containment system

Abstract

To provide an automatic warehouse system capable of being flexibly constituted, as an objective according to the present disclosure.SOLUTION: An automatic warehouse system 100 according to one embodiment comprises: a first loading part 34 and a second loading part 36 that are capable of loading a loading pallet 12 where a cargo is loaded; a picking device 32 for preparing another loading pallet by taking out the cargo from the loading pallet 12 loaded on the first loading part 34 to move the cargo to a second loading part 36; and a carrying vehicle 18 for transferring the loading pallet 12 to the first loading part 34 by moving a lower portion of the picking device 32, that is movable while autonomously changing a moving direction.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to Detention a system.

Background Art

[0002] Patent Document 1 describes a picking device that picks up articles stacked on a pallet in layer units. This picking device has a gripping device that grips the articles of a single-variety pallet positioned at the loading / unloading position in layer units and transfers them to each of a plurality of shipping pallets positioned at the loading position, and a load transfer device that enables this gripping device to move up and down with respect to the shipping pallet.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In an automated warehouse system, there is a process of creating a mixed-load pallet in which a plurality of types of loads are mixed according to the requirements of the destination, from a single-load pallet on which a single type of load is stacked in multiple layers. This process includes dividing the loads on the single-load pallet into predetermined units (hereinafter referred to as "cases"), storing the divided cases, and collecting the divided and stored cases to create a mixed-load pallet according to the requirements of the destination (hereinafter referred to as "picking").

[0005] In the picking device described in Patent Document 1, the equipment is large-scale and it is difficult to have a flexible configuration.

[0006] The present invention has been made in view of such problems, and one of its objectives is to provide an automated warehouse system that can be configured flexibly.

Means for Solving the Problems

[0007] To solve the above problems, an automated warehouse system in one aspect of the present invention comprises: a first loading section and a second loading section on which loaded pallets can be placed; a picking device that takes a load from a loaded pallet placed in the first loading section and moves it to the second loading section to create another loaded pallet; and a transport vehicle that can move autonomously while changing its direction of movement and moves under the picking device to transport the loaded pallet to the first loading section.

[0008] 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]

[0009] According to the present invention, a flexibly configurable automated warehouse system can be provided. [Brief explanation of the drawing]

[0010] [Figure 1] This is a schematic plan view showing an example of an automated warehouse according to the embodiment. [Figure 2] This is a perspective view showing an example of an assembly of multiple stacked loads. [Figure 3] Figure 1 is a schematic front view showing an example of the transport vehicle. [Figure 4] Figure 3 is a side view showing the transport vehicle. [Figure 5] Figure 1 is a plan view showing the picking device. [Figure 6] Figure 5 is a side view showing the picking device. [Figure 7] Figure 5 is a bottom view showing the retrieval unit of the picking device. [Figure 8] This is a schematic front view showing an example of the first bogie in Figure 1. [Figure 9] This is a schematic front view showing an example of the second bogie in Figure 1. [Figure 10]Figure 1 is an explanatory diagram illustrating an example of the first operation of an automated warehouse. [Figure 11] Figure 1 is an explanatory diagram illustrating an example of the third operation of the automated warehouse. [Modes for carrying out the invention]

[0011] 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.

[0012] 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.

[0013] [Embodiment] The overall configuration of the automated warehouse system 100 according to the embodiment will be described with reference to Figure 1. Figure 1 is a schematic plan view showing an example of the automated warehouse system 100 according to the embodiment. For the sake of explanation, as shown in the figure, an XYZ Cartesian coordinate system is defined where a certain horizontal direction is the X-axis direction, a horizontal direction perpendicular to the X-axis direction is the Y-axis direction, and a direction perpendicular to both, i.e., the vertical direction, is the Z-axis direction. The positive direction of the X-axis, Y-axis, and Z-axis is defined by the direction of the arrow in each figure, and the negative direction is defined in the direction opposite to the arrow. The X-axis direction is sometimes called the "row direction," the Y-axis direction is sometimes called the "column direction," and the Z-axis direction is sometimes called the "up and down direction." Such directional notation does not limit the configuration of the automated warehouse system 100, and the automated warehouse system 100 can be used in any configuration depending on the application.

[0014] As shown in FIG. 1, the automated warehouse system 100 includes a storage shelf 22, a picking area 30, a shipping area 38, and a control unit 50. The first cart 14 and the second cart 16 are arranged on the storage shelf 22. In the picking area 30, a transport cart 18, a picking device 32, a first placement unit 34, and a second placement unit 36 are provided. In the shipping area 38, a shipping unit 40 is provided. In the example of FIG. 1, from the viewpoint of facilitating the travel of the transport cart 18, the unloading section 23 of the storage shelf 22, the first placement unit 34, the second placement unit 36, and the shipping unit 40, which will be described later, are arranged on the same floor Fr.

