System, Method For Order Fulfillment and Method For Stock Management

Abstract

The present invention relates to an order fulfillment system that maps individual items or bundle sets stored in a plurality of bucket cells on a 1:1 basis, and triggers a plurality of buckets by a PLC (Programmable Logic Controller) signal to perform picking when a real-time order occurs. The configuration is a system in which a plurality of independently operated product supply units are arranged in parallel; wherein the product supply units include: a linear member installed in a closed-loop form; a linear member driving unit that continuously drives the linear member; a plurality of movable buckets installed at regular intervals along the extension direction of the linear member and providing storage spaces for holding products; a product discharge means for dropping products contained in the movable buckets in a downward direction; a product support means located in the downward direction of the product discharge means and supporting products falling in a downward direction by the product discharge means; and a picking control unit that controls the linear member driving unit and the product discharge means according to a product order command. The above picking control unit automatically completes consolidation within one second by sequentially controlling the discharge of multiple moving buckets included in a single order in real-time linkage with the WMS, and the occupancy status of each moving bucket is calculated as a real-time inventory quantity. The system of the present invention is mounted on a transport container, enabling order fulfillment even while the vehicle is in motion.

Description

Technology Field

[0001] The present invention relates to the field of logistics automation, and more specifically, to an order fulfillment system and method comprising a driving structure that circulates a moving bucket in a vertical direction by directly connecting it to a linear member (hereinafter collectively referred to as a "chain") which is one of a motor and a chain, belt, rope, or wire, and a picking system that automatically discharges goods contained in the moving bucket by linked control between a WMS (Warehouse Management System) and a PLC, and a mobile fulfillment system that is mounted on a transport container and capable of order fulfillment even while in motion. Background Technology

[0002] Driven by changes in current lifestyles and the infrastructure of the logistics industry, online orders for a wide variety of products in small quantities have rapidly spread. To fulfill these orders, logistics fulfillment centers store incoming products and perform picking and packaging operations when an order is placed.

[0003] Order picking in current logistics fulfillment centers is broadly classified into the following methods.

[0004] 1) Single Picking: This is a method where workers move around the warehouse for every order to collect goods. This method involves excessive movement distances for workers and has a low UPH (units picked per hour) (approximately 70 items / hour). Therefore, in reality, a large workforce is mobilized for picking tasks, resulting in excessive costs.

[0005] 2) Batch Picking: This is a method of grouping multiple orders together to collect them simultaneously. While this method reduces the travel distance for workers, it requires a separate consolidation process.

[0006] 3) Zone Picking and QPS Conveyor: This is a method of dividing the warehouse into zones and transporting cartons using conveyors. With this method, a UPH of 150 to 250 can be achieved, but there is a problem that excessive equipment investment is required.

[0007] 4) GTP (Goods-to-Person) system: This is a method in which a robot transports totes or bins to a picking station. With this method, a UPH of over 475 can be achieved, but there is a structural limitation in that multiple SKUs are mixed within the tote, requiring the operator to search through them one by one.

[0008] There are limitations to using robots for picking tasks; when the product is irregular, small, thin, or slender, the ability to perform the task cannot be guaranteed, and the work speed drops too low, which actually leads to a decrease in productivity.

[0009] As such, according to the prior art, it can be summarized that there are approximately the following important problems.

[0010] Since the physical environment inevitably involves workers moving within a space or relocating equipment, a waiting time ranging from a few seconds to tens of seconds occurs until picking is completed. In other words, there are limitations to reducing the time and cost required for picking when an order is placed.

[0011] In addition, since location coordinates and quantity counting must be performed separately for inventory management, there is a high possibility of errors. Furthermore, there is a problem that accurate inventory management is almost impossible due to various reasons such as returns, damage, and theft.

[0012] In addition, separate sorter or slide chute systems are required for consolidation based on bundle orders, which leads to an excessive increase in equipment costs.

[0013] The existing Vertical Carousel Module (VCM) operates by circulating carrier shelves vertically using motors and chains, and requires a worker to manually retrieve goods from ports. This method has problems such as limited storage density due to the structural thickness of the carrier shelves, the necessity of manual picking by workers, and the requirement for a separate sorter process for consolidation when an order contains multiple items.

