JPS62222901A - Control method and device for automatic warehouse - Google Patents

Abstract

PURPOSE:To prevent a mistake in picking and shipping in the case of taking in and out article per packed shipping box to/from an article storing means, by carrying out the picking independently of the shipping to re-warehouse the shipping boxes and shipping the articles from the packed shipping boxes which are in the state ready for shipping. CONSTITUTION:Transfer devices 130 and 150 for take-in and take-out are attached to an article storing means 110 for storing packed boxes containing articles therein. A warehousing line 120 and a shipping line 165 are connected to the transfer devices 130 and 150 for take-in and take-out, respectively. The transfer device 130 for take-in is adapted to take in the articles per packed shipping box to the storing means 110. A re-warehousing line 140 is also connected to the take-in device 130, so as to re-warehouse the packed shipping boxes prepared by picking to the storing means 110. On the other hand, a picking line 160 is connected to the transfer device 150 for take-out so as to take out the packed boxes for picking. Thus, only the packed boxes necessary for the picking may be delivered independently of a shipping step.

Description

[Detailed description of the invention] [Table of contents] - Overview - Field of industrial application - Prior art - Problems to be solved by the invention - Means for solving the problems - Actions - Examples - Effects [Overview] Required: When loading and unloading packaging boxes into and out of the goods storage means of an automated warehouse, picking is performed separately from shipping and re-stocking, and at the time of shipment, the shipping packaging in the goods storage means in a ready-to-ship state is Shipment starts from inside the box.

Thereby, picking and shipping operations can be performed efficiently and without errors.

(Industrial Application Field) The present invention relates to a control method and apparatus for an automatic warehouse that automatically performs loading and unloading work of goods, and particularly relates to a control method and apparatus for an automatic warehouse suitable for cases where picking work is required. .

[Conventional technology]

2. Description of the Related Art Automated warehouses using multi-stage horizontal rotating shelves are known as automated warehouses that reduce the space for storing articles and efficiently carry out loading and unloading of articles.

FIG. 9 shows the basic configuration of a conventional automated warehouse equipped with rotating shelves.

In FIG. 9, reference numeral 210 denotes article storage means, which includes a plurality of horizontal rotating shelves 220. Note that each horizontal rotating shelf is designated by a common reference numeral 220. This means that the horizontal rotating shelf 220
The same applies to other elements constituting the .

As shown in FIG.
3 are connected and rotated. Each horizontal rotating shelf 220 is independently controlled to rotate.

As shown in FIG. 10, each tray 223 has a single storage section configuration of 1 stage x 1 row for storing one storage box. Each horizontal rotating shelf 220 is rotationally controlled using this single storage section as one moving vehicle position.

230 is a warehousing line that transports the storage boxes to a warehousing transfer machine.

240 is a warehousing transfer machine, and 250 is a warehousing transfer table. or,
260 is a shipping transfer machine, and 270 is a shipping transfer table.

Each of the transfer tables 250 and 270 includes a plurality of transfer shelves corresponding to each stage of the horizontal rotary shelf 220.

The transfer table 250 on the warehousing side is a buffer for temporarily holding the storage boxes that enter the horizontal rotating shelf 220, and the outgoing transfer table 270 temporarily holds the storage boxes that are delivered from the horizontal rotating shelf 220. This is a buffer for storing data.

Each transfer machine 240 and 260 has one lifting platform (not shown)
It is equipped with The warehousing transfer machine 240 is connected to the warehousing line 230
The storage box transported from the storage box is transported to a predetermined transfer shelf on the warehousing transfer table 250. The shipping transfer machine 260 is a horizontal rotary shelf 22
The receiver picks up the storage box that has been taken out from 0 and is placed on the transfer shelf of the delivery transfer table 270, transports it up and down, and carries it out to the delivery line (not shown).

Note that the storage box is moved between the transfer machine 240 and the transfer table 250 by a belt conveyor provided in the transfer machine 240.

To move the storage box between the transfer table 250 and the horizontal rotating shelf 220,
This is done by pushers (not shown) provided at each stage of the transfer table.

Further, the storage boxes are moved between the horizontal carousel 220 and the transfer table 270 by pushers (not shown) provided at each stage of the horizontal carousel on the delivery side.

The storage box is moved between the transfer table 270 and the transfer machine 260 by pushers (not shown) provided at each stage of the transfer table.

Next, each operation of loading and unloading will be explained.

(A) Warehousing operation Storage boxes transported to the automated warehouse are transported to the warehousing line 230.
is transported to the warehousing transfer m240.

The warehousing transfer machine 240 uses a lifting platform (not shown) to move the storage boxes to the warehousing transfer table 2 corresponding to the horizontal rotating shelf 220 of the scheduled storage stage.
When the storage box is transported to the transfer shelf No. 50, a belt conveyor (not shown) sends the storage box to the transfer shelf.

The rotational movement of the horizontal rotating shelf 220 of the scheduled storage stage is controlled so that the storage scheduled tray 223 of that stage comes to the position of the warehousing transfer table 250.

When the horizontal rotary shelf 220 rotates to a predetermined position, a pusher (not shown) stores the storage box in a predetermined tray 223 of the horizontal rotary shelf 220, that is, a predetermined storage section.

The warehousing transfer machine 240 is released when the storage box is sent to the transfer shelf of the warehousing transfer table 250, and moves on to the work of transporting the next storage box. Thereby, the work of storing the storage boxes on the horizontal rotating shelf 220 can be performed efficiently.

