Automated warehouse
Patent Information
- Application Number
- PCT/JP2026/014401
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2025-04-15
- Filing Date
- 2026-04-07
- Publication Date
- 2026-10-22
Smart Images
Figure JP2026014401_22102026_PF_FP_ABST
Abstract
Description
Automated Warehouse
[0001] The present invention relates to an automated warehouse comprising a warehouse unit for storing articles, and a loading / unloading device that performs at least one of loading and unloading of articles with respect to the warehouse unit.
[0002] An example of the automated warehouse as described above is disclosed in Japanese Patent Laid-Open No. 2017-124933 (Patent Document 1). Hereinafter, in the description of this background art, the reference numerals and names in Patent Document 1 are cited in parentheses.
[0003] The automated warehouse (three-dimensional automated warehouse 1) disclosed in Patent Document 1 includes a warehouse unit (storage warehouse section 2) for storing articles (5), and a loading / unloading device (loading / unloading section 4) disposed at a position adjacent to the warehouse unit (storage warehouse section 2). The loading / unloading device (loading / unloading section 4) performs loading and unloading of articles (5) with respect to the warehouse unit (storage warehouse section 2).
[0004] The warehouse unit (storage warehouse section 2) includes a storage shelf (single storage rack 212) capable of storing a plurality of articles (5), and a tiered transport device (transport mechanism 3). The tiered transport device (transport mechanism 3) transports the articles (5) to be unloaded from the storage shelf (single storage rack 212), and transports the articles (5) that have been loaded from the loading / unloading device (loading / unloading section 4) and are to be stored in the storage shelf (single storage rack 212). In the automated warehouse (three-dimensional automated warehouse 1) disclosed in Patent Document 1, by arranging the storage shelves (single storage rack 212) on both sides of the path along which the tiered transport device (transport mechanism 3) moves, the storage capacity of articles (5) in the entire warehouse unit (storage warehouse section 2) is ensured to a certain extent, while the transport efficiency of articles (5) within the warehouse unit (storage warehouse section 2) is improved.
[0005] Japanese Patent Laid-Open No. 2017-124933
[0006] However, in the recent situation where the amount of articles (5) that need to be stored is increasing, even the automated warehouse (three-dimensional automated warehouse 1) as disclosed in Patent Document 1 may not have sufficient storage capacity for the articles (5).
[0007] Accordingly, it is desired to realize an automated warehouse that can easily increase the storage capacity of articles.
[0008] The automated warehouse according to this disclosure comprises a warehouse unit having storage shelves that have storage areas on multiple vertically arranged floors and each storage area can accommodate multiple articles, a floor transport device for transporting the articles in each storage area, and a lifting transport device for transporting the articles vertically across the multiple floors; and an inbound / outbound area located at a height corresponding to a specific floor which is part of the multiple floors, where an inbound device for receiving the articles into the warehouse unit and an outbound device for retrieving the articles from the warehouse unit are located, wherein at least a part of the floors different from the specific floor is designated as the target floor, and the target area, which is part of the storage area of the target floor, is located at a position that overlaps with the inbound / outbound area when viewed in the vertical direction.
[0009] In this configuration, the target area, which is part of the storage area of the target floor, is located in the space above the loading / unloading area and overlapping with the loading / unloading area when viewed vertically. Therefore, compared to a configuration without the target area, a larger space can be secured for arranging the storage area of the storage shelves. In other words, the storage area can be expanded by utilizing the dead space caused by the arrangement of the loading / unloading area, thereby effectively utilizing the space that the automated warehouse can occupy and increasing the storage capacity of goods in the automated warehouse.
[0010] Further features and advantages of the technology relating to this disclosure will become clearer from the following description of exemplary and non-limiting embodiments, with reference to the drawings.
[0011] A schematic plan view of the automated warehouse of this embodiment. A schematic side view of the automated warehouse of this embodiment. A view from III-III of Figure 2. A view from IV-IV of Figure 2. A detailed view of Figure 2. A diagram illustrating the movement of the transport vehicle shown in Figure 5.
[0012] The automated warehouse 100 of the embodiment will be described with reference to Figures 1 to 6.
[0013] As shown in Figures 1 and 2, the automated warehouse 100 is used for storing multiple items W. Items W brought into the automated warehouse 100 are transported to a predetermined storage location inside the automated warehouse 100 and then stored without the need for human intervention. On the other hand, items W stored inside the automated warehouse 100 are automatically transported to a predetermined retrieval location outside the automated warehouse 100 without the need for human intervention. The type and appearance of the items W are not particularly limited, but in this embodiment, items W are boxes containing cargo. Note that in each figure, cargo and boxes are represented without distinction as items W.
[0014] In this specification, as described above, the terms "receiving" and "removing" are used to describe the movement of articles W to and from the automated warehouse 100. Receiving includes bringing articles W into a predetermined storage location set inside the automated warehouse 100, and removing articles W stored in the automated warehouse 100 includes removing them from the automated warehouse 100.
[0015] The automated warehouse 100 includes a warehouse unit 1 for storing goods W, and an inbound / outbound system 6 that performs at least one of the following: receiving goods W into the warehouse unit 1 and retrieving goods W from the warehouse unit 1.
[0016] The receiving and dispatching system 6 includes at least one of the following functions: receiving goods W into the warehouse unit 1 from the work entity M and handing them over to the warehouse unit 1; and handing over goods W that have been dispatched from the warehouse unit 1 to the work entity M. Examples of work entity M include workers or robots that handle the exchange of goods W between the warehouse unit 1 and the work entity M. For example, a work entity M provided in equipment that ships goods W stored in an automated warehouse 100 is a worker or robot that transports goods W that have been dispatched from the automated warehouse 100 to the shipping location.
