Automated warehouse system and warehouse management method

Abstract

To store and take out articles efficiently through article management on a warehouse.SOLUTION: An automatic warehouse system has: a management part which manages information on states of a plurality of conveyance devices, arrangements of containers on shelves and articles stored in containers, and information on travel routes of the plurality of conveyance devices and whether the plurality of conveyance devices can be elevated and lowered at the respective shelves; a traffic optimization part which uses the information managed by the management part to optimize the travel routes of conveyance of the containers by the plurality of respective conveyance devices and elevating / lowering operations at the shelves; and an instruction part which instructs the plurality of respective conveyance devices to convey the containers through the travel routes and elevating / lowering operations optimized by the traffic optimization part.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present disclosure relates to an automated warehouse system and a warehouse management method.

Background Art

[0002] Conventionally, in warehouses such as distribution bases for articles, a large number of articles are managed, and according to requests, the articles are taken out from storage shelves and preparation for delivery is carried out. The number and types of articles to be managed are extremely large, and it is required to improve the efficiency of storage and retrieval thereof. For example, Patent Document 1 discloses a configuration in which relocation of containers is performed by machine learning in order to improve the efficiency and scalability of product storage and retrieval.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In view of the above-described conventional circumstances, the present disclosure has been devised, and an object thereof is to provide an automated warehouse system and a warehouse management method capable of improving the efficiency of storage and retrieval of articles in article management in a warehouse.

Means for Solving the Problems

[0005] The present disclosure includes a management unit that manages the states of a plurality of transfer devices, the arrangement of containers on shelves, information on articles stored in the containers, the travel routes of each of the plurality of transfer devices, and information on whether or not each of the plurality of transfer devices can move up and down on the shelves, and uses the information managed by the management unit to determine the travel routes and the up-and-down movements on the shelves when containers are transferred by each of the plurality of transfer devices Selection to conductThe traffic optimization department and the traffic optimization department choice Based on the specified travel path and lifting operation, each of the multiple transport devices has an instruction unit that instructs it to transport a container. The traffic optimization unit determines at least one of the following for each of the plurality of transport devices: the travel path and travel timing, the standby position and standby timing, and the lifting / lowering position and lifting / lowering timing on the shelf. We provide automated warehouse systems.

[0006] Furthermore, this disclosure describes how the processor works in cooperation with memory to manage the status of each of the multiple transport devices, the arrangement of containers on shelves, information about the items stored in the containers, the travel paths of each of the multiple transport devices, and information on whether each of the multiple transport devices can be raised or lowered on the shelves. What to do and Using the managed information, the travel path and lifting / lowering operation on the shelves during container transport by each of the multiple transport devices are determined. Selection of What to do , choice Based on the specified travel path and lifting / lowering operation, each of the multiple transport devices is instructed to transport the container. thing and , The selection of the travel path and the lifting / lowering operation on the shelf includes determining at least one of the travel path and travel timing, standby position and standby timing, and lifting / lowering position and lifting / lowering timing for each of the plurality of conveying devices, We provide warehouse management methods.

[0007] Furthermore, any combination of the above components, as well as any conversion of the expressions of this disclosure between methods, apparatus, systems, storage media, computer programs, etc., are also valid forms of this disclosure. [Effects of the Invention]

[0008] According to this disclosure, it becomes possible to streamline the storage and retrieval of goods in warehouse inventory management. [Brief explanation of the drawing]

[0009] [Figure 1] Block diagram showing an example of the system configuration according to Embodiment 1 [Figure 2] External perspective view illustrating an example of the warehouse configuration according to Embodiment 1 [Figure 3] Conceptual diagram illustrating the movement of a transport robot within a warehouse according to Embodiment 1. [Figure 4] Block diagram showing an example of the functional configuration of the control system according to Embodiment 1. [Figure 5] Block diagram showing an example of the functional configuration according to Embodiment 1 [Figure 6] Block diagram showing an example of the functional configuration according to Embodiment 1 [Figure 7] Sequence diagram of the process according to Embodiment 1 [Figure 8] Flowchart of the process according to Embodiment 1 [Figure 9] Flowchart of the process according to Embodiment 1 [Figure 10] Flowchart of the process according to Embodiment 1 [Modes for carrying out the invention]

[0010] (Background leading to this disclosure) In recent years, the number of deliveries in logistics has increased dramatically, and there is a need to improve the efficiency of storage and retrieval of goods in warehouses and other facilities. Traditionally, necessary items have been retrieved from shelves using transport devices such as AGVs (Automatic Guided Vehicles). To achieve the above-mentioned efficiency improvements, it is conceivable to optimize the storage location of goods, the retrieval of goods by transport devices, and the transport routes. Patent Document 1 discloses a system that assumes a transport robot capable of operating on a grid structure that constitutes a shelf, but it does not consider the transport control of the transport robot in areas surrounding the shelf or shelves with different structures. In particular, it did not optimize transport by multiple transport robots, taking into account the travel route around the shelf, standby operation, and shelf lifting operation.

[0011] Hereinafter, embodiments specifically disclosing the warehouse management method and the automated warehouse system according to the present disclosure will be described in detail with appropriate reference to the accompanying drawings. However, a more detailed description than necessary may be omitted. For example, detailed descriptions of well-known matters or redundant descriptions of substantially the same configuration may be omitted. This is to avoid making the following description unnecessarily redundant and to facilitate the understanding of those skilled in the art. The accompanying drawings and the following description are provided for those skilled in the art to fully understand the present disclosure, and are not intended to limit the subject matter described in the claims thereby.

[0012] <Embodiment 1> [System Configuration] FIG. 1 is a block diagram showing a configuration example of the system according to the embodiment. The automated warehouse system according to the present embodiment includes a control system 100, a transport robot 200, a work instruction device 300, an inventory management system 400, and a higher-level external system 500.

