JP2017064817A - Picking device and recover program - Google Patents

Abstract

PROBLEM TO BE SOLVED: To automatically reposit a commodity which has been erroneously picked.SOLUTION: A picking device (100) comprises: a robot (51) which picks a commodity in a commodity container in which there ae commodities which are planned to be located in a transportation container, and locates the picked commodity into the transportation container; an acquisition part (41) which acquires an image concerning the commodity container before and after picking; a specification part (41) which specifies a commodity, which has been erroneously picked, based on the image concerning the commodity container before and the after picking; and an indication part (49) which indicates the robot to execute a recovery operation for returning the erroneously picked commodity from the transportation container to the commodity container.SELECTED DRAWING: Figure 4

Description

  The present invention relates to a picking apparatus and a recovery program.

  Various proposals have been made on retry methods when picking objects cannot be picked in a picking system that picks up picking objects placed in a box by a robot (for example, Patent Documents 1 and 2).

JP 2001-179669 A JP 2010-069542 A

  However, in the prior art, a recovery method when a picking target is picked by mistake has not been sufficiently studied.

  In one aspect, an object of the present invention is to provide a picking apparatus and a recovery program that can automatically return an item picked in error.

  In one aspect, the picking device picks a product in a product container containing a product to be placed in a transport container, and places the picked product in the transport container, and before and after the picking. An acquisition unit that acquires an image related to the product container, a specifying unit that specifies an erroneously picked product based on the images related to the product container before and after the picking, and the erroneously picked product from the transport container An instruction unit for instructing the robot to perform a recovery operation to return the product container.

  As one aspect, a product picked in error can be automatically restored.

It is a figure showing roughly the composition of the goods picking device concerning one embodiment. Fig.2 (a)-FIG.2 (d) are the figures for demonstrating a distance image. It is a block diagram which shows an example of the hardware constitutions of a control apparatus. It is a functional block diagram of a control device. FIG. 5A and FIG. 5B are diagrams for explaining erroneous picking. It is a flowchart which shows the process performed by the control apparatus at the time of picking. Fig.7 (a)-FIG.7 (e) are the figures for demonstrating the process of FIG. It is a flowchart which shows the detail of the recovery process (step S50) of FIG. FIG. 9A to FIG. 9D are diagrams (No. 1) for explaining the restoration process. It is a figure for demonstrating a relative position. Fig.11 (a)-FIG.11 (d) are the figures (the 2) for demonstrating a recovery process. FIGS. 12A to 12D are views (No. 3) for explaining the recovery process. FIG. 13A and FIG. 13B are diagrams for explaining output of picking results.

  Hereinafter, an embodiment of a commodity picking apparatus will be described in detail with reference to FIGS.

  FIG. 1 is a diagram schematically illustrating a configuration of a product picking apparatus 100. As shown in FIG. 1, the product picking device 100 includes a processing device 30, a product placement line L <b> 10, a product delivery line L <b> 20, a finished container delivery device 80, an empty container supply device 20, and a finished container discharge conveyor C <b> 3. . The product picking apparatus 100 includes product supply lines L1 to L4.

  The processing device 30 controls the operation of each component so that the components of the product picking device 100 can cooperate and perform picking efficiently. Further, the product picking apparatus 100 notifies the number of products to be picked to the control device 40 provided in the product supply lines L1 to L4 described later.

  The product arrangement line L10 includes a plurality of container stop stations R1, R2, R3, and R4, a first transfer conveyor C1, and buffer stations B1, B2, and B3 along the transfer direction. The conveyance direction is arbitrary, but in the present embodiment, it is assumed to be the J direction shown in FIG. The product arrangement line L10 does not have to be a straight line, and may include a curve.

  The container stop stations R1, R2, R3, and R4 are places where the transport containers where the picked goods are arranged (stored) are stopped. A transport container is supplied to each of the container stop stations R1, R2, R3, and R4 by the first transport conveyor C1. A product container may be transferred from the corresponding product container station O1, O2, O3, O4 to each of the container stop stations R1, R2, R3, R4.

  The first transport conveyor C1 is, for example, a belt conveyor or a roller conveyor. As shown in FIG. 1, the first conveyor C1 is provided between each station in the product arrangement line L10. Moreover, the 1st conveyance conveyor C1 is provided between the empty container supply apparatus 20 and the most upstream container stop station R1, as shown in FIG.

  Each first conveyor C <b> 1 operates independently of each other under the control of the processing device 30. The 1st conveyance conveyor C1 between each station conveys the conveyance container on each station to the downstream station. Moreover, the 1st conveyance conveyor C1 between the empty container supply apparatus 20 and the uppermost container stop station R1 conveys the empty conveyance container from the empty container supply apparatus 20 to the container stop station R1. The transport container may have any configuration, and may be formed of any material such as plastic or paper.

  In addition, you may form each 1st conveyance conveyor C1 by arranging the roller conveyor which has a rotating shaft in a K direction continuously in a J direction including each station. In this case, each station is formed by stopping the roller conveyor in the corresponding area.

  For example, one buffer station B1, B2, and B3 is provided between the container stop stations R1, R2, R3, and R4, and a transport container is supplied by the first transport conveyor C1. However, in the buffer stations B1, B2, and B3, the placement of the product in the transport container is not executed.

  The product delivery line L20 is provided in parallel with the product arrangement line L10. That is, the product payout line L20 is arranged side by side in the K direction at a position away from the product arrangement line L10 by a predetermined distance. In this embodiment, as shown in FIG. 1, the K direction is a direction perpendicular to the transport direction. The product payout line L20 need not be parallel to the product placement line L10, and may have a shape including a curve or the like.

  The product delivery line L20 includes a plurality of completed container receiving stations S1, S2, S3, and S4, a second transport conveyor C2, and buffer stations B4, B5, and B6 along the transport direction.

