JPH06321323A - Wall-panel picking system - Google Patents

Abstract

PURPOSE:To eliminate picking error and item lack, and also reduce the fluctuation of a cycle time to improve fixed time production capacity by automating the picking of a wall panel. CONSTITUTION:In a wall panel picking system 10, wall panels stored in a panel storing rack 14 in a storehouse are picked in turn of use in production on a panel housing rack 13 on a dolly 12 moving in a storehouse 11 by using a host computer 50 (operation means), a work station 60 (operation means), and a dolly control device 70.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wall panel picking system for picking wall panels in the order in which they are used in production in a warehouse for picking wall panels in a factory for assembling and manufacturing unit buildings and the like.

[0002]

2. Description of the Related Art Conventionally, in a factory for assembling and manufacturing a unit building, as described in JP-A-51-113265, each component is carried into a line in sequence and assembled and manufactured by a flow work system. ing. At this time, when picking the wall panel from the warehouse, the operator visually confirms that the wall panel in the panel storage rack is the target product type according to the list sheet describing the production instruction sequence, and the target product type is lined. It is transferred to a panel storage rack (carrying box) for supplying to.

[0003]

However, the prior art has the following problems. Since picking is performed manually by a worker who uses a list sheet, there is a possibility that a product type error or a stockout may occur during picking.

Picking is performed depending on the ability of the operator, the variation in cycle time is large, and the regular production capacity is reduced.

Since the transmission of information from the order receipt to the production line on the factory side is not a series, the number of man-hours at the information relay point is large.

It is an object of the present invention to automate picking of wall panels, eliminate picking mistakes and missing items, and reduce variations in cycle time to improve regular production capacity.

[0007]

According to the building production instruction data, the present invention uses, in production, a panel storage rack on a truck moving in a warehouse and a wall panel stored in a panel storage rack in the warehouse. It is a wall panel picking system that picks in order, and searches which panel storage rack contains a large number of picking target types specified by the building production instruction data, and also uses each panel storage rack as a storage destination of those target types. Computation means for allocating each of the plurality of panel storage units provided by, so that the pitching order of the target product type allocated to each panel storage unit of each panel storage rack is the order close to the traveling route of the trolley,
And a trolley control device for moving the trolley so as to position each panel storage part of each panel storage rack to the panel storage rack corresponding to the picking order. It is the one.

[0008]

[Operation] The picking order of the target product type based on the building production instruction data is processed by the computing means, and each panel storage unit of the panel storage rack on the truck is positioned by the truck control device to the panel storage rack corresponding to the picking order. Therefore, picking is semi-automated or fully automated, and picking mistakes and missing items can be removed.

As a result of semi-automated or fully-automated picking, variation in cycle time can be reduced and regular production capacity can be improved.

[0010] Incidentally, it is possible to easily make online from the order receipt to the production line on the factory side, and it is possible to save the man-hour (cost) at the information relay point.

[0011]

1 is a block diagram showing an embodiment of a picking system of the present invention, FIG. 2 is a schematic diagram showing an example of an automated warehouse to which the picking system is applied, FIG. 3 is a schematic diagram showing a picking system, 4 is a front view showing the panel storage rack, FIG. 5 is a side view showing the panel storage rack, FIG. 6 is a schematic view showing the panel storage rack, FIG. 7 is a table showing output data of a factory host computer, and FIG. 8 is a work. It is a chart which shows the output data of a station.

According to the building production instruction data, the wall panel picking system 10 stores the wall panels 1 stored in the panel storage rack 14 in the warehouse 11 in the panel storage rack 13 on the carriage 12 moving in the automatic warehouse 11. Picking is done in the order in which they are used in production.

In this embodiment, the picking method (A) below is adopted. The picking method of (B) can also be adopted.

(A) Collection picking system All wall panels 1 are stored in the panel storage rack 1 in the warehouse 11.
4 is placed for each type, and necessary types are picked up in the panel storage rack (carrying box) 13 in the order of use. After all the picking work is completed, the panel storage rack 13 is transported to the line (FIG. 3 (A)).