[0013] The control system 100 controls the entire automated warehouse system according to the present embodiment. The control system 100 is configured to be communicable with the work instruction device 300, the inventory management system 400, and the higher-level external system 500 via a wired or wireless network, and acquires various instructions and data. Further, the control system 100 gives instructions to the transport robot 200 connected by wireless communication based on the various instructions and data acquired.

[0014] The control system 100 is a server device configured to include a processing unit 101, a memory 102, a storage device 103, a communication unit 104, and an interface unit 105. The processing unit 101 provides various functions described below by reading and executing various data and programs held in the memory 102 and the HDD 103. The processing unit 101 may be configured using, for example, a CPU (Central Processing Unit), MPU (Micro Processing Unit), DSP (Digital Signal Processor), GPU (Graphical Processing Unit), or FPGA (Field Programmable Gate Array). The memory 102 is a storage area for storing and holding various data, and may be composed of, for example, a non-volatile storage area such as a ROM (Read Only Memory) and a volatile storage area such as a RAM (Random Access Memory). The storage device 103 is a storage area for storing and holding various data and programs, and may be composed of, for example, an HDD (Hard Disk Drive). The communication unit 104 communicates with an external device via a network such as wired / wireless, and transmits and receives various data and signals. The communication method by the communication unit 104 is not particularly limited, and may support a plurality of communication methods. For example, a WAN (Wide Area Network), LAN (Local Area Network), power line communication, short-range wireless communication (e.g., Bluetooth (registered trademark)), etc. may be used. The interface unit 105 is an interface for transmitting and receiving data with an external device. Further, the interface unit 105 may include an input / output unit for receiving data of an instruction from a user from a mouse or keyboard not shown, or outputting data of various information to a display or the like not shown. Each part included in the control system 100 is communicably connected by an internal bus or the like not shown.

[0015] The transport robot 200 is an unmanned transport device for retrieving containers containing items according to this embodiment from shelves and transporting them to a desired location (in this embodiment, a work area). The transport robot 200 also transports the containers from the desired location to shelves and stores them on the shelves. Multiple transport robots 200 are configured to travel within a warehouse where shelves are installed.

[0016] The transport robot 200 is composed of a control unit 201, a memory unit 202, a container transfer unit 203, a mobile drive unit 204, a sensor unit 205, and a communication unit 206. The control unit 201 is responsible for the overall control of the transport robot 200. The control unit 201 may be composed of, for example, a CPU, MPU, DSP, GPU, or FPGA. The memory unit 202 may be composed of various volatile / non-volatile memory devices. The container transfer unit 203 is the part that loads containers placed on shelves onto the transport robot 200 and returns containers loaded on the transport robot 200 to the shelves. Here, the process of taking a container from a shelf and moving it to the transport robot 200, and returning a container loaded on the transport robot 200 to the shelf, will be collectively referred to as "transfer" in this explanation. The container transfer unit 203 may be composed of, for example, a robot capable of gripping containers, a fork capable of lifting containers, and motors for operating these.

[0017] The mobile drive unit 204 is the part that allows the transport robot 200 to move. The mobile drive unit 204 may include, for example, tires for traveling on the floor of a warehouse where shelves are installed, and a motor for travel. The mobile drive unit 204 may also include a lifting mechanism for the transport robot 200 to move up and down on the shelves. The mobile drive unit 204 may also include a battery, which is the power source for the transport robot 200. The sensor unit 205 is the part that acquires information about the surroundings of the transport robot 200. The sensor unit 205 may include, for example, a camera, distance sensor, acceleration sensor, gyroscope sensor, position sensor, load sensor, etc. The communication unit 206 communicates with external devices (for example, a control system 100 or other transport robots 200) via wireless communication and sends and receives various data and signals. The communication method used by the communication unit 206 may be, for example, Bluetooth® or Wi-Fi®, but is not particularly limited and may support multiple communication methods. Each component of the transport robot 200 is connected via an internal bus (not shown) or the like, enabling communication between them.

[0018] The work instruction device 300 is a device operated by a worker in a work space such as a warehouse where the automated warehouse system according to this embodiment is installed. The work instruction device 300 may be a stationary information processing terminal such as a PC (Personal Computer), or a portable terminal such as a POS terminal or tablet terminal. Multiple work instruction devices 300 may be provided depending on the layout of the warehouse and the number of workers.

[0019] The inventory management system 400 is a system for managing the inventory status of goods managed in a warehouse where the automated warehouse system according to this embodiment is introduced, as well as the movement of goods in and out of the warehouse. The inventory management system 400 may be implemented with the same device configuration as the control system 100. Alternatively, the control system 100 and the inventory management system 400 may be integrated into a single configuration.

[0020] The higher-level external system 500 is a system that provides various types of information used in the automated warehouse system according to this embodiment. The information provided by the higher-level external system 500 is not particularly limited, but may include, for example, information related to forecasting demand for goods, information related to the transportation of goods (such as weather information and shipping schedule information), and information related to the storage plan for goods. Furthermore, the higher-level external system 500 may consist of multiple systems depending on the information and functions provided.

[0021] The control system 100, inventory management system 400, and higher-level external system 500 may each be configured as either on-premise systems or cloud-based systems.

[0022] [Warehouse configuration] Figure 2 is an external perspective view showing an example of the interior of a warehouse where the automated warehouse system according to this embodiment can be introduced. In Figure 2, the three-dimensional coordinate system is shown using the x, y, and z axes, with the z axis corresponding to the height direction. In this embodiment, shelves 220 capable of arranging (storing) multiple containers 210 are installed so that the retrieval sides of the containers 210 face each other. The shelves 220 are also configured to accommodate two containers 210 along the x-axis. In this case, the storage area on the front side is shown as storage area 220a, and the storage area on the back side is shown as storage area 220b. The shelves 220 are installed so that a transport robot 200 can pass between opposing shelves 220 and between shelves 220 arranged in the y-axis direction. In the following description, in the shelves 220, the arrangement of storage areas in the y-axis direction is shown as a "row," the arrangement of storage areas in the z-axis direction is shown as a "tier," and the arrangement of storage areas in the x-axis direction is shown as a "layer." Therefore, for example, Figures 2 and 3 show, as an example, a single shelf 220 with a configuration of 7 columns × 7 rows × 2 layers.

