Picking equipment, automated warehouse systems, stacking methods

Abstract

To provide a picking device capable of efficiently loading loads.SOLUTION: A picking device 10 for loading a second load assembly 12 including one or more loads 1 on a first load assembly 11 including one or more loads 1 comprises: an acquisition unit for acquiring load information related to the size and quantity of the loads 1 of the first load assembly 11; a determination unit for determining a loading region for loading the second load assembly 12 based on the load information acquired by the acquisition unit; and a transfer mechanism 6 for loading the second load assembly 12 in the loading region determined by the determination unit.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a picking device, an automated warehouse system, and a stacking method.

Background Art

[0002] There is known a picking device that moves the goods in a certain storage section to another storage section. The applicant has disclosed in Patent Document 1 a technology related to an automated warehouse system equipped with a picking device. This picking device includes a holding section, a plurality of suction sections provided on the bottom surface of the holding section, and a gantry-type crane mechanism, and can take out the target goods from above one storage section, move them horizontally, and lower the target goods onto the pallet of another storage section from above.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The inventor has obtained the following new recognition regarding the picking device. In the picking device, when taking out some goods from a pallet on which goods are loaded and stacking them on another pallet, from the viewpoint of efficient stacking, it is desirable to stack as many goods as possible in one operation. In this case, depending on the mode of stacking new goods on top of the goods stacked earlier, the stability of the goods on the pallet may decrease, and there is a possibility of goods collapse when transporting the goods. From these, the conventional picking device has room for improvement from the viewpoint of efficiently stacking goods.

[0005] The present invention has been made in view of such problems, and one of the objectives is to provide a picking device capable of efficiently stacking goods. [Means for solving the problem]

[0006] To solve the above problems, a picking device according to one aspect of the present invention is a picking device that stacks a second load set containing one or more loads on top of a first load set containing one or more loads, comprising: an acquisition unit that acquires load information relating to the size and quantity of loads in the first load set; a determination unit that determines a stacking area for stacking the second load set based on the load information acquired by the acquisition unit; and a transfer mechanism that stacks the second load set in the stacking area determined by the determination unit.

[0007] Another aspect of the present invention is an automated warehouse system. This automated warehouse system comprises shelves having a storage section for storing goods, and a picking device for moving goods from the storage section, wherein the picking device is a device for stacking a second set of goods, which includes one or more goods, on top of a first set of goods, which includes one or more goods, and comprises an acquisition unit for acquiring goods information relating to the size and quantity of goods in the first set of goods, a determination unit for determining a stacking area for stacking the second set of goods based on the goods information acquired by the acquisition unit, and a transfer mechanism for stacking the second set of goods in the stacking area determined by the determination unit.

[0008] A further aspect of the present invention is a stacking method. This method involves stacking a second stack containing one or more loads on top of a first stack containing one or more loads, and includes: acquiring load information relating to the size and quantity of loads in the first stack; determining a stacking area for stacking the second stack based on the acquired load information; and stacking the second stack in the determined stacking area.

[0009] Furthermore, any combination of the above components, or in which the components or expressions of the present invention are mutually substituted among methods, systems, etc., are also valid embodiments of the present invention. [Effects of the Invention]

[0010] According to the present invention, a picking device capable of efficiently stacking cargo can be provided. [Brief explanation of the drawing]

[0011] [Figure 1] This is a schematic plan view illustrating the automated warehouse system of the embodiment. [Figure 2] This is a front view showing an example of a picking device according to an embodiment. [Figure 3] Figure 1 is a block diagram showing the functional blocks of the automated warehouse system. [Figure 4] This is a diagram illustrating the first example of the determination conditions for the determination section. [Figure 5] This diagram illustrates a second example of the determination conditions for the determination section. [Figure 6] This diagram illustrates a third example of the determination conditions for the determination section. [Figure 7] This diagram illustrates a fourth example of the determination conditions for the decision section. [Figure 8] This diagram illustrates the fifth example of the determination conditions for the determination section. [Figure 9] This diagram illustrates an example of the position determination conditions for the determination unit. [Modes for carrying out the invention]

[0012] The present invention will be described below with reference to the drawings, based on preferred embodiments. In embodiments and modifications, the same or equivalent components and members will be denoted by the same reference numerals, and redundant explanations will be omitted as appropriate. In addition, the dimensions of the members in each drawing will be enlarged or reduced as appropriate for ease of understanding. Furthermore, some members that are not important for explaining the embodiments will be omitted from the drawings.

[0013] Furthermore, while terms including ordinal numbers such as "first" and "second" are used to describe various components, these terms are used solely to distinguish one component from others, and do not limit the components themselves.

[0014] [Embodiment] The configuration of an automated warehouse system 100 including a picking device 10 according to an embodiment will be described with reference to the drawings. FIG. 1 is a plan view schematically showing the automated warehouse system 100.

