Loading system
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- KAWASAKI JUKOGYO KK
- Filing Date
- 2026-01-26
- Publication Date
- 2026-08-06
Smart Images
Figure JP2026002366_06082026_PF_FP_ABST
Abstract
Description
Stacking System
[0001] The present disclosure relates to a stacking system.
[0002] Patent Document 1 discloses a conventional lifting and conveying device. The lifting and conveying device includes a first lifting device, a second lifting device, a buffer conveyor, and an inlet / outlet section (inlet section or outlet section) of each stage shuttle-type automated warehouse. The first lifting device raises and lowers a first load platform. The second lifting device raises and lowers a second load platform. The buffer conveyor is disposed between the first lifting device and the second lifting device. The inlet / outlet section is provided adjacent to the first lifting device. The inlet / outlet section has a plurality of stages for conveying loads respectively.
[0003] According to Patent Document 1, when moving a load between the first lifting device and the second lifting device, the buffer conveyor can temporarily store the load. The buffer conveyor can adjust the transfer timing of the load.
[0004] Japanese Unexamined Patent Application Publication No. 2016-169083
[0005] The conventional lifting and conveying device transfers the load from the buffer conveyor to the first or second lifting device in the same order as the loading order onto the buffer conveyor. The transfer destination of the load is fixed in advance according to the stage of the inlet / outlet section adjacent to the first lifting device. The conventional lifting and conveying device cannot flexibly change the transfer order and transfer position of the load from the buffer conveyor.
[0006] However, when stacking on a stacking target such as a cart, it is necessary to stack the randomly conveyed loads in a predetermined order based on a predetermined stacking plan at a predetermined position in the stacking target. Since the conventional lifting and conveying device cannot flexibly change the transfer order of the load as described above, it is inconvenient for use in automated stacking.
[0007] This disclosure relates to a stacking system. The stacking system includes a stacking robot having a robotic hand that sequentially stacks multiple types of packages supplied from a predetermined source onto a stacking target using the robotic hand; a relay unit interposed between the source and the stacking robot that accommodates multiple packages so that they can be retrieved in any order by the robotic hand; and a control unit that operates the relay unit or the stacking robot based on a predetermined stacking plan to sequentially transfer the packages from the relay unit to the stacking robot.
[0008] The aforementioned stacking system, by interposing an intermediate unit between the supplier and the stacking robot, can accommodate multiple types of cargo in a state where they can be retrieved in any order by the robot hand. Because the stacking system can flexibly change the order in which cargo is retrieved, it can automate the stacking of cargo onto the target object.
[0009] Figure 1 is a schematic diagram showing a stacking system. Figure 2 is a block diagram of the stacking system. Figure 3 is a perspective view illustrating a robot system. Figure 4 is a schematic diagram illustrating a robot system. Figure 5 is a diagram illustrating the packaging configuration achieved on the stacking target. Figure 6 is a diagram illustrating the operation of the robot system. Figure 7 is a diagram illustrating the operation of the robot system. Figure 8 is a diagram illustrating the operation of the robot system. Figure 9 is a diagram illustrating the operation of the robot system. Figure 10 is a diagram illustrating the operation of the robot system. Figure 11 is a diagram illustrating the operation of the robot system. Figure 12 is a diagram illustrating the operation of the robot system. Figure 13 is a diagram corresponding to Figure 4 showing a stacking system according to a first modified example. Figure 14 is a diagram corresponding to Figure 3 showing a stacking system according to a second modified example. Figure 15 is a diagram corresponding to Figure 3 showing a stacking system according to a third modified example.
[0010] The following describes an embodiment of the stacking system S. The following description is illustrative.
[0011] <System Configuration> Figure 1 is a schematic diagram showing the loading system S. Figure 2 is a block diagram of the loading system S. The loading system S is constructed, for example, in a logistics center. A logistics center is a collection and delivery hub where incoming cargo W is sorted and loaded. Note that the loading system S is not limited to application to logistics centers.
[0012] In the following description, "upstream" refers to the upstream direction relative to the transport direction of the cargo W. Similarly, in the following description, "downstream" refers to the downstream direction relative to the transport direction of the cargo W.
[0013] As shown in Figure 1, the stacking system S according to this embodiment comprises a supply unit 1, a sorting unit 2, one or more robot systems 3, a system controller 4, and a code reader 5. The supply unit 1, sorting unit 2, and robot systems 3 are connected in the order of transporting the cargo W. Note that the supply unit 1, sorting unit 2, and code reader 5 are not essential.
[0014] (Supply Unit) The supply unit 1 sequentially transports multiple types of packages W to the sorting unit 2. The supply unit 1 functions as a "supplier" that supplies packages W to the robot system 3 via the sorting unit 2. Specifically, the supply unit 1 transports different types of packages W to the sorting unit 2, one or more packages of each type.
[0015] The categories used to distinguish each package W include, for example, broad categories such as "soft drinks" and "alcoholic beverages," and subcategories such as "product name of alcoholic beverage." As an example, the supply unit 1 according to this embodiment transports different types of packages W to the sorting unit 2 without distinguishing between the aforementioned broad and subcategories.
[0016] As shown in Figure 1, the supply unit 1 according to this embodiment has a conveyor 11. The conveyor 11 is, for example, a roller conveyor. The conveyor 11 includes an upstream end to which the cargo W is supplied and a downstream end connected to the sorting unit 2.
[0017] More specifically, a robot or worker is located at the upstream end of the supply unit 1 to unpack the palletized packages W. The supply unit 1 sequentially supplies the packages W, which have been depalletized by the robot or worker, toward the sorting unit 2.
[0018] (Sorting Unit) The sorting unit 2 sorts the packages W supplied from the supply unit 1 according to their destination and type. The sorting unit 2 is located between the supply unit 1, which is the source of the supplies, and the robot system 3, which is the destination of the supplies.
[0019] As an example, sorting unit 2 sorts the packages W supplied from supply unit 1 according to their destination and the aforementioned major classification. Sorting unit 2 transports the packages W supplied from supply unit 1 to robot system 3, with different types of packages mixed together according to the minor classification. In the following description, the terms "type" and "multiple types" refer to "minor classification" unless otherwise specified. Sorting unit 2 transports packages W of different types to robot system 3, one or more packages per type.
[0020] As shown in Figure 1, the sorting unit 2 according to this embodiment includes a conveyor 21 and a branching mechanism 22. The conveyor 21 is, for example, a roller conveyor. The branching mechanism 22 is, for example, a mechanism for switching the conveying direction for the roller conveyor. Both the conveyor 21 and the branching mechanism 22 are electrically connected to the system controller 4.
[0021] The conveyor 21 includes an upstream end to which the cargo W is supplied from the supply unit 1, and one or more downstream ends. The conveyor 21 branches off to one or more downstream ends along the way from the upstream end to the downstream end, depending on the destination and type of cargo W. Each downstream end is connected to the corresponding robot system 3.
