, shape, range, etc. Therefore, the present invention is not necessarily limited to the position, size, shape, range, etc. disclosed in the drawings.

[0014] Examples of various types of information may be described using expressions such as "table," "list," and "queue," but the various types of information may also be expressed using data structures other than these. For example, various types of information such as "XX table," "XX list," and "XX queue" may also be expressed as "XX information." When describing identification information, expressions such as "identification information," "identifier," "name," "ID," and "number" are used, but these are interchangeable.

[0015] When there are multiple components with the same or similar functions, they may be described using the same reference numeral with different subscripts. When there is no need to distinguish between these multiple components, the subscripts may be omitted.

[0016] In the embodiments, processing performed by executing a program may be described. Here, a computer executes the program using a processor (e.g., a CPU or a GPU) and performs processing defined by the program using storage resources (e.g., a memory) and interface devices (e.g., a communication port). Therefore, the entity performing the processing by executing the program may be the processor. Similarly, the entity performing the processing by executing the program may be a controller, device, system, computer, or node having a processor. The entity performing the processing by executing the program may be any computing unit, and may include a dedicated circuit that performs specific processing. Here, the dedicated circuit may be, for example, an FPGA (Field Programmable Gate Array), an ASIC (Application Specific Integrated Circuit), or a CPLD (Complex Programmable Logic Device).

[0017] A program may be installed on a computer from a program source. The program source may be, for example, a program distribution server or a computer-readable storage medium. When the program source is a program distribution server, the program distribution server may include a processor and a storage resource for storing the program to be distributed, and the processor of the program distribution server may distribute the program to be distributed to other computers. In addition, in an embodiment, two or more programs may be realized as one program, or one program may be realized as two or more programs.

[0018] Next, an outline of an embodiment of the present invention will be described.

[0019] In e-commerce using a logistics center, products are stored on storage shelves, and the number of stored products is managed by an inventory server. E-commerce users who order online can order the number of products according to the number in the inventory server. In other words, if a product is not stored on the storage shelf and the remaining number is not recorded in the inventory server, it cannot be provided to the user. Replenishing products on the storage shelf must be done quickly. In logistics centers that use AGVs to transport the aforementioned storage shelves to the sorters, each product must be carefully handled by hand to avoid damage during shipping. During warehousing, multiple products are placed, so trays, boxes, and baskets can be used to store them quickly and without excessive manual handling of each product.

[0020] In such a logistics system, the storage shelves where popular products are stored are more likely to be called by AGVs than other storage shelves. Sorting efficiency can be improved by locating storage shelves close to sorting workers. To further increase efficiency, it is effective to configure storage shelves that store many popular products or to configure storage shelves with products related to a certain product (for example, screws, washers, nuts).

[0021] As order history accumulates, it becomes possible to identify popular products and related products. For example, statistical analysis of order history data can extract order frequency and correlations. Based on this analysis, it is possible to configure storage shelves for popular products or for products related to a product. For example, consider configuring storage shelves for popular products. At least one storage shelf will need to be called up, and the contents removed, which will require work. In the case of a logistics center using AGVs, it is effective to call up two storage shelves, swap the contents based on the order of product popularity, and then reconfigure the storage shelves.

[0022] This reconfiguration of storage shelves is similar to the warehousing operation, so containers such as trays, boxes, and baskets can be used, and it can be performed by a device that replaces these containers. Since it is automated and not a shipping operation, it does not require many workers. For example, the replacement can be performed late at night when there are no (or few) workers picking products for shipping.

[0023] Next, an embodiment of the present invention will be described with reference to the drawings.

[0024] FIG. 1 is a block diagram showing an example of the configuration of an information processing system according to an embodiment of the present invention.

[0025] The information processing system of this embodiment includes a warehouse control device 100, a network 180, a plurality of conveying devices 1, a plurality of station terminals 7, and one or more item replacement devices 90. The plurality of conveying devices 1, the plurality of station terminals 7, and the one or more item replacement devices 90 are connected to the warehouse control device 100 via the network 180.

[0026] In this embodiment, an operator operates a station terminal 7 set up in a warehouse at a logistics center, and the warehouse control device 100 causes the conveying device 1 to convey a shelf 8 (storage unit) to a work station for picking, and the operator performs the picking work. The warehouse control device 100 also causes the conveying device 1 to convey the shelf 8 (storage unit) to the work station for item replacement, and controls the item replacement device 90 to replace (and / or replenish) the items stored on the shelf 8.

[0027] In the following description, each of the multiple shelves 8 may be described separately, such as shelf 8A, shelf 8B, etc.

[0028] The warehouse control device 100 is a computer including an arithmetic unit 110, a memory 120, an input unit 130, an output unit 140, a storage unit 150, and a communication interface 170. The warehouse control device 100 is not limited to the configuration shown in FIG. 1. The warehouse control device 100 may be composed of a single computer or multiple computers. Furthermore, each device included in the warehouse control device 100 may be located on a single computer or may be composed of multiple devices in a distributed manner. Each program and each piece of information included in the storage unit 150 may be stored in a single storage unit or may be stored in multiple storage units in a distributed manner.

[0029] The storage device 150 has a non-volatile storage medium and stores programs executed by the arithmetic device 110 and data used by the programs. Examples of the programs stored in the storage device 150 include a path creation program 161, a data input / output program 162, a data analysis program 163 (control unit), a transport device control program 164, and an article rearrangement device control program 165, and the arithmetic device 110 loads the necessary programs into the memory 120 and executes them.

[0030] Examples of data stored in the storage device 150 include order information 200, inventory information 220, shelf information 230, route data 270, and item replacement data 280.

[0031] The path creation program 161 calculates the path along which the conveying device 1 will travel based on preset map information (not shown). The path creation program 161 calculates the path along which the conveying device 1 will travel, for example, from the location of the item to be picked (e.g., a product to be shipped) and the location of the destination picking work station. The path creation program 161 also calculates paths for the two conveying devices 1 to transport two shelves 8 storing items identified by a data analysis program 163 (described later) as items to be replaced to the work station for item replacement.

[0032] The transport device control program 164 transmits a transport instruction to an available transport device 1, specifying the shelf 8 to be transported and the work station to which the item is to be transported, based on the route calculated by the route creation program 161, etc.

[0033] The data input / output program 162 executes the processes of receiving order information, receiving input from the station terminal 7 operated by the worker, receiving sensor data from the conveying device 1, and receiving sensor data from the article replacement device 90, and stores the data in the storage device 150. Furthermore, when the data input / output program 162 receives a command to start the conveying device 1 from the station terminal 7, it transmits a command generated by the conveying device control program 164 to the conveying device 1.

[0034] The data analysis program 163 identifies the items to be replaced and the shelves on which they are stored based on the order information 200, inventory information 22, and shelf information 230, and stores the results in the item replacement data 280.

