JPS61206730A - Cargo loading planning system - Google Patents

Abstract

PURPOSE:To enable the loading efficiency to be augmented by allowing both panned loading information and loading work information to be operated based on the information which is stored in advance, permitting the resultant to be displayed, documented, and memoried, in a loading plan where various kinds of cargoes are mixedly loaded. CONSTITUTION:When a shipping cargo is designated by a light pen 21, a computer 10 reads out data for the cargo specification from an auxiliary memory 24, then, the data is set in a memory device 13 allowing it to be displayed 22. Subsequently, if the condition required for the planned loading is designated by an operator while the display 22 is being watched, the computer 10 determines the required number, the required size, and the allocation of a pallet. This allows them to be stored 14 and 15 permitting the loading allocation to be displayed 22. After being checked by the operator, it is inputted 21 as an acceptance signal. A coordinate for a loading position is stored 16 by the computer 10. The loading is performed while the loading position which has been already loaded, is being watched on the display panel 22. After the loading has been completed, the resultant is stored 17 allowing an automatic operation sequence to be determined, stored 18, and automatically processed. Thus, this configuration enables efficiency to be augmented.

Description

[Detailed Description of the Invention] [Field of Application of the Invention] The present invention relates to a cargo stowage planning system when various types of cargo are mixedly loaded. Information necessary for warehouse management, namely the number and dimensions of external cases.

A cargo stowage plan that determines the distribution of cargo to each outer case, the stowage arrangement, the order of stowage, and the robot operation sequence so that the cargo requested for transportation can be efficiently stowed by robots on the outer cases. Method % Formula % [Background of the Invention] Conventionally, multiple types of exterior cases (referring to cases for cargo loading such as trucks, containers, wooden boxes, pallets, etc.) each having different dimensions have been used. There are automatic palletizers and palletizing robots (also called robot palletizers) as equipment that automatically stacks cargo of the same type and size on one pallet. Therefore, when the need for high-mix, low-volume transportation arises, the number of products that must be stacked on one pallet increases, and conventional palletizing robots cannot
Loading work becomes impossible.

By the way, when a palletizing robot automatically stacks various cargoes (cargos with different dimensions and irregular shapes) on one pallet, there is a first problem.

(1) The number of combinations in which various cargoes are distributed to each pallet becomes very large. In this distribution, when deciding on cargo distribution without manual labor, it is necessary to satisfy pallet specifications (height limits, weight limits, etc.) and constraints (combinations of cargo to be stowed on the same pallet, etc.). It takes a lot of time to find combinations that satisfy the constraints.

In addition, since the number of combinations of cargo stowage arrangements becomes extremely large,
When determining the cargo loading arrangement manually, the loading efficiency with respect to the effective loading space on the pallet tends to decrease. Therefore, there is a need for a method for generating a stowage arrangement that satisfies the constraints and achieves high loading efficiency.

(2) When using the conventional playback-type teaching method for various cargoes, it is necessary to teach the robot's movements for each cargo, but since the content of these movements differs for each cargo, it is necessary to teach the robot's movements for each cargo. The number of man-hours is large. Therefore, there is a need for a method that automatically determines the cargo loading order and robot operation sequence, which are operation teaching data to the robot, at the same time as generating the above-mentioned loading arrangement.

[Purpose of the invention]

The object of the present invention is to provide a cargo distribution that satisfies various constraints and a simple loading arrangement that achieves high loading efficiency within the limited effective loading space on the pallet in response to the requirements for cargo transportation using pallets. We have developed a cargo loading planning method that can be designed in a short amount of time by operation, and at the same time can automatically determine the cargo loading order and robot movement sequence from the above loading planning information, with the aim of reducing the man-hours required to teach robot movements. It is about providing.

[Summary of the invention]

The method of the present invention consists of the following two functions.

(1) When allocating cargo based on each exterior case specification and cargo specification, humans specify weight values for various constraint conditions according to their importance, and a computer assigns constraints according to the specified weights. The combination that best satisfies the conditions is calculated according to predetermined rules, and the distribution status is displayed. In addition, regarding the loading arrangement, in order to use the effective loading space without wasting cargo, we have made it possible for humans to specify the loading position of each cargo according to the type, shape, and quantity of cargo.
From this placement result, the computer graphically displays the placement status of the loaded cargo on a graphic display device in order to facilitate recognition of empty spaces.

In this way, cargo distribution and stowage arrangement are determined through human-computer interaction.