(B) Home delivery picking method The wall panels 1 are distributed to the panel storage racks 13 in the warehouse 11 according to the type of use in order of use, and when all the deliveries are completed, the panel storage racks 13 from the top are sequentially lined. (Fig. 3 (B)).

The home delivery method cannot be carried out until the last one is inserted into the panel storage rack 13. This means that after all deliveries have to be supplied to the line all at once, it is not suitable for line production. Also, in terms of space, the panel storage racks 13 for at least two days must be lined up, and it is difficult for the operator to understand, so the collection method was adopted in this embodiment.

An outline of the picking work in the picking system 10 will be described below (FIG. 2).

The wall panel 1 arrived by truck is temporarily placed on the first floor temporary storage shelf 21, and the lift driver who receives the loading instruction places one pile of the product on the supply rack 15 on the first floor hydraulic type inversion machine 22. Put. The supply rack 15 is placed on the inverted machine 22 in a state of being laid down in advance.

The product is erected by the inversion machine 22 together with the supply rack 15 and loaded on the carriage 12 via the conveyor 25. At the same time, an empty panel storage rack 13 is loaded.

When the worker inputs the destination of the supply rack 15, the truck 12 is raised to the second floor by the north side elevator 23 and the work is started.

Supplying operation: The truck 12 runs to the designated empty panel storage rack 14 and stops. Thereafter, the operator manually pushes the product into the panel storage rack 14.

Picking work: The dolly 12 travels to the designated panel storage rack 14 and stops, and when the worker puts one target product in the panel storage rack 13, the trolley 12 reaches the panel storage rack 14 of the next designated product. To run. When the next picking product is in the same rack 14, the carriage 12 moves by the distance to the corresponding slit.

Thereafter, the above operation is repeated, and the wall panel 1 is picked until the panel storage rack 13 becomes full.

When the work on the second floor is completed, the truck 12 moves up to the third floor in the south elevator 23 to perform the work.

After the work, the carriage 12 returns to the station on the first floor via the north elevator 23 again, and the panel storage rack 13 containing the product is discharged and the empty supply rack 15 is also discharged.

Next, the panel storage rack 13 and the panel storage rack 14 used in the picking system 10 will be described.

(1) Panel storage rack 13 (FIGS. 4 and 5) In the panel storage rack 13, a plurality of (for example, 20) partitions 32 are arranged at regular intervals (for example, 90 mm) inside a frame body that constitutes the rack body 31. By arranging in parallel with each other, the slit 33A between the adjacent partitions 32 is used as the panel storage portion 33.

When the wall panel 1 is stored in each panel storage portion 33, a slight gap is left between the wall panel 1 and the partition 32. Also, each panel storage unit 3
When the wall panel 1 is stored in 3, the wall panel 1 and the partition 3
In order to protect the surface of the wall panel 1 while avoiding direct contact with 2, the artificial grass 34 is attached to a part of the surface of the partition 32 (FIG. 4).

Further, the panel storage rack 13 is provided with a free roller 35 on the bottom of each panel storage portion 33, on which the lower end portion of the wall panel 1 is placed and rolls.

Further, in the panel storage rack 13, a curved panel drawer 36 is provided at the entrance of the partition 32 in order to allow the operator to easily draw out the wall panel 1 housed in each panel housing 33. ing. Each panel storage part 33
Part of the side surface of the wall panel 1 housed in the panel is exposed to the outside at the panel drawer 36.

The panel storage rack 13 has wall panel holding rods 3 that cross the respective panel storage portions 33 on both front and rear surfaces.
It has a hook 38 that allows 7 to be detached. The wall panel holding rods 37 are attached to the hooks 38 after the wall panels 1 are stored in all the panel storage portions 33, and prevent the wall panels 1 from popping out during transportation.

