Warehouse management method and warehouse management system

Abstract

A warehouse management method for managing a warehouse, the method comprising: a step for acquiring operating range information that indicates an operating range of a picking robot for performing picking work of an article; a step for acquiring dropping position information that indicates a dropping position where a first article is to be dropped from the picking robot; a step for acquiring arrangement position information that indicates the arrangement state of respective apparatuses within the warehouse; and a step for determining, on the basis of the operating range of the picking robot, the dropping position of the first article, and the arrangement state of the respective apparatuses, whether or not it is necessary to move a bin in which the article is to be stored.

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, the warehouse management method comprising the steps of: acquiring operating range information indicating the operating range of a picking robot that picks items; acquiring drop position information indicating the drop position of a first item from the picking robot; acquiring placement status information indicating the placement status of each piece of equipment within the warehouse; and determining whether or not it is necessary to move a bin that stores the item based on the operating range of the picking robot, the drop position of the first item, and the placement status of each piece of equipment.

[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 of a first item from the picking robot, acquires placement status information indicating the placement status of each piece of equipment within the warehouse, and determines whether or not it is necessary to move a bin that stores the item based on the operating range of the picking robot, the drop position of the first item, and the placement status of each piece of equipment.

[0007] According to the present disclosure, even if an item falls inside a warehouse, a decrease in the warehouse's operating efficiency can be suppressed.

[0008] FIG. 1 is a diagram showing an example of the configuration of a warehouse system in the first embodiment. FIG. 2 is a diagram showing an example of the 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 the range of a picking station. FIG. 10 is a diagram showing a first example of bin movement when the item drop position is in the inter-bin area and is within the operating range of the picking robot. FIG. 11 is a diagram showing a second example of bin movement when the item drop position is in the inter-bin area and is within the operating range of the picking robot. FIG. 2 is a diagram for supplementary explanation of a first example of the operation of the warehouse system when the dropped position is outside the operating range of the picking robot. FIG. 3 is a diagram for supplementary explanation of a second example of the operation of the warehouse system when the dropped position is outside the operating range of the picking robot. FIG. 4 is a diagram showing an example of recovery of a re-dropped item when the re-drop position is in an area inside the bin. FIG. 5 is a diagram showing a first example of recovery of a re-dropped item when the re-drop position is in an area other than the area inside the bin in the warehouse. FIG. 6 is a diagram for explaining a modified example of the movement of a bin when a dropped item is in an area inside the bin.

[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, if an item to be picked falls, the placement of bins is not taken into consideration when recovering the fallen item. As a result, when recovering the item, the bins may act as a barrier, making it difficult for the picking robot to grasp the item or for the recovery worker to move to the location where the item fell. As a result, the bins may become an obstacle when the recoverer tries to recover the item, which may reduce the operating efficiency of the warehouse.

[0011] In the following embodiments, a warehouse management method and a warehouse management system that can prevent 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 (movable 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 included in the robot configuration information and stored in the memory 22, for example.

[0046] For example, the processor 21 acquires information on the location and time at which a specific item 80 has fallen from the picking robot 40. The processor 21 may recognize the location of the item based on, for example, detection information detected by a sensor in the warehouse or an image captured by a camera 60 in the warehouse. The time of the item's fall may be the time at which the item was detected.

[0047] For example, the processor 21 acquires information (equipment layout information) on the layout status of each piece of equipment in the warehouse (e.g., the picking robot 40, the transport robot 42, the automated warehouse 50, and the bins 70). The equipment layout information may be represented, for example, as mapping information MP (see FIG. 6 , 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 piece of equipment in the warehouse based on the detection information and the captured images. The processor 21 may acquire the equipment layout information by generating the mapping information MP. Furthermore, the processor 21 may sequentially acquire the detection information and the captured images in chronological order to sequentially recognize the position, etc. of each piece of equipment. Therefore, the processor 21 may sequentially generate mapping information MP that changes over time, and sequentially acquire the equipment layout information. Furthermore, the processor 21 may generate the equipment layout information by including information on the fall position of a dropped item in the equipment layout information.

[0048] For example, the processor 21 may determine whether or not the bin 70 needs to be moved based on the operating range of the picking robot 40, the position where the dropped item 80 falls, and the layout of each piece of equipment in the warehouse.

[0049] For example, when it is determined that the bin 70 needs to be moved, the processor 21 may control the movement (e.g., evacuation) of the bin 70. The processor 21 may generate movement path information regarding a path along which the bin 70 should be moved based on the operating range of the picking robot 40, the position of the dropped item, and the layout of each device. The movement path information may be, for example, a path along which the transport robot 42 for moving the bin travels (also referred to as an AGV path). The processor 21 may control the movement of the bin 70 by issuing a transport instruction to the transport robot 42, which transports the bin 70, based on the movement path information via the communication device 24. The transport robot 42 moves the bin 70 in accordance with the control of the movement of the bin 70, i.e., in accordance with the transport instruction.

[0050] For example, the processor 21 may control the picking robot 40 to recover the item 80 that has been dropped. In this case, the processor 21 may send a recovery instruction to the picking robot 40 to instruct the picking robot 40 to recover the item 80 that has been dropped by the picking robot 40. The picking robot 40 controls the arm 40a and the hand 40h in accordance with the recovery instruction, and recovers the dropped item 80 by grasping it and storing it in the bin 70 to which it is to be recovered.

[0051] For example, the processor 21 may transmit a recovery instruction to a terminal 65 carried by a recovery worker who recovers the fallen item 80, instructing the recovery worker to recover the fallen item 80. The recovery instruction may include guidance information related to the recovery work. The terminal 65 displays the guidance information in accordance with the recovery instruction. The guidance information may include, for example, identification information of the recoverer (the picking robot 40 or the recovery worker), identification information (item ID) of the fallen item 80, information on the location (i.e., the recovery location) of the fallen item 80 (i.e., the object to be recovered), mapping information MP indicating the positional relationship of each device in the warehouse, and the like.

[0052] <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 to each system in accordance with inputs made by operating the terminal 65, etc.

[0053] <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.

[0054] 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, a shipping bin ID, and a 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 shipping bin ID is the ID of the shipping bin. The time information is the data issuance time when the picking instruction information is issued.

[0055] 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 40 is installed, and is represented by, for example, X and Y coordinates, such as (X, Y) = (12, 3).

[0056] 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.

[0057] <Details of Device Layout Information> Next, the device layout information will be described.

[0058] Fig. 5 is a diagram showing a first example of mapping information MP as device layout information. Fig. 5 is a diagram showing a second example of mapping information MP.

[0059] The equipment layout 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 layout of each piece of equipment based on the unit areas AU.

[0060] 5 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.