[0035] Order information 200 is information about an order requesting shipment of an item, and stores information about the item to be picked. Order information 200 may include information about orders for items that are about to be shipped, as well as information about orders for items that have already been shipped. Inventory information 220 stores information about the inventory of items, such as information about the shelf 8 on which the item is located, the item's location within the shelf 8, the quantity, weight, and the tray that holds the item. Shelf information 230 stores information such as the shelf location and weight.

[0036] The route data 270 stores information on routes within the warehouse for each conveyance device 1 calculated by the route creation program 161. The item replacement data 280 stores information on items to be replaced identified by the data analysis program 163 and the shelves on which they are stored.

[0037] The input device 130 is configured with a keyboard, a mouse, a touch panel, etc. The output device 140 is configured with a display, etc. The communication interface 170 communicates with the transport device 1, the station terminal 7, and the article replacement device 90 via a wireless or wired network 180.

[0038] The conveying device 1 is an autonomous mobile body that can automatically convey shelves 8 loaded with items in response to commands from a warehouse control device 100. The conveying device 1 is an automatic conveying device that includes a control device 2, a storage device 4, a drive device 3, a sensor 5, and a communication interface 6. The sensor 5 includes, for example, a vibration sensor (acceleration sensor) and an image sensor.

[0039] The control device 2 includes a calculation device (not shown) and a memory (not shown). The calculation device executes a program stored in the memory, and the control device 2 performs processes such as self-position estimation based on information acquired from the sensor 5 and travel control of the drive device 3 so that the conveyance device 1 travels along the route generated by the warehouse control device 100.

[0040] The storage device 4 is configured as a non-volatile storage medium and stores each program and data used by each program. Examples of data include route data and map information. The route data stores route data 270 received from the warehouse control device 100. The map information stores map information (not shown) received from the warehouse control device 100.

[0041] The drive device 3 includes a cart (not shown), drive wheels (not shown), a table (not shown), auxiliary wheels (not shown), a motor (not shown) as a power source for driving the drive wheels and the table, and a battery (not shown) for supplying power to the motor. The drive wheels and the table may each be driven by an independent motor.

[0042] The drive device 3 moves under the shelf 8 and then raises the table, thereby lifting the shelf 8. Then, with the shelf 8 raised, the drive device 3 travels toward the specified position and lowers the table to lower the shelf 8 onto the floor.

[0043] The station terminal 7 is installed at a picking work station where a worker performs picking work. The station terminal 7 displays the work schedule information transmitted from the warehouse control device 100 to present the work details to the worker, and also receives input from the worker and transmits it to the warehouse control device 100.

[0044] The station terminal 7 includes a communication interface 71, an input device 72, an output device 73, a control device 74, and a storage device 75. The communication interface 71 communicates with the warehouse control device 100 via a network 180. The input device 72 is composed of a touch panel or a keyboard, etc. The output device 73 is composed of a display or a speaker, etc. The control device 74 is composed of a microcomputer, etc., and executes a predetermined program. The storage device 75 stores the program and data.

[0045] The station terminal 7 receives the work schedule to be performed at the work station from the warehouse control device 100 and stores it in the picking work information 76 in the storage device 75. The station terminal 7 outputs instructions and the like according to the work status of the worker from the picking work information 76 to the output device 73.

[0046] The article replacement device 90 is installed at a work station for article replacement. The article replacement device 90 has a mechanism for pulling out articles stored on the shelves 8 and pushing articles onto the shelves 8, and can replace the articles stored on the two shelves 8.

[0047] The item rearrangement device 90 has a communication interface 91, a control device 92, a storage device 93, a sensor 94, and a drive device 95. The communication interface 91 communicates with the warehouse control device 100 via a network 180. The control device 92 is composed of a microcomputer or the like and executes a predetermined program. The storage device 93 stores programs and data. The sensor 94 detects the position of each part driven by the drive device 95. The control device 92 controls the drive device 95 based on control information received from the warehouse control device 100 and information detected by the sensor 94.

[0048] The drive device 95 pulls out articles stored on the shelf 8 and pushes articles onto the shelf 8. The drive device 95 has a motor 96, a moving device 97, and a carriage device 98. The motor 96 is a power source that drives the moving device 97 and the carriage device 98. The drive device 95 may have multiple motors 96, and the moving device 97 and the carriage device 98 may each be driven by one or more motors 96.

[0049] The moving device 97 moves the carriage device 98 to the arrangement position of the item on the shelf 8 where the replacement work is to be performed. The carriage device 98 performs operations such as pulling out the item from the arrangement position of the item on the shelf 8 from which the item is to be replaced, and pushing the item into the arrangement position of the item on the shelf 8 to which the item is to be replaced. Details of these mechanisms will be described later.

[0050] FIG. 2 is a perspective view showing an example of the layout of a warehouse in a distribution center according to an embodiment of the present invention.

[0051] The logistics center has a storage space 12. Within the storage space 12, a plurality of shelves 8 are arranged in a grid pattern in the vertical and horizontal directions. In the example of FIG. 2, the shelves 8 form an "island" consisting of 2 x 6 or 1 x 6 shelves 8.

[0052] A plurality of conveying devices 1 are arranged within the storage space 12. The conveying devices 1 enter beneath the shelves 8, lift up the shelves 8, and then move them. A plurality of chargers 15 for charging the conveying devices 1 are arranged at predetermined locations around the storage space 12.

[0053] A plurality of work stations 16-1 to 16-4 are arranged at predetermined positions on the outer edge of the storage space 12. At the work stations 16-1 to 16-3, workers 17-1 to 17-3 perform the work of storing and retrieving items, and at the work station 16-4, a work robot 18-1 performs the work of storing and retrieving items.

[0054] In the following description, when a work station is not individually specified, the symbol "16" is used, with the parts after "-" omitted, and the work station is referred to as work station 16. The same applies to the symbols of the other components.

[0055] A station terminal 7 is disposed at the work station 16 where the worker 17 works. In addition, work spaces 19-1 to 19-4 where sorting and packing are performed are installed at predetermined positions on the periphery of the work station 16. The size of the work space 19 and the size of the storage section for boxes or the like where sorting and packing are performed may differ for each work station 16.

[0056] Although all four work stations 16 shown in FIG. 2 are work stations 16 for picking work, the logistics center also includes one or more work stations 16 for item replacement. For example, at least one of the work stations 16 shown in FIG. 2 may be a work station 16 for item replacement. An item replacement device 90 is installed in the work station 16 for item replacement. One work station 16 may serve as a work station 16 for picking during times when goods are shipped, such as during the day, and as a work station 16 for item replacement during times when goods are not shipped, such as at night. The work station 16 for item replacement may replace items as described below, and replenish inventory items that have been reduced by shipping. The configuration and operation of the work station 16 for item replacement will be described in detail below.

