Warehouse system

Abstract

In a warehouse system (2), a rack (20) is formed by connecting a plurality of rack units (22) to each other, each of the plurality of rack units (22) defining a space in which a pallet (24) for placing an article (23) is disposed. The plurality of rack units (22) form a plurality of floors (21), each of which defines a surface (24) on which a transport robot (25) that transports the pallets (24) between the plurality of rack units (22) can move.

Description

Warehouse System

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

[0002] For example, Patent Document 1 discloses a warehouse. In this warehouse, storage shelves are arranged on which trays on which items are stored are arranged. The storage shelves have a configuration with multiple levels of shelf boards. The multiple shelf boards are supported by, for example, multiple vertical members arranged at predetermined intervals. Since the vertical members have, for example, the same length as the height of the storage shelves, it is not easy to construct the storage shelves.

[0003] International Publication No. 2018 / 189110

[0004] An object of the present invention is to provide a warehouse system in which racks can be easily constructed.

[0005] A warehouse system according to one aspect of the present invention is a warehouse system in which a plurality of rack units, each defining a space for placing pallets for loading items, are connected to each other to form a rack, and the plurality of rack units form a plurality of floors, each defining a surface on which a transport robot for transporting the pallets can move between the plurality of rack units.

[0006] The rack units can be connected to one another horizontally and / or vertically.

[0007] Two horizontally adjacent rack units are directly connected to each other or connected by a connecting member.

[0008] Each of the rack units has support legs that lift and support the pallet off the surface.

[0009] The support legs are configured to be removable.

[0010] The robot lifts the pallet from below and transports the pallet.

[0011] The pallets can be loaded into each of the rack units from the outer circumferential surface of the rack, or can be removed from each of the rack units from the outer circumferential surface of the rack.

[0012] The system further includes a forklift for loading or unloading the pallet.

[0013] The forklift recognizes the rack unit using pose estimation.

[0014] The system further includes a transport mechanism that transports the pallets between the plurality of floors.

[0015] The system is communicatively connected to another warehouse system that picks the items.

[0016] 1 is a perspective view schematically showing an automated warehouse system 1 used in conjunction with the warehouse system of the present invention. FIG. 2 is a perspective view schematically showing the structure of a warehouse system 2 according to an embodiment of the present invention. FIG. 3 is a perspective view schematically showing the structure of a rack unit 22 according to a specific example. FIG. 4 is a front view schematically showing the structure of a rack unit 22 according to a specific example. FIG. 5 is a perspective view schematically showing a state in which a pallet 24 is arranged in a rack unit 22 according to a specific example. FIG. 6 is a perspective view schematically showing a state in which a transport robot 25 is arranged in a rack unit 22 according to a specific example. FIG. 7 is an enlarged view of a portion of a rack 20 schematically showing the structure of the rack 20. FIG. 8 is a perspective view schematically showing the structure of a connecting member 50 according to a specific example. FIG. 9 is an enlarged view of a portion of a rack 20A schematically showing the structure of a rack 20A according to a modified example. FIG. 10 is an enlarged view of a portion of a rack 20B schematically showing the structure of a rack 20B according to another modified example. FIG. 11 is a diagram for explaining the processing of a 3D calculation step. FIG. 12 is a diagram for explaining the processing of a 3D calculation step. FIG. 13 is a diagram for explaining the processing of a 3D calculation step. 1A and 1B are enlarged perspective views schematically showing a support leg 36 according to one modified example, an enlarged perspective view schematically showing a support leg 36A according to another modified example, and an enlarged perspective view schematically showing a support leg 36B according to yet another modified example.

[0017] An embodiment of the present invention will be described below with reference to the accompanying drawings. FIG. 1 is a perspective view schematically illustrating an automated warehouse system 1 used in conjunction with a warehouse system of the present invention, which will be described later. The automated warehouse system 1 is an automated warehouse system that can automate a series of operations, from receiving goods, including merchandise, to storing and retrieving them, under centralized management. The automated warehouse system 1 is constructed, for example, on the floor of a building (not shown). The automated warehouse system 1 defines x-axis and y-axis directions that extend horizontally and are perpendicular to each other, and z-axis directions that extend vertically and are perpendicular to the x-axis and y-axis directions. The z-axis direction is the height direction.

