Item picking system

Abstract

To provide a system for picking goods, which does not interfere with the running of unmanned vehicles, shortens the time required for picking and reduces picking errors when unmanned vehicles collect picked goods.SOLUTION: Goods picking system 1 has a goods storage part where goods to be picked are stored, an unmanned vehicle floor 30 on which one or more unmanned vehicles 32 carrying goods collection containers 40 into which the picked goods can be deposited are running and / or on which the unmanned vehicles 32 pick up and convey the goods to be picked, a picking floor 10 provided for picking operations between the goods storage part and the unmanned vehicle floor 30 and an information display part 24 that has a pop-out function and displays information regarding picking or collection of the goods by projecting images by a projector 23 at a predetermined location in the goods storage part and / or at a location associated with the goods collection container 40.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to an article picking system for taking out articles (merchandise) to be delivered from an article storage unit and storing the articles in collection containers for each delivery destination.

Background Art

[0002] In the field of physical distribution, a large number of picking systems of various methods have been put into practical use, in which workers take out merchandise from article storage units such as shelves (picking) and store the merchandise in collection containers for each delivery destination.

[0003] Among them, a system in which an article storage unit such as a flow rack is provided in front of a worker, and a conveyor for transporting collection containers is provided between the article storage unit and the worker is widely used. In particular, a DPS (Digital Picking System) in which a digital display unit is provided at the frontage of a shelf of the article storage unit that stores the merchandise to be picked by the worker, thereby instructing the worker to perform picking work, has been widely used in recent years.

[0004] That is, the digital picking system is a piece picking system that picks up merchandise according to instructions from a digital display mounted on an article storage unit, for example, a merchandise shelf. It can support a wide range of applications from small varieties in large quantities to large varieties in small quantities, enables space-saving and small-staff operations, limits the scope of responsibility of workers, and displays merchandise instructions and quantities, so it has features such as good work efficiency and reduced picking errors.

[0005] Here, for transporting the collection containers, conveyor transportation using a belt conveyor, roller conveyor, slat conveyor or the like is common, but as described in Patent Document 1, a method in which an automated guided vehicle transports the collection containers to the worker instead of the conveyor is also used.

[0006] In other words, the description outlines a technical concept in which a robot (automated guided vehicle) travels to one of several picking zones, and operators waiting in each picking zone place designated items onto the trays (collection containers) of the stopped robot.

[0007] In this case, when an automated guided vehicle (AGV) is used to transport the collected containers, it is undesirable to provide a storage area for items such as a flow rack on the side where the AGV travels (the front of the worker) in order to allow the AGV to travel without restriction. It is preferable to provide the storage area on the opposite side of where the AGV travels (the back of the worker).

[0008] However, this approach presents a problem: because workers are not constantly monitoring the storage area, even with a digital display, it is not easy to find the opening of the shelf to be picked the moment they turn around. This can lead to longer picking times or even picking errors. [Prior art documents] [Patent Documents]

[0009] [Patent Document 1] Japanese Patent Publication No. 2022-050240 [Patent Document 2] Japanese Patent Publication No. 2008-222386 [Overview of the project] [Problems that the invention aims to solve]

[0010] Therefore, in order to solve the above problems, the present invention aims to provide a system that does not hinder the movement of an automated guided vehicle (AGV) when collecting picked items, shortens the time required for picking, and reduces picking errors. [Means for solving the problem]

[0011] In order to solve the above problems, the inventors conducted further research and focused on the pop-out function described below. Specifically, they discovered that the above problems could be solved by combining the pop-out function with the transportation of goods by an automated guided vehicle (AGV).

[0012] In other words, in order to solve the above problems, a first aspect of the present invention is an article picking system, - An item storage section for storing items to be picked, - An automated guided vehicle (AGV) floor on which one or more AGVs that transport collection containers into which the picked items can be placed travel, -A picking floor is provided between the item storage area and the automated guided vehicle floor for performing picking operations. - An information display unit having a pop-out function to display information related to picking or collection by projecting an image from a projector in a predetermined location in the parts storage section and / or in a location associated with the collection container. It is characterized by having the following features.

[0013] Here, the term "automated guided vehicle" includes AGVs guided by guided vehicles and AMRs using unguided driving methods, but it may also refer to other types of vehicles, and may be called unmanned vehicles or unmanned transport vehicles.