[0061] The mapping information MP in Fig. 6 includes position information for the empty area, the area inside the bin, and the area outside, similar to Fig. 6. Furthermore, the mapping information MP in Fig. 6 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.

[0062] 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.

[0063] 7 is a diagram showing an example of the range of a picking station PS. The picking station PS is, for example, a rectangular area, and includes an area where the picking robot 40 or the picking worker 45 that performs the picking work is located, and an area that the picking robot 40 or the picking worker 45 can approach. Bins 70 that can be moved by a transport robot 42 or the like can freely enter and exit the picking station PS.

[0064] <Movement of Bin Depending on Drop Position of Article> Next, an example of the operation of the bin depending on the drop position of the article 80 will be described.

[0065] The fall position P80D (see FIG. 8, etc.) of the fallen item 80 (falling item 80D) (see FIG. 8, etc.) may be, for example, an area within 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, an area near the bin 70 but not an inter-bin area (an area next to the bin), or other areas, as shown in FIG. 6. The inter-bin area and the area next to the bin may be included in the area around the bin. For example, the processor 21 may determine the position (area) within the warehouse where the fall position P80D is located based on the acquired fall position P80D and the mapping information MP.

[0066] <Operation when the article drop position is in the bin area> First, a case where the article drop position is inside the bin (inside the bin area) or above the transport robot 42 (above the AGV area) will be described.

[0067] The processor 21 of the warehouse operations management system 20 determines whether the drop position P80D is within the operating range of the picking robot 40. If the drop position P80D is within the operating range of the picking robot 40, the processor 21 may determine that it is not necessary to move the bin 70. This is because the fallen item 80D can be recovered by the picking robot 40. On the other hand, if the drop position P80D is not within the operating range of the picking robot 40, the processor 21 may determine that it is necessary to move the bin 70. This is because a recovery worker needs to recover the fallen item 80D, and space is needed for the recovery worker to pass through and perform the recovery work.

[0068] In addition, the processor 21 determines an AGV route for moving the source bin 70 (source bin 70B), i.e., the bin 70 containing the fallen item 80D, and the destination bin 70 (destination bin 70A) into the operating range of the picking robot 40.

[0069] <Operation when the article drop position is in the inter-bin area> Next, a case where the article drop position is between adjacent bins 70 (inter-bin area) will be described.

[0070] First, the case where the picking robot 40 is within its operating range will be described.

[0071] The processor 21 of the warehouse operations management system 20 determines whether the drop position P80D is within the operating range of the picking robot 40. If the drop position P80D is within the operating range of the picking robot 40, the processor 21 may determine that the bin 70 needs to be moved. This is because it is impossible or difficult for the arm 40a or hand 40h of the picking robot 40 to enter the area between the bins, so it is necessary to secure the space necessary for the picking robot 40 to recover, and to secure space for recovery workers to pass through and perform recovery work.

[0072] Furthermore, the processor 21 determines a route for moving the bins 70 at both ends of the drop position P80D as the AGV route for moving the bins. By moving the bins 70 at both ends, the warehouse operations management system 20 can remove obstacles that would prevent the picking robot 40 from performing recovery work.

[0073] The processor 21 also determines the area between the placement positions of the bins 70 on both sides of the drop position P80D as an AGV travel prohibited area A1, in which the transport robot 42 is prohibited from traveling.

[0074] FIG. 8 is a diagram showing a first example of the movement of the bin 70 when the article falls in the area between the bins and is within the operating range of the picking robot 40.

[0075] 8 shows the layout of the bins 70 around the picking station PS and the AGV-prohibited area A1. The changes in the state of the warehouse over time can be recognized and visualized by the mapping information MP obtained sequentially.

[0076] In state A1, five bins 70 are arranged within the operating range of the picking robot 40. For example, suppose that the picking robot 40 accidentally drops an item 80 while gripping and moving the item 80 to be picked from a storage bin 71 to a shipping bin 72. The fallen item 80D is located between two adjacent bins 70 (70C1, 70C2). In other words, the fallen item 80D is in the intra-bin area.

[0077] When the processor 21 recognizes a fallen object 80D based on detection information from the sensor or an image captured by the camera 60, it determines an AGV no-go area A1 based on equipment layout information, etc. The transport robot 42 is prohibited from traveling within the determined AGV no-go area A1, ensuring safety. In state A1, the arm 40a of the picking robot 40 cannot enter the area inside the bin, and the picking robot 40 cannot recover the fallen object 80D.

[0078] In response to this, the processor 21 sends a transport instruction to the transport robot 42 to move at least the bins 70C1 and 70C2 located on both sides of the drop position P80D. The transport robot 42 moves the bins 70C1 and 70C2 to be moved in accordance with the transport instruction. Note that if the processor 21 recognizes, based on the equipment layout information, that another bin 70C3 exists at the position where the bins 70C1 and 70C2 to be moved are to be moved, it sends a transport instruction to the transport robot 42 to move that bin 70 as well. The transport robot 42 moves the other bins 70 to be moved in accordance with the transport instruction.

[0079] In state A2, one or more bins 70 to be moved are being moved by the transport robot 42. Specifically, the bins 70C1, 70C2, and 70C3 are being moved (evacuated) away from the picking robot 40.

[0080] Furthermore, a recovery destination bin 70A for recovering the fallen item 80D is disposed in the picking station PS. The processor 21 controls the movement of the recovery destination bin 70A within the operating range of the picking robot 40. The operating range of the picking robot 40 depends on the length and angle of the arm 40a and the hand 40h, and is, for example, an area within the picking station PS, but is not limited to this. If the recovery destination bin 70A is disposed outside the operating range of the picking robot 40, even if the picking robot 40 can approach and grasp the fallen item 80D, it will be unable to approach the recovery destination bin 70A and store the fallen item 80D in the recovery destination bin 70A, and therefore will not be able to recover the fallen item 80D.

[0081] In state A2, if bin 70C2 is to be moved in the direction of destination bin 70A, it is necessary to move destination bin 70A out of the operating range of picking robot 40. Therefore, processor 21 moves bins 70C1 and 70C2 to be moved so that state A2 is reached. In states A1 and A2, destination bin 70A is not moved, and its location remains unchanged.

[0082] It is preferable that the processor 21 controls the movement of the bin 70 so as not to move the recovery destination bin 70A as much as possible, even if it is within the operating range of the picking robot 40. This is because the recovery destination bin 70A is often a shipping bin 72, and the order of picking work and the storage location of each item 80 may be determined taking into account the position of the shipping bin 72.

[0083] In state A2, the restorer (here, the picking robot 40) restores the fallen item 80D by placing the fallen item 80D inside the restoration destination bin 70A and storing it therein.

