Automated warehouse management system and management method

Abstract

By using robotic arms to handle everything from receiving goods into the warehouse to retrieving them, it becomes possible to sell a wide variety of products to customers without human intervention. [Solution] An automated warehouse comprising a substantially cylindrical rack 2, a plurality of user terminals 5 provided around the rack, and a robot arm 3 provided in the central part of the cylindrical rack, wherein the rack is provided with a plurality of shelf sections a for storing storage boxes, and the robot arm is used to place the storage boxes containing a plurality of products supplied from the outside into predetermined shelf sections for storage, and an information processing unit 12 controls the retrieval of the storage boxes from the stored shelf sections and provides the desired products stored therein to the user.

Description

Technical Field

[0001] The present invention relates to a management system and a management method for an automated warehouse that can perform warehousing and shipping without human intervention.

Background Art

[0002] Conventionally, as the management of an automated warehouse, a warehouse storage robot that travels vertically and horizontally in the warehouse is known (for example, see Patent Document 1). Here, a configuration is disclosed in which a transport component 113 of a first warehouse storage robot 11 takes out a cargo box from a storage unit, transports it, picks up the cargo from the cargo box, and controls the robot arm to place the taken-out cargo on a corresponding sorting device. Further, Patent Document 2 discloses a technology as a warehouse management system that moves a tray in which goods are stored from a rack to a predetermined position and displays information such as information for identifying goods to be taken out from the tray (goods identification information), the number of goods to be taken out (picking number), and the position of the goods on the tray to be taken out (picking area) on an operation panel.

[0003] However, none of these technologies manages inventory while considering that consumers (users) of goods purchase goods in the warehouse, but only manages inventory within the warehouse. In order to sell goods to consumers, it is necessary to transport the necessary goods from the stored warehouse to the sales store, so time and expenses are required for the transportation of goods. Also, at the sales store of the destination, manual labor is required for tasks such as sorting goods and selling goods, and labor costs are also incurred.

[0004] If it were possible to directly sell goods to consumers using the functions of an automated warehouse, it would be possible to reduce the above-mentioned costs. However, it is necessary to secure a large space for installing the warehouse, and it is also necessary to be able to store as many types of goods as possible to meet the needs of consumers. Therefore, it is also necessary to consider accepting goods from multiple operators.

[0005] Furthermore, a different management system will be required compared to conventional warehouse handling, including the location of the warehouse, the methods for receiving multiple businesses and various types of goods, and the methods for managing their inventory. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] Japanese Patent Publication No. 2024-32981 [Patent Document 2] Japanese Patent Publication No. 2020-62707 [Overview of the project] [Problems that the invention aims to solve]

[0007] The problem we are trying to solve is that in order to modify and utilize the functions of a conventional automated warehouse as if it were a retail store, not only the warehouse structure but also functions such as the management system must be changed. [Means for solving the problem]

[0008] The most important feature of this invention is that the automated warehouse is roughly cylindrical in shape, making it easy for multiple users to use simultaneously, and that it has a management system that can store large quantities of goods regardless of type and provide the goods that users want. [Effects of the Invention]

[0009] The automated warehouse management system and management method of the present invention have the advantage of improving user convenience, automatically identifying various types of goods brought in by businesses and storing them in the warehouse, and automatically providing users with the desired goods without human intervention. Furthermore, by making the warehouse roughly cylindrical in shape, the operating rate of the robotic arms used can be improved, and the earthquake resistance of the warehouse itself can also be enhanced. [Brief explanation of the drawing]

[0010] [Figure 1] This is a diagram illustrating the internal structure of an automated warehouse according to the present invention. [Figure 2] This is a block diagram showing the configuration of an automated warehouse system according to the present invention. [Figure 3] This diagram shows a monitor screen used to display goods being stored in an automated warehouse. [Figure 4] This diagram shows the screen of the user terminal's control panel. [Figure 5] This diagram shows a robotic arm retrieving a product from a storage box. [Figure 6] This is a diagram showing how an automated warehouse is used according to the present invention. [Figure 7] This diagram shows the rack forming a shelf section. [Modes for carrying out the invention]