[0014] Alternatively, the picked items may be placed into a collection container while it is loaded onto an automated guided vehicle (AGV), or they may be separated from the AGV, transported by a conveyor belt, and then placed into a collection container, which is then re-loaded onto the AGV.

[0015] The item storage area for the items to be picked is preferably a fixed shelf with one or more openings, or an inclined flow rack (flow rack), each storing the same or different items. However, it is not limited to such a structure, and horizontal flow racks or flat storage are also acceptable.

[0016] Furthermore, the designated location in the parts storage section where picking information is displayed is preferably the entrance where the items are stored or in its vicinity, but is not limited to that, and may be any location where picking information can be effectively provided.

[0017] Furthermore, the location associated with the collection container, which displays information related to the collection operation in which picked items are placed into the collection container, can be any location that can indicate the place where the items should be collected, such as the collection container itself, the conveyor (described later) that transports the collection container, or an automated guided vehicle.

[0018] Furthermore, the information display unit using a projector, as described in Patent Document 2, is a projection mapping system that uses a projector instead of a digital display, and has been put into practical use due to its low equipment costs and ease of handling product changes.

[0019] Next, the term "pop-out function" refers to a function known in cognitive psychology, which occurs when, in a situation where multiple cognitive objects exist, one of them possesses different cognitive characteristics from the others, and the object is perceived inevitably, that is, in a way that is beyond the control of human will.

[0020] Specifically, it is preferable to display picking instruction information in a way that has significantly different cognitive characteristics from surrounding objects, such as shelves and objects to be picked.

[0021] Next, a second aspect of the present invention is an article picking system according to the first aspect, characterized in that an article container presentation conveyor is provided on the automated guided vehicle floor and / or the picking floor as a conveying and buffering function for the article containers into which the articles to be picked are placed.

[0022] That is, the collection container is once transferred from the automated guided vehicle to the collection container presentation conveyor, and the collection container into which articles have been loaded on the collection container presentation conveyor is transferred again from the collection container presentation conveyor to the automated guided vehicle for transportation.

[0023] In this case, the collection container presentation conveyor is not limited to staying on the automated guided vehicle floor and may extend to the picking floor, so the above expression is adopted.

[0024] With this configuration, the collection container presentation conveyor can be provided with a temporary storage (buffer) function, making it possible to reduce the number of automated guided vehicles and simplify operations.

[0025] Next, a third aspect of the present invention is the article picking system according to the first aspect, wherein as the pop-out function, the projector may perform blinking or lighting display on a predetermined location of the component storage unit and / or a location associated with the collection container.

[0026] With this configuration, the pop-out function is effectively exerted, and the efficiency of picking or collection work can be improved and errors can be reduced.

[0027] Next, a fourth aspect of the present invention is the article picking system according to the first aspect, wherein as the pop-out function, the projector performs blinking or lighting display on a predetermined location of the component storage unit, and then performs blinking or lighting display on a location associated with the collection container.

[0028] With this configuration, the pop-out function can accurately instruct the work sequence, and prevent the occurrence of errors related to the work sequence. Effects of the Invention

[0029] According to the present invention, a picking system that is quick and error-free can be realized by not installing an item storage unit that would obstruct the movement of the automated guided vehicle (AGV) used for picking on the AGV floor or picking floor, and by having a pop-out function in a designated location in the item storage unit or in a location related to the picking container. [Brief explanation of the drawing]

[0030] [Figure 1] This is a perspective view of an article picking system according to the first embodiment of the present invention. [Figure 2] This is a plan view of an article picking system according to the first embodiment of the present invention. [Figure 3] This is an explanatory diagram of the information display unit of the system according to the first embodiment of the present invention. [Figure 4] This is a flowchart illustrating the operation of the system according to the first embodiment of the present invention.

[0031] The picking system for articles according to the first embodiment of the present invention will be described below with reference to the drawings. In the following, the scope necessary for explaining how to achieve the objectives of the present invention will be schematically shown, and the scope necessary for explaining the relevant parts of the present invention will be mainly explained, with any parts that are omitted from the explanation being based on prior art.