[0023] Furthermore, the shelf 220 in this embodiment is provided with a fitting portion (not shown) for the transport robot 200 to move up and down. The fitting portion may be, for example, a hole provided on the front part (aisle side) of the frame of the shelf 220. The mobile drive unit 204 of the transport robot 200 is equipped with a hook that can be fitted into such a fitting portion on the shelf 220 side, and uses these to perform the up and down operation. In this embodiment, the distance between opposing shelves 220 is set to a distance that allows one transport robot 200 to pass through (see Figure 3). The mobile drive unit 204 of the transport robot 200 then performs the up and down operation using the fitting portions of each of the opposing shelves 220 (i.e., the shelves 220 on both sides).

[0024] The transport robot 200 moves to a desired position on the shelf 220, rises, and then performs a transfer operation using the container transfer unit 203, that is, an operation to remove the container 210 from the shelf 220 or an operation to return the container 210 to the shelf 220. At this time, the transport robot 200 is controlled based on instructions from the control system 100 to place the container 210 in either the front storage compartment 220a or the back storage compartment 220b. Similarly, the transport robot 200 is controlled based on instructions from the control system 100 to remove the container 210 placed in the front storage compartment 220a or the container 210 placed in the back storage compartment 220b.

[0025] The appearance of the transport robot 200 shown in Figure 2 is an example and is not limited to this. Furthermore, the arrangement and structure of the container 210 when the transport robot 200 performs transport are not limited to the example in Figure 2.

[0026] Figure 3 is a conceptual diagram illustrating the movement of the transport robot 200 around the shelves 220. As shown in Figure 2, shelves 220 with a depth (layer) capable of storing two containers 210 are arranged in the warehouse. It can also be seen that each shelf 220 has seven storage compartments. Around the shelves 220, work areas 250 are provided for workers to take out items 215 stored in the containers 210 or to replenish the containers 210 with items 215. In this example, three work areas 250 are provided, each equipped with a work instruction device 300. Based on instructions from the control system 100, the transport robot 200 transports the containers 210 containing the target items 215 between a predetermined position on the shelf 220 and the work area 250.

[0027] The white circle indicates node 230, which represents the working position (lifting / lowering position) or standby position of the transport robot 200. For example, the transport robot 200 will perform the lifting / lowering operation at the node 230 in front of the shelf 220. Also, if another transport robot 200 is working at or around the target shelf 220, the transport robot 200 can wait at a nearby node 230 until that work is completed.

[0028] The dashed arrow indicates path 240, which represents the travel route of the transport robot 200. Path 240 connects nodes 230. In this example, path 240 is configured to travel in one direction.

[0029] In this embodiment, considering the size of the storage compartments of the shelves 220, the size of the containers 210, and the size of the transport robots 200, when work is being performed in a row (node ​​230) of the shelves 220, work (waiting or lifting / lowering) in the rows (nodes 230) on either side of that row is controlled to be disabled. Similarly, when work is being performed in a row (node ​​230) of the shelves 220, work in storage compartments at different heights in the same row is controlled to be disabled. If a transport robot 200 has risen to a certain height or higher in a row (node ​​230), the system may be controlled to allow other transport robots 200 to pass through the passage below. Also, if a transport robot 200 is waiting because another transport robot 200 is working, it may remain waiting in the same location (node ​​230). Alternatively, it may wait by moving from one empty node 230 to another (circling) to avoid obstructing the movement of other transport robots 200 or causing congestion on their travel paths. When performing a circuit, the circuit route is not limited to the shortest route to the target node 230, but may be determined based on the congestion prediction results due to the presence of other transport robots 200. Also, the waiting position is not limited to the running surface (floor) as shown in Figure 3, but may be configured to wait at node 230 in front of shelf 220 with the robot raised on shelf 220. Note that these constraints are examples and may be adjusted as appropriate depending on the size of the transport robot 200, container 210, shelf 220, etc.

[0030] In the example shown in Figure 3, all shelves 220 are shown as having two layers (i.e., storage compartments with two depths), but a warehouse can also be constructed by combining shelves with a single layer configuration.

[0031] [Functional Configuration] Figure 4 is a block diagram showing an example of the functional configuration of the control system 100 according to this embodiment. Each function shown as a module may be realized by the processing unit 101 of the control system 100 reading and executing a program stored in the storage device 103 or the like. Furthermore, the module configuration shown in Figure 4 is just one example; multiple blocks may be combined into one, or one block may be further divided into more detailed components. Also, the arrows shown in Figure 4 indicate the transmission and reception of data between modules. Note that the transmission and reception of data is not limited to the flow shown in Figure 4, and may be further performed between modules as needed.

[0032] The control interface 111 controls data communication with the higher-level external system 500 and the inventory management system 400. For example, the control interface 111 requests data from the external system or retrieves data from the external system in response to instructions or requests from other modules.

[0033] The task management module 112 manages the tasks performed by the transport robot 200. In this embodiment, a "task" refers to a series of operations related to the transport of desired items that the transport robot 200 should perform within the warehouse. For example, a task may be set to include a series of operations from taking a container 210 stored on a shelf 220, transporting it to a work area 250, and then returning it to the shelf 220. The finer units of operation included in a task (hereinafter also referred to as "subtasks") are not limited to the above; for example, a task may consist of a series of operations from taking a container 210 stored on a shelf 220 and rearranging it in a different storage area. Therefore, the subtasks that make up a task can be set arbitrarily. Furthermore, the task management module 112 generates information such as the type and number of items that an operator should take from the container 210 transported by the transport robot 200 (described later as "picking instruction data"). The picking instruction data is generated based on the shipping instructions for items (hereinafter also referred to as "orders") transmitted from the inventory management system 400.