(B) Retrieval operation The horizontal rotary shelf 220 in which the storage box containing the desired item to be unloaded is stored is controlled to rotate, and the tray 223 on which the storage box is mounted is moved to the position of the retrieval transfer table 270. move it. Thereafter, a pusher (not shown) moves the storage box from the tray 223 of the horizontal rotating shelf 220 to the unloading transfer table 27.
Move to transfer shelf 0.

When the elevating platform (not shown) of the unloading transfer machine 260 reaches the transfer shelf, the storage box is moved to the elevating platform by a pusher (not shown), and is further moved from the unloading transfer machine 260 to the unloading line (not shown). It is transported and shipped.

When shipping goods, it is necessary to package the goods with the same type and quantity for each user. Therefore,
When shipping items, desired items are taken out from storage boxes that have been delivered, and sorting is performed to match the types and quantities of items to be shipped to each user.

If there is an excess or deficiency in the desired quantity depending on the existing storage boxes, the next storage box is called and a picking operation is performed to arrange the desired quantity.

Through the above operations, the types and quantities of items to be shipped for each user are arranged, and the items are stored and packaged in cardboard boxes for shipping. A destination label is attached to each shipping cardboard box, and shipping slips and delivery notes are grouped together for each user and placed in the final shipping cardboard box.

[Problem that the invention seeks to solve]

As described above, the conventional control system for an automatic warehouse equipped with multi-stage horizontal rotating shelves manages the storage, storage, and storage using one storage box per moving model.

This control method has the advantage that it can be applied to any type of item without being affected by the size, weight, etc. of the item.
There are problems similar to the reverse method, which are especially problematic when producing a wide variety of small, lightweight parts.

■ If several types of items are mixed in one storage box,
Since there is picking work at the time of shipping, errors are likely to occur.

■ Since sorting and picking operations are performed in parallel during shipping, not only are errors likely to occur, but picking operations take a lot of time, resulting in overall delays in shipping operations.

- Each horizontal rotating shelf has one storage box, so if it is made into a multi-stage system, the storage efficiency will decrease.

[Means for solving problems]

Means taken by each invention of the present application to solve the above-mentioned problems in conventional automated warehouse management systems will be explained with reference to FIG. 1, which is a diagram illustrating the principle of each invention of the present application. below,
The invention stated in the first claim is referred to as the first invention, and the invention stated in the fifth claim is referred to as the second invention.

In FIG. 1, reference numeral 110 denotes article storage means in which packaging boxes containing articles are stored.

120 is a warehousing line, and 130 is a warehousing transfer device that connects the article storage means 110 and the warehousing line 120. These constitute the warehousing means of the second invention, and the warehousing step of the first invention,
That is, a step is performed in which the articles are stored in the article storage means 110 in units of packaging boxes.

Reference numeral 140 denotes a re-warehousing line, which constitutes the re-warehousing means of the second invention together with the warehousing transfer device 130, and is used for the re-warehousing process of the first invention,
That is, a process of re-stocking the shipping packaging boxes created by picking into the article storage means 110 is performed.

Reference numeral 160 is a picking line through which packaging boxes are carried out during picking, and reference numeral 150 is a shipping transfer device that connects the article storage means IIO and the pick line 160. These constitute the picking and dispensing means of the second invention, and perform the picking and dispensing step of the first invention, that is, the step of discharging only the packaging boxes necessary for picking independently of the shipping process.

Reference numeral 165 denotes a shipping line through which packaging boxes for shipping are carried out, which constitutes the shipping means of the second invention together with the shipping transfer device 150, and is used in the shipping process of the first invention, that is, stored in the article storage means 110 and ready for shipping. A process of shipping from a shipping packaging box is performed. The packaging boxes for shipping are composed of packaging boxes that have been received and are changed to packaging boxes for shipping without picking, and packaging boxes that have been created by the above-mentioned picking.

Note that the configuration of the second invention is not limited to the configuration shown in FIG. For example, the warehousing transfer bag W130 may be installed separately without being shared by the warehousing means and the re-warehousing means. Similarly, the shipping transfer device 150 is
The picking and dispensing means and the retrieval means may be provided separately without being shared. Furthermore, the article storage means 110 is not limited to a horizontal rotating shelf configuration.

[For production]

The effects of the first invention and the second invention are as follows.

When the articles are stored in the warehouse, the articles are stored in the article storage means 110 by the carrying means in packages.

When picking for shipping is required, only the packaging boxes necessary for picking are discharged from the article storage means 110 by the picking and discharging means independently of the shipping process. When the picking is completed, the shipping packaging boxes created by the picking are re-stored into the article storage means 110 by the re-warehousing means.

At the time of shipping, the goods are shipped by the unloading means from the shipping packaging box stored in the article storage means 110 and ready for shipping.

As mentioned above, since the shipping work and picking work are not performed simultaneously, and the picking work is set up independently of the shipping work, only the picking work is performed, so that the picking work can be done error-free and efficiently. I can do it. Furthermore, since the product is shipped from within the shipping packaging box that is ready for shipping, the shipping work can be carried out efficiently and without errors.

〔Example〕

Embodiments of the first invention and the second invention will be described with reference to FIGS. 1 to 9.