[0032] <Structure> Figure 1 is a perspective view of an article picking system according to the first embodiment of the present invention, and Figure 2 is a plan view of the same system.

[0033] The item picking system 1 includes a roughly rectangular picking floor 10 (dotted shaded area in the figure) where workers P (sometimes called pickers) perform picking work, a flow rack 20 which is an item storage area located outside the picking floor 10, an automated guided vehicle floor 30 located outside the picking floor 10, opposite the flow rack 20, on which an automated guided vehicle 32 can travel, and a system control unit 50 which controls the item picking system 1.

[0034] Furthermore, the automated guided vehicle (AGV) floor 30 may include a portion of the picking floor 10 if the AGV 32 can travel on it.

[0035] In the diagram, the Flow Rack 20 has openings that allow for the storage of four types of items on three shelves, each serving as the responsibility of one worker P. Item storage containers 21 are placed in each opening, and the diagram shows three sets (Flow Racks 20a, 20b, and 20c). However, there are no limitations on the number of shelves or the number of items per shelf, nor on the number of workers; any number of sets is acceptable as long as it is for at least one worker.

[0036] Furthermore, if the quantity of items stored in the item storage containers 21 of the flow rack 20 becomes insufficient after picking, it is possible to replenish them from the rear of the flow rack 20 according to instructions from the system control unit 50.

[0037] The goods storage container 21 may be a designated container such as an Ori-con, or it may be a cardboard box used for packing and transporting the goods.

[0038] A projector 23, supported by a support 22, is provided at the top of the flow rack 20. A short-throw or ultra-short-throw projector 23 is preferable for this system configuration.

[0039] The support 22 may have a movable (manual or with a drive mechanism) connection part so as to adjust the projection direction of the projector 23.

[0040] An information display unit 24 is provided above each item storage container 21 on each shelf of the Flow Rack 20, corresponding to each item storage container 21. This information display unit 24 is a screen capable of displaying image information projected from a projector 23. Structurally, it is preferably made of resin and includes reflective elements of metal or glass, but is not limited to this and can be made of any material. While it is shown as being provided at each opening, it may be continuous across each shelf, and it may be provided at the bottom or side of the item storage container 21 instead of the top.

[0041] Figure 3 is an explanatory diagram of the information display unit of an item picking system according to the first embodiment of the present invention. In this embodiment, a screen directly above the item storage container 21 to be picked is provided as an item information display unit 241 that can display the number, appearance, and name of the items to be picked. An operation unit 242 for inputting the completion of work, etc., is provided near the item information display unit 241 (on the right side in the figure).

[0042] The operating unit 242 may also display a downward arrow or the like to indicate the location of the item.

[0043] This operation unit 242 is a touch panel, and when the picking work is finished, the system control unit 50 can be notified that the work has been completed by touching this part. When the completion of the work is notified, the information display unit 24 will turn off.

[0044] Furthermore, the operating unit 242 is not limited to a touch panel that requires physical contact; it may also use proximity sensors such as capacitive sensors, ultrasonic sensors, or image sensors that can detect when an operator P brings their hand close. All of these sensors have the advantage of being less prone to failure and having a long lifespan because they do not have any mechanically moving parts.

[0045] Furthermore, the control unit 242 may be configured with an image sensor. This eliminates the need for a panel-like design, and allows for the determination of work completion by detecting the worker's hands, etc. This approach offers advantages such as reducing the number of parts, increasing flexibility in installation location, and simplifying construction.

[0046] The automated guided vehicle (AGV) floor 30 has an AGV 32 equipped with a container transport conveyor 31 on top, and a container presentation conveyor 33 for receiving the collected containers 40 that are transported on the container transport conveyor 31 of the AGV 32 and presenting them in front of the worker P.

[0047] While it is preferable for the automated guided vehicle 32 to be an AMR with a non-guided driving system from the standpoint of configuration flexibility, it may also be an AGV guided by a dielectric from the standpoint of cost and ease of control.

[0048] The container collection conveyor 33 is roughly U-shaped and consists of an introduction section 331, a presentation section 332, and a delivery section 333, with the introduction section 331 and the presentation section 332, and the presentation section 332 and the delivery section 333 being perpendicular to each other. Each conveyor is preferably a roller conveyor with a drive unit, and a well-known direction change mechanism can be used for perpendicular direction changes.