[0015] For convenience of explanation, as shown in the drawing, an XYZ orthogonal coordinate system is defined in which a horizontal direction is the X direction, a horizontal direction orthogonal to the X direction is the Y direction, and a direction orthogonal to both, i.e., the vertical direction, is the Z direction. Also, the X direction may be referred to as the lateral direction, the Y direction as the front-rear direction, and the Z direction as the up-down direction. Such notations of directions do not limit the configuration of the automated warehouse system 100, and the automated warehouse system 100 can be used in any configuration according to the application.

[0016] In this specification, the following terms are used for the load. A case such as a cardboard box containing the contents is referred to as a "load". A load may contain a plurality of articles. A load may also be the minimum unit to be handled when picking. A set of single or multiple loads is referred to as a "load set". Also, a load set placed on a pallet, including the pallet, is referred to as a "load set".

[0017] First, the overall configuration of the automated warehouse system 100 will be described. As shown in FIG. 1, the automated warehouse system 100 mainly includes a shelf 5 having a plurality of storage parts 52 capable of storing a load 1, moving means 74, 75, 76 for moving the load 1 into or out of the shelf 5, a picking device 10 for holding and moving the load 1, and an information processing unit 80.

[0018] The moving means 74, 75, 76 includes a first moving means 74 (e.g., a first cart), a second moving means 75 (e.g., a second cart), and a third moving means 76 (e.g., a lifting device). The first moving means 74, the second moving means 75, and the third moving means 76 constitute a conveying means for moving the load 1 in the X direction, Y direction, and Z direction. The first moving means 74 can move the load 1 along the Y direction. The second moving means 75 can move the load 1 along the X direction. The third moving means 76 can move the load 1 in the Z direction.

[0019] For example, the transport means can unload the load 1 from the storage section 52 of the shelf 5. For example, the transport means can load the load 1 into the storage section 52 of the shelf 5. For example, the transport means can transport the load 1 from one storage section 52 of the shelf 5 to another storage section 52 of the shelf 5.

[0020] Shelf 5 is a storage space capable of storing a large number of loads 1, and is sometimes referred to as a storage shelf. In this embodiment, shelf 5 is divided into shelf 55 on the right side of the figure and shelf 56 on the left side of the figure, separated by the second travel path 73. The configuration of shelf 5 is not particularly limited as long as it can accommodate and store multiple loads 1. In this example, shelf 5 includes a plurality of storage sections 52 arranged along the X, Y, and Z directions (stage directions). The plurality of storage sections 52 arranged in the X and Y directions are called storage stages. In other words, shelf 5 has a plurality of storage stages (for example, 3 stages) arranged in the stage directions. Each storage section 52 is configured to accommodate loads 1.

[0021] Shelf 5 is provided with a first travel path 71 (e.g., a first rail) for the first moving means 74 to travel on, and a second travel path 73 (e.g., a second rail) for the second moving means 75 to travel on. The first travel path 71 extends in the Y direction through shelves 55, 56 and the picking space 58, which will be described later. The first moving means 74 can travel under each storage section 52. The second travel path 73 extends in the X direction adjacent to shelves 55, 56 and the picking space 58.

[0022] The first moving means 74 is driven by a motor (not shown) and travels along the first travel path 71 in the Y direction, either empty or loaded with load 1. The first moving means 74 can get on and off the second moving means 75 and the third moving means 76. The second moving means 75 is driven by a motor (not shown) and travels along the second travel path 73 in the X direction. The second moving means 75 transports the first moving means 74, either empty or loaded with load 1. The third moving means 76 is provided adjacent to the second travel path 73. The third moving means 76 can raise and lower the first moving means 74 and load 1 from any storage stage to another storage stage. In the example in Figure 1, a single loading / unloading section 77 is provided for all stages, and the third moving means 76 is connected to the loading / unloading section 77.

[0023] In this example, the goods to be stored (1) are brought into the storage area (77) by an external transport means (not shown), such as a forklift, and then moved to the desired level by a third moving means (76). The goods to be shipped out (1) are raised and lowered from the level where they were stored to the level of the storage area (77) by the third moving means (76), transported to the storage area (77), and then shipped out from the storage area (77) by an external transport means.

[0024] The information processing unit 80 will be described with reference to Figure 3. Figure 3 is a block diagram showing the functional blocks of the automated warehouse system 100. Each block of the information processing unit 80 shown in Figure 3 can be realized in hardware terms by elements and mechanical devices such as the CPU (Central Processing Unit) of a computer, and in software terms by computer programs, etc., but here, the functional blocks realized by the cooperation of these are depicted. Therefore, it will be understood by those skilled in the art who have read this specification that these functional blocks can be realized in various forms by combinations of hardware and software.

