JP7405061B2 - picking system - Google Patents

Description

TECHNICAL FIELD The present invention relates to a picking system, and particularly to one in which a worker sorts packages by placing them in a tray.

As a sorting system and a sorting method, it is known that loading work is performed in a work space on the back of a rack (see, for example, Patent Document 1).

International Publication No. 2012/032865

Conventionally, when there are multiple types of boxes into which articles are placed, it has not been possible to efficiently transport the boxes after picking.

An object of the present invention is to enable a picking system to efficiently carry out a plurality of types of cargo after picking.

A plurality of aspects will be described below as means for solving the problem. These aspects can be arbitrarily combined as necessary.

A picking system according to an aspect of the present invention is a system for an operator to input cargo into a tray having a vertically penetrating portion. The picking system includes a rack, a transfer device, an input opening, a cut-out conveyor, and an output conveyor.
The rack includes a plurality of tray storage sections.
The input opening is disposed at the bottom of the rack and has an opening that allows an operator to input cargo.
The transfer device is disposed in front of the rack and transfers the tray between the tray storage section and the loading opening.
The cut-out conveyor includes a tray support part that supports at least a part of the edge of the tray from below when the tray containing the luggage is transferred by the transfer device, and a tray that penetrates below the tray that has been transferred to the tray support part. By lowering the tray supporting section relative to the conveying section and the conveying section, the conveying section passes through the tray's penetration section and the load in the tray is supported from below by the conveying section. It has a section and a.
The carry-out conveyor is arranged adjacent to the cut-out conveyor, and carries out the cargo supplied from the cut-out conveyor.

In this picking system, a transfer device transports a tray from a tray storage section of a rack to a loading opening. Then, the worker puts the baggage into the tray through the opening of the loading slot. As an example, a worker places a luggage box on a tray and places a plurality of products (an example of luggage) in the luggage box.
Next, the transfer device cuts out the tray containing the luggage box and places it on the tray support section of the conveyor.
Next, the elevating section lowers the tray support section relative to the transport section. Then, the conveyance section passes through the through-hole of the tray and supports the cargo in the tray from below.
Finally, the conveyance section carries out the cargo to the carry-out conveyor, and the carry-out conveyor further carries out the load.

In this picking system, the items in the tray are separated from the tray by a cut-out conveyor, and are further carried out by a carry-out conveyor. Therefore, by preparing trays that can accommodate a plurality of types of packages, the packages can be efficiently carried out after being picked.

The cut-out conveyor and the unloading conveyor may be arranged on the opposite side of the rack to the input frontage opening of the rack.
The discharge conveyor may extend along the direction of extension of the rack, and may have an end located at a position further extending from the end of the rack.
This picking system allows the operator to quickly access the end of the output conveyor without having to go around the back of the rack. Therefore, the operator can continuously remove the baggage after putting the baggage in the tray.

The cut-out conveyor and the discharge conveyor may be arranged on the side of the input opening.
With this picking system, a worker can move from the front of the input opening and access the load smoothly and quickly onto the output conveyor. Therefore, the operator can continuously remove the baggage after putting the baggage in the tray.

The picking system may further include a feed opening. The supply opening may be provided separately from the input opening and may be capable of supplying the cargo to the worker.
In this picking system, for example, a worker can receive a cargo box (a type of cargo) from a supply opening and place the cargo box on a tray in an inputting door.

The conveyance unit may be fixed in the vertical direction.
The elevating section may support the cargo on the transport section by lowering the tray support section.
In this picking system, since the tray support section, which is lighter than the conveyance section, is moved, the driving force of the elevating section can be set small.

With the picking system of the present invention, multiple types of cargo can be efficiently transported after being picked.

FIG. 1 is a schematic perspective view of a picking system according to a first embodiment. A schematic perspective view of a picking system. A schematic plan view of the picking system. FIG. 2 is a block diagram showing the control configuration of the picking system. A schematic perspective view of a cutting conveyor. A schematic perspective view of a cutting conveyor. A schematic plan view of a cutting conveyor. FIG. 3 is a schematic plan view of a state in which a tray is placed on a cutting conveyor. FIG. 3 is a schematic plan view of a state in which a luggage box is placed on a tray. FIG. 3 is a schematic front view showing one state of operation of the cutting conveyor. FIG. 3 is a schematic front view showing one state of operation of the cutting conveyor. FIG. 3 is a schematic front view showing one state of operation of the cutting conveyor. FIG. 3 is a schematic perspective view of a picking system according to a second embodiment. A schematic perspective view of a picking system.