[0018] The automated warehouse system 1 includes, for example, a rack 10 arranged on a floor surface. The rack 10 includes a plurality of floors 11 and a plurality of support columns 12 that respectively support each of the plurality of floors 11. The plurality of floors 11 are configured by stacking floors 11 in the z-axis direction, each floor 11 defining a surface along the x-y plane. Each floor 11 is formed from a plurality of floor panels 13 arranged adjacent to each other in the x-axis direction and the y-axis direction. The floor panels 13 are formed, for example, from a resin material. The surfaces of the plurality of floor panels 13 adjacent to each other in the x-axis direction and the y-axis direction are defined to be flush with each other. The flat surface of each floor 11 is defined by the plurality of floor panels 13.

[0019] The rack 10 includes one or more transport elevators 14 that occupy one section of the floor 11. The transport elevator 14 can move between each floor 11 in the z-axis direction. The transport elevator 14 includes one floor panel 13 and a drive mechanism (not shown) arranged under the floor panel 13. The drive mechanism causes the floor panel 13 to rise and fall in the z-axis direction along elevator shafts at the four corners. The transport elevator 14 may be arranged, for example, in an inner section of the rack 10, or multiple transport elevators 14 may be arranged in the rack 10. Also, a transport elevator 14 that moves between only some of the floors 11 may be arranged.

[0020] One or more storage bins 15 for storing items are arranged on the floor 11 of the rack 10. One or more types of items are stored in the storage space of the storage bin 15. The type of item is identified, for example, by a unique stock keeping unit (SKU) assigned to the item. Furthermore, the storage bins 15 are identified by a unique ID assigned to each storage bin 15. For each storage bin 15, the unique ID is managed in association with the SKU of the item. One storage bin 15 occupies one floor panel 13, i.e., one compartment. The outline of the storage bin 15 in a plan view is similarly arranged inside the outline of the floor panel 13 in a plan view.

[0021] The automated warehouse system 1 includes one or more transport robots 16 for transporting storage bins 15. Each transport robot 16 has an outline smaller than the outline of one floor panel 13 in a plan view. The transport robot 16 is an autonomous transport robot that can autonomously travel within the rack 10 by determining its own position on a map of the rack 10. The transport robot 16 has, for example, a flat cubic shape. The top surface of the transport robot 16 is, for example, defined as flat. The transport robot 16 can lift the storage bin 15 from the surface of the floor 11 with its top surface and travel on the floor panel 13. The transport robot 16 can ride on the transport elevator 14.

[0022] The automated warehouse system 1 includes one or more picking stations 17 for sorting items stored in storage bins 15. The picking stations 17 are integrally formed on the floor 11. A transport robot 16 transports storage bins 15 arranged on the floor 11 of the rack 10 to the picking stations 17. At the picking stations 17, an operator OP picks desired items from the storage bins 15 into shipping bins 15 for storing items for shipping. The shipping bins 15 have the same configuration as the storage bins 15. The picking stations 17 include a workspace where the operator OP performs picking. The picking stations 17 define a surface that is continuous with the surface of the second floor 11, for example.

[0023] The automated warehouse system 1 includes a management server (control system, not shown) that manages the operation and status of the storage bins 15, shipping bins 15, transport robots 16, and picking stations 17 in relation to the receiving, storage, and retrieval of the automated warehouse system 1. This management is achieved by the control unit executing a program stored in a memory unit. Specifically, these processes are executed in accordance with the information processing described in the program. The management server may be implemented as a physical server installed, for example, in a building or in a rack 10, or may be implemented as a cloud server, for example. This management server can communicate with the warehouse system according to the present invention, which will be described later. In other words, the management server can also manage the operation and status of the warehouse system according to the present invention.

[0024] FIG. 2 is a perspective view schematically illustrating the structure of a warehouse system 2 according to one embodiment of the present invention. The warehouse system 2 is a storage shelf for storing items picked by the automated warehouse system 1 described above. Specifically, the warehouse system 2 is a storage shelf for storing a large number of identical or different items together in cardboard boxes or on pallets. The warehouse system 2 is constructed, for example, on the floor of the same building in which the automated warehouse system 1 is constructed. The warehouse system 2 includes, for example, racks 20 arranged on the floor. The racks 20 include multiple floors 21 that define a surface along the xy plane. In this example, the racks 20 include four floors 21. The racks 20 are constructed of multiple rack units 22 connected to each other in the x-axis, y-axis, and z-axis directions. In this example, the warehouse system 2 is formed into a rectangular shape when viewed in a plan view in the z-axis direction, but may be formed into other shapes, such as an L-shape, a U-shape, or an H-shape.