[0017] The loading / unloading system 6 occupies a designated loading / unloading area 7 outside the warehouse unit 1. The loading / unloading area 7 is a three-dimensional area through which the movement of goods W brought into the loading / unloading system 6 and the movement of goods W being unloaded from the loading / unloading system 6 passes, and where the equipment constituting the loading / unloading system 6 (including the loading / unloading device 61 described later) is arranged. In the examples shown in Figures 1 and 2, the loading / unloading system 6 is located adjacent to the outside of the warehouse unit 1. The inside and outside of the automated warehouse 100 are defined by appropriate boundaries. If the automated warehouse 100 is surrounded by walls or fences, the above boundaries are those walls or fences. If there are no walls or fences, the boundary defining the area that workers cannot enter when loading and unloading are performed is set as the boundary between the inside and outside of the automated warehouse 100.
[0018] The receiving and shipping area 7 is equipped with one or more receiving and shipping devices 61 that constitute the receiving and shipping system 6. The receiving and shipping devices 61 are at least one of a receiving device 62 that receives goods W into the warehouse unit 1, and a shipping device 63 that ships goods W out of the warehouse unit 1. The receiving and shipping devices 61 include, for example, belt conveyors, roller conveyors, other conveyor devices, and picking stations. The conveyor devices include receiving conveyors that transport goods W to a handover position with the warehouse unit 1, and shipping conveyors that transport goods W from the handover position with the warehouse unit 1 to a predetermined position. The picking station is a station where workers or robots perform the task of selecting the required goods W and delivering them to the warehouse unit 1.
[0019] As shown in Figure 2, the warehouse unit 1 comprises multiple layers 2 arranged in the vertical direction Z. As shown in Figure 1, the multiple layers 2 are arranged along orthogonal planes perpendicular to the vertical direction Z. Examples of layers 2 include virtual planes defined for each specific position in the vertical direction Z, and floor surfaces constituting each layer of a multi-layered building. The automated warehouse 100 of this embodiment has a structure that combines multiple columns and structural members, and the layers 2 are defined along virtual planes defined for each specific position in the vertical direction Z.
[0020] Hereafter, for the sake of explanation, this specification will refer to the directions that are mutually orthogonal to each other in a view along the vertical Z direction as the X direction and the Y direction, respectively, and will describe the positional relationships of each component. The X direction and the Y direction are indicated by arrows labeled "X" and "Y" in each drawing.
[0021] Each of the multiple layers 2 is stacked vertically along the Z direction from the reference surface 10. The reference surface 10 is the surface that supports the warehouse unit 1, and examples include the floor or ground located inside a building. In this embodiment, the reference surface 10 also serves as the surface that supports the loading and unloading system 6. Hereafter, for the sake of explanation, a layer 2 that is directly supported by the reference surface 10 may be referred to as the reference layer 20, a layer 2 that is directly stacked on the reference layer 20 may be referred to as the second layer, and a layer 2 that is stacked on top of the second layer may be referred to as the third layer.
[0022] Multiple levels 2 include a specific level 21 and a target level 22.
[0023] The specific floor 21 is a part of multiple floors 2, and corresponds to the loading / unloading area 7 in the vertical Z direction. That is, the loading / unloading area 7 is located at a height corresponding to the specific floor 21, which is a part of multiple floors 2. More specifically, the specific floor 21 is a floor 2 that, in a Y-direction view along the Y direction, partially or entirely overlaps with the loading / unloading area 7. In the example shown in Figure 2, the loading / unloading area 7 overlaps with the base floor 20 to the third floor in a Y-direction view. In other words, in Figure 2, the base floor 20 to the third floor are represented as the specific floor 21.
[0024] The target level 22 is at least a part of a level 2 that is different from the specific level 21. In the example shown in Figure 2, all levels 2 above the specific level 21 are represented as the target level 22. More specifically, in the example shown in Figure 2, the fourth level stacked on top of the third level and the levels 2 located above the fourth level are represented as the target level 22. If the warehouse unit 1 has one or more levels 2 below the specific level 21, the levels 2 below the specific level 21 may also be considered the target level 22. Furthermore, the warehouse unit 1 may be configured to have target levels 22 on both the upper and lower sides of the specific level 21.
[0025] At least a portion of the target floor 22 of the warehouse unit 1 overlaps with the loading / unloading area 7 in a vertical Z-view. In other words, a portion of the warehouse unit 1 is located in the area directly above or directly below the loading / unloading area 7. In this embodiment, a portion of the warehouse unit 1 is located in the area directly above the loading / unloading area 7.
[0026] In this embodiment, the system comprises at least two warehouse units 1. The automated warehouse 100 illustrated in Figures 1 and 2 comprises two warehouse units 1. For the sake of explanation, when distinguishing between the two warehouse units 1, one of the two warehouse units 1 will be referred to as the first warehouse unit 1A, and the other as the second warehouse unit 1B. The two warehouse units 1 are spaced apart along the Y direction.
[0027] The receiving and shipping system 6 takes at least one of the first warehouse unit 1A and the second warehouse unit 1B as the target warehouse unit and performs at least one of receiving and shipping of goods W to the target warehouse unit. In this embodiment, the automated warehouse 100 comprises a plurality of receiving and shipping systems 6 corresponding to each of the plurality of warehouse units 1. The automated warehouse 100 illustrated in Figure 1 comprises a pair of receiving and shipping systems 6 corresponding to the first warehouse unit 1A and the second warehouse unit 1B, respectively. Hereafter, one of the pair of receiving and shipping systems 6 will be referred to as the first receiving and shipping system 6A, and the other of the pair of receiving and shipping systems 6 will be referred to as the second receiving and shipping system 6B. The first receiving and shipping system 6A corresponds to the first warehouse unit 1A, and the second receiving and shipping system 6B corresponds to the second warehouse unit 1B.
[0028] The first receiving / shipping system 6A performs at least one of receiving goods W into the first warehouse unit 1A and shipping goods W out of the first warehouse unit 1A. In this embodiment, the first receiving / shipping system 6A performs both receiving and shipping goods W to and from the first warehouse unit 1A.
[0029] The second receiving / shipping system 6B performs at least one of receiving goods W into the second warehouse unit 1B and shipping goods W out of the second warehouse unit 1B. In this embodiment, the second receiving / shipping system 6B performs both receiving and shipping goods W to and from the second warehouse unit 1B.
