JP7800519B2 - Goods sorting equipment - Google Patents

Description

The present invention relates to an item sorting facility that includes a container storage facility in which multiple storage containers are stored, a work area in which items contained in the storage containers are removed and sorted into multiple collection containers, and a transport system that transports the storage containers from the container storage facility to the work area.

An example of an item sorting facility that sorts items is disclosed in Japanese Patent Laid-Open No. 2002-154605 (Patent Document 1). Below, in the description of this background art, reference numerals from Patent Document 1 will be quoted in parentheses. The facility disclosed in Patent Document 1 is configured so that items released from an automated warehouse (11) are supplied to a sorting area (13) where items are sorted by shipping destination.

Japanese Patent Application Laid-Open No. 2002-154605

In an article sorting facility, it is conceivable that a group of stacked containers, each containing storage containers required for sorting, may be transported by a conveying system to a work area where the sorting work is carried out (a material handling area in Patent Document 1). When transporting a group of stacked containers to a work area in this way by a conveying system, it is desirable that the conveying system transport the storage containers with high efficiency. However, Patent Document 1 does not mention this point.

Therefore, it is desirable to develop technology that can easily improve the efficiency of transporting storage containers using a transport system when transporting stacked containers into a work area.

The item sorting equipment according to the present disclosure is an item sorting equipment comprising: a container storage facility in which a plurality of storage containers are stored; a work area in which sorting work is performed in which items contained in the storage containers are removed and sorted into a plurality of collection containers; a transport system that transports the storage containers from the container storage facility to the work area and transports the storage containers from the work area to the container storage facility; and a control system that controls the transport system, wherein the storage containers are configured to be stackable in the vertical direction, and the transport system is configured to create a stacked container group in which a predetermined number of the storage containers are stacked and transport the stacked container group to the work area, and the control system is configured to group the sorting work for the predetermined number of collection containers into one batch and sort the items into a plurality of the When the transport system is caused to execute a batch loading process in which the storage containers required for the sorting operation included in each batch are loaded into the work area in the order in which the batches are processed, one of the batches is designated as a first batch, and the batch processed after the first batch is designated as a second batch, the transport system is caused to execute a second loading process in which the stacked container group, some of which are storage containers belonging to the first batch and the remainder are storage containers belonging to the second batch, loaded into the work area between a first loading process in which the stacked container group, some of which are storage containers belonging to the first batch and the remainder are storage containers belonging to the second batch, is loaded into the work area, and a third loading process in which the stacked container group, some of which are storage containers belonging to the first batch and the remainder are storage containers belonging to the second batch, is loaded into the work area.

With this configuration, when storage containers required for sorting work contained in each of multiple batches are brought into the work area in a stacked container group with a set number of tiers in the order in which the multiple batches are processed, it is possible to create stacked container groups that contain a mixture of storage containers belonging to two batches that are processed in different (consecutive) orders, rather than just creating stacked container groups separated by batch. This reduces the need to create stacked container groups with fewer tiers than the set number, making it easier to increase the efficiency with which the transport system transports storage containers. As described above, with this configuration, it is easier to increase the efficiency with which the transport system transports storage containers when the control system transports stacked container groups into the work area.

Further features and advantages of the article sorting equipment will become apparent from the following description of the embodiments, which are illustrated with reference to the drawings.

FIG. 1 is a plan view of a portion of an article sorting facility according to a first embodiment; 1 is a side view of a transport vehicle according to a first embodiment; FIG. 1 is a plan view of a work area according to a first embodiment; 1 is a perspective view of a work area according to a first embodiment; Control block diagram according to the first embodiment FIG. 1 is an explanatory diagram of a batch carry-in process according to a first embodiment; FIG. 1 is an explanatory diagram of a batch carry-in process according to a first embodiment; 10 is a plan view of a work area according to a second embodiment; FIG. 10 is a plan view showing a part of a work area according to a third embodiment; 10 is a plan view of a work area according to a third embodiment; 10 is a perspective view of a work area according to a third embodiment; Plan view of a work area according to a fourth embodiment. 10 is a perspective view of a work area according to a fourth embodiment;

First Embodiment
A first embodiment of an article sorting system will be described with reference to the drawings (FIGS. 1 to 7). As shown in FIGS. 1 and 5, the article sorting system 100 includes a container storage facility 8, a work area A, and a conveying system 40. The article sorting system 100 also includes a control system 5 (see FIG. 5) that controls the conveying system 40. In the following description, two mutually orthogonal horizontal directions are referred to as the X direction and the Y direction. One side in the X direction is referred to as the X direction first side X1, and the other side in the X direction is referred to as the X direction second side X2. One side in the Y direction is referred to as the Y direction first side Y1, and the other side in the Y direction is referred to as the Y direction second side Y2.