[0025] Each rack unit 22 defines a space for placing a pallet 24 on which an item 23 is placed. In this embodiment, on each floor 21, a first row 22A to a seventh row 22G of rack units 22 extending in the x-axis direction are arranged in the y-axis direction. In this example, the spaces for placing the pallets 24 are formed in the first row 22A, the third row 22C, the fourth row 22D, the sixth row 22F, and the seventh row 22G. As is clear from FIG. 2 , all four sides of the rack 20 are open so that the pallets 24 can be accessed from any of the outer periphery, i.e., any of the four sides of the rack 20. In this example, a forklift (not shown) can load a pallet 24 into the rack 20 from any of the four sides of the rack 20 or remove a pallet 24 from the rack 20 from any of the four sides of the rack 20.

[0026] On the other hand, the second row 22B and the fifth row 22E are defined as paths along which one or more transport robots 25 transporting pallets 24 move. The transport robot 25 is an autonomous transport robot that can autonomously navigate within the rack 20 by determining its own position on a map of the rack 20. In this example, the transport robot 25 can only move on the floor 21 on which it is located. The transport robot 25 can transport a pallet 24 loaded into the rack 20 by, for example, a forklift, to a rack unit 22 at a predetermined position within the rack 20 via the second row 22B or the fifth row 22E. Similarly, a pallet 24 stored in a predetermined position can be transported to a desired position along the side of the rack 20 for retrieval by a forklift. The rows forming the arrangement space for the pallets 24 may be changed as long as the movement of the transport robot 25 is ensured.

[0027] FIG. 3 is a perspective view schematically illustrating the structure of a rack unit 22 according to one specific example. FIG. 4 is a front view schematically illustrating the structure of a rack unit 22 according to one specific example. As shown in FIGS. 3 and 4 , the rack unit 22 includes a base 31 that is rectangular in plan view and a frame 32 that is connected to the base 31 and defines, for example, a rectangular parallelepiped space. The base 31 includes, for example, four frame members 33A to 33D that are rectangular in plan view. The frame members 33 are formed, for example, in the shape of a prism. The frame member 33A is disposed on the front side of the rack unit 22, the frame members 33B and 33C are disposed on the side sides, and the frame member 33D is disposed on the rear side. The frame members 33A and 33D extend parallel to each other along the x-axis direction, while the frame members 33B and 33C extend parallel to each other along the y-axis direction.

[0028] The base 31 includes a panel 35 attached to the frame members 33A to 33D and defining a flat surface 34 extending along the x-y plane. In this example, the panel 35 is disposed, for example, inside the panels 33A to 33D. The base 31 further includes, for example, four support legs 36 extending upright from the surface 34. Each support leg 36 is formed, for example, in a cylindrical shape. Each support leg 36 extends through the panel 35 from a reinforcing member (not shown) disposed, for example, on the rear side of the panel 35 and connected to the frame members 33A to 33D. The support legs 36 are disposed adjacent to the four corners of the rectangular base 31 in a plan view. The heights of the support legs 36 from the surface 34 are set equal. The support legs 36 are configured to lift and support the pallet 24 from the surface 34, as described below. Therefore, the arrangement of the support legs 36 may be determined according to the size of the pallet 24.

[0029] A pair of lines 34a extending in the x-axis direction and a pair of lines 34a extending in the y-axis direction of the panel 35 are drawn on the surface 34 of the panel 35 of each rack unit 22. In this example, the two pairs of lines 34a are perpendicular to each other. The lines 34a extend to the frame members 33A to 33D. On each floor 21, a plurality of rack units 22 are arranged adjacent to each other in the x-axis and y-axis directions, and the lines 34a define a pair of x-axis lines extending in the x-axis direction and a pair of y-axis lines extending in the y-axis direction. The x-axis lines and y-axis lines extend from edge to edge of the rack 20. The lines 34a are colored white, for example. Using the line tracing function, the transport robot 25 can travel on the surface of each floor 21 along the x-axis lines and y-axis lines extending from one end of each floor 21 to the other.

[0030] The base 31 further includes a pair of supported members 37, 37 attached to the lower sides of the frame members 33B and 33C in the z-axis direction. The pair of supported members 37, 37 extend parallel to each other in the y-axis direction. In this example, the supported member 37 extends from the front end to the rear end of the base 31. The supported member 37 is also disposed along the bottom surface of the rack unit 22, as shown in FIG. 4. In the front view shown in FIG. 4, the supported member 37 has a triangular recessed groove 38 defined on its upper side in the z-axis direction. That is, the groove 38 opens downward from the bottom surface of the rack unit 22. The frame members 33A to 33D, the support legs 36, and the supported member 37 are formed, for example, from a metal material. The frame members 33A to 33D, the support legs 36, and the supported member 37 are joined to each other, for example, by welding.