[0057] FIG. 3 is a plan view showing an example of the arrangement of items in a warehouse in an embodiment of the present invention.

[0058] For example, when multiple items that are frequently collected for the same order, such as items that are frequently shipped to the same destination at the same time, are stored distributed across multiple shelves 8A-8D, it becomes increasingly necessary to call shelves 8A-8D to work station 16 to collect all of the items for one order. However, if those items are stored on a single shelf 8E, it is only necessary to call shelf 8E to collect those items, which reduces the number of times that shelf 8 is called to work station 16 and reduces the time spent moving shelf 8 in the overall shipping work, thereby making the shipping work more efficient. Furthermore, by locating shelf 8E close to work station 16, the travel distance and travel time are reduced, making the shipping work more efficient.

[0059] FIG. 4 is a perspective view showing an example of the configuration of the shelf 8 in the embodiment of the present invention.

[0060] Each shelf 8 is divided into multiple levels by multiple shelf boards 81, and one or more trays 401 can be placed on each level. Items (not shown) are accommodated in the trays 401 and stored on the shelf 8. In the example of FIG. 4, up to four trays 401 are placed on each level of each shelf 8. The placement position of each tray 401 is the placement position of the item, and is also called the frontage.

[0061] Articles can be pulled out from the shelf 8 together with the tray 401. The shelf 8 may have an opening where no tray 401 is arranged. While FIG. 4 shows an example in which the tray 401 is arranged only on one side of the shelf 8, in reality, the tray 401 may also be arranged on the opposite side of the shelf 8.

[0062] In the following description, when it is necessary to distinguish between the plurality of trays 401, they may be referred to as trays 401A, 401B, and so on.

[0063] FIG. 5 is a perspective view showing an example of the configuration of the work station 16 for replacing items in the embodiment of the present invention.

[0064] An article replacement device 90 is installed at a position of the work station 16 for article replacement adjacent to the storage space 12. Two shelves 8 to be replaced with articles are transported and placed on the storage space 12 side of the article replacement device 90 by the transport device 1. Meanwhile, on the opposite side of the storage space 12 side of the article replacement device 90, a shelf 501 is installed for temporarily storing trays 401 pulled out from the shelf 8. The shelf 501 may be of any type as long as it can accommodate trays 401, and may be the same as the work space 19, for example, or the same as the shelf 8.

[0065] In the following description, for convenience, the direction of the boundary line between the work station 16 and the storage space 12 on the horizontal plane will be referred to as the Y direction, the vertical direction as the Z direction, and the direction perpendicular to the YZ plane as the X direction.

[0066] FIG. 6 is a perspective view showing an example of the configuration of an article replacement device 90 according to an embodiment of the present invention.

[0067] The carriage device 98 constituting the article replacement device 90 pulls out the tray 401 from the shelf 8 or the shelf 501, and pushes the tray 401 into the shelf 8 or the shelf 501. These operations and the configuration of the carriage device 98 for realizing them will be described in detail later.

[0068] The moving device 97 constituting the article replacement device 90 includes a horizontal moving device 97A and a vertical moving device 97B. The horizontal moving device 97A is a device that moves the carriage device 98 in the horizontal direction (i.e., the Y direction, also described as the left-right direction). The vertical moving device 97B is a device that moves the horizontal moving device 97A and the carriage device 98 in the vertical direction (i.e., the Z direction, also described as the up-down direction).

[0069] By controlling the horizontal movement device 97A and the vertical movement device 97B, the carriage device 98 can be moved to the arrangement position of the tray 401 to be replaced. Note that the specific mechanisms for realizing the operation of the horizontal movement device 97A and the vertical movement device 97B are not limited, but can be realized by, for example, a chain or a timing belt.

[0070] FIG. 7A is a front view showing an example of the configuration of a carriage device 98 in an embodiment of the present invention.

[0071] Here, the carriage device 98 is shown as a front view when viewed in the Y direction in FIG.

[0072] The carriage device 98 has a plurality of sprockets 701, a chain 702 wound around the sprockets, a hook portion 703 attached to the chain 702, and a table 704. While Fig. 7A shows four sprockets 701 and one chain 702 wound around them, in reality, as shown in a plan view etc. described below, the carriage device 98 has another set of four sprockets 701 and one chain 702, and the hook portion 703 is installed to connect the two chains 702. The carriage device 98 also has two hook portions 703, each installed at a position spaced apart by approximately half a circumference of the chain 702.

[0073] 7A, the trajectory of the chain 702 between the two sprockets 701 on the left side is set so that its upper portion protrudes outside the carriage device 98. Similarly, the trajectory of the chain 702 between the two sprockets 701 on the right side is also set so that its upper portion protrudes outside the carriage device 98.

[0074] When at least one of the four sprockets 701 is driven by a motor 96 (not shown in FIG. 7A) and rotates in either direction, the rotation is transmitted to the hook portion 703 by the chain 702, and the hook portion 703 moves on the track of the chain 702. As will be described later, the tray 401 can be pulled out from the shelf 8 by hooking the hook portion 703 into a recess provided in the tray 401 of the shelf 8 and moving it. The table 704 is a stand on which the pulled-out tray 401 can be placed. In addition, the tray 401 can be pushed into a desired position on the shelf 8 by bringing the hook portion 703 into contact with the tray 401 placed on the table 704 and moving it.

[0075] 7A shows a mechanism for moving hook portion 703 that is made up of a combination of multiple sprockets 701 and chain 702 wound around them. However, this is just one example of a winding transmission device made up of a rotating member and a winding member, and may be replaced by a winding transmission device made up of multiple pulleys and a belt or wire wound around them. Hook portion 703 is attached to a winding member such as a chain, belt, or wire, and moves with the rotation of the sprocket or pulley.

[0076] FIG. 7B is an enlarged view of the hook portion 703 in a front view showing an example of the configuration of the carriage device 98 in the embodiment of the present invention.

[0077] Hook portion 703 has a rod-shaped connecting portion 711 that connects two chains 702, a base portion 712 rotatably attached to connecting portion 711, two claws 713 attached to base 712, springs 714 attached to each claw 713, and a buffer portion 715 attached to a portion of the connecting portion. Claw 713 is attached to base 712 so that its tip faces upward (i.e., in the Z direction) and is movable in the X direction within a range restricted by a stopper (not shown), and spring 714 applies a force in a direction that increases the distance between the tip and the connecting portion. Base 712 is attached to connecting portion 711 so that it can rotate about connecting portion 711, and in the absence of external force, its own weight causes the tip of claw 713 to face upward, as shown in FIG. 7B .

[0078] FIG. 7C is a plan view showing an example of the configuration of the carriage device 98 in the embodiment of the present invention.

[0079] As shown in Fig. 7C, the carriage device 98 has two sets of four sprockets 701 and one chain 702. For ease of explanation, Fig. 7C omits the illustration of the lower two sprockets 701 in each set and the lower hook portion 703 of the two hook portions 703 shown in Fig. 7A.

