Warehouse system

Abstract

To provide a highly practical warehouse system.SOLUTION: In a warehouse system, in a warehouse Wh provided with a plurality of storage rows #01-40 in which a plurality of storage sections &1-5 for storing articles G are arranged in one row, a plurality of conveyors CR1-3 run in the warehouse to carry articles into the storage sections and out of the storage sections, the articles to be carried out at the same time are managed so as to be stored in one or a plurality of storage rows adjacent to each other, so that the one or the plurality of storage rows function as a passage CP of the conveyors after the articles are carried out. The efficiency of carry-in and carry-out work by the conveyors is improved.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present invention relates to a warehouse system for storing articles.

Background Art

[0002] In a warehouse where articles are stored in storage compartments, when carrying out the articles stored using a transporter, the articles stored in the innermost storage compartments not facing the passage cannot be carried out unless the articles stored in the front storage compartments are removed. Therefore, in the technique described in the following patent document, ranking is performed for the storage compartments according to the efficiency in carrying out, so as to improve the carrying-out efficiency.

Prior Art Document

Patent Document

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] When storing articles in storage compartments by a plurality of transporters, it is desired that the efficiency of loading and unloading is high. According to the technique described in the above patent document, some improvement can be expected. There are various types of warehouse systems, and depending on the type, efficiency can be improved by other means, and a highly practical system can be constructed. The present invention has been made in view of such circumstances, and an object thereof is to provide a highly practical warehouse system.

Means for Solving the Problems

[0005] To solve the above problems, the warehouse system of the present invention a warehouse provided with a plurality of storage rows in which a plurality of storage compartments for storing articles respectively are arranged in a line; Multiple conveyors that travel within the warehouse to transport goods into and out of storage areas, A management device for managing the storage of items in storage compartments and A warehouse system equipped with, The management device manages items to be unloaded at the same time to be stored in one or more adjacent storage rows, so that after the items have been unloaded, the one or more storage rows can function as passages for the multiple conveyors. [Effects of the Invention]

[0006] From the perspective of warehouse storage efficiency, it is desirable to have fewer aisles for conveyors in order to provide more storage compartments. On the other hand, fewer aisles can lead to longer travel routes for conveyors and the inability to bypass other conveyors that are performing other tasks, thus reducing transport efficiency. According to the warehouse system of the present invention, since the storage rows from which goods have been unloaded are used as aisles for conveyors, it is possible to reduce the number of permanent aisles relatively, and it is possible to improve the storage efficiency of the warehouse while maintaining high transport efficiency by conveyors. Embodiment of the Invention

[0007] The term "article" in this invention is not particularly limited. For example, it may be a single item, a container containing liquids, powders, etc., or multiple items placed on a stand. In view of the storage efficiency of the warehouse, it is desirable that the "storage rows" be arranged without spacing or at very small intervals. In a warehouse where storage rows are arranged in this way, it is desirable to load and unload articles from the end of each storage row. Also, in view of the storage efficiency of the warehouse, it is desirable that the number of storage compartments constituting each storage row be large, but if it is assumed that articles will be loaded and unloaded from the end, the efficiency of loading and unloading will deteriorate if the number of storage compartments constituting each storage row is large. Taking these factors into consideration, the number of storage compartments in each storage row, that is, the length of each storage row, should be determined appropriately.

[0008] In typical warehouses, aisles are permanently installed for the movement of conveyors. Considering the storage efficiency of such warehouses, it is desirable that the number of permanent aisles (hereinafter sometimes referred to as "permanent aisles") be small and that the width of each aisle be relatively small. In the present invention, since the aforementioned aisles, that is, aisles formed by storage rows from which goods have been unloaded (hereinafter sometimes referred to as "empty aisles"), are available, the significance of utilizing empty aisles is particularly great in warehouses with relatively few permanent aisles.