[0031] The frame 32 has four pillars 39A to 39D rising from the four corners of the base 31 in the z-axis direction. The pillars 39A and 39B are located on the front side of the rack unit 22, while the pillars 39C and 39D are located on the rear side of the rack unit 22. As is clear from FIG. 4 , in this example, the pillars 39A and 39B are located adjacent to the outer side of the frame members 33B and 33C in the x-axis direction. On the other hand, as shown in FIGS. 3 and 4 , the pillars 39C and 39D are located adjacent to the inner side of the frame members 33B and 33C in the x-axis direction. The frame 32 has a connecting member 40 that connects the upper ends of the pillars 39C and 39D to each other. The connecting member 40 extends parallel to the frame member 33D in the y-axis direction. The pillars 39A to 38D and the connecting member 40 are formed, for example, in a rectangular column shape.

[0032] The frame 32 further includes a pair of support members 41, 41 that connect the upper ends of the support columns 39A and 39B to the upper ends of the connecting member 40. The pair of support members 41, 41 extend parallel to each other in the y-axis direction. As shown in FIG. 4 , the positions of the support members 41, 41 correspond to the positions of the supported members 37, 37, respectively, in the x-axis direction. Furthermore, in the front view shown in FIG. 4 , the support member 41 defines a triangular convex support surface 42 on its upper side in the z-axis direction. In this example, the length of the support member 41 in the y-axis direction corresponds to the length of the supported member 37 in the y-axis direction. Note that in this example, the upper ends of the support columns 39A and 39B are not connected to each other. The support columns 39A to 39D, the connecting member 40, and the support member 41 are formed, for example, from a metal material. The support columns 39A to 39D, the connecting member 40, and the support member 41 are joined to each other, for example, by welding.

[0033] In this example, the supported member 37 and the supporting member 41 have the same shape. Specifically, the supported member 37 and the supporting member 41 are elongated members having an L-shaped cross section perpendicular to the longitudinal direction. With this configuration, the supported member 37 can be stacked on the supporting member 41. That is, the groove 38 of the supported member 37 is supported by the support surface 42 of the supporting member 41. As will be described later, the support surfaces 42, 42 of the supporting members 41, 41 of one rack unit 22 receive the grooves 38, 38 of the supported members 37, 37 of another rack unit 22, allowing multiple rack units 22 to be stacked in the z-axis direction. For example, in the example shown in FIG. 2, four rack units 22 are stacked in the z-axis direction.

[0034] FIG. 5 is a perspective view schematically illustrating a state in which a pallet 24 is arranged in a rack unit 22 according to one specific example. As shown in FIG. 5 , in each rack unit 22, a space, for example, a rectangular parallelepiped, is formed within the frame 32. A pallet 24 carrying an item 23 is accommodated in this space. The pallet 24 is supported at its bottom by four support legs 36 in a state in which it is elevated above the surface 34 of the base 31. In plan view, the pallet 24 is shaped like, for example, a rectangular flat plate. A pair of insertion openings 24a for inserting forks of a forklift are formed on each of the four side surfaces of the pallet 24. The pallet 24 is made of, for example, wood, resin, or metal. The pallet 24 has a shape and size that conform to predetermined standards currently in circulation on the market.

[0035] An item 23 is placed on the pallet 24. In this example, the item 23 is placed on the pallet 24, for example, in a state where it is contained in multiple cardboard boxes. Although not shown, the cardboard boxes are secured to the pallet 24 by, for example, wrapping bands or film material around them to prevent them from falling off the pallet 24. A transport robot 25, which will be described later, can enter the space below the pallet 24 between a pair of adjacent support legs 36, 36 and lift the pallet 24 upward from the support legs 36. The transport robot 25 can transport the pallet 24 in a lifted state. During transport by this transport robot 25, the maximum height of the item 23 in the z-axis direction from the surface 34 of the base 31 is a height at which the connecting member 40 and the support member 41 do not interfere with the transport robot 25's transport of the item 23 and the pallet 24 to the adjacent rack unit 22.

[0036] FIG. 6 is a perspective view schematically illustrating a transport robot 25 disposed within a rack unit 22 according to one specific example. The transport robot 25 has, for example, multiple drive wheels 25a. The drive wheels 25a are, for example, Mecanum wheels, allowing the transport robot 25 to move in the x-axis and y-axis directions without changing its orientation. As described above, the transport robot 25 can move on the surface of the floor 21, for example, by using a line tracing function. The transport robot 25 has, for example, a flat cubic shape. The top surface of the transport robot 25 is, for example, flat. The height of the top surface of the transport robot 25 in the z-axis direction is set to be smaller than the height of the support legs 36. The lengths of each side of the transport robot 25 in the x-axis and y-axis directions are set to be smaller than the distance between a pair of adjacent support legs 36. In other words, the transport robot 25 can enter the space below the pallet 24. Therefore, the transport robot 25 can move on the surface 34 of all rack units 22, regardless of whether a pallet 24 is present or not.

