JPWO2011013336A1 - Automatic warehouse and article confirmation control method - Google Patents

Abstract

The automatic warehouse 1 will be described. The rack 2 has a plurality of shelves 6 for storing the articles F. The transfer device 16 is a device for transferring articles between the shelves 6 and is movable between the shelves 6 through the front of the shelves 6. The sensor 51 is provided on the stacker crane 3. The detected object 10 is provided on the shelf 6. When the article F is placed on the shelf 6, the detected object 10 is on the back side of the article F and is hidden from the sensor 51 by the article F placed on the shelf 6. And no part. The main controller 43 determines whether or not the article F is placed on the shelf 6 using the detection result of the sensor 51, and the article F is switched from detection to non-detection of the detected object 10. Used to determine whether or not

Description

  The present invention relates to an automatic warehouse and an article confirmation control method used in the automatic warehouse, and more particularly, an article is transferred between a rack having a plurality of shelves for storing articles and the shelves and is movable between shelves. The present invention relates to an automatic warehouse including a transfer device and an article confirmation control method used in the automatic warehouse.

  A conventional automatic warehouse has, for example, a pair of racks, a stacker crane, and a loading / unloading station. The pair of racks are provided at a predetermined interval in the front-rear direction. The stacker crane is provided so as to be movable in the left-right direction between the front and rear racks. The warehousing station is arranged on the side of one rack. The delivery station is arranged on the side of the other rack. The rack has a large number of article storage shelves (hereinafter referred to as shelves) arranged vertically and horizontally. The stacker crane has a traveling carriage, a lifting platform that can be raised and lowered by a mast provided therein, and an article transfer mechanism (for example, a slide fork that is slidable in the front-rear direction). is doing.

  As an example of such an automatic warehouse, a stocker for storing a FOUP (Front Opening Unified Pod) in a semiconductor factory is known. In the stocker, for example, at the time of warehousing, the overhead conveyance vehicle carries the FOUP into the warehousing port, and then the stacker crane conveys the FOUP to a predetermined shelf. At the time of delivery, the stacker crane conveys the FOUP from a predetermined shelf to the exit, and then the overhead transport vehicle carries the FOUP from the exit.

  By the way, the actual storage situation differs from the data stored in the automatic warehouse computer. For example, even if the data is empty, there is actually a situation where an article is placed on a shelf. Such a situation occurs, for example, when an operator forgets to place an item on a stacker crane fork on an empty shelf and then put it back on the fork. In this way, although a certain shelf is empty in data, an article is actually placed, and when an article is transferred there, the articles may come into contact with each other and both may be damaged.

  Therefore, an article storage device having an article placement unit, a transfer device, and a sensor provided in the transfer device for detecting the presence or absence of an article in the article placement unit is known. The sensor is arranged to project light in a substantially horizontal direction. A reflection plate is disposed on the back side of the article placement unit. The transfer device does not transfer the article to the article placement unit when the sensor does not receive the reflected light from the reflection plate (see, for example, Patent Document 1).

JP 2007-55720 A

In a conventional automatic warehouse, the transfer device stops in front of the shelf and then uses a sensor to check the state of the shelf before the transfer (there is a first-in item and no first-in item). The presence or absence of goods is confirmed. Then, after the confirmation is completed, the transfer operation is performed.
Similarly, at the time of inventory, the transfer device once stops in front of the shelf and confirms the presence or absence of the article.
As described above, in the conventional technique, it is necessary to stop the transfer apparatus in front of the shelf in order to confirm the presence / absence of an article, which takes a lot of time.

  The subject of this invention is shortening the time for confirming whether the article | item is put on the shelf in an automatic warehouse.

  Hereinafter, a plurality of modes will be described as means for solving the problems. These aspects can be arbitrarily combined as necessary.

  An automatic warehouse according to an aspect of the present invention includes a rack, a transfer device, a detector, a detected object, and a detection determination unit. Raku has a plurality of shelves for storing items. The transfer device is a device for transferring articles between shelves, and is movable between shelves through the front of the shelves. The detector is provided in the transfer device. The object to be detected is provided on the shelf, and is located on the back side of the article when the article is placed on the shelf, and has a portion hidden from the detector by the article placed on the shelf and a portion not hidden. The detection determination unit determines whether or not the article is placed on the shelf using the detection result by the detector, and whether or not the article is placed on the shelf from the detection to the non-detection of the detected object. Used to determine whether or not.

  In this automatic warehouse, when the transfer device reaches the target shelf and moves in front of the shelf, the detector first detects a portion that is not hidden by the article to be detected. The transfer device uses a change from detection of the detection target to detection to be detected. That is, if there is no article, a result that there is no “switch” is obtained, and if there is an article, a result that there is “switch” is obtained. In this way, since the detection determination unit can confirm whether or not the article is placed on the shelf while the transfer device is moving, the time until confirmation of whether or not the article is placed on the shelf is shortened. it can.

The detected object may have at least one linear portion extending in one direction on the shelf. In this case, the transfer device can be freely moved in front of a shelf other than the target shelf, but is allowed to move only in one direction in front of the target shelf.
In this automatic warehouse, the transfer device can freely move in front of the shelf other than the intended shelf, so the travel time to the shelf can be shortened. In addition, since the transfer device moves along the extending direction of the straight portion in front of the intended shelf, the number of places to be detected can be reduced.

The at least one straight line portion may have a first straight line portion extending in a horizontal direction and a second straight line portion extending in a vertical direction on the shelf. In this case, the transfer device can simultaneously move in the horizontal direction and the vertical direction in front of the shelf other than the target shelf, but either the horizontal direction or the vertical direction moves in front of the target shelf. Only allowed.
In this automatic warehouse, the transfer device can freely move in front of the shelf other than the intended shelf, so the travel time to the shelf can be shortened. Moreover, since the transfer device moves along the extending direction of the first straight line portion and the second straight line portion in front of the intended shelf, it is possible to reduce the number of places to be detected.