[0015] The storage shelf 22 can store a plurality of goods 10. The first placement unit 34 and the second placement unit 36 can each place a load pallet on which a plurality of goods 10 are stacked. The picking device 32 takes out the goods 10 from the load pallet 12 placed on the first placement unit 34, moves them to the second placement unit 36, and creates another load pallet 12. The transport cart 18 can move while autonomously changing the moving direction, moves under the picking device 32, and transfers the load pallet 12 to the first placement unit 34. The goods 10 and the load pallet 12 will be described later.

[0016] The control unit 50 is configured to include an MPU (Micro Processing Unit) or the like. The control unit 50 controls the operation of the picking device 32 in order to pick the goods 10. Further, the control unit 50 controls the operations of the first cart 14, the second cart 16, and the transport cart 18 in order to transfer the load pallet 12 based on the operation result from the user.

[0017] FIG. 2 is a perspective view showing an aggregate in a state where a plurality of loads are stacked. In this specification, an object in which one or more articles are housed in a case such as cardboard is referred to as a load 10. A pallet without a load is simply referred to as "pallet 12j". An object in which one or a plurality of loads 10 are placed on one pallet 12j is referred to as a "loaded pallet 12". The loaded pallet 12 refers to the combination of the pallet 12j and the load 10 on the pallet 12j. The loaded pallet 12 may be composed of a plurality of stacked layers, and each layer may include a plurality of loads 10. In the example of FIG. 2, the loaded pallet 12 includes eight loads 10 in each of the three layers. The loaded pallet 12 may be the minimum unit for warehousing, storage, and shipping in the automated warehouse system 100. The load 10 may be the minimum unit to be handled when picking.

[0018] The transport vehicle 18 will be described with reference to FIGS. 3 and 4. FIG. 3 is a front view schematically showing an example of the transport vehicle 18. FIG. 4 is a side view of the transport vehicle 18. The transport vehicle 18 is a transport means for transporting loads based on a command from the control unit 50. The transport vehicle 18 functions as an automated guided vehicle (AGV) that can autonomously travel to reach a target position by controlling the rotation of wheels and the steering angle based on the target position and its own vehicle position. The travel route of the transport vehicle 18 may include a preset travel route and a travel route determined autonomously.

[0019] The transport vehicle 18 includes a mounting table portion 18c for mounting the loaded pallet 12 (hereinafter including the empty pallet 12j), and a lift mechanism 18d for raising and lowering the mounting table portion 18c. The transport vehicle 18 drives a plurality of wheels 18f by a motor (not shown) and travels with the loaded pallet 12 mounted thereon. The transport vehicle 18 raises and lowers the loaded pallet 12 on the mounting table portion 18c by the lift mechanism 18d. In FIGS. 3 and 4, the mounting table portion 18c in the raised state is shown by a dashed line, and the mounting table portion 18c in the lowered state is shown by a solid line.

[0020] The transport vehicle 18 lifts and holds the loaded pallet 12 at the transport source. The transport vehicle 18 autonomously travels along the route from the transport source to the transport destination and transports the loaded pallet 12. The transport vehicle 18 unloads the loaded pallet 12 at the transport destination. The transport source and transport destination include, but are not limited to, the storage rack 22, the first loading section 34, the second loading section 36, the retrieval section 40, etc.

[0021] Various known induction methods can be employed for the autonomous navigation of the transport vehicle 18. In this embodiment, the transport vehicle 18 is guided based on a weak induced current from an induction wire 18g embedded in the floor. The transport vehicle 18 is equipped with safety devices such as proximity sensors and ultrasonic distance meters to prevent collisions.

[0022] The picking device 32, the first mounting section 34, and the second mounting section 36 will be described with reference to Figures 1, 5, and 6. Figure 5 is a plan view showing the picking device 32. Figure 6 is a side view showing the picking device 32. Some columns and beams are omitted in these figures. The picking device 32 is installed in the picking area 30 for picking. In this embodiment, the picking area 30 is installed near the storage shelves 22. The picking area 30 is located on the same floor as the unloading section 23 of the storage shelves 22, which will be described later.

[0023] The first loading section 34 and the second loading section 36 are provided in the picking area 30 and are arranged to overlap with the picking device 32 in a plan view. The first loading section 34 mainly holds loading pallets 12 (hereinafter referred to as "single-load pallets 12S") that carry multiple loads of a single type. The second loading section 36 mainly holds loading pallets 12 (hereinafter referred to as "mixed-load pallets 12M") that carry a mixture of multiple types of loads. The picking device 32 takes the loads 10 from the single-load pallets 12S before picking and transfers them to the mixed-load pallets 12M to create the mixed-load pallets 12M after picking. There are no limitations on the arrangement of the first loading section 34 and the second loading section 36, but in the example in Figure 1, they are arranged adjacent to each other along the direction of travel of the transport vehicle 18 (hereinafter referred to as the "direction of entry") in the first loading section 34 and the second loading section 36. The first mounting section 34 and the second mounting section 36 may be connected in series.