[0030] In this embodiment, each of the pair of inbound / outbound systems 6 is positioned adjacent to each of the two warehouse units 1 in the Y direction. Specifically, the first warehouse unit 1A is positioned adjacent to the first inbound / outbound system 6A in the Y direction. On the other hand, the second warehouse unit 1B is positioned adjacent to the second inbound / outbound system 6B in the Y direction.
[0031] In the example shown in Figure 1, the first inbound / outbound system 6A and the second inbound / outbound system 6B are arranged one unit each on either side in the Y direction. The first inbound / outbound system 6A is located on one side in the Y direction (to the left of the center of the paper), and the second inbound / outbound system 6B is located on the other side in the Y direction (to the right of the center of the paper). In the example shown in Figure 1, the inbound / outbound area 7 of the second inbound / outbound system 6B (second inbound / outbound area 7B) has a wider area on one side in the X direction (upwards towards the paper) than the inbound / outbound area 7 of the first inbound / outbound system 6A (first inbound / outbound area 7A).
[0032] In this embodiment, a non-location area 71 is provided between the first inbound / outbound area 7A and the second inbound / outbound area 7B in the Y direction. With this configuration, the work entity M can use the non-location area 71 to transport goods W or as a space to install maintenance equipment when performing maintenance on the automated warehouse 100. Therefore, the non-location area 71 makes it easier to operate the automated warehouse 100 efficiently.
[0033] Hereafter, for the sake of explanation, one side in the Y direction will be referred to as the first side Y1, and the other side in the Y direction will be referred to as the second side Y2. The first side Y1 is the side closer to the inbound / outbound system 6 in the Y direction, relative to warehouse unit 1. Conversely, the second side Y2 is the side further away from the inbound / outbound system 6 in the Y direction, relative to warehouse unit 1. In the example shown in Figures 1 to 5, since there is a pair of warehouse units 1, the first side Y1 and the second side Y2 are based on each warehouse unit 1. For example, relative to the first warehouse unit 1A, the side closer to the first inbound / outbound system 6A is the first side Y1, and relative to the second warehouse unit 1B, the side closer to the second inbound / outbound system 6B is also the first side Y1.
[0034] In this embodiment, the first warehouse unit 1A and the second warehouse unit 1B are positioned to sandwich a pair of inbound / outbound systems 6 from both sides. More specifically, as shown in Figure 2, a specific floor 21 of the first warehouse unit 1A and a specific floor 21 of the second warehouse unit 1B are positioned opposite each other across the inbound / outbound area 7. A portion of the target floor 22 of the first warehouse unit 1A is partially opposite the target floor 22 of the second warehouse unit 1B. The target floor 22 of the first warehouse unit 1A overlaps with the first inbound / outbound system 6A in a vertical Z-view. The target floor 22 of the second warehouse unit 1B overlaps with the second inbound / outbound system 6B in a vertical Z-view. In this embodiment, the target floor 22 of the first warehouse unit 1A is connected to the target floor 22 of the second warehouse unit 1B at the same height.
[0035] In this embodiment, each of the pair of storage systems 6 is equipped with a pair of storage devices 61. In the example shown in Figure 1, the storage device 62 is located on the upper side of the plane of the paper, and the storage device 63 is located on the lower side of the plane of the paper. The storage device 62 illustrated in Figures 1 and 2 is a storage conveyor. On the other hand, the storage device 63 illustrated in Figure 1 is a storage conveyor. The goods W transported to a predetermined location by the storage device 63 are loaded onto pallets by, for example, a robot (not shown) and transported by a pallet conveyor or automated guided vehicle.
[0036] In this embodiment, as shown in Figure 2, the loading / unloading area 7 is located on the first side Y1 in the Y direction relative to the warehouse unit 1. In addition, as shown in Figure 1, the loading / unloading area 7 is located so as to overlap with a portion of the X-direction area of a specific floor 21 when viewed in the Y direction. The loading / unloading device 61 is connected to the warehouse unit 1 from the first side Y1 in the Y direction. In the example shown in Figure 1, the first loading / unloading area 7A is located so as to overlap with the central X-direction area of the specific floor 21 of the first warehouse unit 1A when viewed in the Y direction. Similarly, in the example shown in Figure 1, the second loading / unloading area 7B is also located so as to overlap with the central X-direction area of the specific floor 21 of the second warehouse unit 1B when viewed in the Y direction.
[0037] Details of Warehouse Unit 1 are described below.
[0038] As shown in Figures 1 to 5, the warehouse unit 1 includes a storage rack 3 (see Figures 1 and 2) capable of accommodating multiple items W, a hierarchical transport device 4 (see Figures 3 and 4) for transporting the items W, and a lifting transport device 5 (see Figures 2 to 5).
[0039] As shown in Figure 2, the storage shelves 3 are shelves arranged across multiple levels 2. The lifting and transporting device 5 transports goods W in the vertical direction Z across the multiple levels 2. When goods W are received into the warehouse unit 1, the receiving and retrieving system 6 first hands over the goods W to the lifting and transporting device 5. The goods W handed over to the lifting and transporting device 5 are transported to the designated level 2, and then, as shown in Figure 4, are transported to the storage shelves 3 by the level transporting device 4. Conversely, when goods W are retrieved from the warehouse unit 1, the level transporting device 4 removes the goods W from the storage shelves 3 and hands them over to the lifting and transporting device 5. The goods W removed from the storage shelves 3 are then handed over from the lifting and transporting device 5 to the receiving and retrieving system 6.
[0040] As shown in Figures 3 to 5, the storage shelf 3 has a storage area 31 on each of its multiple levels 2. Each storage area 31 located on each level 2 is an area capable of accommodating multiple items W.
