Automated warehouse

Abstract

Provided is a shuttle type automated warehouse that can improve the cargo loading and unloading capacity while suppressing an increase in installation space. A shuttle type automated warehouse 1 according to the present invention comprises: racks 2 having a plurality of shelf stages 8; and a shuttle cart 4 that travels in a horizontal direction along a flat shelf 6 of each of the shelf stages. The racks 2 are disposed on both sides along a travel path 10 of the shuttle cart 4 and comprise: a pair of outside lifting / lowering conveyance devices 24, 26 each provided on an extension line of a back-side storage position (A1) of each of the racks 2; a pair of inside lifting / lowering conveyance devices 48, 50 disposed inside and between the pair of outside lifting / lowering conveyance devices; outside buffer conveyors 28, 30 provided corresponding to at least some of the shelf stages; and inside buffer conveyors 52, 54 provided corresponding to the shelf stages that are not provided with the outside buffer conveyors.

Description

Automated warehouse

[0001] The present invention relates to an automated warehouse, and particularly to a shuttle-type automated warehouse including a rack having a plurality of shelf levels in the vertical direction and a shuttle cart that travels horizontally along the flat shelf of each shelf level of the rack.

[0002] Conventionally, an automated warehouse including a rack having a plurality of shelf levels in the vertical direction, a shuttle cart that transports goods on each shelf level, and a lifting and conveying device for transferring goods between the shuttle carts is known (for example, Patent Document 1).

[0003] Japanese Unexamined Patent Application Publication No. 2023-107024

[0004] Here, in the technical field of automated warehouses, improving the goods in-and-out ability (in-and-out efficiency) is an important issue. In response to such an issue, the inventor of the present invention focused on the fact that the goods in-and-out efficiency in an automated warehouse mainly depends on the conveying ability of the lifting and conveying device. In other words, there is a problem that the conveying ability of the lifting and conveying device can become a bottleneck for the goods in-and-out ability of the entire automated warehouse.

[0005] Therefore, the present invention has been made to solve the above-described problems, and an object thereof is to provide a shuttle-type automated warehouse capable of improving the goods in-and-out ability while suppressing an increase in the installation space.

[0006] To achieve the above objective, the present invention provides a shuttle-type automated warehouse comprising a rack having multiple shelves in the vertical direction and a shuttle trolley that travels horizontally along the flat shelves of each shelf of the rack, wherein the racks are arranged on both sides along the travel path of the shuttle trolley, and each rack on both sides is capable of storing goods in a front storage position, which consists of multiple items arranged on the flat shelves on the side closer to the travel path of the shuttle trolley, and a rear storage position, which consists of multiple items arranged on the flat shelves on the side further from the travel path of the shuttle trolley, and the automated warehouse is provided on the extension of the rear storage position, which consists of multiple items arranged on the racks. The system is characterized by comprising: a pair of external lifting and conveying devices for lifting and conveying cargo; a pair of internal lifting and conveying devices positioned inside the pair of external lifting and conveying devices for lifting and conveying cargo; an external buffer conveyor provided corresponding to at least some of the shelves among the multiple shelves of the rack, extending from the external lifting and conveying devices to the vicinity of the shuttle cart's travel path; and an internal buffer conveyor provided corresponding to the shelves among the multiple shelves of the rack that are not provided with an external buffer conveyor, extending from the internal lifting and conveying devices to the vicinity of the shuttle cart's travel path.

[0007] With the present invention configured in this way, the amount of cargo lifted and transported can be increased by two pairs of lifting and transporting devices (a pair of outer lifting and transporting devices and a pair of inner lifting and transporting devices), thereby improving the loading and unloading capacity of cargo in an automated warehouse. Furthermore, since outer buffer conveyors are provided for at least some of the shelves, while inner buffer conveyors are provided for shelves where outer buffer conveyors are not provided, a space can be created at each shelf where no buffer conveyor is placed, and the drive devices for each buffer conveyor can be placed in such a space. Therefore, the present invention makes it possible to improve the loading and unloading capacity of cargo while suppressing an increase in the installation space of the automated warehouse.

[0008] Furthermore, in the present invention, preferably, the outer lifting conveying device and the inner lifting conveying device each include a lifting platform and a mast equipped with a drive mechanism for raising and lowering the lifting platform, and the lifting platforms of the outer lifting conveying device and the inner lifting conveying device are provided at a predetermined distance from each other, and the masts of the outer lifting conveying device and the inner lifting conveying device are provided in this predetermined space so as to be offset in the direction of cargo transport. With the present invention configured in this way, since the outer lifting conveying device and the inner lifting conveying device are provided so as to be offset in the space between each lifting platform, an automated warehouse with improved loading and unloading capacity can be realized in a more space-saving manner.

