Automated warehouse

Abstract

Provided is a truck-type automated warehouse capable of quickly loading and unloading cargo while adjusting the stopping position of a truck according to the cargo. This automated warehouse 1 comprises an anti-origin-side buffer conveyor 32. A truck 4 comprises: a transfer device 40 including a fixed arm 52 disposed on the anti-origin side and a movable arm 54 disposed on the origin side on the truck; a cargo detection sensor 70 disposed at a position more on the anti-origin side than the fixed arm 52; and controllers 34, 44. The controllers are configured to: make the truck 4 travel at a low speed (V2) in a cargo detection area (position C to position D) of the anti-origin-side buffer conveyor 32 when the truck is traveling on the anti-origin-side buffer conveyor 32 in order to load or unload cargo; and make the truck stop on the basis of the detection of an anti-origin side end part of cargo (W) present on the anti-origin side-buffer conveyor 32 by means of an anti-origin-side photoelectric sensor 70.

Description

Automated Warehouse

[0006] ,

[0001] The present invention relates to an automated warehouse, and particularly to a shuttle trolley type automated warehouse including a plurality of tiers of racks, a shuttle trolley traveling along each of the plurality of tiers of racks, a buffer conveyor provided on each of the plurality of tiers, and a lifting conveyor.

[0002] Conventionally, there is known a shuttle trolley type automated warehouse provided with a transfer device for loading and unloading goods on a shuttle trolley to or from a rack or a buffer conveyor, or for loading goods stored in a rack or on a buffer conveyor onto the shuttle trolley (for example, Patent Document 1). The transfer device of the shuttle trolley in this Patent Document 1 includes a pair of slide arms that extend and contract for transferring goods, one of the slide arms being a fixed arm fixed to the trolley, and the other slide arm being a movable arm that moves in the moving direction of the trolley according to the width of the goods.

[0003] Japanese Patent No. 7396506

[0004] Here, for example, when loading goods placed on the buffer conveyor on the inbound station side, in the transfer device as in Patent Document 1, since the fixed arm is fixed on the shuttle trolley, after the shuttle trolley stops, it may not be in a position corresponding to the width of the goods. Therefore, conventionally, on the buffer conveyor, while ensuring that one end in the width direction of the goods (the end corresponding to the fixed arm of the goods) is always in a fixed position, the stop target position of the fixed arm is determined based on this fixed position and the trolley is run for loading. <00​​​Therefore, the present invention has been made to solve the above-mentioned problems, and aims to provide a shuttle cart type automated warehouse that can quickly load cargo while adjusting the stopping position of the shuttle cart according to the cargo.

[0007] To achieve the above objective, the present invention provides a shuttle cart type automated warehouse comprising: a plurality of racks; a shuttle cart that travels along each of the plurality of racks; buffer conveyors provided on each of the plurality of racks; and a lifting conveyor, wherein the automated warehouse comprises: an origin-side inbound / outbound conveyor provided on the origin side, which is one end of the rack; and an anti-origin-side inbound / outbound conveyor provided on the anti-origin side, which is the other end of the rack; the lifting conveyor includes an origin-side lifting conveyor provided on the origin side and an anti-origin-side lifting conveyor provided on the anti-origin side; the buffer conveyor includes an origin-side buffer conveyor provided on the origin side and an anti-origin-side buffer conveyor provided on the anti-origin side; and the shuttle cart is positioned on the anti-origin side on the shuttle cart. The transfer device includes a fixed arm and a movable arm positioned on the origin side of the shuttle cart, the distance between the fixed arm and the transfer device can be changed; a load detection sensor positioned on the shuttle cart at a position opposite the origin to the fixed arm of the transfer device; and a controller that controls the running motion of the shuttle cart, wherein the controller is configured to run the shuttle cart at a predetermined low speed in a predetermined load detection area of ​​the buffer conveyor opposite the origin when the shuttle cart is running to load loads on the buffer conveyor opposite the origin, and to stop the shuttle cart based on the detection of the end of the load on the buffer conveyor opposite the origin by the load detection sensor.

[0008] With the present invention configured as described above, when the shuttle cart is traveling to load cargo on the buffer conveyor on the non-origin side, the shuttle cart is driven at a predetermined low speed within a predetermined cargo detection area of ​​the buffer conveyor on the non-origin side, and the shuttle cart is stopped based on the detection of the non-origin side end of the cargo present on the buffer conveyor on the non-origin side by the cargo detection sensor. This allows the stopping position of the shuttle cart to be changed according to the width of the cargo. In other words, when loading cargo on the buffer conveyor on the non-origin side, even if the position of the non-origin side end of the cargo located on the fixed arm side is different (even if the width of the cargo is different) as seen from the shuttle cart side, the fixed arm can be stopped at a position corresponding to the non-origin side end of the cargo. Therefore, loading can be performed quickly while adjusting the stopping position of the shuttle cart according to the cargo.

[0009] Furthermore, in the present invention, preferably, the fixed arm of the transfer device and the load detection sensor are arranged at a predetermined distance from each other in the direction of travel of the shuttle cart, and the controller is configured to travel a certain distance until the shuttle cart is stopped after the load detection sensor detects the end of the load on the side opposite the origin. With the present invention configured in this way, the load detection sensor is positioned on the shuttle cart at a position closer to the origin than the fixed arm, and is spaced at a predetermined distance from the fixed arm, and the shuttle cart travels a certain distance until it is stopped after detecting the end of the load on the side opposite the origin. As a result, there is a margin of distance and time between the load detection sensor detecting the end of the load on the side opposite the origin and the shuttle cart stopping, which ensures that the fixed arm is stopped at a position corresponding to the end of the load on the side opposite the origin.