[0041] The storage area 31 includes a placement area 32, a target area 33 (see Figure 4), and a second target area 35, as shown in Figures 3 and 4. The placement area 32, the target area 33, and the second target area 35 are regions that include a storage section in which a plurality of articles W are stored, a transport passage 44 (described later) for transporting the articles W, and other configurations necessary for transporting the articles W to the storage section. The placement area 32 is part of the storage area 31 of the specific floor 21 and part of the storage area 31 located on the target floor 22. The target area 33 is part of the storage area 31 located on the target floor 22. The second target area 35 is part of the storage area 31 located on at least the specific floor 21.
[0042] The storage area consists of a mounting surface on which articles W can be placed. The mounting surface is a flat surface supported by a column at a reference position in each of the floor levels 2. The mounting surfaces of the storage areas in the mounting area 32, target area 33, and second target area 35 shown in Figure 2 have an area on which multiple articles W can be placed along the X and Y directions. The size of the mounting surface is determined considering the weight of the articles W to be supported by the mounting surface and the configuration of the structural material supporting the mounting surface. For example, the mounting surface may be a surface that supports the entire underside of the article W. Such a mounting surface is made up of a flat plate-like member. Alternatively, the mounting surface may be multiple surfaces that support multiple locations on the underside of the article W. For example, such a mounting surface could be a pair of rails that support two locations on the underside of the article W that are spaced apart in the width direction.
[0043] The placement area 32, the target area 33, and the second target area 35 are arranged in a distributed manner within the accommodation areas 31 respectively disposed on the respective tiers 2. The plurality of placement areas 32 exemplified in FIGS. 3 and 4 (the upper side when facing the page) include a plurality of storage area groups adjacent in the Y direction. The plurality of placement areas 32 are arranged at intervals in the X direction. At least two storage areas are arranged adjacent to each placement area 32. In the example shown in FIGS. 3 and 4 (the lower side when facing the page), the target area 33 and the second target area 35, similarly to the placement area 32, each include a storage area group adjacent in the Y direction, and are arranged in a distributed manner within the respective accommodation areas 31. In the example shown in FIG. 4 (the center when facing the page), the target areas 33 are arranged at intervals in the X direction, and the second target areas 35 are also arranged at intervals in the X direction. In the reference tier 20, as shown in FIG. 3, the plurality of placement areas 32 and the plurality of second target areas 35 are arranged in regions excluding the region occupied by the loading / unloading device 61 and the tier transport device 4. Further, in the target tier 22, as shown in FIG. 4, the plurality of placement areas 32, the plurality of target areas 33, and the plurality of second target areas 35 are arranged in regions excluding the region occupied by the tier transport device 4.
[0044] The placement area 32 is disposed on the Y-direction second side Y2 relative to the loading / unloading system 6. The placement area 32 is disposed in all the accommodation areas 31 of the reference tier 20, the specific tier 21, and the target tier 22, and accommodates most of the plurality of articles W stored by the warehouse unit 1. Some of the placement areas 32 exemplified in FIGS. 3 and 4 are arranged at positions overlapping the elevating transport device 5 when viewed in the Y direction.
[0045] As shown in Figures 1 and 2, the target area 33 is positioned in a location that overlaps with the loading / unloading device 61 in a vertical Z-view. The target area 33 illustrated in Figure 2 is positioned in the upper space of the loading / unloading area 7. Here, the target area 33 may also be positioned in a location that does not overlap with the loading / unloading device 61 in a vertical Z-view, as long as it does not interfere with the loading / unloading device 61. The target area 33 shown in Figure 1 overlaps with most of the first loading / unloading area 7A in a vertical Z-view. The target area 33 also overlaps with a part of the second loading / unloading area 7B. In detail, the target area 33 overlaps with the central part of the second loading / unloading area 7B in a vertical Z-view. On the other hand, the target area 33 does not overlap with the upper part of the second loading / unloading area 7B in a vertical Z-view. The target area 33 illustrated in Figure 4 is positioned at a distance from the mounting area 32 to the first side Y1 in the Y direction. The lifting and transporting device 5, illustrated in Figure 4, is positioned between the loading area 32 and the target area 33.
[0046] In this embodiment, the target area 33 of the first warehouse unit 1A and the target area 33 of the second warehouse unit 1B are connected to each other. More specifically, the target area 33 of the first warehouse unit 1A is located adjacent to the target area 33 of the second warehouse unit 1B in the same target floor 22. In the examples shown in Figures 1 and 4, the target area 33 of the first warehouse unit 1A and the second warehouse unit 1B that are connected to each other is not clearly distinguished. The target area 33 is treated as being shared by the first warehouse unit 1A and the second warehouse unit 1B.
[0047] As shown in Figure 1, the second target area 35 is arranged at a position that does not overlap with the storage and retrieval area 7 when viewed in the Y direction, and overlaps with the storage and retrieval area 7 when viewed in the X direction along the X direction. The second target area 35 is a part of the storage area 31, and is a portion extended from the region where the placement area 32 is arranged toward the storage and retrieval area 7 within a range that does not interfere with the storage and retrieval area 7 on the specific floor 21. The second target area 35 included in the first warehouse unit 1A is not connected to the second warehouse unit 1B, and is arranged at an interval from the second warehouse unit 1B. According to this configuration, for example, a passage for a worker who performs work can be secured in the area between the first warehouse unit 1A and the second warehouse unit 1B, and articles W can be efficiently stored into or retrieved from the warehouse. Note that the second target area 35 may interfere with the storage and retrieval area 7 to such an extent that it does not interfere with the storage and retrieval device 61 or various configurations arranged in the storage and retrieval area 7.
[0048] In the present embodiment, the second target area 35 is configured to overlap with the floor 2 having the same height as the reference floor 20, the specific floor 21, and the target floor 22 when viewed in the Y direction. In the example shown in Figure 1, the first warehouse unit 1A includes the second target areas 35 on both sides of the first storage and retrieval area 7A in the X direction. Therefore, the first warehouse unit 1A can store a larger number of articles W. Further, in the example shown in Figure 1, the second warehouse unit 1B includes the second target area 35 on one side of the second storage and retrieval area 7B in the X direction. Specifically, the second warehouse unit 1B includes the second target area 35 in a region on the lower side toward the paper surface relative to the second storage and retrieval area 7B. According to this configuration, it is easy to enlarge the second storage and retrieval area 7B, and in turn, it is easy to secure the movement line of the work subject M that performs storage and retrieval work with respect to the second storage and retrieval system 6B. The second target area 35 illustrated in Figure 3 and Figure 4 is arranged at an interval on the first Y-direction side Y1 from the placement area 32 which is arranged at a position not overlapping with the storage and retrieval area 7 when viewed in the Y direction.