[0080] As shown in Fig. 7C, connecting portion 711 is a rod-shaped member that connects two chains 702. In the example of Fig. 7C, buffer portions 715 are attached to two locations on connecting portion 711. Buffer portions 715 are, for example, substantially cylindrical (or may be polygonal prism-shaped) resin members that are attached so as to wrap around connecting portion 711. When hook portion 703 pushes tray 401, buffer portions 715 come into contact with the tray, and the pushing force of hook portion 703 is transmitted to tray 401 mainly via buffer portions 715.

[0081] The two claws 713 are attached at positions facing each other across a portion of the connecting portion 711 different from the portion where the buffer portion 715 is attached (the central portion of the connecting portion 711 in the example of FIG. 7C).

[0082] FIG. 7D is a left side view showing an example of the configuration of the carriage device 98 in the embodiment of the present invention.

[0083] For ease of explanation, of the two hook portions 703 shown in Fig. 7A, the lower hook portion 703 shown in Fig. 7A is not shown in Fig. 7D. Base portion 712 is attached to connecting portion 711 so as to be rotatable about connecting portion 711, and in the absence of external force, the tip of claw 713 is oriented upward due to its own weight.

[0084] 8A to 8F are explanatory diagrams showing an example of the operation of pulling out and pushing in the tray 401 by the carriage device 98 in the embodiment of the present invention.

[0085] FIG. 8A shows carriage device 98 moved by moving device 97 (omitted in FIG. 8A) to the front of tray 401 to be extracted. However, sprocket 701 is not shown. A recess 402 that opens downward is provided on the edge of tray 401. A stopper 82 is provided on the edge of shelf 81 on which tray 401 is placed. This is intended to prevent tray 401 from falling off shelf 81, and is provided, for example, by making the edge of shelf 81 higher than the upper surface of the portion of shelf 81 on which tray 401 is placed. Note that items loaded on tray 401 are not shown in FIGS. 8A to 8F.

[0086] In the example of FIG. 8A, the chain 702 rotates clockwise, and of the two hook portions 703, the hook portion 703 closer to the tray 401 approaches the recessed portion 402 of the tray 401 from an obliquely downward direction.

[0087] FIG. 8B shows a state in which the claw 713 of the hook portion 703 is inserted into the recess 402 and moves further upward, pushing up the recess 402, thereby lifting the front side of the tray 401 (i.e., the side closer to the carriage device 98) and making the bottom surface of the front side of the tray 401 higher than the stopper 82. At this time, the path of the chain 702 is set so that the upper part protrudes outward from the carriage device 98. Therefore, when the hook portion 703 moves upward, the direction of movement includes not only an upward component but also a horizontal component toward the outside of the carriage device 98. Therefore, after contacting the tray 401, the hook portion 703 slightly pushes the tray 401 toward the back of the shelf 8. As a result, the corner formed by the bottom and side surface of the tray 401 does not come into contact with the stopper 82, and the tray 401 can be lifted smoothly.

[0088] 8C shows a state in which hook portion 703 has moved further to the right and tray 401 has been partially pulled out from shelf 8. Tray 401 is pulled by hook portion 703 and moves from above shelf board 81 onto table 704.

[0089] 8D shows the state in which tray 401 is fully pulled out. Tray 401 is entirely placed on table 704, the movement direction of hook portion 703 changes to downward as the chain rotates, and pawl 713 disengages from recess 402.

[0090] As chain 702 continues to rotate to the right, hook portion 703 on the opposite side comes into contact with tray 401 and pushes tray 401 to the right, as shown in Fig. 8E. At this time, if claw 713 comes into contact with tray 401 before buffer portion 715 does, as shown in Fig. 8F, the displacement of spring 714 (not shown in Fig. 8F) causes claw 713 to move toward connecting portion 711, and buffer portion 715 comes into contact with tray 401.

[0091] When the hook portion 703 moves further to the right due to the rotation of the chain 702, the tray 401 is pushed out to the right side of the carriage device 98. This allows the tray 401 to be pushed onto a shelf placed on the opposite side of the shelf 8 (for example, another shelf 8 or a temporary storage shelf 501, etc.).

[0092] 8D, after the entire tray 401 is placed on the table 704, the chain 702 may be rotated in the opposite direction (i.e., counterclockwise). As a result, the state transitions sequentially to the states of FIGS. 8D, 8C, 8B, and 8A, in the opposite direction to the above, and the tray 401 is pushed into the shelf 8. However, in the states of FIGS. 8C and 8B when the tray is rotated in the opposite direction, the tray comes into contact with the buffer section 715 and is pushed in.

[0093] For example, when swapping trays 401A and 401B shown in Fig. 5, tray 401A may be moved first to temporary storage shelf 501 in the order shown in Figs. 8A to 8F. Then, moving device 97 moves carriage device 98 to the position where tray 401B will be placed, and carriage device 98 places tray 401B on table 704 in the order shown in Figs. 8A to 8D. Then, moving device 97 moves carriage device 98 to the position where tray 401A was placed (now empty), and chain 702 is rotated left to execute the order shown in Figs. 8A to 8D in reverse, thereby pushing tray 401B into the position where tray 401A was placed.

[0094] In this embodiment, one carriage device 98 has two hook portions 703, and one hook portion 703 is attached to a position on the track formed by the chain 702 approximately halfway around from the position where the other hook is attached. This makes it possible to pull out the tray 401 using one hook portion 703 as shown in Figures 8A to 8D, and then push in the tray 401 using the other hook portion 703 as shown in Figures 8E to 8F. This makes it possible to quickly replace the tray 401.

[0095] However, carriage device 98 may have only one hook portion 703. In that case, after tray 401 has been pulled out as shown in Fig. 8D, hook portion 703 may be further moved to the position of hook portion 703 on the left side in Fig. 8E to push tray 401 in.

[0096] FIG. 9 is an explanatory diagram showing an example of the shape of the shelf board 81 and the tray 401 in the embodiment of the present invention.

[0097] Stopper 82 of shelf board 81 shown in Fig. 9 is curved so that the inner radius of curvature is equal to or greater than a predetermined value. Furthermore, corner 403 formed by the side and bottom surfaces of tray 401 is curved so that the outer radius of curvature is equal to or greater than a predetermined value. In the example of Fig. 9, both stopper 82 and corner 403 are curved, but only one of them may be curved. This reduces the impact caused by tray 401 colliding with shelf 8 when tray 401 is pulled out from or pushed into shelf 8 as shown in Figs. 8A to 8F, thereby protecting the items loaded on tray 401.

[0098] FIG. 10 is an explanatory diagram showing an example of the order information 200 in the embodiment of the present invention.