1. First Embodiment (1) Configuration of Picking System A picking system 1 will be explained using FIGS. 1 to 3. FIG. 1 is a schematic perspective view of a picking system according to a first embodiment. FIG. 2 is a schematic perspective view of the picking system. FIG. 3 is a schematic plan view of the picking system.
In the picking system 1, a worker W sorts a plurality of products P (for example, products, product parts, etc.) stored in product containers 15 (described later) into cargo boxes B (described later) determined for each shipping destination. It assists in sorting by inputting the material. In the following description, the left-right direction in FIG. 3 will be referred to as a first horizontal direction (arrow X), and the up-down direction in FIG. 3 will be referred to as a second horizontal direction (arrow Y). The first horizontal direction and the second horizontal direction are orthogonal. Note that the vertical direction is indicated by an arrow Z.

The picking system 1 includes a rack 3, an input opening 5, a crane 7, a cut-out conveyor 9, and an output conveyor 11.

The rack 3 has a plurality of tray storage shelves 3a for storing trays T at the upper part. The rack 3 extends in the first horizontal direction in plan view.
The tray T has an open top and is a container that accommodates a luggage box B and a product P to be placed in the luggage box B. The tray T can store a plurality of types of luggage boxes B of different sizes. As shown in FIGS. 5 to 9 (described later), the tray T has a plurality of notches T1 (an example of a penetrating portion) that penetrate in the vertical direction. The plurality of cutouts T1 extend in parallel to the second horizontal direction.

The input opening 5 is arranged at the lower part of the rack 3, as shown in FIGS. 1 and 2. The loading opening 5 is a facility on which a tray T is placed, and a luggage box B can be loaded onto the tray T. A plurality of input openings 5 (for example, eight) are provided. The input opening 5 has an opening 5a that allows the worker W to input cargo. The opening 5a faces the first side (lower side in FIG. 3) in the second horizontal direction. That is, the first side of the input opening 5 in the second horizontal direction becomes a work space R in which the worker W performs sorting work.

In the work space R, the worker W arranges the luggage box B on the tray T located at the loading opening 5, and further loads the product P into the tray T.
The product P is stored in a product container 15, as shown in FIG. The product container 15 is a container that stores the product P, and is used when transporting the product P to the picking system 1 for sorting. The product containers 15 are supplied to the work space R by a cart rack 17. In the present embodiment, the product container 15 contains a mixture of a plurality of types of products P that have undergone primary picking. Therefore, the sorting of the products P can be made more efficient.
The cart rack 17 and the products P in the product containers 15 placed on the cart rack 17 are given IDs such as barcodes, two-dimensional codes, and RFID tags.

A conveyor (not shown) for conveying luggage boxes B is connected to the supply opening 19 . The supply opening 19 is provided in the rack 3 separately from the input opening 5, and is capable of supplying the luggage box B to the worker. In this case, the operator can receive the luggage box B from the supply opening 19 and place the luggage box B on the tray T in the input opening 5. Note that the supply opening 19 may be integrated with the rack 3 or may be separate. Moreover, the supply opening may be arranged at multiple locations above the input opening. Furthermore, the luggage boxes may be automatically supplied to the tray by a robot or the like without providing a supply opening.

The crane 7 transfers the tray T between the tray storage shelf 3a, the input opening 5, and the cutting conveyor 9. The crane 7 is arranged in front of the rack 3, and specifically, it is located on the opposite side of the rack 3 to the work space R in the second horizontal direction (second side in the second horizontal direction).
The crane 7 is a known technology, and includes a frame 7a, a first horizontally extending rail 7b supported by the frame 7a so as to be movable in the vertical direction, an elevating section 7c that raises and lowers the rail 7b, and a rail 7b mounted on the rail 7b. The transfer device 7d has a drive unit 7e that causes the transfer device 7d to travel in the first horizontal direction along the rail 7b. The transfer machine 7d is a front hook type transfer machine. By using the front hook type, the gap can be reduced and the storage efficiency of the tray storage shelf 3a can be increased.