[0024] There are no limitations on the configuration of the first mounting section 34 and the second mounting section 36, but the mounting section of this embodiment has a plurality of mounting platforms arranged on either side of the access path for the transport vehicle 18 to enter. In the example of Figure 1, the first mounting section 34 has two mounting platforms 34p arranged spaced apart in the width direction of the transport vehicle 18, and the second mounting section 36 has two mounting platforms 36p arranged spaced apart in the width direction of the transport vehicle 18.

[0025] From the viewpoint of facilitating the entry and exit of the transport vehicle 18, the platforms 34p and 36p are configured as follows: The distance between the two platforms 34p and the distance between the two platforms 36p is set to a width equal to the width of the transport vehicle 18 plus a predetermined margin. The height of the platforms 34p and 36p is set to be higher than the lowered mounting platform 18c and lower than the raised mounting platform 18c. The front-to-back length (length in the entry direction) of the platforms 34p and 36p is set to a length equal to the length of the transport vehicle 18 plus a predetermined margin.

[0026] The picking device of this embodiment retrieves the load 10 from above the first loading section 34 and loads the load onto the second loading section 36 from above the second loading section 36. In the example shown in Figure 1, the picking device 32 includes a so-called gantry-type crane mechanism. The picking device 32 comprises a pair of vertical beams 32e, a cross beam 32k, a crane trolley 32d, a suspension section 32j, and a retrieval unit 32h. The pair of vertical beams 32e are provided spaced apart on both sides in the Y-axis direction in the upper space of the picking area 30. Both ends of the vertical beams 32e are supported by the upper ends of the vertical columns 32g.

[0027] The transverse girder 32k is a rail-like structure extending in the Y-axis direction and is spanned between a pair of longitudinal beams 32e. The transverse girder 32k is configured to be self-propelled on the longitudinal beams 32e in the X-axis direction. The transverse girder 32k is sometimes referred to as a crane girder. The crane trolley 32d is a trolley that is self-propelled on the transverse girder 32k in the Y-axis direction. The crane trolley 32d is sometimes referred to as a trolley trolley. The suspension section 32j suspends the take-up unit 32h from the crane trolley 32d and can move it up and down in the Z-axis direction. The suspension section 32j can also rotate the take-up unit 32h horizontally. The take-up unit 32h is provided at the tip of the suspension section 32j and is configured to lift the load 10.

[0028] The picking device 32 supports the retrieval unit 32h so that it can move freely in the horizontal direction (X-axis direction and Y-axis direction). The picking device 32 also supports the retrieval unit 32h so that it can move in the vertical direction (Z-axis direction).

[0029] The extraction unit 32h will now be described. Figure 7 is a bottom view of the extraction unit 32h. The extraction unit 32h has a roughly rectangular shape when viewed from below. Multiple suction parts 32s are arranged in a matrix on the bottom surface of the extraction unit 32h in the X-axis and Y-axis directions. Each of the multiple suction parts 32s generates an suction force by drawing in air. The magnitude of the suction force of the suction parts 32s can be adjusted. Note that each of the suction parts 32s may be divided into multiple sections.

[0030] The suction unit 32s is configured to be switchable between an ON state, which generates an suction force capable of holding the load 10, and an OFF state, which generates virtually no suction force. The OFF state includes not only a state of complete non-generation but also a state in which a small suction force is generated that is not sufficient to hold the load 10. The retrieval unit 32h can adjust the suction force of the multiple suction units 32s to hold and retain all the loads 10 in the layer. Furthermore, the retrieval unit 32h can adjust the suction force generation area to select and hold one or more loads 10 from the loads 10 in the layer.

[0031] The removal unit 32h may have a clamping mechanism (not shown) that clamps the load 10 from the horizontal direction, either in place of the suction part 32s or in addition to the suction part 32s.

[0032] Referring to Figure 1, the storage rack 22 will be described. The storage rack 22 is a shelf unit capable of storing multiple loads 10. The configuration of the storage rack 22 is not particularly limited as long as it can accommodate and store multiple loads 10. The storage rack 22 includes multiple storage units 24 arranged along the X-axis and Y-axis. Each storage unit 24 is configured to store loads 10. In particular, the storage rack 22 can store single-load pallets 12S, mixed-load pallets 12M, and empty pallets 12j in each storage unit 24.

[0033] This embodiment includes N layers of storage shelves 22 (where N is an integer of 1 or more, for example, 3) arranged vertically. Figure 1 shows the first layer of storage shelves 22 closest to the floor Fr. From the second layer onward, the Nth layer of storage shelves 22 is positioned above the N-1th layer of storage shelves 22. Each layer of storage shelves 22 may have a similar configuration to the others. In particular, each layer of storage shelves 22 is provided with one or more sets of first trolleys 14 and second trolleys. A lifting mechanism (not shown) may also be provided to raise and lower the first trolleys 14, either loaded with cargo 10 or empty, between multiple layers of storage shelves 22.

[0034] The storage rack 22 is provided with a first rail 26 as a travel path for the first trolley 14 and a second rail 28 as a travel path for the second trolley 16. The first rail 26 extends in the Y-axis direction on the storage rack 22. The first trolley 14 is a transport means that can travel under each storage section 24. The second rail 28 extends in the X-axis direction adjacent to the storage rack 22.