[0037] The transport robot 25 can change its height between a first position, in which the height of its upper surface is set to a first height, and a second position, in which the height of its upper surface is set to a second height higher than the first height. The transport robot 25 in the first position can enter the space below the pallet 24. In the space below, the transport robot 25 changes its height from the first position to the second position, so that the transport robot 25 holds the bottom surface of the pallet 24 with its upper surface. As a result, the pallet 24 is lifted from the support legs 36. In both the first position and the second position, the transport robot 25 can travel on the surface 34 of the panel 35 of each rack unit 22, i.e., the floor 21.

[0038] FIG. 7 is an enlarged view of a portion of the rack 20, illustrating the schematic structure of the rack 20. In the example illustrated in FIG. 7 , the rack 20 has a stacked structure in which two rack units 22 are stacked in the z-axis direction, and three rack units 22 are arranged in each of the x-axis and y-axis directions. In this example, the supported member 37 of the upper rack unit 22 is supported by the support members 41, 41 of the lower rack unit 22. As described above, in each rack unit 22, the support columns 39A and 39B are positioned further outward in the x-axis direction than the frame members 33B and 33C. Therefore, when the support column 39A of one rack unit 22 and the support column 39B of the other rack unit 22 arranged in the x-axis direction are positioned in contact with each other, a gap is formed between the frame member 33C of one rack unit 22 and the frame member 33B of the other rack unit 22.

[0039] In this example, in each row of rack units 22 arranged in the x-axis direction, a connecting member 50 is placed in the gap between rack units 22, 22 adjacent to each other in the x-axis direction on each floor 21. In this way, the rack units 22, 22 adjacent to each other in the x-axis direction are connected by the connecting member 50. Similarly, in each row of rack units 22 arranged in the y-axis direction, a connecting member 50 is placed in the gap between rack units 22, 22 adjacent to each other in the x-axis direction on each floor 21. In this way, the rack units 22, 22 adjacent to each other in the y-axis direction are connected by the connecting member 50. As a result, a rack 20 is constructed by connecting a plurality of rack units 22 in the x-axis, y-axis, and z-axis directions.

[0040] FIG. 8 is a perspective view schematically illustrating the structure of a connecting member 50 according to one specific example. The connecting member 50 has a flat, rectangular pillar-shaped main body 51 extending longitudinally in, for example, a first direction FD. The connecting member 50 further has a pair of first locking members 52, 52 and a pair of second locking members 53, 53 protruding in opposite directions from the main body 51 along a second direction D2 perpendicular to the first direction D1. The first locking members 52 and the second locking members 53 all have the same shape. Specifically, the locking members 52, 53 extend along the top surface of the main body 51 in the second direction D2 and then extend parallel to the side surfaces of the main body 51. The main body 51, the first locking members 52, and the second locking members 53 are formed, for example, from a metal material. The first locking members 52 and the second locking members 53 are joined to the main body 51 by welding, for example. The main body 51 is also formed with the aforementioned line 34a extending in the second direction D2.

[0041] 6 to 8 , adjacent rack units 22, 22 in the x-axis direction are connected by a connecting member 50. Specifically, when the main body 51 of the connecting member 50 is placed in the gap between the frame member 33C of one rack unit 22 and the frame member 33B of the other rack unit 22 between the adjacent rack units 22, 22, the first locking members 52, 52 of the connecting member 50 are locked to the frame member 33C of the one rack unit 22. At the same time, the second locking members 53, 53 of the connecting member 50 are locked to the frame member 33B of the other rack unit 22. At this time, it is preferable that the upper surface of the main body 51 of the connecting member 50 is positioned flush or nearly flush with the surface 34 of the base 31 of the rack unit 22. In this manner, the connecting member 50 can form part of the movement path of the transport robot 25.

[0042] Similarly, adjacent rack units 22, 22 in the y-axis direction are connected by a connecting member 50. Specifically, when the main body 51 of the connecting member 50 is placed in the gap between the frame member 33D of one rack unit 22 and the frame member 33A of the other rack unit 22 between adjacent rack units 22, 22, the first locking members 52, 52 of the connecting member 50 are locked to the frame member 33D of the one rack unit 22. At the same time, the second locking members 53, 53 of the connecting member 50 are locked to the frame member 33A of the other rack unit 22. At this time, it is preferable that the upper surface of the main body 51 of the connecting member 50 is positioned flush or nearly flush with the surface 34 of the base 31 of the rack unit 22. In this way, the connecting member 50 can form part of the movement path of the transport robot 25.