(2) Configuration of cutting conveyor The cutting conveyor 9 will be explained using FIGS. 5 to 9. 5 and 6 are schematic perspective views of the cutting conveyor. FIG. 7 is a schematic plan view of the cutting conveyor. FIG. 8 is a schematic plan view of the tray placed on the cutting conveyor. FIG. 9 is a schematic plan view of the luggage box placed on the tray.
The cut-out conveyor 9 separates the luggage box B placed on the tray T from the tray T and makes it ready for transport. The cutting conveyor 9 is arranged on the opposite side of the rack 3 to the opening 5a of the input opening 5 of the rack 3 (second side in the second horizontal direction). Specifically, the cutting conveyor 9 is arranged on the opposite side of the crane 7 from the rack 3.

The cutting conveyor 9 includes a tray support plate 21, a roller device 23, a lifting device 25, and a frame 27.
The tray support plate 21 (an example of a tray support part) is movable in the vertical direction with respect to the frame 27. The tray support plate 21 is a rectangular frame-shaped member, and when the tray T containing the luggage box B is transferred by the crane 7, it supports the edge of the tray T from below.

The roller device 23 (an example of a conveying section) includes a plurality of free rollers 23a and a motor roller 23b, as shown in FIGS. 5 to 7. The free roller 23a and the motor roller 23b extend long in the second horizontal direction. The motor roller 23b is located at the center in the first horizontal direction. The free roller 23a and the motor roller 23b are arranged so that the entire conveying surface is a sloped surface where the first side in the first horizontal direction (the left side in FIG. 1) is higher than the second side in the first horizontal direction (the right side in FIG. 1). has been done. Further, as shown in FIG. 8, the free roller 23a and the motor roller 23b are arranged below the tray T transferred to the tray support plate 21, corresponding to the slit or notch T1. Specifically, the free roller 23a and the motor roller 23b are smaller than the notch T1 in plan view and are disposed directly below the notch T1, so that they can pass through the notch T1 in the vertical direction. The roller device 23 is fixed to the frame 27 in the vertical direction.

The elevating device 25 (an example of an elevating section) moves the tray support plate 21 up and down. The elevating device 25 is a known technology and includes a motor, a mechanism for vertically converting the rotational force of the motor (for example, a ball screw mechanism, a rack and a pinion), a guide mechanism, and the like. When the tray support plate 21 is in the upper position (FIG. 5), the tray T from the crane 7 can be transferred thereto, as shown in FIG. When the tray support plate 21 descends with the tray T on it, the tray T also descends. Therefore, when the tray support plate 21 is in the lower position (FIG. 6), the roller device 23 projects upward from the notch T1 of the tray T and supports the luggage box B from below. As a result, the luggage box B is separated from the tray T. Then, the luggage box B is conveyed downstream by the inclined structure of the roller device 23 and the drive of the motor roller.
As described above, since the tray support plate 21, which is lighter than the roller device 23, is moved, the driving force of the lifting device 25 can be set small.

The carry-out conveyor 11 carries out the luggage box B supplied from the cut-out conveyor 9. The carry-out conveyor 11 is disposed on the opposite side of the input opening 5 of the rack 3, and is disposed adjacent to the cut-out conveyor 9 on the downstream side. The carry-out conveyor 11 is, for example, a roller chute in which a plurality of free rollers are arranged at gradually lower positions, and the cargo boxes B are buffered therein. Note that a braked roller or a stopper is arranged at the downstream end of the carry-out conveyor 11 to stop the luggage box B.
The carry-out conveyor 11 extends along the extension direction (first horizontal direction) of the rack 3, and has an end portion 11a located at a position further extending from the end portion 3b of the rack 3.

