Warehouse management method and warehouse management system

Abstract

This warehouse management method is for managing a warehouse, and includes: a step for acquiring operation range information indicating an operation range of a picking robot which performs picking work on an article; a step for acquiring dropping position information indicating a dropping position which is a position where a first article was dropped from the picking robot, and dropping time information indicating a dropping time which is the time at which the first article was dropped from the picking robot; a step for acquiring arrangement state information indicating an arrangement state of a moving body the position of which moves within the warehouse; and a step for determining collection information related to a collection method for the first article, on the basis of the operation range of the picking robot, the dropping position and the dropping time of the first article, and the arrangement state of the moving body at the dropping time.

Description

Warehouse management method and warehouse management system

[0001] The present disclosure relates to a warehouse management method and a warehouse management system.

[0002] In recent years, automated warehouse systems have become increasingly common. Automated warehouse systems use machinery and automation technology to store, transport, manage, and otherwise manage goods. A known conventional automated warehouse system includes a plurality of automated warehouses, a plurality of work stations, a travel route that is provided to allow access to the plurality of automated warehouses and the plurality of work stations, a plurality of automated guided vehicles that travel along the travel route, and a controller that determines an area that includes at least a portion of the travel route as a travel area in which the automated guided vehicles will travel, and controls the automated guided vehicles to transport goods between the automated warehouses and the work stations that belong to the travel area (see Patent Document 1).

[0003] Patent No. 7276595

[0004] The present disclosure provides a warehouse management method and a warehouse management system that can suppress a decrease in warehouse operating efficiency even if an item falls inside the warehouse.

[0005] One aspect of the present disclosure is a warehouse management method for managing a warehouse, comprising the steps of: acquiring operating range information indicating the operating range of a picking robot that performs item picking work; acquiring drop position information indicating the drop position where a first item was dropped from the picking robot and drop time information indicating the drop time where the first item was dropped from the picking robot; acquiring placement state information indicating the placement state of a mobile object that moves within the warehouse; and determining collection information regarding a method for collecting the first item based on the operating range of the picking robot, the drop position and drop time of the first item, and the placement state of the mobile object at the drop time.

[0006] One aspect of the present disclosure is a warehouse management system that includes a processor and manages a warehouse, wherein the processor acquires operating range information indicating the operating range of a picking robot that performs item picking work, acquires drop position information indicating the drop position where a first item was dropped from the picking robot and drop time information indicating the drop time where the first item was dropped from the picking robot, acquires placement state information indicating the placement state of a mobile object that moves within the warehouse, and determines collection information regarding a method for collecting the first item based on the operating range of the picking robot, the drop position and drop time of the first item, and the placement state of the mobile object at the drop time.

[0007] According to the present disclosure, even if an item to be picked falls, it is possible to prevent a decrease in the efficiency of the picking operation.

[0008] FIG. 1 is a diagram showing an example of the configuration of a warehouse system in a first embodiment; FIG. 2 is a diagram showing an example of an environment within a warehouse in this embodiment; FIG. 3 is a diagram showing an example of a hardware configuration applicable as a device constituting a warehouse operations management system; FIG. 4 is a diagram showing an example of picking instruction information; FIG. 5 is a diagram showing an example of robot configuration information; FIG. 6 is a diagram showing an example of item information; FIG. 7 is a diagram showing a first example of mapping information; FIG. 8 is a diagram showing a second example of mapping information; FIG. 9 is a diagram showing an example of correction of the drop position; FIG. 10 is a diagram showing a supplementary explanation when the drop position is in an intra-bin area; FIG. 11 is a diagram showing a supplementary explanation when the drop position is in an inter-bin area;

[0009] Hereinafter, embodiments will be described in detail with reference to the drawings as appropriate. However, more detailed description than necessary may be omitted. For example, detailed description of well-known matters or redundant description of substantially identical configurations may be omitted. This is to avoid unnecessary redundancy in the following description and to facilitate understanding by those skilled in the art. Note that the accompanying drawings and the following description are provided to enable those skilled in the art to fully understand the present disclosure, and are not intended to limit the subject matter described in the claims.

[0010] (Background to the development of the embodiments of the present disclosure) In the automated warehouse system of Patent Document 1, when an item to be picked falls, no consideration is given to the method of recovering the fallen item, the timing of recovery, the equipment or area in which the robot should be stopped, etc. Therefore, for example, if a picking robot accidentally drops an item to be picked during a picking operation, the fallen item may cause an obstruction and reduce the operating efficiency of the warehouse.

[0011] In the following embodiments, a warehouse management method and a warehouse management system that can suppress a decrease in the operating efficiency of a warehouse even if an item falls inside the warehouse will be described.

[0012] (First embodiment) <Configuration of warehouse system> Fig. 1 is a diagram showing an example of the configuration of a warehouse system 5 according to the first embodiment. The warehouse system 5 includes a warehouse management system 10, a warehouse operations management system 20, a warehouse control system 30, a picking robot 40, a transport robot 42, an automated warehouse 50, and a camera 60. The warehouse system 5 supports the execution of item picking operations.

[0013] The warehouse management system 10, also known as a Warehouse Management System (WMS), is a system for facilitating logistics within a warehouse. The warehouse management system 10 manages items such as inventory. The warehouse management system 10 has inventory management functions and inventory / shipping management functions. The warehouse management system 10's inventory management function manages information about the status of currently stored inventory. The information about the inventory status includes, for example, the item's storage location (storage area), arrival date, quantity, expiration date, color, size, etc. The warehouse management system 10's inventory / shipping management function manages records of the inventory / shipping of items. The warehouse management system 10 can manage inventory / shipping schedules and record inventory / shipping results. The warehouse management system 10 also has functions to facilitate tasks associated with inventory / shipping, such as creating picking lists and slips for items.

[0014] The warehouse operations management system 20 has warehouse management and warehouse control functions and is also called a Warehouse Execution System (WES). The warehouse operations management system 20 is an intermediate system between the warehouse management system 10 and the warehouse control system 30. The warehouse operations management system 20 is also capable of grasping on-site operation data such as inventory management, warehousing, and picking of goods in real time. In other words, the warehouse operations management system 20 is a system for comprehensively controlling people, goods, facilities (machines), etc. within a warehouse.

[0015] The warehouse operations management system 20 has a work management function and an equipment control function. The warehouse operations management system 20's work management function visualizes the work status of various pieces of equipment in the warehouse (e.g., picking robots 40, transport robots 42, automated warehouses 50, cameras 60) or workers, enabling real-time progress monitoring. The system is also capable of sending predetermined instructions to devices carried by workers (e.g., wearable devices, audio terminals) or terminals installed in the work area (e.g., displays). The warehouse operations management system 20's equipment control function enables it to control various pieces of equipment in the warehouse.

[0016] The warehouse management system 10 and the warehouse operations management system 20 may be integrated, with one having the functions of the other.

[0017] The warehouse control system 30 controls various equipment in the warehouse in real time, enabling goods to be received and sent according to an optimal schedule. The warehouse control system 30 is also called a Warehouse Control System (WCS). The warehouse control system 30 can monitor the operation of the equipment in real time and send predetermined instruction information to the equipment.

[0018] It should be noted that only one warehouse control system 30 may be provided, or multiple warehouse control systems 30 may be provided, or one system may be provided for each piece of equipment in the warehouse.

[0019] The various types of equipment contribute to the automation of various tasks in the warehouse. The various types of equipment include the picking robot 40, the transport robot 42, the automated warehouse 50, and the camera 60, and may also include other equipment (for example, various sensors).

[0020] The picking robot 40 picks various items stored in a storage bin 71 in response to instructions from the warehouse control system 30, and moves the items to a shipping bin 72 for storage. The picking robot 40 has an arm and a hand. The arm can approach a predetermined position inside the bin 70. The arm may be an orthogonal mechanism arm, a multi-axis arm, or other arm. The hand is attached to the tip of the arm. The hand is capable of picking items in the bin 70. The hand may be of a suction type that grasps items by suction, or may be of a multi-fingered hand type that grasps items, or may grasp items in other ways.

[0021] The transport robot 42 transports bins 70 (see FIG. 2 ) in which various items managed in the warehouse are stored. The transport robot 42 is, for example, an automated guided vehicle (AGV). The transport robot 42 is configured to include a traveling unit for performing operations related to movement, a sensor for acquiring peripheral information (e.g., a sensor for detecting position), a communication device, etc. The transport robot 42 may include a transport robot 42 that travels within an automated warehouse 50 in the warehouse and a transport robot 42 that travels outside the automated warehouse 50 in the warehouse. The bins 70 include storage bins 71 in which received items are stored and shipping bins 72 in which shipped items are stored. Note that the bins 70 themselves may operate as the transport robot 42, i.e., the bins 70 may be self-propelled.