[0049] As shown in Figures 3 and 4, the hierarchical transport device 4 transports the articles W within each of the storage areas 31. In this embodiment, the hierarchical transport device 4 is positioned in each of the storage areas 31 located on multiple floors 2. In this embodiment, the hierarchical transport device 4 moves the articles W only within the storage area 31 of each floor 2.
[0050] In this embodiment, the hierarchical transport device 4 comprises a plurality of transport vehicles 41 for transporting articles W, and transport passages 44 that form the movement paths of the transport vehicles 41. The transport passages 44 constitute a part of the loading area 32, the target area 33, and the second target area 35, respectively. The transport passages 44 connect at least the position where the transport vehicles 41 transfer articles W between the storage area and the transport vehicle 41 to the position where the transport vehicles 41 transfer articles W between the lifting transport device 5 and the storage area. The transport vehicles 41 transport articles W by traveling along the transport passages 44 on each hierarchical level 2. By traveling along the transport passages 44, the transport vehicles 41 move articles W at least between the storage area and the lifting transport device 5.
[0051] The transport passage 44 includes a plurality of first passages 4Y and a second passage 4X. The first passage 4Y passes through the position where the transport vehicle 41 transfers articles W between the storage area provided in the containment area 31 and the lifting transport device 5 or other transport vehicles 41. The second passage 4X connects at least two or more first passages 4Y. Here, connecting two passages means that each of the two passages is positioned in a positional relationship that allows the transport vehicles 41 to move back and forth between them.
[0052] Each of the multiple first passages 4Y extends along the Y direction, passing through a position adjacent to the storage area of the loading area 32 in the X direction. In this embodiment, the first passages 4Y are arranged side by side with gaps in the X direction. The storage area of the loading area 32 is positioned between two adjacent first passages 4Y. The transport vehicle 41 transfers the articles W between the storage area of the loading area 32 and the first passage 4Y at a position adjacent to the storage area in the X direction.
[0053] A portion of the multiple first passages 4Y extends at least from a position adjacent in the X direction to the storage area of the loading area 32 to a position adjacent in the X direction to the lifting conveyor 5. In the example shown in Figures 3 and 4 (near the center of the page), the first passage 4Y included in the loading area 32 that overlaps with the lifting conveyor 5 in a Y-direction view extends to a position adjacent in the X direction to the lifting conveyor 5. As a result, the transport vehicle 41 can move to a position in the first passage 4Y adjacent in the X direction to the lifting conveyor 5 and transfer the articles W between it and the lifting conveyor 5.
[0054] In this embodiment, as shown in Figures 3 and 4, a portion of the plurality of first passages 4Y extends at least from a position adjacent in the X direction to the storage area of the loading area 32 to a position adjacent in the X direction to the storage area of the second target area 35. For the sake of explanation, such first passages 4Y will be referred to as extended passages 8 hereafter. In the example shown in Figures 3 and 4, the extended passages 8 are a plurality of first passages 4Y located near the right and left sides of the page. The transport vehicle 41 moves to a position in the extended passage 8 adjacent in the X direction to the storage area of the second target area 35 and transfers the articles W between the transport vehicle and the storage area.
[0055] In this embodiment, as shown in Figures 4 and 5, some of the multiple first passages 4Y arranged in the target level 22 extend at least from a position adjacent in the X direction to the storage area of the loading area 32 to a position adjacent in the X direction to the storage area of the target area 33. For the sake of explanation, such first passages 4Y will be referred to as connecting passages 9 hereafter. In the example shown in Figures 4 and 5, the connecting passages 9 are multiple first passages 4Y arranged near the center of the page. The transport vehicle 41 transfers articles W between the target area 33 and the storage area of the target area 33 at a position in the connecting passages 9 adjacent in the X direction to the storage area of the target area 33. The connecting passages 9 illustrated in Figures 4 and 5 extend from a position adjacent in the X direction to the storage area of the loading area 32, through a position adjacent in the X direction to the lifting transport device 5, to a position adjacent in the X direction to the storage area of the target area 33. With this configuration, the transport vehicle 41 can easily transport the goods W efficiently between the loading area 32 and the target area 33 and the lifting transport device 5.
[0056] The second passage 4X intersects the first passage 4Y in the vertical Z-direction. In this embodiment, the second passage 4X is located second to the Y-direction Y2 from the lifting and transporting device 5 and extends in the X-direction. The second passage 4X connects at least two adjacent first passages 4Y in the X-direction. The second passage 4X illustrated in Figures 3 and 4 is connected to all first passages 4Y located on the same floor 2. With this configuration, it is easy to set the movement path of the transport vehicles 41 so that the goods W can be transported efficiently depending on the position of the transport vehicles 41 arranged around them and the status of goods W being loaded and unloaded.
[0057] As shown in Figures 1 and 5, the connecting passage 9 connects the target floor 22 of the first warehouse unit 1A and the target floor 22 of the second warehouse unit 1B. That is, the target floor 22 of the first warehouse unit 1A and the target floor 22 of the second warehouse unit 1B are connected to each other by the connecting passage 9. In this embodiment, the connecting passage 9 of the first warehouse unit 1A and the connecting passage 9 of the second warehouse unit 1B are connected. Therefore, the transport vehicle 41 can move back and forth between the connecting passage 9 of the first warehouse unit 1A and the connecting passage 9 of the second warehouse unit 1B.
