JP2023164120A - Stacking pattern generation device and method - Google Patents

Abstract

To provide: a stacking pattern generation device and method which improve working efficiency of stacking work without adversely affecting a post process after stacking; and a stacking system.SOLUTION: A stacking pattern generation device receives inputs of lengths of any two sides of a parallelepiped case, the number of cases arranged in a single layer, and lengths of two sides of a rectangular region where the case is arranged, as pattern generation conditions; and generates a case stacking pattern on the basis of the input pattern generation conditions. Furthermore, the stacking pattern generation device is provided with a robot for stacking the cases according to the generated stacking pattern.SELECTED DRAWING: Figure 10

Description

The present invention relates to a stacking pattern generation device and method, and is suitable for application to, for example, a stacking pattern generation device that generates a pattern for stacking cases on a pallet.

In recent years, with the expansion of the e-commerce market, the logistics industry is required to shorten shipping lead times and respond quickly to changing customer needs. Traditionally, the logistics industry has absorbed fluctuations in demand due to changes in customer needs primarily by reassigning workers. However, while Japan's working population continues to decline over the long term, labor wages are rising even in developing countries, making it increasingly difficult to secure cheap labor worldwide.

Under these circumstances, the logistics industry is proceeding with the automation of various tasks such as loading cargo onto pallets, basket trucks, and other loading platforms, and robots that can flexibly respond to such automation are being developed. Its use is seen as promising. However, although robots have high productivity when performing the same task over and over again, there is a problem in that they cannot necessarily respond flexibly to changes in the shape of the objects they handle.

Here, Patent Document 1 discloses a simulation system that generates a stacking pattern that allows the maximum number of cardboard boxes to be stacked on a pallet, a basket car, etc. by inputting each dimension of the cardboard boxes.

Japanese Patent Application Publication No. 2000-7155

By the way, when using robots to automate the loading work that was conventionally done manually, if a loading pattern is generated to maximize area efficiency, the packaging will look different from the conventional manual work, and it will be difficult to carry out subsequent processes. There were cases where it had an adverse effect. For example, if the number of cases stacked on a loading platform is changed by automation, there is a problem in that when shipping products by loading platform, it becomes necessary to increase or decrease the number of cases stacked on the loading platform.

The present invention has been made in consideration of the above points, and attempts to propose a stowage pattern generation device, method, and stowage system that improve the work efficiency of stowage work without adversely affecting post-stowage processes. That is.

In order to solve this problem, the present invention provides a stacking pattern generation device that generates a stacking pattern of cases, the length of any two sides of the rectangular parallelepiped-shaped cases, the number of cases arranged in a single layer, and an input unit for inputting the length of two sides of a rectangular area in which the cases are to be stacked as a pattern generation condition; and a pattern generation unit for generating the stacking pattern of the cases based on the pattern generation condition input by the input unit. A new section has been established.

Further, in the present invention, in the stowage pattern generation method executed by a stowage pattern generation device that generates a case stowage pattern, cases are arranged in a single layer by the length of any two sides of the rectangular parallelepiped-shaped cases. a first step of inputting the number and the length of two sides of a rectangular area in which the cases are placed as pattern generation conditions; and generating the stacking pattern of the cases based on the input pattern generation conditions. A second step has been added.

Furthermore, in the present invention, in the stacking system for stacking cases loaded on a first pallet onto a second pallet, the length of any two sides of the rectangular parallelepiped cases, the number of cases arranged in a single layer, and inputting the lengths of two sides of a rectangular area in which the case is placed on the second pallet as a pattern generation condition, and calculating the product of the case with respect to the second pallet based on the input pattern generation condition. a stowage pattern generation device that generates a stowage pattern; and a multi-axis that stacks the cases loaded on the first pallet onto the second pallet using the stowage pattern generated by the stowage pattern generation device. A robot was added.

According to the stacking pattern generation device and method of the present invention, it is possible to generate a stacking pattern in which the number of cases specified as the pattern generation condition is arranged in a single layer. Further, according to the stacking system of the present invention, it is possible to generate a stacking pattern in which the number of cases specified as the pattern generation condition is arranged in a single layer, and further stack the cases using the stacking pattern.

According to the present invention, it is possible to realize a stowage pattern generation device, a method, and a stowage system that improve the efficiency of stowage work without adversely affecting post-stowage processes.

1 is a block diagram showing a hardware configuration of a stowage pattern generation device according to a first embodiment; FIG. 1 is a block diagram showing a logical configuration of a stacking pattern generation device according to a first embodiment; FIG. FIG. 3 is a diagram illustrating a configuration example of a stowage pattern generation condition setting screen according to the first embodiment. (A) is a diagram showing a block piling pattern, (B) is a diagram showing a brick piling pattern, (C) is a diagram showing a pinhole piling pattern, and (D) is a diagram showing a double pinhole piling pattern. It is a diagram. It is a figure which shows the example of a structure of a stowage pattern display screen. 3 is a flowchart showing the processing procedure of pattern generation processing. 3 is a flowchart showing the processing procedure of pattern generation processing. 3 is a flowchart showing the processing procedure of pattern generation processing. FIG. 3 is a block diagram showing a hardware configuration of a stowage pattern generation device according to a second embodiment. FIG. 2 is a block diagram showing the logical configuration of a stacking pattern generation device according to a second embodiment. FIG. 7 is a diagram illustrating a configuration example of a stowage pattern generation condition setting screen according to the second embodiment. FIG. 7 is a block diagram showing the logical configuration of a stowage pattern generation device according to a third embodiment. 1 is a conceptual diagram conceptually showing a configuration example of a simultaneous depalletizing/palletizing robot system.

An embodiment of the present invention will be described in detail below with reference to the drawings.

(1) First Embodiment (1-1) Problems with the Prior Art In physical distribution, objects to be transported are generally housed in rectangular parallelepiped cases. The shape of the rectangular parallelepiped is uniquely determined by three sides: length, width, and height, but the length of each side of the case varies depending on the shape and number of objects to be stored. Therefore, it is necessary to select an appropriate stacking pattern that matches the size and shape of the case when stacking the cases on a loading platform for transportation.

When cases are stacked on the same loading platform, stacking cases of the same type is called single loading, and stacking multiple types of cases is called mixed loading. In the case of mixed loading, unless the conditions are met that at least one side of different types of cases is equal in length and that side is stacked parallel to the height direction, a difference in height will occur on the top surface when cases are stacked in one layer. As a result, the degree of freedom in the stowage pattern for higher layers is lost, making it difficult to realize a stowage pattern that prevents cargo from collapsing on the loading platform and preventing unbalanced stacking that may lead to the entire loading platform falling over.

Therefore, it is desirable that the single-layer stacking pattern on the cargo handling platform consists of cases of the same size. However, since cases to be stowed on the same loading platform must be destined for the same destination, and the number of cases stowed on the loading platform for each case type differs depending on the shipping order, the cases to be stowed on the loading platform must be Under the constraint that the number of cases in each case must be the specified number of cases, it is desirable to improve transportation efficiency by maximizing the total volume of cases that are mixed on the same loading platform.

Regarding this point, the applicant has proposed that the method of searching for a pattern that allows the maximum number of cases to be stowed with respect to the area of the cargo handling platform allows cases to be unloaded in a number other than an integral multiple of the number of the generated stowage patterns. It has been found that this method is insufficient when processing shipping orders in units of cases because some cases result in fractional numbers when stacking on a platform, and as a result, loading efficiency during mixed loading is impaired. Hereinafter, a stacking pattern generation device that can solve such problems will be described.

(1-2) Configuration of the stowage pattern generation device according to the present embodiment In FIG. 1, reference numeral 1 indicates the stowage pattern generation device according to the present embodiment as a whole. This stacking pattern generation device 1 is designed to generate a stacking pattern for one layer when a case such as a cardboard box containing products or parts ordered by a customer is loaded singly onto a loading platform for the customer in a warehouse or the like. This is a computer device that has the function of generating.

Actually, the stowage pattern generation device 1 is configured to include information processing resources such as a CPU (Central Processing Unit) 2, a storage device 3, an input device 4, and a display device 5.

The CPU 2 is a processor that controls the operation of the entire stowage pattern generation device 1 . Furthermore, the storage device 3 is composed of a volatile semiconductor memory and a large-capacity nonvolatile storage medium such as a hard disk device or an SSD (Solid State Drive). The storage area provided by the semiconductor memory is used as a work memory for the CPU 2, and various programs and various data that need to be stored for a long period of time are stored in the storage area provided by the nonvolatile storage medium. A condition setting screen display program 6, a pattern generation condition input program 7, a pattern generation program 8, and a case information output program 9, which will be described later, are also stored and retained in the storage device 3.

The input device 4 includes, for example, a mouse and a keyboard, and is used by the user to input various information and input various operations to the stowage pattern generation device 1. Further, the display device 5 is composed of a liquid crystal display, an organic EL (Electro-Luminescence) display, etc., and is used to display necessary information. Note that a touch panel in which the input device 4 and the display device 5 are integrated may be used.

(1-3) Logical configuration of the stowage pattern generation device according to the present embodiment FIG. 2 shows the logical configuration of the stowage pattern generation device 1 according to the present embodiment. As shown in FIG. 2, the stowage pattern generation device 1 includes a condition setting screen display section 10, a pattern generation condition input section 11, a pattern generation section 12, and a case information output section 13.