[0035] The first trolley 14 will be described with reference to Figure 8. Figure 8 is a schematic front view showing an example of the first trolley 14. The first trolley 14 drives multiple wheels 14f by a motor (not shown) and travels along the first rail 26 in the Y-axis direction with the load pallet 12 loaded on it. The first trolley 14 raises and lowers the load pallet 12 on the mounting platform 14c by a lift mechanism 14d. In Figure 8, the mounting platform 14c in the raised state is shown by a dashed line, and the mounting platform 14c in the lowered state is shown by a solid line. The first trolley 14 can lower the load pallet 12 into the storage section 24. The first trolley 14 can lift and support the load pallet 12 from the storage section 24. The first trolley 14 can get on and off the second trolley 16.

[0036] The second trolley 16 will be described with reference to Figure 9. Figure 9 is a schematic front view showing an example of the second trolley 16, with the first trolley 14 mounted on it. The second trolley 16 is a transport means that drives multiple wheels 16f by a motor (not shown) and travels along the second rail 28 in the X-axis direction. The second trolley 16 can transport the first trolley 14 with a loaded pallet 12 or with an empty load.

[0037] The storage rack 22 transports the goods 10 brought into the loading area (not shown) to a designated storage area 24 using the first trolley 14 and the second trolley 16 for storage. The storage rack 22 then transports the goods 10 stored in the designated storage area 24 to the unloading area 23 using the first trolley 14 and the second trolley 16 for unloading.

[0038] As shown in Figure 1, the storage rack 22 has an exit section 23 for unloading the loaded pallets 12. The exit section 23 is configured to allow a first trolley 14 and a transport vehicle 18 to enter. The exit section 23 is provided with a first rail 26 for the first trolley 14 to enter. In other words, the first trolley 14 enters the exit section 23, unloads the loaded pallets 12, and exits. Next, the transport vehicle 18 enters the exit section 23, holds the loaded pallets 12, and exits. The reverse is also possible. In other words, the exit section 23 functions as a transfer section for transferring the loaded pallets 12 between the first trolley 14 and the transport vehicle 18. From these points, it can be said that the exit section 23 is the entrance and exit of the storage rack 22.

[0039] There are no limitations on the configuration of the unloading section 23, but in this embodiment, the unloading section 23 has a plurality of platforms arranged on either side of the access path for the transport vehicle 18 to enter. In the example shown in Figure 1, the unloading section 23 has two platforms 23p that are spaced apart in the width direction of the transport vehicle 18.

[0040] From the viewpoint of facilitating the entry and exit of the transport vehicle 18, the distance between the two platform 23p is set to a width that is the width of the transport vehicle 18 plus a predetermined margin, and the height of the platform 23p is set to be higher than the lowered mounting platform 18c and lower than the raised mounting platform 18c. The front-to-back length (length in the entry direction) of the platform 23p is set to a length that is the length of the transport vehicle 18 plus a predetermined margin.

[0041] Referring to Figure 1, the outbound section 40 will be described. The outbound section 40 is a platform for shipping the picked mixed pallets 12M to their destination. There are no limitations on the configuration of the outbound section 40, but in this embodiment, the outbound section 40 has a plurality of platforms arranged on either side of the access path for the transport vehicle 18 to enter. In the example in Figure 1, the outbound section 40 has two platforms 40p that are spaced apart in the width direction of the transport vehicle 18. The two platforms 40p can be configured in the same way as the two platforms 34p of the first platform 34.

[0042] The operation of the automated warehouse system 100 configured as described above will now be explained. In this operation, the transport vehicle 18 autonomously travels along the induction wire 18g to its destination while detecting the induced current of the induction wire 18g. When the transport vehicle 18 approaches the target platform, it uses the detection result of a sensor that detects the platform to correct its own position relative to the platform and travels while ensuring an appropriate gap with the platform. Examples of sensors that detect the platform include laser sensors and image sensors. After the operation is completed, the transport vehicle 18 moves to a predetermined standby position and waits.

[0043] (1st action) The first operation is a transfer operation. An example of the first operation will be explained with reference to Figure 10. Figure 10 is an explanatory diagram illustrating the first operation. The first operation is a transfer operation in which the transport vehicle 18 transfers the single pallets 12S stored on the storage rack 22 to the first placement unit 34 based on a command from the control unit 50 (hereinafter simply referred to as "command").

[0044] (1) In the first operation, the first trolley 14 and the second trolley 16 first transport the single pallets 12S stored in the designated storage section 24 of the storage rack 22 to the unloading section 23. During this process, the first trolley 14 places the single pallets 12S on its raised mounting platform 14c and enters the unloading section 23 (Figure 10(a)). Once inside the unloading section 23, the first trolley 14 lowers its mounting platform 14c and lowers the single pallets 12S onto the platform 23p of the unloading section 23. After lowering the single pallets 12S, the first trolley 14 exits the unloading section 23 and moves into the storage rack 22.