[0034] The placement optimization control module 113 optimizes the placement of containers 210 (i.e., items 215) in each storage compartment of the multiple shelves 220. The placement of items 215 is optimized according to factors such as retrieval frequency and inventory level. The algorithm for the optimization process performed by the placement optimization control module 113 is not particularly limited, but optimization here refers to improving the placement of containers 210 (i.e., items) on the shelves 220 with the aim of improving the efficiency of item retrieval throughout the entire automated warehouse system. Details of the placement optimization control module 113 will be explained using Figure 6.

[0035] The location map management module 114 manages the arrangement of shelves 220, the configuration of storage compartments, the location of work areas 250, and the settings of nodes 230 and paths 240. If the configuration of shelves 220 is changed, the location map management module 114 accepts the map update accordingly. In addition, the location map management module 114 also manages the number and type of items 215 in containers 210, as well as the location of items 215 within the warehouse, based on information obtained from the inventory management system 400.

[0036] The transport command control module 115 generates and issues delivery commands for controlling the transport robot 200 based on a task or subtask. The transport command may include information such as the location of the container 210 to be transported, the travel path used for transport, and standby positions (nodes) corresponding to the work status and travel paths of other transport robots 200.

[0037] The traffic optimization control module 116 optimizes the travel path of the transport robot 200 when it is executing a task. The travel path may be optimized according to the processing status of tasks by multiple transport robots 200. Furthermore, even after the travel path has been determined for a single task, the optimization may be configured to update the travel path as needed, depending on the progress of that task and other tasks. The algorithm for the optimization process by the traffic optimization control module 116 is not particularly limited, but optimization here refers to improvements to the travel path of the transport robot 200 and the selection and execution timing of its lifting and lowering movements, with the aim of improving the efficiency of retrieving goods in the entire automated warehouse system. Details of the traffic optimization control module 116 will be described later with reference to Figure 5.

[0038] The robot interface module 117 controls data communication with each of the multiple transport robots 200 in the warehouse. The robot interface module 117 sends transport commands to the transport robots 200 and receives various data from the transport robots 200 (for example, information acquired by the sensor unit 205 and battery level information).

[0039] The robot state management module 118 manages the status of the transport robot 200. For example, the robot state management module 118 manages the position information of the transport robot 200, information about the assigned task, and so on.

[0040] Figure 5 is a block diagram showing the detailed configuration of the traffic optimization control module 116 according to this embodiment. Map graph data 501 is graph structure data of nodes and paths that constitute the travel route of the transport robot 200. Map graph data 501 may be obtained, for example, by querying the location map management module 114. Path status data is information indicating the status of a path, and may include information such as availability, occupancy, and reservation status. Lifting / lowering feasibility data 503 is data indicating whether each row of the shelf 220 can be lifted or lowered. As described above, for example, if the transport robot 200 is performing work (lifting / lowering) on ​​a row of the shelf 220, lifting / lowering of that row and the rows on either side of it is managed as not possible. Lifting / lowering feasibility data 503 may be configured by referring to robot status data 510 managed by the robot status management module 118.

[0041] The route search unit 504 uses map graph data 501 and the like to search for routes from the current position of each of the multiple transport robots 200 to the target node. The routes search here may include only transport robots 200 that are not currently performing a task, or it may also include transport robots 200 whose tasks are nearing completion. Furthermore, if there are multiple containers 210 containing the target items 215, the route search unit 504 may search for routes to each of the containers 210. The congestion prediction unit 505 predicts routes where congestion may occur, i.e., routes where work may be delayed, based on the travel routes of the transport robots 200 currently performing tasks. The congestion prediction unit 505 predicts congestion at nodes and paths by considering, for example, the number of transport robots 200 that can travel, routes that are reserved or in use, estimated arrival times, waiting times, the time required for ascending and descending to the shelves 220, and the time required for transfer operations. The traffic scheduling unit 506 schedules travel timings and waiting times at nodes based on the travel routes that the multiple transport robots 200 are scheduled to travel. The route calculation unit 507 works in cooperation with the route search unit 504, the congestion prediction unit 505, and the traffic scheduling unit 506 to calculate the travel routes for the transport robots 200. The route calculation unit 507 may prioritize selecting a travel route from among the multiple travel routes, even if it is physically farther away, if it does not cause congestion and allows for more efficient transport of the containers 210.

[0042] Figure 6 is a block diagram showing the detailed configuration of the placement optimization control module 113 according to this embodiment. Container position data 601 indicates the position of the container 210 in which the goods 215 are stored. The position of the container 210 may include not only its placement on the shelf 220, but also its position in the work area 250, its position during transport by the transport robot 200, etc. The placement scheduling unit 602 schedules the timing of the placement and re-placement of the container 210. For example, if the re-placement operation of the container 210 is performed while normal transport work is being carried out, the normal transport work may be delayed. Therefore, the placement scheduling unit 602 may set a plan so that the re-placement is completed within the timing and time required for the re-placement to be executed. The placement calculation unit 603 optimizes the placement of the container 210 and determines its placement position. Inventory item position data 611 is data indicating the inventory status and item of goods 215. Demand forecast data 612 is data related to the future demand for goods. The demand forecast data 612 may be generated by the control system 100 performing demand forecasting using a predetermined algorithm based on information provided by the higher-level external system 500, or it may be obtained from the inventory management system 400 or the higher-level external system 500. The reference data 613 may include, for example, the priority of shipments from the warehouse, the schedule of the trucks for shipment, and the classification of the goods items.

[0043] The types of data shown in Figures 5 and 6, and the entities that manage each piece of data, are merely examples and are not limited to these. The data may be used and managed commonly across modules, or it may be managed integrally by a specific module. Furthermore, each piece of data may be updated by the control system 100 querying an external system as needed, or it may be updated based on content transmitted from an external system. The configuration of the database managing each piece of data is also not particularly limited.

[0044] [Processing Sequence] Figure 7 shows the control sequence according to this embodiment. Each processing sequence is performed in cooperation with the control system 100, the transport robot 200, the work instruction device 300, the inventory management system 400, and the higher-level external system 500. For the sake of simplicity, the transport robot 200 and the work instruction device 300 are shown as a single unit. Also, the same processing content is indicated by the same reference number.