[0014] It is impossible for any existing automated picking system to be mounted on a shipping container and perform order fulfillment while the vehicle is in motion. This is because existing systems are designed for fixed installation, and the automated picking mechanism does not operate in vibration environments that occur during transport. Consequently, transit time has been treated as purely wasted logistics time. Prior art literature

[0015] Republic of Korea Patent Registration No. 10-2908180 Republic of Korea Patent Publication No. 10-2023-0054773 U.S. Patent Registration US6158566 U.S. Patent Registration US8649899 U.S. Patent Registration US10035649 The problem to be solved

[0016] The present invention has been devised to solve the above-mentioned problems, and

[0017] The purpose is to provide an order fulfillment system that can fully automate picking, which can dramatically improve the time and cost associated with order fulfillment by making the worker's travel distance zero or close to zero and allowing the product to move to the picking point on its own.

[0018] In addition, it aims to provide an order fulfillment system capable of accurate inventory management.

[0019] The purpose is to provide an order fulfillment system capable of responding quickly and accurately to orders for bundled products.

[0020] In addition, the purpose is to provide an order fulfillment system that is modular, thereby possessing mobility and scalability.

[0021] In addition, the purpose is to provide an order fulfillment system that automatically triggers the corresponding bucket immediately upon receiving an order through real-time linkage between a WMS (Warehouse Management System) and a PLC, thereby completing the combined packaging of one order within one second.

[0022] In addition, the aim is to provide a mobile fulfillment system that is mounted on a shipping container and enables order fulfillment even while the vehicle is in motion. means of solving the problem

[0023] The above objective is achieved as a system in which multiple independently operated product supply units are arranged in parallel;

[0024] The above product supply unit;

[0025] A linear member installed in a closed-loop form and operating in an endless track manner;

[0026] A linear member driving unit that continuously drives the above linear member;

[0027] A plurality of movable buckets installed at regular intervals along the extension direction of the above linear member, providing storage space for holding goods;

[0028] A product discharge means for dropping a product contained in the above-mentioned moving bucket in a direct downward direction; and

[0029] A product support means positioned directly below the product discharge means, for supporting a product falling directly downward by the product discharge means;

[0030] A picking control unit that controls the linear member driving unit and the product discharge means according to a product order command;

[0031] This is achieved by an order fulfillment system characterized by including...

[0032] According to another feature of the present invention, it may include an empty bucket detection unit for determining whether a product is contained in the moving bucket.

[0033] According to another feature of the present invention, the product support means may include a conveyor providing a horizontal transfer surface and a picking box placed on the conveyor.

[0034] According to another feature of the present invention, the linear member may be any one of a belt, a chain, a rope, or a wire.

[0035] According to another feature of the present invention, each of the moving buckets may contain a minimum order unit of goods.

[0036] According to another feature of the present invention, the product discharge means may be a tilting mechanism that tilts or flips the moving bucket so that the product falls downward by gravity.

[0037] According to another feature of the present invention, the product supply unit is installed on a single upright frame; a plurality of product supply units are installed on the upright frame; and products of different items can be contained in the moving buckets of each product supply unit installed on the upright frame. Furthermore, since the upright frames are connected linearly in a continuous manner, the order fulfillment system of the present invention may have a modular configuration.

[0038] Unlike the GTP method, where inventory storage totes or boxes are transferred to a worker station and a worker searches for and picks individual items, this system can form order bundles by first assigning a moving bucket or order cell corresponding to order information and allowing the necessary individual items from each product supply unit to be directly collected in the corresponding moving bucket. Accordingly, the reloading process into an intermediate tote or box, the worker search process, and a separate order joining process can be reduced or eliminated.

[0039] According to one embodiment of the present invention, the order fulfillment function can be implemented without requiring a robot gripper, a vision recognition device, or a complex autonomous transfer device as essential components. That is, since order bundles can be automatically formed solely through a combination of the circulation of linear members, the positional alignment of moving buckets, the mechanical operation of product discharge means, and sensor-based judgment, the facility structure can be simplified while improving maintainability and economic efficiency.

[0040] According to another feature of the present invention, the picking control unit receives real-time order information from a WMS (warehouse management system), generates a list of identification numbers (bucket IDs) of moving buckets corresponding to a plurality of products included in the order, and sequentially generates discharge signals when each bucket ID reaches the product discharge means, so that a plurality of products included in one order can be combined on the product support means to automatically complete combined packaging.

[0041] According to another feature of the present invention, each moving bucket is assigned a unique identification number (bucket ID), and the picking control unit tracks the occupancy status of the moving buckets in real time (Occupied: stored in goods, Vacant: empty bucket), recognizes the number of buckets in the occupied state among the moving buckets assigned to a specific product as the current inventory quantity of the product, and updates the corresponding bucket ID to the empty state immediately upon completion of product discharge, thereby enabling real-time inventory management without separate inventory counting.