[0011] The system was designed to automate the storage and retrieval of goods in the warehouse, enabling the sale of a wide variety of products to customers without human intervention. Hereinafter, embodiments of the automated warehouse according to the present invention will be described with reference to the drawings. In the drawings, identical or functionally similar components are denoted by the same reference numerals and their descriptions are omitted. [Examples]

[0012] Figure 1 is a diagram illustrating the internal structure of an automated warehouse according to the present invention, where 1 is the automated warehouse. The automated warehouse 1 is a substantially cylindrical structure, and is composed of multiple racks 2 combined such that its cross-section forms a polygon (octagon), with each rack on the octagon forming multiple shelf sections a. Figure 7 is a diagram showing the state in which one side of the rack 2 forms a shelf section a. A robotic arm 3 is installed in the central part of the roughly cylindrical structure. This arm is 360-degree rotatable, and is configured so that its tip can be moved to any required shelf on rack 2 simply by rotating it. This increases the operational efficiency of the robotic arm 3.

[0013] In the figure, reference numeral 4 is an inlet formed in one shelf portion. When a goods carrier puts goods into a predetermined storage box, a predetermined loading operation for storage, which will be described later, is performed at the inlet 4. Reference numeral 5 is a user terminal, and a user can specify and purchase a desired product. In this embodiment, the user terminals 5 are provided at four surfaces out of eight surfaces. Reference numeral 6 is a goods outlet (see FIG. 6), and one shelf portion of each surface where the user terminal 5 is provided corresponds to the outlet 6.

[0014] In the figure, reference numeral 7 is a temporary platform, which is temporarily used when the robot arm 3 takes out goods from the storage box. Reference numeral 8 is a hand for transferring the storage box, which is attached to the tip of the robot arm 3 and is equipped with a hand capable of holding the storage box. Reference numeral 9 is a three-dimensional camera, which will be described later. Reference numeral 10 is a monitor screen for registering in advance product names and the like when a carrier brings goods into the warehouse. Reference numeral 11 is a two-dimensional camera for photographing and checking the goods to be brought in. In this embodiment, the automatic warehouse 1 has a substantially cylindrical shape and is configured as an octagon, but it is not limited thereto, and any polygon having a substantially cylindrical shape can be applied.

[0015] Figure 2 is a block diagram showing the configuration of an automated warehouse system according to the present invention, where 12 is an information processing unit that performs various processes from the delivery of goods to the provision of goods to users. 13 is the delivery processing unit, which photographs and recognizes goods brought in by the delivery company using a two-dimensional camera 11, reflects them on the monitor screen 10, and sends signals to the information processing unit 12 such as a signal to the robot arm 3 to place storage boxes on predetermined shelves. 14 is the delivery processing unit, which sends data and signals to the information processing unit 12 based on the operation of the user terminal 5, instructs the robot arm 3 to perform an operation command to remove a storage box from the shelf, temporarily places it on a temporary storage stand 7, detects and processes the state of the goods inside the storage box using a three-dimensional camera 9, retrieves the desired goods from the storage box using the optimal operating path of the robot arm 3, places the goods at the retrieval opening 6 for provision to users, and sends a cycle completion signal to the information processing unit 12. The user terminal 5 sends information instructed by the user on the operation panel 15, which will be described later, to the information processing unit 12.