[0045] The control system 100, the transport robot 200, and the inventory management system 400 work together to control the transfer position movement (step S700). Transfer position movement control is the control to move the transport robot 200 to the desired position for each operation. Details of this process will be described later with reference to Figure 8.

[0046] The control system 100 and the transport robot 200 work together to perform lifting and transfer control (step S800). Lifting and transfer control is the control that causes the transport robot 200 to lift and lower and the container 210 to transfer at a desired position on the shelf 220. Details of this process will be described later with reference to Figure 9.

[0047] The control system 100 and the transport robot 200 work together to perform transport control (step S900). Details of this process will be described later using Figure 8.

[0048] The control system 100 generates picking instruction data based on an order from the inventory management system 400 (step S1101). The picking instruction data generated here may include, for example, information about the items to be picked from container 210 (item type, quantity, etc.).

[0049] The control system 100 transmits the picking instruction data generated in step S1101 to the work instruction device 300 in the corresponding work area 250 (step S1102).

[0050] The work instruction device 300 displays the contents of the picking instruction data received from the control system 100 and instructs the worker to retrieve the desired item from the container 210 that is being transported to the work area 250 by the transport robot 200 (step S1103). Furthermore, after the retrieval operation is completed, the work instruction device 300 accepts a completion signal from the worker.

[0051] Upon receiving the operation to complete the work, the work instruction device 300 sends a notification to the control system 100 indicating that the picking work has been completed (step S1104).

[0052] The control system 100 determines the completion of the task corresponding to the picking instruction data upon receiving a completion notification from the work instruction device 300 (step S1105).

[0053] The control system 100 notifies the inventory management system 400 that the processing corresponding to the order has been completed, in accordance with the completion of the task (step S1106).

[0054] The process up to this point corresponds to the process in which the transport robot 200 takes out the container 210 (i.e., the item 215) placed on the shelf 220 and transports it to the work area 250. The subsequent processes correspond to the process in which, after the picking operation, the container 210 is returned to the shelf 220 from the work area 250, or a series of processes in which the container 210 placed on the shelf 220 is rearranged after optimizing its placement for improved transport efficiency.

[0055] The control system 100, the inventory management system 400, and the higher-level external system 500 work together to perform a placement optimization planning process (step S1000). In the placement optimization planning process, the container 210 may be returned to its original location from which it was removed, or it may be relocated to a different, more appropriate location. Details of this process will be described later using Figure 10.

[0056] The control system 100 and the transport robot 200 work together to perform transport control (step S900). Details of this process will be described later using Figure 8.

[0057] The control system 100 and the transport robot 200 work together to perform lifting and transfer control (step S800). Details of this process will be described later with reference to Figure 9.

[0058] (Transfer position movement control processing) Figure 8 shows the processing flow of the transfer position movement control process according to this embodiment, and corresponds to step S700 in Figure 7. This process is carried out by the cooperation of the control system 100, the transport robot 200, and the inventory management system 400.

[0059] The inventory management system 400 issues an order to the control system 100 for items to be shipped from the warehouse (step S701). The order may include information such as the item name, quantity, and priority (delivery date) of the items to be shipped from the warehouse.

[0060] The control system 100 generates tasks based on orders received from the inventory management system 400 (step S702). The content of the tasks generated here may vary depending on the content of the order; for example, one order may consist of multiple tasks. More specifically, if an order specifies the shipment of multiple items, tasks corresponding to the transportation of each of the multiple items may be generated. Alternatively, one order may be configured to correspond to one task.

[0061] The transport robot 200 notifies the control system 100 of its own device status (step S703). This step may be initiated by the transport robot 200 sending the information to the control system 100, or it may be performed when the control system 100 queries the transport robot 200. Note that the transmission and reception of status notification data between the control system 100 and the transport robot 200 is not limited to this timing and may be performed as appropriate.

[0062] The control system 100 determines which transport robot 200 to assign the task generated in step S702 from among the multiple transport robots 200 (step S704). This assignment may be based, for example, on the battery remaining time, location information, reservation information, etc., of the transport robot 200.

[0063] Next, the control system 100 and the transport robot 200 work together to perform transport control (step S900). This process is repeated until the transport robot 200 reaches the target position (node ​​230). Transport control consists of steps S901 to S906.

[0064] The control system 100 optimizes traffic conditions and schedules operations to determine the travel path of the transport robot 200 to which a task has been assigned (step S901). The control system 100 optimizes traffic conditions and schedules operations based, for example, on the location and travel path of transport robots 200 already performing tasks, their reservation status, and the location of the target container 210. This process may also include scheduling of other transport robots 200 in addition to the transport robot 200 to which a task was newly assigned in step S704, in order to improve the overall efficiency of transport in the automated warehouse system.

[0065] The control system 100 generates a transport command for the transport robot 200 based on the schedule determined in step S901 (step S902). The transport command may specify information such as the travel path, waiting position, waiting timing, and travel conditions (such as travel speed).

[0066] The control system 100 transmits the transport command generated in step S902 to the transport robot 200 and instructs it to perform a transport operation based on the transport command (step S903).

[0067] The transport robot 200 performs a transport operation based on a transport command received from the control system 100 (step S904). At this time, the transport robot 200 may control its operation based on information detected by the sensor unit 205 in addition to the instructions of the transport command.

[0068] The transport robot 200 notifies the control system 100 of its own status information (step S905). The status information may include the progress of the task (transport command) and information detected by the sensor unit 205. This notification operation may be performed periodically or depending on the progress of the task.

[0069] The control system 100 determines whether the transport robot 200 has arrived at a predetermined position based on the status information received from the transport robot 200 in step S905 (step S906). The predetermined position here corresponds to the position in front of the target shelf 220 where the lifting and lowering operation is performed. If the transport robot 200 is in a waiting position until another transport robot 200 completes its work, or if it is in transit, it may be determined that the transport robot 200 has not yet arrived. If it has arrived, this processing flow is completed and the process proceeds to the next lifting / lowering and transfer control (step S800). If it has not arrived, the transport control (step S900) is repeated until it arrives.