[0022] The branching mechanism 22 supplies the cargo W supplied from the supply unit 1 to the robot system 3 corresponding to one of the downstream ends, via that downstream end. The branching mechanism 22 is located in the middle of the conveyor 21.
[0023] (Code Reader) The code reader 5 detects the two-dimensional code attached to each package W. The code reader 5 is located between the supply unit 1 and the branching mechanism 22 of the sorting unit 2.
[0024] The code reader 5 is electrically connected to the system controller 4. The code reader 5 inputs a detection signal to the system controller 4. Based on the detection signal received from the code reader 5, the system controller 4 controls the operation of the branching mechanism 22.
[0025] The branching mechanism 22, controlled by the system controller 4, sequentially sorts the packages W supplied from the supply unit 1 according to their destination and the type indicating the major classification. Each robot system 3 receives packages W supplied from the supply unit 1 in a state that has been pre-sorted by the sorting unit 2.
[0026] (Robot System) Figure 3 is a perspective view illustrating robot system 3. Figure 4 is a schematic diagram illustrating robot system 3. Figure 4 corresponds to a side view of robot system 3.
[0027] The robot system 3 sequentially loads multiple types and quantities of packages W supplied from the sorting unit 2 onto the transport cart 10, which is the loading target, in order to achieve a predetermined loading order and loading position. As shown in the specific example described later, the number of packages W loaded onto the transport cart 10 may differ for each type. Note that the loading target is not limited to the transport cart 10. The loading target includes general items in which multiple packages W are loaded in order to achieve a predetermined loading order and loading position.
[0028] As shown in Figure 4, the robot system 3 according to this embodiment includes a stacking robot 6, a relay unit 7, sensors 8, and a robot controller 9. Note that the sensors 8 are not essential.
[0029] The stacking robot 6 has a robot hand 62. The stacking robot 6 uses the robot hand 62 to sequentially stack multiple types of packages W supplied from the supply unit 1 via the sorting unit 2 onto the transport cart 10.
[0030] In detail, the loading robot 6 lifts the cargo W supplied from the supply unit 1 from the relay unit 7 and loads it onto the transport cart 10. The loading robot 6 is, for example, an articulated robot. In the illustrated example, the loading robot 6 is a vertical articulated robot.
[0031] More specifically, the stacking robot 6 has a multi-jointed robotic arm 61. A robotic hand 62, which serves as an end effector, is connected to the tip of the robotic arm 61. The stacking robot 6 may also be able to move around within the logistics center by being mounted on a vehicle. The vehicle may be, for example, an AGV (Automated Guided Vehicle) or an AMR (Autonomous Mobile Robot).
[0032] The relay unit 7 is interposed between the supply unit 1 and the stacking robot 6. The relay unit 7 houses multiple packages W so that they can be retrieved in any order by the robot hand 62.
[0033] More specifically, the relay unit 7 is located between the sorting unit 2 and the stacking robot 6. Multiple types and multiple packages W supplied from the supply unit 1 are sequentially supplied to the relay unit 7 in a sorted state by the sorting unit 2. The relay unit 7 temporarily stores the multiple packages W supplied from the sorting unit 2 and then hands them over to the robot hand 62. More specifically, the relay unit 7 temporarily stores the multiple types and multiple packages W supplied from the sorting unit 2 and then sequentially hands over the packages W to the robot hand 62.
[0034] Specifically, the relay unit 7 according to this embodiment includes a temporary storage unit 71, a transport unit 72, a handover unit 73, and a loading unit 74. The temporary storage unit 71, transport unit 72, handover unit 73, and loading unit 74 operate based on control signals received from a system controller 4, which acts as a control device. In this embodiment, the temporary storage unit 71, transport unit 72, handover unit 73, and loading unit 74 are each conveyors electrically connected to the system controller 4. The conveyors are, for example, roller conveyors. Note that the handover unit 73 and loading unit 74 are not essential.
[0035] The temporary storage unit 71 temporarily stores multiple packages W. More specifically, the temporary storage unit 71 temporarily stores multiple packages W of multiple types. The temporary storage unit 71 can store more packages W than the number that can be loaded onto the transport cart 10. The temporary storage unit 71 can move the packages W stored in the temporary storage unit 71 to the loading robot 6 via the transport unit 72.
[0036] More specifically, the temporary storage unit 71 includes a first storage unit 711 and a second storage unit 712. The first storage unit 711 stores multiple packages W, more specifically multiple types and multiple packages W, in the order they are supplied from the supply unit 1. When transporting packages W from the temporary storage unit 71 to the handover position Pr to the stacking robot 6, the second storage unit 712 removes other packages W that are not the packages to be handed over from the first storage unit 711.
[0037] The first storage section 711 is composed of a plurality of first conveyors 7a arranged in a first direction A1 perpendicular to the floor surface of the logistics center. Each first conveyor 7a can carry a plurality of packages W and move the packages W in a second direction A2 perpendicular to the first direction. The first conveyors 7a are electrically connected to a system controller 4. Based on electrical signals input from the system controller 4, the first conveyors 7a can move the packages W loaded on them in two directions along the second direction A2. Note that there may be only one first conveyor 7a instead of multiple. Also, the arrangement of the first conveyors 7a is not limited to the first direction A1.
[0038] The second storage section 712 is composed of a plurality of second conveyors 7b arranged in the first direction A1. The second conveyors 7b can carry a plurality of packages W and move the packages W in the second direction A2. The second conveyors 7b are electrically connected to the system controller 4. Based on electrical signals input from the system controller 4, the second conveyors 7b can move the packages W loaded on the second conveyors 7b in two directions along the second direction A2. Note that there may be only one second conveyor 7b instead of multiple. Also, the arrangement of the second conveyors 7b is not limited to the first direction A1.
[0039] The transport unit 72 transports the packages W individually from the temporary storage unit 71 to the handover position Pr to the loading robot 6. More specifically, the transport unit 72 transports multiple types and multiple packages W individually from the temporary storage unit 71 to the handover unit 73, and then individually to the handover position Pr via the handover unit 73.
[0040] In this embodiment, the transport unit 72 transports the cargo W from the loading unit 74 to the first storage unit 711 or the second storage unit 712. The transport unit 72 transports the cargo W between the first storage unit 711 and the second storage unit 712. The transport unit 72 transports the cargo W from the first storage unit 711 or the second storage unit 712 to the handover unit 73.