Fig. 1 is an explanatory diagram of the principle of each invention of the present application, Fig. 2 is an explanatory diagram of an embodiment of each explanation, Fig. 3 is an explanatory diagram of a horizontal rotating shelf, and Fig. 4 is an explanatory diagram of the embodiment of each invention of the present application.
The figure is a system flowchart, Figure 5 is an explanatory diagram of the actual inventory management file, Figure 6 is an explanatory diagram of the storage status file,
FIG. 7 is a location determination flowchart, FIG. 8 is an explanatory diagram of a shipping/output management file, and FIG. 9 is an explanatory diagram of the basic configuration of a conventional automated warehouse.

In the following description, packaging boxes will be referred to as follows depending on each work stage or processing stage. These names are consistent with those already explained above.

■ Single packaging box: A packaging box containing items of the same size,
The model rating is the type of article or product name.

■ Fully packed box: A single packaging box that contains all the items that can be stored in a single packaging box.

■ Fractional box: A single packaging box containing a fractional number of items.

■ Fully reserved box: A fully loaded box that has been reserved for shipping.

■ Reserved fractional boxes: Fractional boxes that have been reserved for shipping.

■ Reserved box: A single packaged box that includes both reserved full boxes and reserved fractional boxes, and is awaiting shipment.

■Shipping packaging box: Reserved box with shipping instructions.

(A) Structure of the embodiment In FIG.
, warehousing transfer device 130, re-warehousing line 140, warehousing transfer device 150, picking line 160, shipping line 16
5 is as explained in FIG.

The article storage means 110 has a multi-stage horizontal rotating shelf structure as shown in FIG.

FIG. 3 shows the configuration of each horizontal rotating shelf used in this embodiment. In FIG. 3, 170 is a horizontal rotating shelf, 171 is a frame, 172 is a rubber roller, 173
is a tray.

The tray 173 is divided into nXm storage sections arranged in n stages x m columns, and each storage section stores a single packaging box, that is, one packaging box containing the same type of article. . FIG. 3 shows an example of six storage compartments arranged in two stages and three rows, forming one moving vehicle position as a whole. Tray 17
3 is about the same size as or slightly larger than the tray 223 in FIG. 10, and is large enough to smoothly rotate around the semicircular portion of the horizontal rotating shelf 170.

Each horizontal rotating shelf can have the structure shown in Fig. 3 or the structure shown in Fig. 10, but in this embodiment, all the horizontal rotating shelves have the structure shown in Fig. 3. Suppose that Therefore, in the following explanation regarding the horizontal carousel,
The symbols in FIG. 3 are used. In addition, the packaging box refers to a single packaging box.

The horizontal rotating shelf 1 with one moving vehicle position and multiple storage compartment configuration shown in Fig. 3
By using 70, storage efficiency can be improved compared to the horizontal rotating shelf shown in FIG. 10, and the cost of the horizontal rotating shelf can be reduced. In addition, since it is possible to carry out loading and unloading operations and management of packaging boxes for each of the nXm storage sections, each operation and management at the time of warehousing, picking, and shipping can be performed efficiently and rationally.

The warehousing transfer device 130 is a warehousing transfer tJM similar to that shown in FIG.
131 and a warehousing transfer table 135, and the warehousing transfer device 150 also consists of a warehousing transfer machine 151 and a warehousing transfer table 155 similar to those shown in FIG.

The warehousing transfer machine 131 and the warehousing transfer machine 151 each include a lifting platform (not shown), and the warehousing transfer table 135 and the warehousing transfer table 155 each have a transfer shelf (not shown) corresponding to each horizontal rotating shelf 170.
(not shown), and their configurations are also the same as in the case of FIG. The movement of packaging boxes between each transfer machine, transfer table, and horizontal rotating shelf is carried out by a belt conveyor and a pusher type in the case of warehousing, and by a pusher type in the case of unloading.

181 to 184 are barcode leagues (BCR). 191 is a receiving buffer storage, 192 is a fixed shelf line, 195 is a receiving inspection area where receiving inspection is performed, 196 is a picking area where picking work is performed, and 197 is a re-stocking area where each fractional box that has been picked is inspected and re-stocked. ,1
Reference numeral 98 is a shipping and packing area where shipping and packaging work is performed. The fixed shelf line 192 is a line for temporarily docking packaging boxes to be stored on fixed shelves (not shown).

A control device 200 controls the operation of each device in the automated warehouse system shown in FIG.

(B) Operation of the Example Each operation such as warehousing, picking, and shipping performed in FIG. 2 is explained with reference to the process flowchart in FIG. 4.
The explanation will be given according to the processing order (indicated by the number ■ in the circle).

In FIG. 4, the communication management block, actual inventory management block, location management block, shipping priority management block, picking work management block, and shipping issue management block surrounded by a rectangle in the center are performed by the host computer. Each management function. Storing, picking and discharging, re-storing, and shipping surrounded by parallelograms are operations performed by the automated warehouse system of FIG. 2. Process control system, acceptance inspection, enclosed in an oval
The order receiving and shipping management system is a management function or work performed by a separate system. vDTl is a terminal with a display to which a picking issue request is input;
T2 is a terminal with a display from which shipping and exit instructions are given. Arrows indicate flow of control, circled numbers ■
indicates the general processing sequence from warehousing to warehousing.

(al) From the warehousing instruction processing process management system, information regarding articles that are scheduled to be warehousing (warehousing schedule information) is sent via communication to the communication management block of the host computer.