[0099] The order information 200 includes a serial number 201, a slip number 202, a store name 203, a store code 204, an item name 205, an item code 206, a quantity 207, a delivery date 208, and an order reception date and time 209 in one record.

[0100] The serial number 201 is a unique number assigned by the warehouse control device 100. The slip number 202 is a unique number assigned to each order by the warehouse control device 100. The retailer name 203 indicates the shipping destination of the item.

[0101] In this embodiment, even if the slip number 202 is the same, if the item name 205 and item code 206 are different, a different serial number 201 is assigned. This is because if the item name 205 and item code 206 are different, there is a possibility that the respective items are stored on different shelves 8.

[0102] The quantity 207 indicates the ordered quantity of the item identified by the item name 205 and item code 206 in the slip number 202 of the record. The order reception date and time 209 stores the date and time when the warehouse control device 100 (or the logistics center) received the order for the slip number 202.

[0103] FIG. 11 is an explanatory diagram showing an example of the inventory information 220 in the embodiment of the present invention.

[0104] The inventory information 220 includes a serial number 221, an item name 222, an item code 223, an inventory quantity 224, a shelf ID 225, an arrangement position within the shelf 226, and a tray ID 227 in one record.

[0105] The shelf ID 225 stores the identifier of the shelf 8 on which the item is stored. The placement position within the shelf 226 stores information used to identify the position where the item is placed, for example, at the picking work station 16, where the worker 17 or robot 18 will perform the picking work. The tray ID 227 is information that identifies the tray that stores the item. In this embodiment, one tray corresponds to one placement position. For example, the first record shown in Figure 11 indicates that 23 items with the item name "SS" are stored in a tray with tray ID "T001" and are placed in the second position from the right (R) on the third shelf from the top (U) on a shelf with shelf ID "S046".

[0106] FIG. 12 is an explanatory diagram showing an example of shelf information 230 in an embodiment of the present invention.

[0107] The shelf information 230 includes a serial number 231, a shelf ID 232, a storage location 233, a shelf weight 234, and an item weight 235 in one record.

[0108] The shelf ID 232 stores a unique identifier assigned to each shelf 8. For example, the identifier of the shelf 8 assigned by the warehouse control device 100 may be stored as the shelf ID 232. The storage location 233 stores location information of the storage space 12 in which the shelf 8 is stored, such as coordinates of map information. When the shelf 8 is being transported, the storage location 233 stores "in transport".

[0109] The shelf weight 234 stores the weight of the shelf 8 itself, and the item weight 235 stores the weight of the items (more specifically, the items and the trays for storing them, etc.) carried on the shelf 8. The weight of the transported items (shelf + items) transported by the transport device 1 is at least the sum of the "shelf weight" and the "product weight."

[0110] FIG. 13 is a flowchart showing an example of a process related to picking an item that is executed by the information processing system according to the embodiment of the present invention.

[0111] First, a user orders an item (step S1301). For example, the user may order an item (item) via a product site provided by a retailer, etc. At this time, the item name, quantity, user information, delivery address, etc. are input.

[0112] The server of the product site receives the order from the user, and determines a logistics center or the like that has the item in stock based on the item, quantity, delivery address, etc. ordered by the user, and sends a request to ship the item (step S1302). Information such as the ordered item, quantity, delivery address, etc. is stored as order information 200.

[0113] The control system of the logistics center or the like that receives the shipping request for the item generates a picking instruction based on the shipping request and inventory information (step S1303). Here, an example will be described in which the warehouse control device 100 of Fig. 1 is used as a control system of the logistics center or the like.

[0114] Next, the warehouse control device 100 identifies the shelf 8 on which the item to be picked is stored, determines the conveying device 1 to transport the shelf, determines the transport route for the shelf 8 by the conveying device 1, and sends transport instructions and picking instructions to the conveying device 1 and the picking work station 16, respectively (step S1304).

[0115] The conveyance device 1 conveys the shelf 8 to the picking work station 16 based on the received conveyance instruction (step S1305). When the conveyed shelf 8 arrives at the picking work station 16, a picker performs the picking work based on the picking instruction (e.g., which opening and how many items to pick) output from the picking work station 16, and inputs the results of the picking work to the picking work station 16 (step S1306). The picking work station 16 transmits the results of the picking work to the warehouse control device 100.

[0116] When the picking operation is completed, the warehouse control device 100 transmits a shelf return instruction to the conveyance device 1 (step S1307). The conveyance device 1 follows the instruction and transports the shelf 8 to a specified position in the storage space 12 (step S1308). The destination position at this time may be the same as the position where the shelf 8 was located before being transported to the work station 16, or it may be a different position. When the shelf return is completed, the conveyance device 1 transmits a shelf return completion notification to the warehouse control device 100 (step S1309). Then, the process returns to step S1304.

[0117] FIG. 14 is a flowchart showing an example of a process relating to replacement and replenishment of items executed by the information processing system according to the embodiment of the present invention.

[0118] First, the warehouse control device 100 identifies the shelves 8 to be rearranged, the locations on each shelf 8, and the items stored at each location, and generates a rearrangement instruction (step S1401). Specifically, for example, the warehouse control device 100 executes the data analysis program 163 to identify combinations of items that are frequently shipped at the same time (for example, combinations of items that are frequently shipped to the same destination on the same flight), and identifies the items of those items, the shelves 8 on which they are stored, and their locations. Based on the item rearrangement data 280 containing this information, the warehouse control device 100 generates an item rearrangement instruction and transmits it to the conveyance device 1 and the item rearrangement device 90 installed in the work station 16 for item rearrangement.

[0119] 5, if the items stored in tray 401A stored on shelf 8A and the items stored in tray 401C stored on shelf 8E are frequently shipped at the same time, and in contrast, the items stored on tray 401A and the items stored on tray 401B stored on shelf 8E are rarely shipped at the same time, it may be decided to swap the items stored on tray 401A and the items stored on tray 401B (i.e., swap trays 401A and 401B that store those items). By performing such a swap, the frequency with which both shelf 8A and shelf 8E are called when picking items for one shipment to one destination decreases, and shipping operations become more efficient.

[0120] Based on the received item replacement instruction, the conveyance device 1 transports the source and destination shelves 8 to the item replacement work station 16 (step S1402). When the transported shelves 8 arrive at the item replacement work station 16, the item replacement device 90 performs the item replacement work in accordance with the item replacement instruction (step S1403). This work is performed, for example, according to the procedure shown in FIGS. 8A to 8F, and items are replaced along with the trays 401. When the item replacement work is completed, the item replacement device 90 transmits a notification of the completion of the item replacement work to the warehouse control device 100.

[0121] When the item replacement work is completed, the warehouse control device 100 transmits a shelf return instruction to the transport device 1 (step S1404). The transport device 1 follows the instruction and transports the shelf 8 to a specified position in the storage space 12 (step S1405). The destination position at this time may be the same as the position where the shelf 8 was located before being transported to the work station 16, or it may be a different position. When the shelf return is completed, the transport device 1 transmits a shelf return completion notification to the warehouse control device 100 (step S1406). Then, the process returns to step S1401.