(3) Control configuration of picking system The control configuration of the picking system 1 will be explained using FIG. 4. FIG. 4 is a block diagram showing the control configuration of the picking system. The picking system 1 has a controller 51.
The controller 51 is a computer having a processor (e.g., CPU), a storage device (e.g., ROM, RAM, HDD, SSD, etc.), and various interfaces (e.g., A/D converter, D/A converter, communication interface, etc.). It is a system. The controller 51 performs various control operations by executing programs stored in a storage unit (corresponding to part or all of the storage area of the storage device).

The controller 51 may be composed of a single processor, or may be composed of a plurality of independent processors for each control.
Part or all of the functions of each element of the controller 51 may be realized as a program executable by a computer system that constitutes the control section. In addition, some of the functions of each element of the controller 51 may be configured by a custom IC.

The controller 51 is connected to the crane 7 (elevating section 7c, transfer device 7d, drive section 7e) and cutting conveyor 9 (motor roller 23b, elevating device 25), and the controller 51 can control these devices. .
The picking system 1 includes a first ID reader 53 for reading the ID of the cart rack 17, a second ID reader 55 for reading the ID of the product P, and a display for displaying which tray T to sort the product P into. 57 are provided.

By reading the ID of the cart rack 17, the controller 51 reads the ID of the product therein and the position data of the tray T to be sorted, and by reading the ID of the product P, determines the input width 5 to be sorted. and is displayed on the display 57 of the corresponding input opening 5. Note that the configuration and operation of the display 57 are known techniques.
Although not shown, the controller 51 is connected to sensors for detecting the size, shape, and position of the tray T, luggage box B, etc., sensors and switches for detecting the status of each device, and an information input device.

(4) Operation of the picking system In the picking system 1, the worker W carries the cart rack 17 on which the luggage boxes B containing the products P to be sorted are placed to the work space R.
In the picking system 1, the crane 7 transports the tray T from the tray storage shelf 3a of the rack 3 to the input opening 5.

A worker W sets a luggage box B (an example of luggage) on a tray T.
The worker W scans the ID of the cart rack 17, then takes out the product P from the product container 15 and reads the ID using a barcode reader or the like. The read product P information is transmitted to the controller 51.

The controller 51 identifies the shipping destination of the product P. The controller 51 assigns a shipping destination of the product P to each input opening 5, and instructs the worker W of the specified shipping destination. The shipping destination is taught, for example, by lighting up the display 57 provided corresponding to each input opening 5 of the picking system 1. The worker W can put the product P into the tray T of the appropriate shipping destination by putting the product P into the loading slot 5 where the display 57 is lit.

As described above, after taking out the product P from the product container 15, the worker W recognizes the shipping destination of the product P, and inserts the product P from the input opening 5 to which the recognized shipping destination is assigned. Accordingly, the product P can be placed in the luggage box B of the appropriate shipping destination. As a result, the efficiency of the sorting work in the picking system 1 can be improved, so that the overall performance of the picking system 1 can be improved.

When a specified quantity of all the specified types of products P are placed in the tray T placed in the loading opening 5 and a luggage box B in which the sorting of the products P is completed is completed, the crane 7 loads the tray T. The tray T is carried out from the frontage 5, cut out and placed on the tray support plate 21 of the conveyor 9. That is, the tray T on which the product P has been completely loaded is directly conveyed by the crane 7 from the loading opening 5 to the cutting conveyor 9.
In addition, as a modification, the loading opening 5 can be made available for another work by storing the tray T in which the cargo boxes B in progress for which the sorting of the products P has not been completed is stored in the rack 3.

(5) Operation of the cutting conveyor The operation of the cutting conveyor 9 will be explained using FIGS. 5 to 12. FIG. 9 is a schematic plan view of the luggage box placed on the tray. 10 to 12 are schematic front views showing one state of operation of the cutting conveyor.
As shown in FIGS. 5 and 10, when the tray T is placed, the tray support plate 21 is in the upper position on the cutting conveyor 9. Therefore, the tray T is placed on the tray support plate 21.