[0042] According to another feature of the present invention, the product supply unit and the upright frame are mounted inside a transport container, so that even while the vehicle carrying the container is moving, the WMS receives real-time orders and the picking control unit triggers the moving bucket to discharge products, thereby allowing the travel time to be utilized as time for picking and consolidation processing.

[0043] The object of the present invention is an order fulfillment method using an order fulfillment system in which a linear member circulates in a closed-loop form and movable buckets, each assigned a unique identification number (bucket ID) to the linear member, are installed at regular intervals, comprising: (a) a receiving step in which individual items or bundle sets are stored in each movable bucket in a 1:1 ratio and the corresponding bucket IDs are registered in the WMS as occupied; (b) an order receiving step in which the WMS receives a real-time order and generates a list of bucket IDs corresponding to the items in the order; (c) a trigger step in which a PLC generates a discharge signal when the linear member drive unit is operated and the movable bucket of the corresponding bucket ID reaches a product discharge means; (d) a discharge step in which the triggered movable bucket is tilted or overturned so that the product falls to a product support means by gravity; and (e) a consolidation packaging step in which a plurality of products included in one order are combined at the product support means to complete consolidation packaging. and (f) an inventory update step that deducts inventory in real time by updating the triggered bucket ID to a Vacant state in the WMS; can be achieved by an order fulfillment method including

[0044] Here, steps (b) to (f) may be performed while the vehicle carrying the container is moving, with the order fulfillment system loaded inside the transport container, so that the vehicle's movement time is utilized as time for picking and consolidating the goods.

[0045] In addition, prior to the receiving step, the WMS may further include a bundle pre-combination step in which the WMS analyzes past order data to identify product combinations that are ordered together at a frequency exceeding a threshold, and pre-combines multiple products of the combination into a single moving bucket for storage, thereby completing the combined packaging of the bundle order with only one trigger in the trigger step.

[0046] The objective of the present invention can be achieved by an inventory management method for an order fulfillment system in which a moving bucket, to which a unique bucket ID is assigned to a linear member, is connected, comprising: (a) registering the bucket ID in the WMS as occupied when the individual item is received in each moving bucket; (b) updating the bucket ID to a vacant state when the item is discharged by a trigger of a picking control unit; (c) calculating in real time the number of buckets in the occupied state among all moving buckets assigned to a specific SKU as the current inventory quantity of the SKU; and (d) generating an inventory shortage notification for a SKU that has no buckets in the occupied state. Effects of the invention

[0047] According to the present invention, an order fulfillment system is provided that enables rapid packaging and delivery by minimizing various factors, such as the movement of workers required for picking, by automatically supplying ordered goods to a destination point (e.g., a point where a worker is located).

[0048] In addition, an order fulfillment system is provided that can quickly respond to orders for bundled products by allowing products of the minimum order unit to be placed in a single unit transfer bucket.

[0049] According to the present invention, an order fulfillment system capable of thorough inventory management is provided by determining whether a product is contained in a moving bucket, thereby identifying the inventory quantity in real time.

[0050] According to the present invention, an order fulfillment system is provided that can increase the space utilization of a warehouse or factory by making the installation range of the linear member larger or smaller as much as desired.

[0051] The system according to the present invention is modular, making it extremely easy to expand or modify the system.

[0052] According to the present invention, a system is provided that enables order fulfillment without spatial restrictions even while in transit by installing it in a transport container.

[0053] According to the present invention, since processing from order reception to consolidation completion is completed within 1 second without the movement of a worker through real-time linkage between WMS and PLC, an order fulfillment system is provided that achieves picking speed equivalent to or greater than that of existing GTP systems (AutoStore, Kardex VCM, etc.) while having an investment cost that is 1 / 10 of that of existing GTP systems.