[0122] Furthermore, the system according to the embodiment of the present invention may be configured as follows.

[0123] (1) An article replacement device (e.g., article replacement device 90) having a carriage device (e.g., carriage device 98) that pulls out a tray (e.g., tray 401) placed on a shelf (e.g., shelf 8) from the shelf and pushes the tray onto the shelf, and a moving device (e.g., moving device 97) that moves the carriage device, the carriage device having a hook portion (e.g., hook portion 703), a transmission device that moves the hook portion, and a table (e.g., table 704), the hook portion having a claw portion (e.g., claw 713) with an upward-facing tip. After the moving device moves the carriage device to a position on the shelf where the tray to be pulled out is stored, the transmission device moves the hook portion upward, and the claw portion is inserted into a downward-opening recess (e.g., recess 402) provided on the edge of the tray, and then moves the hook portion horizontally to pull the tray out of the shelf and place it on a table (e.g., the process of Figures 8A to 8D), and after the moving device moves the carriage device to a position on the shelf where the tray is to be stored, the transmission device brings the hook portion into contact with the tray placed on the table, horizontal 8E-8F, or the reverse of the process of FIGS. 8A-8D).

[0124] This allows stored items in each location on the shelf to be moved all at once, while reducing damage to the stored items, thereby realizing a high-speed and efficient item replacement device.

[0125] (2) In (1) above, the transmission device is a wrapping transmission device having a plurality of rotating parts (e.g., sprocket 701) and a wrapping part (e.g., chain 702) wrapped around the plurality of rotating parts, the hook part is attached to the wrapping part, and the carriage device has a motor (e.g., motor 96) that drives at least one of the plurality of rotating parts, and when the motor rotates at least one of the plurality of rotating parts, the hook part moves vertically and horizontally along a track formed by the wrapping part wrapped around the plurality of rotating parts.

[0126] This makes it possible to reduce damage to stored items and achieve efficient item pulling and pushing operations with a relatively simple configuration and simple control.

[0127] (3) In (2) above, the transmission device has two sets of at least four rotating parts and one winding part that is wound around the at least four rotating parts, and the hook part is attached to connect the two winding parts.

[0128] This makes it possible to reduce damage to stored items and achieve efficient item pulling and pushing operations with a relatively simple configuration and simple control.

[0129] (4) In (3) above, the hook portion has a connecting portion (e.g., connecting portion 711) that connects the two wrapping portions and a base portion (e.g., base portion 712) that is rotatably attached to the connecting portion, and the claw portion is attached to the base, and the base assumes a position in which the tip of the claw portion faces upward due to its own weight.

[0130] This makes it possible to reduce damage to stored items and achieve efficient item pulling and pushing operations with a relatively simple configuration and simple control.

[0131] (5) In (4) above, the claw portion is attached to the base so as to be movable horizontally within a predetermined range, and the hook portion further has a buffer portion attached to the connecting portion and a spring (e.g., spring 714) that applies a force to the claw portion in a direction away from the connecting portion. When the hook portion moves horizontally and the claw portion comes into contact with the tray placed on the table before the buffer portion does, the displacement of the spring causes the claw portion to move toward the connecting portion, and the buffer portion comes into contact with the tray (e.g., Figure 8F).

[0132] This reduces damage to the tray and operating noise caused by contact.

[0133] (6) In (3) above, the plurality of rotating parts are arranged so that the upward movement of the hook part includes a horizontal component toward the outside of the carriage device.

[0134] This makes it possible to reduce damage to stored items and achieve efficient item pulling and pushing operations with a relatively simple configuration and simple control.

[0135] (7) In the above (2), the plurality of rotating parts are a plurality of sprockets, and the winding part is a chain wound around the plurality of sprockets.

[0136] This makes it possible to reduce damage to stored items and achieve efficient item pulling and pushing operations with a relatively simple configuration and simple control.

[0137] (8) In (2) above, the carriage device has two hook portions, of which the first hook portion is attached to the winding portion, and the second hook portion is attached to the winding portion at a position approximately halfway around the track from the position at which the first hook portion is attached.

[0138] This makes it possible to reduce damage to stored items and achieve efficient item pulling and pushing operations with a relatively simple configuration and simple control.

[0139] (9) In (2) above, the moving device has a horizontal moving device (e.g., moving device 97A) that moves the carriage device horizontally, and a vertical moving device (e.g., moving device 97B) that moves the horizontal moving device and the carriage device vertically.

[0140] This makes it possible to reduce damage to stored items and achieve efficient item pulling and pushing operations with a relatively simple configuration and simple control.

[0141] (10) An item replacement system includes a warehouse control device (e.g., warehouse control device 100), a plurality of conveying devices (e.g., conveying device 1), a plurality of shelves stored in a storage space (e.g., storage space 12) in a warehouse, and an item replacement device installed in a work station (e.g., work station 16) adjacent to the storage space, wherein the plurality of shelves each have a plurality of trays arranged at a plurality of placement positions, and the plurality of trays each store items. The warehouse control device holds order information indicating the item, quantity, and shipping destination of the ordered item, inventory information indicating the item, quantity, shelf, and placement position within the shelf of the item stored in the warehouse, and shelf information indicating the storage positions of the plurality of shelves. The item replacement device includes a carriage device that pulls out trays placed on the shelf from the shelf and pushes the trays into the shelf, and a moving device that moves the carriage device. The carriage device has a hook portion, a transmission device that moves the hook portion, and a table. The hook portion has a claw portion with an upward-facing tip. The warehouse control device receives the order information and the inventory information. Based on this, two shelves and their locations on which items that are frequently shipped at the same time are stored are identified, and item replacement information indicating the replacement of items between the two identified shelves is generated in order to consolidate items that are frequently shipped at the same time onto one shelf. Based on the shelf information, instructions to transport the two identified shelves to a work station are sent to two conveying devices, and the two conveying devices transport the two identified shelves to the work station in accordance with the instructions. After the moving device moves the carriage device to a position on one of the two transported shelves where the tray to be replaced is stored, the transmission device moves the hook portion upward and inserts the claw portion into a downwardly opening recess provided on the edge of the tray, and then moves it horizontally to pull the tray out of the shelf and place it on a table. After the moving device moves the carriage device to a storage position for the tray to be replaced on the other of the two transported shelves, the transmission device brings the hook portion into contact with the tray placed on the table and then moves in the direction of the tray, thereby pushing the tray into the shelf.

[0142] This allows stored items in each location on the shelf to be moved all at once, while reducing damage to the stored items. This allows for a high-speed, efficient item replacement device to be realized. In addition, by consolidating items that are frequently shipped at the same time, the efficiency of subsequent shipping operations is improved.