[0058] In this embodiment, the transport passage 44 connects the first warehouse unit 1A and the second warehouse unit 1B at the same height target floor 22. In the example shown in Figure 5, the connecting passage 9 of the first warehouse unit 1A is connected to the connecting passage 9 of the second warehouse unit 1B, which is located on floor 2 at the same height as the connecting passage 9. More specifically, the connecting passage 9 of the first warehouse unit 1A is integrally structured with the connecting passage 9 of the second warehouse unit 1B, which is located on floor 2 at the same height as the connecting passage 9. This configuration makes it easier to simplify the structure of the connecting passage 9 for moving the transport vehicle 41 between the first warehouse unit 1A and the second warehouse unit 1B. Note that the connecting passage 9 may also connect target floors 22 at different heights in the first warehouse unit 1A and the second warehouse unit 1B.
[0059] The connecting passage 9 is positioned in a location that overlaps with the loading / unloading area 7 in a vertical Z-view. In this embodiment, in each of the target floors 22, the four connecting passages 9 located in each target floor 22 are positioned in the upper space of the loading / unloading system 6. At least a portion of each of the four connecting passages 9 is positioned in a location that overlaps with the first loading / unloading area 7A and the second loading / unloading area 7B in a vertical Z-view.
[0060] In the positional relationship with the first loading / unloading area 7A, the four connecting passages 9 exemplified in Figures 1 and 5 have, in a vertical Z-view, a portion of the two connecting passages 9 located at both ends in the X-direction overlap with the first loading / unloading area 7A. More specifically, the portions of these two connecting passages 9 that are away from the second target area 35 in the X-direction overlap with the first loading / unloading area 7A in a vertical Z-view. The remaining connecting passages 9 of the four connecting passages 9 have their entirety in the X-direction overlap with the first loading / unloading area 7A in a vertical Z-view.
[0061] Furthermore, in relation to the second loading / unloading area 7B, the four connecting passages 9 illustrated in Figures 1 and 5, when viewed vertically, have three connecting passages 9 located at positions away from the second target area 35 in the X direction (upwards from the plane of the paper), and their entirety in the X direction overlaps with the second loading / unloading area 7B. In the remaining connecting passage 9, a portion in the X direction overlaps with the second loading / unloading area 7B. In this connecting passage 9, the portion away from the second target area 35 in the X direction overlaps with the second loading / unloading area 7B when viewed vertically in the Z direction.
[0062] In this embodiment, of the four connecting passages 9, two connecting passages 9 located on both sides in the X direction are positioned so as not to overlap with the loading / unloading device 61 when viewed in the vertical Z direction. The remaining two connecting passages 9 are positioned so as to overlap with the loading / unloading device 61 when viewed in the vertical Z direction.
[0063] The connecting passage 9 includes rails that connect the first warehouse unit 1A and the second warehouse unit 1B. In this embodiment, the rails are laid along the connecting passage 9. The rails in this embodiment have a structure that supports the transport vehicle 41 from below and guides the direction of travel of the transport vehicle 41. Furthermore, in this embodiment, the transport passages 44 other than the connecting passage 9 are also constructed of rails.
[0064] In this embodiment, multiple transport vehicles 41 transport goods W by moving along a transport path set between the source and destination. The transport path is set on a first passage 4Y and a second passage 4X. The transport path of each transport vehicle 41 is set so as not to obstruct each other's passage, and so as to equalize the degree of overlap of the transport paths of each transport vehicle 41 and the load on each transport vehicle 41.
[0065] Each of the multiple transport vehicles 41 is equipped with a travel mechanism 42 and a transfer device 43, as shown in Figure 4 (bottom center as viewed from the page).
[0066] The running mechanism 42 comprises a chassis 421, a plurality of first wheels that roll on the first passage 4Y, and a plurality of second wheels that roll on rails laid along the second passage 4X. When the running mechanism 42 travels along the first passage 4Y, the plurality of second wheels roll with the rails laid along the second passage 4X separated from the rails laid along the second passage 4X, while the plurality of first wheels roll with the rails laid along the first passage 4Y in contact with the rails laid along the first passage 4Y. When the running mechanism 42 travels along the second passage 4X, the plurality of first wheels roll with the rails laid along the first passage 4Y separated from the rails laid along the first passage 4Y, while the plurality of second wheels roll with the rails laid along the second passage 4X in contact with the rails laid along the second passage 4X.
[0067] The transfer machine 43 comprises a loading section 431 on which the article W is placed, and a pair of arms 432 that extend and retract toward the storage area. The loading section 431 is a flat surface provided on the upper part of the chassis 421. The pair of arms 432 are installed on the upper part of the chassis 421 with the loading section 431 in between.
[0068] When moving an item W placed on top of the chassis 421 to the storage area, the pair of arms 432 extend toward the storage area with the item W hooked onto claws (not shown) protruding from each arm into the space on which the item W is placed. As a result, the item W moves from the placement section 431 to the storage area in conjunction with the movement of the claws protruding from each of the pair of arms 432. Conversely, let's describe the case where an item W stored in the storage area is moved onto the placement section 431. In this case, each of the pair of arms 432 is retracted from its extended state toward the storage area, with the item W hooked onto the claws protruding from each arm into the space on which the item W is placed. As a result, the item W moves from the storage area to the placement section 431 in conjunction with the movement of the pair of arms 432.
[0069] As shown in Figures 3 and 4, the lifting and transporting device 5 comprises a support column 51 extending in the vertical direction Z, a lifting platform 52 that moves up and down in the vertical direction Z along the support column 51, and a lifting and transferring machine that moves up and down together with the lifting platform 52. In this embodiment, multiple lifting and transporting devices 5 are arranged adjacent to each other in the X direction. As shown in Figure 3, on the base level 20, an inbound / outbound device 61 is arranged between each of the multiple lifting and transporting devices 5. Then, as shown in Figure 4, on levels 2 other than the base level 20, a first passage 4Y is arranged between each of the multiple lifting and transporting devices 5.