[0070] (Lifting / Transfer Control Processing) Figure 9 shows the processing flow of the lifting and transfer control process according to this embodiment, and corresponds to step S800 in Figure 7. This process is performed by the coordinated operation of the control system 100, the transport robot 200, and the inventory management system 400. This process begins after the transport robot 200 arrives at the lifting position in front of the target shelf 220.

[0071] The control system 100 transmits an upward command to the transport robot 200 (step S801). The upward command may include information such as the height, speed, and timing of the upward movement.

[0072] Based on the upward command received from the control system 100, the transport robot 200 performs an upward movement by connecting the mobile drive unit 204 to the shelf 220 (step S802).

[0073] When the transport robot 200 has risen to the position specified by the rise command, it sends a rise completion notification to the control system 100 (step S803).

[0074] In step S803, the control system 100 receives a notification from the transport robot 200 that the lifting is complete, and in response, it instructs the transfer of the container 210 (step S804). At this time, it is specified whether to take out the container 210 or return the container 210 to the shelf. Also, as shown in Figure 3, the shelves 220 are arranged so that the retrieval sides of the shelves 220 face each other, so it is also specified which side of the shelf the container 210 should be transferred to. Furthermore, it is also specified whether the transfer should be performed on the front side (storage section 220a) or the back side (storage section 220b) of the storage section.

[0075] In step S804, the transport robot 200 performs a transfer operation by operating the container transfer unit 203 based on the transfer instruction received from the control system 100 (step S805).

[0076] The transport robot 200 sends a transfer completion notification to the control system 100 when the transfer operation is completed (step S806).

[0077] The control system 100 notifies the inventory management system 400 that the position of the container 210 has changed based on the transfer operation of the transport robot 200 (step S807). The inventory management system 400 manages the placement of the container 210 on the shelf 220, along with the items stored in the container 210, and the container 210 mounted on the transport robot 200.

[0078] The control system 100 optimizes and schedules the transport robot 200's traffic based on the traffic conditions at that time (step S808). Since other transport robots 200 may be traveling in the passage below the raised position, the control system 100 may, if necessary, schedule the transport robot 200 to wait in the raised position on the shelf 220. This process may be the same as the process in step S901 in Figure 8.

[0079] The control system 100 issues a descent command to the transport robot 200 based on the schedule determined in step S808 (step S809). The descent command may include information such as the speed and timing of the descent.

[0080] The transport robot 200 performs a downward movement by operating the mobile drive unit 204 based on a downward command received from the control system 100 (step S810).

[0081] Upon completion of its descent, the transport robot 200 sends a descent completion notification to the control system 100 (step S811). After this, the process flow ends, and the process proceeds to transport control (step S900). Transport control (step S900) is the same as the transport control described using Figure 8. Through this transport control, for example, the transport robot 200 transports the loaded container 210 to the designated work area 250.

[0082] (Placement optimization planning process) Figure 10 shows the processing flow of the arrangement optimization process according to this embodiment, and corresponds to step S1000 in Figure 7. This process is performed by the cooperation of the control system 100, the inventory management system 400, and the higher-level external system 500. This process may be performed after the completion of step S1106 in Figure 7, that is, at the time when the transport robot 200 returns the container 210 to the shelf 220. Alternatively, it may be performed at predetermined time intervals or at predetermined timings.

[0083] The control system 100 requests reference data 613 from the higher-level external system 500 (step S1001).

[0084] The higher-level external system 500 notifies the control system 100 of reference data 613 in response to a request from the control system 100 in step S1001 (step S1002). The type of reference data 613 notified here is not particularly limited; it may be specified by the control system 100, or the higher-level external system 500 may notify any data. Furthermore, the reference data 613 may only notify the latest information, or it may notify information for a certain period as historical information. In addition, the reference data 613 may be data used by the control system 100 or the inventory management system 400 to forecast the demand for goods, or it may be the demand forecast data 612 itself.

[0085] The control system 100 requests inventory item location data 611 from the inventory management system 400, which indicates the inventory and location of the item 215 on shelf 220 (step S1003).

[0086] In response to a request from the control system 100 in step S1003, the inventory management system 400 notifies the control system 100 of the inventory item location data 611 (step S1004). The inventory item location data 611 includes the type and quantity of the items 215 stored in the container 210, and their storage location on the shelf 220.

[0087] The control system 100 determines the optimal placement of the goods 215 (i.e., containers 210) based on reference data 613 obtained from the higher-level external system 500 and inventory item location data 611 obtained from the inventory management system 400 (step S11005).

[0088] Based on the arrangement determined in step S1005, the control system 100 notifies the inventory management system 400 of a reservation for a change in the storage location of the container 210 (S1006). After that, this processing flow ends and the process proceeds to transport control (step S900) and lifting / transfer control (step S800). These controls are similar to the processes explained using Figures 8 and 9, but the transport and transfer of the container 210 are performed based on the new arrangement (storage location of the container) calculated in the arrangement optimization calculation process in Figure 10.

[0089] [Control example] The control example in the automated warehouse system described above will be explained further. As mentioned above, there are several constraints on the control due to the configuration of the shelves 220 and the configuration of the transport robots 200. Here, we will explain an example of control that takes these constraints into account.

[0090] As shown in Figure 3, in the above embodiment, the storage compartments of the shelf 220 are configured on a front side and a back side. In such a configuration, when retrieving a container from the back side, it is necessary to retrieve the container from the front side first. In this case, one transport robot 200 may be used to first move the container from the front side to another position, and then retrieve the container from the back side. Alternatively, two transport robots 200 may be used, with one transport robot 200 (first transport device) first retrieving and moving the container from the front side, and then the other transport robot 200 (second transport device) retrieving the container from the back side. Which method is more efficient in transporting the containers 210 will vary depending on the situation, so a configuration that allows switching between these controls is acceptable.