[0010] Furthermore, in the present invention, preferably, the controller is configured to detect the origin-side end of the load using a load detection sensor while the shuttle trolley is in motion, and to adjust the spacing of the movable arms of the transfer device based on the detection result. With the present invention configured in this way, even if a load being transported toward the origin on the anti-origin-side buffer conveyor exceeds or is repelled by a guide member (a so-called stopper, etc., for restricting the position of the origin-side end of the load to a certain position), the origin-side end of the load can be detected, so such loads can be loaded effectively.

[0011] Furthermore, in the present invention, preferably, the controller detects the end of the load on the side opposite the origin using a load detection sensor, and then causes the shuttle trolley to travel a certain distance until it stops. The controller is configured to detect the end of the load on the side opposite the origin that is present on the buffer conveyor on the side opposite the origin using a load detection sensor, and then starts adjusting the spacing of the movable arms of the transfer device while the shuttle trolley is traveling a certain distance. With the present invention configured in this way, loading can be performed quickly.

[0012] Furthermore, in the present invention, preferably, the controller is configured to cause the load detection sensor to detect the origin end of the load while the shuttle trolley is in motion. The controller is also configured to adjust the spacing of the movable arms of the transfer device while the shuttle trolley is in motion, based on the distance traveled by the shuttle trolley from the time the origin end was detected, both before the non-origin end of the load is detected and after the load detection sensor has detected the origin end of the load. With the present invention configured in this way, loading can be performed quickly.

[0013] According to the present invention, it is possible to quickly load cargo while adjusting the stopping position of the shuttle cart according to the cargo.

[0014] This is a front view showing the schematic configuration of a shuttle trolley type automated warehouse according to an embodiment of the present invention. This is a plan view showing the schematic configuration of a shuttle trolley type automated warehouse according to an embodiment of the present invention. This is a plan view showing the schematic configuration of a shuttle trolley according to an embodiment of the present invention. This is a block diagram showing the control device for a shuttle trolley according to an embodiment of the present invention. This is a diagram showing the details of the shuttle trolley's travel speed control by the control device for a shuttle trolley according to an embodiment of the present invention, along with schematic diagrams of the shuttle trolley and the buffer conveyor on the opposite side of the origin. This is a schematic diagram for explaining the travel operation of a shuttle trolley by the control device for a shuttle trolley according to an embodiment of the present invention. This is a schematic diagram for explaining the travel operation of a shuttle trolley by the control device for a shuttle trolley according to an embodiment of the present invention. This is a schematic diagram for explaining the travel operation of a shuttle trolley by the control device for a shuttle trolley according to an embodiment of the present invention.

[0015] Next, an embodiment of the shuttle-type automated warehouse according to the present invention will be described with reference to the attached drawings.

[0016] First, the schematic configuration of a shuttle-type automated warehouse according to an embodiment of the present invention will be described with reference to Figures 1 and 2. Figure 1 is a front view showing the schematic configuration of a shuttle-type automated warehouse according to an embodiment of the present invention, and Figure 2 is a plan view showing the schematic configuration of a 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 a rack 2 and a plurality of loading / unloading carts (hereinafter referred to as "carts") 4. The rack 2 is a multi-tiered rack with a plurality of shelf levels 8 arranged vertically (Z direction in the figure), each having a series of shelves 6 arranged horizontally (X direction in the figure). Note that each of the plurality of shelves 6 may be a separate unit or may be formed integrally. In this embodiment, in this automated warehouse 1, one end of the rack 2 is defined as the origin side, and the other end is defined as the anti-origin side, and these origin side and anti-origin side are shown in Figures 1 and 2.

[0017] Next, as shown in Figure 2, each of the multiple trolleys 4 moves independently from one another in the left-right direction along a travel path 10 having a pair of rails, and unloading cargo onto the racks 2 and loading cargo from the racks 2 onto the trolleys 4 is performed by a transfer device 40, which will be described later. One trolley 4 is placed at each of the multiple shelf levels 8. As shown in Figure 2, the racks 2 have a pair of racks 2 facing each other across the travel path 10 of the trolleys 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 at every three shelf levels 8, and cargo can be stored at each of the three shelf levels 8 using that single trolley.

[0018] Next, as shown in Figures 1 and 2, the automated warehouse 1 is equipped with first and second stations 14 and 16 on both sides for loading goods to be stored in racks 2 and unloading goods taken out of racks 2. The first station 14 is an inbound / outbound station located on the origin side for loading goods in from outside or unloading goods to outside, and as shown in Figure 1, it is positioned vertically to correspond to the lowest shelf 8, and as shown in Figures 1 and 2, the first station is equipped with an outbound conveyor (a roller conveyor in this embodiment) 18 and an inbound conveyor (a roller conveyor in this embodiment) 20. The second station 16 is an inbound / outbound station located on the opposite side of the origin for loading goods in from outside or unloading goods to outside, and as shown in Figure 1, it is positioned vertically to correspond to the uppermost shelf 8, and as shown in Figures 1 and 2, it is equipped with an outbound conveyor (a roller conveyor in this embodiment) 18 and an inbound conveyor (a roller conveyor in this embodiment) 20. The vertical position of each station 14, 16 is not limited to the embodiment described above.