[0022] The automated warehouse 50 is a warehouse in which operations such as storage (shelving), sorting, and collection (picking) are automated.

[0023] <Warehouse Environment> FIG. 2 is a diagram showing an example of the warehouse environment of this embodiment.

[0024] The warehouse of this embodiment includes an automated warehouse 50 and a picking station PS. Storage shelves 51 that store bins 70 are arranged within the automated warehouse 50. The storage shelves 51 are partitioned planarly or spatially and can store a large number of bins 70. The transport robot 42 receives a transport instruction, for example, from the warehouse operations management system 20, and transports the bins 70 stored on the storage shelves 51 to one of the multiple picking stations PS. The storage shelves 51 store storage bins 71, and the storage bins 71 may be transported from the storage shelves 51 to a predetermined picking station PS at a predetermined time. The shipping bins 72 may be located, for example, near the storage shelves 51 or at an outgoing station, and may be transported to a predetermined picking station PS at a predetermined time.

[0025] A picking robot 40 or a picking worker 45 is positioned at each picking station PS to perform the picking work. Picking station PS0 is a picking station where picking work is performed by a person. Picking station PS1 is a picking station where picking work is performed by a picking robot 40. Three or more picking stations PS may be provided. Also, multiple picking stations PS1 for the picking robot 40 may be provided.

[0026] When the picking operation at the picking station PS is completed, the transport robot 42 receives a transport instruction from, for example, the warehouse operations management system 20 and transports the shipping bin 72 to a predetermined position (for example, a shipping station). The shipping station is, for example, a spatial area where the items are inspected and packed into boxes for delivery.

[0027] The picking work is the work of picking up an item from a storage bin 71, moving the item to a shipping bin 72, and placing the item in the shipping bin 72. In other words, the picking work is a pick-and-place work.

[0028] In addition, if it is desirable to temporarily wait for the bins 70 instead of moving them into the automated warehouse 50 from the viewpoint of improving the efficiency of the entire shipping process, a waiting area for waiting the bins 70 may be provided.

[0029] Since the bins 70 are movable within the warehouse, the arrangement of the bins 70 around the picking station PS in the automated warehouse 50 changes over time.

[0030] The bins 70 have, for example, a substantially rectangular parallelepiped shape, and items can be placed in and removed from above. Therefore, the picking robot 40 and the picking operator 45 place items in and remove items from the bins 70 from above. The shapes of the bins 70 may be the same or different. The transport robot 42 may move the bins 70 by pushing or pulling them, or the bins 70 may be placed on the transport robot 42 and moved. Different transport robots 42 may be used for transporting storage bins and shipping bins, or the same transport robot 42 may be used. Furthermore, the bins 70 may be transported by a method other than transport by the transport robot 42 (for example, transport using a belt conveyor).

[0031] Returning to FIG. 1 , the camera 60 is positioned so as to capture images of the inside of the bin 70. The camera 60 is used, for example, to recognize the state inside the bin 70. The camera 60 is installed at the picking station PS and may be installed inside or near the picking robot 40. The camera 60 may also be installed outside the picking station PS. The captured image captured by the camera 60 reflects, for example, items stored in the storage bin 71 or the shipping bin 72, making it possible to understand how the items are arranged. Furthermore, the captured image captured by the camera 60 reflects the presence or absence of the storage bin 71 or the shipping bin 72, making it possible to determine whether the storage bin 71 or the shipping bin 72 has arrived at the destination picking station PS based on the captured image. Note that one or more cameras 60 may be installed. Furthermore, sensors and cameras 60 may be installed at various locations within the warehouse and used to detect the position of each piece of equipment within the warehouse.

[0032] The warehouse operations management system 20 controls the operation of various pieces of equipment either via the warehouse control system 30 or without the warehouse control system 30 .

[0033] <Configuration of the warehouse operations management system> Each system shown in FIG. 1 (warehouse management system 10, warehouse operations management system 20, and warehouse control system 30) may be configured as an on-premise server device at the base where the warehouse is located, or may be configured as a cloud-based system on a network.

[0034] FIG. 3 is a diagram showing an example of a hardware configuration applicable to devices constituting the warehouse operations management system 20. Note that the configurations of systems other than the warehouse operations management system 20 (i.e., the warehouse management system 10 and the warehouse control system 30) may also be similar to the configuration shown in FIG. 3. Note that in each system, some of the components shown in FIG. 3 may be omitted or other components may be added depending on the functions provided. Furthermore, each system may have each of the components shown in FIG. 3 as an independent device.

[0035] As shown in FIG. 3 , the warehouse operations management system 20 includes a processor 21 , a memory 22 , an input device 23 , a communication device 24 , and an input / output interface 25 .

[0036] The processor 21 may be configured using, for example, a Central Processing Unit (CPU) or a Digital Signal Processor (DSP). The processor 21 may be configured using various integrated circuits (for example, a Large Scale Integration (LSI) or a Field Programmable Gate Array (FPGA)). The processor 21 realizes various functions by executing programs stored in the memory 22. The processor 21 comprehensively controls each part of the warehouse operations management system 20 and performs various processes. The processing by the processor 21 may be, for example, processing in the cloud.

[0037] The processor 21 may control the operation of equipment in the warehouse (e.g., the picking robot 40, the transport robot 42, the automated warehouse 50, and the camera 60) via the communication device 24. The processor 21 may control the transport of bins 70 by the transport robot 42 by controlling the travel of the transport robot 42. The processor 21 may control the picking work by the picking robot 40 by controlling the operation of the arm and hand of the picking robot 40. The processor 21 may control the picking work based on picking instruction information.

[0038] The processor 21 acquires various types of information via the input device 23 or the communication device 24. For example, the processor 21 acquires captured images captured by the camera 60 and detection information detected by a sensor. The processor 21 may detect various events based on the acquired captured images or detection information. For example, the processor 21 may recognize whether or not a bin 70 has arrived at each picking station PS, the coordinates at which the bin 70 is placed in the picking station, and information about the items stored inside the bin 70 (e.g., the presence, shape, weight, material, and size of the item).

[0039] The memory 22 includes a primary storage device (for example, a random access memory (hereinafter referred to as "RAM") or a read only memory (hereinafter referred to as "ROM")). The memory 22 may include a secondary storage device (for example, a hard disk drive (hereinafter referred to as "HDD") or a solid state drive (hereinafter referred to as "SSD")) or a tertiary storage device (for example, an optical disk or an SD card). The memory 22 may also be an external storage medium, or may be detachable from the warehouse operations management system 20. The memory 22 stores various data, information, programs, etc.

[0040] The memory 22 may store, for example, picking instruction information relating to instructions for picking work, robot configuration information relating to the configuration of the picking robot 40, and item information relating to items.

[0041] The input device 23 may include various buttons, keys, a keyboard, a touch panel, a microphone, or other input devices. The input device 23 accepts input of various data, information, etc. The input device 23 is operated, for example, by an administrator or worker (e.g., a worker performing a picking operation or other worker) who manages the warehouse operations management system 20. The input device 23 may also include a sensor. For example, a sensor may be provided for each picking robot 40 inside or around the picking robot 40. For example, a sensor may be provided for each transport robot 42 inside or around the transport robot 42.

[0042] The communication device 24 communicates various data, information, etc. using a wired or wireless communication method. The communication device 24 may be communicatively connected to the network NT. The communication method used by the communication device 24 may include, for example, a local area network (Local Area Network), a wide area network (WAN), a mobile phone network, or power line communication. The communication device 24 communicates with external systems (e.g., the warehouse management system 10, the warehouse control system 30, or other systems) and external devices. The communication device 24 also communicates with various pieces of equipment in the warehouse (e.g., the picking robot 40, the transport robot 42, the automated warehouse 50, and the camera 60) via the warehouse control system 30 or without the warehouse control system 30. The communication device 24 also communicates with a terminal 65 via the network NT or without the network NT. Furthermore, the communication device 24 may sequentially acquire information such as the position, speed, acceleration, angle, or posture of the arm or hand from each picking robot 40 in chronological order. The communication device 24 may send an instruction to transport the bin 70 to the transport robot 42, and sequentially acquire information such as the current position from the transport robot 42 in chronological order. The communication device 24 may sequentially acquire information such as the current position of the bin in chronological order.

[0043] The input / output interface 25 inputs and outputs information and data between the processor 21 , the memory 22 , the input device 23 , and the communication device 24 .

[0044] For example, the processor 21 may detect that the article 80 has fallen based on information detected by a sensor or an image captured by the camera 60. For example, the processor 21 may detect that the article 80 has fallen from the hand 40h when a detection value (a value of the gripping force detected by the gripper (e.g., a current value)) detected by a pressure sensor or a sensor that detects gripping force changes to a predetermined value or less. For example, the processor 21 may detect that the article 80 has fallen from the hand 40h when a contact sensor changes from a contact state to a no-contact state. For example, the processor 21 may detect that the article 80 has fallen from the hand 40h based on an image captured by the camera 60.