The communication management block is a block that controls communication between the host computer and other systems connected online, and sends the received inventory schedule information to the actual product inventory management block (FIG. 4 - ).

The physical inventory management block has a physical inventory management file,
This block manages the articles and packaging boxes stored on the horizontal rotating shelf 170, and records the warehousing schedule information in the actual item inventory management file.

Figure 5 shows an example of the actual inventory management file, which shows the model of the item stored in the packaging box, the classification of the warehouse where the packaging box is stored (warehouse classification), and the storage location of the packaging box. Inventory management information, such as whether the item is in the current state or in the picking state, and quantity aggregation information for each state are filed. As shown in the figure, this file includes a warehousing schedule information group, a full box inventory information group, a fractional box inventory information group, an allocated box information group,
It is managed for each group, such as a picking work payment birth information group, a post-picking restorage schedule information group, etc.

The warehousing schedule information transferred from the communication management block is recorded in the warehousing schedule information group file.

(False) Warehousing operation Before the warehousing operation, sampling inspections, destructive tests, etc. are conducted on each loft for the products transported from the factory, and packaging boxes of products that pass are marked with label classification, EDP number, box serial number, and warehouse. A label on which barcodes and printed characters indicating classification, check digits, etc. are printed is attached, and the product is sent to the acceptance inspection site 195 in FIG. 2.

(bl) Acceptance Inspection When the packaging box is delivered to the acceptance inspection site 195, the worker at the acceptance inspection site 195 reads the label affixed to the packaging box and identifies the product name and quantity of the items stored in the packaging box. Open the packaging box and inspect the actual product to see if the information matches the information on the label (Figure 4 Receiving Inspection).

The barcode data of the label on the packaging box that passed the inspection is input into a barcode league (not shown) and transferred to the actual inventory control block (Fig. 4, ■).

(b2) Based on the input barcode information, the actual item inventory management block transfers the information of the full box from the warehousing schedule information group in the actual item inventory management file to the full box inventory information group,
The information on the fractional boxes is transferred to the fractional box inventory information group.

In addition, the actual item inventory management block sends the received transaction information based on the input barcode information to the order receiving and shipping management system that is in charge of inventory management at all shipping centers (4th block).
Figure ■).

(b3) Packaging boxes that have passed the acceptance inspection are transported in lot units to the warehousing buffer storage 191 and temporarily stopped in front of the BCR 181.

The actual inventory management block rechecks that the packaging box is the packaging box that is scheduled to be stocked based on the barcode information read by the BCR 181, and also fixes the packaging box to the horizontal rotating shelf 170 based on the warehouse classification information. The control device 200 of the automated warehouse is instructed as to which shelf it is.

By performing this recheck, it is possible to reliably prevent packaging boxes other than those that have undergone acceptance inspection from being erroneously stocked.

The control device 200 switches the warehousing line according to the instruction, and the packaging boxes to be stocked on the horizontal rotating shelf 170 are placed on the warehousing line 1.
Packaging boxes carried into the fixed shelf line 192 are carried into the fixed shelf line 192.

(b4) The packaging boxes stored on the horizontal rotating shelf 170 are transported on the storage line 120 and stopped in front of the storage transfer m1si. BC on the warehousing line side in front of the warehousing transfer machine 131
R182 reads the barcode on the label on the stopped packaging box and sends the information to the actual inventory management block (
Figure 4 ■).

The actual inventory management block checks whether the packaging box can be accepted based on this barcode information, and if the packaging box is acceptable, requests the location management block to determine the storage location (Fig. 4 ).

(b5) Location determination processing The location management block is equipped with a storage status file illustrated in FIG. 6, and manages whether all locations (addresses of storage sections) of the horizontal rotating shelf 170 are vacant or in use.
Based on the storage location determination request from the actual inventory management block, the location where the packaging box should be stored is determined and notified using a predetermined algorithm (Fig. 4 ■, ■
).

The storage status file is stored on horizontal rotating shelf 1 as shown in Figure 6.
It corresponds to the configuration of 70 and is divided into areas of i columns×j stages. That is, j stages correspond to the total number of stages of the horizontal rotating shelf 170, and i
A row corresponds to all storage compartments within one horizontal carousel. Note that the total number of stages j and the total storage compartments l of the horizontal rotating shelf 170 are 1
If the horizontal carousel 170 uses trays 173 with n stages x m rows as shown in FIG.
There will be one row and one row. As a result, one storage section, that is, one packaging box corresponds to 10 cases, and management can be performed in units of packaging boxes. Location: 2nd row and 2nd row
determined by the value 1 (i.

j) indicates the location of the third stage of the first column. a to g are examples of locations where packaging boxes are stored. In this way, the storage location is represented by (9 rows), and the lower case letters in FIG. 6 indicate that one packaging box is stored.

Hereinafter, with reference to the location determination flowchart of FIG. 7, the location determination processing performed in the location determination block will be described according to its steps.

This location determination process allows the storage section of the packaging box to be determined in a completely free location manner. Note that B u f (1) in FIG. 7 indicates the third stage transfer buffer, and i indicates the location within the first stage.

(11 Step S+ The total number of stages of the horizontal rotating shelf 170 (assumed to be j ma) and the position W of the lifting platform of the warehousing transfer machine 131 at the time of starting the operation
(given by the stage value of the horizontal rotating shelf).

(2) Step S20 The case management block is waiting in the Read state, and when there is a storage location determination request (■ in Figure 4) from the actual inventory management block, the location is determined in the following steps. .