[0091] Furthermore, in the above embodiment, when the transport robot 200 is performing up and down movements in a row containing shelf 220, it is restricted from performing up and down movements in the rows on either side of that row. Therefore, the transfer and transport of containers are controlled so that the rows where up and down movements are not possible overlap as much as possible. This enables more efficient transport.

[0092] Furthermore, the arrangement of the shelves 220 may be planned to appropriately distribute the available spaces where the containers 210 can be placed. For example, assuming that it is necessary to move the containers in the front when retrieving the containers in the back, the available spaces where the containers in the front can be placed can be distributed. This reduces the transportation costs associated with moving containers to distant spaces.

[0093] Furthermore, containers containing frequently retrieved items may be controlled to be placed on lower shelves or in the front storage compartments. Even further, containers may be controlled to be placed in storage compartments close to the work area. For example, items may be ranked or classified as "Item A," "Item B," "Item C," etc., based on demand forecasts, and the retrieval frequency may be defined accordingly. Also, if frequently retrieved items are grouped together on nearby shelves 220, congestion is likely to occur around those shelves; therefore, the placement of items may be controlled to distribute them according to their rank. Similarly, in the work area 250, transport control may be implemented to distribute the ranks of items rather than only handling items with a biased rank distribution. In this case, the destination work area 250 may be determined by considering the physical distance between the shelf 220 containing the target item and each of the multiple work areas 250. Note that the ranks are not limited to the three classifications mentioned above and may be further subdivided.

[0094] Furthermore, by placing items that are not frequently retrieved (for example, "C-grade" items) at the back of shelf 220, it is possible to reduce transportation costs.

[0095] Furthermore, even for items of the same type, items that need to be shipped earlier, for example due to their expiration date, may be controlled to be transported to the work area 250 with greater priority. In this case, the container 210 of the relevant item may be controlled to be placed in a storage area closer to the work area 250 or in the front storage area 220a.

[0096] Furthermore, as mentioned above, the retrieved container 210 does not necessarily have to be returned to the same storage area. For example, it may be configured to be placed closer to the work area 250 based on the number of items stored in the container 210 and the frequency of retrieval within the most recent predetermined period. Conversely, for containers 210 of items that tend to be retrieved less frequently within the most recent predetermined period, even if the overall retrieval frequency is high, the return position of the container 210 may be determined to be further away from its original storage position.

[0097] Furthermore, in the above embodiment, cooperation with a higher-level external system 500 is performed, and the information obtainable from the higher-level external system 500 may include information such as time of day, weather, and temperature. In addition, the system may be configured to perform demand forecasting using this information and rearrange the containers 210 according to the results. The rearrangement of the containers 210 may be achieved, for example, by performing a placement optimization calculation process (step S1000), transport control (step S900), and lifting / transfer control (step S800) when manual work is interrupted, such as at night or during lunch breaks. In addition, the rearrangement of the containers may be scheduled to be completed within a predetermined time period or within a predetermined time frame by issuing transport instructions.

[0098] Furthermore, the system may be configured to plan certain storage sections of the shelves 220 as empty sections, anticipating the storage of new items in the warehouse. For example, a higher-level external system 500 may acquire information on new item demand and trends, and the system may be configured to adjust the proportion of empty sections based on this information. This allows containers 210 containing new items to be appropriately placed in the empty sections, and their placement may be controlled to be distributed based on demand forecasts. The setting of empty sections may be based on a percentage of the total storage sections of the shelves 220 (e.g., 10%), or empty sections may be set for each shelf 220. Alternatively, it may be set whether or not a storage section can be used as an empty section.

[0099] Furthermore, empty containers 210 can be placed in the storage compartments of shelves 220, and empty storage compartments can be managed separately. New items can be stored in the empty containers 210. On the other hand, new containers 210 can be placed in the empty storage compartments. Therefore, these can be used and configured according to the results of demand forecasts and other factors.

[0100] Furthermore, the standby position of a transport robot 200 when it is not assigned a task may be set to be different from the standby position when it is performing a transport operation. Also, tasks may be assigned priorities, and a higher-priority task may be assigned as an interrupt to a transport robot 200 that has already been assigned a task. In this case, the original task may be reassigned to a different transport robot 200, or it may be assigned to be executed by the same transport robot 200.

[0101] As described above, the control system 100 of the automated warehouse system according to this embodiment includes a management unit (e.g., task management module 112, location map management module 114, robot state management module 118) that manages the status of each of the multiple transport robots 200, the arrangement of containers 210 on shelves 220, information on items stored in containers 210, the travel paths of each of the multiple transport robots 200, and information on whether each of the multiple transport robots 200 can be raised or lowered on shelves 220; a traffic optimization unit (e.g., traffic optimization control module 116) that uses the managed information to optimize the travel paths and raising / lowering operations on shelves when each of the multiple transport robots 200 transports the containers 210; and an instruction unit (e.g., transport command control module 115, robot interface module 117) that instructs each of the multiple transport robots 200 to transport the containers 210 based on the optimized travel paths and raising / lowering operations.

[0102] This makes it possible to streamline the storage and retrieval of goods in warehouse inventory management.

[0103] Furthermore, the control system 100 includes a placement optimization unit (for example, a placement optimization control module 113) that uses managed information to optimize the placement of containers 210 on shelves 220, and based on the optimized placement, each of the multiple transport robots 200 is instructed to transport the containers 210.

[0104] This makes it possible to optimize the placement of items within the warehouse in a timely manner, and to streamline the storage and retrieval of items.

[0105] Furthermore, the control system 100 includes an acquisition unit (for example, a control interface 111) that acquires information related to the forecasting of goods demand, and the arrangement of containers 210 on the shelves 220 is optimized based on the information related to the forecasting of goods demand.

[0106] This makes it possible to optimize the placement of goods within the warehouse in a timely manner based on constantly changing demand forecasts for goods shipments, thereby streamlining the storage and retrieval of goods.