[0045] For example, the processor 21 acquires information about the operating range of the picking robot 40 that performs the work of picking items. The operating range is, for example, a range that the arm 40a and the hand 40h can reach (approachable range) by the operation of the picking robot 40. The information about the operating range of the picking robot 40 may be stored in, for example, the memory 22.

[0046] For example, the processor 21 acquires information on the drop position and drop time when a specific item 80 is dropped from the picking robot 40. The drop position may include the drop start position and drop completion position of the item 80, and the drop start position and drop completion position of the item 80 may be combined into one drop position. The drop time may include the drop start time and drop completion time of the item 80, and the drop start time and drop completion time of the item 80 may be combined into one drop position.

[0047] For example, the processor 21 acquires information (mobile object arrangement information) on the arrangement status of mobile objects (e.g., transport robots 42, bins 70) that can move within the warehouse. The mobile object arrangement information may be represented, for example, as mapping information MP (see FIG. 7 , etc.). The processor 21 may acquire detection information from various sensors and captured images from the camera 60, and recognize the position, speed, acceleration, etc. of each device within the warehouse based on the detection information and captured images. The processor 21 may generate the mapping information MP by mapping the position of each device within the warehouse on a two-dimensional plane. The processor 21 may acquire the mobile object arrangement information by generating the mapping information MP. Furthermore, the processor 21 may sequentially acquire detection information and captured images in chronological order and sequentially recognize the position, etc. of each device. Therefore, the processor may sequentially generate mapping information MP that changes over time, and sequentially acquire the mobile object arrangement information.

[0048] For example, the processor 21 may determine collection information regarding a method for collecting the item based on the operating range of the picking robot 40, the position and time at which the dropped item 80 fell, and the positional state of the moving object at the time of the fall. The method for collecting the item (collection information) includes at least one of information on the person who will collect the fallen item 80D (e.g., the picking robot 40 or a collection worker) and information on the collection timing. The processor 21 may also determine areas and equipment to be decommissioned within the warehouse in connection with the collection of the item 80.

[0049] For example, the processor 21 notifies the collector to collect the fallen item 80D. For example, if the collector is a picking robot 40, the processor 21 transmits a collection instruction for the fallen item 80D to the picking robot 40 via the communication device 24. The picking robot 40 controls the arm 40a and the hand 40h in accordance with the collection instruction to grasp and collect the fallen item 80D. For example, if the collector is a collection worker, the processor 21 transmits a collection instruction for the fallen item 80D to the terminal 65 of the collection worker via the communication device 24. The collection instruction includes guide information for guiding the collection of the fallen item 80D. The terminal 65 displays the guide information in accordance with the collection instruction. The guide information includes identification information of the collector, identification information (item ID) of the fallen item 80D, information on the dropped position (i.e., collection position) of the fallen item 80D (i.e., the item to be collected), information on the collection timing of the fallen item 80D, mapping information MP indicating the positional relationship of each device in the warehouse, etc.

[0050] <Configuration of Terminal> The terminal 65 is a PC (Personal Computer), a smartphone, a tablet terminal, a mobile terminal, or the like. The terminal 65 has a hardware configuration similar to that of a general terminal, including a processor, a memory, a communication device, an input device, a display device, and the like. As shown in FIG. 1 , the terminal 65 may communicate various data and information with the warehouse management system 10, the warehouse operations management system 20, and the warehouse control system 30, receive notifications and instructions of various information, perform operations in accordance with the notifications and instructions, and issue various instructions in accordance with inputs made by operating the terminal 65, etc.

[0051] <Details of Information Handled by the Warehouse Operations Management System> Next, we will explain the details of the data handled by the warehouse operations management system 20. The data handled by the warehouse operations management system is stored in, for example, the memory 22, and may be updated as necessary.

[0052] FIG. 4A is a diagram showing an example of picking instruction information I1. Picking instruction information I1 is instruction information related to picking issued by the warehouse management system 10. Picking instruction information I1 includes information on a task (work) ID, a task type, a storage bin ID, an output bin ID, and time. The task ID is a unique ID (identification information). The task type is information indicating the work content to be performed by the picking robot 40 or the picking operator 45. This work content includes information such as the item ID of the item to be picked and the number of items to be picked. The storage bin ID is the ID of the storage bin 71 transported from the storage shelf 51. The output bin ID is the ID of the output bin. The time information is the data issuance time when the picking instruction information is issued.

[0053] 4B is a diagram showing an example of robot configuration information I2. Robot configuration information I2 includes information on a structure type ID, a hand type ID, and robot installation coordinates. The structure type ID is information indicating the type of structure of the picking robot 40 (e.g., Cartesian robot, vertical articulated robot, or other structure type). The hand type ID is information indicating the type of hand (e.g., suction, two-fingered, multi-fingered, or other hand type). The robot installation coordinate information is information indicating the position where the picking robot is installed, and is represented by, for example, X and Y coordinates, such as (X, Y) = (12, 3).

[0054] 4C is a diagram showing an example of the item information I3. The item information I3 holds information such as an item ID, the shape of the item 80, the material of the item 80, the weight of the item 80, and the size of the item 80. The shape of the item 80 is, for example, a box, a cylinder, or a bag. The material of the item 80 is, for example, paper, metal, plastic, or the like.

[0055] <Example of Estimation of Drop Position> Next, an example of estimation of the drop position of the article 80 will be described.

[0056] 5 is a diagram for explaining an example of estimating the dropped position of the item 80. In this embodiment, the example mainly shows a case where the picking robot 40 drops the item 80 to be picked during the picking operation.

[0057] In FIG. 5 , the picking robot 40 uses the arm 40 a and the hand 40 h to pick an item 80 from a predetermined storage position P1 in a storage bin 71 and place the item 80 at a predetermined place position P2 in a shipping bin 72. If the item 80 held by the hand 40 h of the picking robot 40 is accidentally dropped at the drop start position P3, it is estimated that the item 80 has fallen to a drop position P4 (a drop completion position). In this case, the processor 21 of the warehouse operations management system 20 detects that the item 80 has fallen from the hand 40 h. The processor 21 determines the time at which the drop is detected as the drop time. The position of the hand 40 h detected at the drop time is the drop start position P3. In this way, the processor 21 estimates and acquires the drop start position P3. The processor 21 also estimates the drop position P4 based on at least one of the position, velocity, and acceleration of the hand 40h of the picking robot 40 when the item is dropped, the characteristics of the item, and the type of the hand 40h (e.g., suction type, multi-finger type). The type of the hand 40h is included in the robot configuration information I2. The processor 21 acquires at least one of the position, velocity, and acceleration of the hand 40h, for example, based on detection information detected by any of the sensors when the item is dropped. The processor 21 acquires information on the characteristics of the item (e.g., shape, weight, material, size) from, for example, the item information I3 stored in the memory 22. In this way, the processor 21 estimates and acquires the drop position P4. The processor 21 may also estimate at least one of the drop start position P3 and the drop position P4 based on an image captured by the camera 60.

[0058] The processor 21 may also calculate the fall time by adding an offset value to the time when the item 80 leaves the hand 40h (fall start time). This offset value may be calculated by K x h, where K is an estimation coefficient and h is the height of the item 80. The height of the item 80 may be the height from the floor of the warehouse, or the height from the loading surface of the bin 70 or transport robot 42 below the item 80.

[0059] <Details of Mobile Object Location Information> Next, the mobile object location information will be described.

[0060] Fig. 6 is a diagram showing a first example of mapping information MP as moving object location information, and Fig. 7 is a diagram showing a second example of mapping information MP.

[0061] The mobile object location information is obtained, for example, as mapping information MP of each piece of equipment (device) on a two-dimensional plane when the warehouse is viewed from the ceiling (above). For example, the warehouse is divided into a plurality of unit areas AU of the same size and shape (e.g., rectangular) on the two-dimensional plane. The mapping information MP describes the location of each piece of equipment based on the unit areas AU.

[0062] 6 includes position information (placement information) of an empty area indicating an area in the automated warehouse 50 where nothing is placed, an in-bin area indicating an area inside the bin 70, and an outside area indicating an area outside the automated warehouse. The mapping information MP shows, for example, information including such areas as a minimum configuration.

[0063] The mapping information in Fig. 7 includes position information for the empty area, the area inside the bin, and the area outside, similar to Fig. 6. Furthermore, the mapping information in Fig. 7 includes position information for the bin surrounding area, which indicates the area around the bin 70, the area on the AGV, which indicates the area where the transport robot 42 (also referred to as AGV) is located, and the AGV surrounding area, which indicates the area around the transport robot 42.