(3) Step 53134: Check whether there is a recommendation to end the location determination process.Step S3). Stop the location determination process when a recommendation to end is received (Step S4). Performed when the system is closed.

(4) Step S5 If there is no recommendation for termination, the position (j5ave) of the lifting platform of the warehousing transfer machine 131 is saved. At times other than when the operation is started, the lifting platform is stopped at the position when the packaging box was stored last time, so that value is saved as j5ave.

(5) Steps Se, S7: A counter (not shown) for counting the number of stages of the horizontal rotating shelf 170 is counted up by "1" (Step S6), and it is checked whether the count value is equal to j5ave (Step S6). St). The current value j is j until the counter counts up and returns to the j5ave value again.
Since it is not equal to 5ave, the process moves to the next step S8.

(6) Step S8 It is checked whether the count value j fJ<j max has been reached. If oj>jma, the horizontal rotating shelf 170
Since the search for empty locations from the (j5ave+l) stage to the jmax stage has been completed, the count value j is set to 0", and the process returns to step S6 to
A search is made to search for an empty location between the (J 5ave 1 ) rows.

If j<jmax, the next process of step S9 is performed.

(7) Step S also checks whether or not the transfer shelf of the warehousing transfer table 135 corresponding to the third stage of the horizontal rotary shelf is vacant by referring to the storage status file shown in FIG. If there is no vacancy, step S6
Return to , and search for vacancies for the next stage.

If the transfer rack is empty, the horizontal rotating rack at that level is selected as a candidate for storing the packaging box, and the processes from the next step 81o are performed.

(8) Step S+o, So, St2 With reference to the storage status file shown in FIG. 6, empty locations are searched in order from the beginning of stage j (step S+o).

If there is no vacant location, the process returns to step Ss and a vacant search for the next stage is performed.

If an empty location is detected, the first empty location detected is set as the location for storing the packaging box, and the location l (i, j) is placed in use (step 512), and the process of the next step 313 is performed.

(9) Step S13 The location (determined location) l2 (I S J) indicating the storage section in which the requested packaging box is to be stored is notified to the actual inventory management block (FIG. 4 - ). When this notification ends, the process returns to step S2 and waits for a storage location determination request for the next packaging box.

(10) Step S7 The value when the counter is counted up is j5ave
, the total number of stages of the horizontal rotating shelf 170 (1
.

(11) Step S)4. If j=jsave, the S+s, S-corresponding location management block increments the count value CNT of another counter (not shown) by "1" (step SM). This counter allows
In the vacant location search processing performed in steps 86 to So described above, the number of times that no vacant location is detected is counted.

In the next step Sls, it is checked whether the count value CNT has reached a predetermined value (for example, 10 times).

If the count value CNT is 10 or less, after waiting for a certain period of time (step Si), the process returns to step S6 and the above-described vacant location search process is repeated.

If the vacancy is not detected 10 or more times in a row (step 5yb), an alarm display is instructed to indicate that the warehousing operation will not be performed (step 517). Based on this alarm display instruction, an alarm is displayed on the control device 200 of the automated warehouse system and in the section where the warehousing work is performed, informing the operator that the warehousing work is in a waiting state and at the same time prompting the worker to carry out the shipping work.

(b6) When the actual inventory management block receives the location determination notification from the location management block, it sends it to the automated warehouse control device 200 (FIG. 4 -).

(b7) The control device 200 controls the warehousing transfer machine 131,
Horizontal rotating shelves 17 with the number of stages specified by the location determination notification
The packaging box is transported to a height of 0, and sent to the transfer shelf of the warehousing transfer table 135 corresponding to that stage by a belt conveyor (not shown).

Next, the horizontal rotary shelf 170 is rotated, and when the storage compartment designated by the location determination notice comes to the position of the transfer shelf, the packaging box is stored in the storage compartment by a pusher (not shown).

By searching for vacant locations in advance as described above, packaging boxes can be stored in the storage section of the horizontal rotating shelf 170 in a completely free location manner, and the functions of the transfer machine with a transfer table can be fully utilized. This makes it possible to prevent a waiting state from occurring and to make the warehousing work extremely efficient.

(c) Common shipping and picking operations (cl) When shipping the packaging boxes stored in the horizontal carousel 170, shipping instruction information containing the shipping destination, shipping item name, shipping number, etc. is sent from the order shipping management system. is sent to the host computer (Figure 4, ■).

(C2) The host computer receives the shipping instruction information through the communication management system and transfers the contents to the shipping priority management block (FIG. 4 - ).

(C3) The shipping priority management block calculates the number of fully loaded boxes required for shipping from the number of shipped items in the transferred shipping instruction information, and sends the withdrawal date switching information to the actual inventory management block (
Figure 4 ■).

When the actual inventory management block receives this allocation date switching information, it moves each full box indicated by the allocation date switching information from the full box inventory information group of the actual inventory management file shown in FIG. 5 to the reserved box information group. The processing is carried out, and the shipping priority management block is notified that the date has been changed ((■' in FIG. 4).

The shipping priority management block instructs picking if the predetermined number of shipped items cannot be obtained from the number of fully loaded boxes alone and a fractional number occurs. This picking instruction is sent to the automated warehouse control device 200. Since picking is typically performed on multiple items, those pickings are registered in a picking queue (not shown). It is an exception that picking is not performed; picking is normally performed.