[0143] (11) In (10) above, each shelf has one or more shelf boards (e.g., shelf board 81) each carrying one or more trays, and a stopper (e.g., stopper 82) higher than the top surface of the part where the trays are loaded is provided on the edge of each shelf board, and the transmission device moves the hook portion upward, and after the claw portion is inserted into the recess of the tray, the hook portion is further moved upward until the bottom surface of the tray is higher than the stopper, and then moved horizontally, thereby pulling the tray out of the shelf and placing it on a table.

[0144] This prevents the tray from falling off the shelf, and also allows the tray to be pulled out beyond the stopper when being pulled out.

[0145] (12) In the above (11), the stopper of each shelf is a curved surface whose inner radius of curvature is equal to or greater than a predetermined value.

[0146] This prevents damage to the articles on the tray caused by the impact when the tray is pulled out or pushed in, and reduces operating noise, etc.

[0147] (13) In the above (11), the corner formed by the side surface and bottom surface of each tray is a curved surface whose outer radius of curvature is equal to or greater than a predetermined value.

[0148] This prevents damage to the articles on the tray caused by the impact when the tray is pulled out or pushed in, and reduces operating noise, etc.

[0149] The present invention is not limited to the above-described embodiments and includes various modifications. For example, the above-described embodiments have been described in detail to provide a better understanding of the present invention, and the present invention is not necessarily limited to those including all of the described configurations. Furthermore, it is possible to replace part of the configuration of one embodiment with the configuration of another embodiment, or to add the configuration of another embodiment to the configuration of one embodiment. Furthermore, it is possible to add, delete, or replace part of the configuration of each embodiment with other configurations.

[0150] Furthermore, the above-described configurations, functions, processing units, processing means, etc. may be partially or entirely implemented in hardware, for example, by designing them as integrated circuits. The above-described configurations, functions, etc. may also be implemented in software, with a processor interpreting and executing a program that implements each function. Information such as the programs, tables, and files that implement each function can be stored in storage devices such as nonvolatile semiconductor memory, hard disk drives, and solid-state drives (SSDs), or in computer-readable, non-transitory data storage media such as IC cards, SD cards, and DVDs.

[0151] In addition, the control lines and information lines shown are those that are considered necessary for the explanation, and not all control lines and information lines in the product are necessarily shown. In reality, it can be considered that almost all components are interconnected.

Claims

1. An article replacement device, a carriage device that pulls out a tray placed on a shelf from the shelf and pushes the tray onto the shelf, and a moving device that moves the carriage device; the carriage device has a hook portion, a transmission device that moves the hook portion, and a table; The hook portion has a claw portion with an upwardly facing tip, After the moving device has moved the carriage device to a position on the shelf where the tray to be pulled out is stored, the transmission device moves the hook portion upward, and after the claw portion is inserted into a recess that opens downward and is provided on the edge of the tray, moves the hook portion horizontally, thereby pulling out the tray from the shelf and placing it on the table; an article replacement device, characterized in that after the moving device moves the carriage device to a storage position of the tray on the shelf, the transmission device brings the hook portion into contact with the tray placed on the table and then moves the hook portion in a horizontal direction, thereby pushing the tray into the shelf; The transmission device is a wrapping transmission device having a plurality of rotating parts and a wrapping part wrapped around the plurality of rotating parts, The hook portion is attached to the wrapping portion, the carriage device has a motor that drives at least one of the plurality of rotating parts, An item replacement device characterized in that the motor rotates at least one of the multiple rotating parts, causing the hook part to move vertically and horizontally along a track formed by the wrapping part that is wrapped around the multiple rotating parts.

2. An article exchange device as described in claim 1, the transmission device includes two sets of at least four rotating parts and one winding part wound around the at least four rotating parts; The article exchange device is characterized in that the hook portion is attached so as to connect the two wrapping portions.

3. An article exchange device as described in claim 2, the hook portion has a connecting portion that connects the two wrapping portions and a base portion that is rotatably attached to the connecting portion, The claw portion is attached to the base portion, The article exchange device is characterized in that the base portion assumes a position in which the tips of the claw portions face upward due to its own weight.

4. An article exchange device as described in claim 3, the claw portion is attached to the base portion so as to be movable in a horizontal direction within a predetermined range, the hook portion further includes a buffer portion attached to the connecting portion and a spring that applies a force to the claw portion in a direction away from the connecting portion, An item exchange device characterized in that when the hook portion moves horizontally and the claw portion contacts the tray placed on the table before the buffer portion, the spring displacement causes the claw portion to move toward the connecting portion, and the buffer portion contacts the tray.

5. An article exchange device as described in claim 2, The article replacement device, wherein the plurality of rotating parts are arranged so that upward movement of the hook part includes a horizontal component toward the outside of the carriage device.

6. An article exchange device as described in claim 1, The article exchange device, characterized in that the plurality of rotating parts are a plurality of sprockets, and the winding part is a chain wound around the plurality of sprockets.

7. An article exchange device as described in claim 1, the carriage device has two of the hook portions, a first hook portion of the two hook portions attached to the wrapping portion; An item replacement device characterized in that the second hook portion of the two hook portions is attached to the wrapping portion at a position approximately halfway around the track from the position at which the first hook portion is attached.

8. An article exchange device as described in claim 1, The article replacement device is characterized in that the movement device has a horizontal movement device that moves the carriage device horizontally, and a vertical movement device that moves the horizontal movement device and the carriage device vertically.

9. An item replacement system, The warehouse includes a warehouse control device, a plurality of conveying devices, a plurality of shelves stored in a storage space within the warehouse, and an article replacement device installed in a work station adjacent to the storage space, Each of the plurality of shelves has a plurality of trays arranged at a plurality of placement positions, each of the plurality of trays stores an item; The warehouse control device The warehouse holds order information indicating the item, quantity and shipping destination of the ordered item, inventory information indicating the item, quantity, shelf and arrangement position within the shelf of the item stored in the warehouse, and shelf information indicating the storage positions of the plurality of shelves, The article replacement device is a carriage device that pulls out a tray placed on a shelf from the shelf and pushes the tray onto the shelf, and a moving device that moves the carriage device; the carriage device has a hook portion, a transmission device that moves the hook portion, and a table; The hook portion has a claw portion with an upwardly facing tip, The warehouse control device Identifying the two shelves and locations where the items that are frequently shipped at the same time are stored based on the order information and the inventory information; generating item replacement information indicating the replacement of the items between the two specified shelves in order to consolidate the items that are frequently shipped at the same time onto one shelf; transmits instructions to the two transport devices to transport the two identified shelves to the work station based on the shelf information; the two transport devices transport the two identified shelves to the work station in accordance with the instructions; After the moving device has moved the carriage device to a position on one of the two transported shelves where the tray to be replaced is stored, the transmission device moves the hook portion upward, and after the claw portion is inserted into a recess that opens downward and is provided on the edge of the tray, moves the hook portion horizontally, thereby pulling out the tray from the shelf and placing it on the table; An item replacement system characterized in that after the moving device moves the carriage device to the storage position of the tray to be replaced on the other of the two transported shelves, the transmission device brings the hook portion into contact with the tray placed on the table and then moves it horizontally to push the tray into the shelf.