The detection determination unit acquires a detection distance at which the detection target is detected by the detector while the transfer device is moving, and uses the detection distance to determine whether the article is placed on the shelf. Also good.
In this automatic warehouse, for example, if the detection distance is equal to or greater than a predetermined distance, the detection determination unit determines that the article is not placed on the shelf. In this way, it can be determined whether or not the article is placed on the shelf while the transfer device is moving.

  The detection determination unit may determine that the article is not placed on the shelf if the detection distance reaches the first predetermined distance.

  The first predetermined distance may be shorter than the distance from the end to the center of the portion where the detected object is provided on the shelf corresponding to the detected object.

The detection determination unit may acquire a non-detection distance at which the detection target is not detected by the detector while the transfer device is moving, and may use the non-detection distance to determine whether the article is placed on the shelf. .
In this automatic warehouse, for example, if the non-detection distance is a predetermined distance or more, the detection determination unit determines that the article is placed on the shelf. By incorporating the non-detection distance into the determination criterion in this way, the possibility that a non-first-in product is erroneously determined as a first-in product is reduced.

  The detection determination unit may determine that the article is placed on the shelf if the non-detection distance reaches the second predetermined distance.

  If the detection determination unit switches from the non-detection state to the detection state before the non-detection distance reaches the second predetermined distance while the transfer device is moving, an object other than the target article is placed on the shelf. You may judge.

The article confirmation control method according to another aspect of the present invention is used in an automatic warehouse extending below. The automatic warehouse is provided with a rack having a plurality of shelves for storing articles, a transfer apparatus capable of moving and transferring operations for transferring articles between the shelves, and a transfer apparatus. A detector that is provided on the shelf and is on the back side of the article when the article is placed on the shelf, and has a portion that is hidden from the detector by the article placed on the shelf and a portion that is not hidden. And a detector. This method comprises the following steps.
◎ First step of determining whether the detection distance detected by the detector while the transfer device is moving in front of the shelf has reached the first predetermined distance ◎ When the transfer device is moving If the detection state switches to the non-detection state before the detection distance reaches the first predetermined distance, the second step of determining that at least something is placed on the shelf. In this method, the transfer device reaches the shelf. When moving in front of the shelf, the detector first detects the object to be detected. If the detection distance reaches the first predetermined distance in the first step, it is determined that nothing is placed on the shelf. Then, if the detection state is switched from the detection state to the non-detection state before the detection distance reaches the first predetermined distance, it is determined that at least something is placed on the shelf.

The method may further comprise the following steps.
◎ Third step of determining whether or not the non-detection distance where the detected object is not detected while the transfer device is moving has reached the second predetermined distance ◎ The non-detection distance is the second when the transfer device is moving If the non-detection state is switched to the detection state by the time the predetermined distance is reached, the fourth step of determining that something other than the target article is placed on the shelf. In this method, the non-detection distance is the second predetermined distance. If the state is switched from the non-detection state to the detection state before reaching, it is determined that something other than the target article is placed on the shelf. In this manner, since it can be confirmed whether or not the article is placed on the shelf while the transfer device is moving, it is possible to shorten the time required to confirm whether or not the article is placed on the shelf.

  In the automatic warehouse according to the present invention, the time for checking the presence or absence of an article is shortened.

1 is a schematic plan view of an automatic warehouse in which an embodiment of the present invention is adopted. The schematic side view of an automatic warehouse. The schematic side view of a rack. The side view of the shelf in which goods are not put. The side view of the shelf where the article | item is put. The block diagram which shows the control structure of a stacker crane. The side view of a transfer apparatus and the shelf in which goods are not put. The transfer apparatus and the side view of the shelf in which goods are placed. FIG. 3 is a plan view of a transfer device and a shelf that are moving in front of a shelf on which an article is placed, and shows a first stage of the transfer device. FIG. 4 is a plan view of a transfer device and a shelf that are moving in front of a shelf on which an article is placed, and shows a second stage of the transfer device. The flowchart which shows the control action at the time of transferring goods to a shelf. The flowchart which shows the control operation at the time of transferring an article | item to a transfer apparatus. The flowchart which shows the control action at the time of inventory. The side view of the shelf in which goods are not put in other embodiments. The side view of the shelf in which articles | goods are placed in other embodiment.

(1) Whole automatic warehouse Hereinafter, the automatic warehouse 1 as one Embodiment which concerns on this invention is demonstrated using FIGS. 1-3. FIG. 1 is a schematic plan view of an automatic warehouse as one embodiment of the present invention. FIG. 2 is a schematic side view of the automatic warehouse. FIG. 3 is a schematic side view of the rack. In the following embodiment, an object to be conveyed / stored is a FOUP and is expressed as an article F.

  The automatic warehouse 1 is mainly composed of a rack 2 and a stacker crane 3.

(2) Rack The rack 2 has a first rack 2A and a second rack 2B. The first rack 2A and the second rack 2B are arranged side by side in the Y direction so as to sandwich the rail 4 in the stacker crane passage extending in the X direction in FIG. A plurality of shelves 6 are provided in the first rack 2A and the second rack 2B.

  The configuration of the first rack 2A will be described with reference to FIG. The first rack 2 </ b> A has a plurality of shelves 6. The shelf 6 has an article placement plate 7 and a back plate 8. The article placing plate 7 has a flat upper surface. The back plate 8 is arranged on the back side when viewed from the stacker crane 3 side. The back plate 8 has a flat surface and extends in the vertical direction.

  As shown schematically in FIG. 3, a plurality of detection bodies 10 are attached to the back plate 8. The detection target 10 has an elongated shape, and includes a first reflecting plate 10A extending linearly in the horizontal direction and a second reflecting plate 10B extending linearly in the vertical direction. The first reflecting plate 10A is located in the middle in the vertical direction of the back plate 8, and the second reflecting plate 10B is located in the middle in the horizontal direction of the back plate 8. As a result, the first reflecting plate 10A and the second reflecting plate 10B are located. The plate 10 </ b> B intersects with the central portion of the back plate 8. As described above, in the back plate 8, a cross-shaped reflector is formed by the first reflector 10A and the second reflector 10B.