[0016] Figure 3 shows an example of a monitor screen 10 for receiving (delivering) goods into automated warehouse 1, and shows specific display images of the monitor screen 10. Businesses bringing in goods place the goods to be stored in storage boxes of a predetermined size, which are divided into six sections in advance. By passing the boxes through the entrance 4, the goods are registered in the automated warehouse 1. Specifically, by placing the storage boxes on the shelves of the entrance 4, six two-dimensional cameras 11 installed on the racks 2 above the shelves photograph the goods placed in each of the six sections and display them on the monitor screen 10. Businesses check the goods on the monitor screen 10 and input necessary information such as product name, expiration date, quantity, and search key, corresponding to the displayed product number. In this embodiment, goods are placed in two sections. Furthermore, for user convenience, you may select pre-categorized search keys such as "tea" or "instant noodles." A two-dimensional camera is used because a three-dimensional camera would make it difficult to identify products if there is overlap or other issues with the products being searched. In addition, in this embodiment, an example of a storage box divided into six sections is shown, but it is not limited to this, and if necessary, arbitrarily divided storage boxes and cameras may be used. For the input of necessary information, the product name etc. can be input using the barcode of the product, or input can be made by voice etc. using AI (Artificial Intelligence). For example, even if the operator inputs an unclear product name, it can be corrected by the confirmation request of AI.

[0017] On the monitor screen 10, in addition, the name of the operator, the date of delivery, the identification number of the storage box to be newly stored, the inventory status by the name of the operator, the identification number of the storage box to be input when wanting to retrieve, etc. are displayed. When the predetermined input by the operator is completed (confirmed), the newly delivered storage box is assigned an identification number, and the product name, image, etc. contained in the storage box together with the identification number are stored in the information processing unit 12, and the storage box is arranged by the robot arm 3 in the empty storage shelf part of the rack 2 and stored. In the information processing unit 12, the locations of all the storage boxes arranged in the shelf part are stored corresponding to the positions of the shelf part, and the inventory status is always managed.

[0018] At this time, the operator can check the expiration date of the product by looking at the inventory status, and when wanting to retrieve the product or when the storage box is already empty, etc., the storage box can be retrieved by inputting the identification number of the corresponding storage box. That is, when instructed to retrieve, the information processing unit 12 instructs the robot arm 3 to search for the shelf part corresponding to the identification number and take out the storage box and carry it to the loading entrance 4. Also, by specifying (inputting) the product name, it can be configured to sequentially take out the storage boxes with the identification numbers containing the corresponding product and extract the corresponding product. At this time, each time the product is taken out, its quantity is subtracted and stored in the information processing unit 12. After the operator takes out the product in the storage box, if there are still other products remaining, then again at the loading entrance 4, input the necessary information on the monitor screen 10 and register the storage box with a new identification number.

[0019] Figure 4 shows an example of the screen of the operation panel 15 of the user terminal 5. The user terminals 5 are installed in multiple locations around the approximately cylindrical automated warehouse 1 (around the racks 2), and in this embodiment, they are installed in four locations corresponding to each side (Figure 1). As shown in Figure 4, when a user specifies or selects, for example, "tea," as a search key on the operation panel 15, the information processing unit 12 searches for a "product name" that matches the same or similar search key stored in the system and displays the "product name" that is in stock. In this embodiment, four types of product names, A to D, are displayed.

[0020] When the user selects one of the items (product name B), an image of product B stored in the information processing unit 12 is displayed on the confirmation image, allowing the user to confirm the product. After entering the required quantity, the total amount is displayed. Once the user confirms and pays the fee, the information processing unit 12 outputs a signal to the robot arm 3 to retrieve the storage box with the identification number containing product B from the shelf. Alternatively, instead of displaying each product individually, all (A-D) or some of the relevant products may be displayed simultaneously on the confirmation screen. If the same product is stored in storage boxes with multiple identification numbers, the product can be retrieved sequentially, starting with the box with the longest storage period.