[0049] Furthermore, the container display conveyor 33 may be straight or curved rather than roughly U-shaped, and it may not be divided into sections for each worker P, but rather arranged continuously.

[0050] Furthermore, the container presentation conveyor 33 is not limited to a roller conveyor, but may be other types of conveyors such as a belt conveyor.

[0051] Furthermore, the height of the transport surface of the container collection conveyor 33 from the floor is approximately the same as the height of the transport surface of the container transport conveyor 31 above the automated guided vehicle 32 from the floor. This allows the automated guided vehicle 32, with the container collection containers 40 placed on the container transport conveyor 31, to be brought into close contact with or near the end of the introduction section 331 of the container collection conveyor 33, and the container transport conveyor 31 to be driven to transfer the container collection containers 40 to the container collection conveyor 33.

[0052] The collection container 40 is transported from the introduction section 331 to the presentation section 332 of the collection container presentation conveyor 33 and presented in front of worker P. There, the collection container 40 into which worker P has placed the goods is transported to the delivery section 333, and from the end of the delivery section 333 it is transferred onto the container transport conveyor 31 of the automated guided vehicle 32, and then transported to the next process by the automated guided vehicle 32.

[0053] The system control unit 50 controls the system and is preferably a general-purpose server or PC. It is equipped with a CPU, memory unit, input / output unit, display unit, communication interface, etc. It can communicate with each part of the system (flow rack 20 including projector 23 and information display unit 24, product container display conveyor 33, automated guided vehicle 32) and can issue instructions for their operation.

[0054] The system control unit 50 may be included in a WMS (Warehouse Management System) that controls the entire logistics facility, or it may utilize external resources as cloud computing.

[0055] Furthermore, if the aforementioned operation unit 242 is an image sensor, the system control unit 50 may combine the image sensor with AI functions to detect errors in the picking worker's movements, determine the worker's fatigue level from their movements, and, based on the fatigue level, reassign the worker's tasks to another worker. By doing so, the system can function as a high-value-added system, thereby realizing a user-friendly picking system that is even more useful in reducing picking errors and managing the health of workers.

[0056] Furthermore, in the above-described embodiments, the collection container 40 was transferred from the automated guided vehicle 32 to the collection container display conveyor 33 and presented in front of the worker P. However, in an embodiment where the automated guided vehicle 32 carrying the collection container 40 moves itself to the front of the worker P without using the collection container display conveyor 33, the container transport conveyor 32 on top of the automated guided vehicle 32 may not be necessary.

[0057] In the above-described embodiments, the information display unit using a projector was assumed to be located on the item storage unit side. However, it may also be provided on the item collection container side, in addition to or instead of this. (Illustrations are omitted.)

[0058] In other words, information regarding the process of placing items into the collection container is displayed. In this case, the information may be displayed in any location that can indicate the location to be collected, such as the collection container itself, the collection container display conveyor 33 that transports the collection container, or, if no conveyor is used, the automated guided vehicle 32.

[0059] <Operation> Next, the operation of the article picking system according to the first embodiment of the present invention, with this configuration, will be described.

[0060] Figure 4 is a flowchart illustrating the operation of the item picking system according to the first embodiment of the present invention.

[0061] When the picking operation begins, the system control unit 50, Automated Guided Vehicle 32 The system is instructed to transport the collection container 40, which will collect the items to be picked first. (Step S01)

[0062] In this embodiment, a container presentation conveyor 33 is used, and therefore, containers 40 that are to be collected are loaded in advance. Automated Guided Vehicle 32 The containers are then transferred to the collection container display conveyor 33 so that they can be displayed in front of the worker.

[0063] In the case of an embodiment in which items are collected (placed) into the collection container 40 mounted on the automated guided vehicle 32 without using the collection container presentation conveyor 33, the transfer operation is unnecessary.

[0064] Next, with worker P facing the flow rack 20 on the picking floor 10, the system control unit 50 issues a picking instruction with a pop-out function (described in detail later) to the information display unit 24 of the flow rack 20. (Step S02) This allows worker P to easily and accurately recognize the location, type, and quantity of the items to be picked and perform the work.