[0009] Furthermore, in the present invention, preferably, outer buffer conveyors and inner buffer conveyors are alternately arranged for each shelf level of the rack. With the present invention configured in this way, since outer buffer conveyors and inner buffer conveyors are alternately arranged for each level, the buffer conveyor drive devices and the like can be positioned to protrude into the empty space in the vertical direction where buffer conveyors are not located, making effective use of the space and minimizing the height difference between each shelf level. In addition, since the outer buffer conveyors and inner buffer conveyors, which have a common structure, can be constructed to overlap each other vertically in each shelf level, costs can be reduced.

[0010] Furthermore, in the present invention, preferably, the automated warehouse includes a shuttle trolley, an outer lifting and conveying device, an inner lifting and conveying device, an outer buffer conveyor, and a controller that controls the operation of the inner buffer conveyor. The controller is configured to store items that are frequently moved in and out of the automated warehouse in racks on shelves equipped with inner buffer conveyors. With the present invention configured in this way, the overall capacity of the automated warehouse can be improved by storing high-frequency items, which are moved in and out frequently, in racks on shelves of inner buffer conveyors where the shuttle transfer time is short.

[0011] According to the present invention, it is possible to improve the loading and unloading capacity of goods while suppressing an increase in the installation space required for automated warehouses.

[0012] Figure 2 is a schematic front view showing the general configuration of a shuttle-type automated warehouse according to an embodiment of the present invention. Figure 3 is a schematic plan view showing the general configuration of a shuttle-type automated warehouse according to an embodiment of the present invention. Figure 4 is a schematic plan view showing the loading and unloading device at odd-numbered levels of the shuttle-type automated warehouse according to this embodiment shown in Figure 2. Figure 5(A) is a plan view showing the lifting and conveying device of this embodiment, and Figure 5(B) is a side view of the lifting and conveying device of this embodiment viewed from the side. Figure 5(A) is a schematic plan view showing the loading and unloading device at odd-numbered levels of a shuttle-type automated warehouse according to a modified example of the present invention. Figure 5(B) is a schematic plan view showing the loading and unloading device at even-numbered levels of a shuttle-type automated warehouse according to a modified example of the present invention.

[0013] Next, an embodiment of the shuttle-type automated warehouse according to the present invention will be described with reference to the attached drawings.

[0014] First, the schematic configuration of the shuttle-type automated warehouse according to an embodiment of the present invention will be explained with reference to Figures 1 and 2. Figure 1 is a front view showing the schematic configuration of the shuttle-type automated warehouse according to an embodiment of the present invention, and Figure 2 is a plan view showing the schematic configuration of the shuttle-type automated warehouse according to an embodiment of the present invention. As shown in Figures 1 and 2, reference numeral 1 indicates the shuttle-type automated warehouse of this embodiment (hereinafter referred to as "automated warehouse"). This automated warehouse 1 comprises racks 2 and a plurality of loading and unloading carts (hereinafter referred to as "carts") 4. As shown in Figure 2, the racks 2 have a pair of racks 2 facing each other across the travel path 10 of the carts 4. In Figure 2, the rack 2 on the far side when viewed from the front is indicated by reference numeral 2a, and the rack 2 on the near side is indicated by reference numeral 2b. Also, as shown in Figure 1, one cart 4 is arranged on each of the plurality of shelf levels 8.

[0015] Rack 2 has multiple shelf levels 8 arranged vertically (in the Z direction as shown in the diagram), each having a series of shelves (flat shelves) 6 arranged horizontally (in the X direction as shown in the diagram). Note that each of the multiple shelves 6 may be a separate unit or may be formed as a single unit.

[0016] Next, as shown in Figure 2, each of the multiple trolleys 4 moves independently from one another in the left-right direction along a running track 10 having a pair of rails, and the transfer device 12 transfers cargo (indicated by symbol A) to and from the rack 2, that is, unloads cargo onto the rack 2 and loads cargo from the rack 2 onto the trolleys 4.

[0017] Although not shown in the diagram, the transfer device 12 has one or more movable arms extending from the base arm, and a hook that can be opened and closed for pushing and pulling the load as the movable arms move, and can store two loads (A1, A2) in the depth direction of the rack 2 (2a, 2b). Since this storage is performed for all shelves 6, multiple rear storage positions (the position of load A1 shown in Figure 2 as a representative example) and front storage positions (the position of load A2 shown in Figure 2 as a representative example) are lined up along the direction of travel of the trolley 4. As a modification of the automated warehouse 1 of this embodiment, for example, an automated warehouse 1 may be provided in which one loading / unloading trolley with a lifter is placed for every three shelves 8, and loads can be stored in each of the three shelves 8 using that single trolley.

[0018] In this embodiment, the trolley 4 is a so-called double-reach type shuttle trolley capable of storing two packages (packages A1 and A2) in the depth direction of the rack 2. On the other hand, as a modification, the trolley 4 may be a so-called double-deep type shuttle trolley capable of storing one package (large package) and two packages (small packages) in the depth direction of the rack 2, or it may be a so-called multi-deep type shuttle trolley capable of storing two packages (large packages) in the depth direction of the rack 2 and three or more packages (small packages) side by side in the depth direction of the rack 2. The rear storage position and front storage position described above are positions defined when storing two packages (A1 and A2) in the depth direction, regardless of the type of shuttle trolley.