The panel storage rack 13 has a claw hole 39A penetrating from the front surface to the rear surface at the bottom of the rack body 31.
And a claw hole 39B penetrating between the left and right side surfaces. The claw holes 39A and 39B are holes for inserting the claws of the forklift, and the claw holes 39A depending on the carrying direction of the forklift.
Or one of the claw holes 39B is used.

(2) Panel storage rack 14 (FIG. 6) The number of installed panel storage racks 14 is 40 units / row × 2 rows / floor, which is 160 units in total for the second and third floors. A free roller conveyor 41 was provided in contact with the bottom surface of each panel and the panel surface located on the innermost side for transfer from the dolly 12. However, since all the packaged items are mounted on the same roller 41,
In order to slide only the foremost panel 1 into the panel storage portion 33 of the panel storage rack 13, only one sheet needs to be lifted. Therefore, a free wheel conveyor 43 that can be lifted up by the air cylinder 42 is provided between the rollers of the lower surface conveyor 41. However, panel storage rack 1
Since the number of remaining products of the product No. 4 is indefinite and the carry-out position to the cart 12 is determined (the product is brought closer to the worker side and carried out each time when picking), the chain 45 driven by the forward and reverse rotations of the geared motor 44. Then, the free wheel conveyor 43 is slid in the roller axial direction.

Next, the control system of the picking system 10 will be described (FIGS. 1, 7, and 8).

(1) Factory host computer (FIGS. 1 and 7) The host computer 50 searches which panel storage rack 14 contains a large number of picking target types indicated by the building production instruction data, and A calculation is performed to allocate each of the plurality of panel storage units 33 included in each panel storage rack 13 as the storage destination of the target product type. FIG. 7 shows output data of the host computer 50.

The types of products stored and stored in 160 panel storage racks 14 are fixed product numbers, and the product numbers of 5000 types must be assigned. Multiple product numbers are assigned to the mixed product rack in the same rack. In addition, it is desirable to store the mixed products arriving from the panel manufacturing factory in the rack in the warehouse 11 without opening the seals, and therefore it is necessary to arrange and deliver the mixed products for each shape. For this reason, mixed products are classified by shape.

(2) Workstation 60 (FIGS. 1 and 8) The workstation 60 is a target product type assigned to each panel storage section 33 of each panel storage rack 13 based on the picking information transferred from the host computer 50. A calculation for sorting the respective panel storage portions 33 is performed so that the picking order of 1 is closer to the travel route of the carriage 12. FIG. 8 shows the output data of the workstation 60.

(3) Truck Control Device 70 (FIG. 1) The truck control device 70 receives picking and supply part number data from a terminal provided in the workstation 60 when each truck 12 leaves the first floor station. . For the data transfer between the workstation 60 and the trolley control device 70, a contact method of optical communication is adopted.

That is, at the time of picking, the dolly 12 is moved so that each panel storage part 33 of each panel storage rack 13 is positioned on the panel storage rack 14 corresponding to the picking order of (2).

Since the operator does not know which panel storage rack 14 the product placed on the dolly 12 should be put into when supplying the product, the product number assigned to the number of each panel storage rack 14 is stored in the terminal and is supplied at the time of supply. Access the street address. For mixed products, multiple product numbers are assigned in the same rack.

The traveling speed of the carriage 12 is 50 (high speed), 30.
(Medium speed), 5m / min (low speed) 3rd speed, high speed when traveling more than 10 racks, medium speed in the rack 2 racks before the stop rack, slow speed in the rack 1 rack in front, slow by inverter control To go down. However, in consideration of safety, a safety mat is laid on the dolly 12 at the position where the worker is riding so that the worker can travel at high speed only when the worker is riding and the accelerator button is pressed. In order to stop at the designated panel storage rack 14, the position at which the elevator 23 descends is set to zero, and the number of racks 14 is counted by a sensor provided at the tip of the truck 12 during traveling. Further, at the time of the picking work, the position where the carriage 12 is once stopped on the panel storage rack 14 is set as the zero position, and the encoder is controlled to move to the designated panel storage portion 33 in the panel storage rack 13. Trolley control device 70 and each elevator 23,
For the data transfer with the elevator control device 80, a contacted method of optical communication is adopted.