[0064] In this way, the warehouse operations management system 20 can visualize the layout status of each piece of equipment in the warehouse at each timing using the mapping information MP.

[0065] <Correction of Drop Position> Next, an example of correcting the drop position of an article will be described.

[0066] FIG. 8 is a diagram for explaining an example of correction of the drop position.

[0067] The processor 21 sequentially acquires moving object location information including the times before and after the time when the object 80 falls. A plurality of pieces of mapping information MP is obtained according to the plurality of pieces of moving object location information. The processor 21 can estimate, for example, the position of the falling object 80D after a collision between the transport robot 42 and the falling object 80D based on the sequentially acquired moving object location information.

[0068] The mapping information MPA1 shows the position P42 of the transport robot 42 and the drop position P80D where the item 80 (falling item 80D) fell. The drop position P80D corresponds to the drop position P4 shown in FIG. 5. The drop position P80D in the mapping information MPA1 is the initial drop position of the falling item 80D. The position P42 of the transport robot 42 is shown in the area above the AGV and the area around the AGV. The transport robot 42 is moving in the direction where the falling item 80D is located.

[0069] The mapping information MPA2 indicates that the falling object 80D has collided with the transport robot 42. As a result, the landing position P80D of the falling object 80D and the position P42 of the transport robot 42 are moving within the warehouse, that is, moving on the map. The transport robot 42 is about to continue moving in the direction of the arrow YA.

[0070] In the mapping information MPA3, the transport robot 42 moves and stops after the falling object 80D is dragged by the transport robot 42. At this time, the fall position P80D of the falling object 80D has been changed from the initial fall position P80D (PD1), so the fall position P80D is corrected to the changed fall position PD2.

[0071] The processor 21 also determines a suspended area A1 for each piece of equipment in the warehouse based on the initial drop position PD1 of the falling object 80D and the changed drop position PD2. Equipment located in the suspended area A1 is suspended and becomes a suspended equipment. Therefore, the transport robot 42 located in the suspended area A1 is suspended and prohibited from use.

[0072] As described above, the warehouse operations management system 20 may detect a change in the drop position P80D due to an external factor, such as the transport robot 42, after the item has fallen. Even in this case, the warehouse operations management system 20 corrects the drop position P80D and outputs information about the correction result (changed drop position PD2) to the picking robot 40 or the terminal 65 of the collection worker, thereby allowing other equipment and the collector to recognize the changed drop position PD2. Furthermore, by determining the out-of-use area A1 and out-of-use equipment, the warehouse operations management system 20 can suspend system operation only in a portion of the warehouse where, for example, the transport robot 42 or the fallen item 80D is located. This minimizes a decrease in system availability. Furthermore, by determining the out-of-use area A1 and out-of-use equipment, the position of each piece of equipment within the out-of-use area A1 remains unchanged, preserving its status. Therefore, the warehouse operations management system 20 can prevent excessive movement of the fallen item 80D, making it easier for the collector to collect the item. Furthermore, safety can be ensured when, for example, a collection worker (person) collects the item.

[0073] The processor 21 may determine whether or not the drop position P80D needs to be corrected based on the direction of movement, or may determine whether or not the drop position P80D needs to be corrected based on the characteristics (e.g., size) of the falling object 80D.

[0074] <Method for recovering fallen objects according to the position where the objects have fallen> Next, an example of a method for recovering the objects 80 according to the position where the objects 80 have fallen will be described.

[0075] The drop position of the item 80 may be, for example, an area inside a bin in the warehouse, an area around the bin, an area around the AGV, an area above the AGV, an empty area, an outside area, an inter-bin area which is an area between adjacent bins 70, or other areas, as shown in Figure 7. For example, the processor 21 may determine the location within the warehouse of the drop position P80D based on the acquired drop position P80D and the mapping information MP.

[0076] First, a case where the article falls inside the bin (inside the bin area) will be described.

[0077] If it is determined that the drop position P80D of the falling object 80D is inside the bin 70, the processor 21 sets the collection timing to a later time, rather than when the drop of the object 80 is detected (when the drop is detected, when the drop position is determined). In other words, the processor 21 controls the automatic warehouse 50 to continue operating, rather than quickly collecting the falling object 80D when the object falls. This is because there is a low possibility that the falling object 80D will be damaged or lost if it is collected at a later time.

[0078] Alternatively, the processor 21 may leave the collector undetermined. In this case, any worker in the warehouse may be designated as the scheduled collector, and the processor 21 may notify the collector's terminal 65 that the items need to be collected. The processor 21 may then notify the collector at the collection timing that the items need to be collected. In this case, the collector is the picking robot 40 or the collection worker. That is, the processor 21 sends an instruction to collect the items to the picking robot 40 via the communication device 24, or sends an instruction to collect the items to the collection worker's terminal 65. The timing to collect the items may be, for example, when the bin 70 containing the fallen items 80D is used, or when a simultaneous collection operation is performed, etc.

[0079] The processor 21 also holds the bin ID as information on the corrected (changed) drop position PD2. This is because the falling object 80D is inside the bin and may move along with the bin 70. By storing the information on the corrected drop position PD2 as the bin ID, the processor 21 can obtain the position information of the bin 70 at a later time based on the bin ID to obtain the corrected drop position PD2. Furthermore, if the drop position P80D is inside the bin 70, the processor 21 determines that there is no disabled area A1 and no disabled equipment.

[0080] FIG. 9 is a diagram for supplementary explanation of the case where the drop position P80D is in the area inside the bin.

[0081] In the mapping information MPB1, the falling position P80D of the falling object 80D is inside the bin 70 (the area inside the bin). In this case, the processor 21 determines that there is no out-of-use area A1, and therefore does not put the bin 70 in an out-of-use state. Therefore, the bin 70 can be moved within the warehouse by being transported by, for example, the transport robot 42.

[0082] The processor 21 may also acquire a bin ID from the bin 70 via the communication device 24. For example, the bin 70 may have a communication device and be capable of transmitting the bin ID. This allows the warehouse operations management system 20 to track the position of the bin 70 based on the bin ID and track the fall position P80D of the fallen item 80D.

[0083] In the mapping information MPB2, the falling object 80D also moves together with the movement of the bin 70.

[0084] In this way, depending on the fall position P80D of the fallen item 80D, the warehouse system 5 does not immediately recover the fallen item 80D, but continues to operate the automated warehouse 50. Therefore, the warehouse system 5 can suppress a decrease in warehouse operation efficiency and a decrease in picking work efficiency. Furthermore, even if the fallen item 80D is recovered by the picking robot 40 or a worker at a later predetermined timing, it is possible to suppress the item 80D being dragged by the transport robot 42, making it difficult to recover, or being damaged.

[0085] Next, a case where the article 80 falls around the bin 70 (the area around the bin) or around the transport robot 42 (the area around the AGV) will be described.

[0086] In this case, there is a possibility that the fallen object 80D has come into contact with the transport robot 42. Therefore, the processor 21 determines the area around the bin or the area around the AGV as a suspended area A1, and further determines the transport robot 42 that collided with the fallen object 80D as a suspended device and stops it.

[0087] Furthermore, if the fallen item 80D is within the operating range of the picking robot 40, the processor 21 determines the picking robot 40 to be the collector, and if the fallen item 80D is not within the operating range of the picking robot 40, the processor 21 determines the collector to be the collector. This determination may be the same even if the dropped item 80D is in another area. The processor 21 instructs the picking robot 40 or the terminal 65 of the collector to collect the fallen item 80D.

[0088] In addition, there is a possibility that the fallen object 80D has fallen onto the floor in the warehouse, which would hinder the movement of the moving object. Therefore, when the processor 21 detects the fall, it transmits an instruction to collect the fallen object 80D via the communication device 24 to the picking robot 40 or the terminal 65 of the collection worker.

[0089] Furthermore, when a falling object 80D exists in the moving direction of the transport robot 42, the processor 21 corrects the drop position P80D to the position where the transport robot 42 stopped after moving, and sets this as the changed drop position PD2. On the other hand, when a falling object 80D exists in the moving direction of the transport robot 42, the processor 21 does not correct the drop position P80D.

[0090] The processor 21 also determines the range from the fall position P80D of the falling object 80D to the travel range of the transport robot 42 that may have come into contact with the falling object 80D after the contact as a suspended area A1. The processor 21 also determines the transport robot 42 that may have come into contact with the falling object 80D as a suspended device.

[0091] Next, a case where the item 80 is dropped in an area (empty area) within the automated warehouse 50 will be described.