The condition setting screen display section 10 is realized by the CPU 2 (FIG. 1) of the stowage pattern generation device 1 executing the condition setting screen display program 6 (FIG. 1) stored in the storage device 3 (FIG. 1). This is a functional section that The condition setting screen display unit 10 displays a stowage pattern generation condition setting screen 20 as shown in FIG. 3 on the display device 5 (FIG. 1) in response to a predetermined user operation.

This stowage pattern generation condition setting screen 20 allows the user to set various conditions for generating a stowage pattern for one layer when stacking multiple cases CA of the same type (see FIG. 4) on a loading platform. As shown in FIG. 3, this screen includes a loading platform condition specification area 21, a stowage case condition specification area 22, an overhang tolerance specification area 23, a placement case number specification area 24, a set button 25, and a cancel button 26. It is composed of:

The loading platform condition specification area 21 is an area for the user to specify an area on the loading platform where the case CA can be placed (hereinafter referred to as a case placement area). The case placement area set on the cargo handling platform is usually a rectangle or square with two sides of arbitrary length. Even if the shape of the top surface of the loading platform is a circle, an ellipse, or a more complicated shape, any rectangle or square whose central axis passes through the center of gravity of the loading platform and is inscribed in the top surface of the loading platform is a case. This is the shape of the placement area. For this reason, the loading platform condition specification area 21 is provided with a vertical width column 21A for specifying the vertical width of the case placement area and a width column 21B for specifying the horizontal width of the case placement area.

In addition, the stowage case condition specification area 22 is an area for the user to specify the vertical width and width of the case CA to be stowed on the loading platform at that time. , and a width field 22B for specifying the width of the case CA.

Furthermore, the overhang tolerance specification area 23 specifies the vertical and horizontal overhang tolerances (hereinafter referred to as overhang This is an area for the user to specify a permissible overhang value (referred to as a permissible value), and includes a vertical permissible value column 23A for specifying a vertical overhang permissible value, and a horizontal permissible value column 23B for specifying a horizontal overhang permissible value. It is equipped with

Further, the placement case number specification area 24 is an area for the user to specify the number of case CAs to be placed on the same layer (number of cases) when stacking the case CAs on the loading platform, and the number of cases is specified. 24A for specifying the number of cases.

In the stowage pattern generation condition setting screen 20, the vertical width field 21A and the width field 21B of the loading platform condition specification area 21, the vertical width field 22A and the width field 22B of the stowage case condition specification area 22, and the overhang tolerance value. Enter the corresponding or desired values in the vertical tolerance field 23A and horizontal tolerance field 23B of the specified area 23 and the number of cases designation field 24A of the number of arranged cases designation field 24, and then press the setting button 25. By doing so, these specified values can be registered in the stowage pattern generation device 1 as pattern generation conditions. In this case, this pattern generation condition is notified from the condition setting screen display section 10 to the pattern generation condition input section 11. Also, on the stowage pattern generation condition setting screen 20, by pressing the cancel button 26, each value specified on the stowage pattern generation condition setting screen 20 at that time can be discarded without being registered in the stowage pattern generation device 1. I can do it.

The pattern generation condition input unit 11 is a functional unit that is realized when the CPU 2 of the stowage pattern generation device 1 executes the pattern generation condition input program 7 (FIG. 1) stored in the storage device 3. The pattern generation condition input section 11 has a function of inputting pattern generation conditions given from the condition setting screen display section 10 and passing them to the pattern generation section 12 .

Further, the pattern generation unit 12 is a functional unit that is realized when the CPU 2 of the stowage pattern generation device 1 executes the pattern generation program 8 (FIG. 1) stored in the storage device 3. The pattern generation unit 12 generates several stowage pattern templates (hereinafter referred to as It has a function of generating case posture information of each case CA of the same type arranged on the same layer as a stacking pattern by using a stacking pattern template (this is called a stacking pattern template).

"Case posture information" here refers to two axes that are parallel to the long and short sides of the case placement area, with a certain vertex on the case placement area of the loading platform as the origin, and the x-axis and y-axis (or This information includes the coordinate values of the reference position (hereinafter referred to as the case reference position) of each case CA in a two-dimensional coordinate system with the y-axis and x-axis) and the rotation angle from the reference posture. . In the following, the case reference position is the center of gravity of the case CA, but as long as the reference is the same for all cases CA, the case reference position may be any position such as one of the vertices of the case CA. .

FIGS. 4A to 4D show examples of stowage pattern templates held in advance by the pattern generation unit 12. The pattern generation unit 12 uses block stacking as a stacking pattern template that can be applied to any number of cases as shown in FIG. 4(A), or when the number of cases is three or more as shown in FIG. 4(B). Brick masonry applicable when the number of cases is a multiple of 4 as shown in Figure 4 (C), pinhole masonry applicable when the number of cases is a multiple of 4 as shown in Figure 4 (D), and when the number of cases is 9 as shown in Figure 4 (D) It holds templates such as double pinhole stacking that can be applied to In addition, there are other typical stowage patterns for Case CA, such as split stowage and window stowage, but these stowage patterns are generated using the framework of the brickwork generation algorithm. , will be treated here as a form of bricklaying.

In the case of the stowage pattern generation device 1 of this embodiment, since the number of cases CA to be stowed on the same layer is set in advance by the user as described above, it is possible to prepare multiple types of stowage pattern templates in this way. By doing so, candidate stowage pattern templates can be selected in advance, which has the effect of reducing the amount of calculation by the pattern generation unit 12. The stowage pattern template used by the pattern generation unit 12 may be single or multiple depending on the number of cases CA of the same type to be stowed. , respectively generate stowage patterns based on all stowage pattern templates to be used.

For example, when the block stacking shown in FIG. A number (hereinafter referred to as the user-specified case number) is expressed as a product of one or more sets of two integers by factorization. Then, as shown in FIG. 4(A), a pattern in which the same number of cases CA as the two integers constituting the product are arranged adjacently in the vertical and horizontal directions is created for each combination of the two integers. The rotation angle of case CA (hereinafter simply referred to as case rotation angle) is generated for cases where the rotation angle is 0 degrees and when it is 90 degrees.

In addition, when the brickwork shown in FIG. 4(B) is selected, the pattern generation unit 12 generates a pattern with no gaps in the vertical or horizontal direction of the case placement area on the loading platform when the case rotation angle is 0 degrees or 90 degrees. , the number of cases CA is less than the number of cases set by the user (denoted as N) and is 2 or more (denoted as n). In the following, the "two or more cases" arranged here will be referred to as an n-case group G1, and the axis in the direction in which these cases CA are lined up in the n-case group G1 will be referred to as an n-case arrangement axis.

Next, the pattern generation unit 12 arranges the remaining number of cases (N−n) using a block stacking method to generate a block stack pattern portion (hereinafter referred to as a block stack pattern group) G2. However, the rotation angle of each case CA in block stacking pattern group G2 is a different angle from each case CA forming n case group G1, that is, when the rotation angle of each case CA forming n case group G1 is 0 degrees. If the rotation angle of each case CA that makes up block stacking pattern group G2 is 90 degrees, and the rotation angle of each case CA that makes up n case group G1 is 90 degrees, then each case that makes up block stacking pattern group G2 Let the rotation angle of CA be 0 degrees.

Furthermore, the total length of each case CA in the block stacking pattern group G2 in the n case arrangement axis direction is determined by the total length of each case CA in the block stacking pattern group G2 in the n case arrangement axis direction Among the numbers that are less than or equal to the total length in the case arrangement axis direction, the number that makes the maximum number of pieces arranged in the n case arrangement axis direction is adopted.

At this time, for example, a case in which the total length of the block stacking pattern group G2 in the n case arrangement axis direction is smaller than the total length of the n case arrangement axis direction of the n case group G1, and the block stacking pattern group G2 is arranged in the n case arrangement axis direction. When the number of CAs is two or more, the pattern generation unit 12 generates a pattern so that the total length of the n-case group G1 in the n-case arrangement axis direction matches the total length of the block product pattern group G2 in the n-case arrangement axis direction. After adding equal gaps between each of the cases CA constituting these block stacking pattern group G2, each case CA of these block stacking pattern group G2 is arranged in n case group G1 in the direction orthogonal to the n case arrangement axis. Place it adjacent to.

Furthermore, if the number of remaining cases (N-n) described above is greater than or equal to n, the pattern generation unit 12 generates an n-case group G1 different from the first n-case group G1 in a direction perpendicular to the n-case arrangement axis. It is arranged adjacent to the n case group G1. The bricklaying pattern generation operation is repeated as many times as there are combinations of an integer n that satisfies the condition and the number m of columns of n case groups such that the number of remaining cases (N-n) is less than n.

On the other hand, when the pinhole stacking shown in FIG. If N/4 is 3 or more, a sub-stacking pattern is generated using the brick-laying method. When a plurality of sub-stacking patterns exist, a rectangle with the smallest circumscribed area for each sub-stacking pattern is calculated, and the sub-stacking pattern with the smallest difference between its long side and short side is selected.