[0019] Next, with reference to Figures 1 to 4, the loading and unloading device for loading and unloading goods to and from the rack 2 described above, according to this embodiment, will be explained. Figure 3 is a schematic plan view showing the loading and unloading device at odd-numbered levels of the shuttle-type automated warehouse according to this embodiment shown in Figure 2, and Figure 4 is a schematic plan view showing the loading and unloading device at even-numbered levels of the shuttle-type automated warehouse according to this embodiment shown in Figure 2. First, as shown in Figures 1 and 2, reference numeral 14 indicates a loading and unloading device having four loading and unloading routes according to this embodiment, and in this embodiment, this loading and unloading device 14 is located on the origin side and not on the opposite side of the origin. As shown in Figures 1 and 2, the loading and unloading device 14 according to this embodiment comprises a pair of outer loading and unloading devices 16 and a pair of inner loading and unloading devices 18.

[0020] As shown in Figure 2, these external loading / unloading devices 16 and internal loading / unloading devices 18 are formed symmetrically in the front-rear direction with respect to the extension line L of the trolley 4's travel path 10, which extends in the left-right direction (symmetrical with respect to the extension line L in a plan view, or symmetrical with respect to a plane containing a similar extension line at each shelf level 8), and have the same device configuration. However, even though the device configuration is the same, the direction of cargo transport is different.

[0021] Furthermore, as shown in Figures 3 and 4, the external storage access devices 16 are arranged to correspond to the odd-numbered shelf levels 8, and the internal storage access devices 18 are arranged to correspond to the even-numbered shelf levels 8.

[0022] Next, the general configuration of the external loading / unloading device 16 will be explained with reference to Figures 1, 2, and 3. First, as shown in Figures 1, 2, and 3, the external loading / unloading device 16 comprises external loading / unloading conveyors 20 and 22 connected to loading stations (not shown) and loading-side conveyors of other automated warehouses, respectively; external lifting and transporting devices 24 and 26 for transferring goods between these external loading / unloading conveyors 20 and 22 and for lifting and transporting goods to and from each shelf level 8 (odd-numbered levels); external buffer conveyors 28 and 30 for transferring goods between these external lifting and transporting devices 24 and 26 and for transporting goods for transfer by a transfer device 12 on a trolley 4; and sliding plates 32 and 34 (shown as dashed lines in Figure 2) for sliding goods between the trolley 4 and the transfer device 12 described above.

[0023] Next, as shown in Figure 1, the outer loading / unloading conveyors 20 and 22 are roller conveyors installed on the foundation G. In Figure 2, as indicated by the arrows indicating the direction of cargo transport, the outer loading / unloading conveyor 20 on the far side is used for unloading, and the outer loading / unloading conveyor 22 on the near side is used for loading. Next, as shown in Figures 1 and 2, the outer lifting and transporting devices 24 and 26 each have roller conveyors, lifting platforms 36 and 38 that move up and down, and masts 40 and 42 that have drive mechanisms (not shown) for raising and lowering these lifting platforms 36 and 38.

[0024] Next, as shown in Figures 1, 2, and 3, the outer buffer conveyors 28 and 30 have one end that extends to a position adjacent to the rack 2, where goods are transferred by the transfer device 12 of the trolley 4, while the other end extends to a position adjacent to the lifting platforms 36 and 38 in a plan view. The outer buffer conveyors 28 and 30 are roller conveyors provided to correspond to the odd-numbered shelves 8, with the outer buffer conveyor 28 on the far side being used for outbound goods, and the outer buffer conveyor 30 on the near side being used for inbound goods.

[0025] Next, as shown in Figure 3, the sliding plates 32 and 34 are provided corresponding to the odd-numbered shelf levels 8 and are formed so that goods can slide on their top surfaces. The rear sliding plate 32 is used for outbound loading, and the front sliding plate 34 is used for inbound loading. The trolley 4 stops at the loading receiving section 3, which is located adjacent to the end of the rack 2, as shown in Figure 3, and transfers goods between it and the outer buffer conveyors 28 and 30.

[0026] Here, as shown in Figure 3, the outer loading / unloading conveyors 20, lifting platform 36, and outer buffer conveyor 28, each located on the rear side, are positioned in a plan view on the extension line L1 of the rear storage position (A1) of the cargo in the rear racks 2a, which are arranged in multiple rows along the travel path 10. The outer loading / unloading conveyors 22, lifting platform 38, and outer buffer conveyor 30, each located on the front side, are positioned in a plan view on the extension line L2 of the rear storage position (A1) of the cargo in the front racks 2b, which are arranged in multiple rows along the travel path 10.