Next, the picking operation will be explained.

+d) Picking operation (d+) When the worker at the picking work area 196 receives a picking instruction and is ready for picking, the worker at the terminal V
DTr notifies the picking work management block of the picking delivery request (FIG. 4 [phase]).

(d2) Upon receiving this notification, the picking work management block issues a picking request to the shipping priority management block (FIG. 4, 0).

(d3) Upon receiving a picking request, the departure priority management block extracts the location information of the fractional boxes that satisfy the specified quantity from the picking queue of the fractional boxes on the return trip to be picked, and stores the fractional boxes in the picking work management block. A picking work request including box location information is sent (Fig. 4 ■').

(d.) Based on this picking work request, the picking work management block sends a picking issue request to the actual item inventory management block (FIG. 4 O).

(d5) The actual inventory management block picks the information on the odd boxes to be picked from the odd box inventory information group in the actual inventory management file (Figure 5) based on the location information of the odd boxes to be picked in the picking issue request. Move to work payment birth information group.

When the fraction box containing the remaining number after the picking operation is to be re-stored, it is managed as "planned to be re-stored", and after the picking operation, a new storage location is determined and the box is re-stored.

On the other hand, information regarding the return route, quantity, storage location, etc. of the fractional boxes for shipping (allocated fractional boxes) newly created by the picking operation and scheduled to be restocked is created, and the information is added to the post-picking restorage schedule information group. recorded.

When each of the above processes is completed, the actual inventory management block notifies the picking work management block of the delivery location and instructs the location of the fractional boxes to be picked (
Figure 4 @).

(d.) When the picking operation management block receives the notification of the shipping location date, it instructs the control device 200 of the automated warehouse system in FIG. 2 to pick and issue (FIG. 4).

The picking work management block further sends picking dispatch information to the location management block (Fig. 4 [phase]
).

Based on this payout information, the location management block sets vacancy information to locations that become vacant due to picking.

(d7) Upon receiving the picking dispensing instruction, the control device 200 controls the horizontal rotating shelf 170, the unloading transfer table 155, and the unloading transfer machine 151, and controls the picking dispensing instruction based on the location information in the picking dispensing instruction. The work of discharging the fractional boxes from the horizontal rotating shelf 170 is performed. This dispensing operation is the reverse of the warehousing operation described above in (b7), and is obvious from the warehousing operation, so the explanation will be omitted.

(d8) Fractional box for picking is picking line 16
When 0 is paid out, the BCR 11i3 reads the barcode on the label on the fraction box and sends the contents to the control device 200.

Since the work location for picking differs depending on the return journey of the article, the control device 200 determines whether the fractional boxes are located at the picking location 190 based on the barcode information sent from the BCR 183.
When the box is transported to a predetermined work location, a pusher (not shown) is controlled to send the fractional box to a workbench at the predetermined work location, and a picking label is printed out. When sorting for multiple users from one fraction box,
A picking label for each user is printed out. Each picking label has a barcode printed with the return route, quantity, etc.

The worker performs a predetermined picking operation according to the instructions on the picking label, and attaches a picking label to each newly created fractional box for shipping and to the original fractional box in which the remaining quantities are stored.

While the worker is picking, the host computer dispatches the next packing box to be picked to the work location in the same manner. This eliminates the waiting time between picking tasks for workers and greatly improves picking efficiency.

When the picking operation is completed, each fractional box is placed in the re-entry area 19.
7, and a worker inspects whether the contents of each fraction box match the contents of the picking label.

Each fractional box that passes the inspection is sent to the restocking line 140. Each fractional box is transported to the front of the automatic warehousing transfer device 130 by the re-warehousing line 140. When the first fractional box reaches the warehousing automatic transfer device 130, the BCR 184 on the re-stocking line reads the barcode on the label on the fractional box, and uses this information to manage the picking operation as a restorage request that also serves as a picking completion report. Send to block (4th
Figure [phase]).

In addition, since the number of fractional boxes to be dispensed for picking work is known in advance, the control device 20 of the automated warehouse system
0 counts the number of fractional boxes that have been dispensed, and when it is determined that all fractional boxes have been transferred to the work table, notifies the picking work management block of the completion of dispensing. When the picking work management block receives this notification of completion, it requests the shipping priority management block to issue the next picking work request.

(d9) The picking operation management block notifies the actual item inventory management block of the restorage request (FIG. 4@).

When the physical inventory management block receives this restorage request,
A request is made to the location management block to determine the storage location of the fraction box.

The location management block determines the storage location of the fractional boxes according to the same procedure as the storage location determination procedure at the time of warehousing described above, and notifies the actual product inventory management block.

In addition, for each fractional box that is re-stored after picking,
Since empty locations for the fractional number of boxes are reserved in advance, there will be no situation where re-storage is not possible due to a lack of empty locations. This is to prioritize shipping work.

When the actual inventory management block receives the storage location determination notification, it sends it to the automated warehouse system and stores the fractional boxes in a predetermined storage section of the horizontal rotating shelf 170 in the same manner as the warehousing operation described above.

The actual item inventory management block further transfers the fractional boxes for shipping to be restored from the post-picking restorage schedule information group of the actual item inventory management file to the allocated box information group as allocated fractional boxes.

Therefore, the reserved box information group stores information on reserved full boxes and reserved fractional boxes that are ready for shipping.