[0041] More specifically, the transport unit 72 includes a third conveyor 7c that moves up and down in the first direction A1. The third conveyor 7c loads the cargo W supplied from the sorting unit 2 and can move the cargo W in the second direction A2. The third conveyor 7c is electrically connected to the system controller 4. Based on electrical signals input from the system controller 4, the third conveyor 7c can move the cargo W loaded on the third conveyor 7c in two directions along the first direction A1 and two directions along the second direction A2. Note that there may be more than one third conveyor 7c. Also, the direction of movement of the third conveyor 7c is not limited to the first direction A1.
[0042] More specifically, the third conveyor 7c can transfer the cargo W supplied from the sorting unit 2 via the loading unit 74 to the first conveyor 7a by moving the cargo W in the second direction A2. The third conveyor 7c can receive the cargo W from the first conveyor 7a and transfer the cargo W to the second conveyor 7b or the transfer unit 73.
[0043] The transfer unit 73 transports the cargo W, which has been transported by the transport unit 72, to the transfer position Pr. In this embodiment, the transfer unit 73 can temporarily accommodate multiple cargo W.
[0044] More specifically, the delivery unit 73 includes a fourth conveyor 7d. The fourth conveyor 7d can carry a plurality of packages W and move the loaded packages W to the delivery position Pr along the second direction A2. At the upstream end of the fourth conveyor 7d, a third conveyor 7c as the conveying unit 72 can be moved. At the downstream end of the fourth conveyor 7d, a delivery position Pr to the robot hand 62 is set.
[0045] More specifically, the fourth conveyor 7d is electrically connected to the system controller 4. The fourth conveyor 7d moves the package W loaded on the fourth conveyor 7d based on an electrical signal input from the system controller 4.
[0046] The loading unit 74 is connected to the downstream end of the sorting unit 2. The loading unit 74 sequentially conveys a plurality of types and a plurality of packages W from the sorting unit 2 to the conveying unit 72.
[0047] More specifically, the loading unit 74 includes a fifth conveyor 7e. The fifth conveyor 7e can carry the package W supplied from the supply unit 1 via the sorting unit 2 and move the package W in the second direction A2. At the upstream end of the fifth conveyor 7e, the downstream end of the sorting unit 2 is connected. At the downstream end of the fifth conveyor 7e, a third conveyor 7c as the conveying unit 72 can be moved.
[0048] More specifically, the fifth conveyor 7e is electrically connected to the system controller 4. The fifth conveyor 7e moves the package W loaded on the fifth conveyor 7e based on an electrical signal input from the system controller 4.
[0049] The sensors 8 acquire information on the packages W sequentially conveyed by the fifth conveyor 7e. The sensors 8 are one or more sensors. The one or more sensors are electrically connected to the system controller 4. The one or more sensors input a detection signal to the system controller 4.
[0050] More specifically, the sensors 8 according to this embodiment include a posture sensor 81 and a type sensor 82. A labeling device 83 may be placed adjacent to the sensors 8 as needed. The labeling device 83 prints or attaches a label to each package W conveyed by the fifth conveyor 7e.
[0051] The posture sensor 81 identifies the posture of each package W supplied from the supply unit 1 to the relay unit 7 individually and in the order of supply. As an example, the posture sensor 81 in this embodiment measures the dimensions of each package W in the longitudinal direction along the transport direction of the fifth conveyor 7e, or in the short direction perpendicular to the longitudinal direction. The system controller 4 can determine the vertical and horizontal posture of each package W based on the detection signal from the posture sensor 81. Note that the posture sensor 81 is not essential.
[0052] The type sensor 82 identifies the type of each package W supplied from the supply unit 1 to the relay unit 7 individually and in the order of supply. As an example, the type sensor 82 in this embodiment reads the two-dimensional code attached to each package W on the fifth conveyor 7e. The system controller 4 can determine the type of each package W based on the detection signal from the attitude sensor 81. As an example, the type sensor 82 in this embodiment identifies the "subcategory" as defined above. Note that the type sensor 81 is not essential.
[0053] The robot controller 9 is electrically connected to the stacking robot 6. The electrical connection includes wired or wireless connections. The robot controller 9 controls the operation of the stacking robot 6.
[0054] The robot controller 9 is connected to the system controller 4 in a communicative manner. This communicative connection includes wired or wireless connections. The robot controller 9 controls the operation of the stacking robot 6 based on the control signals it receives from the system controller 4.
[0055] More specifically, the control signal input from the system controller 4 to the robot controller 9 includes information related to the shape of the next load W to be lifted. The robot controller 9 controls the robot hand 62 according to the shape of the next load W to be lifted, and moves the load W lifted by the robot hand 62 to a predetermined stacking position in the transport cart 10. The shape of the load W can be determined, for example, based on the posture of each load W detected by the posture sensor 81.
[0056] Specifically, the robot controller 9 has a processor 91 and a memory 92, as shown in Figure 2. The processor 91 calculates the operation command for the stacking robot 6 according to the data stored in the memory 92. The robot controller 9 inputs a signal corresponding to the operation command to the stacking robot 6. The stacking robot 6 operates according to the input signal.
[0057] (System Controller) The system controller 4 operates the relay unit 7 or the loading robot 6 based on a predetermined loading plan Pc, thereby sequentially transferring multiple types of cargo W from the relay unit 7 to the loading robot 6.
[0058] Specifically, the system controller 4 has a processor 41 and a memory 42, as shown in Figure 2. The processor 41 calculates the operation command for the relay unit 7 according to the data stored in the memory 42. The system controller 4 inputs a signal corresponding to the operation command to the relay unit 7. The relay unit 7 operates according to the input signal.
[0059] As an example, the system controller 4 according to this embodiment controls the relay unit 7 based on the stacking plan Pc. The system controller 4 functions as a control unit in this embodiment. The system controller 4 may be common to multiple robot systems 3, or it may be set up individually for each robot system 3.
[0060] Controlled by the system controller 4, the relay unit 7 transports the cargo W to the handover position Pr in the order based on the loading plan Pc. Multiple types and multiple pieces of cargo W are transported to the handover position Pr in the loading order corresponding to the loading plan Pc.
[0061] The loading robot 6 receives the packages W in the order they were transported to the handover position Pr, and loads the received packages W onto the transport cart 10, which is the target for loading. Multiple types and multiple packages W are loaded onto the transport cart 10 in the order that matches the loading order.
[0062] More specifically, the system controller 4 is connected to the WMS (Warehouse Management System) 11 via communication. The WMS 11 inputs a stacking plan PC, which indicates the stacking order and stacking position for each transport cart 10, to the system controller 4 and the robot controller 9.
[0063] The system controller 4 determines the storage status of the packages W in the relay unit 7 based on the identification results from the type sensor 82. As an example of storage conditions, the system controller 4 grasps the type and storage location of each package W stored in the temporary storage unit 71.
[0064] The system controller 4 controls the operation of the relay unit 7 or the stacking robot 6 based on the stacking plan Pc and the storage status. By referring to the storage status of the cargo W, the system controller 4 can achieve the desired stacking order.