(4) Elevator control device 80 (FIG. 1) In the elevator control device 80, if the stop position of the elevator 23 and the floor of the stop floor deviate by ± 2 mm, it becomes impossible to transfer. Therefore, we decided to provide a drive motor that controls the flow rate adjustment valve separately from the hydraulic unit, and to finely control the pressure reduction timing. In addition, a positioning device using a power cylinder was installed inside the elevator,
We decided to position the pedestal on the floor of the stop floor by placing the load on it.

(5) Conveyor control device 90 (FIG. 1) The conveyor control device 90 controls the inverted machine 22 and the conveyor 25. For the data transfer between the conveyor control device 90, the inversion device 22, and the conveyor 25, a contacted method of optical communication is adopted.

The operation of this embodiment will be described below. The host computer 50 and the workstation 60 perform information processing on the picking order of the target product type based on the building production instruction data, and the cart control device 70 causes the panel storage units 33 of the panel storage rack 13 on the cart 12 to correspond to the picking order. Since it is positioned on the panel storage rack 14, picking is semi-automated or fully automated, and picking mistakes and missing items can be removed.

As a result of semi-automated or fully-automated picking, variation in cycle time can be reduced and regular production capacity can be improved.

It should be noted that it is possible to easily make online from the order receipt to the production line on the factory side in a consistent system, and to save the man-hour (cost) at the information relay point.

The embodiment of the present invention has been described in detail above with reference to the drawings. However, the specific structure of the present invention is not limited to this embodiment, and changes in design within the scope not departing from the gist of the present invention can be made. Even if it exists, it is included in the present invention. For example, the operation by the host computer 50 and the operation by the workstation 60 may be performed by a single arithmetic circuit. Further, the loading and unloading of the wall panel 1 to and from the panel storage rack 13 and the panel storage rack 14 in the automated warehouse 11 may be mechanized and automated by a handling device without the need for the operator's hand.

[0048]

As described above, according to the present invention, picking of a wall panel can be automated to eliminate picking mistakes and missing items, and variation in cycle time can be reduced to improve regular production capacity. .

[Brief description of drawings]

FIG. 1 is a block diagram showing an embodiment of a picking system according to the present invention.

FIG. 2 is a schematic diagram showing an example of an automated warehouse to which a picking system is applied.

FIG. 3 is a schematic diagram showing a picking method.

FIG. 4 is a front view showing a panel storage rack.

FIG. 5 is a side view showing a panel storage rack.

FIG. 6 is a schematic view showing a panel storage rack.

FIG. 7 is a chart showing output data of a factory post computer.

FIG. 8 is a chart showing output data of a workstation.

[Explanation of symbols]

 1 Wall Panel 10 Picking System 11 Automatic Warehouse 12 Truck 13 Panel Storage Rack 14 Panel Storage Rack 33 Panel Storage 50 Host Computer (Calculator) 60 Workstation (Calculator) 70 Cart Controller

Claims (1)

[Claims] 1. A wall panel picking system for picking wall panels stored in a panel storage rack in a warehouse in the order in which they are used in production in a panel storage rack on a truck that moves in the warehouse according to building production instruction data. In addition to searching for which panel storage rack contains a large number of picking target varieties designated by the building production instruction data, a plurality of panel storage units provided in each panel storage rack are stored as storage destinations of those target varieties. Calculation means for allocating each of them, and calculation for sorting each panel storage part in the picking order so that the pitching order of the target products allocated to each panel storage part of each panel storage rack is close to the traveling route of the trolley Positioning means and each panel storage part of each panel storage rack to the panel storage rack corresponding to the above picking order A wall panel picking system, comprising: a carriage control device for moving the carriage so as to move.