(d+o) The picking operation management block notifies the shipping priority management block of the completion of picking for the re-stored fractional boxes (FIG. 4 [phase]).

(c) Shipping operation (cl) The shipping priority management block receives the notification that the allocation account has been switched from the actual inventory management block (Fig. 4 ■') and the picking completion notification (the fourth
Based on the diagram [phase]), information regarding the shipping destination user, full boxes and fractional boxes in the reserved flow that can be shipped is notified to the shipping/output management block.

(c2) The shipping/outputting management block is provided with a shipping/outputting management file and performs shipping/outputting management.

Figure 8 shows an example of a shipping/output management file.
It has a hierarchical structure as shown in the figure.

Level 0 is the entry level, where entries for the entire shipping ratio jIF management file are defined.

Level l is the shipping area level, which divides the entire country into multiple shipping areas, and files information regarding each shipping area.

Level 2 is the intra-area user level, where information regarding each user within one area is filed.

Level 3 is the user internal pattern route level, and shipping pattern information (return route name, number of items to be shipped, shippable state indication flag, etc.) is filed for each user.

Level 4 is the return packaging box level, which is shipping packaging box information for one shipping type, i.e., information about reserved full boxes and reserved fractional boxes for shipping (number of stored items, location where each section is stored, etc.) is filed. Information regarding allocated fractional boxes is filed in ((1)-c) to ((1)-n) at the left end of the shipping packaging box information group, and information regarding allocated full boxes is filed in the other items. .

Now, assuming that the goods for the return trip (1) are to be shipped to user 1, the shipping priority management block notifies the shipping user name (user 1) and information regarding the full boxes and fractional boxes for shipment for the return trip (1). According to the above-mentioned levels 0 to 4, one user of area 1 has the shipping packaging box information group ((11-a) to ((1) to (C)
) is filed with information regarding full boxes and fractional boxes that have been reserved for shipping.

When the information regarding the reserved fractional boxes for shipping is finally filed in the shipping packaging box information ((11-c), the required number of shipments in return trip (11) is all ready for shipment, so level 3
The shippable state instruction flag in the shipping type information (1) is set to ON, and the ship waits for a shipping/output instruction.

(c3) When shipping and leaving the warehouse, the shipping and leaving instruction information is notified from the terminal VDT 2 to the shipping and leaving management block (Fig. 4 @).

(c4) Based on this shipping/shipping instruction information, the shipping/issue management block refers to the destination-specific user, shipping type/class information, and shipping/packing box information in the shipping/distributing management file, and determines whether the shipment is ready for shipment. The location information of packaging boxes for shipping, that is, full boxes and fractional boxes that have been reserved for shipping, is summarized for each user by type, and the automatic warehouse system is instructed to take it out (FIG. 4, ■).

At the same time, destination labels, shipping slips, and delivery notes are printed out at each work location in the shipping and packing area 198 of the automated warehouse system.

(c5) In the automated warehouse system, in the same manner as in the above-mentioned warehousing operation or picking operation, the shipping packaging boxes at the location where the shipping instruction has been given are sequentially carried out from the horizontal rotating rack 170 to the shipping line 165, and Send to 19B.

(c8) At the shipping packing area 19B, after inspecting whether the contents of the shipping packaging boxes that have been transported match the contents of the shipping slip, each user places a predetermined number of shipping packaging boxes (for example, 4 pieces) Store and pack them together. A destination label is affixed to each shipping cardboard box, and the shipping slip and delivery note are grouped together for each user and placed in the final shipping cardboard box.

(c7) The shipping/issue management block issues a shipping instruction and also notifies the stock inventory management block of the completion of shipping (fourth
figure@).

Upon receiving this dispatch completion notification, the actual item inventory management block marks the shipped allocated boxes in the allocated box information group of the actual item inventory management file as shipped. Furthermore, transaction data regarding shipping is created and sent to the order receiving and shipping management system via the communication management block.

(c8) The shipping and issue management block also notifies the location management block of the completion of the issue (Fig. 4 [phase])
.

Upon receiving this shipping completion notification, the location management block empties the location in the storage status file of the shipped packaging box and updates information regarding the vacated location.

In the manner described above, warehousing work, picking work, and shipping work can be performed efficiently.

(C) Control System The automated warehouse system of the present invention is an online real-time system. Therefore, since a system down even for a short period of time is fatal, in the present invention, the entire system is connected to a host block and a LAN (Localarea nettomo network) as described below.
rk) It is divided into two blocks. This creates a fall-tolerant system.

(11 host blocks The host blocks are shown in FIG. 4, including a communication management block, an inventory management block, a location management block,
The contents include a shipping priority management block, a picking work management block, and a shipping issue management block. The functions and processing contents of each block are as already explained.

+21 LAN block The LAN block controls each operation of storing, picking and discharging, re-storing, and restocking shown by the parallelogram blocks in FIG. 4, that is, each operation in the automated warehouse system shown in FIG. 2. This is done by device 200. Their control operations are as already explained.

The host block and LAN block in the present invention are configured as follows.

(The price of the 11-host block host computer occupies a considerable weight of the entire system, and this
r Duplex) would incur enormous costs and result in extremely poor cost performance. Also, with the recent rapid development of hardware reliability technology (+?As), MTBF (Mean Time Between
MTTR (Mean Time To Repair) is getting longer, and MTTR (Mean Time To Repair) is getting longer.
Since r) has been shortened, the effect of redundant investment has almost disappeared.