  The detected object 10 on the shelf 6 will be described in more detail with reference to FIGS. 4 and 5. FIG. 4 is a side view of an article storage shelf in which articles are not placed, and FIG. 5 is a side view of an article storage shelf in which articles are placed. Both FIG. 4 and FIG. 5 are views when the shelf 6 is viewed from the front.

  As shown in FIG. 4, the first reflecting plate 10 </ b> A extends in the horizontal direction in the middle of the back plate 8 in the vertical direction in the shelf 6. In addition, the second reflecting plate 10 </ b> B extends in the vertical direction in the left-right direction middle of the back plate 8 in the shelf 6. In this embodiment, the first reflector 10 </ b> A and the second reflector 10 </ b> B are formed continuously from end to end of the back plate 8.

As shown in FIG. 5, in the situation where the article F is placed on the shelf 6, the intersection part of the first reflecting plate 10 </ b> A and the second reflecting plate 10 </ b> B and part of both sides thereof are hidden by the article F. Part of the end portions of the reflecting plate 10A and the second reflecting plate 10B is exposed.
Arrows A to D indicate an entrance through which a crane transfer device (described later) can enter the front of the shelf 6 and a traveling direction in which the crane can move. However, in this figure, since the detection target 10 is not exposed on the arrow D side with the article F placed, a transfer device (described later) enters the front of the article storage shelf along the arrow D. Never come.

(3) Mechanism of stacker crane The stacker crane 3 will be described with reference to FIG.

  The stacker crane 3 is guided along the rail 4 so as to be movable in the X direction. The stacker crane 3 includes a traveling carriage 12, a pair of masts 13 provided on both sides in the traveling direction of the upper portion of the traveling carriage 12, a lifting platform 14 mounted on the mast 13 so as to be movable up and down, and an article provided on the lifting platform 14. And a slide fork 15 for transferring F.

  The traveling carriage 12 is provided with wheels (not shown) whose upper surface of the rail 4 is a traveling surface. The traveling carriage 12 further includes a traveling motor 21 (FIG. 6) and a speed reducer (not illustrated) for rotating wheels (not illustrated).

  The lifting platform 14 has a pair of guide members 25 guided by the mast 13 and a support platform 26 extending between the guide members 25.

  The slide fork 15 provided with the slide fork 15 can be advanced in the Y direction (FIG. 1) and in the horizontal direction on the support base 26 of the lifting platform 14. The slide fork 15 is connected to the transfer motor 23 (FIG. 6) via a speed reducer and a belt.

  In order to raise and lower the lifting platform 14, a belt (not shown) for driving the lifting platform 14, a lifting pulley (not shown), and a lifting motor 22 (FIG. 6) for driving the lifting pulley are provided. It has been.

  Since the lifting platform 14 and the slide fork 15 can be transferred in accordance with the shelf 6 and are configured to move together, the lifting platform 14 and the slide fork 15 are collectively transferred below. Let's call it 16.

(4) Control Configuration of Stacker Crane Next, the crane controller 31 and the system controller 32 of the stacker crane 3 will be described with reference to FIG. FIG. 6 is a block diagram showing a control configuration of the stacker crane.
The crane controller 31 is mounted on the stacker crane 3 and can communicate with a system controller 32 that controls the entire automatic warehouse 1.

  The crane controller 31 includes a main controller 43, a travel control unit 44, a lift control unit 45, and a transfer control unit 46. This includes computer hardware such as a CPU and memory, and is represented as a functional block realized by the cooperation of the computer hardware and software in FIG. Note that these may be realized by a single computer having a plurality of functions.

  The main controller 43 can communicate with the travel control unit 44, the elevation control unit 45, and the transfer control unit 46.

  The traveling control unit 44 is a control unit for controlling traveling / stopping of the traveling carriage 12, and is connected to the traveling motor 21 and the rotary encoder 47. The lifting control unit 45 is a control unit for moving the lifting platform 14 up and down along the mast 13, and is connected to the lifting motor 22 and the rotary encoder 48. The transfer control unit 46 is a control unit for driving the slide fork 15, and is connected to the transfer motor 23 and the rotary encoder 49.

  The memory of the main controller 43 stores the arrangement status of the articles F in the rack 2 and the like. The main controller 43 refers to the contents of the memory and updates it as necessary.

(5) Sensor The sensor 51 will be described with reference to FIGS. FIG. 7 is a side view of the article storage shelf on which the transfer device and the article are not placed, and FIG. 8 is a side view of the article storage shelf on which the transfer device and the article are placed. FIG. 9 is a plan view of the transfer device and the shelf that are moving in front of the shelf on which the article is placed, and shows a first stage of the transfer device. FIG. 10 is a plan view of the transfer device and the shelf that are moving in front of the shelf on which the article is placed, and shows a second stage of the transfer device.

  The sensor 51 is a sensor for detecting the detection target 10 and is an optical reflection type sensor. As shown in FIG. 6, the sensor 51 is mainly composed of a light projecting element 52 and a light receiving element 53. In the sensor 51, the light projecting element 52 emits visible light or infrared sensor light (laser light) almost horizontally, and the light receiving element 53 receives reflected light.

The sensor 51 is provided on one of the guide members 25 of the lifting platform 14 and the other of the guide members 25 of the lifting platform 14. When the light emitted horizontally from the light projecting element 52 of the sensor 51 strikes the detected object 10, the reflected light is incident on the light receiving element 53 as shown in FIGS. 7 and 9. In addition, when the light emitted from the light projecting element 52 strikes the article F, the laser light does not reach the detection target 10 as shown in FIGS.
The main controller 43 can transmit a drive signal to the light projecting element 52 and can receive a detection signal from the light receiving element 53.
As another embodiment, the light projecting element may be provided on one side of the guide member 25 of the lifting platform 14 and the light receiving element may be provided on the other side of the guide member 25 of the lifting platform 14.