[0065] When the picking operation is completed, worker P inputs picking completion information from the operation unit 242, the system control unit 50 receives the picking completion signal, and the picking instruction display on the information display unit 24 ends. (Step S03)

[0066] Almost simultaneously, the system control unit 50 instructs the picked items to be placed into a designated collection container 40. (Step S04) Here, the collection container 40 may be designated as the collection container 40 located in the center of the display section 332 of the collection container display conveyor 33 without any special display, or by providing a display on the collection container display conveyor 33 and using that display to give instructions, or by providing a display function on the collection container 40 itself, or any other method of designation is possible.

[0067] Worker P rotates his body within the picking floor 10 to face the item container display conveyor 33 and places the picked items into the designated item container 40.

[0068] Furthermore, information can be displayed using a projector with a pop-out function, similar to the method used for picking, during the item collection process. This will achieve the same effect as during the picking process.

[0069] Regarding the completion of loading items into the collection container 40, it is acceptable to assume that the items have been loaded after a predetermined time has elapsed without specifically notifying the user of completion, or to notify the user of completion by providing an operation unit to notify the user of completion, or by detecting the hand movements of worker P. Furthermore, it is also possible to check whether the items were loaded correctly using an optical sensor or the like.

[0070] Next, the system control unit 50 instructs the automated guided vehicle 32 to transport the collected container 40 after the loading is complete. (Step S05)

[0071] If there are still items to pick, the process returns to the first step and continues. At this point, in order to pick the next item, worker P rotates their body from facing the collection container 40 to facing the flow rack 20.

[0072] In this process, it is extremely important for the system's operation that information regarding picking (picking instructions) can be transmitted quickly and accurately to worker P.

[0073] Here, these information displays are equipped with a visual pop-out function. In other words, by making these information displays have significantly different cognitive characteristics from the surrounding objects, such as the shelves of the flow rack 20, the objects to be picked, or the item storage container 21, the human cognitive characteristics are further inevitably stimulated.

[0074] In the first embodiment of the present invention, as an example of a visual pop-out, only the information display unit 24 of the opening on which the item to be picked is placed is made to flash, while the information display units 24 of the other openings remain off.

[0075] In this way, as worker P finishes placing the previous item into the collection container 40, turns around, and the moment the flow rack 20 comes into view, a pop-out occurs, inevitably allowing them to recognize the information display regarding the item to be picked and receive the displayed information. This enables them to pick the next item to be picked accurately and quickly and place it into the collection container 40.

[0076] The pop-out principle stimulates even the picker's unconscious mind; that is, whether the picker is aware of it or not, they inevitably receive certain information (for example, information about the items to be picked and their quantities; both of these will collectively be referred to as "picking information" below). This minimizes the room for human cognition errors. This is because, as a result of the stimulation and information reception area extending beyond the realm of conscious awareness, it becomes possible to exchange information, such as picking information, in an area where there is no room for cognitive errors, which are the source of errors.

[0077] Let me elaborate on this point. Pickers don't make mistakes on purpose. It's understandable that they would try to avoid picking errors as much as possible because it directly impacts their own work performance. However, as is the limitation of being human, even the most accurate worker can make mistakes if they are unwell, for example. Also, even healthy people are more likely to make mistakes due to fatigue if they perform the same / similar task continuously for a long period of time. The same can be said for those who have accumulated fatigue. All of these stem from errors in perception that are inherent to being human. In other words, if a person picks "3 units of item A" and then picks "4 units of item B," and is now fatigued, and receives picking information to "pick up 2 units of item A," it is thought that the information they visually see is "item A" and "2 units," but this confusion occurs (in the picker's brain) with the information they had visually seen as picking information a little while earlier and immediately converted into action information to trigger the picking action, namely "item A" and "3 units." If fatigue levels are not high, such malfunctions are corrected internally before they manifest. However, if fatigue levels are high or the user is in an unhealthy state, these internal corrections are not made, and the aforementioned misrecognition manifests as incorrect picking behavior.

[0078] In contrast, this invention aims to prevent the aforementioned misperception by stimulating areas outside of human conscious perception through a situation that triggers an unavoidable perception called "pop-out." Here, "pop-out" is defined as the phenomenon in which, when searching for a target stimulus that is uniquely different from a group of distracting stimuli, the target stimulus can be perceived instantaneously without exploring all of the stimuli.