[0019] Furthermore, the automated warehouse 1 is equipped with first and second vertical conveying devices 22 and 24 that transfer goods between each station 14 and 16 and transport the goods by raising and lowering them to the height of the target shelf 8. The first vertical conveying device 22 is a home-side vertical conveying device, and the second vertical conveying device 24 is a non-home-side vertical conveying device. The first vertical conveying device 22 is provided on the home-side and is equipped with a lifting platform 26 that moves up and down by a drive mechanism (not shown) provided on the mast. The lifting platform 26 is equipped with a roller conveyor. The second vertical conveying device 24 is provided on the non-home-side and is equipped with a lifting platform 28 that moves up and down by a drive mechanism (not shown) provided on the mast. The lifting platform 28 is equipped with a roller conveyor.

[0020] Furthermore, the automated warehouse 1 is equipped with first to fourth buffer conveyors 30, 31, 32, and 33 that transfer goods between each of the lifting and conveying devices 22 and 24 and can temporarily store goods. As shown in Figure 2, the first buffer conveyor 30 is an outbound origin-side buffer conveyor (the "origin-side buffer conveyor" of the present invention), the second buffer conveyor 31 is an inbound origin-side buffer conveyor, the third buffer conveyor 32 is an inbound anti-origin-side buffer conveyor (the "anti-origin-side buffer conveyor" of the present invention), and the fourth buffer conveyor 33 is an outbound anti-origin-side buffer conveyor. These buffer conveyors 30 to 33 are provided adjacent to the rack 2 for each shelf 8 and transfer goods between them and the trolley 4 of each shelf 8. In this embodiment, these buffer conveyors 30 to 33 are roller conveyors equipped with drive rollers and driven rollers.

[0021] As can be understood by referring to Figure 5, which will be described later, the receiving buffer conveyor 32 on the origin side is provided with a guide member 35 that functions as a so-called stopper, which restricts the position of the origin-side end of the conveyed cargo. The receiving buffer conveyor 31 on the origin side (see Figure 2) is also provided with a similar guide member. These guide members have a so-called stopper function, similar to the prior art, to stop the conveyed cargo and restrict its end to a certain position, and a detailed explanation of their structure and other aspects will be omitted here.

[0022] Furthermore, the automated warehouse 1 is equipped with a controller (higher-level controller) 34 that comprehensively controls the operation of buffer conveyors 30-33 and trolleys 4, etc. The buffer conveyors 30-33 and trolleys 4, etc., operate according to control signals transmitted from the controller 34 via wireless or wired communication. The controller 34 consists of a processing unit (circuit) which is one or more processors (typically CPUs), a memory (ROM, RAM, etc.) for storing various programs, and a computer equipped with input / output devices, etc.

[0023] Here, the basic loading and unloading operations of the automated warehouse 1 by the controller 34 will be explained. First, as part of the loading operation, on the side opposite the origin, the goods transported by the loading conveyor 20 are placed by the lifting and transporting device 24 onto the buffer conveyor 32, which is at a height corresponding to the shelf level 8 into which the goods are to be loaded. Then, the goods placed on this buffer conveyor 32 are loaded onto the trolley 4 of the corresponding shelf level 8 and transferred (unloaded) onto one of the shelves 6 of that shelf level 8.

[0024] Here, when loading cargo onto the trolley 4 using the buffer conveyor 32, the trolley 4, which is located at either the left or right position on the shelf 8, travels along the travel path 10 of the shelf 8 from the origin to the opposite direction of the origin, and is controlled by speed / stop control to stop at a predetermined position that matches the width of the cargo on the buffer conveyor 32, as will be described later (see Figure 5, etc.).

[0025] On the other hand, as part of the cargo retrieval operation, cargo placed on any shelf 6 of the shelf tier 8 is loaded onto the trolley 4 of that shelf tier 8 and transported to the buffer conveyor 30 at the origin side of the height position corresponding to that shelf tier 8. Then, the cargo transported to the buffer conveyor 30 is moved via the lifting and transporting device 22 to the retrieval conveyor 18, and further transported to the destination connected to the retrieval conveyor 18.

[0026] Next, the schematic configuration of the loading / unloading cart and its transfer device for the shuttle-type automated warehouse of this embodiment will be described with reference to Figures 3 and 4. Figure 3 is a plan view showing the schematic configuration of the shuttle cart according to an embodiment of the present invention, and Figure 4 is a block diagram showing the control device for the shuttle cart according to an embodiment of the present invention. First, as shown in Figures 3 and 4, each cart 4 is equipped with a transfer device 40 for transferring (loading / unloading) cargo between the shelves 6 and each buffer conveyor 30-33, and a traveling device 42 for moving the cart 4 on the travel path 10.

[0027] Furthermore, as shown in Figure 4, each trolley 4 is equipped with a controller 44 for controlling the loading operation of the load by the transfer device 40 and the driving operation of the trolley 4 by the traveling device 42, based on transport commands from the higher-level controller 34. This controller 44 consists of a processing unit (circuit) which is one or more processors (typically CPUs), a memory (ROM, RAM, etc.) for storing various programs, and a computer equipped with input / output devices, etc., and is connected to the higher-level controller 34 via wireless communication. Photoelectric sensors 70 and 72, which will be described later, are also connected to the controller 44.