[0009] The "management device" manages the storage of items in storage compartments and can be computer-based. For example, it is desirable that it has the function of determining which items to move into which storage compartment in which storage column, and which items to remove from which storage compartment in which storage column. It is also desirable that it has the function of remembering which items are stored in which storage compartment in which storage column, and conversely, the function of recognizing which storage columns are empty and can be used as passages for the conveyor.

[0010] Furthermore, if the management device has a function to determine which item to move into which storage compartment of which storage row and store it, it is desirable to configure it to determine which storage row to store the item in based on the time when the item is to be removed, in order to secure the empty aisles mentioned above.

[0011] The "conveyor" in the present invention may be capable of both loading articles into a storage area and unloading articles from a storage area, and may be configured to include a loading machine that can only load articles into a storage area and an unloading machine that can only unload articles from a storage area.

[0012] The conveyor may be operated by a driver or it may operate automatically. If the conveyor operates automatically, the control device may also manage the operation of the conveyor. More specifically, it may have the function of determining the travel route for each of the multiple conveyors within the warehouse during the loading and unloading of goods. If the control device recognizes which storage rows are empty aisles, it is desirable to include those empty aisles in the travel route it determines. If the control device determines a travel route that includes empty aisles, the control device will contribute to maintaining high transport efficiency by the conveyors. [Brief explanation of the drawing]

[0013] [Figure 1] This diagram shows the overall configuration of the warehouse system in the example. [Figure 2] This is a perspective view showing a transport robot that functions as a conveyor in the warehouse system of the embodiment. [Figure 3] This is a perspective view showing a transport robot carrying goods. [Figure 4] This diagram illustrates how a transport robot travels through an empty storage aisle (empty aisle). [Figure 5] These are the outbound shipment plan, the list of stored items, and the inbound shipment slip, which are referenced by the management device in the warehouse system. [Figure 6] This chart shows the flow of processes performed by a control device to give instructions to a transport robot during the loading and unloading of goods. [Modes for carrying out the invention]

[0014] Hereinafter, a warehouse system, which is an embodiment of the present invention, will be described in detail with reference to the drawings as an embodiment for carrying out the present invention. In addition to the embodiments described below, the present invention can be carried out in various forms by making various changes and improvements based on the knowledge of those skilled in the art, starting with the forms described in [Embodiments of the Invention] above. [Examples]

[0015] [A] Overall Configuration of Warehouse System This warehouse system includes a warehouse Wh shown in FIG. 1, a transport robot CR as a transporter that travels inside the warehouse Wh to transport goods G, and a management device M that manages the storage of goods G and the operation of the transport robot CR inside the warehouse Wh. Regarding the directions in the warehouse Wh, hereinafter, the upper side of the figure will be referred to as north (N), the lower side as south (S), the right side as east (E), and the left side as west (W), respectively.

[0016] A number of storage compartments Cs for storing goods G are provided in the warehouse Wh. Specifically, five storage compartments Cs are arranged in a row without gaps in the north-south direction to form one storage row Rs, and a plurality of such storage rows Rs are arranged without gaps in the east-west direction to form one storage block Bs. Six storage blocks Bs are set inside the warehouse Wh. Each storage block Bs is set with a symbol as shown in the upper left shoulder of the figure, that is, a symbol from "A" to "F". In the following description, each storage block Bs may be referred to as storage block A, storage block B, ···, storage block F, respectively. Storage block A and storage block B are provided with 40 storage rows Rs, and storage blocks C to F are provided with 12 storage rows Rs. The storage rows Rs that make up each storage block Bs are numbered #01 to #40 from the west side to the east side in storage blocks A and B, and #01 to #12 in storage blocks C to F. And the storage compartments Cs that make up each storage row Rs are numbered &1 to &5 in order from the north side. Hereinafter, the storage rows Rs and storage compartments Cs will be specified according to those symbols and numbers. For example, the storage compartment Cs indicated by ★ in the figure may be called storage compartment D#03&4, and the storage row Rs where the storage compartment D#03&4 is located may be called storage row D#03.