[0025] As shown in Figure 3, the information processing unit 80 includes an input unit 801, a first control unit 802, a second control unit 803, an acquisition unit 3, a determination unit 4, a calculation unit 804, and a storage unit 805. The input unit 801 acquires user operation inputs entered into the operation input unit 822. The first control unit 802 controls the moving means 74, 75, and 76 to receive, ship, transport, etc., the cargo 1 based on the user operation input. The second control unit 803 controls the operation of the transfer mechanism 6 (crane mechanism 60, holding unit 67) of the picking device 10 to pick the cargo 1. The acquisition unit 3, determination unit 4, calculation unit 804, and storage unit 805 will be described later.

[0026] (Picking device) The picking device 10 will be described with reference to Figures 1 and 2. Figure 2 is a schematic front view showing an example of the picking device 10. The picking device 10 performs picking operations in the picking space 58.

[0027] Picking is the process of taking one or more items from one load and stacking them on another load to consolidate the loads. In the example in Figure 2, multiple single-load pallets 14, each loaded with a single type of item, are prepared (for example, three types), and an assembled pallet 15 is created with a mixture of multiple types of items according to the customer's requirements.

[0028] When creating an assembled pallet, the picking device 10 can pick one or more items from one layer of single-load pallets 14 and transfer them to the assembled pallet 15. The single-load pallets 14 are the source loads for picking, and the assembled pallets 15 are the loads formed by picking.

[0029] A cargo assembly containing one or more items 1 taken from a single-load pallet 14 for picking is called a second cargo assembly 12. The cargo assembly to which the second cargo assembly 12 is stacked is called the first cargo assembly 11, and the cargo assembly formed by stacking the second cargo assembly 12 on the first cargo assembly 11 is called a combined cargo assembly.

[0030] (Picking space) The picking space 58 is provided with a first area 521 for placing single pallets 14 and a second area 522 for placing assembled pallets 15. Therefore, the second area 522 is where the first load assembly 11 in the process of forming the assembled pallet 15 is placed.

[0031] The picking space 58 may be located outside the shelf 56, but in this example it is located inside the shelf 56. The first area 521 and the second area 522 do not refer to specific locations within the picking space 58, but rather to areas for temporarily storing the goods 1. Therefore, the location and extent of the first area 521 and the second area 522 in the picking space 58 may change with each picking operation. The first area 521 and the second area 522 in this embodiment have the same configuration as the storage section 52.

[0032] In the picking space 58 of this embodiment, a first travel path 71 extends in the Y direction. The first area 521 and the second area 522 are located on the first travel path 71. The first moving means 74 can travel beneath the first area 521 and the second area 522. The single pallets 14 before picking are carried into the first area 521 by the first moving means 74. The picking device 10 picks up the second load assembly 12 from the single pallets 14, moves it in a predetermined direction, and loads it onto the first load assembly 11. The assembled pallets 15 after picking are carried out from the second area 522 by the first moving means 74.

[0033] (transfer mechanism) The picking device 10 includes a transfer mechanism 6. The transfer mechanism 6 includes a crane mechanism 60, a holding part lifting mechanism 66, and a holding part 67. In this embodiment, the crane mechanism 60 is a so-called gantry-type crane mechanism that supports the holding part lifting mechanism 66 and the holding part 67. In Figure 2, some columns, beams, frames, etc. are omitted from the description. The crane mechanism 60 includes a pair of crossbeams 63, a cross girders 62, a crane trolley 64, and a holding part lifting mechanism 66. The pair of crossbeams 63 are provided spaced apart on both sides in the Y direction in the upper space of the picking space 58. Both ends of the crossbeams 63 are supported by the upper ends of the vertical columns 61.

[0034] The transverse girder 62 is a rail-like structure extending in the Y direction and is spanned between a pair of transverse beams 63. The transverse girder 62 is configured to be self-propelled on the transverse beams 63 in the X direction. The transverse girder 62 is sometimes referred to as a crane girder. The crane trolley 64 is a trolley that is self-propelled on the transverse girder 62 in the Y direction. The holding mechanism 66 suspends the picking device 10 from the crane trolley 64 and can move the picking device 10 up and down in the Z direction.

[0035] The crane mechanism 60 supports the picking device 10 so that it can move freely in the horizontal X and Y directions. The crane mechanism 60 also supports the picking device 10 so that it can move vertically.

[0036] As shown in Figure 2, the holding part 67 is connected to the lower end of the holding part lifting mechanism 66, and the upper end of the holding part lifting mechanism 66 is connected to the crane trolley 64 of the crane mechanism 60.

[0037] A holding part 67 is connected to the lower end of the holding part lifting mechanism 66. Based on the control of the information processing unit 80, the holding part lifting mechanism 66 can raise and lower the holding part 67 by a driving means (not shown) including a motor. Based on the control of the information processing unit 80, the holding part lifting mechanism 66 can rotate the holding part 67 around a vertical rotation axis.

[0038] The holding portion 67 is capable of holding one or more loads 1. In this example, the holding portion 67 comprises a plurality of suction portions 68 supported by a bracket. The plurality of suction portions 68 are arranged in a matrix at predetermined intervals in the X and Y directions.