[0027] Next, the general configuration of the internal loading / unloading device 18 will be explained with reference to Figures 1, 2, and 4. First, as shown in Figures 1, 2, and 4, the internal loading / unloading device 18 includes internal loading / unloading conveyors 44 and 46 connected to loading stations (not shown) and loading-side conveyors of other automated warehouses, respectively; internal lifting and transporting devices 48 and 50 for transferring goods between these internal loading / unloading conveyors 44 and 46 and for lifting and transporting goods to and from each shelf level 8 (even-numbered levels); and internal buffer conveyors 52 and 54 for transferring goods between these internal lifting and transporting devices 48 and 50 and for transporting goods to and from the trolley 4. The detailed configuration of the internal buffer conveyors 52 and 54 will be described later, but in this embodiment, they are configured as crank-shaped roller conveyors.

[0028] Next, in this embodiment, the inner in / out conveyors 44 and 46 are roller conveyors installed on the foundation G (for convenience, they are shown at the second level height in Figure 1), and as indicated by the arrows in Figure 2, the inner in / out conveyor 44 on the far side is used for outbound transport, and the inner in / out conveyor 46 on the near side is used for inbound transport. Next, as shown in Figures 1 and 2, the inner lifting and transport devices 48 and 50 each have roller conveyors and include lifting platforms 56 and 58 that move up and down in the vertical direction, and masts 60 and 62 that have a drive mechanism (not shown) for raising and lowering these lifting platforms 56 and 58.

[0029] Next, as shown in Figure 4, the inner buffer conveyors 52 and 54 are roller conveyors provided corresponding to the even-numbered shelf levels 8, and transport goods between the trolley 4 and the lifting platforms 56 and 58. More specifically, the inner buffer conveyors 52 and 54 are adjacent to the aforementioned load receiving section 3 and comprise first buffer conveyors 64 and 66 extending in the left-right direction, and conversion conveyors (second buffer conveyors) 68 and 70 for transporting goods between these first buffer conveyors 64 and 66 and the lifting platforms 56 and 58.

[0030] Of these, the first buffer conveyors 64 and 66 have one end that extends to a position adjacent to the rack 2, where the load is transferred by the transfer device 12 of the trolley 4, while the other end extends to a position adjacent to the conversion conveyors 68 and 70. While the outer buffer conveyors 28 and 30 described above are located on the extension line L1 of the rear storage position (A1) of the load in the rack 2, the inner first buffer conveyors 64 and 66 are located on the extension line of the front storage position (A2), which is arranged in a row along the travel path 10 in a plan view. Note that the illustration of the extension line is omitted.

[0031] The first buffer conveyors 64 and 66 are roller conveyors that transport loads in the left-right direction, while the conversion conveyors 68 and 70 are roller conveyors that transport loads in the left-right direction and also convert the direction of transport of loads by 90 degrees to transport them in the front-back direction. These first and second inner buffer conveyors 64, 66, 68, and 70 are equipped with drive mechanisms (not shown).

[0032] Here, an example of the operation of the conversion conveyors 68 and 70 by the drive mechanism will be explained. As shown in Figure 4, when the conversion conveyor 68 receives a load from the first buffer conveyor 64 during retrieval, the conversion conveyor 68 transports the load in the left-right direction (in the example in Figure 4, the left direction which is the retrieval direction) and places it on the conversion conveyor 68, then transports the load in the front-back direction, and after the load has been transported to a position corresponding to the lifting platform 56, the load is transported in the left-right direction (in the example in Figure 4, the left direction which is the retrieval direction) and handed over to the lifting platform 56.

[0033] On the other hand, as shown in Figure 4 as an example, when the convertible conveyor 70 receives goods from the lifting platform 58 during warehousing, the convertible conveyor 70 transports the goods in the left-right direction (in the example in Figure 4, the left direction which is the warehousing direction) and places them on the convertible conveyor 70, then transports the goods in the front-back direction, and after the goods have been transported to a position corresponding to the first buffer conveyor 66, the goods are transported in the left-right direction (in the example in Figure 4, the right direction which is the warehousing direction) and handed over to the first buffer conveyor 66.

[0034] In addition, as the second buffer conveyor for changing the direction of cargo transport, instead of the roller conveyor described above, it may be a slide plate conveyor equipped with a pusher mechanism that pushes out cargo with a predetermined mechanism, a tracked trolley type conveyor (traverser trolley) that moves along a rail extending in the front-rear direction and has a roller conveyor on its upper surface and wheels on its lower surface, or a curved conveyor (roller conveyor extending in a curved shape) that curves and extends so as to connect the lateral edges of the first buffer conveyors 64 and 66 with the lateral edges of the lifting platforms 56 and 58.

[0035] In this embodiment, the inner buffer conveyor 52 on the far side is used for outbound cargo, and the inner buffer conveyor 54 on the near side is used for inbound cargo. As shown in Figure 2, the trolley 4 stops at the cargo receiving section 3 located adjacent to the end of the rack 2 and transfers cargo between it and the first buffer conveyors 64 and 66.