  The completed container receiving stations S1, S2, S3, and S4 are provided in association with the container stop stations R1, R2, R3, and R4 in the product arrangement line L10. The transport containers on the corresponding container stop stations R1, R2, R3, R4 are discharged to the completed container receiving stations S1, S2, S3, S4, respectively. For example, the transport container on the container stop station R1 is discharged to the completed container receiving station S1 by the completed container discharge conveyor C3. This discharge is executed when all the planned products are placed in the transport container, that is, when the last product has been placed in the transport container. Therefore, the transport container in which the last product is arranged at the container stop station R1 is discharged from the container stop station R1 to the finished container receiving station S1. On the other hand, the transport container in which the last product is arranged at the container stop station R4 is discharged from the container stop station R4 to the finished container receiving station S4.

  Similar to the first transport conveyor C1, the second transport conveyor C2 is, for example, a belt conveyor or a roller conveyor, and is provided between each station in the product delivery line L20. The second transfer conveyor C2 is provided between the most downstream completed container receiving station S4 and the completed container delivery device 80.

  Further, the second transport conveyor C2 has the same transport direction as the transport direction of the first transport conveyor C1. In the example shown in FIG. 1, the second transport conveyor C2 transports a transport container in the J direction. The second conveyor C2 may extend to the downstream side of the product arrangement line L10.

  Each second transport conveyor C2 operates independently of each other under the control of the processing device 30. The 2nd conveyance conveyor C2 between each station conveys the conveyance container on each station to one downstream station. The second transfer conveyor C2 between the most downstream completed container receiving station S4 and the completed container unloading apparatus 80 conveys the transfer container on the completed container receiving station S4 to the complete container unloading apparatus 80.

  In addition, you may form each 2nd conveyance conveyor C2 by arranging a plurality of roller conveyors which have a rotating shaft in a K direction continuously in a J direction including each station. In this case, each station is formed by stopping the roller conveyor in the corresponding area.

  As shown in FIG. 1, the completed container delivery device 80 is disposed on the downstream side of the product delivery line L20. The transport containers on the product delivery line L20 are sequentially delivered to the completed container delivery device 80 one by one.

  The empty container supply device 20 is arranged on the upstream side of the product arrangement line L10. The empty container supply device 20 supplies empty conveyance containers one by one to the product arrangement line L10 under the control of the processing device 30. The empty transport container supplied by the empty container supply device 20 is moved to the container stop station R1 by the first transport conveyor C1.

  The completed container discharge conveyor C3 is provided in association with each of the container stop stations R1, R2, R3, R4. Each completed container discharge conveyor C3 controls the processing apparatus 30 to transfer the conveyance containers on the corresponding container stop stations R1, R2, R3, R4 to the corresponding completed container receiving stations S1, S2, S3, S4 in the K direction. To discharge.

  The product supply lines L1 to L4 include product container stations O1, O2, O3, and O4, respectively. Each of the product supply lines L1 to L4 includes a remaining number picking conveyor C4, a robot 51, a distance sensor 71, a distance sensor 72, and a control device 40.

  The product container stations O1, O2, O3, and O4 are provided in association with the container stop stations R1, R2, R3, and R4, respectively. In the product container stations O1, O2, O3, and O4, product containers containing the products to be picked are arranged. In the example shown in FIG. 1, the product containers on the product container stations O1, O2, O3, and O4 are transferred from the corresponding stock product container stations P1, P2, P3, and P4 by the conveyor C5. The types of products in the product containers arranged at the product container stations O1, O2, O3, and O4 may be different or the same. Note that stock product containers are transferred from the product container supply device 82 to the stock product container stations P1, P2, P3, and P4 by the conveyor C6. In addition, although the goods in a goods container are arbitrary, in this embodiment, suppose that it is the goods (for example, bread) packed in a bag.

  The remaining number picking conveyor C4 is provided in association with each of the container stop stations R1, R2, R3, R4 (and the product container stations O1, O2, O3, O4). The remaining number picking conveyor C4 is provided between the container stop station R1 and the product container station O1, and between the container stop station R2 and the product container station O2. The remaining number picking conveyor C4 is provided between the container stop station R3 and the commodity container station O3 and between the container stop station R4 and the commodity container station O4.

  The remaining number picking conveyor C4 transfers the product containers on the corresponding product container stations O1, O2, O3, and O4 to the corresponding container stop stations R1, R2, R3, and R4 under the control of the processing device 30. Hereinafter, such transfer by the remaining number picking conveyor C4 is also referred to as “remaining number picking”. In this way, the commodity containers transferred onto the container stop stations R1, R2, R3, and R4 by the remaining number picking conveyor C4 become transport containers after the transfer. Accordingly, the product containers transferred onto the container stop stations R1, R2, R3, and R4 by the remaining number picking conveyor C4 are discharged to the finished container unloading device 80 via the product discharge line L20 as a transfer container after the transfer. It will be. Therefore, the product container has the same configuration as the transport container.

  In addition, the remaining number picking conveyor C4 includes a plurality of roller conveyors having a rotation axis in the J direction continuously in the K direction, including the corresponding conveyors C5 and C6, and the corresponding product container stations and stock product container stations. You may form by arranging. In this case, the merchandise container station and the stock merchandise container station are formed by stopping the roller conveyor in the corresponding area.

  The distance sensor 71 is provided for each of the commodity container stations O1, O2, O3, and O4. The distance sensor 71 is installed near the center of the product arrangement range of the product container CA20, for example, as shown in FIGS. 2 (a) to 2 (c). For example, as shown in FIG. 2A, the distance sensor 71 is a distance in a predetermined product arrangement range of the product container CA20 arranged on the product container stations O1, O2, O3, and O4 from above the product container CA20. Information (hereinafter referred to as “distance information”). The distance information is distance information in the Z-axis direction when the bottom surface of the product container CA20 is the XY plane. For example, the distance information represents the distance from the bottom surface of the product container CA20 with reference to the bottom surface of the product container CA20 (the surface in contact with the lower surface of the product G). That is, when the product G is arranged in a predetermined product arrangement range of the product container CA20, the distance information is information regarding the height of the product G. The reference of the distance information may be other than the bottom surface of the product container CA20. The distance sensor 71 acquires distance information at a plurality of points along each of the X-axis direction and the Y-axis direction, and generates, for example, a distance image shown in FIG. 2D based on the distance information. As shown in FIG. 2D, in the distance image, the product container and each product placed in the product container can be confirmed. The distance sensor 71 outputs the generated distance image to the control device 40.

