JP6219779B2 - Automatic warehouse system - Google Patents

Description

  The present invention relates to an automatic warehouse system, and more particularly to a technique for determining the placement of containers in an automatic warehouse system.

  Automatic warehouse systems are often introduced at sites that store large quantities of goods such as distribution centers. In a general automatic warehouse system, a plurality of containers are stacked in a hangar, and the arrangement of containers is appropriately changed by a crane.

From the hangar, articles are replenished and picked (removed) several times a day. Prior to this replenishment / picking operation, the container arrangement is changed (hereinafter referred to as “replacement operation”). Containers subject to replenishment / picking (hereinafter referred to as “working containers”) are moved from the reserve area above the hangar to the lower face area by a crane, and the non-target containers (hereinafter referred to as “storage containers”). Are saved from the face area to the reserved area. The worker performs an article replenishment / picking operation for a work container arranged in the face area.
The face area is divided into a plurality of stages, for example, an upper stage / middle stage / lower stage, and in general, the lowermost work container is most easily operated (see Patent Document 1).

JP 2008-174349 A

  The size, weight, and shape of the articles stored in the container vary, and the contents of the container and the total weight of the container also change due to the refill / picking operation. Since the worker usually grabs the work container in the face area from the top and pulls it forward to perform the replenishment / picking work, the work efficiency deteriorates when the heavy work container is pulled out from the upper stage. It is desirable that a heavy container or a container for storing a large article is arranged as low as possible.

  However, as described above, the contents and total weight of the container change during operation of the automatic warehouse system. Heavy containers don't stay heavy, and light containers don't stay light. For example, a container placed at the top in the first refill / picking operation should not necessarily be relocated to the top in the next refill / picking operation.

  The present invention has been made in view of the above problems, and its main purpose is to improve workability and safety in an automatic warehouse system.

In an automatic warehouse system according to an aspect of the present invention, a container in which a plurality of containers for storing articles are arranged in the vertical direction and separated into an upper reserve area and a lower face area, and the container between the reserve area and the face area A crane that changes the arrangement of the container by moving the container up and down, and a movement control device that instructs the crane to place the container.
The face area provided for replenishment / picking of articles has a plurality of installation locations in the vertical direction, and when the movement control device moves the container from the reserve area to the face area, the total weight of the container is set. Accordingly, the height of the container installation location in the face area is determined.
The movement control device is connected to an inventory database in which the IDs of articles stored in the container and the total weight of the container are registered.
The movement control device recalculates the total weight of the container and updates the inventory database when the container is refilled or picked.

  According to the present invention, the workability and safety of an automatic warehouse system can be improved.

It is a hardware block diagram of an automatic warehouse system. It is an enlarged view of a face area. It is a functional block diagram of a movement control device. It is a data structure figure of a goods master database. It is a data structure figure of an inventory database. It is a figure which shows a determination rule. It is a flowchart of the process in a replenishment / picking operation | work. It is a flowchart of the movement operation | movement of a container.

  The present invention will be described below based on preferred embodiments with reference to the drawings. The same or equivalent components, members, and processes shown in the drawings are denoted by the same reference numerals, and repeated descriptions are omitted as appropriate. The embodiments do not limit the invention but are exemplifications, and all features and combinations thereof described in the embodiments are not necessarily essential to the invention.

FIG. 1 is a hardware configuration diagram of the automatic warehouse system 100.
The automatic warehouse system 100 in this embodiment stores and manages mail order merchandise. The automatic warehouse system 100 includes a hangar 102, a crane 104, a movement control device 106, a merchandise master database 108, and an inventory database 110.

  The hangar 102 has a plurality of installation locations (hereinafter referred to as “spaces 166”) in the vertical direction, and the containers 112 are stored in the spaces 166. The hangar 102 is divided into a reserve area 114 and a face area 116. The reserve area 114 is an area in which a container 112 (storage container) that is not scheduled to be loaded and unloaded for the time being is to be stored, and is located above the storage 102. The face area 116 is an area where the container 112 (working container) scheduled to be loaded and unloaded is to be accommodated, and is located below the storage 102. The face region 116 in this embodiment includes a three-stage space 166 and is referred to as a lower space, a middle space, and an upper space from the bottom. The height of the face region 116 is preferably equal to or less than the general height of the worker, and is preferably about 120 to 160 cm, for example.