(6) Warehousing work Warehousing work will be described with reference to FIG. FIG. 11 is a flowchart showing a control operation when an article is transferred to a rack. The transfer device 16 can simultaneously perform the traveling operation and the lifting operation before the shelf 6 other than the target shelf 6, but performs only one of the lifting operation and the traveling operation in front of the target shelf 6. . In this way, the time required for the transfer device 16 to move to the shelf 6 can be shortened.
In the flowchart, the determination operation in which the main controller 43 determines the presence or absence of the article F based on the detection result of the detection target 10 by the sensor 51 will be mainly described. In this flowchart, the transfer device 16 will be described as an example in which the transfer device 16 enters and moves in front of the shelf 6 in the horizontal direction.

  In step S1, the main controller 43 waits for the transfer device 16 to reach the target shelf 6. Subsequently, the transfer device 16 moves in front of the shelf 6 in the horizontal direction. At this time, the transfer device 16 moves so that the projection light from the light projecting element 52 of the sensor 51 follows the first reflecting plate 10A. The sensor 51 used at this time is a sensor 51 on the front side in the traveling direction as shown in FIG.

  In step S2, the main controller 43 determines whether or not the detection distance at which the sensor 51 has detected the detected object 10 has reached a first predetermined distance. If the first predetermined distance has not been reached, the control flow proceeds to step S3, and if the first predetermined distance has been reached, it is determined that “there is no article F on the shelf 6”, and the control flow proceeds to step S10. . The “first predetermined distance” is, for example, a distance at which it can be determined that the article F is not placed on the shelf 6, and is preferably a distance shorter than the distance from the end of the back plate 8 to the center. As a result, the transfer device 16 can determine whether it has passed or stopped before reaching the center of the back plate 8.

  In step S <b> 10, the main controller 43 transmits a stop command to the travel control unit 44. As a result, the traveling control unit 44 stops driving the traveling motor 21, thereby stopping the transfer device 16 at a predetermined position (center of the back plate 8).

  In step S <b> 11, the main controller 43 transmits a transfer command to the transfer control unit 46. As a result, the transfer control unit 46 drives the transfer motor 23 so that the slide fork 15 transfers the article F to the shelf 6.

  In step S <b> 3, the main controller 43 determines whether or not the sensor 51 continues to detect the detection target 10. If the detection continues, the control flow returns to step S2, and when the detection ends, the control flow moves to step S8. Note that “the detection is completed” means that the detected object 10 is hidden from the sensor 51 by the article F as shown in FIG.

  In step S <b> 8, the main controller 43 continues to send a travel command to the travel control unit 44. As a result, the traveling control unit 44 continues to drive the traveling motor 21, and thus the transfer device 16 continues to move. In other words, for example, as shown in FIG. 10, the main controller 43 determines that there is a first-in article when the detected object 10 is not detected during the warehousing operation, and stops warehousing on the shelf 6 based on that. As a result, the article F is stored in the other shelf 6.

As described above, when there is a first-in article on the shelf 6 during the warehousing operation, the transfer device 16 detects the presence without stopping (S3) and passes through (S8).
In this automatic warehouse 1, when the transfer device 16 reaches the shelf 6 and moves in front of it, the sensor 51 first detects a portion that is not hidden by the article F of the detected object 10. The transfer device 16 uses the presence / absence of switching from detection of the detection target 10 to detection to be detected. That is, if there is no article F, the result that there is no “switching” is obtained, and if there is the article F, the result that there is “switching” is obtained. In this way, the main controller 43 can confirm the presence / absence of the article F while the transfer device 16 is moving, and therefore the time required to confirm the presence / absence of the article F can be reduced.

(7) Outgoing work The outgoing work will be described with reference to FIG. FIG. 12 is a flowchart showing a control operation when an article is transferred to the transfer device.
In the flowchart, the determination operation in which the main controller 43 determines the presence or absence of the article F based on the detection result of the detection target 10 by the sensor 51 will be mainly described. In this flowchart, the transfer device 16 will be described as an example of entering and moving in front of the shelf 6 in the horizontal direction.

  In step S1, the main controller 43 waits for the transfer device 16 to reach the target shelf 6. Subsequently, the transfer device 16 moves in front of the shelf 6 in the horizontal direction. At this time, as shown in FIG. 9, the transfer device 16 moves so that the projection light from the light projecting element 52 of the sensor 51 follows the first reflecting plate 10A. The sensor 51 used at this time is a sensor 51 on the front side in the traveling direction as shown in FIG.

  In step S2, the main controller 43 determines whether or not the detection distance at which the sensor 51 has detected the detected object 10 has reached a first predetermined distance. If the first predetermined distance has not been reached, the control flow proceeds to step S3. If the first predetermined distance has been reached, it is determined that “there is no article F on the shelf 6”, and the control flow proceeds to step S14. .

  In step S <b> 14, the main controller 43 continues to transmit a travel command to the travel control unit 44. As a result, the traveling control unit 44 continues to drive the traveling motor 21, so that the transfer device 16 passes through the intended shelf 6.

  In step S <b> 3, the main controller 43 determines whether or not the sensor 51 continues to detect the detection target 10. If the detection continues, the control flow returns to step S2, and when the detection ends, the control flow moves to step S4. Note that “the detection is completed” means that the detected object 10 is hidden from the sensor 51 by the article F as shown in FIG.

  In step S4, the main controller 43 calculates the distance that the sensor 51 has detected the detected object 10, and stores it in a memory (not shown).

  In step S5, the main controller 43 determines whether or not the non-detected distance where the sensor 51 has not detected the detected object 10 has reached the second predetermined distance. If the second predetermined distance has not been reached, the control flow proceeds to step S6, and if the second predetermined distance has been reached, it is determined that “there is an article F on the shelf 6,” and the control flow proceeds to step S12. . The “second predetermined distance” is a distance that can be recognized as a normal article F, and is preferably a distance shorter than the distance from the end of the back plate 8 to the center together with the detection distance. As a result, the transfer device 16 can determine whether it has passed or stopped before reaching the center of the back plate 8.

  In step S <b> 12, the main controller 43 transmits a stop command to the travel control unit 44. As a result, the traveling control unit 44 stops driving the traveling motor 21, thereby stopping the transfer device 16 at a predetermined position (center of the back plate 8).