(2) The above final stowage plan information (stowage cargo distribution).

In order to determine the loading order for each outer case using the cargo loading distribution, the loading order is determined according to rules given in advance.

Furthermore, once the above final stowage plan information and the stowage order of each cargo are determined, in the case of any cargo, the placement status of the cargo that has already been stowed (already stowed cargo) can be known. Therefore, the movement route for stowing each cargo can be determined. In this way, the operation sequence of the robot is determined.

[Embodiments of the invention]

EMBODIMENT OF THE INVENTION Below, one embodiment of the present invention will be described in detail based on the drawings.

FIG. 1 is an example showing an overview of related equipment such as a palletizing robot which is the background of the cargo loading planning method of the present invention. In this embodiment, a case where the outer case is a pallet will be explained. IA is a valetizing robot, IB is a pallet, IC is a device that automatically takes out designated cargo such as a car warehouse, ID is a cargo supply conveyor, IE is a cargo confirmation device, and IF is a cardboard box, etc. Cargo, IG is a device that supplies pallets loaded with cargo, and IH supplies pallets IB to robot IA.

1■ is a device for stocking unloaded pallets corresponding to the loading plan information. In the above configuration, cargo is loaded from the automated warehouse IC to the supply conveyor ID according to a predetermined loading order.

On the other hand, the palletizing robot IA stacks each cargo IF one after another on the pallet IB according to a predetermined operation sequence. When the loading on the pallet IB is completed, the pallet supply device IH.

Palletizing robot IA handles unloaded pallets.
supply to.

The method of the present invention is based on the number of external cases such as pallets,
It concerns the stowage planning method that determines the dimensions of each outer case, the distribution of loaded cargo to each outer case, the stowage arrangement within each outer case, the loading order of the palletizing robot, and the robot operation sequence.

FIG. 2 is a diagram showing the positional relationship of the cargo 2B on the pallet 2A.9For example, a Cartesian coordinate system with the left end on the robot side as the origin is set to designate the cargo loading position. Strictly speaking, the coordinates of the point 2C of the cargo that is closest to the origin are cargo 2B.
Defined as the stowage position. The cargo loading direction is determined by whether the cargo 2B is oriented along the X-axis in the longitudinal direction (denoted as L) or in the transverse direction (denoted as S).

FIG. 3 is an example of displaying the loading order of each cargo in a plan view. As a general rule, when viewed from the robot side, (i) from bottom to top, (it) from back to front.

(fit) This is an example of stacking according to the priority rule from the left end to the right end.

FIG. 4 is an example in which the robot moves the cargo 4B supplied onto the supply conveyor 4A over the cargoes 4E and 4G with storage, and shows the loading operation path at position 4D. Since the model, dimensions, and operating characteristics of the palletizing robot are known,
The movement pattern for cargo loading is given in advance. Furthermore, the dimensions of the cargo 4B to be stowed are known, and the placement of the cargo with cargo can be known from the cargo loading position and cargo loading order, so these obstacles can be avoided and the route taken is the shortest. The optimal teaching point 4F and route 4G can be determined. Therefore, it is possible to determine the robot operation sequence of the teaching point positions (X, Y, Z) and operating conditions such as speeds in the coordinate system shown in FIG. 2.

FIG. 5 is a block diagram schematically showing the overall configuration of the cargo stowage planning system according to the present invention, in which 10 is a computer as an arithmetic unit, 21 is a light bench for data input, 22 is a graphic display device, 23 24 is a hard copy output device, 24 is an auxiliary storage device, 25 is a cargo specification input device, and 26 is a loading plan information output device.

The computer 10 includes a storage section 11, a control section 19 that operates according to a program stored in the storage section 11, and seven data storage sections 12-18. In the storage unit 12, specification data for each pallet that can be selected, for example, as shown in FIG. 6, is inputted from the input device 25 and stored in the form of a table. Furthermore, the storage unit 13
For example, as shown in FIG. 7, specification data for each cargo is inputted from the input device 25 and stored in the form of a table. The storage units 14 and 15 respectively store the dimensions of each pallet and the specifications of the cargo to be loaded, corresponding to the number of pallets calculated from the storage units 12 and 13.

The storage unit 16 stores the cargo loading position and loading direction input by the operator from the light van 21 for each pallet. The storage units 17 and 18 store the computer-calculated cargo loading order and robot operation sequence for each pallet from the storage units 12 to 16, respectively.