[0065] The system controller 4 determines the orientation of each package W in the relay unit 7 based on the identification results from the orientation sensor 81. The system controller 4 grasps the orientation of each package W stored in the temporary storage unit 71.
[0066] The system controller 4 controls the operation of the loading robot 6 based on the orientation of each load W. By referring to the orientation of each load W, the system controller 4 controls the robot hand 62 according to the orientation of each load W, in addition to the shape of the load W.
[0067] <Example of using the stacking system> Figure 5 is a diagram illustrating the package configuration Wb achieved in the stacking target. Figures 6 to 12 illustrate the operation of the robot system 3.
[0068] The following describes an example of the use of the stacking system S, specifically the case where the loading configuration Wb shown in Figure 5 is to be implemented on the transport cart 10. The loading configuration Wb shown in the upper part of Figure 5 consists of three Type 1 packages W, four Type 2 packages W, and five Type 3 packages W stacked in order from the left side of the page. The Type 1 packages W are labeled "A". The Type 2 packages W are labeled "B". The Type 3 packages W are labeled "C".
[0069] The WMS 11 transmits a stacking plan Pc corresponding to the packaging Wb to the system controller 4. The stacking plan Pc is set for each transport cart 10. In the example in Figure 5, the stacking plan Pc and the stacking order corresponding to the stacking plan Pc are set as follows. Note that the following stacking plan Pc is illustrative. A conceptual diagram of an exemplary stacking plan Pc is shown in the lower part of Figure 5.
[0070] (1) First, three Type 1 packages W are loaded onto the left side of the transport cart 10.
[0071] (2) Next, four Type 2 packages W are loaded into the center of the transport cart 10.
[0072] (3) Next, six Type 3 packages W are loaded onto the right side of the transport cart 10.
[0073] On the other hand, consider the case where multiple types of cargo W are supplied from the supply unit 1, as shown in Figure 4. The multiple types of cargo W are loaded onto the fifth conveyor 7e of the loading unit 74 in an order different from the loading plan Pc. The multiple types of cargo W need to be arranged in a way that matches the loading order according to the loading plan Pc.
[0074] First, as shown in Figure 6, the system controller 4 operates the fifth conveyor 7e of the loading section 74, thereby loading one type 1 package W onto the third conveyor 7c that constitutes the transport section 72.
[0075] Next, as shown in Figure 7, the system controller 4 raises the third conveyor 7c, on which one of the first type packages W is loaded, in the first direction A1. The system controller 4 then positions the third conveyor 7c adjacent to one of the multiple first conveyors 7a that constitute the first storage section 711.
[0076] Next, as shown in Figure 8, the system controller 4 operates the third conveyor 7c and the first conveyor 7a so that one Type 1 package W is transported in the second direction A2. Through this operation, one Type 1 package W is moved to a predetermined position on the first conveyor 7a.
[0077] The system controller 4 performs the process illustrated in Figure 6, the process illustrated in Figure 7, and the process illustrated in Figure 8 for each package W loaded on the fifth conveyor 7e. By performing the processes illustrated in Figures 6 to 8, the system controller 4 transfers the multiple packages W that were loaded on the fifth conveyor 7e onto the first storage unit 711.
[0078] The system controller 4, based on the detection signal from the attitude sensor 81, understands the storage status and orientation of each package W in the first storage section 711. The system controller 4 understands the storage order of each package W stored in the first storage section 711, the type of each package W, and the orientation of each package W.
[0079] Next, the system controller 4 transports multiple types of cargo W to the handover position Pr according to the loading order corresponding to the loading plan Pc. In the case of the loading plan Pc mentioned above, it is convenient if the first type of cargo W, labeled "A", can be transported to the handover position Pr first.
[0080] In the storage configuration illustrated in Figure 9, the system controller 4 determines that the first type of cargo W can be transported smoothly from the first storage unit 711 located at the top. This determination is made based on the aforementioned storage configuration.
[0081] As shown in Figure 10, the system controller 4 operates the first conveyor 7a, the third conveyor 7c, and the fourth conveyor 7d to transport the first type of cargo W to the transfer position Pr. Once the cargo W has been transported to the transfer position Pr, the robot controller 9 operates the loading robot 6 to transfer it to the robot hand 62.
[0082] The system controller 4 may, by controlling the loading robot 6 via the robot controller 9, load the packages W that have been transported to the transfer position Pr onto the transport cart 10 each time, or, as illustrated in Figure 12 described later, each package W may be loaded onto the transport cart 10 from the transfer position Pr, provided that multiple packages W have been transported to the transfer unit 73.
[0083] In order to achieve the aforementioned stacking order, the system controller 4 needs to transport the second first-class cargo W to the handover position Pr, following the first first-class cargo W. However, in both the uppermost first storage section 711 and the lowermost first storage section 711, the third-class cargo W marked "C" is obstructing the removal of the first-class cargo W. For example, in the uppermost first storage section 711, two third-class cargo W are obstructing the removal of one first-class cargo W.
[0084] Therefore, when transporting the cargo W to the handover position Pr, the system controller 4 moves any other cargo W that would hinder the realization of the stacking order and thus the stacking plan Pc from the first storage unit 711 to the second storage unit 712.
[0085] For example, as shown in Figure 11, the system controller 4 operates the first conveyor 7a, the third conveyor 7c, and the second conveyor 7b to move any other cargo W that would hinder the realization of the stacking plan Pc from the first storage unit 711 to the second storage unit 712 via the transport unit 72. In the illustrated example, the two third-type cargo W mentioned above correspond to the "other cargo".
[0086] Next, as shown in Figure 12, the system controller 4 transports the predetermined loads W according to the stacking order to the handover position Pr, with any other loads W that would interfere with the stacking order being moved aside.
[0087] In the illustrated example, the system controller 4 transports one Type 1 package W located in the uppermost first storage section 711 to the transfer position Pr. This transport is achieved by operating the first conveyor 7a, the transport section 72, and the fourth conveyor 7d, respectively.
[0088] Subsequently, the system controller 4 may move one or more packages W that have been moved to the second storage unit 712 to the first storage unit 711, or it may omit this movement. In the latter case, the system controller 4 will transport one or more packages W that have been moved to the second storage unit 712 to the transfer unit 73 and the transfer position Pr, one by one, according to the stacking order.
[0089] As the processes illustrated in Figures 6 to 12 are repeated, the system controller 4 loads the cargo W onto the transport cart 10 according to the loading sequence corresponding to the loading plan Pc. Following the loading sequence results in the cargo configuration Wb illustrated in Figure 5.