Then, the pattern generation unit 12 rotates the entire sub-stacking pattern that shares the upper side of the rectangle with the smallest area circumscribing the selected sub-stacking pattern by 90 degrees to the right side, and rotates the entire sub-stacking pattern that shares the left side by 90 degrees. Place the sub-stacking patterns adjacent to each other on the bottom side, and place the sub-stacking pattern on the right side with the sub-stacking pattern that is rotated 180 degrees and shares the bottom side with the sub-stacking pattern that is rotated 90 degrees. Place them adjacent to each other in a pinhole stack pattern.

On the other hand, when the double pinhole stacking shown in FIG. 4(D) is selected, the pattern generation unit 12 arranges stacking patterns of pinhole stacking adjacent to each other with one case CA as a sub stacking pattern. Furthermore, for each case CA whose short side is in contact with the long side of the case CA that shares the pinhole stacking pattern, each case CA whose long side is not in contact with the other case CA is One pin is placed in a stacking pattern of double pinhole stacking.

Of the stacking patterns generated as described above, when the center of gravity of the stacking pattern coincides with the center coordinates of the case placement area on the cargo handling platform, the pattern generation unit 12 generates the data on each side of all the cases CA. Extracts the stowage pattern in which the case CA is within the case placement area, or the distance between each side of the case CA outside the case placement area on the loading platform and the case placement area is less than or equal to the overhang tolerance value. . If multiple stowage patterns are extracted, the risk of cargo collapse when stacking multiple layers is reduced by selecting the pattern with the largest short side of the rectangle with the smallest circumscribed area for each stowage pattern. can be reduced. Thereafter, the pattern generation unit 12 outputs case attitude information of each case CA that constitutes the selected stowage pattern to the case information output unit 13.

The case information output unit 13 is a functional unit that is realized when the CPU 2 of the stowage pattern generation device 1 executes the case information output program 9 (FIG. 1) stored in the storage device 3. This case information output unit 13 generates a stacking pattern of each case CA of the same type to be arranged in the same layer, which is generated by the pattern generation unit 12, based on the case attitude information of each case CA given from the pattern generation unit 12. information (hereinafter referred to as stowage pattern information) is output. Note that the format of the stowage pattern information may be data representing the case reference position of each case CA, or data on a screen that visualizes the case reference position of each case CA.

FIG. 5 shows a screen displayed on the display device 5 based on the screen data when the case information output unit 13 outputs the stowage pattern information as screen data (hereinafter referred to as a stowage pattern display screen). 30 configuration examples are shown. As shown in FIG. 5, the stowage pattern display screen 30 includes a stowage pattern display area 31 and a case placement position and rotation angle display area 32.

In the stowage pattern display area 31, a layout diagram of each case CA in the stowage pattern generated by the pattern generation unit 12 is displayed. In addition, in the case placement position and rotation angle display area, a list of the X coordinates, Y coordinates, and rotation angles of each case CA is displayed when a predetermined position of the case placement area of the cargo handling platform is set as the origin. Note that FIG. 5 is an example in which the case size of each case CA is 300 mm in length and 400 mm in width, and a stacking pattern in which eight cases CA are stacked by pinhole stacking is generated by the pattern generation unit 12.

(1-4) Specific Processing Contents of the Pattern Generation Unit FIGS. 6A to 6C are flowcharts showing more specific processing content regarding the generation of the stowage pattern by the pattern generation unit 12. The pattern generation unit 12 generates all possible stacking patterns among block stacking, brick stacking, pinhole stacking, and double pinhole stacking according to the processing procedure shown in FIGS. 6A to 6C.

More specifically, among the steps in FIGS. 6A to 6C, the pattern generation unit 12 generates a block stacking pattern in step S2, and generates a brick stacking pattern in steps S3 to S15. Then, a pinhole stacking pattern is generated in steps S16 to S32, and a double pinhole stacking pattern is generated in steps S33 to S34.

Then, from the viewpoint of preventing cargo collapse, the pattern generation unit 12 selects the stacking pattern in which the short side of the circumscribed rectangle with the smallest area is the largest from among the generated stacking patterns, as the currently generated stacking pattern and outputs it to the case information output unit 13. Output to.

In practice, when the pattern generation condition is given from the pattern generation condition input section 11, the pattern generation section 12 starts a series of processes shown in FIGS. 6A to 6C (hereinafter referred to as pattern generation process). , obtains the pattern generation conditions given from the pattern generation condition input section 11 (S1).

Next, the pattern generation unit 12 factors the user-specified number of cases into a combination of integers whose product is the user-specified number of cases (N) (hereinafter referred to as an integer set) based on the acquired pattern generation conditions. In addition, in these calculated integer sets, a block stacking pattern (hereinafter referred to as a block stacking pattern) is generated when the rotation angle of case CA is set to 0 degrees or 90 degrees, respectively. All of the generated block stacking patterns are registered in a first list (not shown) (S2).

For example, if "8" is set as the user-specified number of cases, the integer sets whose product is "8" are (1, 8), (2, 4), (4, 2), and (8, There are four cases (1), and each set of integers has two states in which the case rotation angle is 0 degrees and 90 degrees, so a total of eight block stacking patterns are generated. Therefore, in this case, the pattern generation unit 12 registers each of the eight generated block stacking patterns in the first list.

Next, the pattern generation unit 12 determines whether the number of user-set cases is three or more (S3). Obtaining a negative result in this judgment means that bricklaying cannot be performed in the user-set number of cases. Thus, at this time, the pattern generation unit 12 proceeds to step S16.

On the other hand, obtaining a positive result in the determination in step S3 means that bricklaying can be performed using the user-set number of cases. Thus, at this time, the pattern generation unit 12 sets the value of the integer n representing the number of cases CA constituting the above-mentioned n case group G1 (FIG. 4) in bricklaying to 2 (S4).

Subsequently, the pattern generation unit 12 generates all n case groups G1 that can be generated at that time in bricklaying (S5). Therefore, in this step S5, there is an n case group G1 in which n cases CA are arranged vertically with a rotation angle of 0 degrees, and an n case group G1 in which n cases CA are arranged in a horizontal direction with a rotation angle of 0 degrees. , a group of n cases G1 in which cases CA are arranged in a vertical direction with a rotation angle of 90 degrees, and an n case group G1 in which cases CA are arranged in a horizontal direction with a rotation angle of 90 degrees are generated, respectively.

Next, the pattern generation unit 12 calculates a set of integers whose product is (N-n), and creates a block stacking pattern group G2 when the rotation angle of the case CA for each of these calculated integer sets is set to 0 degrees or 90 degrees. are all generated (S6). For example, when N=8 and n=2, there are four integer sets whose product is (N-n): (1,6), (2,3), (3,2), and (6,1). In these integer sets, a block stacking pattern group G2 in which the rotation angle of case CA is 0 degrees or 90 degrees is generated. Therefore, in this case, a total of eight block stacking pattern groups G2 are generated.

Next, the pattern generation unit 12 generates all combinations of the n case group G1 generated in step S5 and the block stacking pattern group G2 generated in step S6 (S7), and Among the combinations of pattern group G2, one combination that has not been processed after step S9 is selected (S8).

The pattern generation unit 12 also determines whether the rotation angles of the cases CA in the n case group G1 and the block stacking pattern group G2 that constitute the selected combination (hereinafter referred to as the first selected combination) are different. (S9).

If the pattern generation unit 12 obtains a negative result in this judgment, the process proceeds to step S13, and if it obtains a positive result, it generates a block stack pattern group in the arrangement direction of the cases CA of the n case group G1 in the first selection combination. It is determined whether the total length of G2 is less than or equal to the total length of n case group G1 (S10).

If the pattern generation unit 12 obtains a negative result in this judgment, the process proceeds to step S13, and if it obtains a positive result in this judgment, the total length of the block stacking pattern group G2 in the arrangement direction of the cases CA of the n case group G1. A gap of equal size is set between each case CA of the block stacking pattern group G2 so that CA corresponds to the total length of the n case group G1 (S11).

Next, the pattern generation unit 12 generates a bricklaying pattern by arranging the n case group G1 and the blocklaying pattern group G2 adjacently, and registers the generated bricklaying pattern in the above-mentioned first list ( S12).

Further, the pattern generation unit 12 determines whether processing has been completed for all combinations of the n case group G1 generated in step S7 and the block stacking pattern group G2 (S13). When the pattern generation unit 12 obtains a negative result in this determination, the process returns to step S8, and thereafter repeats the processing from step S8 to step S12 until a positive result is obtained in step S13. On the other hand, when the pattern generation unit 12 obtains a positive result in the judgment in step S13, it increments the integer n (increases the value by "1") (S14), and after this, the value of the integer n becomes the user-set case. It is determined whether the number is equal to or greater than the number (N) (S15). When the pattern generation unit 12 obtains a negative result in this determination, the process returns to step S5, and thereafter repeats the processing from step S5 to step S15 until a positive result is obtained in step S15. Through this repeated process, all bricklaying patterns in which the number of cases arranged on the same layer is the user-specified number of cases (N) are generated, and these bricklaying patterns are each registered in the first list.

When the pattern generation unit 12 eventually finishes registering all such bricklaying patterns in the first list and obtains a positive result in step S15, the pattern generation unit 12 determines whether the user-set number of cases (N) is a multiple of 4 or not. (S16). If the pattern generation unit 12 obtains a negative result in this determination, the process proceeds to step S33.