An operator using the method of the present invention first specifies the cargo to be transported using the light ben 21. The computer 10 retrieves cargo specification data from the auxiliary storage device 24 and sets it in the storage section 13 according to the specification. The operator confirms the contents of the storage unit 13 on the display device 22 and specifies the conditions necessary to create the stowage plan information. This condition specifies that multiple products should be allocated to the same pallet (for example, left and right symmetrical parts
There are specifications for product types that are not allowed to be mixed (for example, parts used in different factories), and specifications for collecting multiple parts that are not individually packaged and placing them in subcases. Under these conditions, the computer 1o automatically calculates the optimal value for the number of pallets and the dimensions of each pallet while automatically calculating the distribution of cargo to the pallets and the loading arrangement. do. At that time, the calculation result of the allocation is set in the storage section 14.15.

The stowage arrangement is displayed on the display device 22,
The operator uses the light pen 21 to input whether or not he or she is satisfied with each pallet. If the computer 10 is satisfied with the set result, the computer 10 sets the result in the storage unit 16. If unsatisfactory, the stowage arrangement will be determined manually as follows.

That is, first, the first cargo code to be stowed, its stowage position and stowage direction are designated. These specifications are made via the light pen 21. As a result, the coordinates (X
data indicating the loading direction (longitudinal direction and transverse direction S) are set respectively.

Next, the computer 10 displays the stowage arrangement of the already stowed cargo in the form of a plan view on the display device 22. The operator searches for an empty loading space while looking at the screen displayed on the display device 22, and determines whether or not to load more. To continue loading, the above procedure is repeated and cargo is loaded one after another into the effective loading space of the pallet.

After repeating the above procedure, when the operator finally determines to complete the stowage, he uses the light pen 21 to instruct the computer 10 to finish. In this way, when the automatic or manual stowage arrangement is determined, the computer 10 determines the stowage order of each cargo based on the stowage position information set in the storage unit 16, and Set it in the storage section 17. In this case, the storage unit 17 is set with data indicating the loading order of the cargo and the cargo code in the stowage layer, respectively, in the format shown in FIG. 9, for example. Furthermore, the computer 10
Based on the information set in the storage units 12 to 17, a robot operation sequence is determined for each loading order and set in the storage unit 18. In this case, the data is stored in the storage unit 18 in the format shown in FIG. 10, for example.

Data indicating the operation sequence is set for each loading order.

11 and 12 show flowcharts of programs stored in the storage unit 11 to perform the above-described control operations.

The specific operation of the system of the present invention will be explained below by following the operation steps of the flowchart.

FIG. 11 shows a schematic flowchart of a program stored in the storage unit 11 for performing the control operation for creating the above-mentioned stowage plan information.

Hereinafter, specific operations will be explained in detail following operation steps 31 to 40 of this flowchart.

In step 31, the computer 10 waits for the operator to specify the cargo to be transported, for example, by destination and product name. Proceed to the next step 32.

In step 32, the computer 10 retrieves the specification data of the cargo to be transported from the auxiliary storage device 24 for the specified destination and product name, and displays it on the display device 22.

In step 33, the operator inputs (designates) stowage plan information creation conditions from the cargo specification data displayed on the display device 22. In specifying the creation conditions, which pallets are selected with priority. designation of whether to give priority to equalization of weight or volume for cargo distribution,
There are specifications for multiple types of cargo to be allocated on the same pallet, and specifications for cargo that are not allowed to be mixed.

In step 34, the computer 10 waits until all of the above creation conditions are input.
In step 1, if creation of stowage plan information is specified, the process proceeds to the first step.

In step 35, the computer 10 calculates the total volume of the cargo, and calculates the minimum number and dimensions of pallets using the following equation (1).

Number of pallets = (total cargo volume) / (volume of pallets)...
・(1) What is the integer part of the number of pallets determined by this formula (1)?

Regarding the number of priority pallets and the decimal part as a rounding, the pallet whose volume is equal to or larger than the corresponding volume and which is closest to the volume is selected. After the number and dimensions of pallets are calculated in this way, the next step 3
Proceed to step 6.

At step 36, the computer 10 divides the cargo into groups according to the conditions for distribution, and for each group, sorts the priority characteristics of weight or volume for homogenization.

Allocate them to each palette in the sorted order.

Once all the cargo has been distributed, the process proceeds to the first step 37.