Next, the lifting device 25 of the cutting conveyor 9 lowers the tray support plate 21 relative to the roller device 23. When the tray support plate 21 reaches the lower position, the roller device 23 passes through the notch T1 of the tray T and supports the luggage box B in the tray T from below, as shown in FIGS. 6 and 11.
Finally, as shown in FIG. 12, the roller device 23 of the cutting conveyor 9 carries out the luggage box B to the carry-out conveyor 11, and the carry-out conveyor 11 carries out the luggage box B.

In this picking system 1, the luggage boxes B in the tray T are separated from the tray T by the cut-out conveyor 9, and further carried out by the carry-out conveyor 11. The cutting conveyor 9 has a simple structure and can perform the above operations efficiently.
In the above operation, the tray T remains on the cutting conveyor 9, as shown in FIG. The remaining trays T are collected by the crane 7 and stored in the rack 3.

In the picking system 1, as described above, the unloading conveyor 11 extends along the extension direction (first horizontal direction) of the rack 3, and the end 11a of the rack 3 extends further from the end 3b. have. Therefore, the worker W can quickly access the end portion 11a of the carry-out conveyor 11 from the first side in the second horizontal direction without turning to the second side in the second horizontal direction of the rack 3. Therefore, the worker W can continuously remove the luggage boxes B after loading the luggage boxes B onto the tray T.

2. Second Embodiment In the first embodiment, the cut-out conveyor and the discharge conveyor were arranged on opposite sides of the input opening. However, the cut-out conveyor and the discharge conveyor only need to be adjacent to each other, and their positions are not particularly limited.

A modified example of the cut-out conveyor and the carry-out conveyor will be described as a second embodiment with reference to FIGS. 13 and 14. FIG. 13 is a schematic perspective view of the picking system of the second embodiment. FIG. 14 is a schematic perspective view of the picking system.
Note that the basic configuration and basic operation of the second embodiment are the same as those of the first embodiment. The different points will be explained below.

As shown in FIGS. 13 and 14, the cut-out conveyor 9A and the discharge conveyor 11A are arranged on the side of the input opening 5. Specifically, the cutting conveyor 9A is arranged on one side of the input opening 5 in the first direction (on the right side in FIG. 14). Furthermore, the carry-out conveyor 11A is arranged on one side in the first direction (the right side in FIG. 14) of the cut-out conveyor 9A.
In this picking system 1A, the worker W can move from in front of the loading opening 5 and smoothly and quickly access the luggage box B on the unloading conveyor 11A. Therefore, the worker W can continuously remove the luggage box B after putting the product P into the tray T.

3. Common features of the embodiments The first embodiment and the second embodiment have the following in common.
In a picking system (for example, picking system 1, 1A), a worker (for example, worker W) picks up a tray (for example, tray T) having a vertically penetrating portion (for example, notch T1). This is a system for inputting luggage (for example, luggage box B, product P). The picking system includes a rack, a transfer device, an input opening, a cut-out conveyor, and an output conveyor.
The rack (for example, rack 3) includes a plurality of tray storage sections (for example, tray storage shelf 3a).
The loading opening (for example, loading opening 5) is arranged at the lower part of the rack, and has an opening (for example, opening 5a) that allows an operator to input cargo.
A transfer device (for example, crane 7) is arranged in front of the rack, and transfers the tray between the tray storage section and the loading opening.
The cut-out conveyor (for example, cut-out conveyor 9, 9A) has a tray support section (for example, a tray support plate) that supports at least a part of the edge of the tray from below when the tray containing the luggage is transferred by the transfer device. 21), a conveyance section (for example, free roller 23a and motor roller 23b) arranged below the tray transferred to the tray support section corresponding to the penetration section, and a tray support section relative to the conveyance section. It has an elevating section (for example, an elevating device 25) that allows the conveying section to pass through the tray's penetrating section and support the cargo in the tray from below by lowering the section.
The carry-out conveyor (for example, carry-out conveyor 11, 11A) is arranged adjacent to the cut-out conveyor, and carries out the cargo supplied from the cut-out conveyor.

In this picking system, the items in the tray are separated from the tray by a cut-out conveyor, and are further carried out by a carry-out conveyor. Therefore, if a plurality of types of packages can be stored in each tray, the packages can be efficiently carried out after being picked.