[0036] Here, the installation heights of the four systems of inbound and outbound conveyors 20, 22, 44, and 46 described above are not limited to the example described above in which the outer inbound and outbound conveyors 20, 22 and the inner inbound and outbound conveyors 44, 46 are all installed on the foundation G, but may also be as follows. As a variation, for example, the outer inbound and outbound conveyors 20, 22 may be installed on the foundation G, while the inner inbound and outbound conveyors 44, 46 may be installed at the height of the second level. Alternatively, the outer inbound and outbound conveyors 20, 22 and the inner inbound and outbound conveyors 44, 46 may all be installed at the height of the second level. Alternatively, the outbound inbound and outbound conveyor may be installed on the foundation G, and the inbound inbound and outbound conveyor may be installed at the height of the upper level. Alternatively, each inbound conveyor may be installed at a different level height from each other. Alternatively, the outer inbound / outbound conveyors 20, 22 and the inner inbound / outbound conveyors 44, 46 may be installed on the foundation G, and other outer inbound / outbound conveyors (20, 22) and inner inbound / outbound conveyors (44, 46) may be installed on a second level, thereby providing a large number of combinations of inbound / outbound conveyors. In other words, the installation height and number of such inbound / outbound conveyors 20, 22, 44, 46 should be appropriately set according to the specifications of the automated warehouse 1 and the inbound / outbound station (not shown).

[0037] Here, the automated warehouse 1 is equipped with a controller 80 that controls the operation of each trolley 4, each lifting and transporting device 24, 26, 48, 50, each conveyor 20, etc. The trolleys 4, each lifting and transporting device, each conveyor, etc. operate according to control signals transmitted from the controller 80 via wireless or wired communication. Specifically, the controller 80 is composed of a microprocessor, interface circuit, communication circuit, memory, and software to operate these (not shown).

[0038] Here, an example of the loading and unloading operations of goods in the automated warehouse 1 by the controller 80 will be explained. In this example, with reference to Figure 4, the loading and unloading operations of high-frequency goods that are loaded and unloaded frequently will be explained. First, in the loading operation, goods transported from a loading station (not shown) by a predetermined conveyor are transported in the following order: the inner loading / unloading conveyor 46, the lifting platform 58 of the inner lifting / unloading device 50, and the inner buffer conveyor 54 of a predetermined shelf tier 8. After the goods are received by the trolley 4, the trolley 4 is moved and stored in a predetermined storage position on the rack 2 (in this example, racks 2a and 2b of the even-numbered shelf tiers 8) using the transfer device 12.

[0039] On the other hand, for the outbound operation, the goods stored in rack 2 are loaded onto trolley 4 by transfer device 12, the trolley 4 is driven to the receiving section 3, and then the goods are transported in the following order: inner buffer conveyor 52, lifting platform 56 of inner lifting conveyor device 48, and inner inbound / outbound conveyor 44, and then outbound to a designated outbound station or the like on a predetermined conveyor (not shown).

[0040] In this example, in the internal loading / unloading device 18, the trolley 4 and the first buffer conveyors 64 and 66 are adjacent, and the transfer time by the transfer device 12 is short, thus reducing the time required for loading and unloading, making it effective. In contrast, in the external loading / unloading device 16, the load is transferred between the trolley 4 and the external buffer conveyors 28 and 30 via the slide plates 32 and 34 using the transfer device 12 of the trolley 4. Thus, in the external loading / unloading device 16, there is a transfer time due to the slide plates 32 and 34. Therefore, the internal loading / unloading device 18 is effective because it does not involve the slide plates 32 and 34 as in the external loading / unloading device 16, thus reducing the load transfer time.

[0041] Next, the positional relationship between the outer lifting conveying device 24 and the inner lifting conveying device 48, and the positional relationship between the outer lifting conveying device 26 and the inner lifting conveying device 50 will be explained with reference to Figures 3 and 5. Figure 5(A) is a plan view showing the lifting conveying device of this embodiment, and Figure 5(B) is a side view of the lifting conveying device of this embodiment as seen from the side. As shown in Figures 5(A) and 5(B), the outer lifting conveying device 24 and the inner lifting conveying device 48 are provided such that their lifting platforms 36 and 56 are spaced apart from each other in the front-rear direction by a predetermined distance (reference setting space) S. In this embodiment, this predetermined distance (reference setting space) S is larger than the front-rear width of the masts 40 and 60, and the masts 40 and 60 of each lifting conveying device 24 and 26 are positioned within this predetermined distance space S with their positions offset in the direction of cargo transport. The positional relationship between the other outer lifting conveying device 26 and the inner lifting conveying device 50 is similar.