[0084] 9 is a diagram showing a second example of the movement of the bin 70 when the item falls in the area between the bins and is within the operating range of the picking robot 40. In FIG. 9, the same matters as those in FIG. 8 will not be described or will be simplified.

[0085] In state B1 of Fig. 9, as in state A1 of Fig. 8, five bins 70 are arranged within the operating range of the picking robot 40, and the fallen item 80D is located in the intra-bin area. However, one of the two bins 70 on either side of the fallen item 80D is the recovery destination bin 70A.

[0086] In this case, in order for the picking robot 40 to recover the fallen item 80D, the recovery destination bin 70A becomes the bin 70 to be moved. The processor 21 instructs the transport robot 42 to move the recovery destination bin 70A within the operating range of the picking robot 40. As a result, in state B2, the recovery destination bin 70A is moving in the direction of the arrow YA.

[0087] Next, a case where the item falls outside the operating range of the picking robot 40 will be described.

[0088] The processor 21 may determine that the bin 70 needs to be moved if the drop position P80D is in an inter-bin area and not within the operating range of the picking robot 40. This is because a recovery worker needs to recover the fallen item 80D, and space is required for the recovery worker to pass through and perform the recovery work. In this case, the processor 21 determines a flow line FL (see FIG. 10 ) that the recovery worker will follow during the recovery work within the warehouse based on the equipment layout state after the fallen item 80D has fallen. The flow line FL may be, for example, the shortest path connecting the recovery worker 46 (see FIG. 10 ), the drop position P80D, and the recovery destination bin 70A, taking into account the layout state of each piece of equipment within the warehouse. Therefore, the flow line FL is a path that allows the recovery worker to efficiently perform the recovery work.

[0089] The processor 21 may determine, for example, an area encompassing the flow line FL along which the recovery worker moves toward the drop position P80D, the drop position P80D, and the recovery destination bin 70A as an arm entry prohibited area A2 (see FIG. 10 ) into which the arm 40a of the picking robot 40 is prohibited from entering. The arm entry prohibited area A2 may be, for example, a rectangular range of the minimum size that encompasses the flow line FL, the drop position P80D, and the recovery destination bin 70A.

[0090] Furthermore, if the drop position P80D is not within the operating range of the picking robot 40, the processor 21 determines an AGV route for moving the bin. This AGV route is a route for moving the bin 70 located on the flow line FL along which the recovery worker will pass. The processor 21 then transmits a recovery instruction to the recovery worker's terminal 65 via the communication device 24. This recovery instruction may be issued after the arm entry restriction area A2 is determined. The recovery instruction includes guide information for guiding the recovery of the fallen object 80D. The terminal 65 displays the guide information in accordance with the recovery instruction. The guidance information may include, for example, identification information of the recovery worker, identification information (item ID) of the fallen object 80D, information on the drop position (i.e., the recovery position) of the fallen object 80D (i.e., the object to be recovered), information on the flow line FL, etc. The guidance information may also include information on the recovery timing of the fallen object 80D, mapping information MP indicating the positional relationship of each device within the warehouse, etc.

[0091] <Operation when the item falls in another area> Next, we will explain what happens when the item falls in an area other than the area inside the bin, the area on the AGV, or the area between the bins (also referred to as the other area). The other area is, for example, the area around the bin, the area around the AGV, the empty area, or the outside area.

[0092] The processor 21 may determine that it is not necessary to move the bin 70 if the drop position P80D is within the operating range of the picking robot 40. This is because the recovery person (the picking robot 40 or the recovery worker) can recover the fallen item 80D without moving the bin. Therefore, it is not necessary to determine the AGV route for moving the bin.

[0093] On the other hand, if the drop position P80D is outside the operating range of the picking robot 40, the processor 21 performs the same processing as when the drop position P80D is in the area between bins and outside the operating range of the picking robot 40, as described above.

[0094] <Operation when item drop position is outside the operating range of the picking robot> Figure 10 is a diagram for supplementary explanation of a first example of the operation of the warehouse system 5 when the drop position P80D is in another area and outside the operating range of the picking robot 40. As mentioned above, the operation is the same as that shown in Figure 10 when the drop position P80D is in the area between bins and outside the operating range of the picking robot 40. In other words, if the drop position P80D is in an area that is neither inside a bin nor on an AGV in the warehouse, and the drop position P80D is outside the operating range of the picking robot 40, the operation is the same as that shown in Figure 10.

[0095] 10, the drop position P80D is outside the operating range of the picking robot 40, and therefore is in a position where the picking robot 40 cannot recover the dropped item 80D. In this case, a recovery worker 46 goes to the drop position P80D, grabs the dropped item 80D, and stores the dropped item 80D in, for example, a recovery destination bin 70A.

[0096] The processor 21 may determine, based on the equipment layout information, whether there is sufficient space for the recovery worker 46 to move toward the drop position P80D or to perform recovery work. In Fig. 10, it is assumed that there is sufficient space for the recovery worker 46 to pass between the recovery destination bin 70A and the picking robot 40. If there is sufficient space, the processor 21 determines that there is no need to move the bin 70 at the picking station PS, and does not change the positions of the recovery destination bin 70A or any other bins 70.

[0097] As described above, the processor 21 determines the arm entry no-go area A2 based on the flow line FL taken by the recovery worker 46, the drop position P80D, and the recovery destination bin 70A. The arm entry no-go area A2 is an area that surrounds the flow line FL, the drop position P80D, and the recovery destination bin 70A, and may be, for example, the smallest rectangular area that surrounds the flow line FL, the drop position P80D, and the recovery destination bin 70A.

[0098] With the arm no-entry area A2 determined, the recovery worker 46 moves along the flow line FL and recovers the fallen item 80D by storing the fallen item 80D at the drop position P80D in the recovery destination bin 70A. At this time, since the arm no-entry area A2 has been determined (set), the arm 40a of the picking robot 40 does not enter the vicinity of the flow line FL, so the warehouse system 5 can prevent the recovery worker 46 from unexpectedly coming into contact with the picking robot 40 during the recovery work. This ensures the safety of the recovery worker 46 during the recovery work.

[0099] 11 is a diagram for supplementary explanation of a second example of the operation of the warehouse system 5 when the drop position P80D is outside the operating range of the picking robot 40. In FIG. 11, the explanation of matters similar to those in FIG. 10 will be omitted or simplified.

[0100] The processor 21 may determine, based on the equipment layout information, whether there is sufficient space for the recovery worker 46 to move to the drop position P80D or to perform recovery work. In Fig. 11, it is assumed that there is not enough space for the recovery worker 46 to pass between the recovery destination bin 70A and the picking robot 40. If there is not enough space, the processor 21 moves (removes) the bin 70 at the picking station PS to ensure space for recovery work.