[0054] According to the present invention, since the inventory quantity is calculated in real time based solely on the occupancy status (Occupied / Vacant) of the moving bucket, inventory accuracy is structurally improved compared to conventional location counting methods, and problems regarding inventory discrepancies caused by returns, damage, or theft are resolved. Brief explanation of the drawing

[0055] FIG. 1 is a side view of a product supply unit of an order fulfillment system according to an embodiment of the present invention. FIG. 2 is a front view of the product supply unit of an order fulfillment system according to an embodiment of the present invention. FIG. 3 is a front view of a product supply unit in which a plurality of upright frames are combined according to the present invention. FIG. 4 is a side view of a tilting mechanism of an order fulfillment system according to an embodiment of the present invention. FIG. 5 is a front view of a tilting mechanism of an order fulfillment system according to an embodiment of the present invention. FIG. 6 is a diagram showing the usage state of a tilting mechanism of an order fulfillment system according to an embodiment of the present invention. FIG. 7 is a side view of a product supply unit installed in a container of an order fulfillment system according to another embodiment of the present invention. FIG. 8 is a front view of a product supply unit installed in a container of an order fulfillment system according to another embodiment of the present invention. FIG. 9 is an example flowchart of an order fulfillment method according to the present invention. Specific details for implementing the invention

[0056] Hereinafter, the specific details of the present invention will be described in detail with reference to the attached drawings. First, the description will be made with reference to FIGS. 1 to 6, and the remaining drawings will be described where necessary.

[0057] The present invention is a system in which a plurality of independently operated product supply units (1) are arranged in parallel. The number of product supply units (1) may be greater than the number of product items sold. This is because there are combined (bundle) products. For example, if there are 300 product items, there may be 300 or more product supply units (1).

[0058] A single unit product supply unit (1) includes a linear member (3), a linear member driving unit, a moving bucket (5), a product discharge means (7), and a product support means (9).

[0059] The linear member (3) is installed in a closed loop form and operates in an endless track manner. The linear member (3) has a considerably long transport path. The linear member (3) is installed in a vertical direction by means of an upright frame (11).

[0060] According to an embodiment of the present invention, the linear member (3) may be any one of a belt, a chain, a rope, or a wire. The linear member (3) illustrated in each drawing is a chain.

[0061] The linear member drive unit drives the linear member (3) continuously or intermittently along a path and includes a plurality of sprockets (13) and a drive motor (15). One or more drive motors (15) may be installed depending on the load.

[0062] Although not shown, a buffer section may be provided along the path of the linear member (3). The buffer section is intended to allow the linear member (3) (located before the buffer section) to be stopped during the process of discharging the item, and to allow for repairs to the device, replacement of the moving bucket, and replenishment of the quantity (while the buffer amount is consumed). Such a buffer system is a system widely used in continuous processing processes such as presses.

[0063] A plurality of movable buckets (5) are installed at regular intervals on the linear member (3). The movable buckets are installed so as to be rotatably suspended from the linear member (3), so that even when the linear member (3) passes through an inflection point, the opening always remains facing upward due to gravity.

[0064] The moving bucket (5) may be an open-top box that provides a storage space for holding goods. According to an embodiment, the bottom plate (5a, see FIG. 4) of the moving bucket (5) may have a concave center so that goods can be gathered at the center of the moving bucket (5). This is to ensure that the center of gravity of the moving bucket (5) converges to the center under any circumstances.

[0065] The moving bucket (5) contains the minimum order unit of goods. That is, the number of multiple moving buckets (5) installed in a single product supply unit (1) and linked together corresponds to the maximum inventory quantity of the goods. In other words, the more empty buckets there are, the smaller the inventory quantity becomes. In this way, the inventory of a specific product can be clearly identified. The method of placing goods into the moving bucket (5) is irrelevant, whether automatic or manual.

[0066] According to one embodiment of the present invention, the moving bucket is not limited to a simple storage or transfer means for individual products, but can be assigned to an order cell representing a single order or a single order bundle. The picking control unit maps a plurality of product lines included in the received order information to the same moving bucket and can control the collection of individual products required from each product supply unit directly into the corresponding moving bucket or the order storage space associated therewith.

[0067] The product discharge means (7) drops the product contained in the moving bucket (5) in a downward direction according to the signal of the control unit. The product discharge means (7) is installed at the bottom of the product supply unit (1).

[0068] A product support means (9) for supporting a product falling in a direct downward direction by a product discharge means (7) is located in a direct downward direction of the product discharge means (7). The product support means (9) may include a conveyor (17) or a chute. A picking box (19) for holding the product may be placed on the upper surface of the conveyor (17). The picking box (19) may be the final packaging box.

[0069] According to an embodiment of the present invention, as shown in FIG. 2, a plurality of product supply units (1) are installed in a single upright frame (11). As illustrated, five product supply units (1) are installed. Each linear member (3) of the plurality of product supply units (1) included in the single upright frame (11) may be driven simultaneously or individually. However, the product discharge means (7) of each product supply unit (1) must be driven independently.