On the other hand, when the pattern generation unit 12 obtains a positive result in the determination in step S16, the pattern generation unit 12 calculates a set of integers whose product is N/4 by factorizing N/4 in the same manner as in step S6. At the same time, block stacking patterns are generated when the rotation angle of the case is 0 degrees or 90 degrees in these calculated integer sets, and these generated block stacking patterns are registered in a second list (not shown) (S17). .

Subsequently, the pattern generation unit 12 determines whether N/4 is 3 or more (S18). If the pattern generation unit 12 obtains a negative result in this judgment, the process proceeds to step S31, and if it obtains a positive result in this judgment, the pattern generation unit 12 returns an integer n representing the number of cases CA constituting the above-mentioned n case group G1 in bricklaying. The value of is set to 2 (S19).

The pattern generation unit 12 also generates all n case groups G1 that can be generated at that time in bricklaying (S20). Therefore, in this step S20, the n case group G1 is arranged in the vertical direction with the rotation angle of n cases CA being 0 degrees, and the n case group G1 is arranged in the horizontal direction with the rotation angle of the cases CA being 0 degrees. , a group of n cases G1 in which cases CA are arranged in a vertical direction with a rotation angle of 90 degrees, and an n case group G1 in which cases CA are arranged in a horizontal direction with a rotation angle of 90 degrees are generated, respectively.

Further, the pattern generation unit 12 calculates a set of integers whose product is (N/4-n), and sets a block stacking pattern group when the rotation angle of case CA for each of these calculated integer sets is set to 0 degrees or 90 degrees. Generate all G2 (S21). For example, when N=24 and n=2, there are three sets of integers whose product is (N/4-n): (1,4), (2,2), and (4,1). A block stacking pattern group G2 in which the rotation angle of case CA is 0 degrees or 90 degrees is generated for each set of integers. Therefore, in this case, a total of six block stacking pattern groups G2 are generated.

Next, the pattern generation unit 12 generates all combinations of the n case group G1 generated in step S20 and the block stacking pattern group G2 generated in step S21 (S22), and One combination that has not been processed after step S24 is selected from among the combinations of pattern group G2 (S23).

The pattern generation unit 12 also determines whether the rotation angles of the cases CA in the n case group G1 and the block stacking pattern group G2 that constitute the combination selected in step S23 (hereinafter referred to as the second selected combination) are different. (S24).

If the pattern generation unit 12 obtains a negative result in this judgment, the process proceeds to step S28, and if it obtains a positive result, it generates a block stack pattern group in the arrangement direction of the cases CA of the n case group G1 in the second selection combination. It is determined whether the total length of G2 is less than or equal to the total length of n case group G1 (S25).

If the pattern generation unit 12 obtains a negative result in this judgment, the process proceeds to step S28, and if it obtains a positive result in this judgment, the total length of the block stacking pattern group G2 in the arrangement direction of the cases CA of the n case group G1. Equally sized gaps are set between each case CA of the block stacking pattern group G2 so that CA corresponds to the total length of the n case group G1 (S26).

Next, the pattern generation unit 12 generates a bricklaying pattern by arranging the n case group G1 and the blocklaying pattern group G2 adjacently, and puts the generated bricklaying pattern in the second list as a sub-stacking pattern. Register (S27).

Further, the pattern generation unit 12 determines whether processing has been completed for all combinations of the n case group G1 generated in step S22 and the block stacking pattern group G2 (S28). When the pattern generation unit 12 obtains a negative result in this determination, the process returns to step S23, and thereafter repeats the processing from step S23 to step S27 until a positive result is obtained in step S28. On the other hand, when the pattern generation unit 12 obtains a positive result in the determination in step S28, it increments the integer n (increases the value by "1") (S29), and thereafter, the value of the integer n is set in the user-set case. It is determined whether the number has reached one-fourth (N/4) or more (S30). If the pattern generation unit 12 obtains a negative result in this determination, it returns to step S20, and thereafter repeats the processing from step S20 to step S30 until it obtains a positive result in step S30.

Then, when the pattern generation unit 12 obtains a positive result in step S30 by finishing registering all the generable bricklaying pattern groups G2 as sub-stacking patterns in the second list, the pattern generation unit 12 registers all of the bricklaying pattern groups G2 that can be generated as sub-stacking patterns in the second list. From among the registered sub-stacking patterns, the sub-stacking pattern with the smallest difference between the long side and the short side of the rectangle with the smallest circumscribed area is selected (S31).

The pattern generation unit 12 also generates a pinhole stacking pattern based on the sub-stacking pattern selected in step S31, and registers the generated pinhole stacking pattern in the first list (S32). Specifically, the pattern generation unit 12 duplicates three sub-stacking patterns selected in step S31, and creates a total of four sub-stacking patterns, including the three duplicated sub-stacking patterns and the original sub-stacking pattern. Rotate two of the stacking patterns 90 degrees. Further, the pattern generation unit 12 generates a pinhole stacking pattern by sequentially and alternately arranging sub-stacking patterns that are not rotated by 90 degrees and sub-stacking patterns that are rotated by 90 degrees adjacent to each other in a ring shape. Register the pinhole stacking pattern in the first list.

Subsequently, the pattern generation unit 12 determines whether the user-set number of cases (N) is "9" (S33). If the pattern generation unit 12 obtains a negative result in this determination, the process proceeds to step S35. On the other hand, if the pattern generation unit 12 obtains a positive result in step S33, the pattern generation unit 12 rotates six of the nine cases with a rotation angle of 0 degrees and the remaining three with a rotation angle of 90 degrees. Then, by arranging these adjacently in a predetermined pattern, a double pinhole stacking pattern as shown in FIG. 4(D) is generated, and the generated double pinhole stacking pattern is registered in the first list (S34).

Next, the pattern generation unit 12 selects one stacking pattern from among the stacking patterns (block stacking pattern, brick stacking pattern, pinhole stacking pattern, and/or double pinhole stacking pattern) registered in the first list so far. A state is simulated in which the center of gravity of the selected stowage pattern (hereinafter referred to as the selected stowage pattern) and the center of the case arrangement area on the cargo handling platform are aligned (S36).

Thereafter, in the simulation in step S36, the pattern generation unit 12 determines that one or more sides of one or more cases CA exist outside the case placement area on the cargo handling platform (protrudes from the case placement area). It is determined whether or not (S37). If the pattern generation unit 12 obtains a negative result in this determination, the process proceeds to step S40.

On the other hand, if the pattern generation unit 12 obtains a positive result in the determination in step S37, the distance between the side of at least one case CA existing outside the case placement area on the cargo handling platform and the case placement area is It is determined whether the overhang tolerance value is greater than the overhang tolerance set by the user (S38). If the pattern generation unit 12 obtains a negative result in this determination, the process proceeds to step S40.

On the other hand, when the pattern generation unit 12 obtains a positive result in the determination in step S38, it deletes the selected stowage pattern from the first list (S39), and thereafter deletes all the selected stowage patterns registered in the first list. It is determined whether the processing of steps S36 to S39 has been completed for the stowage pattern (S40).

When the pattern generation unit 12 obtains a negative result in this determination, the process returns to step S35, and thereafter, while sequentially switching the stowage pattern selected in step S35 to other stowage patterns that have not been processed after step S36, step S35 is performed. ~Repeat the process of step S40. Through this repeated process, at least one of the stowage patterns registered in the first list is placed on the case placement area on the loading platform so that its center of gravity coincides with the center of the case placement area on the loading platform. A stacking pattern in which the side of the case CA exceeds the overhang tolerance and protrudes from the case placement area can be deleted from the first list.

Then, when the pattern generation unit 12 eventually finishes executing the processes of steps S36 to S39 for all the stowage patterns registered in the first list and obtains a positive result in step S40, the pattern generation unit 12 obtains a positive result in step S40. Among all the stowage patterns registered in the list, select the stowage pattern in which the short side of the circumscribed rectangle with the smallest area is the largest, and the ratio of the sum of the total area of case CA to the area of the rectangle is the largest. This is selected as the finally generated stowage pattern (S41). By selecting the stowage pattern in which the short side of the circumscribed rectangle with the smallest area is the largest, the stowage pattern that is most unlikely to collapse is selected from among the stowage patterns registered in the first list. be able to.

Subsequently, the pattern generation unit 12 outputs the stowage pattern selected in step S41 to the case information output unit 13 (FIG. 2) (S42), and thereafter ends this series of pattern generation processing.

(1-5) Effects of the present embodiment As described above, according to the stacking pattern generation device 1 of the present embodiment, when arranging cases CA of the same size in the same layer as the number specified by the user, Case attitude information (stacking pattern) for each case CA can be generated, and by stacking the cases CA on the loading platform based on the case attitude information for each case CA, the case CA can be loaded in the number of cases desired by the user. can be loaded onto a loading platform. Therefore, by using the present stowage pattern generation device 1, it is possible to realize automation of stowage work using a robot, and thus the stowage work can be performed without adversely affecting the post-stowage process. Efficiency can be improved.