[0042] In this embodiment, due to this positional relationship, as shown in Figure 3, the outer inbound / outbound conveyors 20, 22, lifting platforms 36, 38, and outer buffer conveyors 28, 30 are arranged in a plan view along extension lines L1, L2, while minimizing the space S required for the masts 40, 60, thereby increasing the overall space efficiency of the automated warehouse 1. Furthermore, in this embodiment, as is particularly clear in Figure 5(B), in a side view (viewed in the direction of the side of the automated warehouse 1 shown in Figure 1 (X direction)), a portion of the mast 40 and a portion of the mast 60 overlap each other, which further enhances space efficiency.

[0043] Next, the space efficiency effects of the outer loading / unloading device 16 and the inner loading / unloading device 18 will be explained with reference to Figures 2 to 4. In this embodiment, as described above, the outer buffer conveyors 28 and 30 of the outer loading / unloading device 16 are provided to correspond to the odd-numbered shelf levels 8 (see Figure 3), while the inner buffer conveyors 52 and 54 of the inner loading / unloading device 18 are provided to correspond to the even-numbered shelf levels 8 (see Figure 3).

[0044] In this way, in the plurality of shelves 8, the outer buffer conveyors 28 and 30 and the inner buffer conveyors 52 and 54 are alternately arranged in the vertical direction. Thus, in odd-numbered shelves, as shown in FIG. 3, there is a space inside the pair of outer buffer conveyors 28 and 30. On the other hand, in even-numbered shelves, as shown in FIG. 4, there is a space outside the pair of inner buffer conveyors 52 and 54.

[0045] According to this, in the present embodiment, for example, the driving devices of the inner buffer conveyors 52 and 54 can be arranged to project into the empty space, particularly the space inside the pair of outer buffer conveyors 28 and 30 as shown in FIG. 3, so as to improve the space efficiency of the entire automated warehouse 1. Also, such an arrangement makes it possible to secure a space for workers to perform maintenance on each component device. In particular, by providing such a driving device to project into the space in the height direction, the height of each of the plurality of shelves 8 can be set to be as small as possible while ensuring a minimum gap with the height of the assumed load, thereby improving the space efficiency.

[0046] Particularly, as shown in FIGS. 3 and 4, in a plan view, in order to accommodate four sets of loading and unloading devices in a limited installation area, in the inner buffer conveyor, the conveying direction of the goods is changed using conversion conveyors 68, 70, etc. Therefore, the constraints on the placement locations of the driving devices and auxiliary mechanisms of the conveyor and the like are increased. However, in the present embodiment, as described above, by arranging auxiliary mechanisms associated with the conveyor, such as driving devices, in the space inside the pair of outer buffer conveyors 28 and 30 or the space outside the pair of inner buffer conveyors 52 and 54, the space is effectively utilized.

[0047] Also, by constructing the outer buffer conveyors 28 and 30 and the inner buffer conveyors 52 and 54, etc., which have a common structure, to overlap each other in the vertical direction, cost reduction can be achieved.

[0048] In this embodiment, the outer buffer conveyors 28 and 30 and the inner buffer conveyors 52 and 54 are alternately arranged in odd and even stages, but the present invention is not limited to this. For example, among the plurality of shelf levels 8, the outer buffer conveyors (Figs. 3 and 6) and the inner buffer conveyors (Figs. 4 and 7) may be separately arranged between the plurality of lower levels and the plurality of upper levels, or alternately arranged every two levels (that is, for example, stacking two outer buffer conveyors as shown in Fig. 3 and stacking two inner buffer conveyors as shown in Fig. 4 above them), and the inner buffer conveyors and the inner buffer conveyors may be arranged in this way.

[0049] Next, the shuttle-type automatic warehouse 1 according to the modified example of the present invention will be described with reference to Figs. 6 and 7. Fig. 6 is a plan view schematically showing the loading / unloading device at the odd stages of the shuttle-type automatic warehouse according to the modified example of the present invention, and Fig. 7 is a plan view schematically showing the loading / unloading device at the even stages of the shuttle-type automatic warehouse according to the modified example of the present invention. The automatic warehouse 1 according to this modified example is different only in a part of the configuration of the inner loading / unloading device 18 from the automatic warehouse 1 of the above-described embodiment, and the description of the same configuration will be omitted.

[0050] In this modified example, instead of the inner loading / unloading conveyors 44 and 46 of the above-described inner loading / unloading device 18, third inner buffer conveyors 72 and 74 and conversion conveyors 76 and 78 which are fourth inner buffer conveyors are provided. The third inner buffer conveyors 72 and 74 are roller conveyors that transfer goods between the lift tables 56 and 58 of the inner lifting and conveying devices 48 and 50 and transfer goods between the conversion conveyors 76 and 78 to convey the goods.

[0051] The conversion conveyors 76 and 78 are roller conveyors that transfer goods between the above-described outer loading / unloading conveyors 20 and 22 and transfer goods between the third inner buffer conveyors 72 and 74 to convey the goods. Although detailed description is omitted, they have the same configuration as the above-described second buffer conveyor.