  The container 112 may store only one type of product, or may contain a plurality of types of products.

  The crane 104 moves up and down between the two hangars 102 and changes the arrangement of the containers 112. Specifically, the container 112 in the face area 116 is moved to the reserve area 114, and the container 112 in the reserve area 114 is moved to the face area 116.

  The movement control device 106 transmits a control signal to the crane 104 and instructs the arrangement method of each container 112. The configuration of the movement control device 106 will be described later with reference to FIG. 3, and the control method will be described later with reference to FIGS.

  The merchandise master database 108 and the inventory database 110 are connected to the movement control device 106. The product master database 108 is a database for storing attribute information of products stored in the container 112, and details will be described later with reference to FIG. The inventory database 110 is a database for storing inventory information of each container 112, and details will be described later with reference to FIG.

FIG. 2 is an enlarged view of the face region 116.
FIG. 2 shows a situation where the worker takes out the container 112 from the middle space (second row from the bottom) of the face area 116. The container 112 is supported by a support base 118. An arm (not shown) of the crane 104 is inserted from the lower part of the support stand 118 in the direction of the arrow 122. The crane 104 takes out the container 112 with an arm, moves it up and down, and installs it at a place designated by the movement control device 106.

  In order to prevent the operator's hand from hitting the arm, a cover 120 is attached under the support base 118. There is a space between the upper and lower containers 112, and an operator puts his hand into the space from below the cover 120 to grasp the container 112 and pulls out the container 112 in the direction of arrow 124 (frontward direction).

  The worker has a dedicated or general-purpose portable terminal 130 (see FIG. 3), and a work instruction is transmitted from the movement control device 106 to the portable terminal 130. The work instruction here is specifically an instruction as to which article 112 should be taken out from which container 112 and which article should be stored in which container 112. The worker transmits a work completion notification to the movement control device 106 after completion of the specified replenishment / picking work.

  In order to store a large number of containers 112 in the hangar 102, it is preferable that the space between adjacent containers 112 is narrow. However, if the space between the containers 112 is narrow, the cover 120 is also necessary, and thus it is difficult for an operator to put his hand on the container 112. As a result, it becomes difficult for the operator to pull out the container 112. In the present embodiment, the distance between the container 112 and the container 112 is set to ¼ or less of the height of the container 112. The lower space is relatively easy to work with, but the upper space is difficult to work with. In particular, when the work container in the upper space is heavy, workability is significantly reduced. In consideration of the risk of dropping the heavy work container, it is desirable that the heavy work container be arranged in the lower space. At least it is better to avoid placing heavy work containers in the upper space.

FIG. 3 is a functional block diagram of the movement control device 106.
Each component of the mobile control device 106 is centered on an arbitrary computer CPU, memory, a program for realizing the components shown in the figure loaded in the memory, a storage unit such as a hard disk for storing the program, and a network connection interface. It is realized by any combination of hardware and software. It will be understood by those skilled in the art that there are various modifications to the implementation method and apparatus. Each figure described below shows functional unit blocks, not hardware unit configurations.

  The movement control device 106 executes various data processing in response to an instruction from the communication unit 126 and an instruction from the communication unit 126 as an interface with the portable terminal 130 of the worker, the crane 104, the commodity master database 108, and the inventory database 110. A data processing unit 128 is included.

  The communication unit 126 includes a transmission unit 132 and a reception unit 134. The transmission unit 132 transmits various commands / signals such as control signals to the outside, and the reception unit 134 receives various signals / commands from the outside.

  The data processing unit 128 includes a calculation unit 136 and a position determination unit 138. The calculation unit 136 calculates the total weight of the container 112. The position determination unit 138 determines the arrangement of the container 112 based on the total weight of the container 112 and the size of the product stored in the container 112. The position determination unit 138 performs position determination based on a determination rule described later with reference to FIG.