4. Other Embodiments Although one embodiment of the present invention has been described above, the present invention is not limited to the above embodiment, and various changes can be made without departing from the gist of the invention. In particular, the multiple embodiments and modifications described in this specification can be arbitrarily combined as necessary.

(1) Modification of cut-out conveyor (1-1) Modification of lifting device The lifting device may use a cylinder.
In the cut-out conveyor, the tray support plate is fixed immovably up and down, and the rollers may move up and down.
(1-2) Modified example of conveyance section In the cut-out conveyor, the number and position of motor rollers are not limited. The motor roller may be omitted.
In the cutting conveyor, the conveyance surfaces of the plurality of rollers may be horizontal.
In the cutting conveyor, a plurality of rollers may be lined up in the second horizontal direction with respect to one notch.
The notch of the tray T may extend in the first horizontal direction, and in that case, a plurality of rollers may be lined up in the first horizontal direction with respect to one notch. Also, instead of rollers, other types of conveyors, such as belt conveyors, may extend in the first horizontal direction corresponding to the cutouts.

(2) Modification of transfer device The transfer device may be a stacker crane having a traveling section, a lifting section, and a transfer section.
The transfer device may be a rear hook type transfer device or a slide fork.
(3) Others The discharge conveyor may be a drive roller, a slide, or a drive belt conveyor.
The product containers 15 may be supplied to the work space R by a conveyor such as a belt conveyor or a roller conveyor.
The luggage box B may be supplied to the work space R by a conveyor such as a belt conveyor or a roller conveyor.

INDUSTRIAL APPLICABILITY The present invention can be widely applied to picking systems in which a worker sorts packages by placing them in a tray.

1 : Picking system 3 : Rack 3a : Tray storage shelf 3b : End part 5 : Loading opening 5a : Opening 7 : Crane 7a : Frame 7b : Rail 7c : Lifting part 7d : Transfer machine 7e : Drive part 9 : Cutting conveyor 11 : Unloading conveyor 11a : End part 15 : Product container 17 : Cart rack 19 : Supply opening 21 : Tray support plate 23 : Roller device 23a : Free roller 23b : Motor roller 25 : Lifting device 27 : Frame 51 : Controller 52 : Display 53 : 1st ID reader 55 : 2nd ID reader 57 : Display B : Luggage box P : Product R : Work space T : Tray T1 : Cutout W : Worker

Claims (3)

A picking system for a worker to input cargo into a tray having a vertically penetrating portion, the picking system comprising:
A rack with multiple tray storage compartments,
a loading opening disposed at the bottom of the rack and having an opening that allows a worker to load the cargo;
a transfer device that is disposed in front of the rack and transfers the tray between the tray storage section and the loading opening;
a tray support part that supports at least a part of the edge of the tray from below when the tray containing the baggage is transferred by the transfer device; , by lowering the tray supporting section relative to the conveyance section and the conveyance section disposed corresponding to the through-hole, the conveyance section is passed through the through-hole of the tray, and the conveyance section in the tray is moved downwardly. a cut-out conveyor having an elevating section for supporting the cargo from below by the conveying section;
a carry-out conveyor that is disposed adjacent to the cut-out conveyor and carries out the cargo supplied from the cut-out conveyor;
Equipped with
The conveyance section has a free roller and a motor roller arranged in parallel, and after the tray support section is lowered relative to the free roller and motor roller, the free roller and motor roller move the load toward the load. and transport the cargo to the discharge conveyor;
The rack has a substantially rectangular shape in a plan view, and the two opposing long sides of the substantially rectangular shape are a first long side and a second long side, and the opening is arranged on the first long side. When the rack is on the second long side, the cut-out conveyor and the carry-out conveyor are arranged on the second long side of the rack,
The transfer device is arranged between the rack, the cut-out conveyor, and the carry-out conveyor,
The pick-up conveyor extends along the direction of extension of the rack, and has an end extending further than an end of the rack. The picking system according to claim 1 , further comprising a supply opening provided separately from the input opening and capable of supplying the cargo to a worker. The conveyance unit is fixed in the vertical direction,
The picking system according to claim 1 or 2, wherein the elevating section supports the cargo on the transport section by lowering the tray support section.

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