In addition, in the present stowage pattern generation device 1, as described above with respect to step S41 in FIG. 6C, when there are multiple stowage patterns that satisfy the conditions, a rectangle with the smallest circumscribed area is selected from among these stowage patterns. The stowage pattern with the largest short side and the maximum ratio of the total area of case CA to the area of the rectangle is selected as the final generated stowage pattern. The risk of collapse can be reduced.

Furthermore, in this stowage pattern generation device 1, it is possible to set an overhang tolerance value when stacking cases CA on a loading platform, so that the number of cases CA specified by the user can be stacked within the case placement area on the loading platform. Even if it cannot be accommodated, a realistically applicable stacking pattern can be generated.

(2) Second Embodiment In the first embodiment, a case has been described in which a stacking pattern for one layer is generated when a plurality of cases CA of the same type are stacked on a cargo handling platform. On the other hand, in the second embodiment, a case will be described in which a stacking pattern for each case type is generated when multiple types of cases CA are stacked on the same loading platform. In this case, all case CAs stacked on the same layer are of the same type, and the number of case CAs stacked on the same layer is the number set by the user in advance (user-set number of cases), regardless of the case type. Assume that there is.

FIG. 7, in which parts corresponding to those in FIG. 1 are denoted by the same reference numerals, shows a stacking pattern generation device 40 according to the second embodiment. This stowage pattern generation device 40 includes a destination-specific shipping order input screen display program 41, a case master database 42, a packing form generation program 43, a condition setting screen display program 44, a pattern generation condition input program 7, a pattern generation program 8, and A case information output program 9 is stored in the storage device 3.

FIG. 8, in which parts corresponding to those in FIG. 2 are given the same reference numerals, shows the logical configuration of the stacking pattern generation device 40 according to this embodiment. The stowage pattern generation device 40 of this embodiment includes, in addition to a pattern generation condition input section 11, a pattern generation section 12, and a case information output section 13, a destination-specific shipping order input section 50, a case master database 42, and a packaging form generation section. 51 and a condition setting screen display section 52 that displays a stowage pattern generation condition setting screen 60 (FIG. 9) that is different from the condition setting screen display section 10 according to the first embodiment. This is different from the stowage pattern generation device 1 of the embodiment.

In the destination-specific shipping order input unit 50, the CPU 2 (FIG. 7) of the stowage pattern generation device 40 executes the destination-specific shipping order input screen display program 41 (FIG. 7) stored in the storage device 3 (FIG. 7). This is a functional unit that is realized by doing this. The destination-specific shipping order input section 50 contains destination-specific shipping order information including a case type ID representing the type of each case CA to be shipped and the number of items to be shipped for each case type ID. is given from outside. The destination-specific shipping order input unit 50 has a function of acquiring and managing this destination-specific shipping order information.

Further, the case master database 42 is a database defined on a storage area provided by the storage device 3. Case master information is stored in the case master database 42 in advance. The case master information includes the length of each of the three sides (length, width, and height) of the case CA for each case type, the weight of the case CA for each case type, and the number of cases per layer when stacked singly for each case type. This information includes the number of CA cases and the number of layers stacked on the same loading platform (number of layers).

The condition setting screen display section 52 is a functional section that is realized when the CPU 2 of the stowage pattern generation device 40 executes the condition setting screen display program 44 (FIG. 7) stored in the storage device 3. The condition setting screen display unit 52 has a function of displaying a stowage pattern generation condition setting screen 60 as shown in FIG. 9 on the display device 5 in response to a predetermined user operation.

This stowage pattern generation condition setting screen 60 is a screen for the user to set various conditions necessary to generate a stowage pattern for each layer when stacking multiple types of cases CA on a loading platform. As shown in FIG. 9, the stowage pattern generation condition setting screen 60 includes a loading platform condition specification area 61, an overhang tolerance specification area 62, a stowage pattern priority specification area 63, a set button 64, and a cancel button 65. Prepared and configured.

The cargo handling platform condition specification area 61 is an area for setting various constraint conditions regarding the cargo handling platform that is the loading destination, and includes a vertical width column 61A, a width column 61B, a total weight upper limit column 61C, and a height upper limit column 61D. .

In the loading platform condition specification area 61, the vertical width and width of the case placement area of the loading platform can be specified by inputting the vertical width of the case placement area of the loading platform into the vertical width field 61A and the width into the width field 61B. I can do it. In addition, in the cargo handling platform condition specification area 61, by inputting the total weight of cases CA that can be stacked on the cargo handling platform into the total weight upper limit field 61C, it is possible to specify the total weight. By inputting the upper limit of the height when stacking items into the height upper limit column 61D, the height can be specified.

The overhang tolerance designation area 62 includes an overhang tolerance calculation method designation area 62A, an absolute value designation area 62B, and a ratio designation area 62C.

The overhang allowable value calculation method specification area 62A is for setting the calculation direction of the vertical and horizontal allowable values in which the case side of the case CA loaded on the loading platform can overhang outside the case placement area on the loading platform. It is an area. In the case of this embodiment, the user has two methods: a method of specifying from the absolute value for each case type stored in advance as an overhang tolerance value in the case master database (hereinafter referred to as the first calculation method), and It is possible to select from the second method (hereinafter referred to as the second calculation method), which calculates the percentage of the total amount.

For this reason, the overhang tolerance calculation method specification area 62A is provided with a first check box 62AA associated with the first calculation method and a second check box 62AB associated with the second calculation method. It is being In the overhang tolerance calculation method specification area 62A, by clicking the first check box 62AA and displaying a check mark (not shown) in the first check box 62AA, the first check box 62AA is selected as the overhang tolerance calculation method. By clicking the second check box 62AB and displaying a check mark in the second check box 62AB, the second calculation method can be specified as the calculation direction of the allowable value of the overhang. can be specified.

Note that only one of the first and second calculation methods can be specified as the calculation method for the overhang tolerance value. Therefore, a check mark is displayed only in the first or second checkbox 62AA, 62AB corresponding to the selected first or second calculation method. After this, if the other second or first calculation method is reselected, it will be displayed in the first or second checkbox 62AA, 62AB corresponding to the original first or second calculation method. The checked check mark disappears, and a check mark is displayed in the second or first check box 62AB, 62AA corresponding to the other second or first calculation method.

The absolute value specification area 62B is an area for setting the overhang tolerance value when the first calculation method is selected as the calculation method for the overhang tolerance value, and the vertical tolerance column 62BA and the horizontal tolerance column 62BB are Be prepared. Then, in the absolute value specification area 62B, by inputting the vertical overhang tolerance value in the vertical tolerance value field 62BA and inputting the horizontal overhang tolerance value in the horizontal tolerance value field 62BB, it is possible to Allowable values can be specified.

Further, the ratio specification area 62C is an area for setting the ratio of the overhang allowance in the vertical direction and the horizontal direction when the second calculation method is selected as the overhang allowance calculation method, and the vertical allowance ratio field 62CA and horizontal allowable value ratio field 62CB. Then, in the ratio specification area 62C, enter the overhang ratio allowed for the case size in the vertical direction as a percentage in the vertical allowable value ratio column 62CA, and input the ratio of overhang allowed for the case size in the horizontal direction as a percentage. By inputting in the horizontal permissible value ratio field 62CB, the vertical and horizontal permissible values of the overhang can be specified.

The stowage pattern priority specification area 63 includes a first option that prioritizes the load capacity of the loading platform and prevention of collapse of the cases CA stacked on the loading platform as priorities when generating the loading pattern. This is an area for specifying either one of the second options to be given priority, and includes a first check box 63A corresponding to the first option and a second check box 63B corresponding to the second option. We are prepared.

In the stowage pattern priority specification area 63, click the first check box 63A to display a check mark (not shown) in the first check box 63A, and select the priorities when generating the stowage pattern. When generating a stowage pattern, the first option (prioritize load capacity) can be selected as the first option (load capacity is given priority), and a check mark is displayed in the second check box 63B by clicking the second check box. The second option (prioritizing prevention of cargo collapse) can be selected as the priority.

Note that as a priority item for the stowage pattern, only one of the first and second options can be selected. Therefore, a check mark is displayed only in the first or second checkbox 63A, 63B corresponding to the selected first or second option. Further, if the other second or first option is selected again after this, the check box displayed in the first or second check box 63A, 63B corresponding to the original first or second option. The check mark disappears, and a check mark is displayed in the second or first check box 63B or 63A corresponding to the other second or first option.

Then, the user operates the input device 4 (FIG. 7) to display the stowage pattern generation condition setting screen 60 on the display device 5 (FIG. 7), and enters various constraint conditions regarding the loading platform in the loading platform condition specification area 61. At the same time, in the overhang tolerance value designation area 62, vertical and horizontal tolerance values are set when case CA overhangs, and in addition, in the stowage pattern priority designation area 63, priorities for generating a stowage pattern are set. After setting, by pressing the setting button 64, these conditions (hereinafter referred to as user-specified stowage pattern generation conditions) can be registered in the stowage pattern generation device 40. In this case, the packaging pattern generation unit 51 is notified of the user-specified stowage pattern generation conditions from the condition setting screen display unit 52. Furthermore, by pressing the cancel button 65 on the stowage pattern generation condition setting screen 60, various conditions specified on the stowage pattern generation condition setting screen 60 at that time can be discarded without being registered in the stowage pattern generation device 40. I can do it.