  In step S <b> 13, the main controller 43 transmits a transfer command to the transfer control unit 46. As a result, the transfer control unit 46 drives the transfer motor 23 so that the slide fork 15 transfers the article F to the transfer device 16.

  In step S6, the main controller 43 determines whether or not the sensor 51 has detected the detected object 10. If the detection is not continued, the control flow returns to step S4, and when the detection is started, the control flow proceeds to step S7.

  In step S7, the main controller 43 determines that an object other than the predetermined article F has been detected, and executes detection error processing.

  In step S <b> 8, the main controller 43 continues to send a travel command to the travel control unit 44. As a result, the traveling control unit 44 continues to drive the traveling motor 21, and thus the transfer device 16 continues to travel.

  As described above, when there is no first-in article on the shelf 6 during the warehousing operation, the transfer device 16 detects that it does not exist without stopping (S2) and passes through (S14). ).

  In this automatic warehouse 1, for example, if the non-detection distance is equal to or greater than the second predetermined distance, the main controller 43 determines that the article F is on the shelf 6 (S5). By incorporating the non-detection distance into the determination criterion in this way, the possibility that a non-first-in product is erroneously determined as a first-in product is reduced.

(8) Inventory work The inventory work will be described with reference to FIG. FIG. 13 is a flowchart showing the control operation during inventory.
In the flowchart, the determination operation in which the main controller 43 determines the presence or absence of the article F based on the detection result of the detection target 10 by the sensor 51 will be mainly described. In this flowchart, the transfer device 16 will be described as an example of entering and moving in front of the shelf 6 in the horizontal direction.

  In step S1, the main controller 43 waits for the transfer device 16 to reach the target shelf 6. Subsequently, the transfer device 16 moves in front of the shelf 6 in the horizontal direction. At this time, the transfer device 16 moves so that the projection light from the light projecting element 52 of the sensor 51 follows the first reflecting plate 10A. The sensor 51 used at this time is a sensor 51 on the front side in the traveling direction as shown in FIG.

  In step S2, the main controller 43 determines whether or not the detection distance at which the sensor 51 has detected the detected object 10 has reached a first predetermined distance. If the first predetermined distance has not been reached, the control flow proceeds to step S3. If the first predetermined distance has been reached, it is determined that “there is no article F on the shelf 6”, and the control flow proceeds to step S14. .

  In step S <b> 14, the main controller 43 continues to transmit a travel command to the travel control unit 44. As a result, the traveling control unit 44 continues to drive the traveling motor 21, so that the transfer device 16 passes through the intended shelf 6.

  In step S <b> 3, the main controller 43 determines whether or not the sensor 51 continues to detect the detection target 10. If the detection continues, the control flow returns to step S2, and when the detection ends, the control flow moves to step S4. Note that “the detection is completed” means that the detected object 10 is hidden from the sensor 51 by the article F as shown in FIG.

  In step S4, the main controller 43 calculates the distance that the sensor 51 has detected the detected object 10, and stores it in a memory (not shown).

  In step S5, the main controller 43 determines whether or not the non-detected distance where the sensor 51 has not detected the detected object 10 has reached the second predetermined distance. If the second predetermined distance has not been reached, the control flow proceeds to step S6, and if the second predetermined distance has been reached, it is determined that “there is an article F on the shelf 6,” and the control flow proceeds to step S8. .

  In step S6, the main controller 43 determines whether or not the sensor 51 has detected the detected object 10. If the detection is not continued, the control flow returns to step S5, and when the detection is started, the control flow proceeds to step S7.

  In step S7, the main controller 43 determines that an object other than the predetermined article F has been detected, and executes detection error processing.

  In step S <b> 8, the main controller 43 continues to send a travel command to the travel control unit 44. As a result, the traveling control unit 44 continues to drive the traveling motor 21, and thus the transfer device 16 continues to travel.

  As described above, the transfer device 16 detects the presence / absence of the article F without stopping and passes through the front of the shelf 6 in both cases where there is a first-placed item in the shelf 6 at the time of inventory. I will do it.

(9) Features (A) The automatic warehouse 1 will be described. The automatic warehouse 1 includes a rack 2, a transfer device 16, a sensor 51, a detected object 10, and a main controller 43. The rack 2 has a plurality of shelves 6 for storing the articles F. The transfer device 16 is a device for transferring articles between the shelves 6 and can be transferred between shelves through the front of the shelves. The sensor 51 is provided in the transfer device 16. The detected object 10 is provided on the shelf 6, and is located on the back side of the article F when the article F is placed on the shelf 6, and has a part hidden from the sensor 51 by the article F and a part not hidden. The main controller 43 determines whether or not the article F is placed on the shelf 6 using the detection result of the sensor 51, and the article is placed on the shelf when the detected object 10 is switched from detection to non-detection. Used to determine whether or not
In the automatic warehouse 1, when the transfer device 16 reaches the target shelf 6 and moves in front of the shelf 6, the sensor 51 first detects a portion that is not hidden by the article F of the detected object 10. The transfer device 16 uses a change from detection to non-detection of the detected object 10 for detection determination. That is, if there is no article F, the result that there is no “switching” is obtained, and if there is the article F, the result that there is “switching” is obtained. In this way, the main controller 43 can confirm the presence / absence of the article F while the transfer device 16 is moving, and therefore the time required to confirm the presence / absence of the article F can be reduced.

(B) The detected object 10 has at least one linear portion (the first reflecting plate 10A or the second reflecting plate 10B) extending in one direction on the shelf 6. The transfer device 16 can be freely moved in front of other than the target shelf 6, but is allowed to move only in one direction in front of the target shelf 6.
In the automatic warehouse 1, the transfer device 16 can freely move in front of the shelf 6 other than the target shelf 6, so that the travel time to the shelf 6 can be shortened. Further, since the transfer device 16 moves along the extending direction of the straight portion (the first reflecting plate 10A or the second reflecting plate 10B) in front of the target shelf 6, the number of installation locations of the detection target 10 is reduced. be able to.