[0092] The processor 21 sequentially acquires moving object location information before and after the time of the fall, and determines whether or not the falling object 80D has come into contact with the transport robot 42 based on the sequentially acquired moving object location information. If the falling object 80D has come into contact with the transport robot 42, the processor 21 determines the range from the fall position P80D of the falling object 80D to the travel range of the transport robot 42 that may have come into contact with the falling object 80D after the contact as a suspended area A1. The processor 21 also determines the transport robot 42 that may have come into contact with the falling object 80D as a suspended device. On the other hand, if the falling object 80D has not come into contact with the transport robot 42, the processor 21 designates one unit area AU that includes the fall position P80D of the falling object 80D, or, if the fall position P80D has fallen on the boundary of the unit area AU, multiple unit areas AU that include the boundary as the suspended area A1.

[0093] Furthermore, if a falling object 80D exists in the movement direction of the transport robot 42, the processor 21 changes the drop position P80D to a position where the transport robot 42 stopped after moving, and sets this as the changed drop position PD2. On the other hand, if the falling object 80D does not exist in the movement direction of the transport robot 42, the processor 21 does not correct the drop position P80D. Note that if the falling object 80D and the transport robot 42 are not in contact with each other, the processor 21 does not correct the drop position P80D.

[0094] Furthermore, since the fallen item 80D is present in an empty area, it is highly likely that it has fallen onto the floor of the warehouse, and will hinder the movement of the moving object. Therefore, when the processor 21 detects the fall, it transmits an instruction to collect the fallen item 80D to the picking robot 40 or the terminal 65 of the collection worker via the communication device 24.

[0095] Next, a case where the dropped position of the article 80 is above the transport robot 42 (the area above the AGV) will be described.

[0096] The processor 21 may determine an area including the drop position P80D of the falling object 80D as the suspended area A1. Specifically, the processor 21 may determine the range from the drop position P80D of the falling object 80D to the travel range of the transport robot 42 carrying the falling object 80D after the object has fallen as the suspended area A1. The processor 21 may determine the transport robot 42 carrying the falling object 80D as suspended equipment. Then, the processor 21 changes the drop position P80D to the position P42 of the transport robot 42 carrying the falling object 80D. In this case, information on the changed (corrected) drop position PD2 may be used as the ID of the transport robot 42 carrying the falling object 80D.

[0097] Furthermore, since the fallen item 80D is on the transport robot 42, it interferes with the use of the transport robot 42 (transport of the bins 70). Therefore, upon detecting the fall, the processor 21 transmits, via the communication device 24, an instruction to collect the fallen item 80D to the picking robot 40 or the terminal 65 of the collection worker.

[0098] Next, a case where the dropped position of the article 80 overlaps with the surrounding area of ​​multiple bins 70 (a state surrounded by multiple bins 70, an area between bins) will be described.

[0099] FIG. 10 is a diagram for supplementary explanation of the case where the drop position P80D is in the area between bins.

[0100] The inter-bin area is, for example, between adjacent bins 70. It is impossible or difficult for the arm 40a of the picking robot 40 to enter the inter-bin area. Therefore, the processor 21 determines the collection worker as the collection worker. Then, the processor 21 transmits a collection instruction including, for example, collection guidance information to the terminal 65 of the collection worker.

[0101] Furthermore, since the fallen object 80D is present between adjacent bins 70, it interferes with the movement of the bins 70. Therefore, upon detecting the fall, the processor 21 transmits, via the communication device 24, an instruction to collect the fallen object 80D to the terminal 65 of the collection worker.

[0102] Furthermore, when the falling object 80D comes into contact with the transport robot 42, the processor 21 may determine the range from the fall position P80D of the falling object 80D to the travel range of the transport robot 42 that came into contact with the falling object 80D after the object has fallen as the suspended area A1. The processor 21 may determine the transport robot 42 that came into contact with the falling object 80D as suspended equipment.

[0103] Next, a case where the item 80 falls outside the automated warehouse 50 (outside area) will be described.

[0104] If an item 80 falls outside the automated warehouse 50, it has little effect on the automatic bin transport and picking operations within the warehouse. Therefore, the fallen item 80D may be collected at a later time, similar to when the fallen item 80D falls into the bin area. In other words, the processor 21 controls the automated warehouse 50 to continue operating, rather than quickly collecting the fallen item 80D when the item falls.

[0105] Alternatively, the processor 21 may leave the collector undetermined. In this case, any worker in the warehouse may be designated as the scheduled collector, and the processor 21 may notify the worker's terminal 65 that the item needs to be collected. The processor 21 may then notify the collector that the item needs to be collected at the time of collection. In this case, the collector is the picking robot 40 or the collection worker. That is, the processor 21 sends an instruction to collect the item to the picking robot 40 or the collection worker's terminal 65 via the communication device 24. The collection may be performed, for example, at the time of simultaneous collection work. Furthermore, if the drop position P80D is an empty area, the processor 21 determines that there is no suspended area A1 and no suspended equipment.

[0106] <Example of Determining Whether the Area Surrounding or Inside the Bin Taking into Account Estimation Error of the Position at Which an Article Falls> Next, an example of determining whether the area surrounding or inside the bin takes into account estimation error of the position at which an article falls will be described.

[0107] FIG. 11 is a diagram for explaining an example of determining whether an object is located around a bin or inside the bin, taking into consideration an estimation error in the position where the object will fall.

[0108] The bin 70 has, for example, a substantially rectangular parallelepiped shape, and when projected from above onto a two-dimensional plane, the bin 70 has a rectangular shape. If there is an error in estimating the fall position P80D of the falling object 80D, it is difficult to determine whether the falling object 80D fell inside the bin or around the bin.

[0109] 11, a boundary area A2 is defined at the boundary between the periphery of the bin and the interior of the bin. For example, the processor 21 determines the boundary area A2 to be within a range that is a predetermined distance inside the outline W1 of the bin 70 and a predetermined distance outside the outline W2. The outline W1 is the outer frame (outer periphery) of the area within the bin and the inner frame (inner periphery) of the area surrounding the bin. The outline W2 is the outer frame of the area surrounding the bin.

[0110] For example, the processor 21 acquires, via the communication device 24, a fall position P80D of the falling object 80D detected by a sensor with lower position detection accuracy than the position detection accuracy of the camera 60. If the processor 21 determines that the fall position P80D is within the boundary area A2, it sends an image capture instruction to the camera 60 via the communication device 24. Upon receiving the image capture instruction, the camera 60 captures an image of the bin 70, in which the falling object 80D, the area inside the bin, and the area around the bin are reflected, and transmits the captured image to the warehouse operations management system 20. The processor 21 receives the captured image via the communication device 24 and identifies the fall position P80D of the falling object 80D based on the captured image. This allows the warehouse operations management system 20 to accurately detect the fall position P80D.

[0111] This allows the warehouse operation management system 20 to determine with high accuracy whether the falling item 80D has fallen inside the bin or around the bin, even if there is an estimation error in the fall position P80D of the falling item 80D.

[0112] <Example of Determining Between the Surrounding Area and the Inside of the Bin Taking into Account Estimation Errors in the Time at Which an Item Falls> Next, an example of determining between the surrounding area and the inside of the bin taking into account estimation errors in the time at which an item falls will be described.

[0113] FIG. 12 is a diagram illustrating a first example of determining the periphery of the bin and the inside of the bin, taking into account an estimation error in the time at which the item falls.

[0114] In Figure 12, n seconds before the drop time, there is no falling object 80D inside the bin 70. At the drop time (time when the drop is completed), there is a falling object 80D inside the bin 70. At a specified map information acquisition time after the drop, there is a falling object 80D inside the bin 70. These times are examples of multiple different times in a chronological order. Furthermore, the bin 70 is not moving, and the falling object 80D inside the bin is not moving either.

[0115] For example, the processor 21 sequentially acquires, via the communication device 24, time information for different timings included in a fall time period, including before and after the time of the fall of the falling object 80D, detected by a sensor with low time detection accuracy (low reliability). The different timings include, for example, n seconds before the fall time, the fall time, and the time of acquisition of predetermined map information. The processor estimates each fall position P80D based on each acquired fall time. If the processor 21 recognizes that each estimated fall position P80D has not moved, it uses the estimated result of the fall position P80D based on the fall time detected by this sensor for subsequent processing by the processor 21. This is because the estimated result of the fall position P80D is reliable.

[0116] FIG. 13 is a diagram for explaining a second example of determining the periphery of the bin and the inside of the bin, taking into account the estimation error of the time when the item falls.

[0117] In Figure 13, n seconds before the drop time, there is no falling object 80D inside the bin 70. At the drop time (time when the drop is completed), there is a falling object 80D inside the bin 70, and the bin 70 has moved in the direction of arrow YB from position P70 of the bin 70 n seconds before the drop time. At a specified map information acquisition time after the drop, there is a falling object 80D inside the bin 70, and the bin 70 has moved further in the direction of arrow YB from position P70 of the bin 70 at the drop time. As the bin 70 is moving, the falling object 80D inside the bin also moves.