[0043] Next, loading a pallet 24 onto a rack 20 or removing a pallet 24 from a rack 20 will be described. For example, a forklift configured to be able to move on the floor of a warehouse uses a sensor to scan from the top to the bottom of each rack unit 22 arranged on the side of the rack 20 to identify a rack unit 22 that does not house a pallet 24. The forklift then loads the pallet 24 to be loaded into the space within the identified rack unit 22 from the front, side, or back of the rack unit 22. Similarly, the forklift uses a sensor to remove the pallet 24 from the side of the rack unit 22 that houses the pallet 24 to be removed. Note that in the rack 20, for example, a pallet 24 carrying an item 23 with a high turnover rate may be stored in a rack unit 22 on a lower floor of the rack 20 for easier removal.

[0044] In the warehouse system 2 described above, the rack 20 can be easily constructed by interconnecting multiple rack units 22, each of which defines a space for arranging a pallet 24 on which items 23 are placed. In the automated warehouse system 1, the storage bins 15 store items, which are the smallest units. This allows items to be easily picked for shipping. Meanwhile, in the warehouse system 2, the items 23 are stored together in, for example, cardboard boxes, allowing for extremely high storage densities. Furthermore, by using, for example, commonly available pallets based on predetermined standards for the pallets 24, the warehouse system 2 can be easily introduced into existing warehouses. Note that inventory management of the items 23 in the warehouse system 2 and transportation by the transport robot 25 may be managed by a management server of the automated warehouse system 1 via communication with the automated warehouse system 1.

[0045] In the warehouse system 2, the racks 20 may be equipped with a transport mechanism for moving the pallets 24 between the multiple floors 21. The transport mechanism may include a transport elevator, a transport shuttle, or the like. For example, the transport elevator may be disposed at the front or rear of the warehouse system 2. This transport elevator may be capable of moving, for example, a transport robot 25 transporting the items 23 between the floors 21. Furthermore, instead of the transport elevator or the transport shuttle, for example, a hydraulic scissor lift may be used. For example, the scissor lift may be incorporated into the racks 20, or a movable scissor lift may be disposed outside the racks 20. Furthermore, for example, in rack units 22, 22 stacked in the z-axis direction, the supported members 37 and the supporting members 41 may be connected to each other by welding or the like. Furthermore, the connecting member 50 may be connected to the rack unit 22 by welding or the like. Note that the pallets 24 to be loaded into the warehouse system 2 or the pallets 24 removed from the warehouse system 2 may be placed in a temporary storage space formed on the floor surface surrounding the warehouse system 2 and the automated warehouse system 1. In this temporary storage space, individual items may be removed from cardboard boxes or the like for storage in the automated warehouse system 1, for example.

[0046] FIG. 9 is an enlarged view of a portion of a rack 20A, schematically illustrating the structure of a rack 20A according to a modified example. In this rack 20A, the aforementioned connecting member 50 is omitted. Since the structure of the rack units 22 is the same, a redundant description will be omitted. In this example, in the rack units 22 arranged in the x-axis direction, the support column 39B of one rack unit 22 may be connected to the support column 39A of the other rack unit 22 by, for example, welding. On the other hand, in the rack units 22 arranged in the y-axis direction, the frame member 33D of one rack unit 22 may be connected to the frame member 33A of the other rack unit 22 by, for example, welding. In this case, no gap is formed between adjacent rack units 22 in the y-axis direction. Note that an intervening member (not shown) may be placed in the gap formed between the rack units 22 arranged in the x-axis direction to allow movement of the transport robot 25.

[0047] FIG. 10 is an enlarged view of a portion of a rack 20B according to another modified example, illustrating the structure thereof. In this rack 20B, plate-shaped connecting members 50A may be arranged in a row in the y-axis direction instead of the rack units 22. The connecting members 50A have a base 31A having a configuration similar to the base 31 of the rack unit 22. The base 31A includes the frame members 33A-33D, panel 35, and support legs 36, while the supported member 37 is omitted. Furthermore, the first locking members 52, 52 are attached to the frame member 33B, while the second locking members 53, 53 are attached to the frame member 33C. The first locking member 52 is locked to the frame member 33C of the adjacent rack unit 22, while the second locking member 53 is locked to the frame member 33B of the adjacent rack unit 22.