The packing form generation unit 51 is a functional unit that is realized when the CPU 2 of the stowage pattern generation device 40 executes the packing form generation program 43 (FIG. 7) stored in the storage device 3. It has a function to generate the packing appearance of the entire stacked case CA when multiple layers of CA are stacked.

In practice, upon receiving the user-set stowage pattern generation conditions given from the condition setting screen display section 52 at the timing when the setting button 64 on the stowage pattern generation condition setting screen 60 is clicked, the packaging form generation section 51 The shipping order information by destination managed by the separate shipping order input unit 50 and the case master information stored in the case master database 42 are read respectively, and these user-set stowage pattern generation conditions and destinations obtained in this way are Necessary information out of destination-specific shipping order information and case master information is output to the pattern generation condition input section 11 as pattern generation conditions.

Specifically, the packaging form generation unit 51 determines whether the total number of cases for each case type for the destination, which is recognized based on the destination-specific shipping order information, is the same as the number of cases per layer for single loading. If the number of cases is greater than or equal to the product of the number of layers to be stacked on top, the pattern generation condition input unit 11 is informed of the lengths of the case placement area on the loading platform in the vertical and horizontal directions and the cases of each case type to be shipped. The pattern generation condition input section inputs the lengths of the three sides of CA, the number of cases per layer when single loading, and the vertical and horizontal allowable values for case CA to overhang outward from the case placement area on the cargo handling platform. Output to 11.

At this time, if the first calculation method described above is set as the calculation method for the allowable overhang value, the packaging form generation unit 51 generates a corresponding value included in the case master information acquired from the case master database 42. are the permissible values in the vertical and horizontal directions for such overhang, and if the second calculation method described above is selected as the calculation method for the permissible overhang, then the length in the vertical and horizontal directions of case CA is The values obtained by multiplying by the respective set ratios are the allowable values for the vertical and horizontal overhangs, respectively.

The pattern generation conditions outputted from the packaging form generation section 51 to the pattern generation condition input section 11 are given to the pattern generation section 12 via the pattern generation condition input section 11. Further, in the same manner as in the first embodiment, the pattern generation unit 12 generates a stowage pattern (case posture information of each case CA) that satisfies the given pattern generation condition, and converts the generated stowage pattern into a packaging pattern. The generation unit 51 is notified.

At this time, if the pattern generation unit 12 is unable to generate a stowage pattern that satisfies the pattern generation conditions, it notifies the packaging pattern generation unit 51 of this fact (hereinafter, this notification will be referred to as a stowage pattern generation failure notification). call). When the packaging pattern generation unit 51 receives this stowage pattern generation failure notification from the pattern generation unit 12, the packaging pattern generation unit 51 calculates the combination of the lengths of the two sides of the case CA in the vertical direction and the height direction. Generates a pattern generation condition changed to a combination or a combination of horizontal length and height direction length, and outputs the generated pattern generation condition to the pattern generation unit 12 via the pattern generation condition input unit 11 .

Note that, if there is a difference between the length in the vertical direction and the length in the horizontal direction of the case CA, the packaging form generation unit 51 prioritizes the combination of case sides including the longer side and outputs it to the pattern generation condition input unit 11. do. By doing this, if a stacking pattern can be generated using any combination of case sides of case CA, a stacking pattern with a lower height will be generated, so that case CA stacked on the loading platform will The risk of cargo collapse can be reduced.

により求めることができる。 When the packing pattern generation unit 51 is notified of the stacking pattern for a single layer from the pattern generation unit 12, it copies the stacking pattern by the number of layers to be stacked on the loading platform, and copies the stacking pattern for each case CA constituting each layer. New case posture information to which the coordinate in the height direction (Z coordinate) is added is generated for each case CA. At this time, the coordinates in the height direction of the cases CA constituting the p-th layer added by the packaging form generation unit 51 are from the case reference position of the cases CA stacked on the lowest layer to the case placement area on the cargo handling table. If the height is z ₁ and the length of one side that is not output from the packaging form generation unit 51 to the pattern generation condition input unit 11 in each case CA is H, then the following formula

It can be found by

Furthermore, if the loading pattern generation condition setting screen 60 described above with reference to FIG. If the stacking pattern is not axially symmetrical to either of the two axes that pass through the center of the rectangle with the smallest area circumscribing the stacking pattern and are parallel to each side of the rectangle, the stacking pattern The case attitude information of each case CA constituting each even-numbered layer or each odd-numbered layer is changed so that the stacking pattern is reversed with respect to the (non-symmetrical axis).

This operation is to prevent overturning due to unbalanced stacking. In practice, if the center of the rectangle with the smallest area circumscribing the stacking pattern in a single layer does not coincide with the center of gravity of the stacking pattern in that single layer, the center of the case placement area on the loading platform , the XY coordinates of the entire case CA stacked on the loading platform do not match the center of gravity, creating a risk of overturning due to uneven loading. Therefore, the XY coordinates of all the cases CA to be loaded onto the loading platform should be set so that the XY coordinates of the center of the case placement area on the loading platform match the XY coordinates of the center of the entire case CA to be loaded onto the loading platform. Uniform correction can reduce the risk of falling.

Then, the packing form generation unit 51 outputs information on the XYZ coordinates and rotation angle of each case to be loaded on the cargo handling platform generated as described above to the case information output unit 13 as case attitude information of that case. At this time, the packaging form generation unit 51 subtracts the number of cases CA of the case type for which case attitude information has been output to the case information output unit 13 from the total number of cases of the corresponding case type. Then, the packaging form generation unit 51 performs such an operation on all the case CAs of the case type notified as the destination-specific shipping order information from the destination-specific shipping order input unit 50, and performs this operation on the remaining case CAs of the case type. The number is included in the case master information read from the case master database 42. The number of cases CA stacked per layer when single loading is included in the case master information read from the case master database 42, and the number of layers of case CA of the case type stacked on the same loading platform. Repeat until the product is less than the product.

Furthermore, the packing form generation unit 51 performs the following (A) to (C) in order to stack each case CA remaining after such repeated processing (hereinafter referred to as remaining cases) on the same loading platform. In this way, case posture information of each of these remaining cases CA is generated.

(A) Although they are of different types, the lengths of all three sides of each remaining case CA are the same (that is, they are the same case size), and the total number of these remaining cases CA is If the number of stacked cases is equal to or greater than the product of the number of layers stacked on the same loading platform, the same processing as in the case of single loading is executed, and the case posture information of these remaining cases CA is Generate each. However, if there is a difference in weight between the case types, the remaining cases CA of the heavier case type are stacked on the lower layer to lower the center of gravity of the entire case CA stacked on the loading platform and reduce the risk of overturning.

(B) In addition, if the remaining number of cases CA of any case type is not a multiple of the number of cases stacked per layer when single loading, it is necessary to stack case CA of a different case type on any layer. be. The stacking pattern of case CAs in the layer where case CAs of different case types are stacked (hereinafter referred to as a mixed layer) is the same as that of other layers in which the weight of case CAs is uniform; If there is a difference in weight between the case types of each case CA stacked on a mixed load layer, the Search for a combination of case placements that minimizes the distance to the XY coordinates of the center of gravity of the stacking pattern, and select the cases of the necessary remaining cases CA that make up the heterogeneous mixed layer so that the combination of case placements detected through the search is the combination of case placements. Correct posture information. By doing this, uneven stacking of the cases CA as a whole when stacked on the loading platform is suppressed, and the risk of falling is reduced.

(C) If the total weight of the loading platform exceeds the upper limit when the same number of layers are loaded on the same loading platform, the total weight of the loading platform will exceed the upper limit. Reduce the number of cases CA that make up the top layer until the following is achieved, and minimize the area circumscribed to the stacking pattern of other layers instead of the length in the vertical and horizontal directions of the case placement area on the loading platform. The lengths in the vertical and horizontal directions of the rectangle are input from the packaging form generation unit to the pattern generation condition input unit 11 using the number of cases in the top layer instead of the number of cases CA stacked per layer when single loading. The stacking pattern outputted from the pattern generating section 12 to the packaging form generating section 51 as a result is set as the stacking pattern of the uppermost layer.

Next, the packaging form generation unit 51 determines that the total number of cases CA of each case type included in the remaining number of shipping orders by destination is the same as the number of cases CA stacked per layer when single loading. If the product is less than the product of the number of layers to be stacked on the loading platform, all case types that match the multiple of the number of cases CA stacked per layer when single loading, and the rectangle with the smallest area circumscribing the stacking pattern. The case type with the largest area is selected, this case type is set as the first case type, and all cases are set as case posture information on the same cargo handling platform.

The packaging form generation unit 51 uses the rectangle with the minimum area circumscribing the stowage pattern of the case CA of the first case type in place of each length in the vertical direction and the horizontal direction of the case placement area on the loading platform. Among the case types, the case type in which the area of the rectangle with the smallest area circumscribing the stacking pattern is the largest is selected, and all cases are added to the case posture information on the same loading platform as the second case type.

As a result, if the total weight of the loading platform exceeds the total weight upper limit, or if the height of the entire case CA loaded on the loading platform exceeds the height upper limit, the total weight of the loading platform will exceed the total weight. The number of stacked cases CA of the second case type is reduced from the top layer until the height of the cases CA of the second case type becomes below the upper limit and the height of the entire case CA stacked on the loading platform becomes below the height upper limit. If neither upper limit is exceeded, the total weight and height of the loading platform when case CA of the next case type (third case type, fourth case type,...) is loaded on the loading platform. The same process is repeated until one of the values exceeds the upper limit.