[0118] For example, the processor 21 sequentially acquires, via the communication device 24, time information for different timings included in a fall time period, including before and after the time of the falling object 80D, detected by a sensor with low time detection accuracy (low reliability). The different timings include, for example, n seconds before the fall time, the fall time, and a predetermined map information acquisition time. The processor estimates each fall position P80D based on each acquired fall time. If the processor 21 recognizes that each estimated fall position P80D is moving, it transmits an image capture instruction to the camera 60 via the communication device 24. Upon receiving the image capture instruction, the camera 60 captures an image of the bin 70 in which the falling object 80D is reflected and transmits the captured image to the warehouse operations management system 20. The processor 21 receives the captured image via the communication device 24 and identifies the fall position P80D of the falling object 80D based on the captured image. This allows the warehouse operations management system 20 to accurately detect the fall position P80D. The processor 21 uses the result of estimation of the fall position P80D by the camera 60 in subsequent processing by the processor 21. This is because the result of estimation of the fall position P80D by the camera 60 is more reliable than the result of estimation of the fall position P80D based on the fall time obtained by a sensor with low detection accuracy.

[0119] This allows the warehouse operations management system 20 to determine with high accuracy whether the falling object 80D fell into the bin or around the bin, even if there is an error in estimating the time when the falling object 80D fell. Furthermore, if re-estimation of the falling position P80D is not necessary, such as when the falling position P80D obtained at different times is the same, the warehouse operations management system 20 can omit re-estimation of the falling position P80D by the camera 60, thereby reducing the processing load on the warehouse operations management system 20.

[0120] <Operation of Warehouse System> Next, the operation of the warehouse system 5 will be described.

[0121] 14 to 19 are flowcharts showing an example of the operation of the warehouse system 5.

[0122] 14, the processor 21 of the warehouse operations management system 20 detects (S11) that the item 80 (falling item 80D) has fallen from the hand 40h of the picking robot 40. The processor 21 estimates the time when the item 80 fell and estimates the falling position P80D.

[0123] The processor 21 sequentially acquires moving object location information for a time period (fall time period) including the times before and after the fall time (S13). That is, the processor 21 sequentially acquires mapping information MP that may change over time, for example.

[0124] The processor 21 determines the location of the drop position P80D of the falling object 80D based on the mapping information MP. The processor 21 determines, for example, whether the drop position P80D is an area inside the bin, an area around the bin, an empty area, an area around the AGV, or an area on the AGV. The processor executes processing for each drop position of the falling object 80D based on the determination result of the drop position P80D (S14). The processing for each drop position of the object 80D will be described in detail later.

[0125] After performing processing for each falling position of the falling object 80D, the processor 21 determines whether the falling object 80D is a heavy object or a liquid object (S15). For example, information on whether the falling object 80D is a heavy object or a liquid object may be included in the object information I3 as one piece of information on the characteristics of the object 80. Therefore, the processor 21 may determine whether the falling object 80D is a heavy object or a liquid object based on the object information I3.

[0126] If the falling object 80D is neither a heavy object nor a liquid object (No in step S15), the processor 21 determines whether the falling position P80D is within the operating range of the picking robot 40 (S16).

[0127] If the falling position P80D is within the operating range of the picking robot 40 (Yes in step S16), the processor 21 acquires detection information from any sensor or an image captured by the camera 60, and determines whether or not the falling item 80D has been detected based on the detection information or the image captured (S17).

[0128] When a fallen item 80D is detected, the processor 21 determines the picking robot 40 as the collector. Then, the processor 21 transmits an instruction to collect the fallen item 80D to the picking robot 40. Upon receiving this instruction, the picking robot 40 controls the arm 40a and the hand 40h in accordance with the instruction, thereby performing a collection operation to collect the fallen item 80D. After completing the collection operation, the picking robot 40 may notify the warehouse operations management system 20 of a collection completion notification indicating that collection of the fallen item 80D has been completed.

[0129] The processor 21 determines whether the collection of the fallen object 80D by the picking robot 40 has been successful (S18). For example, the processor 21 may acquire detection information from any of the sensors or an image captured by the camera 60 after a predetermined time has elapsed since the picking robot 40 was instructed to collect the object 80D, or upon receiving a collection completion notification from the picking robot 40, and determine whether the collection of the fallen object 80D has been successful based on the detection information or the image captured. For example, if the fallen object 80D has been removed from the position where it fell, it may be determined that the collection of the fallen object 80D has been successful.

[0130] On the other hand, if the falling object 80D is a heavy object or a liquid object (Yes in step S15), if the drop position P80D is outside the operating range of the picking robot 40 (No in step S16), if the falling object 80D is not detected (No in step S17), or if the picking robot 40 has failed to collect the falling object 80D (Yes in step S18), the processor 21 performs the following processing. That is, the processor 21 notifies the terminal 65 of the collection worker of a collection instruction to collect the falling object 80D (S19). The terminal 65 displays the above-mentioned guidance information, etc. in accordance with the collection instruction. After checking the guidance information, the collection worker checks the drop position P80D by referring to, for example, the mapping information MP, and collects the falling object 80D from the drop position P80D.

[0131] This allows the warehouse system 5 to recover the fallen item 80D using the picking robot 40 as much as possible, thereby reducing the burden on the worker. Furthermore, even if the picking robot 40 is unable to recover the fallen item 80D, the warehouse system 5 allows a recovery worker (person) to reliably recover the fallen item 80D. Furthermore, if the fallen item 80D is heavy or liquid, it may be affecting the environment within the warehouse. Even in this case, the recovery worker can check the environment within the warehouse and recover the fallen item 80D. In this case, the terminal 65 may display guidance information including a message such as "Please check the environment around the location where the item fell" in accordance with the recovery instruction.

[0132] 15 is a diagram showing an example of processing for each drop position, in which the drop position P80D is in the area inside the bin.

[0133] If the drop position P80D is within the bin area, the processor 21 acquires the bin ID of the bin 70 containing the dropped item 80D (S21). This allows the warehouse operations management system 20 to track the position of the dropped item 80D even if the bin 70 moves.

[0134] The processor 21 continues the operation of the automated warehouse 50 via the communication device 24 (S22). That is, even if the processor 21 recognizes that an item has fallen, the processor 21 continues the operation of the automated warehouse 50 and each device, and causes the picking robot 40 or the picking operator 45 to continue picking work.

[0135] The processor 21 transmits a collection instruction to a collector (e.g., the picking robot 40 or a collection worker) to instruct the collector to collect the item at a different time (not in real time (immediately) but at a later time) (S23). In this case, the processor 21 transmits the collection instruction to the terminal 65 of the picking robot 40 or the collection worker via the communication device 24.

[0136] 16 is a diagram showing an example of processing for each drop position, in which the drop position P80D is the area around the bin.

[0137] If the drop position P80D is in the area around the bin, the processor 21 determines that the transport robot 42 carrying the bin 70 may be in contact with the falling item 40D. The processor 21 then transmits a stop instruction to the transport robot 42 to stop the transport robot 42 (S31). The transport robot 42 stops in accordance with the stop instruction. This allows the warehouse operations management system 20 to prevent the transport robot 42 from moving the falling item 80D.

[0138] The processor 21 determines the area surrounded by the initial drop position PD1 and the movement path (the area of ​​the movement trajectory, the travel range) of the transport robot 42 after the drop as the out-of-use area A1 (S32).

[0139] The processor 21 determines whether the drop position P80D (initial drop position PD1) is sandwiched between other bins 70, that is, whether it is between adjacent bins 70 (S33).

[0140] If the falling position P80D is a position sandwiched between other bins 70 (Yes in step S33), the processor 21 proceeds to step S19 in Fig. 14 and transmits a collection instruction for the fallen item 80D to the terminal 65 of the collection worker. This is because it would be difficult for the picking robot 40 to collect the fallen item 80D.

[0141] On the other hand, if the drop position P80D is not a position sandwiched between other bins 70 (No in step S33), the processor 21 acquires information on the movement direction of the transport robot 42 transporting the bin 70 around which the fallen object 80D was detected. The processor 21 may acquire information on the movement direction of the transport robot 42, for example, by sequentially acquiring position information of the corresponding transport robot 42 in chronological order and estimating the movement direction of the transport robot 42 based on changes in the sequentially acquired position information. The processor 21 determines whether the fallen object 80D is present in the movement direction of the transport robot 42 (S34).

[0142] If the falling object 80D is present in the movement direction of the transport robot 42 (Yes in step S34), the processor 21 determines that the falling object 80D has come into contact with the transport robot 42. Then, the processor 21 corrects (changes) the drop position P80D of the falling object 80D to the stopping position of the transport robot 42 that came into contact with the falling object 80D (S35). That is, the processor 21 corrects the drop position P80D from the initial drop position PD1 to the changed drop position PD2.

[0143] After the process of step S35, or if there is no fallen object 80D in the moving direction of the transport robot 42 (NO in step S34), the process proceeds to step S15 in FIG.