[0045] (2) The transport vehicle 18 travels toward the unloading section 23 with the loading platform 18c lowered (Figure 10(b)). Once the transport vehicle 18 enters the unloading section 23, it raises the loading platform 18c to lift the single pallet 12S and exits the unloading section 23 (Figure 10(c)).

[0046] (3) Once the transport vehicle 18 has exited the loading section 23, it travels toward the first loading section 34 (Figure 10(d)).

[0047] (4) Once the transport vehicle 18 enters the first loading section 34, it lowers the loading platform 18c to lower the single pallet 12S onto the loading platform 34p of the first loading section 34 (Figure 10(e)). After lowering the single pallet 12S, the transport vehicle 18 exits the first loading section 34.

[0048] (5) The transport vehicle 18 repeats this first operation according to the shipping plan, transferring single pallets 12S of different types of cargo 10 to other first loading sections 34. By operating in this manner, multiple first loading sections 34 are loaded with single pallets 12S containing different types of cargo 10.

[0049] (Second action) The second operation is the picking operation. An example of the second operation of the picking device 32 will be explained with reference to Figure 6. As described above, the second operation is the operation of taking the goods 10 from the single-load pallets 12S placed on the first loading section 34 based on a command corresponding to the shipping plan, and creating a mixed-load pallet 12M for shipment to destinations such as retailers on the second loading section 36. In Figure 6, the first type of goods 10-A is shown with dashed hatching, the second type of goods 10-B is shown with solid hatching, and the third type of goods 10-C is shown as white without hatching.

[0050] (1) The transport vehicle 18 places an empty pallet 12j in the second loading section 36 of the picking area 30 to create a mixed pallet 12M. In this process, the transport vehicle 18 transfers the pallet 12j from a pallet storage area (not shown) that houses the pallet 12j to the designated second loading section 36.

[0051] (2) The picking device 32 takes the required number of first type loads 10-A from the single pallet 12S and places them on the pallet 12j of the second loading section 36. (3) The picking device 32 also takes the required number of second-type loads 10-B from another single-load pallet 12S and places them on top of the first-type loads 10-A on pallet 12j. (4) The picking device 32 then takes the required number of third-type loads 10-C from another single-load pallet 12S and places them on top of the second-type loads 10-B on pallet 12j. (5) In this way, the picking device 32 stacks multiple types of cargo 10 corresponding to the shipping plan onto a pallet 12j to create a mixed pallet 12M.

[0052] (3rd action) The third operation is the preparation operation for dispatch. An example of the third operation will be explained with reference to Figure 11. Figure 11 is an explanatory diagram illustrating the third operation. The third operation is the operation in which, based on a command, the transport vehicle 18 transports the mixed pallet 12M of the second loading section 36 to the dispatch section 40. The third operation may be performed by the transport vehicle 18 that performed the first operation, or it may be performed by a different transport vehicle 18 from the transport vehicle 18 that performed the first operation. In this example, the third operation is performed by the transport vehicle 18 that performed the first operation. In other words, one transport vehicle 18 performs both the first and third operations.

[0053] (1) The transport vehicle 18 travels toward the second mounting section 36 with the mounting platform 18c lowered (Figure 11(a)). (2) Once the transport vehicle enters the second loading section 36, it raises the loading platform 18c to lift the mixed pallet 12M, exits the second loading section 36, and travels towards the outbound section 40 (Figure 11(b)).

[0054] (3) Once the transport vehicle 18 enters the outbound section 40, it lowers the loading platform 18c and lowers the mixed pallet 12M onto the loading platform 40p in the outbound section 40 (Figure 11(c)). After lowering the mixed pallet 12M, the transport vehicle 18 exits the outbound section 40 and repeats the third operation according to the shipping plan.

[0055] (4) The mixed pallets 12M that have been unloaded at the outbound section 40 are loaded onto trucks using transport means such as forklifts and shipped to their destinations.

[0056] In this way, by transporting the mixed pallets 12M to the outbound section 40 using the transport vehicle 18, even if the picking completion times vary, the pallets can be transported by the transport vehicle 18 in the order in which they were picked, providing greater flexibility in outbound operations compared to conveyors, etc.

[0057] (4th action) The fourth operation is the retrieval of empty pallets. As a result of the second operation, empty pallets 12j remain in the first loading unit 34 after picking. The fourth operation is the retrieval of the pallets 12j remaining in the first loading unit 34 by the transport vehicle 18 based on a command.

[0058] In the fourth operation, the transport vehicle 18 enters the first loading section 34 with the loading platform 18c lowered, lifts the pallet 12j, exits the first loading section 34, travels towards the designated pallet storage area, and lowers the pallet 12j into the pallet storage area.

[0059] A dedicated storage area may be provided for pallets, but in this embodiment, a part of the storage rack 22 is used. In this case, the transport vehicle 18 moves the pallets 12j to the storage rack 22. For example, the pallets 12j are moved to the unloading section 23, transferred to the first trolley 14, and then transported to the designated storage section 24 by the first trolley 14 and the second trolley 16.