In step 37, computer 10 calculates, for each pallet, the most efficient stowage pattern for the cargo to be stowed within that pallet. In this embodiment, the operator's experience in creating various stowage patterns in the past is stored in the computer 10 as knowledge, and the operator uses the knowledge to create various stowage patterns in accordance with the stowage situation.

The method was based on knowledge engineering, which applies and accumulates that knowledge.

In step 38, the computer 1o determines whether the stowage patterns created for all the pallets are within the dimensions of each pallet, that is, whether the arrangement is possible. If all arrangements are possible, store the stowage plan information in the storage unit 14.
．． Set it to 15 and exit. If placement is not possible, proceed to the next step 39.

In step 39, computer 10 determines whether the allocation can be changed. At this time, in step 36,
If there is a group of cargo that can be exchanged in the allocation, this is held as data and this data is referred to in step 39.

If the allocation can be changed, the process proceeds to step 36 and reallocation is performed; if the allocation cannot be changed, the process proceeds to the next step 40.

In step 40, the computer 10 decides to use the pallet resulting from the rounding process with one step larger in volume. If it is not possible to increase the pallet size by rounding, increase the number of pallets by 1.
Increase the dimensions of that palette by one and select the smallest one.

Proceed to step 36 to perform redistribution.

FIG. 12 shows a flowchart of the program details of steps 37 and 38 described above.

Hereinafter, specific operations will be explained in detail following operation steps 51 to 66 of this flowchart.

In step 51, the computer 10 waits for a pallet to be specified. When the operator specifies a pallet, step 5
Proceed to step 2.

In step 52, the computer 10 automatically calculates the stowage arrangement, displays the result on the display device 22,
Proceed to step 53.

In step 53, the operator looks at the display device 22 and uses the light pen 21 to input whether or not the stowage pattern is satisfactory. If satisfied, the process proceeds to step 63; if unsatisfied, the process proceeds to step 54, where the stowage arrangement is determined manually.

In step 54, the computer 10
Find the specification data and loaded cargo data of the corresponding pallet from , and display the specification data of the designated pallet and the plan view of the cargo loaded in the effective loading space of the pallet, for example, in the format shown in A in Figure 13. Displayed on the device 22. Further, on the same screen, the remaining quantity for stowage is retrieved from the storage unit 15, and a list of cargoes to be stowed for remaining stowage is displayed on the display device 22, for example, in the format shown in B of FIG.

Furthermore, a selection menu for the loading direction is displayed on the same screen, for example, in the format shown in C of FIG.

In step 55, the computer 10 waits for input of the cargo stowage position. The operator assumes a suitable position and inputs the coordinates using the light pen 21, for example, as shown in D in FIG. When the input is completed, the process advances to the next step 56.

At step 56, the computer waits for input of the cargo code. The operator assumes a cargo code that he deems appropriate and specifies the cargo using the light pen 21, for example, as shown in E in FIG. 13.

In the example shown in FIG. 13, cargo code S01 is selected. When the input is completed, the process advances to the next step 57.

In step 57, the computer 10 waits for input of cargo loading direction. The operator selects the loading direction (L) as he deems appropriate.
or S), and specify L or S using the light pen 21 from the stacking orientation selection menu as shown in C in FIG. 13, for example.

That is, specify the loading direction with respect to the X-axis direction, specifying L if you want the long side of the cargo to be oriented, and S if you want the short side of the cargo to be oriented.

When the input is completed, the process advances to the next step 58.

In step 58, the computer 10 sets the input cargo stowage position, cargo code, and cargo stowage direction in the predetermined columns of the table shown in FIG.

Next, the computer 10 causes the display 22 to display a diagram of the stowage arrangement on the pallet in the format shown in FIG. 14, for example, based on the information set in the storage units 12 to 15. Further, the computer 10 calculates the loading efficiency of the cumulatively loaded cargo and displays it on the same screen.Next, the computer 10 proceeds to step 59.

In step 59, the computer 1o waits for an input as to whether or not to rotate and display cargo with cargo.

As the number of cargoes with stowage increases, there are no cargoes of different heights, so for example, in a diagram showing the stowage arrangement situation in a plan view like Figure 14, the operator has to select the next stowage position. In other words, it is often not easy to recognize empty space. In that case, the operator may request the computer 10 to display the image in rotation. The operator.

If rotational display is specified, the process proceeds to step 60; otherwise, the process proceeds to step 62.

In step 60, the computer 10 waits for input of the rotation angle. The operator assumes an appropriate rotation angle,
An appropriate angle is selected and specified from the rotation angle menu displayed on the display 22. When the input is completed, the process advances to the next step 61.