[0028] Here, the general configuration of the trolley 4 will be explained with reference to Figure 3. The trolley 4 comprises a main body 46 and a fixed arm 52 and a movable arm 54 attached to the main body 46. The fixed arm 52 is a fixed arm 52 that constitutes the transfer device 40 and is fixed to the main body 46. On the other hand, the movable arm 54 is a movable arm 54 that constitutes the transfer device 40 and is fixed to a frame member 48 that is attached to the main body 46 so as to be movable relative to it in the left-right direction.

[0029] Furthermore, the trolley 4 is provided with a pair of guide members 50 that guide the movement of its frame member 48. The frame member 48 is slidably attached to the pair of guide members 50, and the frame member 48 moves in the left-right direction by rotating a ball screw 60 screwed into the frame member 48 with an electric motor (not shown). As the frame member 48 moves, the movable arm 54 moves in the left-right direction (the direction in which the trolley 4 travels / the direction connecting the origin side and the opposite side of the origin). The trolley 4 is also provided with a pair of loading members 68 for placing luggage.

[0030] Next, the trolley 4 is equipped with a running gear 42 consisting of a pair of drive wheels 56 and a pair of driven wheels 58, which are provided at both ends in the front-to-back direction (Y direction) on both sides of the main body 46 in the left-to-right direction (X direction). The drive wheels 56 are driven by an electric motor (not shown), and the controller 44 described above controls the operation of the drive wheels 56 by controlling the electric motor, thereby controlling the running motion of the trolley 4. The pair of drive wheels 56 and the pair of driven wheels 58 travel on and are guided on the L-shaped rail 10.

[0031] Next, the configuration of the transfer device 40 will be described in detail. First, the fixed arm 52, although not shown in detail, has a base arm and a slide arm (for example, a middle arm and a top arm), and the slide arm is designed to extend and retract in the front-rear direction (a direction perpendicular to the direction of travel of the trolley 4) relative to the base arm fixed to the main body 46. The splines of a spline member 62 extending in the left-right direction engage with the slide arm, and by rotating the spline member 62 with an electric motor (not shown), the slide arm extends and retracts in the front-rear direction. Here, by changing the direction of rotation of the splines, the slide arm can be extended and retracted in the opposite direction.

[0032] On the other hand, the movable arm 54, although not shown in detail, has a base arm and a slide arm with a configuration similar to that of the fixed arm 52. In this movable arm 54, the slide arm extends and retracts in the front-rear direction (a direction perpendicular to the direction of travel of the trolley 4) by the rotation of the spline member 62 relative to the base arm, which is fixed to the frame member 48 of the main body 46.

[0033] Furthermore, hooks (rear hooks) 64 are provided at both ends of the fixed arm 52 in the front-rear direction (both ends of the slide arm), and are rotatable around the longitudinal axis of the fixed arm 52. When transferring cargo (loading and unloading), the hooks 64 rotate to a protruding position (not shown) where their longitudinal direction faces the mounting member 68 in order to push the cargo out from the rear. On the other hand, when cargo W is not being transferred, as shown in Figure 3, the hooks 64 are in a retracted position with their longitudinal direction facing upward.

[0034] Similarly, the same hooks (rear hooks) 66 are provided at both ends of the movable arm 54 in the front-rear direction (both ends of the slide arm). When transferring cargo, the hooks 66 rotate relative to the movable arm 54 to a protruding position, pushing the cargo out from behind.

[0035] The transfer device 40, having the fixed arm 52 and movable arm 54 as described above, operates as a rear hook type transfer device capable of transferring (loading and unloading) cargo between a pair of racks 2 or a pair of buffer conveyors 30-33 provided on both sides of the rail 10.

[0036] Here, the loading and unloading operations of this rear hook type transfer device 40 will be explained. First, when loading cargo from rack 2 or the receiving buffer conveyors 31 and 32, firstly, the movable arm 54 is moved left and right according to the width of the cargo to adjust the distance between the fixed arm 52 and the movable arm 54 (adjusted so that a predetermined clearance is formed between the fixed arm 52 and the cargo, and between the movable arm 54 and the cargo, respectively), secondly, the fixed arm 52 and the movable arm 54 are extended toward the cargo, thirdly, the hooks 64 and 66 on the rear side of the cargo are set to a protruding position, and fourthly, while returning the fixed arm 52 and the movable arm 54 to the trolley 4, the cargo is pulled in by the protruding hooks 64 and 66 and loaded onto the trolley 4.

[0037] Next, when unloading cargo onto rack 2 or the outbound buffer conveyors 30 and 33, firstly, on the trolley 4, the hooks 64 and 66 on the side opposite to the side to which the cargo is being transferred are positioned in a protruding position, and secondly, the fixed arm 52 and the movable arm 54 are extended toward the side to which the cargo is to be transferred, and the cargo is pushed out by the hooks 64 and 66 to be unloaded.

[0038] Next, the cargo detection sensor installed on the trolley 4 will be explained with reference to Figure 3. The trolley 4 is equipped with first and second photoelectric sensors 70 and 72 that can detect the end position of the cargo in the cargo width direction based on reflected light from the cargo. The cargo width refers to the cargo width in the direction of travel of the trolley 4 or in the direction of transport by the receiving buffer conveyors 31 and 32.