[0060] In addition, in the fourth operation, the transport vehicle 18 may transfer the pallet 12j from the first loading section 34 to the second loading section 36, which has become empty as a result of the third operation.

[0061] (5th action) The fifth operation is the retrieval of the intermediate pallet. As a result of the second operation, some of the cargo 10 has been removed and the remaining cargo 10 is stacked on a single-load pallet 12S (hereinafter referred to as the "intermediate pallet") in the first loading section 34. For example, if the cargo 10 on the intermediate pallet is not needed in the current shipping plan and it is desired to place a single-load pallet 12S of a different type of cargo 10 in the first loading section 34, the first loading section 34 can be freed up by the fifth operation. The fifth operation is the retrieval of the intermediate pallet remaining in the first loading section 34 by the transport vehicle 18 based on a command.

[0062] In the fifth operation, the transport vehicle 18 enters the first loading section 34 with the loading platform 18c lowered, lifts the intermediate pallet, exits the first loading section 34, travels towards a designated intermediate pallet storage area, and lowers the pallet 12j into the intermediate pallet storage area.

[0063] A dedicated storage area may be provided for intermediate pallets, but in this embodiment, a part of the storage rack 22 is used. In this case, the transport vehicle 18 transfers the intermediate pallet j to the storage rack 22. For example, the intermediate pallet j is transferred to the unloading section 23, loaded onto the first trolley 14, and then transferred to the designated storage section 24 by the first trolley 14 and the second trolley 16.

[0064] In the fifth operation, the transport vehicle 18 may instead transport the single-load pallet 12S, before the load 10 is removed, to the storage rack 22, instead of the intermediate pallet.

[0065] Furthermore, according to the fifth operation, for example, for single pallets 12S with low demand, only the necessary amount of cargo 10 can be taken out, the rest can be temporarily removed from the first loading section 34, and single pallets 12S with high demand can be brought into the first loading section 34.

[0066] (6th action) The sixth operation is the retrieval operation of the mixed pallet 12M. There are cases where it is necessary to temporarily retrieve the mixed pallet 12M from the second loading section 36 or the outbound section 40. For example, when the shipping plan changes, the sixth operation can be used to free up the second loading section 36 or the outbound section 40. The sixth operation is the operation in which the transport vehicle 18 retrieves the mixed pallet 12M from the second loading section 36 or the outbound section 40 based on a command.

[0067] In the sixth operation, the transport vehicle 18 enters the second loading section 36 or the loading section 40 with the loading platform 18c lowered, lifts the mixed pallet 12M, exits the second loading section 36 or the loading section 40, travels toward the designated storage area for the mixed pallet 12M, and lowers the pallet 12j into the storage area for the mixed pallet 12M.

[0068] (7th action) The seventh operation is the operation in which, based on a command, the transport vehicle 18 moves the loaded pallets 12 from the receiving area (not shown) to the storage shelves 22. For example, the loaded pallets 12 are unloaded from the truck to the receiving area by a transport means such as a forklift, the loaded pallets 12 from the receiving area are moved to the unloading area 23 by the transport vehicle 18, the loaded pallets 12 are transferred to the first trolley 14, and the loaded pallets 12 are moved to the designated storage area 24 by the first trolley 14 and the second trolley 16.

[0069] A dedicated storage area may be provided for the mixed pallets 12M, but in this embodiment, a part of the storage rack 22 is used. In this case, the transport vehicle 18 transfers the mixed pallets 12M to the storage rack 22. For example, the mixed pallets 12M are transferred to the unloading section 23, loaded onto the first trolley 14, and then transferred to the designated storage section 24 by the first trolley 14 and the second trolley 16. Note that the mixed pallets 12M include both completed and uncompleted items.

[0070] The above is a description of the first to seventh actions. This example of actions is merely one example, and various variations are possible.

[0071] A separate transport vehicle 18 may be provided for each operation. Alternatively, a transport vehicle 18 may perform multiple operations in a time-sharing manner. One or more transport vehicles 18 can be provided depending on the size of the warehouse and the volume of goods handled.

[0072] As described above, this embodiment includes a first route between the storage rack 22 and the first loading section 34, a second route between the first loading section 34 and the second loading section 36, a third route between the second loading section 36 and the outbound area 38, and a fourth route between the outbound area 38 and the storage rack. A single transport vehicle 18 may transport the loaded pallets along one of the first, second, third, and fourth routes, or a single transport vehicle 18 may transport the loaded pallets along at least two of these four routes, or multiple transport vehicles 18 may share the task of transporting the loaded pallets along these four routes. The configuration can be flexibly adapted to the size and operating conditions of the warehouse.

[0073] The transport vehicle 18 may be configured to travel along the storage shelves 22, and the transport vehicle 18 may function similarly to the first trolley 14. With this configuration, if the design of the transport vehicle 18's path (for example, the structure of the rails, including its width and the structure of the receiving part) is common, the same type of transport vehicle 18 can be used. In this case, when using multiple transport vehicles 18 in the entire system including the storage shelves 22 and the picking area 30, the placement of the transport vehicles 18 can be flexibly managed.