[0039] The suction unit 68 has an suction pad, and air at a pressure lower than atmospheric pressure (hereinafter referred to as "suction fluid") generated by a vacuum source (not shown) is passed through it. The negative pressure generated on the suction pad of the suction unit 68 generates an suction force for adsorbing the load 1. The vacuum source can be configured to include a vacuum pump, ejector, vacuum blower, etc. The suction fluid from the vacuum source is supplied to the suction unit 68 through piping (not shown).

[0040] When the suction unit 68 generates an suction force capable of adsorbing the load 1, the suction unit 68 is referred to as being in the "on state," and when it is not in the "on state," it is referred to as being in the "off state." Based on the control of the information processing unit 80, the holding unit 67 switches the on / off state of each of the multiple suction units 68, thereby turning on the suction unit 68 in the area corresponding to the load 1 to be adsorbed, and is able to adsorb and hold the load 1.

[0041] An example of the picking operation of the picking device 10 will be explained with reference to Figures 1 to 3. The picking operation includes one or more picking cycles. In each picking cycle, the picking device 10 moves the second load assembly 12, which has been taken from the single-load pallet 14 in the first area 521, to the second area 522, and stacks it on top of the first load assembly 11 in the second area 522 to form a combined load assembly. The combined load assembly becomes the first load assembly 11 in the next picking cycle. The combined load assembly in the final picking cycle becomes the assembled pallet 15.

[0042] In the picking device 10, it is important to stack another load in an appropriate area on the top surface of a previously stacked load. However, the top surface of the first load 11, which contains multiple types of loads 1 with different heights, is not uniform and has convex areas at relatively higher positions and concave areas at lower positions than the convex areas. In order to stack the second load 12 on the uneven top surface of the first load 11, the picking device 10 uses information about the unevenness of the top surface (hereinafter referred to as "unevenness distribution information"). The picking device 10 has an acquisition unit 3, a calculation unit 804, and a storage unit 805 to acquire the unevenness distribution information.

[0043] In the picking device 10, the acquisition unit 3 acquires cargo information J regarding the size and quantity of each cargo included in the first cargo set 11 from the higher-level system 112 via the network 111. The higher-level system 112 may be an in-house computer system or an external computer system.

[0044] The calculation unit 804 simulates the state in which the first load assembly 11 is arranged on a virtual pallet based on the load information J acquired by the acquisition unit 3. Furthermore, the calculation unit 804 derives information on the unevenness distribution of the upper surface of each layer of the first load assembly 11 based on the simulation results. In other words, the calculation unit 804 calculates the position, shape, and height of the convex and concave regions from the size and quantity of the loads stacked on the virtual pallet, and derives the unevenness distribution information. Therefore, the unevenness distribution information includes information on the position, shape, and height of the convex and concave regions. The derived unevenness distribution information is stored in the storage unit 805.

[0045] Once the unevenness distribution information is derived, the determination unit 4 extracts a stacking area S that satisfies the determination conditions (hereinafter referred to as "determination conditions") for determining the stacking position of the second load assembly 12 based on the unevenness distribution information, and determines that area as the stacking area S. The transfer mechanism 6 stacks the second load assembly 12 in the stacking area S determined by the determination unit 4. The conditions for determining the stacking area S will be explained below with reference to Figures 4 to 8.

[0046] (Example 1) Referring to Figure 4, the first example of the determination condition is explained. Figure 4 is a diagram illustrating the first example of the determination condition. In Figure 4, (A) is a plan view of the first load assembly 11, (B) is a front view of the first load assembly 11, and (C) is a front view of the integrated load assembly 13. In this example and subsequent examples, L1 represents the first type of load 1, and L2 represents the second type of load 1. L1 and L2 are rectangular parallelepipeds with equal base areas, and the height H2 of L2 is 1.2 times the height H1 of L1.

[0047] The first load assembly 11 contains multiple types of loads 1 with different heights, and if the second load assembly 12 is stacked on an uneven area of ​​the upper surface of the first load assembly 11, there is a high possibility that the stacked loads 1 will collapse due to the unevenness. Therefore, in this embodiment, the determination unit 4 determines, based on the load information J, that the stacking area S of the flat, continuous area (hereinafter simply referred to as the "continuous area") on the upper surface of the first load assembly 11 has a shape on which the second load assembly 12 can be stacked.

[0048] In the example shown in Figure 4, the upper surface of the first load assembly 11 has continuous regions P11 and P12. Furthermore, the continuous regions P11 and P12 have a shape that allows the second load assembly 12 to be stacked, and the transfer mechanism 6 can stack the second load assembly 12 on either of the continuous regions P11 or P12. The shape on which the second load assembly 12 can be stacked is such that the continuous region can encompass the entire planar range (the range projected onto a horizontal plane) of the second load assembly 12.