[0039] As shown in Figure 3, the first photoelectric sensor 70 is attached to both ends of the main body 46 on the fixed arm 52 side in the front-rear direction (direction perpendicular to the direction of travel of the trolley 4), and detects the end position in the width direction of the cargo placed on the pair of racks 2 or the loading buffer conveyors 31 and 32 arranged on either side of the rail 10. All of these photoelectric sensors 70 are positioned opposite the origin to the fixed arm 52 and spaced apart from the fixed arm 52 in the left-right direction (direction of travel of the trolley 4). Here, the left-right distance between the fixed arm 52 and the photoelectric sensor 70 is indicated by the symbol S in Figure 3.

[0040] Furthermore, the second photoelectric sensor 72 is attached to both ends in the front-rear direction of the frame member 48 of the main body 46 on the movable arm 54 side. These photoelectric sensors 72 are located adjacent to the movable arm 54 at a position on the origin side relative to the movable arm 54.

[0041] These photoelectric sensors 70 and 72 primarily emit visible light and infrared light in the forward and backward directions, and detect luggage by receiving reflected light from the luggage. In other words, the controller 44 determines that luggage is present if it receives reflected light, and determines that luggage is not present if it does not receive reflected light.

[0042] In this embodiment, while the trolley 4 is in motion, the light from the photoelectric sensors 70 and 72 is emitted toward the side of the pair of racks 2 or toward the side of the receiving buffer conveyors 31 and 32, and the position where the detection of reflected light from the cargo is interrupted is detected as the end of the cargo in the width direction. Note that the sensor for detecting the end of the cargo in the width direction is not limited to optical reflection type sensors such as photoelectric sensors as in this embodiment (including laser sensors, etc.), but any sensor capable of detecting the end of the cargo in the width direction is acceptable.

[0043] Next, the running control details of the shuttle cart according to an embodiment of the present invention, and the operation of the transfer device therewith, will be explained with reference to Figures 4 to 8. Figure 4 is a block diagram showing the control device for the shuttle cart according to an embodiment of the present invention, Figure 5 is a diagram showing the running speed control details of the shuttle cart by the control device for the shuttle cart according to an embodiment of the present invention, along with schematic diagrams of the shuttle cart and the buffer conveyor on the anti-origin side, Figure 6 is a schematic diagram for explaining the running operation of the shuttle cart by the control device for the shuttle cart according to an embodiment of the present invention, Figure 7 is a schematic diagram for explaining the running operation of the shuttle cart by the control device for the shuttle cart according to an embodiment of the present invention, and Figure 8 is a schematic diagram for explaining the running operation of the shuttle cart by the control device for the shuttle cart according to an embodiment of the present invention.

[0044] First, as shown in FIG. 4, a predetermined signal from each of the above-described photoelectric sensors 70 and 72 (see FIG. 3) is input to the controller 44. In the present embodiment, this input signal mainly includes a detection signal indicating the origin-side end position in the load width direction of the load detected by the photoelectric sensor 72 on the origin side, and a detection signal indicating the anti-origin-side end position in the load width direction of the load detected by the photoelectric sensor 70 on the anti-origin side. In the present embodiment, the controller 44 controls the transfer device 40 and the traveling device 42 (electric motor that drives the drive wheels 56) of the carriage 4 based on these detection signals.

[0045] Next, the control content of the traveling operation of the carriage 4 and the transfer operation of the transfer device 40, which are executed by the controller 44 and / or the upper controller 34, will be described with reference to the diagram shown in FIG. 5. In FIG. 5, the schematic configurations of the carriage 4, the anti-origin-side buffer conveyor 32, and the load W are illustrated in correspondence with the positional relationship with respect to the diagram. In the diagram shown in FIG. 5, the position of the above-described photoelectric sensor 70 on the anti-origin side is shown as the representative position (reference position) of the carriage 4, and the following description will be based on this.

[0046] First, as shown in FIG. 5, the carriage 4 is controlled to travel from the origin side to the anti-origin side at a high traveling speed V1 during normal operation in order to perform loading on the anti-origin-side buffer conveyor 32. Here, the position of point A shown in FIG. 5 is the traveling standby position of the carriage 4 when no load has reached the buffer conveyor 32. If no load has reached, the carriage 4 stops at the position of point A. At that time, deceleration starts from point F in the figure and stops at point A (shown by the dashed line). By stopping the carriage 4 at point A in this way, when a load reaches the buffer conveyor 32, by restarting the travel from that point A, it is possible to measure the end positions of the load while traveling from the origin-side end to the anti-origin-side end of the reached load.

[0047] Next, the position of point B is the luggage regulation position of the guide member 35 described above, and is the position of the origin-side end in the luggage width direction of the luggage conveyed by the buffer conveyor 32 (hereinafter referred to as the "origin-side end of the luggage"). In this embodiment, when the luggage is conveyed on the buffer conveyor 32, the origin-side end thereof is physically regulated to point B by the guide member 35, and the operation of the drive roller (not shown) of the buffer conveyor 32 is controlled to control the stop of the luggage so that it is regulated to point B. In this way, when the luggage is conveyed on the buffer conveyor 32, the origin-side end of the luggage is always made to exist at point B, which is the same position.