In step 61, the computer 10
Based on the information entered in step 0, a diagram of the stowage arrangement of the cargo with cargo as viewed from the designated angle is displayed on the display 22, for example, in the format shown in FIG. 15.Next, the process proceeds to step 62.

In step 62, the computer 10 waits for input of information as to whether or not the stowage arrangement situation is satisfied. The operator looks at the display screen and inputs response information as to whether or not he is satisfied with the stowage arrangement situation. Computer 10 determines this input information and proceeds to step 54 if it is satisfactory; otherwise returns to step 63.

In step 63, the computer 10
Using the final stowage position and stowage direction information obtained in 0 is set in a predetermined column of the table shown in FIG. 9 indicating the order of attachment.Next, the process proceeds to step 64.

In step 64, the computer 10
．． Using the information on the final loading position and loading order obtained in step 17, calculate the coordinates of the loaded cargo for each cargo, determine the robot movement sequence that will avoid collision with them, and The results are set in a predetermined column of the table shown in FIG. 10 which shows the robot motion sequence prepared in the storage unit 18.

Next, the process proceeds to step 65.

In step 65, the computer 10
to print out hard copies of necessary screens such as the stowage layout status diagram and stowage order. This hard copy is used for operation monitoring of the palletizing robot, loading contents manual, etc. Next, the process proceeds to step 66.

In step 66, the computer 10
, 16. List of stowage positions stored in 17.

The loading order and robot operation sequence are stored in the auxiliary storage device 24.
output, and the series of control operations ends.

The information in this auxiliary storage device 24 becomes operation teaching data for the palletizing robot.

In the above embodiment, the programs are executed continuously according to the order, but if the intermediate results of the program processing are stored in the auxiliary storage device 24, there is no need to execute the programs continuously.

〔Effect of the invention〕

As described above, according to the present invention, the optimal number and dimensions of exterior cases with high loading efficiency are automatically determined in response to a transportation request for any cargo, as well as the loading distribution and loading arrangement of the cargo. Furthermore, the cargo loading order and robot operation sequence can be determined based on the obtained information, which has the effect of reducing the number of steps required to teach the robot.

[Brief explanation of the drawing]

Figure 1 is a schematic diagram for explaining the loading method using a palletizing robot to which the cargo loading planning method of the present invention is applied, Figure 2 is a diagram showing the positional relationship of cargo on pallets, and Figure 3 is a diagram showing the positional relationship of cargo on pallets. FIG. 4 is a diagram illustrating an example of determining the robot operation sequence; FIG. 5 is a block diagram illustrating an example of the overall configuration of the system of the present invention; FIG. FIG. 10 is a diagram showing an example of a storage method for various data stored in the storage unit in the above methods, respectively;
FIGS. 11 and 12 are diagrams showing control flowcharts in the system, and FIGS. 13 to 15 are diagrams showing examples of screens displayed on the display device. IA...palletizing robot, IB...valet, LD...cargo supply conveyor, IF...cargo,
lG...Pallet loaded with cargo, 1o...Computer, 11-18...Storage unit, 19...Control unit, 21...Light pen, 22...Graphic
Display device, 23...hard copy output device,
2, 4... Auxiliary storage device, 25... Kugata device with cargo specifications, *r Figure Ir/C 73 Figure Tomori 4 Figure T 5 I\1 VJ 6 Nagi\J 7 times\J F3 Figure 4 Sρl ρ 61θ
ρ L ｨ q ｜ ｨ ￥ 5 / 3 口 f J /! L figure "f, figure 15

Claims (1)

[Claims] Specifications for multiple types of external cases that can be selected and are standardized with different dimensions, specifications for multiple types of cargo with different dimensions to be stowed in the external cases, specifications for external cases determined to be used for stowing all cargo. and stowage plan information that includes the distribution and stowage arrangement of cargo to its outer cases, the loading order of cargo for each outer case to be used based on this stowage plan information, and the operation of the robot that performs the stowage. a storage means for storing stowage work information including a sequence; a calculation device for calculating the stowage plan information and the stowage work information based on instruction information from an input terminal device; and a stowage unit output from the calculation device. a display device for displaying plan information and stowage work information; an output device for documenting and outputting at least cargo stowage order and stowage plan information from the stowage work information outputted from the calculation device; A cargo stowage planning method characterized by comprising an auxiliary storage device for storing stowage plan information and stowage work information output from the device.