[0144] 17 is a diagram showing an example of processing for each drop position, in which the drop position P80D is an empty area.

[0145] If the drop position P80D is an empty area, the processor 21 determines whether or not the transport robot 42 and the fallen object 80D came into contact with each other after the object fell (S41). For example, the processor 21 may sequentially acquire mapping information MP in chronological order from the time the object fell, the mapping information MP including information on the drop position P80D and the positions P42 of each transport robot 42 in the warehouse. Then, the processor 21 may determine whether or not the fallen object 80D that fell into the empty area came into contact with any of the transport robots 42, based on the sequentially acquired mapping information MP.

[0146] If it is determined that the transport robot 42 and the fallen object 80D have come into contact with each other after the object has fallen (Yes in step S41), the warehouse system 5 performs the same processing as steps S31 to S35 shown in FIG.

[0147] 18 is a diagram showing an example of processing for each drop position, in which the drop position P80D is in the area around the AGV.

[0148] If the drop position P80D is in the area surrounding the AGV, the processor 21 determines that there is a possibility that the transport robot 42 and the fallen object 40D have come into contact. The warehouse system 5 performs the same processes as steps S31, S32, S34, and S35 shown in Fig. 16. Note that the process of step S33 does not need to be performed. This is because the transport robot 42 mainly moves, carrying or not carrying a bin 70, and the area surrounding the AGV is unlikely to be an area between adjacent bins 70 that are placed close to each other.

[0149] 19 is a diagram showing an example of processing for each drop position, in which the drop position P80D is in the area above the AGV.

[0150] The area above the AGV indicates that the drop position P80D is above the transport robot 42. When the transport robot 42 is carrying a bin 70, the drop position P80D is above the transport robot 42 but outside the bin 70. When the transport robot 42 is not carrying a bin, the drop position P80D is somewhere above the transport robot 42.

[0151] If the drop position P80D is in the area above the AGV, the processor 21 determines that the fallen object 80D is on top of the transport robot 42 and may move together with the transport robot 42. As in step S31 of FIG. 16 , the processor 21 transmits a stop instruction to the transport robot 42 to stop the transport robot 42. The transport robot 42 stops in accordance with the stop instruction. If the transport robot 42 moves, the fallen object 80D on top of the transport robot 42 may fall from the transport robot 42, and the transport robot 42 may move the fallen object 80D by dragging it, for example. In response to this, the warehouse operations management system 20 can prevent the fallen object 80D from moving further by stopping the transport robot 42.

[0152] As in step S32 of Figure 16, the processor 21 determines the area surrounded by the initial drop position PD1 and the movement path of the transport robot 42 after the drop (the area of ​​the movement trajectory, the travel range) as the suspended area A1.

[0153] The processor 21 corrects (changes) the drop position P80D of the falling object 80D to the stop position of the transport robot 42 (S61). That is, the processor 21 corrects the drop position P80D from the initial drop position PD1 to the changed drop position PD2. For example, if the transport robot 42 has not moved since the falling object 80D fell, the initial drop position PD1 and the changed drop position PD2 are the same. On the other hand, if the transport robot 42 has moved since the falling object 80D fell, the initial drop position PD1 and the changed drop position PD2 are different. Note that, unlike the case in which the drop position P80D is in the area around the bin as assumed in FIG. 16 , if the drop position P80D is in the area above the AGV, the movement direction of the transport robot 42 is not taken into consideration. This is because the falling object 80D and the transport robot 42 are in contact with each other and move together regardless of the movement direction of the transport robot 42.

[0154] According to the warehouse system 5 of the first embodiment, in a warehouse including an automated warehouse 50 in which the arrangement of bins 70 around a picking station PS changes over time, even if, for example, the arm 0a of a picking robot 40 drops an item 80 at an unexpected timing, the warehouse system 5 can detect the fall of the item 80 and appropriately determine a method for recovering the fallen item 80D. Furthermore, the warehouse operations management system 20 can propose different recovery methods depending on the location of the item and can also determine whether or not to operate each piece of equipment in the warehouse depending on the location of the item. Therefore, by recovering the fallen item 80D according to the determined recovery method, the warehouse system 5 can prevent a decrease in warehouse operating efficiency. The warehouse system 5 can then efficiently operate the automated warehouse 50.

[0155] 5 to 10 illustrate an example in which a picking robot 40 is arranged at the picking station PS, but a picking operator 45 may be arranged therein. In addition, in the present embodiment, an example is given in which the fallen object 80D is collected, but collecting the fallen object 80D may include returning the fallen object 80D to a bin 70 or the like as a recovery destination, and may also include using the fallen object 80D for subsequent picking or shipping operations.

[0156] (Summary of the embodiment) As described above, the present disclosure describes at least the following matters. Note that, in parentheses, examples of components corresponding to the above-described embodiment are shown, but the present disclosure is not limited to these.

[0157] (Item 1) A warehouse management method for managing a warehouse, comprising the steps of: acquiring operating range information indicating an operating range of a picking robot (picking robot 40) that performs the picking operation of the item (item 80); acquiring drop position information indicating a drop position (drop position P80D) at which a first item (falling item 80D) fell from the picking robot and drop time information indicating a drop time at which the first item fell from the picking robot; acquiring placement state information (mobile object placement information, mapping information MP) indicating a placement state of a mobile object (transport robot 42, bin 70) that moves within the warehouse; and determining recovery information regarding a method for recovering the first item based on the operating range of the picking robot, the drop position and drop time of the first item, and the placement state of the mobile object at the drop time.

[0158] As a result, the warehouse management method can appropriately determine a method for recovering the first item even if, for example, the picking robot drops the first item at an unexpected time. Therefore, the warehouse system 5 can prevent a decrease in warehouse operating efficiency by recovering the first item according to the determined recovery method.

[0159] (Item 2) The warehouse management method according to item 1, wherein the collection information includes at least one of a collector who collects the first item and a collection timing for collecting the first item.

[0160] This makes it possible for the warehouse management method to determine the collector and collection timing that will result in efficient operation of the warehouse.

[0161] (Item 3) The warehouse management method according to Item 2, further comprising a step of, when the collector is a collection worker who collects the first item, notifying a terminal (terminal 65) of the collection worker of guidance information for guiding the collection of the first item, including information on the dropped location, based on the collection information.

[0162] This allows the warehouse management method to notify the collection worker that the first item needs to be collected, and to provide guidance including the location where the item has fallen.

[0163] (Item 4) The warehouse management method according to Item 2, further comprising the step of, when the collector is the picking robot, sending an instruction to the picking robot to collect the first item based on the collection information.

[0164] This allows the warehouse management method to notify the picking robot that the first item needs to be collected, and to instruct the robot to perform the collection operation at an appropriate time.

[0165] (Item 5) The warehouse management method according to Item 1 or 2, wherein the step of acquiring the drop position information includes a step of estimating the drop position based on at least one of a position, a speed, and an acceleration of a hand (hand 40h) of the picking robot, characteristics of the first item, and a type of the hand.

[0166] This allows the warehouse management method to analyze the tendency of items to fall while taking into account the characteristics of the picking robot and the items, and to appropriately estimate the location where the items will fall.

[0167] (Item 6) The warehouse management method according to item 1 or 2, wherein the mobile object includes at least one of a bin (bin 70) for storing the item and a transport robot (transport robot 42) for transporting the bin.

[0168] This allows collection information to be determined according to the relative positions of bins and transport robots in the warehouse.

[0169] (Item 7) The warehouse management method according to Item 1 or 2, wherein the step of acquiring the positional state information of the moving object includes a step of sequentially acquiring, in chronological order, positional state information of the moving object during a fall time period that includes the fall time of the first item and times before and after the fall time, and further includes a step of correcting the fall position based on the positional state of the moving object acquired in chronological order.

[0170] Depending on the drop position of the item, there is a possibility that the item may be moved unexpectedly by the moving object. Even in this case, the warehouse management method can estimate the movement state of the first item by checking the time-series change in the arrangement state of the moving object, and can change, for example, the initial drop position (initial drop position PD1) to a drop position after the movement (changed drop position PD2).

[0171] (Item 8) The warehouse management method according to Item 7, wherein the mobile body includes a transport robot that transports a bin that stores the item, and the step of correcting the drop position includes the steps of: acquiring movement direction information indicating a movement direction of the transport robot; and correcting the drop position if the drop position is in the movement direction of the transport robot.

[0172] As a result, the warehouse management method can correct the drop position only in cases where there is a high possibility that the transport robot will move the first item on the transport robot when the transport robot is heading towards the drop position, thereby reducing the load associated with the correction.

[0173] (Item 9) The warehouse management method according to Item 1 or 2, further comprising a step of determining at least one of an area within the warehouse and equipment within the warehouse that is to be taken out of service (a discontinued area A1) and equipment that is to be taken out of service, based on the drop position before correction and the drop position after correction.