[0074] For example, when operating four transport vehicles 18, sometimes all of the transport vehicles 18 can be used in the storage shelves 22, or two of the four transport vehicles 18 can be used in the storage shelves 22 and the remaining two can be used in the picking area 30. Also, if there is a tendency for a shortage of transport vehicles 18 used in the picking area 30, one of the transport vehicles 18 used in the storage shelves 22 can be used in the picking area 30 as support, or vice versa, allowing for flexible system operation.

[0075] The features of the automated warehouse system 100 of this embodiment, configured as described above, will now be explained. This embodiment includes storage shelves 22, a first loading section 34, a second loading section 36, a transport vehicle 18, and a picking device 32, so that picking, which involves taking out goods 10 from single-load pallets 12S to create mixed-load pallets 12M, can be achieved with fewer man-hours.

[0076] Furthermore, according to this embodiment, the scale of the first loading section 34, the second loading section 36, and the picking device 32 can be selected according to the size of the warehouse and the volume of goods handled, allowing for a flexible configuration of the automated warehouse system. In addition, when the size of the warehouse or the volume of goods handled changes, the number and operating mode of the transport vehicles 18 can be changed to provide a flexible response. Furthermore, depending on the size of the warehouse and the volume of goods handled, the system can be flexibly adapted by extending the vertical beams 32e and horizontal beams 32k of the crane mechanism, adding movable parts of the crane mechanism, adding the unloading section 23, adding the first loading section 34, adding the second loading section, etc.

[0077] Furthermore, according to this embodiment, the cargo 10 removed from the single-load pallet 12S is loaded directly onto the mixed-load pallet 12M. Therefore, compared to a method in which the cargo 10 removed from the single-load pallet 12S is divided into multiple cases and stored in a separate space, and then the cases stored in the separate space are loaded onto the mixed-load pallet, space efficiency is improved because a separate space for case storage is not used. In addition, since the removal of cargo 10 and loading onto the mixed-load pallet 12M are performed integrally, productivity is improved and equipment costs can be reduced compared to a method in which separation and loading are performed separately.

[0078] Furthermore, according to this embodiment, the travel route of the transport vehicle 18 can be easily changed by replacing the guide wire 18g.

[0079] Furthermore, this embodiment may also include another transport vehicle for moving the mixed pallet 12M from the second loading section 36 to the shipping area 38. In this case, the warehouse throughput can be improved.

[0080] Furthermore, in this embodiment, the transport vehicle 18 used in the first operation can move the mixed pallet 12M from the second loading section 36 to the shipping area 38. In this case, capital investment can be reduced.

[0081] Furthermore, in this embodiment, the transport vehicle 18 can unload the empty pallet 12j from the first loading section 34. In this case, the mechanism for unloading the empty pallet 12j can be omitted.

[0082] Furthermore, in this embodiment, an empty pallet 12j can be loaded into the second loading section 36 by the transport vehicle 18. In this case, the mechanism for loading the empty pallet 12j can be omitted.

[0083] Furthermore, in this embodiment, the transport vehicle 18 can move the single-load pallet 12S or a single-load pallet 12S with some of the load 10 removed from the first loading section 34 to the storage shelf 22. In this case, the first loading section 34 can be used effectively.

[0084] Furthermore, in this embodiment, the unloading section 23, the first placement section 34, the second placement section 36, and the retrieval section 40 each have a plurality of placement platforms arranged on either side of an access path for the transport vehicle 18 to enter. In this case, the unloading section 23, the first placement section 34, the second placement section 36, and the retrieval section 40 can be configured simply.

[0085] Furthermore, in this embodiment, the unloading section 23, the first placement section 34, the second placement section 36, and the retrieval section 40 of the storage rack 22 are located on the same floor Fr. In this case, the step difference in the travel path of the transport vehicle 18 is reduced, allowing the transport vehicle 18 to travel easily.

[0086] 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 this does not mean that design changes are not permitted for contents without such notations. Furthermore, the hatching in the drawings does not limit the material of the object to which the hatching is applied.

[0087] (modified version) The following describes modified examples. In the drawings and descriptions of the modified examples, components and parts that are the same or equivalent as 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.

[0088] The description of the embodiment shows an example in which the automated warehouse system 100 performs the first to seventh operations, but it is not limited to this. It is not necessary to perform all of the first to seventh operations; the automated warehouse system 100 only needs to perform the first and second operations.

[0089] In the description of the embodiment, an example was shown in which the storage rack 22 has a first trolley 14 and a second trolley 16, but it is not limited thereto. For example, the storage rack 22 may not have one or both of the first trolley 14 and the second trolley 16.

[0090] In the description of the embodiment, an example was shown in which the picking device 32 is supported from the ceiling by a gantry-type crane mechanism, 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.

[0091] In the description of the embodiment, an example was shown in which a picking operation takes out a load 10 from a collection of loads 10 of the same type (single load pallet 12S) to create a collection of loads 10 of multiple types (mixed load pallet 12M), but the present invention is not limited to this. The picking operation may include taking out a load 10 from a collection of loads 10 of multiple types, or it may be an operation to create a collection of loads 10 of the same type using the picked loads 10. Furthermore, the collection of loads 10 of the same type created by picking may be shipped out.