[0101] 11, the processor 21 instructs the transport robot 42 via the communication device 24 to move bins 70D1 and 70D2 out of the bins 70 at the picking station PS to the outside of the picking station PS. In other words, the processor 21 controls the movement of bins 70D1 and 70D2 out of the operating range of the picking robot 40. This allows the warehouse operations management system 20 to secure space for the recovery worker 46 to perform the recovery work.

[0102] The processor 21 determines the area encompassing the flow line FL along which the recovery worker 46 will travel during the recovery work, the drop position P80D, and the position of the recovery destination bin 70A as the arm entry prohibited area A2.

[0103] 11, the recovery worker 46 passes between the picking robot 40 and the bin 70 and heads toward the drop position P80D. This eliminates the need to stop the operation of any equipment in areas within the warehouse other than the drop position P80D and the area around the recovery destination bin 70A for the recovery worker 46 to pass through. Therefore, the warehouse operations management system 20 can prevent a decrease in operational efficiency within the warehouse and ensure safety.

[0104] <Recovery Failure by Picking Robot> Next, a description will be given of recovery when recovery failure occurs by the picking robot 40. Note that when recovery is failed, the bin 70 may or may not have been moved.

[0105] When recovery by the picking robot 40 fails, recovery by the picking robot 40 is impossible or difficult, so recovery is performed by the recovery worker 46. The processor 21 controls the movement of the bin 70 so that the recovery worker 46 can easily perform recovery.

[0106] First, we will explain the case where the falling position (also referred to as the re-falling position P80E) of a fallen item 80D (also referred to as a re-falling item 80E) that falls again when the picking robot 40 fails to recover is inside the bin 70 (intra-bin area).

[0107] The processor 21 determines a route for moving the recovery source bin 70B and the recovery destination bin 70A to a position that is easy for the recovery worker 46 to work on as an AGV route for moving the bins for recovery by the recovery worker 46. The recovery source bin 70B here is the item that contains the re-falling item 80E. The processor 21 then transmits a recovery instruction for the re-falling item 80E to the terminal 65 of the recovery worker 46. The guidance information included in this recovery instruction includes, for example, the recovery work position (re-falling position P80E of the re-falling item 80E), identification information (item ID) of the re-falling item 80E, and the number of recoveries.

[0108] FIG. 12 is a diagram showing an example of recovery of a re-falling article 80E when the re-falling position P80E is in the area inside the bin.

[0109] In state C1, the fallen item 80D is located inside the bin 70. It is assumed that the picking robot 40 attempts to recover the fallen item 80D but fails. It is assumed that the re-fallen item 80E is in the same position as the fallen item 80D.

[0110] Since the re-drop position P80E is within the bin area, the re-dropped item 80E can be moved together with the recovery source bin 70B in which the re-dropped item 80E is stored. Therefore, in Fig. 12, the processor 21 moves the recovery source bin 70B and the recovery destination bin 70A to the vicinity of the recovery worker 46, thereby creating an environment in which the recovery worker 46 can easily perform recovery. The vicinity of the recovery worker 46 is, for example, within a predetermined distance from the recovery worker 46.

[0111] The processor 21 acquires the position information of the recovery worker 46. The position information of the recovery worker may be recognized based on, for example, an image captured by the camera 60. The position information of the recovery worker may be obtained by detecting the position of the terminal 65 of the recovery worker 46 using a position detection sensor of the terminal 65, and the position information of the terminal 65 may be acquired as the position information of the recovery worker 46 via the communication device 24.

[0112] As shown in state C2, the processor 21 controls the recovery source bin 70B and the recovery destination bin 70A to move to the vicinity of the recovery worker 46 based on the position information of the recovery worker 46 via the communication device 24. The transport robot 42 transports the recovery source bin 70B and the recovery destination bin 70A to move to the vicinity of the recovery worker 46 in accordance with the control (e.g., transport instructions) of the warehouse operations management system 20.

[0113] As a result, the recovery worker 46 can easily retrieve the re-fallen item 80E from the recovery source bin 70B and store it in the recovery destination bin 70A without moving much himself, thereby recovering the re-fallen item 80E. Furthermore, the warehouse operations management system 20 can prevent the recovery worker 46 from moving around inside the automated warehouse 50, thereby preventing a decrease in the operating efficiency of the automated warehouse 50 and ensuring safety.

[0114] Next, a case where the re-fall position P80E of the re-falling item 80E is an area other than the area inside the bin in the warehouse will be described.

[0115] In this case, the warehouse system 5 performs the same operation as when the initial drop position P80D is outside the operating range of the picking robot 40.

[0116] Specifically, the processor 21 determines a flow line FL (e.g., the above-mentioned shortest path flow line) based on the equipment layout state when the fallen object 80D falls again due to a recovery failure. This flow line FL is a path that allows the recovery worker 46 to efficiently recover the re-falling object 80E. For example, the processor 21 may determine an area that encompasses the flow line FL along which the recovery worker 46 heads toward the re-fall position P80E, the re-fall position P80E, and the recovery destination bin 70A as the arm entry no-go area A2. The arm entry no-go area A2 may be, for example, a rectangular area of ​​the smallest size that encompasses the flow line FL, the re-fall position P80E, and the recovery destination bin 70A.

[0117] The processor 21 also determines an AGV route for moving bins to recover the re-falling object 80E. This AGV route is a route for moving bins 70 located on the flow line FL along which the recovery worker 46 travels. The processor 21 then transmits a recovery instruction for the re-falling object 80E to the recovery worker's terminal 65 via the communication device 24. The recovery instruction may be issued after the arm entry restriction area A2 is determined. The recovery instruction includes guide information for guiding the recovery of the re-falling object 80E. The terminal 65 displays the guide information in accordance with the recovery instruction. The guidance information may include identification information of the recovery worker, identification information (item ID) of the re-falling object 80E, information on the re-falling position P80E (i.e., the recovery position) of the re-falling object 80E, the number of recovery steps for recovering the re-falling object 80E, information on the flow line FL, and the like. The guidance information may also include information on the recovery timing of the fallen object 80D, mapping information MP indicating the positional relationship of each device within the warehouse, and the like.

[0118] FIG. 13 is a diagram showing a first example of recovery of a re-falling object 80E when the re-falling position P80E is an area other than the area inside the bin in the warehouse.

[0119] 13, as shown in state D1, the falling position P80D of the falling item 80D is the area between bins. In this case, as shown in state D2, the processor 21 controls the bins 70 on both sides of the falling item 80D that has been dropped into the area between bins by the picking robot 40 to move (retreat).