[0048] Here, the distance from point B to point C corresponds to the minimum value of the luggage width assumed in the automated warehouse 1 (the luggage with the minimum luggage width is indicated by W1), and the distance from point B to point D corresponds to the maximum value of the luggage width assumed in the automated warehouse 1 (the luggage with the maximum luggage width is indicated by W2). In this embodiment, the section between point C and point D defined based on such luggage width is set as a "luggage detection area" for detecting the position of the end on the anti-origin side in the luggage width direction of the luggage (hereinafter referred to as the "anti-origin side end of the luggage") by the photoelectric sensor 70 on the anti-origin side, and in this area, the anti-origin side end of the luggage is detected. That is, point C becomes the detection start position of the anti-origin side end of the luggage, and the anti-origin side end is detected at any position between point C and point D according to the luggage width.

[0049] Next, as shown in FIG. 5, until the carriage 4 moves to point C (the anti-origin side end detection start position), deceleration control is performed so that the traveling speed decreases to a predetermined low traveling speed V2. The deceleration is set as appropriate, and deceleration starts from the speed V1 at point G as shown in the diagram in FIG. 5.

[0050] Then, in the aforementioned cargo detection area (between points C and D), the trolley 4 is controlled to travel at a constant low speed V2. When the end of the cargo on the side opposite the origin is detected in the cargo detection area (in Figure 5, the diagram shows the detection of the end of the cargo W2 with the maximum cargo width on the side opposite the origin), the trolley 4 is decelerated and, after moving a certain distance, stops at point E. Note that point E, the stopping position, varies depending on the position where the end of the cargo on the side opposite the origin is detected (between points C and D). Furthermore, the distance between the detection position of the end of the cargo on the side opposite the origin and point E is uniquely determined according to the deceleration of the trolley 4.

[0051] Here, the fixed distance until stopping (the distance from point D to point E in Figure 5), as shown in Figure 5, is set to the sum of the distance between the fixed arm 52 and the photoelectric sensor 70 (distance S shown in Figure 3) and the "clearance" between the fixed arm 52 and the load (W1, W2) when the fixed arm 52 is extended toward the load. The "clearance" is set to a distance at which the fixed arm 52 does not interfere with the load when extended, and at which the load can be loaded using the hook 64. For example, the distance S shown in Figure 3 is approximately 70 mm, and the distance from point D to point E is approximately 90 mm, but the values ​​are not limited to these.

[0052] Furthermore, if the trolley 4's travel speed V2 in the cargo detection area is set to a speed higher than the speed shown in Figure 5, the distance from the detection of the cargo's end on the anti-origin side until the trolley 4 stops (assuming constant deceleration) will be longer, and the stopping position E will be further away. In this case, the photoelectric sensor 70 is positioned further away from the fixed arm 52 (the distance S shown in Figure 3 is set to be larger). Then, with respect to the detection position of the anti-origin side of the cargo between point C and point D, the stopping position E is set to be at a longer distance than the position shown in Figure 5.

[0053] Next, with reference to Figures 6 to 8, the operation of the trolley 4 and the transfer device 40 based on the speed control of the trolley 4 by the controller 44 as shown in Figure 5 will be explained. First, Figure 6 shows the state when the trolley 4 is moving and the photoelectric sensor 70 on the non-origin side has passed the luggage restriction position B of the guide member 35. In the luggage detection area after this point (between point C and point D), the trolley 4 travels at a constant speed V2 (see Figure 5).

[0054] Next, Figure 7 shows the state at which the trolley 4 has traveled further and the photoelectric sensor 70 on the non-origin side has detected the non-origin end of the luggage W (in Figure 7, the luggage detection positions are indicated as "C to D"). At this point, the position of the non-origin end of the luggage W coincides with the position of the photoelectric sensor 70. From this point onward, the trolley 4 is controlled to decelerate (see Figure 5).

[0055] Next, after the trolley 4 decelerates, it stops at the position shown in Figure 8 (see Figure 5). That is, as shown in Figure 8, the photoelectric sensor 70 on the anti-origin side (representative position of the trolley 4) is at position E, and at this time, as shown in Figure 8, the fixed arm 52 is in a position that has the aforementioned "clearance" with respect to the position of the anti-origin end of the load W. In other words, as can be understood by comparing with Figure 3, the distance between the position where the anti-origin end of the load W is detected (C to D) and position E is greater than the distance S between the fixed arm 52 and the anti-origin photoelectric sensor 70 by the amount of such "clearance".

[0056] As a variation, the trolley 4's travel speed V2 may be set to a value small enough to allow it to stop immediately, so that the trolley 4 stops at the moment and position when the end of the load W on the side opposite the origin is detected.

[0057] Here, the operation of the transfer device 40, controlled by the controller 44, will be explained with reference to Figures 5 to 8. In this embodiment, after the photoelectric sensor 70 on the non-origin side detects the non-origin end of the load W present on the buffer conveyor 32, the movable arm 54 starts moving before the trolley 4 stops. That is, as shown in Figures 7 and 8, while the trolley 4 is traveling a certain distance from the time it detects the load in the load detection area (between position C and position D in Figure 5) to the stopping position E, the movable arm 54 starts adjusting the distance relative to the fixed arm 52 to correspond to the width of the load W. As a modification, the adjustment of the distance of the movable arm 54 may be started after the trolley 4 has stopped.