[0090] <Effects> As illustrated in Figure 4, the stacking system S has an intermediate unit 7 interposed between the supply unit 1 and the stacking robot 6. The intermediate unit 7 accommodates multiple packages W, specifically multiple types and multiple packages W, so that they can be retrieved in any order by the robot hand 62. The intermediate unit 7 functions as a buffer for adjusting the retrieval order of the packages W. By providing the intermediate unit 7, the stacking system S can flexibly change the retrieval order of the packages W. The stacking system S can automate the stacking of packages W onto the transport cart 10.
[0091] Furthermore, as illustrated in Figure 4, the relay unit 7 includes a temporary storage unit 71 and a transport unit 72. The stacking system S can load multiple packages W into the temporary storage unit 71 or transport each package W loaded into the temporary storage unit 71 to the handover position Pr by appropriately operating the transport unit 72. The stacking system S can automate the loading of packages W onto the transport cart 10 by providing the relay unit 7.
[0092] Furthermore, as illustrated in Figure 11, the temporary storage section 71 includes a second storage section 712 for temporarily relocating the luggage W. The stacking system S can further flexibly change the order in which the luggage W is retrieved by temporarily relocating one or more luggage W to the second storage section 712.
[0093] Furthermore, as illustrated in Figure 4, the temporary storage section 71 includes a first conveyor 7a and a second conveyor 7b. The transport section 72 includes a third conveyor 7c. Since both the temporary storage section 71 and the transport section 72 include conveyors, the order of multiple types of luggage W can be easily rearranged. The conveyors can also be used as storage spaces for luggage W.
[0094] Furthermore, as illustrated in Figure 4, the stacking system S is equipped with a type sensor 82. Based on the detection signal from the type sensor 82, the stacking system S can allow the system controller 4 to understand the storage status of each package W in the relay unit 7. By incorporating the type sensor 82, the stacking system S can change the order in which the packages W are retrieved even more flexibly.
[0095] Furthermore, as illustrated in Figure 4, the stacking system S is equipped with a posture sensor 81. Based on the detection signal from the posture sensor 81, the stacking system S can allow the system controller 4 to understand the posture of each package W housed in the relay unit 7. By providing the posture sensor 81, the stacking system S can appropriately operate the stacking robot 6 when retrieving packages W from the relay unit 7.
[0096] <First Modified Example of the Stacking System> Figure 13 is a corresponding diagram to Figure 4 showing a robot system 103 according to the first modified example. The robot system 103 is replaceable with the robot system 3 in Figure 1.
[0097] As shown in Figure 13, in the robot system 103 according to the first modified example, the transfer unit 73 is omitted. The stacking robot 6 directly receives the cargo W from the transport unit 72. The transfer position Pr is located on the transport unit 72.
[0098] The stacking robot 6 is located below the second conveyor 7b, which constitutes the second storage section 712. By positioning the stacking robot 6 below the second conveyor 7b, the dimensions of the robot system 103 can be reduced in the second direction A2.
[0099] The robot system 103 includes a second transport unit 75, as shown in Figure 13, in addition to the transport unit 72. The second transport unit 75 transports the cargo W from the loading unit 74 to the first storage unit 711. Note that the second transport unit 75 is not essential.
[0100] More specifically, the second conveying section 75 includes a sixth conveyor 7f. The sixth conveyor 7f moves up and down in the first direction A1 and conveys the load W in the second direction A2. The sixth conveyor 7f is electrically connected to the system controller 4. Based on electrical signals input from the system controller 4, the sixth conveyor 7f can move the load W loaded on it in two directions along the first direction A1 and two directions along the second direction A2.
[0101] By including a second transport unit 75 in the robot system 103, some of the functions performed by the transport unit 72 can be omitted. In this embodiment, the transport unit 72 transports the cargo W between the first storage unit 711 and the second storage unit 712. The transport unit 72 transports the cargo W from either the first storage unit 711 or the second storage unit 712 to the stacking robot 6.
[0102] Similar to the above embodiment, the system controller 4, acting as the control unit, operates the relay unit 7 based on a predetermined stacking plan Pc. Multiple types and multiple pieces of luggage W are sequentially transferred from the relay unit 7 to the stacking robot 6 as the relay unit 7 operates.
[0103] <Second Modification of the Stacking System> In the above embodiment and the first modification, the system controller 4, acting as the control unit, operates the relay unit 7 based on a predetermined stacking plan Pc. However, this disclosure is not limited to a configuration that operates the relay unit 7.
[0104] As shown in the second and third modifications below, the system controller 4 or robot controller 9, acting as a control unit, may operate the stacking robot 6 based on a predetermined stacking plan Pc. In this case, multiple packages W, more specifically multiple types and multiple packages W, are sequentially transferred from the relay units 207 and 307 to the stacking robot 6 as the stacking robot 6 operates.
[0105] Figure 14 is a diagram corresponding to Figure 3 showing a robot system 203 according to a second modification. The robot system 203 is interchangeable with the robot system 3 in Figure 1. The robot system 203 is common to the above embodiment and the first modification in that it comprises a relay unit 207, a stacking robot 6, and a robot controller 209. The hardware configuration of the stacking robot 6 itself is also common to the above embodiment and the first modification.
[0106] The relay unit 207 according to the second modified example is interposed between the supply unit 1 and the stacking robot 6, more specifically between the sorting unit 2 and the stacking robot 6. Similar to the above embodiment, the relay unit 207 houses a plurality of packages W, more specifically multiple types and multiple packages W, so that they can be retrieved in any order by the robot hand 62 of the stacking robot 6.
[0107] Specifically, the relay unit 207 according to the second modified example includes an individual housing unit 271 and a housing robot 272. The housing robot 272 is electrically connected to a second robot controller that controls the operation of the housing robot 272.
[0108] The individual storage section 271 accommodates multiple packages W individually. In other words, the individual storage section 271 includes multiple independent storage spaces for each package W.
[0109] More specifically, the individual storage compartment 271 allows the robot hand 62 of the stacking robot 6 to enter. By entering each storage space, the robot hand 62 can retrieve the cargo W stored in that storage space.
[0110] Specifically, the individual storage unit 271 according to the second modified example is an open shelf interposed between the storage robot 272 and the stacking robot 6. The individual storage unit 271 as an open shelf includes a plurality of shelves that are open to both the storage robot 272 and the stacking robot 6. Each of the plurality of shelves functions as the storage space. The storage space allows entry of the robot hand of the storage robot 272 in addition to the robot hand 62.
[0111] The storage robot 272 is interposed between the supply unit 1 and the individual storage unit 271, more specifically between the sorting unit 2 and the individual storage unit 271. The storage robot 272 transfers the packages W to the individual storage unit 271.
[0112] In detail, the storage robot 272 sequentially picks up the packages W supplied from the supply unit 1 via the sorting unit 2. The storage robot 272 then stores the picked-up packages W in the individual storage units 271. The storage status of each package W in the individual storage units 271 is determined by the system controller 4, for example, based on detection signals from sensors located in each storage space.