FIG. 4 is a data structure diagram of the product master database 108.
The product master database 108 stores product attribute information. The product master database 108 includes a product ID column 140 indicating the product ID, a name column 142 indicating the product name, a size column 144 indicating the size of the product, a weight column 146 indicating the weight of the product, and a price column indicating the price of the product. 148, but other information such as a product type and a manufacturer name may be added.

FIG. 5 is a data structure diagram of the inventory database 110.
The inventory database 110 stores inventory information. It is updated by the movement control device 106 every time an entry / exit occurs. The container ID column 150 shows the ID of the container 112. The position information column 152 indicates the installation location of the container 112, the stored product column 154 indicates the ID and number of products stored in the container 112, and the weight column 156 indicates the total weight of the container 112. Other information such as the number of container refills / picking may be added.

  For example, the container 112 with the container ID = 01 in FIG. 5 is installed in a place denoted as “Face (110)”. This indicates that it is installed in the space 166 in the first stage (bottom stage) / tenth row of the face region 116. The container 112 (container ID: 01) stores two products with product ID = 04 and one product with product ID = 18, and its total weight is 24 kilograms. The total weight here may be the sum of the weight of the container 112 and the weight of the entire stored product, or may be only the weight of the entire stored product.

FIG. 6 is a diagram illustrating the determination rule 158.
The position determination unit 138 determines the installation location of the container 112 according to the determination rule 158. The rule ID column 160 indicates the ID of the rule, the weight range column 162 indicates the weight range to which the rule is applied, and the selection order column 164 indicates the search order of the free area in the face area 116. For example, when a container 112 having a total weight of 15 kilograms or more is moved to the face area 116, rule 1 is applied, and an empty space is preferentially searched from the lower stage. When there is no empty space in the lower stage, an empty space is searched from the middle stage, and when there is no empty area, an empty space is searched from the upper stage. The intermediate weight of the container 112 having a total weight of 10 kilograms or more and less than 15 kilograms is prioritized. The light container 112 having a total weight of less than 10 kilograms is prioritized for placement in the upper level.

FIG. 7 is a flowchart of the processing steps in the replenishment / picking operation.
When a work instruction is transmitted from the transmission unit 132 of the movement control device 106 to the portable terminal 130, the worker takes out the designated product from the designated container 112 (work container) or stores the designated product. After the completion, a work completion notification is transmitted from the mobile terminal 130 to the movement control device 106.

When the receiving unit 134 of the movement control device 106 receives the work completion notification, first, the data in the stored product column 154 of the inventory database 110 is updated to reflect the result of the replenishment / picking work (S8). Next, the calculation unit 136 recalculates the total weight of the work container 112 to be refilled / picked (S10). For example, if there are m products A (weight a) and n products B (weight b) in the container 112 after the refill / picking operation, and the weight of the container 112 itself is c, the container 112 The total weight x is
x = c + m × a + n × b
It becomes. Of course, x = m × a + n × b may be used as described above.

  The transmission unit 132 instructs to register the recalculated total weight in the weight column 156 in the inventory database 110 (S12). The stored product column 154 is also updated. Thus, the inventory database 110 is updated each time a replenishment / picking operation is performed.

FIG. 8 is a flowchart of the moving operation of the container 112.
Before the actual replenishment / picking operation is performed several times a day, the replacement operation of the container 112 between the face area 116 and the reserve area 114 is performed as a preliminary preparation for the replenishment / picking operation. The work container that is to be refilled / picked next time is moved from the reserve area 114 to the face area 116, and the storage container that is not to be refilled / picked next time is moved from the face area 116 to the reserved area 114. After the replacement work by the crane 104 is completed, the replenishment / picking work by the worker described with reference to FIG. 7 is executed.

  First, all containers 112 that are not to be refilled / picked next time are sequentially moved from the face area 116 to an empty space in the reserve area 114 (S20). Since the position of the container changes, the movement control device 106 updates the position information column 152 of the inventory database 110 (S22).