  Returning to FIG. 1, a distance sensor 72 is provided for each of the stock commodity container stations P1, P2, P3, P4. Similar to the distance sensor 71, the distance sensor 72 is distance information in a predetermined product arrangement range of the product containers arranged on the stock product container stations P1, P2, P3, and P4, that is, a product arranged in the product container. Get information about the height of the. The distance sensor 72 acquires distance information at a plurality of points along each of the X-axis direction and the Y-axis direction, and generates a distance image based on the distance information. The distance sensor 72 outputs the generated distance image to the control device 40.

  The robot 51 is provided corresponding to each of the product container stations O1, O2, O3, and O4. The robot 51 operates under the control of the control device 40. The robot 51 picks the products in the product containers on the corresponding product container stations O1, O2, O3, and O4. Although the product picking method is arbitrary, in this embodiment, the robot 51 is assumed to pick the product by suction.

  Further, the robot 51 places (puts) the picked goods in the transfer containers on the corresponding container stop stations R1, R2, R3, R4. For example, the robot 51 picks the product in the product container on the product container station O1, and places the picked product in the transport container on the container stop station R1. Hereinafter, such a series of operations is also referred to as “normal picking”. In FIG. 1, normal picking is schematically indicated by an arrow Y1.

  Note that the normal picking by the robot 51 is executed a number of times corresponding to the number of products (picking quantity) scheduled to be put in the transport container. In the present embodiment, it is assumed that the robot 51 can arrange two products by one normal picking. Therefore, for example, when five products are put into the transport container at the container stop station R1, the robot 51 performs normal picking three times (2 + 2 + 1). However, the robot 51 may have a configuration in which one product is arranged by one normal picking or a configuration in which three or more products can be arranged.

  Further, the robot 51 picks the products in the product containers on the corresponding stock product container stations P1, P2, P3, and P4 in a predetermined case. Then, the robot 51 places the picked products in the transport containers (product containers) on the corresponding container stop stations R1, R2, R3, R4. Hereinafter, such a series of operations is also referred to as “replenishment picking”. In FIG. 1, supplementary picking is schematically indicated by an arrow Y2. The replenishment picking is executed along with the remaining number picking by the remaining number picking conveyor C4. In other words, in the replenishment picking, the same type of product as the product in the product container is picked up with respect to the picking quantity in the product container transferred onto the container stop stations R1, R2, R3, R4 by the remaining number picking conveyor C4. This is an operation of arranging the missing number. Replenishment picking is performed subsequent to the remaining number picking. The product containers on the stock product container stations P1, P2, P3, and P4 picked up by replenishment picking are transferred onto the product container stations O1, O2, O3, and O4 by the conveyor C5 after the first picking.

  When the control device 40 receives the number of products to be picked from the processing device 30, the control device 40 controls the robot 51 so that the number of products is arranged in the transport container. The control device 40 has a hardware configuration as shown in FIG. Specifically, as shown in FIG. 3, the control device 40 includes a CPU (Central Processing Unit) 411, a ROM (Read Only Memory) 412, a RAM (Random Access Memory) 413, and a storage device (HDD: Hard Disk Drive). 414, a network interface 415, and a portable storage medium drive 417 that can read data stored in the portable storage medium 416. Each component of the control device 40 is connected to the bus 418. The CPU 411 executes the program (including the recovery program) stored in the ROM 412 or the HDD 414 or the program read by the portable storage medium drive 417 from the portable storage medium 416, thereby controlling the control device 40 of FIG. It functions as each part.

  Specifically, as illustrated in FIG. 4, when the CPU 411 executes the program, the control device 40 serves as an acquisition unit, an erroneous picking determination unit 41 as a specific unit, an instruction unit, a calculation unit, and an output unit. Functions as a recovery processing unit 49.

  The erroneous picking determination unit 41 acquires distance images before and after picking by the robot 51 from the distance sensor 71 or the distance sensor 72. Based on the acquired distance images before and after picking, the erroneous picking determination unit 41 determines whether there is an erroneously picked product (a product that was picked unintentionally), that is, an erroneous picking of the product has occurred. Determine whether or not. Further, when the erroneous picking determination unit 41 determines that erroneous picking has occurred, the erroneous picking determination unit 41 identifies an erroneously picked product based on the distance images before and after the picking.

  Here, erroneous picking of a product will be described with reference to FIGS. 5 (a) and 5 (b). Fig.5 (a) and FIG.5 (b) are the schematic diagrams which looked at the goods arrange | positioned in the goods container from the side. As shown in FIG. 5A, the product 1 packaged in the bag PC1 and the product 2 packaged in the bag PC2 are arranged side by side in the product container. Here, in FIG. 5A, a part of the bag PC2 of the product 2 (for example, the end of the bag) due to the reason that the product 2 is biased to one side of the bag PC2 or the bag PC2 is too large with respect to the product 2. ) Is overlaid on product 1. If the product 1 is picked by suction in such a state, as shown in FIG. 5B, not only the product 1 to be picked but also the bag PC2 that overlaps the product 1 is sucked. 1 and product 2 are picked together. This is false picking.

  The erroneous picking occurs because it is difficult to recognize the bag containing the product in the distance image. The control device 40 recognizes the arrangement of the product in the product container based on the distance image acquired from the distance sensor 71 or 72, determines the picking position of the product, and notifies the robot 51 of it. At this time, if the bag into which the product is placed is transparent, the light from the distance sensors 71 and 72 passes through the bag, so that the bag cannot be recognized. Therefore, the bag containing the product is not recognized in the distance image, and it is difficult to perform picking while avoiding the bag overlapping the product to be picked. When erroneous picking occurs, an incorrect number of products are placed in the transport container, and thus it is necessary to manually correct the number of the products before shipment.