[0070] The conveying direction of the conveyor (17) is perpendicular to the conveying surface of the linear member (3). This is to allow products discharged from multiple product supply units (1) to be collected into a single picking box (19). This is because a single order may contain multiple product items.

[0071] Bundle-type products with a high order frequency can be picked by placing them in a single moving bucket (5), but it is inefficient to do so for all combination-type orders. In this case, it would be efficient to use a conveyor (17) to transport the picking box (19), select and place the products, and supply the picking box (19) to the picking point where the worker is located.

[0072] The picking box (19) may be a final packaging box, or an unmanned transfer container that temporarily holds order bundles before they are transferred to an automatic packaging module or a subsequent sorting line. It may also be configured to selectively transfer normal orders to an unmanned packaging transfer station and exceptional orders to an inspection station.

[0073] Furthermore, it is efficient to use a conveyor (17) to transport the picking box (19), select and pack the goods, and automatically supply the completed orders to an unmanned packaging transfer station or a subsequent sorting process. However, for exceptional orders or orders requiring inspection, the system may be configured to divert supply to a worker inspection point.

[0074] As shown in each drawing, multiple product discharge means (7) may be provided, in which case multiple independent commands according to multiple orders can be executed simultaneously, and the work speed can be increased accordingly.

[0075] The picking control unit controls the linear member drive unit and the product discharge means (7) according to the product order command. When an order for a specific product occurs, the picking control unit drives the linear member drive unit to cause the moving bucket (5) containing the product to pass through the product discharge means. Additionally, at the moment of passing, the product discharge means (7) is activated so that the product can fall from the moving bucket (5) and be placed in the picking box (19). Afterward, the conveyor (17) is started so that a worker waiting on one side can immediately package the product.

[0076] The picking control unit can dynamically assign orders or order bundles to specific moving buckets by considering the location of empty moving buckets, order priority, inventory status, estimated completion time, and the availability of subsequent packing lines. In addition, by controlling individual items discharged from multiple product supply units to be directly accumulated in a single picking box or order storage space corresponding to the same order, order bundles can be formed without a separate intermediate joining tote.

[0077] According to another feature of the present invention, a movable bucket (5) may include an empty bucket detection unit for determining whether a product is contained therein. By means of the empty bucket detection unit, the picking control unit may cause an empty movable bucket, i.e., an empty bucket, to bypass the product discharge means. All movable buckets installed in a single product supply unit are labeled with an identification number. When a product is discharged from a specific movable bucket, this information is applied to the picking control unit and the inventory management unit so that the movable bucket can be identified.

[0078] According to one embodiment of the present invention, at least one of a light sensor, a weight sensor, a position sensor, and a pass sensor can be used to detect double discharge, non-discharge, jamming, bucket misalignment, or an incomplete order state. When an abnormality is detected, the picking control unit can control the order to be diverted to an exception handling buffer or an inspection station, and allow normal orders to continue automatically.

[0079] As illustrated in FIG. 3, multiple upright frames (11) can be connected linearly in succession. In other words, the order fulfillment system of the present invention forms a modular structure. As illustrated, seven upright frames (11) are installed side by side. In this case, a total of 35 product supply units (1) are provided. That is, an order fulfillment system is provided that can select, pick, and package 35 types of products according to a client's order. By expanding this configuration as needed, it becomes possible to store, select, and package as many different types of products as necessary.

[0080] The order fulfillment system of the present invention can be provided with a modular structure. Therefore, if a problem arises or if a different type of moving bucket needs to be used, it is easy to remove a specific upright frame (11) and replace it with another one.

[0081] As shown in FIG. 3, the conveying surfaces of all conveyors (17) installed on several physically independent upright frames (11) can be installed to have continuity. This is so that the product on the far left in FIG. 3 can also be discharged to the opposite side, that is, to the right end in the drawing.

[0082] According to the present invention, the space efficiency of the fulfillment center (especially the upper space) can be maximized by increasing the height (H) of the product supply unit (1).

[0083] Meanwhile, there may be various methods for discharging the goods contained in the moving bucket (5). According to the present embodiment, the goods discharge means (7) may be a tilting mechanism (20) that tilts or flips the moving bucket (5) so that the goods fall downward by gravity. The tilting mechanism (20) will be described below.

[0084] As the linear member (3) moves, the moving bucket (5) can approach the tilting mechanism (20). The linear member (3) and the moving bucket (5) are connected by a connecting pin (21) so that they can rotate relative to each other.