  Next, the position determination unit 138 selects a work container to be a next refill / picking work (S24). The position determination unit 138 refers to the merchandise master database 108 and the inventory database 110, and when the work container stores a merchandise having a predetermined size or more, for example, 40 cm or more in any of vertical / horizontal / height (S26). Y), a predetermined rule is selected (S30). In the present embodiment, it is assumed that the rule 1 is selected for a work container that stores a large product having a predetermined size or larger regardless of the total weight of the work container.

  When a large product larger than the predetermined size is not stored (N in S26), the position determination unit 138 checks the total weight of the work container with reference to the inventory database 110 (S28). The position determination unit 138 selects a rule with reference to the determination rule 158 (S30). The position determination unit 138 searches for an empty space in the face area 116 according to the selected rule (S32).

  The transmission unit 132 transmits a control signal to the crane 104, moves the selected container 112 to the specified empty space in the face area 116 (S34), and updates the position information column 152 of the inventory database 110 (S36). ).

  Furthermore, if there is a work container to be moved from the reserve area 114 to the face area 116 (Y in S38), the process returns to S24, and if there is not (N in S38), the replacement work ends.

  The configuration and control of the automatic warehouse system 100 in the present embodiment has been described above. According to the automatic warehouse system 100 in the present embodiment, the particularly heavy container 112 is preferentially arranged in the lower stage of the face area 116, so that the work efficiency can be improved. Moreover, it is preferable that the heavy container 112 is arrange | positioned at a low level also in terms of safety. Similarly, since the container 112 for storing a large product is also preferentially arranged in the lower part of the face area 116, the work efficiency can be improved in the same manner.

  The contents and total weight of the container 112 change more and more as the replenishment / picking operation is repeated. In the automatic warehouse system 100, the contents and total weight of each container 112 are managed by the inventory database 110 in real time. Since the total weight of the container 112 is recalculated and registered every time the replenishment / picking operation is performed, control is performed so that the heavy container 112 is always preferentially arranged from the lower level when the replacement operation occurs. When a plurality of types of products are mixedly loaded in one container 112, the total weight of the container 112 is likely to change. Therefore, the arrangement control method according to the present embodiment based on the inventory database 110 and the determination rule 158 is particularly effective.

  In the above, this invention was demonstrated based on the Example. It is understood by those skilled in the art that the present invention is not limited to the above-described embodiment, and various design changes are possible, and various modifications are possible, and such modifications are within the scope of the present invention. It is a place.

  For example, a heavy work container 112 of 15 kilograms or more may be specified at the time of replacement work, and first, these heavy containers 112 may be arranged in the priority order of the lower, middle, and upper stages. Next, the intermediate weight container 112 is moved to the face area 116. These intermediate weight containers 112 are also arranged in the priority order of the lower, middle and upper levels. Finally, it is moved to the face area 116 of the light container 112 and arranged in the priority order of the lower, middle and upper stages. Even with such a processing method, a heavier container 112 can be preferentially placed on a lower level. Alternatively, all the containers 112 to be moved from the reserve area 114 to the face area 116 may be sorted (ranked) based on the total weight, moved in order from the heavy container 112, and preferentially arranged from the lower stage.

  Size and weight may be converted into other uniform standards, for example points. For example, 5 points may be given to a container 112 that stores products of 40 cm or more, and 3 points may be given to a container 112 that is 15 kg or more. Thus, the total points may be calculated for each container based on the size and the total weight of the contents of the container, and control may be performed so that the container having a larger point is arranged at a lower level. For example, rule 1 may be applied when 7 points or more, rule 2 when 4 to 6 points, rule 3 when 3 points or less.

  In the present embodiment, the arrangement of the container 112 is determined based on the size of the product stored in the container 112 and the total weight of the container 112. However, the arrangement of the container 112 may be determined based on other information. Good. For example, the rule 1 may be applied to the container 112 that stores the product having the attribute “fragile”, and the rule 1 may be applied when the number of products stored in the container 112 is large.

  In addition, during the replenishment / picking operation, products are arranged so that the total weight of the containers 112 does not exceed a predetermined value, or products of a predetermined type, for example, eight types or more, are not mixedly loaded in one container 112. By arranging, work safety and prevention of work mistakes may be secured.