  Therefore, in the present embodiment, the erroneous picking determination unit 41 determines whether or not erroneous picking has occurred. If erroneous picking has occurred, the robot 51 removes the erroneously picked product from the transport container. Perform recovery processing to return to the product container.

  Specifically, the recovery processing unit 49 instructs the robot 51 to return the erroneously picked product specified by the erroneous picking determination unit 41 from the inside of the transport container to the product container. The restoration process will be described in detail with reference to the flowcharts of FIGS.

  FIG. 6 is a flowchart showing processing executed in the control device 40 when picking a product. The process of FIG. 6 is executed each time the control device 40 instructs the robot 51 to pick a product. For example, when the picking quantity notified from the processing device 30 is 5, the control device 40 first instructs the robot 51 to pick two products from the product container into the transport container. After the instruction, the process of FIG. 6 is executed. When the process of FIG. 6 is completed, the control device 40 also instructs the robot 51 to pick the two products from the product container into the transport container, and executes the process of FIG. After that, when the control device 40 instructs the robot to pick one product from the product container into the transport container, the control device 40 executes the process of FIG.

  In the process of FIG. 6, first, in step S11, the erroneous picking determination unit 41 of the control device 40 is configured so that the picking instructed by the robot 51 places the product in the product container on the product container station in the transport container. It is determined whether or not it is picking. For example, as shown in FIG. 7 (a), the picking instruction to the robot 51 is picking to place the product 1 and the product 2 from the product container CA20 on the product container station O1 into the transport container CA10 on the container stop station R1. If it is an instruction, the erroneous picking determination unit 41 determines that the picking is normal picking, and proceeds to step S13.

  When the process proceeds to step S <b> 13, the erroneous picking determination unit 41 acquires a distance image (a distance image before picking) of the product container on the product container station from the distance sensor 71. For example, the distance image illustrated in FIG. 7B is acquired by the erroneous picking determination unit 41 as the distance image before picking.

  In subsequent step S <b> 15, the erroneous picking determination unit 41 stands by until the robot 51 performs picking. Then, when picking is executed by the robot 51, the process proceeds to step S17.

  When the process proceeds to step S <b> 17, the erroneous picking determination unit 41 acquires a distance image of the product container on the product container station (distance image after picking) from the distance sensor 71. Here, as illustrated in FIG. 7C, it is assumed that the robot 51 picks the products 1 to 3 in response to the picking instructions for the products 1 and 2 and arranges them in the transport container. In this case, for example, the distance image illustrated in FIG. 7D is acquired by the erroneous picking determination unit 41 as a distance image after picking.

  In subsequent step S19, the erroneous picking determination unit 41 determines whether an incorrect product is picked based on the distance images before and after picking, that is, whether erroneous picking has occurred. The erroneous picking determination unit 41, for example, the normal remaining quantity obtained by subtracting the number of products scheduled to be picked up (the number of pickings scheduled) from the number of products recognized from the pre-picking distance image, and the products recognized from the distance image after picking. It is determined whether or not the number (actual remaining quantity) is equal. For example, in FIG. 7A, when the picking of the product 1 and the product 2 is instructed, the planned number of picking is 2. At this time, the number of products before picking recognized from the distance image before picking (FIG. 7B) is 16, and the number of products after picking recognized from the distance image after picking (FIG. 7D). Is thirteen. In this case, since the regular remaining quantity 14 (16-2) is different from the actual remaining quantity 13, the erroneous picking determination unit 41 determines that erroneous picking has occurred, and proceeds to step S50. On the other hand, if the normal remaining quantity and the actual remaining quantity are equal, the erroneous picking determination unit 41 determines that no erroneous picking has occurred, and proceeds to step S60. In this step, the erroneous picking determination unit 41 calculates the number obtained by subtracting the actual remaining quantity from the regular remaining quantity, that is, the number of mispickled products (hereinafter referred to as the number of erroneous picking).

  By the way, if the picking instructed to the robot 51 is not normal picking in step S11, that is, if the determination in step S11 is negative, the process proceeds to step S31. For example, as shown in FIG. 7E, picking instructed by the robot 51 picks a product in the product container CA20 on the stock product container station P1, and transports the picked product on the container stop station R1. When it is replenishment picking arrange | positioned in container (commodity container) CA10, it transfers to step S31.

  In step S31, the erroneous picking determination unit 41 acquires a distance image (a distance image before picking) of the product container on the stock product container station from the distance sensor 72.

  In subsequent step S <b> 33, the erroneous picking determination unit 41 stands by until the robot 51 performs picking. Then, when picking is executed by the robot 51, the process proceeds to step S35.

  In step S <b> 35, the erroneous picking determination unit 41 acquires a distance image (distance image after picking) of the product container on the stock product container station from the distance sensor 72.

  In subsequent step S37, the erroneous picking determination unit 41 determines whether or not an erroneous product has been picked based on the distance images before and after picking, that is, whether or not erroneous picking has occurred, as in step S19. to decide. If the determination is negative, the process proceeds to step S60. If the determination is positive, the process proceeds to step S50. In this step, the erroneous picking determination unit 41 calculates the number obtained by subtracting the actual remaining quantity from the normal remaining quantity, that is, the number of erroneous picking.

(Recovery processing: Step S50)
Here, the details of the recovery processing in step S50 in FIG. 6 will be described with reference to the flowchart in FIG.

  In the process of FIG. 8, first, in step S503, the erroneous picking determination unit 41 identifies an erroneously picked product based on the distance images before and after picking. For example, as shown in FIG. 9A, it is assumed that the product 3 is also picked in response to the picking instructions for the products 1 and 2. The erroneous picking determination unit 41 is picked using a comparison image (FIG. 9D) that compares the distance image before picking (FIG. 9B) and the distance image after picking (FIG. 9C). Product Then, the erroneous picking determination unit 41 identifies, among the picked products, the products 3 other than the products 1 and 2 that are targets of picking as the products that have been picked erroneously.