[0070] The lifting and transporting device 5 is positioned to allow the transfer of goods W between it and the loading / unloading device 61 and the tiered transporting device 4. The loading / unloading device 61 and the tiered transporting device 4 are positioned adjacent to the lifting and transporting device 5. In the example shown in Figure 3, the loading / unloading device 61 is positioned between two adjacent lifting and transporting devices 5 in the X direction. On the other hand, as shown in Figures 3 and 4, the tiered transporting device 4 has its first passage 4Y positioned adjacent to the lifting and transporting device 5 in the X direction. In the example shown in Figures 3 and 4, the second passage 4X is positioned adjacent to the second side of the lifting and transporting device 5 in the Y direction. With this configuration, it is easy to set a short travel path for the transport vehicle 41 to move from the storage area provided by the loading area 32, which is distributed in the X direction, to the lifting and transporting device 5.
[0071] The lifting platform 52 stops at a position in the vertical direction Z where it can transfer items W to each of the multiple transport vehicles 41 located on each of the multiple floor levels 2. The lifting transfer device moves the placed items W toward the transport vehicles 41. Examples of the lifting transfer device include conveyors and other transfer devices installed on the upper surface of the lifting platform 52. The lifting transfer device in this embodiment moves the items W to retrieve items W placed on the loading / unloading device 61 or to hand over items W to the loading / unloading device 61. For example, in the example shown in Figure 3, a lifting / unloading device 5, sandwiched on both sides in the X direction by other lifting / unloading devices 5, hands over items W that have been lifted and transported from floor levels 2 other than the reference floor level 20 to the loading / unloading device 61. The items W that have been handed over to the loading / unloading device 61 are transported to the loading / unloading position.
[0072] In this embodiment, the floor transport device 4 for the target floor 22 in the first warehouse unit 1A and the floor transport device 4 for the target floor 22 in the second warehouse unit 1B are capable of transporting goods W across the storage area 31 of the first warehouse unit 1A and the storage area 31 of the second warehouse unit 1B. In this embodiment, as described above, the connecting passage 9 connects the target floor 22 of the first warehouse unit 1A to the target floor 22 of the second warehouse unit 1B, which is at the same height as the target floor 22 of the first warehouse unit 1A. Therefore, the transport vehicle 41 located on the target floor 22 can travel back and forth between the first warehouse unit 1A and the second warehouse unit 1B by traveling along the connecting passage 9. With this configuration, as shown in Figure 6, goods W stored in the second warehouse unit 1B can be retrieved from the first inbound / outbound system 6A via the first passage 4Y located on the target floor 22.
[0073] [Other Embodiments] Next, other embodiments of the automated warehouse 100 will be described.
[0074] (1) In the above embodiment, the storage device 61, which is either the storage device 62 or the storage device 63, has been described. However, the storage device 61 may also serve as both the storage device 62 and the storage device 63.
[0075] (2) In the above embodiment, the receiving device 62 was described as a conveyor for receiving goods. However, the receiving device 62 may also be a transfer device that receives goods W from an automated guided vehicle or other transport vehicle 41 that transports goods W.
[0076] (3) In the above embodiment, the retrieval device 63 was described as a conveyor for retrieval. However, the retrieval device 63 may also be a transfer device that delivers the goods W to an automated guided vehicle or other transport vehicle 41 that transports the goods W.
[0077] (4) In the above embodiment, the automated warehouse 100 was described as transferring goods W between the lifting and transporting device 5 and the loading and unloading system 6. The transport passage 44 was described as connecting at least the position where the transport vehicle 41 transfers goods W between the storage area and the position where the transport vehicle 41 transfers goods W between the lifting and transporting device 5. However, the automated warehouse 100 may also be configured to transfer goods W between the loading and unloading system 6 and the tiered transporting device 4. In this case, the transport passage 44 is arranged, for example, to pass through the position where the transport vehicle 41 transfers goods W between the loading and unloading system 6.
[0078] (5) In the above embodiment, the transport vehicle 41 was described as comprising a transfer device 43 composed of a pair of arms 432. However, the transfer device 43 may also be a lifting device that raises and lowers a pallet on which a load is placed. Alternatively, the transfer device 43 may be a smaller cart that enters an area where a loading surface is installed and transfers the item W between the loading surface and the cart. In this case, the transport vehicle 41 becomes a larger cart that transports the smaller cart.
[0079] (6) In the above embodiment, the hierarchical transport device 4 was described as being configured to move the articles W only within each of the hierarchical levels 2. However, the hierarchical transport device 4 may be configured to move the articles W across multiple hierarchical levels 2.
[0080] (7) In the above embodiment, the target hierarchy 22 was described as all of the hierarchy 2 above and below the specific hierarchy 21. However, the target hierarchy 22 may consist of only a portion of the hierarchy 2 above and below the specific hierarchy 21.
[0081] (8) In the above embodiment, it was explained that the transport vehicle 41 travels back and forth between the first warehouse unit 1A and the second warehouse unit 1B via a connecting passage 9. However, the transport vehicle 41 does not necessarily have to travel back and forth between the first warehouse unit 1A and the second warehouse unit 1B. Instead, a transfer section may be provided for transferring goods W between the transport vehicle 41 located in the first warehouse unit 1A and the transport vehicle 41 located in the second warehouse unit 1B. The transfer section may be located, for example, at an intermediate point in the connecting passage 9. The transfer section may be configured, for example, as a platform on which goods W can be temporarily placed, and may be configured to allow the transfer of goods W between the transport vehicle 41 located in the first warehouse unit 1A and the transport vehicle 41 located in the second warehouse unit 1B.
[0082] (9) In the above embodiment, it was explained that the second target area 35 of one warehouse unit 1 is not connected to other warehouse units 1 and is arranged at a distance from other warehouse units 1. However, the second target area 35 of one warehouse unit 1 may be connected to other warehouse units 1.
[0083] (10) In the above embodiment, the transport passage 44 was described as having rails that support the transport vehicle 41 from below. However, the transport passage 44 may also have rails that suspend the transport vehicle 41 from above.