[0120] In state D2, it is assumed that the recovery operation by the picking robot 40 is unsuccessful. As a result of the failed recovery, as shown in state D3, the item 80E falls again to the same position P80D as the fall position before recovery, and the re-fallen item 80E is present.

[0121] In state D3, processor 21 determines whether there is sufficient space for the recovery worker 46 to pass through and perform the recovery work. In state D2, it is assumed that there is sufficient space. Processor 21 determines an arm entry no-entry area A2 based on the equipment layout information for this bin 70 layout state. Specifically, processor 21 determines, as the arm entry no-entry area A2, an area that encompasses the flow line FL that the recovery worker 46 will follow during the recovery work, the re-drop position P80E, and the position of the recovery destination bin 70A.

[0122] This allows the recovery worker 46 to secure the space required for work and movement, ensure the safety of this space, and recover the re-falling item 80E, even if the bin 70 cannot move the re-falling item 80E.

[0123] Fig. 14 is a diagram showing a second example of recovery of a re-falling item 80E when the re-fall position P80E is an area other than the bin area in the warehouse. Fig. 14 is a modified example of the second example of recovery of a re-falling item 80E shown in Fig. 13. In Fig. 14, the explanation of the matters explained in Fig. 13 is omitted or simplified.

[0124] States E1 and E2 in Fig. 14 are almost the same as states D1 and D2 in Fig. 13. However, in state E2, it is assumed that there is insufficient space for the recovery work by the recovery worker 46. If there is insufficient space, the processor 21 controls the movement of bins 70 that are on the path that the recovery worker 46 will take.

[0125] In state E3, the bin 70F to be moved so that the recovery worker 46 can pass through has been moved. Therefore, sufficient space is secured for the recovery worker 46 to pass through and perform recovery work. The processor 21 determines the arm entry no-entry area A2 based on the equipment layout information for this bin 70 layout state. Specifically, the processor 21 determines the area surrounding the flow line FL along which the recovery worker 46 will pass during recovery work, the re-drop position P80E, and the location of the recovery destination bin 70A as the arm entry no-entry area A2.

[0126] Therefore, as shown in state E4, when recovering the re-falling item 80E, the recovery worker 46 can move the bin 70, ensuring sufficient space for the recovery work and passage of the recovery worker 46. Then, the recovery worker 46 can move from outside the automated warehouse 50 to the re-falling position P80E of the re-falling item 80E, grab the re-falling item 80E, and store it in the recovery destination bin 70A.

[0127] <Modification of Movement of Bin When Falling Object 80D is in Intra-Bin Area> Next, a modification of movement of the bin 70 when the falling object 80D is in the intra-bin area will be described.

[0128] FIG. 15 is a diagram for explaining a modified example of the movement of the bin 70 when a falling object 80D is in the area inside the bin.

[0129] 15 , as shown in state F1, the spacing between the bins 70 is relatively short. Specifically, the distance r between two adjacent bins 70 in one direction (the x direction) of the horizontal plane on which the bins 70 are arranged is equal to or less than the threshold value th1. Similarly, the distance r between two adjacent bins 70 in the other direction (the x direction) of the horizontal plane on which the bins 70 are arranged, which is perpendicular to the x direction (the y direction), is also equal to or less than the threshold value th1.

[0130] In such an arrangement of the bins 70, if the drop position P80D is between two adjacent bins 70 in the X direction and also between two adjacent bins 70 in the Y direction, the fallen object 80D will be between four bins 70. In this case, as shown in state F2, the processor 21 determines the areas between each of the four bins 70 arranged in a grid pattern as AGV no-travel areas A1.

[0131] In state F3, the processor 21 sends a transport instruction to the transport robot 42 to move at least four bins 70 around the drop position P80D. The transport robot 42 moves the four bins 70 to be moved in accordance with the transport instruction. In state F3, the processor 21 moves (evacuates) the three bins 70 other than the recovery destination bin 70A away from the picking robot 40. Therefore, the three bins 70 other than the recovery destination bin 70A are located outside the operating range of the picking robot 40. On the other hand, the processor 21 moves the recovery destination bin 70A, but moves it so that the position after the movement is still within the operating range of the picking robot 40.

[0132] Therefore, even when the bins 70 are closely spaced and densely arranged around the picking station PS, the warehouse system 5 can suitably recover the fallen objects 80D by the picking robot 40 while changing the arrangement of the bins 70. Furthermore, the warehouse system 5 can expand the AGV no-travel area A1 to improve safety during recovery work by the picking robot 40.

[0133] <Operation of Warehouse System> Next, the operation of the warehouse system 5 will be described.

[0134] 16 to 18 are flowcharts showing an example of the operation of the warehouse system 5.

[0135] 16, the processor 21 of the warehouse operations management system 20 detects the drop position P80D of the item 80 (S11). The processor 21 determines whether the drop position P80D is inside the bin 70 (intra-bin area) or on the transport robot 42 (upper AGV area) (S12).

[0136] The area inside the bin includes at least one of the area inside the bin 70 loaded on the transport robot 42 (also referred to as the area inside the bin with an AGV) and the area inside the bin 70 not loaded on the transport robot 42 (also referred to as the area inside the bin without an AGV). The area above the AGV includes at least one of the area above the transport robot 42 on which the bin 70 is loaded (also referred to as the area above the AGV with a bin) and the area above the transport robot 42 on which the bin 70 is not loaded (also referred to as the area above the AGV without a bin).

[0137] If the area is inside a bin with an AGV, the drop position P80D is any position inside the bin 70 on the transport robot 42. On the other hand, if the area is on an AGV with a bin, the drop position P80D is any position outside the bin 70 on the transport robot 42. Also, if the area is inside a bin without an AGV, the drop position P80D is any position inside a bin 70 that is not loaded on the transport robot 42. On the other hand, if the area is on an AGV without a bin, the drop position P80D is any area on the transport robot 42 where a bin 70 is not loaded.

[0138] If the drop position P80D is in the area inside the bin or the area on the AGV (Yes in step S12), the processor 21 determines whether the drop position P80D is within the operating range of the picking robot 40 (S13).

[0139] If the drop position P80D is outside the operating range of the picking robot 40 (No in step S13), the processor 21 controls the transport robot 42 to move within the operating range of the picking robot 40 (S14). In this case, the processor 21 transmits a movement instruction (transport instruction) to the transport robot 42 via the communication device 24. As a result, if the drop position P80D is within the bin area, the warehouse operations management system 20 moves the transport robot 42 carrying the bin 70 containing the falling item 80D, thereby moving the bin 70 containing the falling item 80D and positioning the falling item 80D within the operating range of the picking robot 40. Furthermore, if the drop position P80D is within the area above the AGV, the warehouse operations management system 20 moves the transport robot 42 carrying the falling item 80D, thereby positioning the falling item 80D within the operating range of the picking robot 40.