[0052] In this modified example, the conveyors for loading and unloading goods are consolidated into two systems, the outer loading and unloading conveyors 20 and 22. As indicated by the arrows in Figures 6 and 7, the loading and unloading operation forms a loading path (see Figure 6) in which goods are loaded and unloaded in the order of the outer buffer conveyor 28, the lifting platform 36, and the loading and unloading conveyor 20, and a loading path (see Figure 7) in which goods are loaded and unloaded in the order of the inner buffer conveyor 52 (first and second buffer conveyors 64 and 68), the lifting platform 56, the third and fourth inner buffer conveyors 72 and 76, and the loading and unloading conveyor 20. Furthermore, for the loading and unloading of goods, a loading and unloading route is formed (see Figure 6) in which goods are transported in the order of loading and unloading conveyor 22, lifting platform 38, and outer buffer conveyor 30 before being loaded and unloaded, and a loading and unloading route is formed (see Figure 7) in which goods are transported in the order of loading and unloading conveyor 20, third and fourth inner buffer conveyors 74, 78, lifting platform 58, and inner buffer conveyor 54 (first and second buffer conveyors 66, 70).

[0053] Here, we will describe some variations in the arrangement of the loading / unloading equipment. First, in the embodiments and variations described above, the loading / unloading equipment 14 is located on the origin side and not on the non-origin side, but this is not limited to this. That is, as a variation, loading / unloading equipment 14 with the same configuration may be arranged on both the origin side and the non-origin side, or, although the explanation will be omitted, loading / unloading equipment with one or two conventional loading / unloading routes equipped with one or two lifting / transporting devices may be arranged on the non-origin side.

[0054] Furthermore, in the embodiments and modifications described above, the outer in / out conveyor 22 and the inner in / out conveyor 46 are set as inbound conveyors, and the outer in / out conveyor 20 and the inner in / out conveyor 44 are set as outbound conveyors, but this is not limited to this. That is, any of the four in / out conveyor systems 20, 22, 44, and 46 of this embodiment, and the two in / out conveyor systems 20 and 22 of the modifications, may be appropriately set for inbound and outbound purposes. For example, the pair of outer in / out conveyors 20 and 22 of this embodiment may be set for inbound purposes, and the pair of inner in / out conveyors 44 and 46 may be set for outbound purposes. Or, the reverse may also be true.

[0055] Furthermore, as described above, when the loading and unloading equipment is located on the side opposite the origin, for example, all four loading and unloading conveyors 20, 22, 44, and 46 of this embodiment, and the two loading and unloading conveyors 20 and 22 of the modified example, may be set up for loading, and the loading and unloading equipment on the side opposite the origin may be set up for unloading. Alternatively, the reverse may also be true.

[0056] Next, the operation and effects of the shuttle-type automated warehouse according to the embodiment and modification of the present invention will be described. First, the shuttle-type automated warehouse 1 according to this embodiment and modification comprises a rack 2 having a plurality of shelves 8 in the vertical direction, and a shuttle trolley 4 that travels horizontally along the flat shelves 6 of each shelf of the rack 2. The rack 2 is arranged on both sides along the travel path 10 of the shuttle trolley 4, and the racks 2a and 2b on both sides are capable of storing cargo A in a front storage position (A2) which is a plurality of items lined up on the flat shelves 6 on the side closer to the travel path 10 of the shuttle trolley 4, and in a rear storage position (A1) which is a plurality of items lined up on the flat shelves 6 on the side further from the travel path 10 of the shuttle trolley 4. The system includes a pair of external lifting and conveying devices 24, 26 for lifting and conveying cargo, a pair of internal lifting and conveying devices 48, 50 positioned inside the pair of external lifting and conveying devices for lifting and conveying cargo, external buffer conveyors 28, 30 provided to correspond to at least some of the shelves among the multiple shelves of the rack and extending from the external lifting and conveying devices 24, 26 to the vicinity of the shuttle cart's travel path, and internal buffer conveyors 52, 54 provided to correspond to shelves among the multiple shelves of the rack that are not provided with external buffer conveyors and extending from the internal lifting and conveying devices to the vicinity of the shuttle cart's travel path.

[0057] With this embodiment and its modified configuration, the lifting and transporting capacity of goods can be increased by the two pairs of internal and external lifting and transporting devices 24, 26, 48, and 50, thereby improving the loading and unloading capacity of goods in the automated warehouse 1. Furthermore, since the external buffer conveyors 28 and 30 are provided for at least some of the shelves (odd-numbered shelves in this embodiment, but not limited thereto), and the internal buffer conveyors 52 and 54 are provided for shelves where external buffer conveyors are not provided (even-numbered shelves in this embodiment, but not limited thereto), a space where no buffer conveyor is placed can be created at each shelf 8, and the drive devices for each buffer conveyor can be effectively arranged in such a space. Therefore, the loading and unloading capacity of goods can be improved while suppressing an increase in the installation space of the automated warehouse 1.