[0017] In the warehouse Wh, there is a permanent passageway (hereinafter sometimes referred to as the "permanent passageway PP") along which the transport robot CR travels, surrounding each storage block Bs. As shown in the figure, the permanent passageway PP is provided with seven passageways extending east-west and four passageways extending north-south. The seven permanent passageways PP are labeled WE1~WE7, and the four permanent passageways PP are labeled NS1~NS4. Hereinafter, according to this labeling, each permanent passageway PP may be referred to as permanent passageways WE1, WE2, ···, WE7, SN1···SN4. Any of the permanent passageways PP has only a width sufficient for the transport robot CR to pass by each other.

[0018] Inside the warehouse Wh, at the central part on the south side, there is an inbound / outbound yard Yio which is a yard for inbound or outbound of the warehouse Wh. In the figure, a state where two trucks Tr, specifically trucks Tr1 and Tr2, are parked in the inbound / outbound yard Yio is depicted. Incidentally, the truck Tr1 is parked to carry out outbound of the article G, and the truck Tr2 is parked to carry out inbound of the article G.

[0019] There are 10 transport robots CR operating inside the warehouse Wh. Each transport robot CR is configured to be responsible for both inbound and outbound operations. In the case of the inbound operation, it receives the article G from the loading platform of the truck Tr2 and transports the article G to the designated storage section Cs. In the case of the outbound operation, it takes out the article G stored in the designated storage section Cs, transports it to the truck Tr1, and loads the article G onto the loading platform of the truck Tr1. The article G is carried in and out from either end of the storage row Rs, specifically, from the north side or the south side of the storage row Rs. No equipment (such as a conveyor, a shooter, etc.) for moving the article G is provided in any of the storage rows Rs, and the transport robot CR can carry in the article G it is transporting over the articles G that have already been stored, and can only carry out the article G that is the closest to the front side when viewed from the north or south side of the storage row Rs.

[0020] The control device M is installed in the control room RM, which is adjacent to the warehouse Wh. The control device M is primarily a computer consisting of a CPU, ROM, RAM, storage device, etc., and is equipped with a wireless communication device for communication with each transport robot CR.

[0021] [B] Conveyor The transport robot CR, as shown in Figure 2, generally has a forklift-like form and has a platform-shaped base 12. The lower right side of the figure is the front and the upper left side is the rear. The rear part of the base 12 functions as a weight and, although not shown in the figure, has a pair of drive wheels on the left and right sides and a pair of steering wheels at the front and rear. A pair of posts 14 are erected on the base 12 on the left and right sides, and a table 16 that can be raised and lowered along the posts 14 is positioned between the pair of posts 14. A slide arm 18 that can move back and forth is positioned on the table 16. A back plate 20 is attached to the front end of the slide arm 18 so as to be movable from side to side. A pair of fork tines 22 are attached to the lower part of the back plate 20 so as to extend forward. The transport robot CR is capable of moving back and forth and can also rotate in place.

[0022] The transport robot CR is electrically powered and therefore has a battery 26 in its base 12. In other words, the transport robot CR moves and performs tasks using the electrical energy stored in the battery 26. Furthermore, since the transport robot CR automatically travels and performs tasks, a camera 28 and a LiDAR 30 are mounted on the top of the backplate 20, and a receiver 32 for receiving signals from beacons B (see Figure 1) installed on the ceiling at the four corners of the warehouse Wh is mounted on the upper end of one of the pair of posts 14. In addition, an antenna 34 for communication with the management device M is installed on the upper end of the other post 14. The method for the transport robot CR's automatic travel and work can be any known method, and the method used in this warehouse system will not be explained here. The transport robot CR also has a computer-based control terminal 36 for controlling itself.

[0023] As shown in Figure 3(a), if the item G is a collection of casings 40 such as cardboard boxes, the item G will be in the form of these casings 40 placed on a single pallet 42. In this case, the transport robot CR will transport the item G with its fork tines 22 inserted into the tine holes 44 provided in the pallet 42. Also, as shown in Figure 3(b), if the item G is a powder, liquid, etc. 46, the item G will be in the form of these powders, liquids, etc. 46 contained in a container 48. In this case, the transport robot CR will transport the item G with its fork tines 22 inserted into the tine holes 44 provided in the bottom of the container 48.