  In subsequent step S505, the restoration processing unit 49 calculates the relative position of the erroneously picked product with respect to the correctly picked product based on the distance image before picking. For example, the recovery processing unit 49 obtains the relative position of the product 3 that has been picked in error with respect to the product 2 that has been picked correctly based on the distance image before picking. Here, it is assumed that the positional relationship between the products 2 and 3 in the pre-picking distance image is as shown in FIG. In this case, the restoration processing unit 49 first obtains the centers of the products 2 and 3 using the pre-picking distance image. Then, the restoration processing unit 49 calculates the difference in the X direction and the difference in the Y direction between the position (coordinate) of the origin and the position (coordinate) of the center of the product 3 with the center of the product 2 as the origin. In the example of FIG. 10, the center of the product 3 is located at −100 mm in the X direction and +10 mm in the Y direction from the center of the product 2. Therefore, for example, the restoration processing unit 49 calculates the relative position as (−100 mm, +10 mm).

  In the subsequent step S507, the restoration processing unit 49 instructs the robot 51 to perform a restoration operation for returning the merchandise incorrectly placed in the transport container to the merchandise container. At this time, the recovery processing unit 49 notifies the robot 51 of the relative position calculated in step S505. The robot 51 is stopped at the position where the commodity is arranged in the transport container after the picking is executed. Therefore, the robot 51 picks the product in the transport container with the position moved by the relative position from the current position as the picking position. Therefore, it is necessary to return the robot 51 to a predetermined position such as the origin position or to calculate the difference between the current position and the picking position in the X direction and the Y direction as compared with the case where the picking position is specified as an absolute position. Since there is no, the time required for the recovery work can be shortened.

  In the case of normal picking, the recovery processing unit 49 notifies the robot 51 of the position in the product container on the product container station as a return destination of the product picked by mistake. On the other hand, in the case of replenishment picking, the commodity containers on the stock commodity container station are transferred to the commodity container station after the first picking. Therefore, the recovery processing unit 49 notifies the robot 51 of the position in the product container on the product container station, not the position in the product container on the stock product container station, as the return destination of the product picked by mistake. .

  In subsequent step S509, the recovery processing unit 49 stands by until the recovery work is executed. Then, when the robot 51 performs the restoration work, the process proceeds to step S511.

  If transfering it to step S511, the recovery process part 49 will acquire the distance image (distance image after recovery work) of the product container on a product container station.

  In subsequent step S513, the restoration processing unit 49 determines whether or not the restoration work has been successful based on the distance image after picking and the distance image after restoration work. In the present embodiment, the restoration processing unit 49 has a difference of 1 between the number of products in the product container recognized from the distance image after picking and the number of products in the product container recognized from the distance image after restoration work. If there is, it is determined that the recovery operation is successful. For example, as shown in FIG. 11A, in response to the picking instructions for the products 1 and 2, the product 3 is erroneously picked, and the product 3 is returned from the transport container to the product container by the recovery operation. Suppose that it was made (FIG.11 (b)). In this case, the recovery processing unit 49 determines the number of products in the product container (13) recognized from the post-picking distance image shown in FIG. 11C and the post-recovery distance image shown in FIG. Since the difference from the number of recognized merchandise in the merchandise container (14) is 1, it is determined that the recovery operation has been successful, and the process proceeds to step S515.

  When the process proceeds to step S515, the recovery processing unit 49 decreases the number of erroneous picking by 1, and the process proceeds to step S521.

  In step S521, the recovery processing unit 49 determines whether the number of erroneous picking is greater than zero. When the determination here is negative, the recovery processing unit 49 ends the recovery processing and proceeds to step S60 in FIG. For example, in the example of erroneous picking shown in FIG. 11A, since the number of erroneous pickings at the start of the recovery process is 1, when the process of step S515 is executed, the number of erroneous pickings becomes 0. Therefore, the determination in subsequent step S521 is denied, and the recovery processing unit 49 ends the recovery processing and proceeds to step S60 in FIG.

  On the other hand, when the number of erroneous picking is greater than 0, that is, when the determination in step S521 is affirmed, the recovery processing unit 49 returns to step S503. For example, the picking instruction to the robot 51 is a picking instruction to place the products 1 and 2 from the product container CA20 on the product container station O1 shown in FIG. 12A in the transport container CA10 on the container stop station R1. Suppose. At this time, as shown in FIG. 12B, if the product 5 and the product 6 are picked by mistake and placed in the transport container CA10 together with the product 1 and the product 2, the number of erroneous picking is 2. In this case, the recovery processing unit 49 first identifies the product 5 as the mis-picked product (step S503), and executes the processes of steps S505 to S511. Here, as shown in FIG. 12C, when the product 5 is successfully returned from the transport container CA10 to the product container CA20 (step S513 / YES), the number of erroneous pickings is changed from 2 to 1 in step S515. But is greater than zero. Accordingly, the determination in the subsequent step S521 is affirmed, and the recovery processing unit 49 returns to step S503, and this time specifies the product 6 as a product that has been picked incorrectly. Thereafter, the recovery processing unit 49 executes the processes of steps S505 to S511. Then, as shown in FIG. 12D, when the product 6 is successfully returned from the transport container CA10 to the product container CA20 (step S513 / YES), the number of erroneous pickings is changed from 1 to 0 in step S515. The In this case, since the determination in subsequent step S521 is denied, the recovery processing unit 49 ends the recovery processing in FIG. 8 and proceeds to step S60 in FIG.

  By the way, when judgment of step S513 is denied, ie, when restoration work fails, the restoration process part 49 transfers to step S517.

  In step S517, the recovery processing unit 49 determines whether the number of executions of the recovery work exceeds a predetermined number (for example, 5 times). When judgment here is denied, it transfers to step S519.

  In step S519, the recovery processing unit 49 instructs the robot 51 to pick the product in the transport container at the new picking position and perform the recovery operation (retry) again, and the process proceeds to step S509. For example, the restoration processing unit 49 instructs to pick the product in the transport container at a position shifted from the current position by a predetermined distance (for example, −10 mm or the like) in the X direction and the Y direction. The new picking position may be a position shifted by the same distance in the X direction and the Y direction from the current position, or may be a position shifted by a different distance. If the new picking position exceeds the movable range of the robot 51, the limit value of the movable range may be specified.