[0085] The tilting mechanism (20) includes a trigger block (27) that is selectively positioned on the movement path of a moving bucket (5) by rotating around a hinge axis (31) by an actuator (35) and standing upright as shown in FIG. 5. When the locking projection (23) of the moving bucket comes into contact with the inclined surface (29) of the trigger block (27), the moving bucket (5) rotates as shown in FIG. 6, and in this process, the product is discharged downward. The trigger block (27) moves elastically by means of a spring (37). The actuator (35) is supported by a bracket (33) connected to the trigger block (27) and causes the trigger block (27) to rotate. The actuator (35) can be selected from various types, such as a pneumatic cylinder, an electromagnet, a motor, or a cam mechanism.

[0086] However, the product discharge means (7) described above is merely an example. For instance, the bottom plate of the moving bucket (5) may be opened like a hinged door, or the side plate may be opened to tilt the moving bucket in that direction or knock out the product. Any method intended to remove the product from the moving bucket (5) is within the scope of the present invention.

[0087] According to another embodiment, the product discharge means may include a discharge control structure that discharges only one product per operation. Additionally, multi-control in a parallel manner is possible. The discharge control structure may be implemented as at least one of an escapement, a rotary gate, a flap, a cam, a stopper, a shutter, and a combination thereof. Accordingly, sequential discharge of individual products is possible without vision recognition or robot gripping.

[0088] Hereinafter, another embodiment of the present invention will be described with reference to FIGS. 7 and 8. In this embodiment, by installing the product supply unit (1') and the upright frame (11') to fit the size of the transport container (41), a foundation can be secured that enables sorting and picking of products even while the vehicle is moving or at any unspecified location.

[0089] FIGS. 7 and 8 illustrate an embodiment in which an upright frame (11') is installed inside a container (39).

[0090] The worker can pack the picked goods on the spot with the door (41) of the container open in a manner similar to a wing body vehicle as shown in FIG. 7. Of course, this method of opening and closing the container is merely an example and can be modified in various ways.

[0091] According to this embodiment, the linear member (3') is arranged in a transverse direction, unlike the previous embodiment. As such, the arrangement method of the linear member (3') can be varied depending on the situation.

[0092] As illustrated in FIG. 8, a picking box (19') for holding goods is loaded on one side of the container (39), and the picking box (19') is taken out one by one and moved to the left in the drawing, and is supplied to a worker who is waiting with a specific product for which an order has been placed.

[0093] In this embodiment, the product supply unit may be configured such that the front side, where product discharge takes place, and the rear or top side, where inventory replenishment takes place, are separated from each other. Accordingly, inventory replenishment can be performed without interference even during order fulfillment operations, and continuous operation can be improved even in a mobile container environment.

[0094] The present invention will be explained further below.

[0095] The picking control unit is a complex control system in which the WMS (Warehouse Management System) and PLC (Programmable Logic Controller) are linked in real time. The order fulfillment flow is as follows.

[0096] (a) When the WMS receives a real-time order, it immediately generates a list of identification numbers (bucket IDs) of the moving buckets corresponding to each product included in the order.

[0097] (b) WMS calculates the expected time when the corresponding bucket reaches the product discharge means (7) from the current driving speed of the linear member and the current position of each bucket ID.

[0098] (c) The PLC generates a discharge signal when the bucket reaches the product discharge means (7) according to the trigger schedule received from the WMS.

[0099] (d) When an order contains multiple products (SKUs), triggers for each bucket are executed sequentially during linear member circulation, and the discharged products are combined at the product support means (9), such as the conveyor (17) or chute, and collected into one picking box (19), thereby automatically completing the combined packaging.

[0100] (e) As soon as the trigger is completed, WMS updates the corresponding bucket ID to empty to reflect the real-time inventory.

[0101] With this WMS-PLC integration structure, processing is completed from order reception to consolidation without the movement of workers, and the processing time per order is reduced to within a few seconds depending on the chain speed and bucket spacing.

[0102] Each moving bucket (5) is assigned a unique identification number (bucket ID). The bucket ID is recognized by a barcode or RFID tag attached to the moving bucket. The WMS manages the bucket ID by mapping it to the stored product (SKU) information.

[0103] · Number of occupied buckets among the moving buckets assigned to a specific SKU = Current inventory quantity of that SKU

[0104] · Immediately after product disposal is complete, the corresponding bucket ID is automatically updated to Vacant status.

[0105] · The empty bucket detection unit (position sensor or weight sensor) checks the occupancy status in real time.