[0049] It is desirable to be able to stack as many loads 1 as possible in a single stacking operation for the second load assembly 12. Therefore, in this embodiment, when there are multiple stackable areas, the determination unit 4 determines the widest of these multiple stackable areas as the stacking area S. In the example in Figure 4, since the continuous area P11 is wider than the continuous area P12, the determination unit 4 determines the continuous area P11 as the stacking area S.

[0050] (Second example) Referring to Figure 5, a second example of the determination conditions will be explained. Figure 5 is a diagram illustrating a second example of the determination conditions. In Figure 5, (A) is a plan view of the first cargo assembly 11, (B) is a front view of the first cargo assembly 11, and (C) is a front view of the integrated cargo assembly 13.

[0051] In the example shown in Figure 5, the upper surface of the first load assembly 11 has continuous regions P21, P22, and P23. Of these, continuous regions P21 and P22 have a shape on which the second load assembly 12 can be stacked, and the transfer mechanism 6 can stack the second load assembly 12 on either of the continuous regions P21 or P22.

[0052] If the second load assembly 12 is stacked at a high position on the upper surface of the first load assembly 11, the maximum height of the stacked load 1 increases, reducing stability. Therefore, in this embodiment, when there are multiple stackable areas, the determination unit 4 determines the lowest-positioned area among the multiple stackable areas as the stacking area S. In the example in Figure 5, since the continuous area P21 is at a lower position than the continuous area P22, the determination unit 4 determines the continuous area P21 as the stacking area S.

[0053] (Third example) Referring to Figure 6, a third example of the determination condition will be explained. Figure 6 is a diagram illustrating a third example of the determination condition. In Figure 6, (A) is a plan view of the first cargo assembly 11, (B) is a front view of the first cargo assembly 11, and (C) is a front view of the integrated cargo assembly 13.

[0054] In the example shown in Figure 6, the upper surface of the first load assembly 11 has continuous regions P31 and P32. The continuous regions P31 and P32 have a shape that allows the second load assembly 12 to be stacked on them. Furthermore, continuous region P31 is wider than continuous region P32. Therefore, the transfer mechanism 6 can stack the second load assembly 12 on either continuous region P31 or P32.

[0055] From the viewpoint of the stability of the integrated cargo assembly 13 formed by stacking the second cargo assembly 12 on the first cargo assembly 11, it is desirable that the ratio of the maximum height of the integrated cargo assembly 13 to the base area of ​​the integrated cargo assembly 13 be low. Therefore, in this embodiment, when there are multiple stackable areas, the determination unit 4 determines the area among the multiple stackable areas as the stacking area S, which has the smallest ratio of the maximum height of the integrated cargo assembly 13 formed by stacking the second cargo assembly 12 on the first cargo assembly 11 to the base area of ​​the integrated cargo assembly 13.

[0056] The base area of ​​the cargo assembly is the sum of the base areas of each cargo in contact with the pallet 20. In the example in Figure 6, when the second cargo assembly 12 is stacked in the continuous area P32, the base area of ​​the integrated cargo assembly 13 is 1.4 times larger and the maximum height of the integrated cargo assembly 13 is 1.3 times larger than when it is stacked in the continuous area P31. Therefore, the ratio of the maximum height of the integrated cargo assembly 13 to the base area is smaller when it is stacked in the continuous area P32. Based on these factors, the determination unit 4 determines the continuous area P32, which has the smallest ratio of maximum height to base area, to be the stacking area S.

[0057] (Fourth example) Referring to Figure 7, a fourth example of the determination condition will be explained. Figure 7 is a diagram illustrating a fourth example of the determination condition. In Figure 7, (A) is a plan view of the first cargo assembly 11, (B) is a front view of the first cargo assembly 11, and (C) is a front view of the integrated cargo assembly 13.

[0058] In the example shown in Figure 7, the upper surface of the first load assembly 11 has continuous regions P41, P42, and P43. The continuous regions P42 and P43 have a shape on which the second load assembly 12 can be stacked, and the transfer mechanism 6 can stack the second load assembly 12 on either of the continuous regions P42 or P43.

[0059] When moving the second load assembly 12 for stacking, if the transfer mechanism 6 interferes with the first load assembly 11, the first load assembly 11 may collapse. Therefore, in this embodiment, when there are multiple stackable areas, the determination unit 4 determines the area S as the stacking area from among the multiple stackable areas, in which the transfer mechanism 6 does not interfere with the first load assembly 11 during stacking.

[0060] In the example shown in Figure 7, the continuous region P42 is located lower than the preceding and succeeding continuous regions P41 and 43, and may interfere with the holding portion 67 of the transfer mechanism 6 when the second load assembly 12 is loaded. For this reason, the determination unit 4 determines the continuous region P43, in which the transfer mechanism 6 does not interfere with the first load assembly 11 during loading, as the loading region S.