  On the other hand, when the determination in step S517 is affirmed, that is, when the number of executions of the recovery work exceeds a predetermined number (for example, 5 times), the recovery processing unit 49 ends the recovery processing of FIG. Control proceeds to step S60 in FIG.

  Returning to step S60 in FIG. 6, the recovery processing unit 49 records the number of products actually picked in response to the picking instruction (actual picking number) in a storage medium such as the HDD 414 or the RAM 413, for example. The whole process of is terminated. For example, the recovery processing unit 49 records the actual picking number in the picking result management table shown in FIG. 13A stored in a storage medium such as the HDD 414 or the RAM 413.

  As shown in FIG. 13A, the picking record management table includes, for example, fields of store, order number, container ID, actual pick number, planned remaining number in the product container after picking, and actual remaining number in the product container after picking. Prepare. In the store field, the name of the store that ordered the item to be picked is stored. The number of products ordered from the store is stored in the order quantity field. The container ID field stores an identification number for uniquely identifying the transport container in which the picked goods are arranged. The actual pick number field stores the number of products actually picked. The field of the expected remaining number in the product container after picking stores the number of products that should remain in the product container after picking. The actual number of items remaining in the product container after picking field stores the number of products actually remaining in the product container after picking.

  For example, it is assumed that the number of products in the product container before picking is 16. In this case, according to the picking record management table of FIG. 13A, the actual pick number is 4 for the order received from the store AA (order number: 4). The planned remaining number and the actual remaining number of 12 coincide with each other. For subsequent orders from store BB (number of orders: 3), erroneous picking occurred and recovery work and retry were not successful, so the actual number of picks was 4, and the product container after picking The actual remaining number is 8 with respect to the planned remaining number 9. Here, a product that should be picked in response to an order received from the store CC has already been picked in error by picking an order received from the store BB. Therefore, for ordering of the store CC (number of orders: 2), one less than the number of orders is picked.

  Based on the picking result management table in FIG. 13A, the recovery processing unit 49, for example, as shown in FIG. 13B, the transport container (excess container ID) in which the products are arranged in excess of the number of orders. Then, due to erroneous picking, the product is output in association with a transport container (shortage container ID) in which the product is arranged to be smaller than the order. For example, the restoration processing unit 49 may output the form shown in FIG. 13B by printing, or may display the form on a display device such as a display. The recovery processing unit 49 may output the form shown in FIG. 13B every predetermined time (for example, every hour) or according to an output instruction from the user. An operator who confirms the product in the transport container can remove the product from the transport container or use the form so that the number of products placed in the transport container matches the number of orders. It is possible to quickly carry out recovery work such as adding goods to the inside.

  As described above in detail, according to the present embodiment, the product picking apparatus 100 picks a product in a product container containing a product to be arranged in the transport container, and places the picked product in the transport container. A distance image of the product container before and after picking, and an erroneous picking determination unit 41 that identifies an erroneously picked product based on the distance image before and after picking, and the erroneously picked A recovery processing unit 49 that instructs the robot 51 to return the product from the transport container to the product container. Thereby, the goods picked by mistake can be automatically returned to the original goods container. That is, even if an accidentally picked product is placed in the transport container, the robot 51 performs a recovery operation to return the erroneously picked product from the transport container to the product container. The probability that a product is placed increases. Therefore, it is possible to reduce the number of workers who perform operations for removing or adding products that are excessively or underexposed due to erroneous picking. Moreover, since the erroneous picking determination unit 41 acquires the distance image of the product container, it is not necessary to install a distance sensor on the transport container side. Thereby, the cost of the product picking apparatus 100 can be reduced.

  Further, according to the present embodiment, the recovery processing unit 49 calculates the relative position of the product picked in error with respect to the correctly picked product based on the distance image before picking (S505), and calculates the relative position. The robot 51 is notified (S507). As a result, the robot 51 only needs to move by the relative position from the current position in order to pick a product that has been picked in the transport container, so that the moving distance can be shortened and the time required for the restoration work can be shortened. can do. Further, it is necessary to return the robot 51 to a predetermined position such as the origin position, or to calculate the difference between the current position and the picking position in the X direction and the Y direction, compared with the case where the picking position is specified as an absolute position. Since there is no, the time required for the recovery work can be shortened.

  Further, according to the present embodiment, the erroneous picking determination unit 41 acquires an image related to the product container every time the robot 51 places the product in the product container in the transport container (S17, S35). It can be confirmed whether or not the correct number of products are arranged in the transport container.

  Further, according to the present embodiment, the recovery processing unit 49 acquires a distance image after the robot 51 performs a recovery operation for returning the product picked by mistake from the transport container to the product container (S511), and after picking Based on the distance image and the distance image after the restoration work, it is determined whether or not the product picked in error has been returned from the transport container to the product container (S513). Specifically, the restoration processing unit 49 determines that the difference between the number of products in the product container recognized from the post-picking distance image and the number of products in the product container recognized from the post-recovery distance image is 1. If there is, it is determined that the recovery operation is successful. Thereby, the success or failure of the recovery work can be determined with a simple configuration.

  Further, according to the present embodiment, when it is determined that the product picked by mistake has not been returned from the transport container to the product container, the recovery processing unit 49 sets the picking position of the product picked by mistake to the previous time. The robot 51 is instructed to execute the recovery operation again as a position moved by a predetermined distance from the picking position (S519). As a result, if the recovery operation is not successful, the picking position is changed and the recovery operation is performed again, so that the probability that an accidentally picked product is returned to the product container is increased.

  Further, according to the present embodiment, the restoration processing unit 49, when the product picked in error is not returned from the transport container to the product container, the information on the transport container in which more products are arranged than planned, For picking, the information of the transport container in which the merchandise is arranged less than planned is output in correspondence (FIG. 13B). As a result, an operator confirming the product in the transport container can remove the product from the transport container or place the product in the transport container so that the number of products placed in the transport container matches the number of orders. Recovery work to be added can be performed quickly.