[0024] In the following explanation, when referring to individual transport robots CR, they will be numbered as transport robots CR1 to CR10.

[0025] [C] Use of empty aisles In this warehouse system, there are relatively few permanent passages PP within the warehouse Wh, and the transport robot CR, in principle, travels along these permanent passages PP to perform the loading and unloading operations described above. Referring to Figure 4, for example, when loading goods G into storage area A#13&1 indicated by a star, the transport robot CR1 will travel along a route such as permanent passage WE3 → permanent passage NS1 → permanent passage WE1, as shown by the solid line. Since this travel route is relatively long, such loading operations become inefficient.

[0026] When goods G are shipped out by one truck Tr, 10 goods G can be shipped out. In this warehouse system, each storage column Rs has 5 storage compartments Cs, and when goods are shipped out by one truck Tr, goods G stored in two storage columns Rs are shipped out. More specifically, goods G stored in two adjacent storage columns Rs are shipped out at the same time. When those goods G are shipped out, each of the two storage columns Rs in which they were stored becomes a storage column Rs in which no goods G are stored in either storage compartment Cs, in other words, an "empty column". With two empty columns adjacent to each other, it becomes possible for a transport robot CR to pass through them. In other words, two adjacent empty columns create a temporary passage, the "empty column passage CP".

[0027] In the diagram, for example, storage rows A#05 and A#06 share one empty aisle CP, while storage rows B#13 and B#14 share another empty aisle CP (hereinafter, these may be referred to as empty aisle A#0506 and empty aisle B#1314). Therefore, in this warehouse system, the transport robot CR1 can travel a different route from the aforementioned travel route, specifically the route shown by the dashed line in the diagram: permanent aisle WE3 → empty aisle B#1314 → permanent aisle WE2 → empty aisle A#0506 → permanent aisle WE1, to transport goods G into storage compartments A#13&1. This travel route is considerably shorter than the travel route using only permanent aisle PP, meaning the travel route is shortened, resulting in more efficient loading operations.

[0028] The advantages of using empty aisle CP are not limited to shortening the travel route. For example, when transport robot CR2 attempts to transport item G into storage compartment F#11&1, indicated by ★, if only the permanent aisle PP is used, transport robot CR2 will travel the shortest route, as shown by the solid line, namely permanent aisle NS4 → permanent aisle WE5. At this time, if another transport robot CR, robot CR3, is performing the task of unloading item G stored in storage compartment F#05&1, the passage of transport robot CR2 along the above route will be obstructed. In other words, transport robot CR2 will be forced to wait before storage aisle F#05, making efficient loading impossible.

[0029] Therefore, in this warehouse system, the transport robot CR2 is configured to use an empty aisle CP as its route instead of the above-mentioned travel route, specifically the route shown by the dashed line: permanent aisle WE3 → empty aisle D#0708 → permanent aisle WE5, to perform loading operations. Even in this situation, using the empty aisle CP enables efficient loading operations.

[0030] As will be explained in more detail later, the travel route of each transport robot CP is determined by the control device M. The control device M understands the movements of all transport robots CP, that is, where they are currently, what they are doing, and what they will do next, and determines the travel route for each transport robot CP based on this understanding.

[0031] In the diagram, eight empty aisles CP are set up, namely empty aisles A#0506, A#2526, B#1314, B#3334, C#0304, D#0708, E#1112, and F#0304. As will be explained in more detail later, the management device M manages to store items G that are shipped out at the same time, that is, items G shipped out on a single truck Tr, in two adjacent storage rows Rs in order to form such empty aisles CP. To achieve this management, when an item G is brought in, the management device M determines the storage row Rs to which the item G will be stored based on when the item G will be shipped out.

[0032] In this warehouse system, as a general rule, the storage row Rs adjacent to the east of each empty aisle CP contains the next item G to be shipped out, and the empty aisle CPs are designed to shift sequentially to the east as the shipping operation progresses.