[0106] According to the present invention, the number of buckets in the occupied state of each moving bucket is equated with the current inventory quantity of the corresponding product. With this method, real-time inventory status can be determined solely by querying the bucket ID, without the need for separate inventory location investigation or quantity counting. Furthermore, the problem of inventory discrepancies caused by reasons such as returns, damage, or theft is structurally resolved.

[0107] The container (39) mounting embodiment shown in FIGS. 7 and FIGS. 8 is utilized in the following operation scenarios.

[0108] (a) Product loading and bucket ID mapping completed in the bucket (5) moving from the source.

[0109] (b) Vehicle loaded with container departs

[0110] (c) WMS receives real-time orders via a wireless network while on the move

[0111] (d) Trigger the corresponding bucket even while the picking control unit is moving → Drop product → Combine into picking box

[0112] (e) Upon arrival at destination, boxes that have already been picked are ready → Ship immediately

[0113] Under this method, vehicle transit time is converted into time for picking and consolidation, enabling immediate shipment upon arrival. It allows for various applications, such as urban micro-fulfillment, temporary expansion during holiday seasons, and pop-up fulfillment.

[0114] The bucket connecting pin (21) and the spring (37) of the hinge structure act as cushions for vehicle vibrations that occur during movement, and the actuator (35) of the tilting mechanism (20) does not operate without a signal from the PLC, so random discharge during driving is prevented.

[0115] The configurations described and illustrated above are merely preferred embodiments based on the technical concept of the present invention. Those skilled in the art may make various modifications based on ordinary technical common sense, but should be aware that such modifications may be included within the scope of protection of the present invention. Various combinations of the embodiments disclosed above are possible, and all possible combinations fall within the scope of rights of the present invention. Explanation of the symbols

[0116] 1,1' : Product supply unit 3,3' : Linear member 5 : Mobile bucket 7 : Product discharge method 9 : Product support means 11,11' : Upright frame 13 : Sprocket 15 : Drive motor 17 : Conveyor 19,19' : Picking box 20: Tilting mechanism 21: Connecting pin 23,25 : Stopper 27 : Trigger block 29 : Inclined surface 31 : Hinge axis 33 : Bracket 35 : Actuator 37 : Spring 39 : Container 41 : Container Door