[0140] The processor 21 controls the picking robot 40 to perform recovery work of grasping the fallen item 80D and storing it in the recovery destination bin 70A. In this case, the processor 21 transmits a recovery instruction to the picking robot 40 via the communication device 24. Upon receiving the recovery instruction, the picking robot 40 performs the recovery work in accordance with the recovery instruction.

[0141] The processor 21 determines whether the recovery by the picking robot 40 has been successful (S15). 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 recovery instruction was issued to the picking robot 40, or upon receiving a recovery completion notification from the picking robot 40, and determine whether the fallen object 80D has been successfully recovered based on the detection information or the image captured. For example, if the fallen object 80D has been removed from the drop position P80D, it may be determined that the recovery of the fallen object 80D has been successful. Furthermore, if the recovery by the picking robot 40 has failed, the processor 21 may perform retry control a predetermined number of times, and may ultimately determine that the recovery has failed if recovery is unsuccessful even as a result of the retries.

[0142] If recovery by the picking robot 40 fails (No in step S15), the processor 21 controls the recovery source bin 70B or the transport robot 42 carrying the re-fallen item 80E, which is the item that has fallen again from the fallen item 80D, and the recovery destination bin 70A to move to the vicinity of the recovery worker 46 (S16). In this case, the processor 21 sends a movement instruction (transport instruction) to the transport robot 42 via the communication device 24. The transport robot 42 moves the recovery source bin 70B or the transport robot 42 carrying the re-fallen item 80E and the recovery destination bin 70A in accordance with the transport instruction.

[0143] The processor 21 notifies the terminal 65 of the recovery worker 46 of a recovery instruction including guidance information (S17). The guidance information includes, for example, information on the re-drop position P80E of the re-dropped object 80E and identification information (bin ID) of the recovery destination bin 70A. The terminal 65 displays the guidance information in accordance with the recovery instruction. This allows the recovery worker 46 to confirm information useful for the recovery work (e.g., the re-drop position P80E, the position of the recovery destination bin 70A, the flow line FL for performing the recovery work, and mapping information MP) using the guidance information and carry out the recovery work.

[0144] In step S12, if the drop position P80D is not in the area inside the bin or the area on the AGV (No in step S12), the process proceeds to Fig. 17. Then, the processor 21 determines whether the drop position P80D is between the bins 70 (inter-bin area) (S21).

[0145] If the drop position P80D is an inter-bin area (Yes in step S21), the processor 21 determines (sets) the area between the two bins 70 on either side of the drop position P80D, or the area between the four bins 70 around the drop position P80D, as the AGV no-travel area A1 (S22).

[0146] The processor 21 controls the transport robot 42 to move two bins 70 on either side of the fallen object 80D or four bins 70 around the fallen object 80D as targets to be moved while avoiding the AGV travel-prohibited area A1 (S23). In this case, the processor 21 transmits a transport instruction to the transport robot 42 via the communication device 24 to move the bins 70 to be moved.

[0147] When controlling the movement of the bin 70 in step S23, the processor 21 determines whether or not the recovery destination bin 70A remains within the picking station PS (within the operating range of the picking robot 40) (S24).

[0148] If the recovery destination bin 70A remains in the picking station PS (Yes in step S24), the processor 21 controls the movement of the bin 70 so as to leave the recovery destination bin 70A in the picking station PS and to vacate the position of the recovery destination bin 70A (S25). For example, as shown in FIG. 9 , if another bin 70 is located at the destination to which the recovery destination bin 70A is to be moved, the processor 21 moves the other bin 70 before moving the recovery destination bin 70A. In this case, the processor 21 controls the movement of the recovery destination bin 70A so as to vacate the position of the recovery destination bin 70A without moving the recovery destination bin 70A outside the operating range of the picking robot 40.

[0149] If the drop position P80D is not in the inter-bin area in step S21 (No in step S21), if there is no recovery destination bin 70A remaining in the picking station PS in step S24 (No in step S24), or after processing in step S25, the process proceeds to Fig. 18. Then, the processor 21 determines whether the drop position P80D is within the operating range of the picking robot 40 (S31).

[0150] If the drop position P80D is within the operating range of the picking robot 40 (Yes in step S31), the processor 21 controls the picking robot 40 to perform recovery work of grasping the fallen item 80D and storing it in the recovery destination bin 70A. In this case, the processor 21 transmits a recovery instruction to the picking robot 40 via the communication device 24. Upon receiving the recovery instruction, the picking robot 40 performs the recovery work in accordance with the recovery instruction.

[0151] The processor 21 determines whether the recovery of the picking robot 40 has been successful (S32).

[0152] If recovery by the picking robot 40 fails (No in step S32), the processor 21 determines a movement line FL for the recovery work by the recovery worker 46 based on the drop position P80D and the equipment layout information (S33).

[0153] The processor 21 controls the movement of bins in the flow line area (S34). The flow line area may be a position on the flow line FL, or may be a broader area including positions around the flow line FL.

[0154] The processor 21 determines (sets) an arm entry no-entry area A2 including the flow line area (S35).

[0155] The processor 21 controls the arm 40 a of the picking robot 40 to move from the determined arm entry no-entry area A2. In other words, the processor 21 controls the picking robot 40 so that the arm 40 a of the picking robot 40 does not enter the arm entry no-entry area A2.

[0156] The processor 21 notifies the terminal 65 of the recovery worker 46 of a recovery instruction including guidance information (S17). The guidance information includes, for example, information on the drop position P80D of the fallen object 80D and identification information (bin ID) of the recovery destination bin 70A. The terminal 65 displays the guidance information in accordance with the recovery instruction. This allows the recovery worker 46 to confirm information useful for the recovery work (e.g., the drop position P80D, the location of the recovery destination bin 70A, the flow line FL for performing the recovery work, and the mapping information MP) using the guidance information and carry out the recovery work.

[0157] 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 the arm 40a of a picking robot 40 unexpectedly drops an item 80, the warehouse system 5 can detect the fall of the item 80 and determine whether the bin needs to be moved (evacuated) to recover the fallen item 80D. Therefore, the warehouse system 5 can prevent the bin 70 from interfering with a recovery person (a picking robot or a recovery worker) attempting to recover the fallen item 80D, thereby reducing the operational efficiency of the warehouse. The warehouse system 5 can efficiently operate the automated warehouse 50. Furthermore, in the warehouse system 5, the picking robot 40 can recover the fallen item 80D whenever possible, and the recovery worker can also assist in recovering the fallen item 80D.