[0061] (Example 5) Referring to Figure 8, a fifth example of the determination condition will be explained. Figure 8 is a diagram illustrating a fifth example of the determination condition. In Figure 8, (A) is a plan view of the first cargo assembly 11, (B) is a front view of the first cargo assembly 11, and (C) is a front view of the integrated cargo assembly 13.

[0062] In the example shown in Figure 8, the upper surface of the first load assembly 11 has continuous regions P51, P52, and P53. The continuous regions P51 and P53 have a shape on which the second load assembly 12 can be stacked, and the transfer mechanism 6 can stack the second load assembly 12 on either of the continuous regions P51 or P53.

[0063] If the second load assembly 12 is stacked on the upper surface of the first load assembly 11 at a location where the second load assembly 12 travels a long distance during picking, the time required for stacking will increase, which is disadvantageous from the standpoint of operational efficiency. Therefore, in this embodiment, when there are multiple stacking areas, the determination unit 4 determines the area with the shortest travel distance for the second load assembly 12 during picking as the stacking area S. The area with the shortest travel distance may be the area closest to the original load assembly (single-load pallet 14) from which the items were picked.

[0064] In Figure 8, arrow F indicates the direction of movement of the transfer mechanism 6. In the example in Figure 8, the movement distance of the second load assembly 12 during picking is shorter in continuous area P51 than in continuous area P53. Therefore, the determination unit 4 determines that continuous area P51, which has the shortest movement distance of the second load assembly 12 during picking, is the loading area S.

[0065] Referring to Figure 9, the position for stacking the second load assembly 12 within the stacking area S will be explained. Figure 9 is a diagram illustrating an example of the position determination conditions. In Figure 9, (A) is a plan view of the first load assembly 11, (B) is a front view of the first load assembly 11, and (C) is a front view of the integrated load assembly 13.

[0066] Once the loading area S is determined, the determination unit 4 determines a position within the loading area S that satisfies predetermined conditions (hereinafter referred to as "position determination conditions") to be the loading position of the second load assembly 12.

[0067] In the example shown in Figure 9, the upper surface of the first load assembly 11 has continuous regions P61 and P62. The continuous region P61 has a shape on which the second load assembly 12 can be stacked, and the transfer mechanism 6 can stack the second load assembly 12 on the continuous region P61.

[0068] When the second load assembly 12 is placed on the continuous area P61 of the first load assembly 11, the uncovered area of ​​the continuous area P61 that is not covered by the second load assembly 12 becomes a continuous area in the next picking cycle. Therefore, it is desirable for the uncovered area to be wide from the viewpoint of facilitating stacking in the next picking cycle. Accordingly, the determination unit 4 may determine the stacking position as the position in which the uncovered area of ​​the continuous area P61 that is not covered by the second load assembly 12 is widest when the second load assembly 12 is placed on the continuous area P61 of the first load assembly 11.

[0069] As shown in Figure 9, the determination unit 4 may determine the position on the far side in the direction of movement of the transfer mechanism 6 within the continuous region P61 as the stacking position. In this case, the uncovered region Q is formed on the near side in the direction of movement of the transfer mechanism 6, making stacking in the next picking cycle easier.

[0070] The first to fifth determination conditions and position determination conditions described above may be used individually, in combination, or in combination with other determination conditions or position determination conditions.

[0071] The features of the picking device 10 of the embodiment will now be described. The picking device 10 is a picking device that stacks a second load set 12 containing one or more loads 1 on top of a first load set 11 containing one or more loads 1, and comprises an acquisition unit 3 that acquires load information J regarding the size and quantity of loads 1 in the first load set 11, a determination unit 4 that determines a stacking area S on which to stack the second load set 12 based on the load information J acquired by the acquisition unit 3, and a transfer mechanism 6 that stacks the second load set 12 in the stacking area S determined by the determination unit 4.

[0072] With this configuration, the loading area S is determined based on the size and quantity of cargo 1. Therefore, an appropriate area on top of a previously loaded cargo assembly can be designated as the loading area S, and another cargo assembly can be loaded into that appropriate area, thus enabling efficient cargo loading.

[0073] In this embodiment, the first load set 11 includes multiple types of loads 1, and the load information J includes information about the size and quantity of each of the multiple types of loads 1. In this case, since the stacking area S is determined based on the information about the size and quantity of each of the multiple types of loads 1, another load set can be stacked on top of the load set of multiple types of loads 1.

[0074] In this embodiment, the determination unit 4 determines, based on the cargo information J, that the stacking area S is a flat, continuous area on the upper surface of the first cargo assembly 11 that is large enough to accommodate the second cargo assembly 12. In this case, the first cargo assembly 11 can be stacked in a continuous, flat area, avoiding areas on the upper surface that have uneven steps.

[0075] In this embodiment, when there are multiple stackable areas, the determination unit 4 determines the largest of the multiple stackable areas as the stacking area S. In this case, by determining the largest area as the stacking area S, the number of loads 1 that can be stacked in a single stacking operation increases, thus enabling more efficient picking.