[0174] This allows the warehouse management method to suspend use of areas and equipment that are hindering the collection of the first item, making it easier for the collector to collect the first item within the warehouse.

[0175] (Item 10) The warehouse management method according to Item 9, wherein the step of determining at least one of an area out of use and the equipment out of use includes the step of determining that the area out of use and the equipment out of use are absent if the drop location is inside a bin that stores the item.

[0176] This allows the warehouse management method to collect the first item during free time or at the same time as other collections, without reducing the operating efficiency of the warehouse, if the drop location is inside the bin.

[0177] (Item 11) The warehouse management method according to Item 2, wherein the step of determining the collection information includes a step of determining the collector as a collection worker who will collect the first item if the first item is a heavy item or a liquid item.

[0178] This allows the warehouse management method to notify that the first item needs to be carefully retrieved or the environment around the first item needs to be checked.

[0179] (Item 12) The warehouse management method according to Item 2, wherein the step of determining the collection information includes a step of determining the collector as a collection worker who will collect the first item if the drop position is outside the operating range of the picking robot.

[0180] This allows the warehouse management method to have a collection worker collect the first item even if the first item falls in an area that the arm of a picking robot cannot reach (for example, an area between bins).

[0181] (Item 13) The warehouse management method described in Item 2 further includes a step of determining whether the picking robot has successfully recovered the first item, and the step of determining the recovery information includes a step of determining the collector as a recovery worker who will recover the first item if it is determined that the picking robot has failed to recover the first item.

[0182] As a result, the warehouse management method can have the collection worker collect the first item as an auxiliary even if the first item cannot be collected.

[0183] (Item 14) The warehouse management method described in Item 6, wherein the step of acquiring the drop position information includes the steps of: capturing an image of an imaging range including the inside of the bin and the periphery of the bin; and, if the drop position is included in the boundary area (boundary area A2) between the inside of the bin and the periphery of the bin, estimating the drop position based on an image of the imaging range.

[0184] This makes it possible for the warehouse management method to obtain highly reliable information on the drop position even when the reliability of the initially obtained drop position is low.

[0185] (Item 15) The warehouse management method described in Item 6, wherein the step of acquiring the drop position information includes the steps of: capturing an image of an imaging range including the inside of the bin and the periphery of the bin; sequentially acquiring the drop positions obtained during a drop time period including the drop time and times before and after the drop time in chronological order; and, if the drop positions obtained sequentially in chronological order have changed, estimating the drop position based on the image of the imaging range.

[0186] This makes it possible for the warehouse management method to obtain highly reliable information on the drop location even if the reliability of the initially obtained drop time is low.

[0187] (Item 16) A warehouse management system (warehouse operations management system 20) that manages a warehouse and includes a processor (processor 21), wherein the processor: acquires operating range information indicating the operating range of a picking robot that performs item picking work; acquires drop position information indicating the drop position where a first item was dropped from the picking robot and drop time information indicating the drop time where the first item was dropped from the picking robot; acquires placement state information indicating the placement state of a mobile object that moves within the warehouse; and determines recovery information regarding a method for recovering the first item based on the operating range of the picking robot, the drop position and drop time of the first item, and the placement state of the mobile object at the drop time.

[0188] This allows the warehouse management system to achieve the same effect as item 1.

[0189] Although various embodiments have been described above with reference to the drawings, it goes without saying that the present disclosure is not limited to such examples. It is clear that a person skilled in the art can conceive of various modifications or alterations within the scope of the claims, and it is understood that these also naturally fall within the technical scope of the present disclosure. Furthermore, the components of the above-described embodiments may be combined in any manner without departing from the spirit of the invention.

[0190] In addition, the above embodiment may also be applicable to a program that realizes the functions of the warehouse management method, which is supplied to a computer (e.g., warehouse operations management system 20) via a network or various storage media, and which is read and executed by the processor of this computer, as well as to the storage media on which this program is stored.

[0191] The present disclosure is useful for a warehouse management method, a warehouse management system, and the like that can prevent a decrease in the efficiency of picking work even if an item to be picked falls.

[0192] 5 Warehouse system 10 Warehouse management system 20 Warehouse operation management system 21 Processor 22 Memory 23 Input device 24 Communication device 25 Input / output interface 30 Warehouse control system 40 Picking robot 42 Transport robot 45 Picking worker 50 Automated warehouse 60 Camera 65 Terminal 70 Bin 71 Storage bin 72 Shipping bin 80 Item 80D Falling item MP Mapping information P80D Falling position PS, PS0, PS1 Picking station

Claims

1. A warehouse management method for managing a warehouse, comprising the steps of: acquiring operating range information indicating the operating range of a picking robot that performs item picking work; acquiring drop position information indicating the drop position where a first item was dropped from the picking robot and drop time information indicating the drop time where the first item was dropped from the picking robot; acquiring placement state information indicating the placement state of a mobile object that moves within the warehouse; and determining recovery information regarding a method for recovering the first item based on the operating range of the picking robot, the drop position and drop time of the first item, and the placement state of the mobile object at the drop time.

2. The warehouse management method according to claim 1, wherein the collection information includes at least one of a collector who will collect the first item and a collection timing for collecting the first item.

3. The warehouse management method according to claim 2, further comprising the step of: if the collector is a collection worker who collects the first item, notifying a terminal of the collection worker of guidance information guiding the collection of the first item, including the dropped location information, based on the collection information.

4. The warehouse management method according to claim 2, further comprising the step of, if the collector is the picking robot, sending an instruction to the picking robot to collect the first item based on the collection information.

5. A warehouse management method as described in claim 1 or 2, wherein the step of acquiring the drop position information includes a step of estimating the drop position based on at least one of the position, speed, and acceleration of the hand of the picking robot, the characteristics of the first item, and the type of the hand.

6. The warehouse management method according to claim 1 or 2, wherein the mobile object includes at least one of a bin for storing the item and a transport robot for transporting the bin.

7. A warehouse management method as described in claim 1 or 2, wherein the step of acquiring the positional state information of the moving object includes a step of sequentially acquiring, in chronological order, positional state information of the moving object during a fall time period that includes the fall time of the first item and times before and after the fall time, and further includes a step of correcting the fall position based on the positional state of the moving object acquired in chronological order.

8. A warehouse management method as described in claim 7, wherein the mobile body includes a transport robot that transports a bin that stores the item, and the step of correcting the drop position includes the steps of: acquiring movement direction information indicating the movement direction of the transport robot; and correcting the drop position if the drop position is in the movement direction of the transport robot.

9. A warehouse management method as described in claim 1 or 2, further comprising a step of determining at least one of an area within the warehouse and equipment within the warehouse to be taken out of service, based on the fall position before correction and the fall position after correction.

10. The warehouse management method according to claim 9, wherein the step of determining at least one of an area out of use and the equipment out of use includes the step of determining that the area out of use and the equipment out of use are absent if the drop location is inside a bin that stores the item.

11. The warehouse management method according to claim 2, wherein the step of determining the collection information includes a step of determining the collector as a collection worker who will collect the first item if the first item is a heavy item or a liquid item.

12. The warehouse management method of claim 2, wherein the step of determining the collection information includes a step of determining the collector as a collection worker who will collect the first item if the drop position is outside the operating range of the picking robot.

13. The warehouse management method of claim 2, further comprising a step of determining whether the picking robot has successfully recovered the first item, wherein the step of determining the recovery information comprises a step of determining the collector as a recovery worker who will recover the first item if it is determined that the picking robot has failed to recover the first item.

14. The warehouse management method of claim 6, wherein the step of acquiring the drop position information includes the steps of: capturing an image of an imaging range including the inside of the bin and the periphery of the bin; and, if the drop position is included in the boundary area between the inside of the bin and the periphery of the bin, estimating the drop position based on an image of the imaging range captured.

15. The warehouse management method of claim 6, wherein the step of acquiring the drop position information includes the steps of: capturing an image of an imaging range including the inside of the bin and the periphery of the bin; sequentially acquiring the drop positions obtained during a drop time period including the drop time and times before and after the drop time in chronological order; and, if the drop positions obtained sequentially in chronological order change, estimating the drop position based on the image captured in the imaging range.

16. A warehouse management system comprising a processor for managing a warehouse, wherein the processor: acquires operating range information indicating the operating range of a picking robot that performs item picking work; acquires drop position information indicating the drop position where a first item was dropped from the picking robot and drop time information indicating the drop time when the first item was dropped from the picking robot; acquires placement position information indicating the placement state of a mobile object that moves within the warehouse; and determines recovery information regarding a method for recovering the first item based on the operating range of the picking robot, the drop position and drop time of the first item, and the placement state of the mobile object at the drop time.