  Further, according to the present embodiment, the robot 51 picks a product by suction. Since picking by suction is less likely to fail than picking by gripping or the like, the picking operation can be performed efficiently.

  Moreover, according to the present embodiment, the product is a packaged product. In particular, when a product bag is transparent, it cannot be recognized by a distance sensor, and is difficult to recognize even in an image taken using a camera or the like. Therefore, even if a part of a bag of another product overlaps the product to be picked, it is difficult to recognize the bag, and erroneous picking is likely to occur. According to the product picking apparatus 100 of the present embodiment, even if the product is packed in a bag, it is determined whether or not erroneous picking has occurred based on the distance images before and after picking. Since the restoration work for returning the product from the transport container to the product container is performed, the probability that the correct number of products are arranged in the transport container is increased.

  In addition, according to the present embodiment, the commodity picking apparatus 100 recovers when the commodity container is transferred from the stock commodity container stations P1 to P4 to the commodity container stations O1 to O4 after the first picking in the replenishment picking. The processing unit 49 instructs the robot 51 to return the product picked in error from the transport container to the product container transferred to the product container stations O1 to O4. Thereby, since the distance until the goods picked by mistake are conveyed from a conveyance container to a goods container becomes short, the time which a recovery operation requires can be shortened.

  In the above-described embodiment, the determination of whether or not erroneous picking has occurred and the identification of an erroneously picked product have been performed using the distance image, but the present invention is not limited to this. For example, an image captured by a camera is used. It may be used. In this case, the product in the product container can be recognized by performing pattern matching on the image captured by the camera. However, when using an image captured by a camera, a sample image of a product is required for pattern matching. When the replacement of products frequently occurs, the registration work of sample images of products is complicated, and the operation load of the system becomes high. Therefore, it is preferable to use a distance image as in the above embodiment. This is because a sample image for pattern matching is unnecessary and the operation load of the system can be reduced.

  In the above embodiment, the erroneous picking determination unit 41 determines the normal remaining quantity obtained by subtracting the number of products to be picked from the number of products recognized from the pre-picking distance image, and the product recognized from the distance image after picking. Although it has been determined whether or not erroneous picking has occurred by determining whether or not the number (actual remaining quantity) is equal, it is not limited to this. For example, the erroneous picking determination unit 41 determines that the number of products recognized from the pre-picking distance image minus the number of products recognized from the post-picking distance image (difference in the number of products before and after picking) is the picking schedule. The occurrence of erroneous picking may be determined based on whether the number matches. For example, when the planned number of picking is 2, if the difference in the number of products before and after picking is 3, it may be determined that erroneous picking has occurred. Alternatively, the erroneous picking determination unit 41 specifies the number of picked products from the comparison image (FIG. 9D) obtained by comparing the pre-picking distance image and the post-picking distance image, and the number is scheduled to be picked. The occurrence of erroneous picking may be determined based on whether the number matches.

In the above embodiment, the recovery processing unit 49 is based on the number of products in the product container recognized from the post-picking distance image and the number of products in the product container recognized from the post-recovery distance image. Although it was determined whether or not the recovery work was successful, it is not limited to this. For example, the restoration processing unit 49 determines that the number of products in the product container (actual remaining quantity) recognized from the post-recovery distance image is the number of scheduled pickings from the number of products in the product container recognized from the pre-picking distance image. Whether or not the restoration work is successful may be determined based on whether or not the number matches the number of products (regular remaining quantity). That is, the restoration processing unit 49 may determine that the restoration work has been successful when the actual remaining quantity of the product in the commodity container after the restoration work matches the regular remaining quantity.

  The above processing functions can be realized by a computer. In that case, a program describing the processing contents of the functions that the processing apparatus should have is provided. By executing the program on a computer, the above processing functions are realized on the computer. The program describing the processing contents can be recorded on a computer-readable recording medium (except for a carrier wave).

  When the program is distributed, for example, it is sold in the form of a portable recording medium such as a DVD (Digital Versatile Disc) or a CD-ROM (Compact Disc Read Only Memory) on which the program is recorded. It is also possible to store the program in a storage device of a server computer and transfer the program from the server computer to another computer via a network.

  The computer that executes the program stores, for example, the program recorded on the portable recording medium or the program transferred from the server computer in its own storage device. Then, the computer reads the program from its own storage device and executes processing according to the program. The computer can also read the program directly from the portable recording medium and execute processing according to the program. Further, each time the program is transferred from the server computer, the computer can sequentially execute processing according to the received program.

  The above-described embodiment is an example of a preferred embodiment of the present invention. However, the present invention is not limited to this, and various modifications can be made without departing from the scope of the present invention.