(C) At least one straight line portion includes a first reflecting plate 10A extending in the horizontal direction and a second reflecting plate 10B extending in the vertical direction on the shelf 6. The transfer device 16 can perform a traveling operation and an elevating operation at the same time in front of other than the target shelf 6, but only one of the elevating operation and the traveling operation is permitted in front of the target shelf 6. Yes.
In the automatic warehouse 1, the transfer device 16 can freely move in front of the shelf 6 other than the target shelf 6, so that the travel time to the shelf 6 can be shortened. In addition, since the transfer device 16 moves along the extending direction of the first reflecting plate 10A and the second reflecting plate 10B in front of the intended shelf 6, it is possible to reduce the number of installation locations of the detected object 10.

(D) The main controller 43 acquires the detection distance detected by the sensor 51 while the transfer device 16 is moving, and determines whether or not the article F is placed on the shelf 6. Used for judgment.
In the automatic warehouse 1, the main controller 43 determines that the article F is not placed on the shelf 6 if the detection distance is equal to or greater than a predetermined distance, for example. In this way, it is possible to determine whether or not an article is placed on the shelf 6 while the transfer device 16 is moving.

(E) When the detection distance reaches the first predetermined distance, the main controller 43 determines that the article F is not placed on the shelf 6.

(F) The 1st predetermined distance is shorter than the distance from the edge part of the part in which the to-be-detected body 10 was provided in the shelf 6 to the center part.

(G) The main controller 43 acquires a non-detection distance at which the detection target 10 is not detected by the sensor 51 while the transfer device 16 is moving, and determines whether or not the article F is placed on the shelf. Used for judgment.
In the automatic warehouse 1, the main controller 43 determines that the article F is placed on the shelf 6 if the non-detection distance is equal to or greater than a predetermined distance, for example. By incorporating the non-detection distance into the determination criterion in this way, the possibility that a non-first-in product is erroneously determined as a first-in product is reduced.
Furthermore, the main controller 43 can also determine the posture of the article F (whether it is placed at the correct position) by grasping the non-detection distance.

(H) The main controller 43 determines that the article F is placed on the shelf 6 when the non-detection distance reaches the second predetermined distance.

(I) If the main controller 43 switches from the non-detection state to the detection state by the time the non-detection distance reaches the second predetermined distance while the transfer device 16 is moving, an object other than the target article F is placed on the shelf 6. It is judged that it is placed in.

(J) The article confirmation control method of the automatic warehouse 1 will be described. This method is an apparatus for transferring an article F between the rack 2 having a plurality of shelves 6 for storing the articles F and the shelves 6, and is movable between the shelves through the front of the shelves. The device 16, the sensor 51 provided in the transfer device 16, and the shelf 6 are provided on the shelf 6. When the product F is placed on the shelf 6, the product is located behind the product F and placed on the shelf 6. It is used in the automatic warehouse 1 provided with the to-be-detected body 10 which has the part hidden from the sensor 51 by F, and the part which is not hidden. This method comprises the following steps.
◎ First step of determining whether or not the detection distance detected by the sensor 51 while the transfer device 16 is moving in front of the shelf 6 has reached the first predetermined distance. If the detection state switches to the non-detection state by the time the detection distance reaches the first predetermined distance during movement, the second step of determining that at least something is placed on the shelf 6. Reaches the shelf 6 and moves in front of the shelf 6, the sensor 51 first detects the detected object 10. If the detection distance reaches the first predetermined distance in the first step, it is determined that nothing is placed on the shelf 6. In the second step, if the detection state is switched to the non-detection state before the detection distance reaches the first predetermined distance, it is determined that at least something is placed on the shelf.

(K) This method further includes the following steps.
◎ Third step of determining whether or not the non-detection distance where the detected object 10 is not detected while the transfer device 16 is moving has reached the second predetermined distance ◎ Non-detection distance when the transfer device 16 is moving If the non-detection state is switched to the detection state before the second predetermined distance is reached, the fourth step of determining that something other than the target article F is placed on the shelf 6. If the non-detection state is switched to the detection state before reaching the second predetermined distance, it is determined that something other than the article F is placed on the shelf 6. In this manner, since it can be confirmed whether or not the article F is placed on the shelf 6 while the transfer device 16 is moving, it is possible to shorten the time required to confirm whether or not the article F is placed on the shelf. .

(10) Other Embodiments Although one embodiment of the present invention has been described above, the present invention is not limited to the above embodiment, and various modifications can be made without departing from the scope of the invention. In particular, a plurality of embodiments and modifications described in the present specification can be arbitrarily combined as necessary.

(A) In the above embodiment, the first reflector 10A and the second reflector 10B are started from the end of the back plate 8 in the shelf 6, but the present invention is not limited to such an embodiment. For example, in the embodiment shown in FIGS. 14 and 15, in the shelf 6, the first reflecting plate 10 </ b> A ′ and the second reflecting plate 10 </ b> B ′ start from a position away from the end of the back plate.

(B) In the above embodiment, the first reflector 10A and the second reflector 10B in the shelf 6 have symmetrical shapes in the left and right and up and down directions, but the present invention is not limited to such an embodiment. For example, when the transfer device 16 enters only one of the horizontal direction and the vertical direction in front of the shelf 6, it is possible to omit the reflector in the direction that does not enter. In that case, only one reflector is provided. Moreover, when it enters from only one side of the same direction, the side which a reflecting plate does not enter can be shortened.

(C) In the said embodiment, although the reflecting plate extended in the horizontal direction and the perpendicular direction with respect to the backplate, this invention is not limited to such an embodiment. For example, two reflecting plates may be provided so as to extend in the diagonal direction of the back plate.

(D) Although the reflecting plate is linear in the embodiment, the present invention is not limited to such an embodiment. For example, the reflector may have a shape other than a straight line.

(E) In the said embodiment, although the reflecting plate was partially provided with respect to the backplate, this invention is not limited to such embodiment. For example, the reflecting plate may be formed over almost the entire surface of the back plate.

(F) In the said embodiment, although the shape of the reflecting plate affixed on all the article storage shelves was the same, this invention is not limited to such embodiment. For example, you may change the shape of a reflecting plate for every goods storage shelf in a center part, a peripheral part, and a corner | angular part in a rack.