[0076] In this embodiment, when there are multiple stackable areas, the determination unit 4 determines the lowest-positioned area among the multiple stackable areas as the stacking area S. In this case, compared to stacking at a high position, the maximum height of the load 1 after stacking is lower, and stability is improved.

[0077] In this embodiment, when there are multiple stacking areas, the determination unit 4 determines the stacking area S to be the area where the ratio of the maximum height of the integrated load assembly formed by stacking the second load assembly 12 on the first load assembly 11 to the base area of ​​the integrated load assembly is smallest. In this case, the stability of the integrated load assembly is improved compared to when it is stacked in an area where the ratio of the maximum height of the integrated load assembly to the base area is high.

[0078] In this embodiment, when there are multiple stacking areas, the determination unit 4 determines the stacking area S from among the multiple stacking areas, which is the area where the transfer mechanism 6 does not interfere with the first load assembly 11 during stacking. In this case, the transfer mechanism 6 can be stacked in the area where it does not interfere with the first load assembly 11.

[0079] In this embodiment, when there are multiple stacking areas, the determination unit 4 determines the area with the shortest travel distance for the second load assembly 12 during picking as the stacking area S. In this case, compared to stacking at a location with a long travel distance, the time required for stacking is reduced, and picking can be performed more efficiently. This travel distance may be the travel distance in a plan view.

[0080] The features of the automated warehouse system 100 of the embodiment will now be described. The automated warehouse system 100 is an automated warehouse system comprising shelves 5 having storage sections 52 for storing goods 1, and a picking device 10 for moving goods 1 in the storage sections 52, wherein the picking device 10 is a device for stacking a second load set 12 containing one or more goods 1 on top of a first load set 11 containing one or more goods 1, and comprises an acquisition unit 3 for acquiring goods information J regarding the size and quantity of goods 1 in the first load set 11, a determination unit 4 for determining a stacking area S for stacking the second load set 12 based on the goods information J acquired by the acquisition unit 3, and a transfer mechanism 6 for stacking the second load set 12 in the stacking area S determined by the determination unit 4.

[0081] With this configuration, the loading area S is determined based on the size and quantity of cargo 1, so an appropriate area on a previously loaded cargo collection can be determined as the loading area S.

[0082] The technology of this disclosure can be applied to a stacking method. This stacking method is a method for stacking a second stacking unit 12, which includes one or more loads 1, on top of a first stacking unit 11, which includes one or more loads 1, and includes: acquiring load information J relating to the size and quantity of loads 1 in the first stacking unit 11; determining a stacking area S on which to stack the second stacking unit 12 based on the acquired load information J; and stacking the second stacking unit 12 in the determined stacking area S.

[0083] According to this method, the loading area S is determined based on the shape and quantity of cargo 1, so an appropriate area on a previously loaded cargo collection can be determined as the loading area S.

[0084] The embodiments of the present invention have been described in detail above. The embodiments described above are merely examples of how to implement the present invention. The contents of the embodiments do not limit the technical scope of the present invention, and many design changes, such as changes, additions, and deletions of components, are possible as long as they do not depart from the spirit of the invention as defined in the claims. In the embodiments described above, such design changes are explained with notations such as "of the embodiments" or "in the embodiments," but design changes may also be permitted in areas without such notations. Furthermore, the hatching in the drawings does not limit the material of the object to which the hatching is applied.

[0085] (modified version) The following describes modified examples. In the drawings and descriptions of the modified examples, components and parts that are the same as or equivalent to those in the embodiments are denoted by the same reference numerals. Descriptions that overlap with those in the embodiments will be omitted as appropriate, and the descriptions will focus on the configurations that differ from those in the embodiments.

[0086] In the description of the embodiments, an example was shown in Figures 4 to 9 where the first load assembly 11 is a single layer, but the present invention is not limited to this. For example, the first load assembly 11 may have two or more layers.

[0087] In the description of the embodiments, an example was shown in Figures 4 to 9 in which the first load set 11 includes two types of loads 1, but the present invention is not limited thereto. For example, the first load set 11 may include three or more types of loads 1.

[0088] In the description of the embodiments, an example was shown in which the picking device 10 is applied to an automated warehouse, but the present invention is not limited to this. For example, the picking device of the present invention can be applied not only to automated warehouses but also to deparating devices and palletizing devices using arm robots.

[0089] In the description of the embodiment, an example was shown in which the picking space 58 is provided integrally with the shelf 5. However, the present invention is not limited to this, and the picking space 58 may be provided outside the shelf 5. In this case, the load 1 may be transported between the shelf 5 and the picking space 58 by a transport mechanism such as a forklift.

[0090] In the description of the embodiment, an example was shown in which the picking space 58 is provided in the same plane as the shelf 5. However, the present invention is not limited to this, and the picking space 58 may be provided in a plane different from the shelf 5. Also, a part of the picking device 10 may be provided in the same plane as the shelf 5, and other parts may extend outward from the planar range of the shelf 5.