However, of course, there is no guarantee that it will never go down, so even if a host goes down, our system has a fail-soft configuration that prevents it from affecting the LAN block, so it is possible to prevent the entire system from going down without reducing cost and performance. is avoided.

(21 LAN/Block■) Everything in the LAN is unified with inexpensive general-purpose personal computers.This has the great advantage of not having to prepare a few spare machines.

Another great feature is that the spare machine can be used as a stand-alone machine during normal times.

■ Each personal computer (Works
Since this device writes log data for the device (functioning as a tation), only this device is dual-configured.

By adopting such a system, the system is configured so that even when the host is stopped (due to regular maintenance, failure, etc.), the minimum necessary import/shipment operations can be performed using only the LAN block.

That is, (i) Every morning from the host database, the horizontal carousel storage status before the start of operation (storage information for each location:
Return route, loft number, box serial number, etc.) are transferred to the hard disk in the file server.

(ii) All loading and unloading to and from the horizontal rotating shelf is done using files.
Logging (recording) is done on the server.

(iii) If the host goes down, all transactions up to the time of the downtime are reflected in the horizontal carousel storage status file received this morning to create a storage status file just before the downtime.

(iv) Using the file created in (iii) above, carry out receiving and shipping operations using only the LAN block. The transactions during this time are pooled on the hard disk, and when the host is restored, they are automatically transferred to the host and reflected in the host's database.

〔Effect of the invention〕

As explained above, according to each invention of the present application, the following effects can be obtained.

(b) Since the picking work is performed independently of the shipping work, the picking work can be performed efficiently without making mistakes.

Furthermore, since the next packaging box to be picked is delivered during one picking operation, the operator's waiting time is eliminated and the overall throughput is greatly improved.

(b) Since the products are shipped from packaging boxes that are already ready for shipping (full boxes and fractional boxes according to the allocation method), shipping operations can be carried out without errors and efficiently.

(c) It is possible to improve the storage efficiency of packaging boxes and reduce the cost of horizontal rotating shelves.

[Brief explanation of drawings]

Figure 1: An explanatory diagram of the principles of each invention of this application, Figure 2...
・Detailed explanatory drawings of each invention, Fig. 3...Explanatory drawing of the horizontal rotating shelf used in the same embodiment, Fig. 4...System flowchart of the same embodiment, Fig. 5...Same implementation Figure 6: An explanatory diagram of the storage status file used in the example. Figure 7: Location determination flowchart of the example. Figure 8:・Explanatory diagram of the shipping/output management file used in the same example, Figure 9...Explanatory diagram of the basic configuration of a conventional automated warehouse, Part 1
Figure 0...Explanatory diagram of the conventional horizontal rotating shelf, Figures 1 and 2
In the figure, 110...article storage means, 120...warehousing line,
130... Incoming transfer device, 140... Re-incoming line, 150... Outgoing transfer device, 160... Picking line, 165... Shipping line, 170... Horizontal rotating shelf, 200... ··Control device.

Claims (11)

[Claims] (1) A control method for an automatic warehouse that automatically carries out loading and unloading of articles into and out of the article storage means (110), which includes: (a) a warehousing step in which articles are placed in the article storage means (110) in packaging boxes; , (b) a picking and discharging process in which only packaging boxes necessary for picking are dispensed independently of the shipping process, and (c) shipping packaging boxes created by picking are returned to the article storage means (110). An automated warehouse characterized by comprising: a re-warehousing step of warehousing; and (d) a shipping step of shipping from a shipping packaging box that is stored in the article storage means (110) and ready for shipment. control method. (2) The automatic warehouse control method according to claim 1, wherein the packaging box is a single packaging box. (3) A patent characterized in that the warehousing process involves searching for an empty location in the article storage means (110) before warehousing, determining the storage location using a free location method, and then warehousing the packaging boxes. A method for controlling an automated warehouse according to claim 1. (4) Automated warehouse control consists of a host block that performs management functions and a local block that directly controls automated warehouse operations.
2. The automated warehouse control method according to claim 1, wherein the automated warehouse control method is divided into two area network blocks. (5) In an automated warehouse that automatically loads and unloads articles into and out of the article storage means (110), (a) Input means (120, 130) that stores articles in packaging boxes in the article storage means (110); ), (b) picking and dispensing means (150, 160) for dispensing only the packaging boxes necessary for picking at the time of picking, and (c) re-entering the packaging boxes for shipping created by picking into the article storage means (110). restocking means (130,
140); and (d) unloading means (150, 165) for unloading shipping packaging boxes from the article storage means (110) at the time of shipment. (6) The article storage means (110) has a horizontal rotating shelf (170).
6. The automated warehouse according to claim 5, further comprising at least one stage. (7) Automatic warehouse according to claim 6, characterized in that the horizontal carousel (170) is provided with a tray (173) provided with a plurality of single packaging box storage compartments. (8) The warehousing means and the re-warehousing means are shared by a common warehousing transfer device (
130) The automatic warehouse according to claim 5 or 6, characterized in that it is equipped with: (9) The automatic warehouse according to claim 5 or 6, characterized in that the picking and discharging means and the warehousing means are provided with a common warehousing transfer device (150). (10) The warehousing transfer device (130) is connected to the warehousing transfer device (13
1) and a warehousing transfer table (135). (11) The outgoing transfer device (150) is connected to the outgoing transfer device (15
1) and an unloading transfer table (155).