[0084] (11) The configurations disclosed in each of the embodiments described above can be applied in combination with configurations disclosed in other embodiments, as long as no inconsistencies arise. With regard to other configurations, the embodiments disclosed herein are merely illustrative in all respects. Therefore, various modifications can be made as appropriate without departing from the spirit of this disclosure.
[0085] [Summary of this embodiment] Below is a summary of the embodiment relating to the automated warehouse described above.
[0086] The automated warehouse comprises a warehouse unit having storage areas on multiple vertically arranged floors, each storage area having storage shelves capable of accommodating multiple items, a floor transport device for transporting items in each storage area, and a lifting transport device for transporting items vertically across the multiple floors; and an inbound / outbound area positioned at a height corresponding to a specific floor which is part of the multiple floors, where at least one of an inbound device for receiving items into the warehouse unit and an outbound device for retrieving items from the warehouse unit is located, wherein at least a part of a floor different from the specific floor is designated as the target floor, and the target area, which is part of the storage area of the target floor, is positioned to overlap with the inbound / outbound area when viewed vertically.
[0087] In this configuration, the target area, which is part of the storage area of the target floor, is located in the space above the loading / unloading area and overlapping with the loading / unloading device when viewed vertically. Therefore, compared to a configuration without the target area, a larger space can be secured for arranging the storage area of the storage shelves. In other words, the storage area can be expanded by utilizing the dead space caused by the arrangement of the loading / unloading area, thereby effectively utilizing the space that the automated warehouse can occupy and increasing the storage capacity of goods in the automated warehouse.
[0088] Here, the warehouse comprises a first warehouse unit and a second warehouse unit, wherein the specific floor of the first warehouse unit and the specific floor of the second warehouse unit are arranged opposite each other across the loading and unloading area, the target area of the first warehouse unit and the target area of the second warehouse unit are connected to each other, and the floor transport device located on the target floor of the first warehouse unit and the floor transport device located on the target floor of the second warehouse unit are preferably capable of transporting the articles across the storage area of the first warehouse unit and the storage area of the second warehouse unit.
[0089] This configuration allows for the transport of goods between the first and second warehouse units using a target area located in the dead space above the loading / unloading area, and a hierarchical transport device that transports goods within that target area. Therefore, the storage location of goods can be changed by moving them from one warehouse unit to the other. Furthermore, this configuration allows for the retrieval of goods stored in one warehouse unit from the loading / unloading area of the other warehouse unit, and for the retrieval of goods stored in one warehouse unit from the loading / unloading area of the other warehouse unit. Consequently, it is easier to increase the flexibility of operations related to the storage and loading / unloading of goods.
[0090] Furthermore, it is preferable that the directions that are orthogonal to each other in a vertical view are defined as the X direction and the Y direction, and that one side of the Y direction is defined as the first Y direction side, and that the loading / unloading area is positioned on the first Y direction side with respect to the warehouse unit, and that the loading / unloading area is positioned so as to overlap with a part of the X direction area of the specific floor in a Y direction view along the Y direction, and that the second target area, which is part of the storage area of the specific floor, is positioned so as not to overlap with the loading / unloading area in a Y direction view, but to overlap with the loading / unloading area in an X direction view along the X direction.
[0091] In this configuration, a second target area, which is part of the storage area of the target floor, is placed in a space that does not overlap with the loading / unloading area in the Y-direction view, but overlaps with the loading / unloading area in the X-direction view. Therefore, compared to a configuration without this second target area, a wider space can be secured for arranging the storage area of the storage shelves. In other words, the storage area can be expanded by utilizing the dead space that occurs at a position shifted in the X-direction relative to the loading / unloading area, thereby effectively utilizing the space that the automated warehouse can occupy and increasing the storage capacity of goods in the automated warehouse.
[0092] The technology relating to this disclosure can be used in an automated warehouse comprising a warehouse unit for storing goods and a storage / dispatch device for receiving and retrieving goods from the warehouse unit.
[0093] 1: Warehouse unit 1A: First warehouse unit 1B: Second warehouse unit 2: Floor 3: Storage rack 4: Floor transport device 5: Lifting transport device 7: Inbound / outbound area 21: Specific floor 22: Target floor 31: Storage area 33: Target area 35: Second target area 62: Inbound device 63: Outbound device 100: Automated warehouse W: Item Y1: First side in the Y direction Z: Up / down direction
Claims
1. An automated warehouse comprising: a warehouse unit having storage shelves with storage areas on multiple vertically aligned levels, each storage area capable of accommodating multiple items; a level transport device for transporting items in each storage area; and a lifting transport device for transporting items vertically across the multiple levels; and an inbound / outbound area positioned at a height corresponding to a specific level which is part of the multiple levels, and where at least one of an inbound device for receiving items into the warehouse unit and an outbound device for retrieving items from the warehouse unit is located, wherein at least a portion of the levels different from the specific level is designated as the target level, and the target area, which is part of the storage area of the target level, is positioned to overlap with the inbound / outbound area in a vertical view.
2. The automated warehouse according to claim 1, comprising a first warehouse unit and a second warehouse unit, wherein the specific floor of the first warehouse unit and the specific floor of the second warehouse unit are arranged opposite each other across the loading / unloading area, the target area of the first warehouse unit and the target area of the second warehouse unit are connected to each other, and the floor transport device located on the target floor of the first warehouse unit and the floor transport device located on the target floor of the second warehouse unit are capable of transporting the articles across the storage area of the first warehouse unit and the storage area of the second warehouse unit.
3. The automated warehouse according to claim 1 or 2, wherein the directions that are mutually orthogonal in a vertical view are defined as the X direction and the Y direction, and one side of the Y direction is defined as the first Y direction side, the loading and unloading area is positioned on the first Y direction side with respect to the warehouse unit, the loading and unloading area is positioned so as to overlap with a part of the X direction area of the specific floor in a Y direction view along the Y direction, and the second target area, which is part of the storage area of the specific floor, is positioned so as not to overlap with the loading and unloading area in a Y direction view, but to overlap with the loading and unloading area in an X direction view along the X direction.