[0092] In the description of the embodiment, an example was shown in which the transport vehicle 18 is guided based on the induced current of an electric wire installed on the floor, but the transport vehicle 18 may employ a different guidance method. Examples of guidance methods for the transport vehicle 18 include using lines drawn on the floor, using the shape of facilities such as walls and shelves using a laser scanner, using light and reflectors, using radio waves and RFID (Radio Frequency Identifier), using magnetic signals from magnetic tape installed on the floor, using radio waves from beacons, and methods combining these.

[0093] Furthermore, the transport vehicle 18 may be configured to recognize its own position and autonomously travel to the destination location based on the recognition result and stored map information. The transport vehicle 18 can be equipped with various methods for recognizing its own position. For example, the transport vehicle 18 may recognize its own position using a plurality of reflectors installed in the warehouse and a laser scanner mounted on the vehicle. For example, the positions of the plurality of reflectors may be stored on the vehicle's map. In this case, the transport vehicle 18 can recognize at least three reflectors with the laser scanner and determine its own position based on the principle of triangulation by referring to the reflector position information stored on the map.

[0094] Furthermore, the transport vehicle 18 may be configured to correct its own position information in order to improve driving accuracy. For example, the transport vehicle 18 may recognize images of the floor, walls, equipment, etc. using an image sensor and correct its own position based on the recognition results. Alternatively, the transport vehicle 18 may correct its own position based on the amount of wheel rotation identified from the detection results of an encoder that detects the rotation of the wheels. Alternatively, the transport vehicle 18 may correct its own position based on the detection results of an acceleration sensor such as a gyroscope.

[0095] In the description of the embodiment, an example was shown in which the transport vehicle 18 is provided separately from the first trolley 14, but the invention is not limited to this. For example, the first trolley 14 that travels on the storage shelves 22 may function as the transport vehicle 18 itself. For example, the first rail 26 of the lowest layer of the storage shelves 22 may be connected to the rail of the loading section of the picking area 30, and the first trolley 14 may directly move the single pallet 12S to the picking area 30. This rail connection relationship may be provided in accordance with the number of loading sections arranged in the X-axis direction of the picking area 30. In this case, a cooperative system can be constructed in which each storage shelf 22 can directly access the loading section of the picking area 30.

[0096] Furthermore, the picking area 30 may be provided with another transport means having the same function as the second trolley 16 and capable of transporting the first trolley 14. In this case, the above-described cooperative system can be constructed by providing at least one rail between the storage rack 22 and the picking area 30, without having to provide rails corresponding to all of the multiple loading sections. In addition, by using this other transport means and the first trolley 14, it is possible to selectively control which of the multiple loading sections a single pallet is delivered to. Furthermore, from the viewpoint of constructing the above-described cooperative system compactly, it is preferable that the picking area 30 and the storage rack 22 are adjacent to each other, and more preferably that they are structurally integrated. In this case, the transport path between the picking area 30 and the storage rack 22 can be shortened.

[0097] In the description of the embodiment, an example was shown in which the transport vehicle 18 moves along the underside of the picking device 32 to transport the loaded pallet 12, but the invention is not limited to this. The transport vehicle 18 may be configured to move alongside the picking device 32. In this case, the travel route of the transport vehicle 18 can be flexibly set.

[0098] In the description of the embodiment, an example was shown in which the base 34p of the first mounting section 34 and the base 36p of the second mounting section 36 are separated from each other, but the embodiment is not limited to this. The base 34p and the base 36p may be connected or formed integrally.

[0099] Each of these modifications produces the same effects as the embodiments.

[0100] 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]

[0101] 10 Load, 12 Loading pallet, 12M Mixed load pallet, 12S Single load pallet, 18 Transport cart, 18g Induction wire, 22 Storage rack, 23 Dispatch unit, 32 Picking device, 34 First loading unit, 36 Second loading unit, 40 Outbound unit, 50 Control unit, 100 Automated warehouse system.

Claims

1. A storage area capable of storing multiple loading pallets, A first and second loading section on which a loaded pallet can be placed in a floor where there is no storage rack below capable of storing multiple loads, A transport vehicle capable of autonomously changing direction of movement and transporting multiple types of single pallets, each consisting of different types of cargo, from the storage unit to the first loading unit, while sequentially holding each single pallet. A picking device including a gantry-type crane mechanism provided to cover the upper part of the first and second loading sections, which picks up a load from a single-load pallet placed on the first loading section and moves the load to the second loading section to create a mixed-load pallet, A containment system equipped with the following features.

2. The storage system according to claim 1, wherein the transport vehicle transfers cargo stored on the same floor as the first and second loading sections of the storage area to the first loading section.

3. The housing system according to claim 1 or 2, wherein the first mounting section and the second mounting section are configured to be selectable from a plurality of mounting sections provided below the gantry-type crane.

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