  In the replacement work of the container 112, as described in relation to S20 in FIG. 8, the storage container is moved to the reserve area 114 and the work container is moved to the face area 116. However, when the face area 116 is already empty, only the work of moving the work container in the reserve area 114 to the face area 116 needs to be executed. Further, instead of moving all containers that are not the target of the next refill / picking from the face area 116 to the reserve area 114, they are the targets of the next refill / picking (the movement from the reserve area 114 to the face area 116 is not performed). Only the number of containers obtained by subtracting the number of empty face areas 116 from the number of required containers may be moved.

  100 automatic warehouse system, 102 hangar, 104 crane, 106 movement control device, 108 commodity master database, 110 inventory database, 112 container, 114 reserve area, 116 face area, 118 support base, 120 cover, 126 communication unit, 128 data processing Part, 130 mobile terminal, 132 transmission part, 134 reception part, 136 calculation part, 138 position determination part, 140 product ID field, 142 name field, 144 size field, 146 weight field, 148 price field, 150 container ID field, 152 Position information field, 154 stored product field, 156 weight field, 158 judgment rule, 160 rule ID field, 162 weight range field, 164 selection order field.

Claims (6)

A plurality of containers for storing articles are arranged in the vertical direction, and the storage is separated into an upper reserve area and a lower face area,
A crane that changes the arrangement of the container by raising and lowering the container between the reserve area and the face area;
A movement control device for instructing the crane to install the container,
The face area provided for the replenishment / picking operation of the article has a plurality of installation locations in the vertical direction,
The movement control device, when moving the container from the reserve area to the face area, according to the total weight of the container, determines the height of the installation location of the container in the face area ,
The movement control device is connected to an inventory database in which an ID of an article stored in the container and a total weight of the container are registered,
The said movement control apparatus updates the said inventory database by recalculating the total weight of the said container, when the replenishment or picking of the said article is performed about the said container . After completion of replenishment or picking of the article, when a work completion notification is sent from the portable terminal of the worker to the movement control device,
The movement control device updates the inventory database by recalculating the total weight of the container subject to replenishment or picking of the article on condition that the work completion notification is received. The automatic warehouse system according to claim 1 . A plurality of containers for storing articles are arranged in the vertical direction, and the storage is separated into an upper reserve area and a lower face area,
A crane that changes the arrangement of the container by raising and lowering the container between the reserve area and the face area;
A movement control device for instructing the crane to install the container,
The face area provided for the replenishment / picking operation of the article has a plurality of installation locations in the vertical direction,
The movement control device, when moving the container from the reserve area to the face area, according to the total weight of the container, determines the height of the installation location of the container in the face area,
The movement control device, by moving the container up or picking of the article has been completed in the face region in the reserved area, automated warehouse system that is characterized by making the free space to the face region. A plurality of containers for storing articles are arranged in the vertical direction, and the storage is separated into an upper reserve area and a lower face area,
A crane that changes the arrangement of the container by raising and lowering the container between the reserve area and the face area;
A movement control device for instructing the crane to install the container,
The face area provided for the replenishment / picking operation of the article has a plurality of installation locations in the vertical direction,
The movement control device, when moving the container from the reserve area to the face area, according to the total weight of the container, determines the height of the installation location of the container in the face area,
When the movement control device moves the container from the reserve area to the face area, the movement control device further determines the height of the installation location of the container in the face area according to the size of an article included in the container. automatic warehouse system that is characterized in that. When the size of the article contained in the container is larger than a second threshold, the movement control device preferentially searches for an empty area from the bottom of the face area as the installation location of the container. The automatic warehouse system according to claim 4 . A plurality of containers for storing articles are arranged in the vertical direction, and the storage is separated into an upper reserve area and a lower face area,
A crane that changes the arrangement of the container by raising and lowering the container between the reserve area and the face area;
A movement control device for instructing the crane to install the container,
The face area provided for the replenishment / picking operation of the article has a plurality of installation locations in the vertical direction,
The movement control device, when moving the container from the reserve area to the face area, determines the height of the installation location of the container in the face area according to the total weight of the container,
Automatic warehouse system in the hangar, characterized in that the cover to protect the operator from the arm of the crane is provided.

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