(G) In the above embodiment, the light projecting element and the light receiving element of the sensor are respectively provided on the pair of guide members of the transfer device, but the present invention is not limited to such an embodiment.

(H) Although a slide fork is used as an apparatus for transferring an article to an article storage shelf in the above embodiment, the present invention is not limited to such an embodiment. For example, a scalar arm or other device may be used.

(I) Although the reflecting plate is used as the object to be detected in the above embodiment, the present invention is not limited to such an embodiment. For example, other materials such as tape and paint may be used as the detection target.

(J) In the above embodiment, the transfer device cannot move upward with respect to the article storage shelf, but the present invention is not limited to such an embodiment. For example, the exposed portion of the detection plate may be secured below the article by disposing the placing plate above the lower end of the article storage shelf.
(K) Although the above embodiment has been described using FOUP as an article to be conveyed and stored, the present invention is not limited to such an embodiment.
(L) The main controller may calculate the distance from the detection by the sensor switching from ON to OFF to the normal stop position to confirm the baggage shift. Specifically, the presence or absence of a baggage shift and the shift amount when there is a shift are confirmed.

  The present invention relates to an automatic warehouse, in particular, an automatic warehouse including a rack having a plurality of shelves for storing articles, and a transfer device that transfers articles between the shelves and is movable between shelves. Widely applicable.

DESCRIPTION OF SYMBOLS 1 Automatic warehouse 2 Rack 2A 1st rack 2B 2nd rack 3 Stacker crane 4 Rail 6 Shelf 7 Article mounting plate 8 Back plate 10 Detected object 10A 1st reflecting plate 10B 2nd reflecting plate 12 Traveling carriage 13 Mast 14 Lifting platform 15 Slide Fork 16 Transfer Device 21 Traveling Motor 22 Lifting Motor 23 Transfer Motor 25 Guide Member 26 Support Stand 31 Crane Controller 32 System Controller 43 Main Controller (Detection Judgment Unit)
44 Travel Control Unit 45 Elevation Control Unit 46 Transfer Control Unit 47 Rotary Encoder 48 Rotary Encoder 49 Rotary Encoder 51 Sensor (Detector)
52 Light Emitting Element 53 Light Receiving Element F Article

[0003]
Aspects can be arbitrarily combined as necessary.
[0010]
An automatic warehouse according to an aspect of the present invention includes a rack, a transfer device, a detector, a detected object, and a detection determination unit. The rack has a plurality of shelves for storing articles. The transfer device is a device for transferring articles between shelves, and is movable between shelves through the front of the shelves. The detector is provided in the transfer device. The object to be detected is provided on the shelf, is located on the back side of the article when the article is placed on the shelf, is larger than the article placed on the shelf, and is not hidden from the detector by the article placed on the shelf. It has a first part and a hidden second part. The detection determination unit determines whether or not the article is placed on the shelf using the detection result by the detector. When the transfer device accesses the intended shelf, the detector first detects the first part of the detected object and then tries to detect the second part of the detected object. The detection determination unit uses the switching from the detection state to the non-detection state when the transfer device is moving in front of the shelf to determine whether or not the article is placed on the shelf.
[0011]
In this automatic warehouse, when the transfer device reaches the target shelf and moves in front of the shelf, the detector first detects a portion that is not hidden by the article to be detected. The transfer device uses a change from detection of the detection target to detection to be detected. That is, if there is no article, a result that there is no “switching” is obtained, and if there is an article, a result that there is “switching” is obtained. In this way, since the detection determination unit can confirm whether or not the article is placed on the shelf while the transfer device is moving, the time until confirmation of whether or not the article is placed on the shelf is shortened. it can.
[0012]
The detected object may have at least one linear portion extending in one direction on the shelf. In this case, the transfer device can be freely moved in front of a shelf other than the target shelf, but is allowed to move only in one direction in front of the target shelf.
In this automatic warehouse, the transfer device can freely move in front of the shelf other than the intended shelf, so the travel time to the shelf can be shortened. In addition, since the transfer device moves along the extending direction of the straight portion in front of the intended shelf, the number of places to be detected can be reduced.
[0013]
The at least one straight line portion may have a first straight line portion extending in a horizontal direction and a second straight line portion extending in a vertical direction on the shelf. In this case, the transfer device

[0005]
It may be determined that it is placed on a shelf.
[0020]
The article confirmation control method according to another aspect of the present invention is used in an automatic warehouse extending below. The automatic warehouse is provided with a rack having a plurality of shelves for storing articles, a transfer apparatus capable of moving and transferring operations for transferring articles between the shelves, and a transfer apparatus. The detector is provided on the shelf and is located behind the article when the article is placed on the shelf, and is larger than the article placed on the shelf and hidden from the detector by the article placed on the shelf. And an object to be detected having a first portion that is not present and a second portion that is hidden. This method comprises the following steps.
When the transfer device accesses the intended shelf, the detector first detects the first part of the detected object and then tries to detect the second part of the detected object.
◎ First step of determining whether the detection distance detected by the detector while the transfer device is moving in front of the shelf has reached the first predetermined distance ◎ When the transfer device is moving If the detection state switches to the non-detection state before the detection distance reaches the first predetermined distance, the second step of determining that at least something is placed on the shelf. In this method, the transfer device reaches the shelf. When moving in front of the shelf, the detector first detects the object to be detected. If the detection distance reaches the first predetermined distance in the first step, it is determined that nothing is placed on the shelf. Then, if the detection state is switched from the detection state to the non-detection state before the detection distance reaches the first predetermined distance, it is determined that at least something is placed on the shelf.
[0021]
The method may further comprise the following steps.
◎ Third step of determining whether or not the non-detection distance where the detected object is not detected while the transfer device is moving has reached the second predetermined distance ◎ The non-detection distance is the second when the transfer device is moving If the non-detection state is switched to the detection state by the time the predetermined distance is reached, the fourth step of determining that something other than the target article is placed on the shelf. In this method, the non-detection distance is the second predetermined distance. If the state is switched from the non-detection state to the detection state before reaching, it is determined that something other than the target article is placed on the shelf. In this way, since it is possible to confirm whether or not the article is placed on the shelf while the transfer device is moving, it is necessary to confirm whether or not the article is placed on the shelf.