[0113] Specifically, the storage robot 272 in the second modified example is, for example, an articulated robot. In the illustrated example, the storage robot 272 is a vertical articulated robot. The storage robot 272 operates based on control signals received from a second robot controller. The second robot controller is electrically connected to the system controller 4. The system controller 4 may control the storage robot 272 via the second robot controller. The second robot controller may be the same as the robot controller 209 for the stacking robot 6.
[0114] The stacking robot 6 is electrically connected to the robot controller 209, similar to the embodiment described above. The robot controller 209 controls the operation of the stacking robot 6.
[0115] The robot controller 209 is connected to the system controller 4 in a communication manner. The robot controller 209 controls the operation of the stacking robot 6 based on the control signals it receives from the system controller 4.
[0116] The system controller 4 controls the stacking robot 6 based on a predetermined stacking plan Pc. For example, the system controller 4 controls the stacking robot 6 via the robot controller 209. By operating the stacking robot 6, the system controller 4 transfers the cargo W sequentially from the transfer unit 207 to the stacking robot 6.
[0117] The system controller 4 functions as a control unit in the second modified example. The system controller 4 may be common to multiple robot systems 3, or it may be configured individually for each robot system 3.
[0118] More specifically, the system controller 4 compares the storage status of each package W in the individual storage unit 271 with the stacking order corresponding to the stacking plan Pc. Based on the comparison result, the system controller 4 causes the robot hand 62 to enter the storage space where the packages W corresponding to the stacking order are stored.
[0119] More specifically, the stacking system S according to the second modified example includes, for example, a type sensor 82 and an attitude sensor 81 near the downstream end of the sorting unit 2, configured in the same manner as in the above embodiment and the first modified example. The system controller 4 grasps the storage status based on the detection signal of the type sensor 82. The system controller 4 adjusts the operation of the robot hand 62 when lifting each load W based on the detection signal of the attitude sensor 81.
[0120] The loading robot 6 lifts the cargo W from the storage space into which the robot hand 62 has entered and loads the cargo W onto the transport cart 10. The loading robot 6 transfers the cargo W sequentially according to the loading order. As the cargo W is transferred sequentially, the loading configuration Wb shown in Figure 5 is achieved, for example.
[0121] As illustrated in Figure 14, the relay unit 7 includes individual storage units 271 and a storage robot 272. The loading system S can load each package W into any storage space in the individual storage units 271 by controlling the operation of the storage robot 272.
[0122] The individual storage compartment 271 allows the robot hand 62 of the stacking robot 6 to enter. The stacking robot 6 can retrieve multiple packages W, specifically multiple types and multiple packages W, stored in the individual storage compartment 271 in any order. The stacking system S can further flexibly change the order in which the packages W are retrieved.
[0123] Furthermore, as illustrated in Figure 14, the individual storage section 271 is an open shelf. The individual storage section 271 allows easy access for the robot hand 62. The stacking system S allows for even more flexible changes in the order in which the packages W are retrieved.
[0124] <Third Modification of the Stacking System> In the second modification described above, the relay unit 7 was equipped with individual storage units 271 as open shelves. However, this disclosure is not limited to individual storage units as open shelves.
[0125] Figure 15 is a diagram corresponding to Figure 3 showing a robot system 303 according to a third modification. The robot system 303 is interchangeable with the robot system 3 in Figure 1. The robot system 303 is common to the above embodiment, the first modification, and the second modification in that it comprises a relay unit 307, a stacking robot 6, and a robot controller 309. The hardware configuration of the stacking robot 6 itself is also common to the above embodiment, the first modification, and the second modification.
[0126] The relay unit 307 according to the third modified example is interposed between the supply unit 1 and the stacking robot 6, more specifically between the sorting unit 2 and the stacking robot 6. Similar to the above embodiment, the relay unit 307 houses a plurality of packages W, more specifically multiple types and multiple packages W, so that they can be retrieved in any order by the robot hand 62 of the stacking robot 6.
[0127] Specifically, the relay unit 307 according to the third modified example includes an individual housing unit 371 and a housing robot 372. The housing robot 372 is electrically connected to a second robot controller that controls the operation of the housing robot 372.
[0128] The individual storage section 371 accommodates multiple packages W individually. In other words, the individual storage section 371 includes multiple independent storage spaces for each package W.
[0129] More specifically, the individual storage compartment 371 allows the robot hand 62 of the stacking robot 6 to enter. By entering each storage space, the robot hand 62 can retrieve the cargo W stored in that storage space.
[0130] Specifically, the individual storage unit 371 according to the third modified example is a horizontal rotating shelf interposed between the storage robot 372 and the stacking robot 6. The individual storage unit 371 as a horizontal rotating shelf includes a plurality of shelf sections that are open to both the storage robot 372 and the stacking robot 6. Each of the plurality of shelf sections functions as the storage space. The storage space allows entry of the robot hand of the storage robot 372 in addition to the robot hand 62. As shown in the illustrated example, the individual storage unit 371 may be composed of a plurality of horizontal rotating shelves.
[0131] The individual housing unit 371 is electrically connected to the system controller 4. Based on the control signals input from the system controller 4, the individual housing unit 371 can rotate around a rotation axis perpendicular to the floor surface.
[0132] The configuration of the housing robot 372 is the same as that of the housing robot 272 in the second modified example. The configuration of the second robot controller is also the same as that of the robot controller in the second modified example.
[0133] The stacking robot 6 is electrically connected to the robot controller 309, similar to the embodiment described above. The robot controller 309 controls the operation of the stacking robot 6.
[0134] The robot controller 309 is connected to the system controller 4 in a communication manner. The robot controller 309 controls the operation of the stacking robot 6 based on the control signals it receives from the system controller 4.
[0135] The system controller 4 controls the stacking robot 6 based on a predetermined stacking plan Pc. For example, the system controller 4 controls the stacking robot 6 via the robot controller 309. By operating the stacking robot 6, the system controller 4 transfers the cargo W sequentially from the relay unit 307 to the stacking robot 6.
[0136] The system controller 4 functions as a control unit in the third modified example. The system controller 4 may be common to multiple robot systems 3, or it may be configured individually for each robot system 3.
[0137] More specifically, the system controller 4 compares the storage status of each package W in the individual storage unit 271 with the stacking order corresponding to the stacking plan Pc. Based on the comparison result, the system controller 4 causes the robot hand 62 to enter the storage space where the packages W corresponding to the stacking order are stored.
[0138] More specifically, the stacking system S according to the second modified example includes, for example, a type sensor 82 and an attitude sensor 81 near the downstream end of the sorting unit 2, configured in the same manner as in the above embodiment and the first modified example. The system controller 4 grasps the storage status based on the detection signal of the type sensor 82. The system controller 4 adjusts the operation of the robot hand 62 when lifting each load W based on the detection signal of the attitude sensor 81.