[0158] In the present embodiment, the recovery destination bin 70A is moved within the operating range of the picking robot 40, but this is not limiting. The recovery destination bin 70A may be temporarily moved (evacuated) outside the operating range of the picking robot 40. At a predetermined timing thereafter, the processor 21 controls the moved recovery destination bin 70A to be moved so that it is positioned within the operating range of the picking robot 40.

[0159] In this embodiment, the fallen items 80D and the re-falling items 80E are stored in the recovery bin 70A and then recovered, but this is not limited to this. For example, the fallen items 80D and the re-falling items 80E may be damaged or malfunctioning, so they may be recovered. The operation of the warehouse system 5 during recovery (recovery work) may be the same as the operation of the warehouse system 5 during recovery (recovery work) in this embodiment.

[0160] (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.

[0161] (Item 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 (picking robot 40) that performs picking work on an item (item 80); acquiring drop position information indicating the drop position (drop position P80D) of a first item (falling item 80D) from the picking robot; acquiring placement status information indicating the placement status of each device within the warehouse; and determining whether or not it is necessary to move a bin (bin 70) that stores the item, based on the operating range of the picking robot, the drop position of the first item, and the placement status of each device.

[0162] As a result, the warehouse management method can determine whether or not it is necessary to move the bin to recover the first item, even if, for example, a picking robot drops the first item at an unexpected time. Therefore, the warehouse management method can prevent the bin from becoming an obstacle when recovering the item, making it difficult for the picking robot to grasp the item or for the recovery worker to move to the location where the item fell. Therefore, it is possible to prevent the bin from becoming an obstacle when a recoverer (a picking robot or a recovery worker) tries to recover the item, resulting in a decrease in warehouse operating efficiency.

[0163] (Item 2) The warehouse management method according to item 1, further comprising the step of controlling the movement of the bin when it is determined that the movement of the bin is necessary.

[0164] This allows the warehouse management method to move bins within the warehouse as needed.

[0165] (Item 3) The warehouse management method described in Item 2, wherein the step of controlling the movement of the bin includes the steps of: generating movement path information regarding a path along which the bin will be moved; and instructing a transport robot (transport robot 42) that transports the bin to transport the bin based on the movement path information.

[0166] This allows the warehouse management method to notify the transport robot of the route along which the bin should be moved for recovery work.

[0167] (Item 4) The warehouse management method according to Item 2 or 3, wherein the step of controlling the movement of the bin includes a step of controlling the movement of the bin so that a destination bin (destination bin 70A) in which the first item is stored is within the operating range of the picking robot.

[0168] This allows the warehouse management method to have the picking robot store the first item in the recovery destination bin, reducing the effort required of the recovery worker.

[0169] (Item 5) A warehouse management method according to any one of items 1 to 4, wherein the step of determining whether or not the bin needs to be moved includes a step of determining that the bin does not need to be moved if the position where the first item falls is a position other than between multiple adjacent bins in the warehouse and is within the operating range of the picking robot.

[0170] As a result, the warehouse management method can recover the first item using the picking robot even with the current bin arrangement, eliminating the need to move unnecessary bins and shortening the time required for recovery.

[0171] (Item 6) The warehouse management method described in any one of Items 2 to 4, wherein the step of determining whether or not the bin needs to be moved includes a step of determining that the bin needs to be moved if the first item falls inside the bin or on the transport robot transporting the bin and is outside the operating range of the picking robot, and the step of controlling the movement of the bin includes a step of controlling the movement of the bin so that the source bin (source bin 70B) containing the first item and the destination bin in which the first item is stored are positioned within the operating range of the picking robot.

[0172] As a result, the warehouse management method can, for example, move a bin that is far from the picking robot forward, bringing it closer to the picking robot and within its range of motion, and then store any fallen items that have fallen into the source bin by the picking robot in the destination bin, thereby recovering them.

[0173] (Item 7) The warehouse management method according to any one of claims 1 to 4, further comprising a step of controlling movement of the transport robot so that the transport robot carrying the first item is positioned within the operating range of the picking robot when the drop position of the first item is on top of the transport robot and outside the operating range of the picking robot.

[0174] As a result, the warehouse management method can, for example, move a transport robot that is far from a picking robot forward, bringing it closer to the picking robot and within its range of motion, allowing the picking robot to recover any fallen items that have fallen onto the transport robot.

[0175] (Item 8) A warehouse management method described in any one of Items 2 to 4, wherein the step of determining whether or not the bin needs to be moved includes a step of determining that the bin needs to be moved if the drop position of the first item is between multiple adjacent bins and is within the operating range of the picking robot, and the step of controlling the movement of the bin includes a step of controlling the movement of the multiple adjacent bins, and further includes a step of determining the area between the multiple adjacent bins as a no-travel area (AGV no-travel area A1) in which the transport robot transporting the bin is prohibited from traveling.

[0176] In this way, the warehouse management method can move adjacent bins to make it easier to pick up the first item. Also, by making the area between the adjacent bins where the first item fell a no-travel area, the transport robot will not enter the no-travel area, reducing obstacles during recovery work and making it easier for the picking robot to retrieve the item.

[0177] (Item 9) The warehouse management method according to any one of Items 1 to 4, wherein the step of determining whether the bin needs to be moved includes the step of determining that the bin needs to be moved if the position where the first item falls is neither inside the bin nor at a position where the transport robot transporting the bin is located within the warehouse, and is outside the operating range of the picking robot; and further includes the steps of determining a movement line (movement line FL) that a recovery worker (recovery worker 46) who recovers the first item within the warehouse will follow during the recovery work; and determining an area that encompasses the movement line, the position where the first item fell, and the position of the recovery destination bin where the first item is stored, as an arm entry prohibited area (arm entry prohibited area A2) into which the arm of the picking robot is prohibited from entering.

[0178] In this way, in the warehouse management method, since the first item cannot be recovered by the picking robot and therefore needs to be recovered by a recovery worker, a traffic line for the recovery worker to recover the first item can be secured. Also, the arm can be prevented from entering an arm-prohibited area including the traffic line, thereby improving the safety of the recovery worker.

[0179] (Item 10) A warehouse management method described in any one of items 2 to 9, further comprising the steps of: acquiring worker position information indicating the position of a recovery worker recovering the first item; and determining whether the picking robot has succeeded in recovering the first item, wherein the step of controlling the movement of the bin includes the step of controlling, based on the worker position information, to move a recovery source bin that is the bin containing the first item and a recovery destination bin that is the bin in which the first item is stored, when it is determined that the recovery of the first item has failed and the re-drop position (re-drop position P80E) of the first item (re-dropped item 80E) is inside the bin.