[0107] Furthermore, the control system 100 optimizes the arrangement of the containers 210, each containing a different item, based on the frequency of retrieval of each item.

[0108] This makes it possible to avoid concentrating frequently retrieved items in certain areas, thereby suppressing congestion during transportation.

[0109] Furthermore, the control system 100 optimizes the arrangement of the containers 210 so that empty storage compartments are provided on the shelves 220 at a predetermined rate, and the predetermined rate is set based on information related to demand forecasting.

[0110] This makes it possible to anticipate sudden changes in trends and allocate sections within the warehouse to accommodate new items.

[0111] Furthermore, the control system 100 schedules the rearrangement of the containers 210 on the shelves 220 so that the rearrangement is completed within a predetermined time period or within a predetermined time frame.

[0112] This makes it possible to rearrange containers at the desired timing to improve transport efficiency while minimizing the impact of rearranging containers during normal transport operations.

[0113] Furthermore, the control system 100 determines at least one of the following for each of the multiple transport robots 200: their travel path and travel timing, their standby position and standby timing, and their lifting / lowering position and lifting / lowering timing on the shelf 220.

[0114] This makes it possible to create a transport plan that takes into account the transport operation of each of the multiple transport robots 200, thereby reducing congestion within the warehouse and improving the overall efficiency of the system.

[0115] Furthermore, the control system 100 optimizes the lifting position and timing of each shelf 220 for each of the multiple transport robots 200 so that the locations on the shelf 220 where lifting or lowering is not possible overlap at the same time.

[0116] This makes it possible to suppress situations where one transport robot 200 is unable to work because it is busy, due to structural constraints such as shelves, and to improve the overall efficiency of the system.

[0117] Furthermore, the control system 100 optimizes the travel path by making the transport robot 200 circle, thereby preventing congestion caused by the transport robot 200's waiting operation.

[0118] This makes it possible to suppress congestion caused by a transport robot 200 remaining stationary in the same location, thereby improving the overall efficiency of the system.

[0119] Furthermore, the shelf 220 can accommodate multiple containers 210 in the depth direction, and the control system 100 optimizes the process so that when retrieving a container located towards the back of the multiple containers 210, the first transport device moves the containers towards the front, and then the second transport device retrieves the container at the back.

[0120] This makes it possible to improve the overall efficiency of the system by distributing the transfer operation of multiple containers, which is caused by structural constraints such as shelves, among multiple transport robots 200.

[0121] <Other Embodiments> Furthermore, this can also be achieved by supplying programs and applications for realizing the functions of one or more embodiments described above to a system or device using a network or storage medium, and by having one or more processors in the computer of that system or device read and execute the programs.

[0122] Alternatively, it may be implemented by a circuit that performs one or more functions (for example, an ASIC (Application Specific Integrated Circuit) or an FPGA (Field Programmable Gate Array)).

[0123] Although various embodiments have been described above with reference to the drawings, it goes without saying that this disclosure is not limited to these examples. It will be clear to those skilled in the art that various modifications, alterations, substitutions, additions, deletions, and equivalents can occur within the scope of the claims, and these will naturally fall within the technical scope of this disclosure. Furthermore, the components of the various embodiments described above can be combined arbitrarily without departing from the spirit of the invention. [Industrial applicability]

[0124] This disclosure is useful for automated warehouse systems and warehouse management methods that can streamline the storage and retrieval of goods in warehouse inventory management. [Explanation of Symbols]

[0125] 100... Control System 101... Processing Section 102...memory 103...Storage device 104... Communications Department 105…Interface section 111... Control Interface 112... Task Management Module 113…Placement Optimization Control Module 114…Location Map Management Module 115... Transport command control module 116…Traffic Optimization Control Module 117…Robot Interface Module 118…Robot State Management Module 200... Transport robot 201... Control Unit 202...Storage section 203...Container Transfer Section 204... Mobile drive unit 205...Sensor unit 206... Communications Department 210... Container 215...Goods 220... shelves 250...Work area 300... Work instruction device 400... Inventory Management System 500… Upper-level external systems

Claims

1. A management unit manages the status of each of the multiple transport devices, the arrangement of containers on the shelves, information on the items stored in the containers, the travel path of each of the multiple transport devices, and information on whether each of the multiple transport devices can be raised or lowered on the shelves. A traffic optimization unit uses the information managed by the aforementioned management unit to select the travel route and the lifting / lowering operation on the shelves for each of the multiple transport devices during container transport, Based on the travel route and lifting operation selected by the traffic optimization unit, an instruction unit instructs each of the multiple transport devices to transport the container, It has, The traffic optimization unit determines at least one of the following for each of the plurality of transport devices: the travel route and travel timing, the waiting position and waiting timing, and the lifting / lowering position and lifting / lowering timing. Automated warehouse system.

2. The system further includes a placement optimization unit that determines the placement of containers on the shelves using the information managed by the aforementioned management unit. The instruction unit instructs each of the multiple transport devices to transport the container based on the arrangement determined by the arrangement optimization unit. The arrangement optimization unit schedules the rearrangement of containers on the shelves so that the rearrangement is completed within a predetermined time period or within a predetermined time. The automated warehouse system according to claim 1.

3. The processor works together with the memory, The system manages the status of each of the multiple transport devices, the arrangement of containers on the shelves, information about the items stored in the containers, the travel paths of each of the multiple transport devices, and information on whether each of the multiple transport devices can be raised or lowered on the shelves. Using the managed information, the travel path and lifting / lowering operation on the shelves are selected for each of the multiple transport devices during container transport. Based on the selected travel path and lifting operation, each of the multiple conveying devices is controlled To instruct the transport of Tena, It has, Selecting the travel path and the lifting / lowering operation on the shelf includes determining at least one of the travel path and travel timing, standby position and standby timing, and lifting / lowering position and lifting / lowering timing for each of the multiple transport devices. Warehouse management method.

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