In addition, the following additional remarks are disclosed regarding description of the above embodiment.
(Appendix 1) A robot for picking a product in a product container containing a product to be placed in a transport container, and placing the picked product in the transport container;
An acquisition unit for acquiring images related to the product container before and after the picking;
Based on images related to the product container before and after the picking, a specifying unit that specifies a product picked in error,
An instruction unit for instructing the robot to perform a recovery operation for returning the erroneously picked product from the transport container to the product container;
Picking device comprising:
(Additional remark 2) The picking apparatus of Additional remark 1 characterized by the image regarding the said product container being a distance image.
(Additional remark 3) The calculation part which calculates the relative position with respect to the goods picked correctly of the goods picked incorrectly based on the picture about the goods container before the picking is provided,
The picking device according to appendix 1 or 2, wherein the instruction unit notifies the robot of the relative position.
(Additional remark 4) The said acquisition part acquires the image regarding the said merchandise container, whenever the said robot arrange | positions the said merchandise in the said merchandise container in the said conveyance container. The picking apparatus according to crab.
(Additional remark 5) The said acquisition part acquires the image regarding the said product container after the said robot performed the said restoration operation | work,
The instructing unit is configured such that the product picked erroneously is transported from the transport container to the product container based on an image related to the product container after the picking or before the picking and an image related to the product container after the restoration operation. The picking device according to any one of appendices 1 to 4, wherein it is determined whether or not it has been returned to step (b).
(Additional remark 6) When the said instruction | indication part determines with the said goods picked accidentally not being returned to the said goods container from the said conveyance container, the picking position of the said goods picked incorrectly is the last picking position. The picking apparatus according to claim 5, wherein the robot is instructed to perform the restoration operation again as a position moved a predetermined distance from the robot.
(Supplementary note 7) When the product picked in error is not returned from the transport container to the product container, the information on the transport container in which the product is arranged more than planned, and the wrong picking, The picking device according to appendix 5 or 6, further comprising an output unit that outputs information in association with information on a transport container in which a product is disposed less than planned.
(Additional remark 8) The said robot picks goods by adsorption | suction, The picking apparatus in any one of Additional remark 1 to 7 characterized by the above-mentioned.
(Supplementary note 9) The picking apparatus according to any one of supplementary notes 1 to 8, wherein the product is a packaged product.
(Additional remark 10) When the said product container moves after picking, the said instruction | indication part instruct | indicates the said robot to return the goods picked by mistake to the said product container after movement, The additional note 1 characterized by the above-mentioned. The picking apparatus in any one of 9-9.
(Additional remark 11) When a robot picks the goods in the goods container containing the goods planned to be placed in the transport container, and places the picked goods in the transport container, the product containers before and after the picking Get images about
Based on the images related to the product container before and after the picking, identify the product picked in error,
Instructing the robot to perform a recovery operation to return the erroneously picked product from the transport container to the product container;
A recovery program for causing a computer to execute processing.
(Supplementary note 12) The restoration program according to claim 11, wherein the image relating to the commodity container is a distance image.
(Additional remark 13) Based on the image regarding the said product container before the said picking, let a computer perform the process which calculates the relative position with respect to the correctly picked goods of the said goods picked incorrectly,
13. The restoration program according to appendix 11 or 12, wherein in the process of instructing, the robot is notified of the relative position.
(Supplementary Note 14) In the acquisition process, the robot acquires an image related to the product container every time the robot places the product in the product container in the transport container. Recovery program described in any one.
(Additional remark 15) In the process to acquire, the robot acquires an image relating to the commodity container after the restoration work is performed,
In the instructing process, based on the image relating to the commodity container after the picking or before the picking and the image relating to the commodity container after the restoration operation, the erroneously picked commodity is taken from the transport container to the commodity. 15. The recovery program according to any one of appendices 11 to 14, wherein it is determined whether or not the container has been returned to the container.
(Supplementary Note 16) In the process of instructing, if it is determined that the erroneously picked product is not returned from the transport container to the product container, the picking position of the erroneously picked product is set to the previous picking. The restoration program according to appendix 15, wherein the robot is instructed to perform the restoration operation again as a position moved by a predetermined distance from the position.
(Supplementary Note 17) If the erroneously picked product is not returned from the transport container to the product container, the information on the transport container in which the product is arranged more than planned, and incorrect picking, The recovery program according to appendix 15 or 16, wherein the computer executes a process of outputting information in association with the information of the transport container in which the merchandise is disposed less than planned.
(Additional remark 18) The said robot picks goods by adsorption | suction, The recovery program in any one of Additional remarks 11 to 17 characterized by the above-mentioned.
(Supplementary note 19) The restoration program according to any one of Supplementary notes 11 to 18, wherein the product is a product packed in a bag.
(Supplementary note 20) When the product container moves after picking, the instructing process instructs the robot to return the product picked by mistake to the product container after the movement. The recovery program according to any one of 11 to 19.

40 Processing Device 41 False Picking Determination Unit 49 Recovery Processing Unit 51 Robot 71 Distance Sensor 72 Distance Sensor 100 Product Picking Device CA10 Transport Container CA20 Product Container

Claims (11)

A robot for picking a product in a product container containing a product to be placed in a transport container, and placing the picked product in the transport container;
An acquisition unit for acquiring images related to the product container before and after the picking;
Based on images related to the product container before and after the picking, a specifying unit that specifies a product picked in error,
An instruction unit for instructing the robot to perform a recovery operation for returning the erroneously picked product from the transport container to the product container;
Picking device comprising:   The picking apparatus according to claim 1, wherein the image related to the commodity container is a distance image. A calculation unit that calculates a relative position of the erroneously picked product with respect to the correctly picked product based on an image related to the product container before picking;
The picking apparatus according to claim 1, wherein the instruction unit notifies the robot of the relative position.   The said acquisition part acquires the image regarding the said goods container, whenever the said robot arrange | positions the said goods in the said goods container in the said conveyance container. The picking device described. The acquisition unit acquires an image related to the product container after the robot has performed the restoration work,
The instructing unit is configured such that the product picked erroneously is transported from the transport container to the product container based on an image related to the product container after the picking or before the picking and an image related to the product container after the restoration operation. 5. The picking device according to claim 1, wherein it is determined whether or not it has been returned to.   If the instruction unit determines that the erroneously picked product is not returned from the transport container to the product container, the instruction unit moves the picking position of the erroneously picked product from the previous picking position by a predetermined distance. 6. The picking apparatus according to claim 5, wherein the robot is instructed to execute the restoration operation again as the position that has been set.   If the erroneously picked product has not been returned from the transport container to the product container, information on the transport container in which the product is arranged more than planned, and the product is out of plan due to incorrect picking. The picking device according to claim 5 or 6, further comprising an output unit that outputs information associated with at least a few transport containers.   The picking apparatus according to claim 1, wherein the robot picks a product by suction.   9. The picking apparatus according to claim 1, wherein the product is a packaged product.   The said instruction | indication part instruct | indicates the said robot to return the goods picked accidentally to the said goods container after movement when the said goods container moves after picking. The picking apparatus of any one of Claims. When the robot picks the product in the product container containing the product to be placed in the transport container and places the picked product in the transport container, the robot acquires images related to the product container before and after the picking. And
Based on the images related to the product container before and after the picking, identify the product picked in error,
Instructing the robot to perform a recovery operation to return the erroneously picked product from the transport container to the product container;
A recovery program for causing a computer to execute processing.

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