[0058] Furthermore, in this embodiment and its modified form, the outer lifting and conveying devices 24, 26 and the inner lifting and conveying devices 48, 50 each include lifting platforms 36, 38, 56, 58 and masts 40, 42, 60, 62 equipped with a drive mechanism (not shown) for raising and lowering the lifting platforms. The outer lifting and conveying devices and the inner lifting and conveying devices are provided with their lifting platforms 36, 38, 56, 58 spaced apart from each other at a predetermined interval S, and the masts 40, 42, 60, 62 of the outer lifting and conveying devices and the inner lifting and conveying devices are arranged in this predetermined space S with offset positions in the cargo conveying direction. This makes it possible to realize an automated warehouse 1 with improved loading and unloading capacity in a more space-saving manner.

[0059] Furthermore, in this embodiment and its modifications, since the outer buffer conveyors 28, 30 and the inner buffer conveyors 52, 54 are alternately arranged for each shelf level 8 of the rack, the drive units for the buffer conveyors can be positioned to protrude into the empty space in the shelf direction (up and down direction) where buffer conveyors are not present, thereby effectively utilizing the space. In particular, the drive units for the inner buffer conveyors 52, 54 can be made to protrude in the up and down direction. Moreover, by effectively utilizing the empty space in the shelf direction in this way, the height difference between each shelf level can be minimized (closer to the expected height of the cargo), allowing for more shelves to be provided within the desired height of the automated warehouse. Additionally, since the outer buffer conveyors 28, 30 and the inner buffer conveyors 52, 54, etc., which have a common structure, can be constructed to overlap each other in the up and down direction at each shelf level, costs can be reduced.

[0060] A. Cargo A1. Cargo in the rear storage position, rear storage position A2. Cargo in the front storage position, front storage position S. Reference setting space between the outer lifting conveyor and the inner lifting conveyor 1. Shuttle-type automated warehouse 2, 2a, 2b. Racks 4. Inbound / outbound cart (shuttle cart) 6. Shelves, flat shelves 8. Shelf levels 10. Travel paths 12. Transfer devices 14. Inbound / outbound devices 16. Outbound / outbound devices 18. Inbound / outbound devices 20, 22. Outbound / outbound conveyors 24, 26. Outbound lifting conveyors 28, 30. Outbound buffer conveyors 32, 34. Slide plates 36, 38. Lifting platforms 40, 42. Masts 44, 46. Inbound / outbound conveyors 48, 50. Inbound lifting conveyors 52, 54. Inbound buffer conveyors 56, 58. Lifting platform 60, 62 Mast 64, 66 First buffer conveyor (inner buffer conveyor) 68, 70 Second buffer conveyor (inner buffer conveyor, conversion conveyor) 72, 74 Third buffer conveyor (inner buffer conveyor) 76, 78 Fourth buffer conveyor (inner buffer conveyor, conversion conveyor) 80 Controller

Claims

1. A shuttle-type automated warehouse comprising a rack having multiple shelves in the vertical direction and a shuttle trolley that travels horizontally along the flat shelves of each shelf of the rack, wherein the rack is arranged on both sides along the travel path of the shuttle trolley, and each rack is capable of storing goods in a front storage position arranged in multiple rows on the flat shelves on the side closer to the travel path of the shuttle trolley and a rear storage position arranged in multiple rows on the flat shelves on the side further from the travel path of the shuttle trolley, the automated warehouse comprising: a pair of external lifting and conveying devices provided on the extension of the multiple rear storage positions of the rack for lifting and conveying goods; a pair of internal lifting and conveying devices provided inside the pair of external lifting and conveying devices for lifting and conveying goods; and an external buffer conveyor provided corresponding to at least some of the shelves among the multiple shelves of the rack, extending from the external lifting and conveying devices to the vicinity of the travel path of the shuttle trolley. A shuttle-type automated warehouse characterized by comprising: an inner buffer conveyor provided in correspondence with the shelves of the racks that are not provided with the outer buffer conveyor, and extending from the inner lifting conveyor to the vicinity of the travel path of the shuttle trolley.

2. The shuttle-type automated warehouse according to claim 1, wherein the outer lifting and conveying device and the inner lifting and conveying device each comprise a lifting platform and a mast equipped with a drive mechanism for raising and lowering the lifting platform, and the lifting platforms of the outer lifting and conveying device and the inner lifting and conveying device are provided at a predetermined distance from each other, and the masts of the outer lifting and conveying device and the inner lifting and conveying device are provided in the space of this predetermined distance such that they are offset in position in the direction of cargo transport.

3. The shuttle-type automated warehouse according to claim 1 or claim 2, wherein the outer buffer conveyor and the inner buffer conveyor are arranged alternately for each shelf level of the rack.

4. The automated warehouse according to claim 1 or 2, comprising the shuttle trolley, the outer lifting and conveying device, the inner lifting and conveying device, the outer buffer conveyor, and a controller for controlling the operation of the inner buffer conveyor, wherein the controller is configured to store items that are frequently moved in and out of the automated warehouse in racks on shelves equipped with the inner buffer conveyor.

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