10. An item replacement system according to claim 9, Each of the shelves has one or more shelves, each of which holds one or more of the trays; A stopper higher than the upper surface of the portion where the trays are loaded is provided on the edge of each shelf board, The transmission device moves the hook portion upward, and after the claw portion is inserted into the recess of the tray, moves the hook portion further upward until the bottom surface of the tray is higher than the stopper, and then moves it horizontally, thereby pulling the tray out of the shelf and placing it on the table.

11. An item replacement system according to claim 10, An article replacement system characterized in that the stoppers of each shelf are curved surfaces whose inner radius of curvature is equal to or greater than a predetermined value.

12. An item replacement system according to claim 10, An article replacement system characterized in that the corners formed by the side and bottom surfaces of each tray are curved surfaces with an outer radius of curvature of a predetermined value or more.

13. An item replacement method executed in an item replacement system, comprising: The item replacement system includes a warehouse control device, a plurality of conveyance devices, a plurality of shelves stored in a storage space in a warehouse, and an item replacement device installed in a work station adjacent to the storage space, Each of the plurality of shelves has a plurality of trays arranged at a plurality of placement positions, each of the plurality of trays stores an item; The warehouse control device The warehouse holds order information indicating the item, quantity and shipping destination of the ordered item, inventory information indicating the item, quantity, shelf and arrangement position within the shelf of the item stored in the warehouse, and shelf information indicating the storage positions of the plurality of shelves, The article replacement device is a carriage device that pulls out a tray placed on a shelf from the shelf and pushes the tray onto the shelf, and a moving device that moves the carriage device; the carriage device has a hook portion, a transmission device that moves the hook portion, and a table; The hook portion has a claw portion with an upwardly facing tip, The item replacement method includes: a step in which the warehouse control device identifies, based on the order information and the inventory information, two shelves and locations where the items that are frequently shipped at the same time are stored; a step in which the warehouse control device generates item reshuffling information indicating the reshuffling of the items between the two specified shelves in order to consolidate the items that are frequently shipped at the same time onto one shelf; a step in which the warehouse control device transmits instructions to the two transport devices to transport the two identified shelves to the work station based on the shelf information; a step in which the two transport devices transport the two identified shelves to the work station in accordance with the instruction; a step in which the moving device moves the carriage device to a position on one of the two transported shelves where the tray to be replaced is stored, and then the transmission device moves the hook portion upward, and the claw portion is inserted into a recess that opens downward and is provided on the edge of the tray, and then moves the hook portion horizontally, thereby pulling out the tray from the shelf and placing it on the table; and after the moving device has moved the carriage device to a storage position for the tray to be replaced on the other of the two transported shelves, the transmission device brings the hook portion into contact with the tray placed on the table and then moves it horizontally to push the tray into the shelf.

14. An item replacement system, The warehouse includes a warehouse control device, a plurality of conveying devices, a plurality of shelves stored in a storage space within the warehouse, and an article replacement device installed in a work station adjacent to the storage space, Each of the plurality of shelves has a plurality of trays arranged at a plurality of placement positions, each of the plurality of trays stores an item; The warehouse control device The warehouse holds order information indicating the item, quantity and shipping destination of the ordered item, inventory information indicating the item, quantity, shelf and arrangement position within the shelf of the item stored in the warehouse, and shelf information indicating the storage positions of the plurality of shelves, The article replacement device is a carriage device that pulls out a tray placed on a shelf from the shelf and pushes the tray onto the shelf, and a moving device that moves the carriage device; the movement device includes a horizontal movement device that moves the carriage device in a horizontal direction, and a vertical movement device that moves the horizontal movement device and the carriage device in a vertical direction, the carriage device has two hook portions, a transmission device for moving each of the hook portions, and a table; Each of the hook portions has a claw portion with an upwardly facing tip, The transmission device includes two sets of at least four sprockets and one chain wound around the at least four sprockets, Each of the hook portions has a connecting portion that connects the two chains and a base portion that is rotatably attached to the connecting portion, the claw portion is attached to the base portion so as to be movable in a horizontal direction within a predetermined range, The base portion assumes a position in which the tip of the claw portion faces upward due to its own weight, Each of the hook portions further includes a buffer portion attached to the connecting portion and a spring that applies a force to the claw portion in a direction away from the connecting portion, the carriage device has a motor that drives at least one of the plurality of sprockets; When the motor rotates at least one of the plurality of sprockets, the hook portion moves vertically and horizontally along a track formed by the chain wound around the plurality of sprockets, a first hook portion of the two hook portions is attached to the chain, and a second hook portion of the two hook portions is attached to the chain at a position on the track that is approximately halfway around the chain from a position at which the first hook portion is attached; the plurality of sprockets are arranged such that upward movement of each hook portion includes a horizontal component toward the outside of the carriage device; Each of the shelves has one or more shelves, each of which holds one or more of the trays; A stopper higher than the upper surface of the portion where the trays are loaded is provided on the edge of each shelf board, The stopper of each shelf is a curved surface having an inner radius of curvature equal to or greater than a predetermined value, The corners formed by the side and bottom surfaces of each tray are curved surfaces with an outer radius of curvature of a predetermined value or more, The warehouse control device Identifying the two shelves and locations where the items that are frequently shipped at the same time are stored based on the order information and the inventory information; generating item replacement information indicating the replacement of the items between the two specified shelves in order to consolidate the items that are frequently shipped at the same time onto one shelf; transmits instructions to the two transport devices to transport the two identified shelves to the work station based on the shelf information; the two transport devices transport the two identified shelves to the work station in accordance with the instructions; After the moving device has moved the carriage device to a position on one of the two transported shelves where the tray to be replaced is stored, the transmission device moves the hook portion upward, and after the claw portion is inserted into a recess that opens downward and is provided on the edge of the tray, the transmission device moves the hook portion further upward until the bottom surface of the tray is higher than the stopper, and then moves it horizontally to pull the tray out of the shelf and place it on the table; After the moving device moves the carriage device to a storage location of the tray to be exchanged on the other shelf of the two transported shelves, the transmission device brings the hook portion into contact with the tray placed on the table and then moves the hook portion in a horizontal direction to push the tray into the shelf, An item replacement system characterized in that when the hook portion moves horizontally and the claw portion contacts the tray placed on the table before the buffer portion, the spring displacement causes the claw portion to move toward the connecting portion, and the buffer portion contacts the tray.

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