[0139] The loading robot 6 lifts the cargo W from the storage space into which the robot hand 62 has entered and loads the cargo W onto the transport cart 10. The loading robot 6 transfers the cargo W sequentially according to the loading order. As the cargo W is transferred sequentially, the loading configuration Wb shown in Figure 5 is achieved, for example.
[0140] When transferring the cargo W from the storage robot 372 to the individual storage unit 371, and when transferring the cargo W from the individual storage unit 371 to the loading robot 6, the system controller 4 rotates the individual storage unit 371 as appropriate.
[0141] As illustrated in Figure 15, the individual storage unit 371 is a horizontal rotating shelf. By rotating the individual storage unit 371, the robot hand 62 can be moved to any position. The stacking system S allows for even more flexible changes in the order in which the packages W are retrieved.
[0142] <Other Modifications> In the above embodiment, one robot system 3 had one stacking robot 6. One robot system 3 may have multiple stacking robots 6. Multiple stacking robots 6 may stack the cargo W on the same transport cart 10, or they may stack the cargo W on different transport carts 10.
[0143] Furthermore, in the above embodiment and the first modified example, the transport unit 72 included a third conveyor 7c. Instead of including a conveyor, the transport unit 72 may include a vertical articulated robot.
[0144] The functions of the elements disclosed herein may be implemented using one or more circuits or processing circuits, including general-purpose processors, special-purpose processors, integrated circuits, ASICs (Application Specific Integrated Circuits), FPGAs (Field Programmable Gate Arrays), and / or conventional circuits. The functions of the elements disclosed herein may be implemented using one or more circuits or processing circuits, including a combination of general-purpose processors, special-purpose processors, integrated circuits, ASICs, FPGAs, and conventional circuits. One or more circuits or processing circuits may be programmed using one or more programs stored together or individually in one or more memories, or may be otherwise configured to perform the disclosed functions. A processor is considered a processing circuit or circuit because it includes transistors and other circuits. A processor may be a programmed processor that executes programs stored in memory. In this disclosure, a circuit, unit, or means is hardware that performs the enumerated functions individually or in combination with each other, or hardware programmed to perform the enumerated functions individually or in combination with each other. The hardware may be any hardware disclosed herein that is programmed or configured to perform the listed functions.
[0145] A computer program, including computer instructions, is stored in memory. The computer instructions provide logic and routines that enable hardware to execute the methods disclosed herein. The hardware includes, for example, processing circuits or circuits. The computer program may be implemented in a known format on computer-readable storage media, computer program products, memory devices, recording media such as CD-ROMs or DVDs, and / or in the memory of FPGAs or ASICs.
[0146] <Embodiment> The above embodiment is a specific example of the following embodiment.
[0147] (Aspect 1) A stacking system (S) comprising: a stacking robot (6) having a robot hand (62) that sequentially stacks multiple types of packages (W) supplied from a predetermined source (1) onto a stacking target (10) using the robot hand (62); a relay unit (7, 207, 307) interposed between the source (1) and the stacking robot (6) that houses multiple packages (W) so that they can be retrieved in any order by the robot hand (62); and a control unit (4) that operates the relay unit (7, 207, 307) or the stacking robot (6) based on a predetermined stacking plan (Pc) to sequentially transfer the packages (W) from the relay unit (7, 207, 307) to the stacking robot (6).
[0148] The stacking system (S) has an intermediary unit (7, 207, 307) between the supplier (1) and the stacking robot (6). The intermediary unit (7, 207, 307) accommodates multiple packages (W), specifically multiple types and multiple packages (W), so that they can be retrieved in any order by the robot hand (62). The intermediary unit (7, 207, 307) functions as a buffer to adjust the retrieval order of the packages (W). By having the intermediary unit (7, 207, 307), the stacking system (S) can flexibly change the retrieval order of the packages (W). The stacking system (S) can automate the stacking of packages (W) onto the stacking target (10).
[0149] (Aspect 2) The stacking system (S) according to Aspect 1, wherein the relay unit (7) has a temporary storage unit (71) for temporarily storing a plurality of the packages (W), and a transport unit (72) for individually transporting the packages (W) from the temporary storage unit (71) to a handover position (Pr) to the stacking robot (6), the control unit (4) controls the relay unit (7) based on the stacking meter (Pc), the relay unit (7) transports the packages (W) to the handover position (Pr) in the order based on the stacking plan (Pc), and the stacking robot (6) receives the packages (W) in the order they were transported to the handover position (Pr) and stacks the received packages (W) onto the stacking target (10).
[0150] The stacking system (S) can load multiple packages (W) into the temporary storage unit (71) or transport each package (W) loaded into the temporary storage unit (71) to a transfer position (Pr) by operating the transport unit (72) as appropriate. The stacking system (S) can automate the loading of packages (W) onto the stacking target (10) by providing a relay unit (7).
[0151] (Aspect 3) The stacking system (S) according to aspect 2, wherein the temporary storage section (71) includes a first storage section (711) for storing a plurality of the packages (W) in the order they are supplied from the supplier (1), and a second storage section (712) for removing a different package (W) from the first storage section (711) when transporting the packages (W) to the handover position (Pr).
[0152] The stacking system (S) allows for more flexible changes in the order in which the packages (W) are retrieved by temporarily moving one or more packages (W) to the second storage section (712).
[0153] (Aspect 4) The stacking system (S) according to aspect 3 or 4, wherein the temporary storage section (71) and the transport section (72) each include conveyors (7a, 7b, 7c) that operate based on control signals received from the control unit (4).
[0154] Since both the temporary storage section (71) and the transport section (72) include conveyors (7a, 7b, 7c), the order of multiple types of luggage (W) can be easily rearranged. The conveyors (7a, 7b, 7c) can also be used as storage space for luggage (W).
[0155] (Aspect 5) The stacking system (S) according to any one of aspects 1 to 4, wherein the relay section (207, 307) includes individual storage sections (271, 371) that allow the robot hand (62) to enter and individually store the packages (W), and storage robots (272, 372) that are interposed between the supplier (1) and the individual storage sections (271, 371) and transfer the packages (W) to the individual storage sections (271, 371), the control unit (4) controls the stacking robot (6) based on the stacking plan (Pc), the stacking robot (6) takes out the packages (W) from the individual storage sections (271, 371) in the order based on the stacking plan (Pc), and stacks the taken-out packages (W) on the stacking target (10).
[0156] The stacking system (S) can load each package (W) into any storage space in the individual storage units (271, 371) by controlling the operation of the storage robots (272, 372). The individual storage units (271, 371) allow the robot hand (62) of the stacking robot (6) to enter. The stacking robot (6) can take out multiple packages (W), specifically multiple types and multiple packages (W), stored in the individual storage units (271, 371) in any order. The stacking system (S) can further flexibly change the order in which the packages (W) are taken out.