[0018]
[0084]
(E) When the detection distance reaches the first predetermined distance, the main controller 43 determines that the article F is not placed on the shelf 6.
[0085]
(F) The 1st predetermined distance is shorter than the distance from the edge part of the part in which the to-be-detected body 10 was provided in the shelf 6 to the center part.
[0086]
(G) The main controller 43 acquires a non-detection distance at which the detection target 10 is not detected by the sensor 51 while the transfer device 16 is moving, and determines whether or not the article F is placed on the shelf. Used for judgment.
In the automatic warehouse 1, the main controller 43 determines that the article F is placed on the shelf 6 if the non-detection distance is equal to or greater than a predetermined distance, for example. By incorporating the non-detection distance into the determination criterion in this way, the possibility that a non-first-in product is erroneously determined as a first-in product is reduced.
Furthermore, the main controller 43 can also determine the posture of the article F (whether it is placed at the correct position) by grasping the non-detection distance.
[0087]
(H) The main controller 43 determines that the article F is placed on the shelf 6 when the non-detection distance reaches the second predetermined distance.
[0088]
(I) If the main controller 43 switches from the non-detection state to the detection state by the time the non-detection distance reaches the second predetermined distance while the transfer device 16 is moving, an object other than the target article F is placed on the shelf 6. It is judged that it is placed in.
[0089]
(J) The article confirmation control method of the automatic warehouse 1 will be described. This method is an apparatus for transferring an article F between the rack 2 having a plurality of shelves 6 for storing the articles F and the shelves 6, and is movable between the shelves through the front of the shelves. The device 16, the sensor 51 provided in the transfer device 16, and the shelf 6 are provided on the shelf 6. When the product F is placed on the shelf 6, the product is located behind the product F and placed on the shelf 6. It is used in the automatic warehouse 1 provided with the to-be-detected body 10 which has the part hidden from the sensor 51 by F, and the part which is not hidden. This method comprises the following steps.
First step of determining whether or not the detection distance detected by the sensor 51 by the sensor 51 has reached the first predetermined distance while the transfer device 16 is moving in front of the shelf 6

Claims (13)

A rack having a plurality of shelves for storing articles;
A device for transferring the article between the shelves, and a transfer device movable between the shelves through the front of the shelves;
A detector provided in the transfer device;
The shelf is provided on the shelf, and is located on the back side of the article when the article is placed on the shelf, and has a portion hidden from the detector and a portion not hidden by the article placed on the shelf. , The detected object,
It is used to determine whether or not the article is placed on the shelf using a detection result by the detector, and when the transfer device is moving in front of the shelf, the detection state is not detected. A detection determination unit, which is used to determine whether the article is placed on the shelf;
Automatic warehouse equipped with. The detected object has at least one linear portion extending in one direction on the shelf,
The automatic transfer device according to claim 1, wherein the transfer device is freely movable in front of a shelf other than the target shelf, but is allowed to move only along the one direction in front of the target shelf. Warehouse. The at least one straight portion includes a first straight portion extending in the horizontal direction and a second straight portion extending in the vertical direction on the shelf,
The transfer device can move in the horizontal direction and the vertical direction at the same time before the target shelf, but only one of the horizontal and vertical movements is allowed in front of the target shelf. The automated warehouse according to claim 2, wherein   The detection determining unit obtains a detection distance detected by the detector while the transfer device is moving, and determines whether the article is placed on the shelf. The automatic warehouse according to claim 1, which is used for determination.   The automatic warehouse according to claim 4, wherein the detection determination unit determines that the article is not placed on the shelf when the detection distance reaches a first predetermined distance.   6. The automatic warehouse according to claim 5, wherein the first predetermined distance is shorter than a distance from an end portion to a center portion of a portion of the shelf corresponding to the detected body where the detected body is provided.   The detection determination unit acquires a non-detection distance at which the detection target is not detected by the detector while the transfer device is moving, and whether the article is placed on the shelf. The automatic warehouse according to claim 4, which is used for the determination.   The automatic warehouse according to claim 7, wherein the detection determination unit determines that the article is placed on the shelf when the non-detection distance reaches a second predetermined distance.   The detection determination unit acquires a non-detection distance at which the detection target is not detected by the detector while the transfer device is moving, and whether the article is placed on the shelf. The automatic warehouse according to claim 1, which is used for the determination.   The automatic warehouse according to claim 9, wherein the detection determination unit determines that the article is placed on the shelf when the non-detection distance reaches a second predetermined distance.   The detection determination unit may place an object other than the target article on the shelf when the transfer device is switched from the non-detection state to the detection state before the non-detection distance reaches the second predetermined distance while the transfer device is moving. The automatic warehouse according to claim 10, wherein the automatic warehouse is determined to be. A rack having a plurality of shelves for storing articles, and an apparatus for transferring the articles between the shelves, and a transfer apparatus that is movable between the shelves through the front of the shelves; A detector provided in the transfer device; provided on the shelf; when the article is placed on the shelf; located on the back side of the article; and the detection by the article placed on the shelf In an automatic warehouse with a detected object having a part hidden from the vessel and a part not hidden,
A first step of determining whether or not a detection distance at which the detected object is detected while the transfer device is moving in front of the shelf has reached a first predetermined distance;
A second step of determining that at least something is placed on the shelf if the detection state is switched to the non-detection state before the detection distance reaches the first predetermined distance while the transfer device is moving; ,
An article confirmation control method for an automatic warehouse comprising: A third step of determining whether or not a non-detection distance in which the detection target is not detected by the detector while the transfer device is moving has reached a second predetermined distance;
If the non-detection state switches to the detection state before the non-detection distance reaches the second predetermined distance while the transfer device is moving, it is determined that an object other than the target article is placed on the shelf. The article confirmation control method according to claim 12, further comprising a fourth step.

Images