[0058] Here, the spacing of the movable arms 54 is adjusted based on the detection position of the origin-side end of the load by the photoelectric sensor 70 on the non-origin side. In this case, since the origin-side end of the load is detected, even if, for example, a load being transported toward the origin on the buffer conveyor 32 exceeds or is deflected by the guide member 35, the origin-side end of the load can be detected, and the spacing between the movable arms 54 and the fixed arms 52 can be appropriately adjusted.

[0059] As a modification, while the trolley 4 is in motion, before the point at which the photoelectric sensor 70 on the non-origin side detects the non-origin side end of the luggage W (see Figure 7), and after the photoelectric sensor 70 on the non-origin side detects the origin side end of the luggage W (in the example of Figure 5, after the photoelectric sensor 70 detects position B), the movable arm 54 may be moved to follow the position of the origin side end of the luggage W, thereby positioning the movable arm 54. That is, when viewed from above, the trolley 4 is in motion, but the movable arm 54 is moved to remain at a position corresponding to the origin side end of the luggage W. In this case, the amount of movement of the movable arm 54 (the distance of the movable arm 54 from the fixed arm 52) is determined based on the distance traveled by the trolley 4 from the point at which the photoelectric sensor 70 detects the origin side end of the luggage. The distance traveled by the trolley 4 can be detected by an encoder or the like (not shown) provided on the trolley 4. In such cases, the adjustment of the spacing of the movable arms 54 can be started earlier than in the above-described embodiment, so that when the trolley 4 stops, the movable arms 54 have completed moving to a position corresponding to the end of the load W on the origin side.

[0060] Next, after the adjustment of the spacing of the movable arms 54 as described above is completed, the controller 44, although not shown in the diagram, firstly extends the movable arms 54 and fixed arms 52 toward the luggage W until their tips have passed the far end of the luggage W in the front-to-back direction, secondly sets the hooks 64 and 66 at the tips to the protruding position, and thirdly pulls back the movable arms 54 and fixed arms 52 to load the luggage W onto the trolley 4.

[0061] Next, the operation and effects of a shuttle trolley type automated warehouse according to an embodiment of the present invention and its modifications will be explained. First, the shuttle trolley type automated warehouse 1 according to this embodiment and its modifications comprises a rack 2 with multiple levels 8, a trolley (shuttle trolley) 4 that travels along each of the multiple levels of racks, buffer conveyors 30 to 33 provided on each of the multiple levels, and lifting conveyors 26, 28. The automated warehouse 1 comprises an origin-side inbound / outbound conveyor 14 provided on the origin side, which is one end of the rack 2, and an anti-origin-side inbound / outbound conveyor 16 provided on the other end of the rack 2, which is the opposite-origin side. The lifting conveyor includes an origin-side lifting conveyor 26 provided on the origin side and an anti-origin-side lifting conveyor 28 provided on the opposite-origin side. The buffer conveyor includes an origin-side buffer conveyor 30 provided on the origin side and an anti-origin-side buffer conveyor 32 provided on the opposite-origin side. The trolley 4 is a fixed trolley positioned on the opposite-origin side. The transfer device 40 includes an arm 52 and a movable arm 54 positioned on the trolley towards the origin and capable of changing the distance from the fixed arm 52; a photoelectric sensor (luggage detection sensor) 70 positioned on the trolley at a position opposite the origin to the transfer device's fixed arm 52; and controllers 34 and 44 that control the running motion of the trolley 4. The controllers 34 and 44 are configured to make the trolley run at a predetermined low speed (V2) in a predetermined luggage detection area (positions C to D) of the buffer conveyor 32 opposite the origin when the trolley 4 is running to load luggage on the buffer conveyor 32 opposite the origin, and to stop the trolley based on the detection of the end of the luggage (W) on the buffer conveyor 32 opposite the origin by the photoelectric sensor 70 opposite the origin.

[0062] According to this embodiment and its modified versions, the stopping position of the trolley 4 can be changed to match the width of the load. That is, when loading on the buffer conveyor 32 on the opposite side of the origin, even if the position of the end of the load on the opposite side of the origin, located on the fixed arm 52 side, is different when viewed from the trolley side (even if the width of the load is different), the fixed arm 52 can be stopped at a position corresponding to the end of the load on the opposite side of the origin. Therefore, loading can be performed quickly while adjusting the stopping position (position E) of the trolley 4 to match the load.

[0063] Furthermore, in this embodiment and its modified form, the fixed arm 52 of the transfer device 40 and the photoelectric sensor 70 are arranged at a predetermined distance (S) in the direction of travel of the trolley, and the controllers 34 and 44 are configured to travel a certain distance until the trolley is stopped after the photoelectric sensor 70 detects the end of the load on the reverse-origin side. This provides a margin of distance and time between the time the photoelectric sensor 70 detects the end of the load on the reverse-origin side and the trolley stops, thereby ensuring that the fixed arm 52 is reliably stopped at a position corresponding to the end of the load on the reverse-origin side.

[0064] Furthermore, in this embodiment and its modified form, the controllers 34, 34 are configured to detect the origin-side end of the load using the photoelectric sensor 70 while the trolley 4 is in motion, and to adjust the spacing of the movable arms 54 of the transfer device 40 based on the detection result. Therefore, even if a load being transported toward the origin on the anti-origin-side buffer conveyor 32 exceeds or is repelled by the guide member 35 (a so-called stopper, etc., for restricting the position of the origin-side end of the load to a certain position), the origin-side end of the load can still be detected, allowing such loads to be loaded effectively.