[0048] Next, we will explain how a forklift truck loading or unloading a pallet 24 onto or from a rack 20 recognizes the rack unit 22. For example, pose estimation software is used for recognition. This pose estimation is achieved by, for example, software stored in a memory unit built into the forklift truck being executed by a control unit. For pose estimation, this software outputs a list of 3D rectangular parallelepiped poses from an input 3D point cloud. Specifically, candidates for the rack unit 22 are detected using slices of the point cloud in 2D space, and then the 3D poses for these candidates for the rack unit 22 are calculated. The pose estimation process is separated into a) point cloud preprocessing step and b) rack unit 22 and 3D pose detection step. Step b) is performed within a specific height range (e.g., 0.15 m) within the height range from the lower end (0.30 m) to the upper end (0.70 m) of the detection height range.

[0049] In step a), the input 3D point cloud is filtered. As will be described later, the filtered 3D point cloud is P ３ＤThe filtering is expressed as follows. Five filters are used for filtering. Specifically, the five filters are a shadow point filter, an intensity filter, a crop box filter, a voxel downsampling, and a radius-based outlier filter. As a result of such filtering, a sparse and denoised point cloud is created. For example, the shadow point filter removes points that streak from the vertical boundaries of an object. The intensity filter removes points with low intensity. The crop box filter removes points outside a specified XY range. The voxel downsampling merges points that belong to the same voxel. The radius-based outlier filter removes points that have no other points nearby. The filtered 3D point cloud P ３Ｄ Based on this, a sliced ​​3D point cloud (P ｒａｄｉａｌ ) is output. This sliced ​​3D point cloud (P ｒａｄｉａｌ ) has only the closest point in each radial direction.

[0050] Step b) is the main step of pose estimation. In step b), first, a 3D point cloud (P ｒａｄｉａｌ ), candidate pairs of points for the left and right support columns on the front side of the rack unit 22 are picked up. All pairs are checked and verified. The array of candidate points for the left support column (P ＬＦ ) and the array of candidate points for the right support (P ＲＦ ) are sorted from smallest to largest distance from the forklift to the rack unit 22. This distance is the 2D (xy) distance of the midpoint from the forklift. The array of candidate points for the left support column (P ＬＦ ) and the array of candidate points for the right support (P ＲＦ ) is between the minimum and maximum width of the rack unit 22. Then, the array of candidate points for the left support column (P ＬＦ ) and the array of candidate points for the right support (P ＲＦ ) and the minimum size 2D rectangle (R ｍｉｎ ) is calculated to calculate the 2D edge points. Then, the minimum size 2D rectangle (R ｍｉｎ) is input into a 2D verification process to detect whether the area is a valid rack unit 22 area.

[0051] In the 3D calculation step, the edge of the rack unit 22 is calculated by expanding the area from 2D to 3D. Figures 11A to 11G are diagrams for explaining the processing of the 3D calculation step. In Figure 11A, the obtained minimum size 2D rectangle R ｍｉｎ is the filtered 3D point cloud P ３Ｄ The 3D point cloud P ３Ｄ The top and bottom points in the z-axis direction are found in the 2D rectangle R. These top and bottom points are set to the maximum and minimum heights of the 3D box of the rack unit 22. ｍｉｎ is the 3D point cloud P ３Ｄ (FIG. 11B). Then, the 2D rectangle R is expanded in the z-axis direction by the predetermined parameters. ｍｉｎ is then reduced (FIG. 11C). ３Ｄ The maximum / minimum points of the 2D rectangle R are found. ｍｉｎ is the 3D point cloud P ３Ｄ The 3D box is then expanded in the x-axis and y-axis directions to the maximum / minimum points of the 3D box (FIG. 11D).The 3D box is then reduced in the x-axis and y-axis directions by predetermined parameters (FIG. 11E).

[0052] The 3D box is then reconstructed into the 3D point cloud P ３Ｄ (FIG. 11F). Similarly, the 3D box is again expanded in the z-axis direction to the top / bottom points of the 3D point cloud P ３Ｄ 11G). In this way, the final 3D box V of the rack unit 22 is ３Ｄ Then, the final 3D box V ３Ｄ Specifically, the 3D box V ３Ｄ is between the maximum and minimum heights of the rack unit 22, or the 3D box V ３Ｄ has two struts on either side (optional), or a 3D box V ３Ｄhas a frame member on the top (optional), and the 3D box V ３Ｄ If these checks fail, the final 3D box V ３Ｄ is a "fake" rack unit. Thus, rack unit 22 is recognized.