[0157] (Aspect 6) The stacking system (S) according to aspect 5, wherein the individual storage section (371) is a horizontal rotating shelf interposed between the storage robot (372) and the stacking robot (6).
[0158] The stacking system (S) allows the robot hand (62) to enter any position by rotating the individual storage section (371). The stacking system (S) also allows for more flexible changes to the order in which the packages (W) are retrieved.
[0159] (Aspect 7) The stacking system (S) according to aspect 5, wherein the individual storage section (271) is an open shelf interposed between the storage robot (272) and the stacking robot (6).
[0160] The stacking system (S) allows the individual storage compartments (271) to easily accommodate the entry of the robot hand (62). The stacking system (S) also allows for more flexible changes in the order in which the cargo (W) is retrieved.
[0161] (Aspect 8) A stacking system (S) according to any one of aspects 1 to 7, wherein the stacking system (S) is provided with respect to the cargo (W) supplied from the supplier (1) to the relay unit (7, 207, 307), the system is equipped with a type sensor (82) that identifies the type of cargo (W) individually and in the order of supply, the control unit (4) determines the storage status of the cargo (W) in the relay unit (7, 207, 307) based on the identification result by the type sensor (82), and controls the operation of the relay unit (7, 207, 307) or the stacking robot (6) based on the stacking plan (Pc) and the storage status.
[0162] The stacking system (S) allows the control unit (4) to understand the storage status of each package (W) in the relay units (7, 207, 307) based on the detection signal from the type sensor (82). By providing the type sensor (82), the stacking system (S) can change the order in which the packages (W) are taken out even more flexibly.
[0163] (Aspect 9) The stacking system (S) according to any one of aspects 1 to 8, wherein the stacking system (S) is provided with respect to the loads (W) supplied from the supplier (1) to the relay units (7, 207, 307), and the loads (W) are individually identified in the order of supply, and the control unit (4) controls the operation of the stacking robot (6) based on the identification results from the loads (W) and the loads (W) (7, 207, 307), wherein the stacking system (S) is provided with respect to the loads (W) supplied from the supplier (1) to the relay units (7, 207, 307), and the control unit (4) controls the operation of the stacking robot (6) based on the identification results from the loads (W) (81).
[0164] The stacking system (S) can cause the control unit (4) to understand the orientation of each load (W) housed in the relay units (7, 207, 307) based on the detection signal from the orientation sensor (81). By providing the orientation sensor (81), the stacking system (S) can appropriately operate the stacking robot (6) when retrieving loads (W) from the relay units (7, 207, 307).
[0165] (Aspect 10) A loading system (S) located between the supplier (1) and the loading system (S), comprising a sorting unit (2) that sorts the cargo (W) supplied from the supplier (1) according to the destination and type of the cargo (W), wherein the cargo (W) supplied from the supplier (1) is supplied to the relay unit (7, 207, 307) in a state that has been sorted in advance by the sorting unit (2).
[0166] The loading system (S) can appropriately load cargo (W) according to its destination and type by using both the sorting section (2) and the transfer section (7, 207, 307).
[0167] S Stacking System W Cargo Pc Stacking Plan Pr Delivery Location 1 Supply Unit (Supplier) 2 Sorting Unit 3 Robot System 6 Stacking Robot 62 Robot Hand 7 Relay Unit 71 Temporary Storage Unit 711 First Storage Unit 712 Second Storage Unit 7a First Conveyor (Conveyor) 7b Second Conveyor (Conveyor) 7c Third Conveyor (Conveyor) 72 Transport Unit 207 Relay Unit 271 Individual Storage Unit 272 Storage Robot 307 Relay Unit 371 Individual Storage Unit 372 Storage Robot 8 Sensors 81 Attitude Sensor 82 Type Sensor 9 Robot Controller 4 System Controller (Control Unit) 5 Code Reader 10 Transport Cart (Loading Target)
Claims
1. A stacking system comprising: a stacking robot having a robotic hand that sequentially stacks multiple types of packages supplied from a predetermined source onto a stacking target using the robotic hand; a relay unit interposed between the source and the stacking robot, which accommodates multiple packages so that they can be retrieved in any order by the robotic hand; and a control unit that operates the relay unit or the stacking robot according to a predetermined stacking plan, thereby sequentially transferring the packages from the relay unit to the stacking robot.
2. The stacking system according to claim 1, wherein the relay unit comprises a temporary storage unit for temporarily storing a plurality of the packages, and a transport unit for individually transporting the packages from the temporary storage unit to a handover position to the stacking robot, the control unit controls the relay unit based on the stacking plan, the relay unit transports the packages to the handover position in the order based on the stacking plan, and the stacking robot receives the packages in the order they were transported to the handover position and stacks the received packages on the stacking target.
3. The stacking system according to claim 2, wherein the temporary storage unit includes a first storage unit for storing a plurality of the packages in the order they are supplied from the supplier, and a second storage unit for removing other packages from the first storage unit when transporting the packages to the handover position.
4. The stacking system according to claim 3, wherein the temporary storage unit and the transport unit each include a conveyor that operates based on a control signal received from the control unit.
5. A stacking system according to any one of claims 1 to 4, wherein the relay unit includes an individual storage unit that allows the robot hand to enter and individually stores the packages, and a storage robot interposed between the supply source and the individual storage unit, which transfers the packages to the individual storage unit, the control unit controls the stacking robot based on the stacking plan, and the stacking robot retrieves the packages from the individual storage unit in the order based on the stacking plan and stacks the retrieved packages on the stacking target.
6. The stacking system according to claim 5, wherein the individual storage unit is a horizontal rotating shelf interposed between the storage robot and the stacking robot.
7. A stacking system according to claim 5, wherein the individual storage unit is an open shelf interposed between the storage robot and the stacking robot.
8. A stacking system according to any one of claims 1 to 7, comprising a type sensor for individually and sequentially identifying the type of cargo supplied from the supplier to the relay unit, the control unit determining the cargo storage status in the relay unit based on the identification result by the type sensor, and controlling the operation of the relay unit or the stacking robot based on the stacking plan and the storage status.
9. A stacking system according to any one of claims 1 to 8, wherein the system is equipped with a posture sensor that identifies the posture of each piece of luggage supplied from the supplier to the relay unit individually and in the order of supply, and the control unit controls the operation of the stacking robot based on the identification results from the posture sensor.
10. A stacking system according to any one of claims 1 to 9, comprising a sorting unit located between the supplier and the stacking system, which sorts the cargo supplied from the supplier according to the destination and type of the cargo, wherein the cargo supplied from the supplier is supplied to the relay unit in a state that has been sorted in advance by the sorting unit.