[0180] As a result, the warehouse management method can reduce the amount of movement of the recovery worker by, for example, moving the bin to a position near the recovery worker that makes it easy to pick up the first item, thereby reducing the amount of work the recovery worker has to do. Furthermore, the warehouse management method can improve the safety of the recovery worker by reducing the amount of movement of the recovery worker within the automated warehouse.

[0181] (Item 11) A warehouse management method described in any one of items 1 to 9, further comprising the steps of: determining whether the picking robot has successfully recovered the first item; if it is determined that the recovery of the item has failed and the location where the first item will be dropped again is outside the bin, determining a route for a recovery worker recovering the item within the warehouse to follow during the recovery work; and determining an arm no-entry area that prohibits the arm of the picking robot from entering an area that encompasses the route, the location where the first item was dropped, and the location of the recovery destination bin where the first item is stored.

[0182] This allows the warehouse management method to ensure a traffic line for a recovery worker to recover the first item even if the picking robot fails to recover the first item. Furthermore, the warehouse management method can prevent the arm from entering the traffic line area, ensuring the safety of the recovery worker recovering the first item that has fallen again.

[0183] (Item 12) The warehouse management method according to Item 9 or 11, wherein the step of controlling the movement of the bins includes a step of controlling the movement of the bins on the movement line after the arm no-entry area is determined.

[0184] In this way, the warehouse management method can move bins that are on the movement line, thereby preventing bins on the movement line from becoming an obstacle to the movement of recovery workers. Furthermore, by moving bins after determining the no-entry area for the arm, it is possible to prevent bins from colliding with the arm and causing malfunctions, etc.

[0185] (Item 13) The warehouse management method according to any one of Items 9, 11, and 12, further comprising a step of transmitting a recovery instruction including flow line information regarding the flow line to a terminal (terminal 65) of the recovery worker after determining the no-arm entry area.

[0186] This allows the warehouse management method to avoid the arm entering no-arm entry areas, including traffic lines, and allows the recovery workers to recover items only after ensuring the safety of the recovery workers passing along the traffic lines.

[0187] (Item 14) 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 of a first item from the picking robot; acquires placement status information indicating the placement status of each piece of equipment within the warehouse; and determines whether or not it is necessary to move a bin that stores the item based on the operating range of the picking robot, the drop position of the first item, and the placement status of each piece of equipment.

[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 suppress a decrease in warehouse operating efficiency even if an item falls inside the warehouse.

[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 80E Re-falling item A1 AGV no-go area A2 Arm no-go area FL Flow line MP Mapping information P80D Falling position P80E Re-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 of a first item from the picking robot; acquiring placement status information indicating the placement status of each piece of equipment within the warehouse; and determining whether or not it is necessary to move a bin that stores the first item, based on the operating range of the picking robot, the drop position of the first item, and the placement status of each piece of equipment.

2. The warehouse control method of claim 1, further comprising the step of: controlling the movement of the bin if it is determined that the movement of the bin is necessary.

3. The warehouse management method of claim 2, wherein the step of controlling the movement of the bin includes the steps of: generating movement path information regarding the path along which the bin will be moved; and instructing a transport robot that transports the bin to transport the bin based on the movement path information.

4. A warehouse management method as described in claim 2 or 3, wherein the step of controlling the movement of the bin includes a step of controlling the movement of the bin so that the destination bin, which is the bin in which the first item is stored, is within the operating range of the picking robot.

5. A warehouse management method as described in claim 1, wherein the step of determining whether or not the bin needs to be moved includes a step of determining that the bin does not need to be moved if the position where the first item falls is a position other than between multiple adjacent bins in the warehouse and is within the operating range of the picking robot.

6. The warehouse management method of claim 3, wherein the step of determining whether or not the bin needs to be moved includes a step of determining that the bin needs to be moved if the location where the first item falls is inside the bin and outside the operating range of the picking robot, and the step of controlling the movement of the bin includes a step of controlling the movement of the bin so that the source bin containing the first item and the destination bin in which the first item is stored are positioned within the operating range of the picking robot.

7. The warehouse management method of claim 1, further comprising the step of controlling the movement of the transport robot so that, if the first item falls onto the transport robot and is outside the operating range of the picking robot, the transport robot carrying the first item is positioned within the operating range of the picking robot.

8. The warehouse management method of claim 2, wherein the step of determining whether or not the bin needs to be moved includes a step of determining that the bin needs to be moved if the position where the first item falls is between multiple adjacent bins and is within the operating range of the picking robot, and the step of controlling the movement of the bin includes a step of controlling the movement of the multiple adjacent bins, and further includes a step of determining the area between the multiple adjacent bins as a no-travel area in which the transport robot transporting the bins is prohibited from traveling.

9. The warehouse management method of claim 1, wherein the step of determining whether or not the bin needs to be moved includes a step of determining that the bin needs to be moved if the position where the first item falls is neither inside the bin nor at a position where the transport robot transporting the bin is located within the warehouse, and is outside the operating range of the picking robot; and further includes a step of determining a route of movement that a recovery worker who recovers the first item within the warehouse will take during the recovery work; and a step of determining an area that encompasses the route of movement, the position where the first item fell, and the position of the recovery destination bin where the first item is stored, as an arm entry prohibited area that prohibits the arm of the picking robot from entering.

10. A warehouse management method as described in claim 2, further comprising the steps of: acquiring worker position information indicating the position of a recovery worker recovering the first item; and determining whether the picking robot has succeeded in recovering the first item; and wherein the step of controlling the movement of the bins includes the step of controlling, based on the worker position information, to move a recovery source bin, which is the bin containing the first item, and a recovery destination bin, which is the bin in which the first item is stored, when it is determined that the recovery of the first item has failed and the position at which the first item will be dropped again is inside the bin.

11. The warehouse management method of claim 1, further comprising the steps of: determining whether the picking robot has succeeded in recovering the first item; and, if it is determined that the recovery of the item has failed and the location where the first item will be dropped again is outside the bin, determining a route of movement to be taken by a recovery worker recovering the item within the warehouse during the recovery work; and determining an arm no-entry area that prohibits the arm of the picking robot from entering an area that encompasses the route of movement, the location where the first item was dropped, and the location of the recovery destination bin where the first item is stored.

12. A warehouse management method as described in claim 9 or 11, wherein the step of controlling the movement of the bins includes a step of controlling the movement of the bins on the movement line after the arm no-entry area has been determined.

13. A warehouse management method as described in claim 9 or 11, further comprising a step of sending a recovery instruction including movement line information regarding the movement line to the terminal of the recovery worker after determining the no-arm entry area.

14. 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 of a first item from the picking robot; acquires placement position information indicating the placement status of each piece of equipment within the warehouse; and determines whether or not it is necessary to move a bin that stores the first item based on the operating range of the picking robot, the drop position of the first item, and the placement status of each piece of equipment.

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