[0053] FIG. 12 is an enlarged perspective view schematically illustrating a support leg 36 according to a modified example. In this modified example, a support plate 36a may be attached to the upper end of the support leg 36. In this example, the support plate 36a is formed from a flat plate extending parallel to the surface 34 of the panel 35. The support plate 36a is formed, for example, rectangular in plan view. In this example, the support plate 36a, made of, for example, a metal material, is attached to the upper end of the support leg 36 by, for example, welding. The support plate 36a formed from a flat plate can stably support the bottom surface of the pallet 24. Note that the shape and size of the support plate 36a may be changed as appropriate depending on the shape and size of the pallet 24. The support plate 36a may be formed, for example, in a circular, triangular, pentagonal, or other polygonal shape in plan view.

[0054] FIG. 13 is an enlarged perspective view schematically illustrating a support leg 36A according to another modification. In this modification, the support leg 36A is configured to be detachable from the panel 35. Specifically, the support leg 36A is attached by threading to a mounting portion 36b that rises from a reinforcing member (not shown) attached to the frame members 33A to 33D. For example, a female thread 36c is formed on the inner circumferential surface of the lower end of the support leg 36A, which is cylindrical. Meanwhile, a male thread 36d is formed on the outer circumferential surface of the mounting portion 36b, which is cylindrical. The support leg 36A is attached to the mounting portion 36b by threading the female thread 36c and the male thread 36d together. By configuring the support leg 36A in this manner so that it is detachable, it is possible to use multiple support legs 36 of different heights, for example. The height at which the pallet 24 is supported can be easily changed.

[0055] FIG. 14 is an enlarged perspective view schematically illustrating a support leg 36B according to yet another modification. In this modification, the support leg 36B includes the aforementioned support leg 36 rising from a reinforcing member (not shown) coupled to the frame members 33A-33D, and the aforementioned support leg 36A attached to the upper end of the support leg 36. Although not shown, the aforementioned mounting portion 36b having a male thread 36d on its outer circumferential surface is formed at the upper end of the support leg 36. Meanwhile, the aforementioned female thread 36c is formed on the inner circumferential surface of the lower end of the support leg 36A. With this support leg 36B, the height of the support leg 36B can be easily changed by replacing the support leg 36A. Note that the support leg 36 may be replaced with the support leg 36A. Furthermore, a support plate 36a may be formed at the upper end of the support leg 36A.

[0056] In the rack unit 22 described above, the frame 32, which is composed of the frame members 33A-33D, the base 31 composed of the support legs 36 and the supported member 37, the support posts 39A-39D, the connecting member 40, and the support member 41, is made of metal. Therefore, it is expected that static electricity will accumulate in the rack unit 22. In the warehouse system 2 constructed using racks 20, the rack units 22 are connected to each other via, for example, connecting members 50, 50A. Furthermore, by electrically connecting at least some of the rack units 22 of the rack 20 to, for example, a wall beam made of a metal material, each rack unit 22 may be grounded to the wall beam. In this way, static electricity can be reliably discharged.

[0057] The same reference numbers are used throughout the drawings to refer to the same or similar components. The following embodiments are not intended to limit the invention, as defined by the claims. While features of the present invention are described herein, changes and modifications can be made without departing from the spirit and scope of the disclosed embodiments. Furthermore, particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments. It is intended that the following detailed description be considered as exemplary only, with a true scope and spirit being indicated by the claims.

Claims

1. A warehouse system in which a number of rack units, each of which defines a space for placing pallets on which items are placed, are connected to each other to form a rack, and the rack units form a number of floors, each of which defines a surface along which a transport robot can move to transport the pallets between the rack units.

2. The warehouse system according to claim 1, wherein the plurality of rack units are connectable to each other horizontally and / or vertically.

3. The warehouse system according to claim 1, wherein two of the rack units that are horizontally adjacent to each other are directly connected to each other or are connected to each other by a connecting member.

4. The warehouse system of claim 1, wherein each of the rack units has support legs for lifting and supporting the pallet off the surface.

5. The warehouse system according to claim 4, wherein the support legs are configured to be removable.

6. The warehouse system according to claim 4, wherein the robot transports the pallet by lifting the pallet from below the pallet.

7. The warehouse system of claim 1, wherein the pallets can be loaded into each rack unit from the outer periphery of the rack, or removed from each rack unit from the outer periphery of the rack.

8. The warehouse system according to claim 7, further comprising a forklift for loading or unloading the pallets.

9. The warehouse system of claim 8, wherein the forklift recognizes the rack unit using pose estimation.

10. The warehouse system of claim 1, further comprising a transport mechanism for transporting the pallets between the plurality of floors.

11. The warehouse system of claim 1, which is communicatively connected to another warehouse system that picks the items.