Finally, the total value of the number of case CAs of each case type included in the remaining number of shipping orders by destination is the number of case CAs stacked per layer when single loading, and the number of case CAs stacked on the same loading platform. of all case types that do not match the multiple of the number of cases CA stacked per layer when single loaded, if the number is less than the product of the number of cases CA stacked per layer when single loaded. is a smaller integer and the total number of case types with the same length of three sides of case CA is a multiple thereof, and cases with different case sizes on the same loading platform (cases of different case types) Execute the same operation as when CA is mixed.

According to the stacking pattern generation device 40 of the present embodiment as described above, cases CA of the same size are stacked in the same layer, and cases are arranged in the same layer so as to suppress the occurrence of fractional cases CA. In order to adjust the number of case CAs, the area of the top layer can be maximized while arranging case CAs of the same case type in succession, thus allowing case CAs of multiple case types to be efficiently placed on the same loading platform. Can be stacked.

(3) Third Embodiment In this embodiment, a stacking system for stacking multiple types of cases CA on a mixed pallet in a distribution warehouse will be described.

FIG. 10, in which parts corresponding to those in FIG. 8 are designated by the same reference numerals, shows a schematic configuration of such a stowage system 70. This stowage system 70 includes a warehouse management system 71, a stowage pattern generation device 72, an automatic pallet warehouse 73, and a simultaneous depalletizing/palletizing robot system 74.

The warehouse management system 71 is a computer device that has a function of managing shipping orders. The warehouse management system 71 extracts managed shipping orders by destination and outputs them to the stowage pattern generation device 72.

The stowage pattern generation device 72 is a computer device having the same hardware configuration as the stowage pattern generation device 40 (FIG. 7) of the second embodiment. The stowage pattern generation device 72 of this embodiment has a logical configuration including a pattern generation condition input section 11, a pattern generation section 12, a case information output section 13, a destination-specific shipping order input section 50, a case master database 42, a cargo In addition to the figure generation section 51 and the condition setting screen display section 52, it is configured to include a robot trajectory generation section 75 and a single pallet loading order generation section 76.

In the stowage pattern generation device 72, the shipping order given from the warehouse management system 71 is input into the destination-specific shipping order input section 50, and based on the input shipping order, the stowage pattern generation device 40 of the second embodiment is generated. In the same manner as in FIG. 7, a stacking pattern for each case CA to be stacked on a loading platform (hereinafter referred to as a mixed pallet) is generated. Then, the information on the stacking pattern generated at this time (stacking pattern information) is given to the robot trajectory generating section 75 and the single pallet loading order generating section 76. Note that this stacking pattern information includes not only the case posture information (XYZ coordinates of the case reference position of each case and the rotation angle of the case) of each case CA in each layer stacked on the mixed pallet, but also the case posture information of each case CA. The type ID is also included.

The robot trajectory generation unit 75 and the single pallet loading order generation unit 76 both execute a corresponding program (not shown) stored in a storage device (not shown) of the stowage pattern generation device 72. This is a functional unit that is implemented by being executed by a CPU that does not have a computer.

Based on the stowage pattern information given from the case information output unit 13, the robot trajectory generation unit 75 causes the case CA to be transported by a multi-axis robot 80 (see FIG. 11), which will be described later, and which constitutes the simultaneous depalletizing/palletizing robot system 74. Generate a trajectory. Then, the robot trajectory generation unit 75 outputs the generated transportation trajectory information to the simultaneous depalletizing/palletizing robot system 74 as robot trajectory information.

Furthermore, the single pallet loading order generation unit 76 generates (calculates) the loading order of single pallets to the depalletizing/palletizing simultaneous robot system 74 based on the stacking pattern information given from the case information output unit 13. The pallet automated warehouse 73 is notified. In practice, the single pallet loading order generation unit 76 sorts the cases CA to be stacked on the mixed pallet in descending order of Z coordinate based on the stacking pattern information given from the case information output unit 13. The case posture information of each case CA stacked on the mixed pallet is arranged in the order of the same layer. In addition, the single pallet loading order generation unit 76 extracts the case type ID of each case CA constituting that layer for each same layer of case CA on the mixed pallet without duplication, and stores the extracted case type ID of each layer in the warehouse. The pallet automated warehouse 73 is notified via the management system 71.

The automatic pallet warehouse 73 stores and stores various cases CA loaded on each single pallet in racks etc. in units of single pallets, and stores the single pallets specified in response to requests from the warehouse management system 71. This system has the function of taking out items from racks, etc. and shipping them out. The automatic pallet warehouse 73 determines which cases CA to be stacked on the mixed pallet based on the case type ID of each layer given from the single pallet input order generation unit 76 of the stacking pattern generation device 72 via the warehouse management system 71. For each layer, a single pallet loaded with cases CA of the corresponding case type ID is delivered. The single pallet taken out at this time is put into the simultaneous depalletizing/palletizing robot system 74 via a conveyor, an AGV (Automatic Guided Vehicle), a forklift, or the like. Note that the number of single pallets that the automatic pallet warehouse 73 takes out at one time is less than the number of single pallets that the simultaneous depalletizing/palletizing robot system 74 can hold at the same time.

As shown in FIG. 11, the depalletizing/palletizing simultaneous robot system 74 includes a multi-axis robot 80 that transfers a case CA from an input single pallet to a mixed pallet, and a multi-axis robot 80 that moves the input single pallet 81 to a predetermined position. A first conveyor 82 transports the mixed pallet 83 to a predetermined position, a second conveyor 84 transports the mixed pallet 83 to a predetermined position, and a vision camera measures the arrangement of the uppermost cases on the loaded single pallet 81. 85.

The depalletizing/palletizing simultaneous robot system 74 uses a robot given by the robot trajectory generating section 75 of the stacking pattern generating device 72 as described above, based on the arrangement of the uppermost cases on the single pallet 81 measured by the vision camera 85. By operating the multi-axis robot 80 according to the trajectory information, the cases CA loaded on the single pallet 81 are transferred to the mixed pallet 83 according to the stacking pattern generated by the stacking pattern generating device 72.

Generally, each case CA is stored in a distribution warehouse on a single pallet together with cases of the same type, and different case CAs from multiple single pallets are collected on the same pallet before being shipped. A mixed pallet is created to fill the order and transported by truck to each destination. In the case of manual work, mixed pallets can be created using a picking method in which the worker moves around each single pallet while transporting the mixed pallet with a forklift, or conversely, a sowing method in which the worker moves around each mixed pallet while transporting the single pallet. It will be done. In either method, it is necessary for a worker to move the case CA between pallets.

On the other hand, in the stowage system 70 of this embodiment, the multi-axis robot 80 of the simultaneous depalletizing/palletizing robot system 74 transfers the cases CA. It is difficult to make the multi-axis robot 80 mobile due to safety and the weight of the robot itself, especially when the payload is large. It is necessary to transport it to a place where it can be handled.

However, in order to fulfill shipping orders with a degree of freedom on a case-by-case basis, if cases CA are fed into the multi-axis robot 80 in units of pallets, frequent replacement work of the pallets (single-loaded pallets 81) will occur, and the multi-axis robot 80 will not be The operating time may increase and the original productivity may not be achieved. A general solution to this problem is to separate the robot for the depalletizing process, which unloads case units from the single pallet 81, and the robot for the palletizing process, which loads the incoming cases CA onto the mixed pallet 83. A conceivable method is to provide an automatic case warehouse between the depalletizing process and the palletizing process, which has the function of temporarily storing and ordering the cases CA. However, this method has the problem of requiring a large floor space and equipment investment.

Regarding this point, by using the stacking pattern generation method described in the second embodiment, different types of cases can be efficiently mixed on the same mixed loading pallet 83 while arranging the same types of cases CA in succession. Since a stacking pattern can be generated, the multi-axis robot 80 directly transfers the load from the single pallet 81 to the mixed pallet 83 while maintaining the advantages of space saving and low cost of the configuration of the depalletizing/palletizing simultaneous robot system 74. By reducing the number of times the pallet 81 is replaced, the productivity of the multi-axis robot 80 can be improved.

Furthermore, master-less depalletizing/palletizing, which does not require pre-registration of stacking patterns, has the advantage of being able to flexibly accommodate case CAs of various sizes; It is necessary to measure with a camera 85, etc., and calculate on the spot the case CA to be gripped next by the multi-axis robot 80 and the robot trajectory to realize it, which poses a problem in that the cost of the measuring device becomes a burden. .

Regarding this point, in the stowage system 70 of the present embodiment, since the case posture information of each case CA to be loaded on the mixed pallet 83 is calculated in advance, the case information output unit 13 of the stowage pattern generation device 72 ( The stowage pattern is based on the case posture information on the mixed pallet 83 of each case CA outputted from FIG. 10) and the information on the length of three sides of each case CA stored in the case master database 42 (FIG. 10). The robot trajectory generation unit 75 of the generation device 72 simulates and reproduces the packaging form in each step of the stowage process, and determines the appropriate stowage order for each case CA and robot trajectory information (robot trajectory information) for each stowage operation. ) can be input to the depalletizing/palletizing simultaneous robot system 74, the vision camera on the mixed pallet 83 side can be omitted, and depalletizing and palletizing can be performed simultaneously with only one vision camera 85 on the single pallet 81 side. be able to.