[0065] Furthermore, in this embodiment and its modified form, the controllers 34 and 44 detect the end of the load on the reverse-origin side using the photoelectric sensor 70, and then cause the trolley 4 to travel a certain distance (the distance from any position between positions C and D to position E) until it stops. The controllers 34 and 44 are configured to detect the end of the load on the reverse-origin side of the buffer conveyor 32 on the reverse-origin side using the photoelectric sensor 70, and then start adjusting the spacing of the movable arms 54 of the transfer device while the trolley 4 is traveling a certain distance, thus enabling rapid loading.

[0066] Furthermore, in this embodiment and its modified form, the controllers 34 and 44 are configured to detect the origin end of the load using the photoelectric sensor 70 while the trolley 4 is in motion. The controllers 34 and 44 are also configured to adjust the spacing of the movable arms 54 of the transfer device while the trolley is in motion, based on the distance traveled by the trolley 4 from the time the origin end was detected, before detecting the non-origin end of the load and after detecting the origin end of the load using the photoelectric sensor 70. This allows for rapid loading of the load.

[0067] W, W1, W2: Luggage; S: Distance of the anti-origin luggage detection sensor relative to the fixed arm; 1: Automated warehouse; 2: Rack; 4: Inbound / Outbound cart (cart); 6: Shelf; 8: Shelf level; 10: Travel path; 14, 16: Inbound / Outbound station; 18: Outbound conveyor; 20: Inbound conveyor; 22: Origin-side lifting and conveying device; 24: Anti-origin-side lifting and conveying device; 26, 28: Lifting platform conveyor; 30: Outbound origin-side buffer conveyor (origin-side buffer conveyor); 31: Inbound origin-side buffer conveyor; 32: Inbound anti-origin-side buffer conveyor (anti-origin-side buffer conveyor); 33: Outbound origin-side buffer conveyor; 34: Higher-level controller; 35: Guide member (stopper); 40: Transfer device; 42: Travel device; 44: Controller; 46: Main body 48 Frame member 50 Guide member 52 Fixed arm 54 Movable arm 56 Drive wheel 58 Driven wheel 64 Hook (rear hook) 70 Photoelectric sensor (anti-origin side load detection sensor) 72 Photoelectric sensor (origin side load detection sensor)

Claims

1. A shuttle trolley type automated warehouse comprising: multiple tiers of racks; a shuttle trolley that travels along each of the multiple tiers of racks; buffer conveyors provided on each of the multiple tiers; and a lifting conveyor, wherein the automated warehouse comprises: an origin-side inbound / outbound conveyor provided on the origin side, which is one end of the racks; and an anti-origin-side inbound / outbound conveyor provided on the other end of the racks, which is the opposite-origin side; the lifting conveyor includes an origin-side lifting conveyor provided on the origin side and an anti-origin-side lifting conveyor provided on the opposite-origin side; and the buffer conveyor includes an origin-side buffer conveyor provided on the origin side and an anti-origin-side buffer conveyor provided on the opposite-origin side. The automated warehouse is characterized in that the shuttle cart comprises a transfer device including a fixed arm positioned on the shuttle cart toward the anti-origin side and a movable arm positioned on the shuttle cart toward the origin side and capable of changing the distance from the fixed arm, a cargo detection sensor positioned on the shuttle cart toward the anti-origin side than the fixed arm of the transfer device, and at least a controller that controls the running motion of the shuttle cart, wherein the controller is configured to run the shuttle cart at a predetermined low speed in a predetermined cargo detection area of ​​the anti-origin side buffer conveyor when the shuttle cart is running to load cargo on the anti-origin side buffer conveyor, and to stop the shuttle cart based on the detection of the anti-origin side end of cargo present on the anti-origin side buffer conveyor by the cargo detection sensor.

2. The automated warehouse according to claim 1, wherein the fixed arm of the transfer device and the cargo detection sensor are arranged at a predetermined distance from each other in the direction of travel of the shuttle cart, and the controller is configured to travel a certain distance until the shuttle cart is stopped after detecting the end of the cargo on the side opposite the origin using the cargo detection sensor.

3. The automated warehouse according to claim 1 or 2, wherein the controller is configured to detect the origin end of the load using the load detection sensor while the shuttle trolley is in motion, and to adjust the spacing of the movable arms of the transfer device based on the detection result.

4. The automated warehouse according to claim 1 or 2, wherein the controller, after detecting the end of the load on the reverse-origin side using the load detection sensor, causes the shuttle trolley to travel a certain distance until it stops, and the controller, after detecting the end of the load on the reverse-origin side of the load present on the reverse-origin side buffer conveyor using the load detection sensor, starts adjusting the spacing of the movable arms of the transfer device while the shuttle trolley is traveling the certain distance.

5. The automated warehouse according to claim 1 or 2, wherein the controller is configured to cause the cargo detection sensor to detect the origin end of the cargo while the shuttle trolley is in motion, and the controller is further configured to adjust the spacing of the movable arms of the transfer device while the shuttle trolley is in motion, based on the distance traveled by the shuttle trolley from the time the origin end was detected, before the non-origin end of the cargo is detected and after the cargo detection sensor has detected the origin end of the cargo.

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