[0033] In this warehouse system, one empty aisle CP was formed by two adjacent empty storage rows Rs. However, one empty aisle CP may be formed by one empty row, as long as a transport robot CP can pass through it. Conversely, one empty aisle CP may be formed by three or more adjacent empty rows.

[0034] Furthermore, in this warehouse system, one storage column Rs is composed of five storage compartments Cs arranged in a row, and when one truck Tr is dispatched, two storage columns Rs become empty. However, for example, the number of storage compartments Cs that make up one storage column Rs may be increased, so that when two or more trucks Tr are dispatched, one or more adjacent storage columns Rs become empty.

[0035] [D] Functions of the control device The management device M has two main functions. One is the stored goods management function, which manages the goods G stored in warehouse Wh, and the other is the transport robot operation management function, which manages the operation of each transport robot CR. These functions will be explained in order below.

[0036] i) Storage item management function The management device M receives an outbound shipment plan for item G shown in Figure 5(a) from an external source. The outbound shipment plan includes information for each truck Tr that will be departing, such as the date and time of departure, the truck Tr number, the name of item G loaded on that truck Tr, and its quantity.

[0037] The management device M stores a list of stored items as shown in Figure 5(b). This list of stored items indicates which items G are stored or should be stored in which storage section Cs of which storage column Rs in which storage block Bs. The dispatch plan is generally sent in advance on a truck-by-truck basis, in the order of dispatch date and time. The management device M updates this list each time a dispatch plan is sent. Specifically, in order to store the items G to be loaded onto that truck Tr in two adjacent storage columns Rs, it sets one of the two adjacent storage columns Rs that are currently empty as the storage column Rs where those items G should be stored.

[0038] On the other hand, each time an item G is received into storage, the management device M receives information about the name and quantity of the item G in the form of a receipt slip as shown in Figure 5(c). As will be explained later, the management device M issues a command to the transport robot CR to move the items G into the storage rows Rs set in the storage item list. When the transport robot CR moves the item G into one of the storage compartments Cs in the designated storage rows Rs, it transmits information to the management device M to that effect. Upon receiving this information, the management device M updates the storage item list to indicate that the item G has been stored.

[0039] Incidentally, since items G can only be brought into each storage column Rs from either end, items G to be stored in that storage column Rs are brought in sequentially from the center toward both ends of the storage column Rs. The order in which items G are received is not yet known when the storage columns Rs are set in the storage item list, so each time an item G is brought in, the storage section Cs in the storage item list are rearranged as necessary, according to the storage section Cs into which the item G was actually brought.

[0040] As will be explained later, the management device M issues a command to the transport robot CR to load items G stored in a specific storage column Rs onto a specific truck Tr, based on the above-mentioned outbound plan. When the transport robot CR has removed items G from its storage column Rs and loaded them onto truck Tr, it transmits this information to the management device M. Based on this information, when all items G that were stored in that storage column Rs have been removed, the management device M updates the list of stored items to indicate that the storage column Rs is now empty.

[0041] The above describes the storage item management function of the management device M. The management device M can, and actually does, determine from the storage item list which storage columns Rs are empty. Based on this determination, the management device M designates two adjacent empty columns as the empty column passage CP mentioned above. The management device M has an empty column passage designation function in addition to its storage item management function.

[0042] ii) Transport robot operation management function As explained earlier, when a truck Tr loaded with goods G enters the loading / unloading yard Yio, the management device M issues an instruction to the transport robot CR to load the loaded goods G into the storage column Rs set in the storage item list. Specifically, this loading instruction process is carried out according to the loading instruction processing flow shown in Figure 6.