Claims

Claim 1 An order fulfillment system comprising a plurality of independently operated product supply units arranged in parallel; wherein the product supply units include: a linear member installed in a closed-loop form and operating in an endless track manner; a linear member driving unit for continuously driving the linear member; a plurality of moving buckets installed at regular intervals along the extension direction of the linear member, each assigned a unique identification number (bucket ID), and storing individual items or bundle sets in a 1:1 ratio; a product discharge means for dropping the items contained in the moving buckets in a downward direction; and a product support means located in the downward direction of the product discharge means for supporting the items falling in a downward direction by the product discharge means; and a picking control unit that receives real-time order information from a WMS (Warehouse Management System), looks up a bucket ID corresponding to the items included in the order, and generates a discharge signal when the moving bucket with the corresponding bucket ID reaches the product discharge means, thereby automatically completing combined packaging by merging multiple items included in one order at the product support means. Claim 2 An order fulfillment system characterized by including, in claim 1, an empty bucket detection unit for determining whether a product is contained in the moving bucket. Claim 3 An order fulfillment system according to claim 1, characterized in that the product support means comprises a conveyor providing a horizontal transfer surface and a picking box placed on the conveyor. Claim 4 An order fulfillment system according to claim 1, wherein the linear member is one of a belt, chain, rope, or wire. Claim 5 An order fulfillment system according to claim 1, characterized in that each of the moving buckets contains a product of the minimum order unit. Claim 6 An order fulfillment system according to claim 1, wherein the product discharge means is a tilting mechanism that tilts or flips the moving bucket so that the product falls downward by gravity. Claim 7 An order fulfillment system according to claim 1, wherein the product discharge means includes a discharge amount control structure that discharges only one product per operation; and wherein the discharge amount control structure is implemented as at least one of an escapement, a rotary gate, a flap, a cam, a stopper, a shutter, and a combination thereof. Claim 8 An order fulfillment system according to claim 1, wherein the picking control unit dynamically assigns an order or order bundle to a specific moving bucket by considering the location of an empty moving bucket, order priority, inventory status, estimated completion time, and the availability status of a subsequent packing line. Claim 9 An order fulfillment system according to claim 1, wherein the product support means comprises a conveyor providing a horizontal transfer surface and a picking box placed on the conveyor; and wherein the picking control unit controls individual products discharged from a plurality of product supply units to be directly accumulated in a single picking box or order storage space corresponding to the same order, thereby enabling the formation of an order bundle without a separate intermediate joining tote. Claim 10 An order fulfillment system according to claim 1, wherein the product supply unit is installed on a single upright frame; a plurality of product supply units are installed on the upright frame; and a product of a different item is contained in the moving bucket of each product supply unit installed on the upright frame. Claim 11 An order fulfillment system according to claim 10, characterized in that the above-mentioned upright frames are connected linearly and continuously to form a modular structure. Claim 12 An order fulfillment system according to claim 1, wherein the picking control unit receives order information in real time from a WMS (warehouse management system), generates a list of identification numbers (bucket IDs) of moving buckets corresponding to each of a plurality of products included in the order, and sequentially generates discharge signals at the time when each ID of the moving bucket reaches the product discharge means, so that a plurality of products included in one order are combined on the product support means to automatically complete combined packaging. Claim 13 An order fulfillment system according to claim 1, wherein the picking control unit detects double discharge, non-discharge, jamming, bucket misalignment, or order incomplete status using at least one of a light sensor, a weight sensor, a position sensor, and a pass sensor; and when an abnormality is detected, the picking control unit transfers the corresponding order to an exception processing buffer or an inspection station, and controls normal orders to continue automatically. Claim 14 An order fulfillment system according to claim 12, wherein the WMS identifies a plurality of products ordered together from past order data at a frequency greater than or equal to a threshold value as a bundle set, and stores the plurality of products constituting the bundle set in a single moving bucket in a pre-combined manner so that when a bundle order occurs, the combined packaging is completed with only one trigger of a single bucket. Claim 15 In Clause 12, the order fulfillment system is characterized by the above WMS analyzing shipment frequency data by product to prioritize assigning the moving bucket of a product with a high shipment frequency to a linear member position adjacent to the product discharge means, and assigning the moving bucket of a product with a high frequency of being ordered together to the same or adjacent product supply unit to minimize the discharge time interval when multiple buckets are triggered. Claim 16 A method for fulfilling an order using any one of claims 1 to 15, wherein a linear member circulates in a closed-loop form and movable buckets, each assigned a unique identification number (bucket ID) to the linear member, are installed at regular intervals, comprising: (a) a receiving step in which individual items or bundle sets are stored in each movable bucket in a 1:1 ratio and the corresponding bucket IDs are registered in the WMS as occupied; (b) an order receiving step in which the WMS receives a real-time order and generates a list of bucket IDs corresponding to the items in the order; (c) a trigger step in which a PLC generates a discharge signal when the linear member drive unit is operated and the movable bucket with the corresponding bucket ID reaches the item discharge means; (d) a discharge step in which the triggered movable bucket is tilted or overturned so that the item falls to the item support means by gravity; and (e) a consolidation packaging step in which multiple items included in one order are combined at the item support means to complete consolidation packaging. and (f) an inventory update step that updates the triggered bucket ID to a vacant state in the WMS to deduct inventory in real time; wherein the number of buckets in the occupied state of each moving bucket is equal to the current inventory quantity of the corresponding product. Claim 17 A method for fulfilling an order according to claim 16, wherein steps (b) to (f) are performed while the vehicle carrying the container is moving, while the order fulfillment system is mounted inside the transport container, so that the vehicle's movement time is utilized as time for picking and consolidating the goods. Claim 18 A method for fulfilling an order according to claim 16, further comprising, prior to the receiving step, a bundle pre-combination step in which the WMS analyzes past order data to identify product combinations whose frequency of being ordered together exceeds a threshold, and pre-combines multiple products of the said combination into a single moving bucket for storage, thereby completing the combined packaging of the said bundle order with only one trigger of a single bucket in the trigger step. Claim 19 A method for managing inventory using any one of claims 1 to 15, wherein each linear member is assigned a unique bucket ID and there are moving buckets that store individual items in a 1:1 ratio, comprising: (a) registering the corresponding moving bucket ID in the WMS as occupied when the storage of individual items in each moving bucket is completed; (b) updating the moving bucket ID to a vacant state when the item has been discharged by a trigger of a picking control unit; (c) calculating in real-time the number of buckets in the occupied state among all moving buckets assigned to a specific SKU as the current inventory quantity of the corresponding SKU; and (d) generating an inventory shortage notification for SKUs that do not have moving buckets in the occupied state.

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