According to the stowage pattern generation method performed using the stowage system 70 of the third embodiment described above, the depalletizing process and the palletizing process can be performed simultaneously by the same multi-axis robot 80. In addition to the effects obtained by the embodiment, it is also possible to reduce the number of times the single pallet 81 is replaced and to improve the productivity of the multi-axis robot 80.

(4) Other Embodiments The present invention is not limited to the embodiments described above, and includes various modifications. For example, the embodiments described above are described in detail to explain the present invention in an easy-to-understand manner, and are not necessarily limited to those having all the configurations described. It is possible to replace a part of the configuration of one embodiment with the configuration of another embodiment, and it is also possible to add the configuration of another embodiment to the configuration of one embodiment. Furthermore, it is also possible to add, delete, or replace some of the configurations of each embodiment with other configurations.

Part or all of the above configurations, functions, processing units, processing means, etc. may be realized by hardware such as an integrated circuit. Each of the above configurations, functions, etc. may be realized by software by a processor interpreting and executing a program for realizing each function. Information such as programs, tables, and files for realizing each function can be stored in a recording device such as a memory, a hard disk, or an SSD, or a recording medium such as a flash memory card or a DVD (Digital Versatile Disk).
In each embodiment, the control lines and information lines are those considered necessary for explanation, and not all control lines and information lines are necessarily shown in the product. In reality, almost all components may be considered interconnected.

INDUSTRIAL APPLICATION This invention can be widely applied to the stowage system of various structures in which cases are stowed on a loading platform etc. by a robot.

1, 40, 72...Stowage pattern generation device, 2...CPU, 3...Storage device, 4...Input device, 5...Display device, 6...Condition setting screen display program, 7...Pattern generation Condition input program, 8... Pattern generation program, 9... Case information output program, 10, 52... Condition setting screen display section, 11... Pattern generation condition input section, 12... Pattern generation section, 13... Case Information output section, 20...Stowage pattern generation condition setting screen, 21...Cargo handling platform condition specification area, 21A, 22A, 23A, 61A...Length column, 21B, 22B, 23B, 61B...Width column, 22 ...Stowage case condition specification area, 23...Overhang tolerance value specification area, 24...Number of arranged cases specification area, 24A...Number of cases specification field, 25, 64...Register button, 26, 65...Cancel button , 30... Stowage pattern display screen, 31... Stowage pattern display area, 32... Case placement position and rotation angle display area, 41... Shipping order input program by destination, 42... Case master database, 43 . . . Packing form generation program, 44 . Platform condition specification area, 61C...Total weight upper limit column, 61D...Height upper limit column, 62...Overhang tolerance value specification area, 62A...Overhang tolerance value calculation method specification area, 62AA, 63A...First check Box, 62AB, 63B...second check box, 62B...absolute value specification area, 62BA...vertical tolerance field, 62BB...horizontal tolerance field, 62C...proportion specification area, 62CA...vertical tolerance value Ratio field, 62CB... Horizontal tolerance ratio field, 63... Stowage pattern priority specification area, 70... Stowage system, 71... Warehouse management system, 73... Pallet automatic warehouse, 74... Depalletizing/palletizing Simultaneous robot system, 75...Robot trajectory generation unit, 76...Single pallet input order generation unit, 80...Multi-axis robot, 81...Single pallet, 82...First conveyor, 83...Mixed pallet , 84...second conveyor, 85...vision camera, CA...case.

Claims (12)

In a stowage pattern generation device that generates a stowage pattern for cases,
an input unit for inputting the length of any two sides of the rectangular parallelepiped-shaped cases, the number of cases arranged in a single layer, and the length of two sides of a rectangular area in which the cases are stacked as pattern generation conditions;
A stowage pattern generation device comprising: a pattern generation section that generates the stowage pattern of the cases based on the pattern generation conditions input by the input section. The stowage pattern generated by the pattern generation unit is a posture of each case constituting the stowage pattern,
The pattern generation section includes:
Searching for a template that can generate the stowage pattern from the number of cases to be arranged in the single layer specified in the pattern generation condition from among a plurality of pre-given stowage pattern templates. ,
Calculate the posture of each case when stacking the cases in the stacking pattern generated using the template detected by the search from the lengths of two sides of the case specified in the pattern generation condition. The stowage pattern generation device according to claim 1, characterized in that: The pattern generation section includes:
If there is a plurality of templates capable of generating the stowage pattern consisting of the number of cases specified in the pattern generation condition, each of the stowage patterns is generated using each of the templates;
For each of the generated stacking patterns, calculate a rectangle with the minimum area that circumscribes each of the stacking patterns,
Selecting the stacking pattern in which the short side of the calculated rectangle is the largest and the ratio of the sum of the total area of the cases to the area of the rectangle is the largest,
The stowage pattern generation device according to claim 2, wherein information on the posture of each of the cases in the selected stowage pattern is output as information on the generated stowage pattern. When stacking the cases in multiple layers, the stacking pattern to be generated can be selected from either the stacking pattern that prioritizes load capacity or the stacking pattern that prioritizes prevention of cargo collapse;
comprising a packing form generation unit that generates a packing form of the entire case when the cases are stacked in multiple layers;
The packaging generation unit includes:
When the stacking pattern giving priority to the load capacity is selected, the single layer stacking pattern generated by the pattern generation unit is duplicated by the number of layers to be stacked, and the duplicated stacking pattern is applied to each layer. Generate the packing form as a stowage pattern,
the stacking pattern that prioritizes prevention of cargo collapse is selected, and the single-layer stacking pattern generated by the pattern generation unit passes through the center of a rectangle with the smallest area that circumscribes the stacking pattern, and If the rectangle is not axially symmetrical with respect to either of the two axes parallel to each side, the single-layer stacking pattern generated by the pattern generation unit is duplicated by the number of layers to be stacked, and an even number of layers is created. and the stacking pattern of any one of the odd-numbered layers is generated by inverting the stacking pattern with respect to the axis to which the stacking pattern is not symmetrical. generator. The pattern generation section includes:
On a plane coordinate parallel to the rectangular area on which the cases are stacked, the plane is arranged such that the coordinates of the center of the rectangular area match the coordinates of the center of gravity of the entire case stacked on the rectangular area. The stacking pattern generation device according to claim 4, wherein the position of each of the cases on coordinates is corrected. The packaging generation unit includes:
When there is a difference in weight between the cases arranged in the single layer, the stacking pattern of the cases in the single layer is the stacking pattern of the cases in the single layer when the weights of all the cases are uniform. Searching for a combination of case placements that minimizes the distance on the plane coordinates between the center of gravity position of the stacking pattern and the center of gravity position of the stacking pattern of the single layer calculated from the weight of each case, and by the search. 6. The stacking pattern generation device according to claim 5, wherein the stacking pattern of the single layer having a difference in weight between the cases is modified so as to match the detected combination of the case arrangements. The packaging generation unit includes:
5. The method of generating a stowage pattern according to claim 4, wherein the packing form is generated by sequentially stacking the cases of the case type in which the area of a rectangle with a minimum area circumscribing the stowage pattern is maximum. Device. The case is stacked on a loading platform,
The packaging generation unit includes:
8. The loading method according to claim 7, wherein the loading form is generated in which the cases of each case type are stacked on the loading platform within a range that does not exceed a height or load capacity limit of the loading platform. Attachment pattern generation device. Based on the stacking pattern generated by the pattern generation unit output from the output unit and the case shape of each case to be stacked, the robot stacks the cases according to the stacking pattern. The stowage pattern generation device according to claim 1, further comprising a robot trajectory generation unit that generates a transportation trajectory as a robot trajectory. The cases are stacked on a first pallet for each case type,
the first pallet is stored in an automated pallet warehouse;
Each of the cases loaded on the first pallet is transferred to a second pallet according to the robot trajectory generated by the robot trajectory generation unit,
The method further includes an order generation unit that generates pallets loaded with the cases of the type according to the stacking pattern generated by the pattern generation unit, in which order the first pallets are loaded from the pallet automated warehouse to the robot. The stowage pattern generation device according to claim 9. In a stowage pattern generation method performed by a stowage pattern generation device that generates a case stowage pattern,
A first step of inputting the length of any two sides of the rectangular parallelepiped-shaped cases, the number of cases arranged in a single layer, and the length of two sides of a rectangular area in which the cases are arranged as pattern generation conditions;
and a second step of generating the stowage pattern of the case based on the input pattern generation condition. In a loading system for loading cases loaded on a first pallet onto a second pallet,
The lengths of any two sides of the rectangular parallelepiped cases, the number of cases to be placed in a single layer, and the lengths of two sides of a rectangular area in which the cases are placed on the second pallet are input as pattern generation conditions. , a stowage pattern generation device that generates the stowage pattern of the cases on the second pallet based on the input pattern generation conditions;
and a multi-axis robot that stacks the cases loaded on the first pallet onto the second pallet using the stacking pattern generated by the stacking pattern generation device. .

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