[0043] According to the delivery instruction processing flow, in step 1 (hereinafter sometimes abbreviated as "S1"), the management device M identifies the item G to be delivered by referring to the receiving slip. In the following S2, the management device M identifies the optimal transport robot CR for delivering the item G from among the 10 transport robots CR, taking into account their current position, work status, etc. Then, in S3, the management device M identifies the storage section Cs in the storage row Rs where the item G should be stored by referring to the stored item list. Then, in S4, the management device M determines the travel route of the transport robot CR that will deliver the item G, specifically the travel route to the truck Tr that will receive the item G, and the travel route from the truck Tr to the identified storage section Cs after receiving the item G, taking into account the current position, work status, empty row aisle CP, etc. of each transport robot CR. In S5, the management device M gives the transport robot CR a delivery instruction for the item G by transmitting information about the item G, the storage section Cs to be stored in, and the travel route to the identified transport robot Cs. Incidentally, since the current position and work status of each transport robot CR change moment by moment, the travel route is also changed moment by moment in accordance with these changes and transmitted to the transport robot CR. Upon receiving this information, the transport robot CR automatically travels and performs the loading operation automatically.

[0044] Furthermore, as explained earlier, when a truck Tr to be dispatched with goods G enters the inbound / outbound yard Yio, the management device M issues an instruction to the transport robot CR to unload goods G, which should be loaded onto the truck Tr, from the storage area Cs set in the stored goods list. Specifically, this unloading instruction process is carried out according to the unloading instruction processing flow shown in Figure 6.

[0045] According to the unloading instruction processing flow, in S11, the management device M identifies the item G to be unloaded by referring to the unloading plan. In the following S12, the management device M identifies the optimal transport robot CR for unloading the item G from among the 10 transport robots CR, taking into account its current position, work status, etc. Then, in S13, the management device M identifies the storage rows Rs and storage compartments Cs in which the item G is stored by referring to the stored item list. Then, in S14, the management device M determines the travel route of the transport robot CR to unload the item G, specifically the travel route to the storage compartment Cs in which the item G is stored, and the subsequent travel route to the truck Tr, taking into account the current position, work status, empty aisle CP, etc. of each transport robot CR. In S15, the management device M sends information about the item G, the storage compartment Cs in which the item G is stored, and the travel route to the identified transport robot Cs, thereby giving the transport robot CR an instruction to unload the item G. Incidentally, just like with the loading of goods G, the current position and work status of each transport robot CR change moment by moment. Therefore, the travel route is also changed moment by moment in accordance with these changes and transmitted to the transport robot CR. Upon receiving this information, the transport robot CR automatically drives and performs the loading operation automatically.

[0046] In this warehouse system, the transport robot CR was designed to automatically travel and perform loading and unloading operations. However, the transport robot could be operated by a human driver. In that case, the transport robot should, for example, be equipped with a display monitor on which loading and unloading instructions from the management device M should be displayed. It is desirable that the display include the travel route, specifically the travel route utilizing the empty aisle CP. [Explanation of symbols]

[0047] Wh: Warehouse G: Goods CR: Transport robot (transporter) M: Management device Cs: Storage section (&1~5) Rs: Storage row (#01~40) Bs: Storage block (A~F) Yio: Inbound / Outbound yard Tr: Truck (Tr1~2) PP: Permanent aisle (WE1~7,NS1~4) CP: Empty aisle

Claims

1. A warehouse having multiple rows of storage compartments, each containing multiple items, arranged in a single row, and Multiple conveyors that travel within the warehouse to transport goods into and out of storage areas, A management device for managing the storage of items in storage compartments and A warehouse system equipped with, A warehouse system in which the management device manages items to be unloaded at the same time to be stored in one or more adjacent storage rows, so that after the items have been unloaded, the one or more storage rows function as passages for the multiple conveyors.

2. The warehouse system according to claim 1, wherein the management device is configured to determine the storage row in which an item is stored based on the timing of its removal when an item is brought in.

3. The warehouse system according to claim 1, wherein the warehouse is configured to load and unload goods from its end to the storage rows.

4. The warehouse system according to claim 1, wherein each of the multiple transporters is capable of autonomous movement.

5. The warehouse system according to any one of claims 1 to 4, wherein the management device is configured to also determine the travel routes of the plurality of conveyors within the warehouse.

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