[0021] Figure 5 shows how the robot arm 3 retrieves a product from a storage box 16. The robot arm 3 retrieves the storage box 16 containing product B with the specified identification number from a designated shelf and places it on the temporary stand 7. Next, the robot arm 3's end effector replaces, for example, the storage box transfer hand 8 with a suction hand 17 so that it can pick up the product from the storage box 16 using suction. The robot arm then retrieves product B from the storage box 16 while confirming its position with a three-dimensional camera 9. The exchange between the storage box transfer hand 8 and the suction hand 17 is performed automatically. That is, by recognizing the shape and size of product B using the three-dimensional camera 9 and utilizing AI (Artificial Intelligence), it is possible to select and replace the optimal end effector for grasping the product from among the pre-prepared suction hands 17, etc. In this embodiment, the suction hand 17 is selected. The retrieved product B is transported by the robotic arm 3 to the requesting user terminal 5 and provided to the user through the terminal's retrieval opening 6 (Figure 6). The information processing unit 12 subtracts the quantity of product B provided and stores it as the new inventory quantity. The retrieval opening 6 is formed on a shelf portion of the rack 2.

[0022] Figure 6 shows an example of how the automated warehouse 1 according to the present invention is actually used. As described above, users can find their desired product by operating the control panel 15, eliminating the need to search through shelves in a store. Furthermore, because it can store a large number of products, it is not limited to specific types of products like a vending machine, allowing users to choose from a wide variety of items. In addition, multiple users can use it simultaneously. [Industrial applicability]

[0023] The automated warehouse according to the present invention enables the automatic receiving, storage, and retrieval of goods, and is therefore not limited to use by retail stores and the like. For example, by configuring the warehouse so that the receiving and retrieval ports are on the user's side, allowing users to use it as a temporary storage space for their own goods, it can be used like a coin locker. Furthermore, it can be used in a multifaceted way, combining a warehouse with a goods sales function, and can be applied to other uses that require the storage of goods. [Explanation of Symbols]

[0024] 1. Automated warehouse 2 racks 3. Robot Arm 4. Loading entrance (receiving entrance) 5. User terminals 6. Dispensing opening (serving opening) 7 Temporary stand 8. Handle for transporting storage boxes 9. Three-dimensional camera 10 Monitor screen 11. Two-dimensional camera 12 Information Processing Section 13. Loading and Processing Section 14. Disposal Processing Unit 15. Control Panel 16 Storage box 17. Suction Hand a. Shelf section

Claims

1. An automated warehouse comprising a substantially cylindrical rack, a plurality of user terminals provided around the rack, and a robotic arm provided in the central part of the cylindrical rack, wherein the rack is provided with a plurality of shelves for storing storage boxes, and the robotic arm is used to place the storage boxes containing a plurality of goods supplied from the outside into predetermined shelves for storage, and the system is equipped with an information processing unit that controls the retrieval of the storage boxes from the stored shelves and provides the desired goods stored inside to the user.

2. The automated warehouse management system according to claim 1, characterized in that the storage boxes supplied from the outside are configured such that the goods stored inside the storage boxes are recognized and identified by cameras installed on the shelves and managed by the information processing unit.

3. The automated warehouse management system according to claim 1, characterized in that the information processing unit is connected to the plurality of user terminals, and is configured to notify the user terminals of the inventory status of the products when the user operates the user terminal, and to allow the user to specify the desired product from among similar products.

4. The automated warehouse management system according to claim 1, characterized in that the information processing unit notifies a business that supplies the storage boxes from an external source by displaying the quantity of the goods in stock supplied by the business to the automated warehouse, and enables the business to select and retrieve a predetermined storage box.

5. The automated warehouse management system according to claim 1, characterized in that a portion of the rack constitutes a receiving port for the storage boxes supplied from the outside or a dispensing port for the goods to be provided to users.

6. The automated warehouse management system according to claim 1, characterized in that the storage boxes removed from the shelves are controlled by the robotic arm to retrieve the desired product from among the plurality of products and provide it to the user.

7. An automated warehouse management method characterized by having a robotic arm installed in the center of a substantially cylindrical rack, the rack being provided with multiple shelves for storing storage boxes, and an information processing unit controlling the robotic arm to place and store the storage boxes containing multiple products supplied from an external source in predetermined shelves, and to retrieve the storage boxes from the stored shelves to provide the desired products to the user.

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