[0091] In the description of the embodiment, an example was shown in which the second moving means 75 and the third moving means 76 are provided separately, but the invention is not limited thereto. As the second moving means, a moving means (for example, a stacker crane) capable of moving the load 1 in the tier direction and in the row direction may be used. In this case, the stacker crane may not be able to mount the first moving means, or it may be able to mount the first moving means together with the load 1.

[0092] In the description of the embodiment, an example was shown in which a single loading / unloading section 77 is provided for each level, and a third moving means 76 is connected to the loading / unloading section 77, but the invention is not limited to this. A loading / unloading section may be provided for each level, and goods to be loaded and unloaded may be moved in and out of each loading / unloading section by a forklift. Alternatively, the loading / unloading section may be divided into a loading section and an unloading section.

[0093] In the description of the embodiment, an example was shown in which the picking device 10 is supported from the ceiling by a gantry-type crane mechanism 60, but the present invention is not limited to this. For example, the picking device may be supported by an articulated robot or by a support means of a different configuration. Alternatively, the picking device may be mounted on a side wall and supported from the side.

[0094] Each of these modifications produces the same functions and effects as the embodiments.

[0095] Any combination of the embodiments and modifications described above is also useful as an embodiment of the present invention. The new embodiments resulting from these combinations possess the combined effects of both the respective embodiments and modifications. [Explanation of Symbols]

[0096] 1. Load, 3. Acquisition unit, 4. Determination unit, 5. Shelf, 6. Transfer mechanism, 10. Picking device, 11. First load assembly, 12. Second load assembly, 13. Integrated load assembly, 100. Automated warehouse system.

Claims

1. A picking device that stacks a second load containing one or more loads on top of a first load containing one or more loads, An acquisition unit that acquires cargo information relating to the size and quantity of cargo in the first cargo set, Based on the cargo information acquired by the acquisition unit, a determination unit determines the loading area for stacking the second cargo assembly, A transfer mechanism for loading the second load assembly onto the loading area determined by the determination unit, Equipped with, The determination unit determines the position of the second load assembly as the stacking position of the second load assembly, based on an evaluation of the size of the uncovered area in the stacking area that is not covered by the second load assembly and can be stacked next as a continuous area, when the second load assembly is placed on the stacking area.

2. The picking device according to claim 1, wherein the first load collection includes loads of multiple types, and the load information includes information regarding the size and quantity of each of the multiple types of loads.

3. The picking device according to claim 1, wherein the determination unit determines, based on the cargo information, a stackable area having a size on which the second cargo assembly can be stacked, from among the flat and continuous areas on the upper surface of the first cargo assembly, as the stacking area.

4. The picking device according to claim 3, wherein, when there are multiple stackable areas, the determination unit determines the largest of the multiple stackable areas as the stackable area.

5. The picking device according to claim 3, wherein, when there are multiple stackable areas, the determination unit determines the area at the lowest position among the multiple stackable areas to be the stackable area.

6. The picking device according to claim 3, wherein, when there are multiple stackable areas, the determination unit determines the area among the multiple stackable areas to be the area where the ratio of the maximum height of the integrated load assembly formed by stacking the second load assembly on the first load assembly to the bottom area of ​​the integrated load assembly is smallest.

7. The picking device according to claim 3, wherein, when there are multiple stackable areas, the determination unit determines the area among the multiple stackable areas in which the transfer mechanism does not interfere with the first load collection during stacking as the stacking area.

8. The picking device according to claim 3, wherein, when there are multiple stackable areas, the determination unit determines the area among the multiple stackable areas that has the shortest travel distance of the second load assembly during picking as the stacking area.

9. An automated warehouse system comprising shelves having a storage section for storing goods, and a picking device for moving goods from the storage section, The picking device is a device that stacks a second load containing one or more loads on top of a first load containing one or more loads, An acquisition unit that acquires cargo information relating to the size and quantity of cargo in the first cargo set, Based on the cargo information acquired by the acquisition unit, a determination unit determines the loading area for stacking the second cargo assembly, A transfer mechanism for loading the second load assembly onto the loading area determined by the determination unit, Equipped with, The determination unit determines the position of the second cargo assembly as the stacking position of the second cargo assembly, based on an evaluation of the size of the uncovered area in the stacking area that is not covered by the second cargo assembly and can be stacked next as a continuous area, when the second cargo assembly is placed on the stacking area.

10. A method of stacking a second load containing one or more loads on top of a first load containing one or more loads, To obtain cargo information regarding the size and quantity of the first cargo set, Based on the acquired cargo information, the loading area for loading the second cargo assembly is determined, The second load assembly is to be loaded into the determined loading area, Includes, A stacking method in which, when the second load assembly is placed on the stacking area, the second load assembly is stacked at a position in the stacking area that is not covered by the second load assembly and is a continuous area where the next load can be stacked, based on an evaluation of the size of the uncovered area.

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