[0079] To create a pop-out effect, instead of simply displaying the element, you should include it with elements like the following: • Turn off all information other than the information you want to highlight (referred to as "surrounding information") and only flash (or light up) the target information. (As shown in the diagram) Alternatively, light up the surrounding information and flash the target information. • Display surrounding information in black and target information in red. • Display surrounding information using normal points and target information using, for example, 1.5 times the normal points.

[0080] In this way, by providing a pop-out storage unit (flow rack) and an automated guided vehicle (AGV) for transporting collected containers on both sides of the worker's picking floor, the picking operation of items is ensured to be carried out reliably by the pop-out function, while the freedom of movement of the AGV is ensured, resulting in extremely high flexibility in system configuration and operational efficiency.

[0081] In the explanation above, the system of this application has been described as a picking system that collects the required number of items from multiple types of items on an order basis. However, it may also be used as an allocation system that sorts the required number of items according to order.

[0082] In other words, the system has an item supply unit that supplies items from an automated guided vehicle, located outside the picking floor of worker P, and an item variety sowing unit (allocation unit) with a pop-out function, located on the opposite side of the item supply unit, also outside the picking floor of worker P.

[0083] The supply of goods by an automated guided vehicle may involve a conveyor, as in the first embodiment of the present invention, or the automated guided vehicle may directly present the goods to the worker.

[0084] The variety sowing unit with a pop-out function comprises a container placed on a grid-like shelf and a projector located near the container. Information regarding the opening to which the material should be inserted is displayed on the projector in a pop-out state, corresponding to each opening on the grid-like shelf.

[0085] In this way, by providing an information display unit with a pop-out function on the variety-specific planting section opposite to the supply side of the goods, the machine can correctly recognize the input opening the moment it holds the supplied goods and turns towards the variety-specific planting section, enabling a fast and error-free variety-specific planting system.

[0086] In other words, by placing the goods supply unit using automated guided vehicles and the goods sowing unit with a pop-out function on both sides outside the worker's picking floor, the freedom of movement of the automated guided vehicles is ensured, and the goods sowing work is reliably performed by the pop-out function, resulting in extremely high flexibility in system configuration and operational efficiency.

[0087] Furthermore, while the pop-out function has been described as visual in previous explanations, it is also acceptable for the function to appropriately stimulate the five senses, such as hearing (sound) or vibration, to produce a pop-out effect, in addition to or instead of visual. [Industrial applicability]

[0088] The item picking system of the present invention can be widely used in the logistics industry, and is superior in terms of convenience and accuracy, making it a highly applicable invention for industrial use. [Explanation of Symbols]

[0089] 1. Item picking system 10 Picking Floor 20(a, b, c) Flowlac 21 Goods storage containers 22 Supports 23 Projectors 24 Information display section 30 Automated Guided Vehicle Floor 31 Belt conveyor 32 Automated Guided Vehicles 33. Container display conveyor for collected items 40 Collection container 50 System Control Unit P Worker (Picker)

Claims

1. - The item storage section where items to be picked are stored, - An automated guided vehicle (AGV) floor on which one or more AGVs that transport collection containers into which the picked items can be placed travel, - A picking floor is provided between the item storage area and the automated guided vehicle floor for performing picking operations, - An information display unit having a pop-out function to display information related to picking or collecting by projecting images from a projector in a designated location in the article storage section and / or in a location associated with the collection container. It has, The aforementioned item storage section and the aforementioned automated guided vehicle floor are located on opposite sides of the picking floor, The information display unit displays the location where the item to be picked is stored as having different cognitive characteristics from the surrounding objects, namely the shelves and / or the item to be picked. A picking system for goods characterized by the following features.

2. The article picking system according to claim 1, characterized in that an article picking system is provided on the automated guided vehicle floor and / or the picking floor as a conveying and buffering system for the article collection containers into which the articles to be picked are placed.

3. The item picking system according to claim 1, characterized in that, as the pop-out function, the projector flashes or lights up to indicate a predetermined location in the item storage section and / or a location associated with the item collection container.

4. The item picking system according to claim 1, characterized in that, as the pop-out function, the projector flashes or lights up to indicate a predetermined location in the item storage section, and then flashes or lights up to indicate a location associated with the item collection container.

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