A plurality of storage containers 1 are stored in the container storage facility 8. As shown in Figure 1, the container storage facility 8 is equipped with storage shelves 9 for storing the storage containers 1. The storage containers 1 are stored in the storage shelves 9 while being supported on the shelf portions of the storage shelves 9. Details are omitted, but in the example shown in Figure 1, the storage shelves 9 are configured as follows: The shelf portions are configured to support a plurality of storage containers 1 lined up in the shelf width direction (Y direction in the example shown in Figure 1). The shelf portions are arranged in multiple levels lined up in the Z direction, which is the up-down direction (vertical direction), and the storage shelves 9 are configured to store storage containers 1 on each of the multiple levels (tiers).

The storage container 1 is formed in a box shape (here, a box shape with an open top). As shown in Figure 4, the storage container 1 is configured to be stackable in the Z direction. A storage container 1 is stacked on another storage container 1 by fitting the bottom of the storage container 1 into the opening at the top of the other storage container 1. The storage containers 1 are configured to be stackable when they contain items 4.

Storage containers 1 contain items 4, such as products or parts. Here, storage containers 1 contain multiple items 4 of one or more types. For example, storage containers 1 contain multiple types of items 4, each with multiple units of each type. A storage container 1 may contain multiple items 4 of a single type, or a storage container 1 may contain one item 4 of each of multiple types. The type (category, item) of item 4 refers to a classification of items 4 to be handled by item sorting equipment 100, separated according to predetermined criteria. For example, the type of item 4 can be classified based on the smallest keeping unit (SKU) of the item 4, i.e., the smallest keeping unit when managing inventory of the item 4. The type of item 4 can also be classified based on the identification code of the item 4 (for example, a product identification code such as a JAN code or EAN code).

The transport system 40 is configured to transport storage containers 1 from the container storage facility 8 to the work area A, and to transport storage containers 1 from the work area A to the container storage facility 8. As shown in FIG. 1, the transport system 40 includes a conveyor (here, the first conveyor 41) that transports storage containers 1 within the work area A, and a transport vehicle 90 that transports storage containers 1 outside the work area A. The transport vehicle 90 transports stacked container groups 10, which are made up of multiple storage containers 1 stacked on top of each other.

The first conveyor 41 will be described in more detail below, but as shown in FIG. 1, the first conveyor 41 includes an inlet section 50 that receives storage containers 1 (here, stacked container groups 10) that have been transported from the container storage facility 8 to the work area A, and an outlet section 60 that transports storage containers 1 (here, stacked container groups 10) from the work area A to the container storage facility 8. The transport vehicle 90 transports the storage containers 1 (here, stacked container groups 10) from the container storage facility 8 to the inlet section 50, and transports the storage containers 1 (here, stacked container groups 10) from the outlet section 60 to the container storage facility 8.

The container storage facility 8 (specifically, the storage shelves 9) is configured to store multiple storage containers 1 in a separated state. The transport vehicle 90 stacks multiple storage containers 1 removed from the storage shelves 9 to form a stacked container group 10, and transports the stacked container group 10 to the loading section 50. The transport vehicle 90 also transports the stacked container group 10 received from the unloading section 60 to the container storage facility 8, and stores the multiple storage containers 1 that make up the stacked container group 10 in a separated state on the storage shelves 9.

The transport vehicle 90 may be an automated guided vehicle that travels autonomously or remotely, or a manned guided vehicle (e.g., a forklift) operated by an operator. In this embodiment, the transport vehicle 90 is an autonomously traveling automated guided vehicle. The transport vehicle 90 may be a rail-guided vehicle (e.g., a stacker crane) that travels along rails installed on the floor or the like, or a trackless transport vehicle such as an AGV (Automated Guided Vehicle) or an AMR (Autonomous Mobile Robot). When the transport vehicle 90 is a trackless transport vehicle, the transport vehicle 90 travels along a virtually formed travel path P rather than a physically formed travel path P using rails or the like (see FIG. 1). For example, multiple detectable objects such as two-dimensional codes or RF (Radio Frequency) tags are placed on the floor, and the travel path P is virtually formed to connect the multiple detectable objects. A configuration in which such detectable objects are not placed on the floor and the travel path P is virtually formed by a route calculated based on the recognition results of the surrounding environment may also be used.

The transport vehicle 90 illustrated in Figure 2 is configured as follows. The transport vehicle 90 includes a traveling body 93, a support unit 94, a first transfer device 91, and a second transfer device 92. The transport vehicle 90 also includes a lifting device 95. The support unit 94, the first transfer device 91, the second transfer device 92, and the lifting device 95 are all mounted on the travel vehicle 93.

The running body 93 is configured to run on the floor surface. Although details are omitted, the running body 93 runs by rotating drive wheels using a driving force source such as an electric motor. The running body 93 has a pair of drive wheels on the left and right, and is configured to turn by rotating the pair of drive wheels in opposite directions.

The support section 94 supports the stacked container group 10. The support section 94 can also support a single storage container 1. In this example, the conveyor that constitutes the second transfer device 92 constitutes the support section 94. Specifically, the conveying surface of the conveyor that constitutes the second transfer device 92 constitutes the support surface for the stacked container group 10 at the support section 94. The conveying surface of the conveyor is, for example, constituted by a plane (imaginary plane) that includes the upper ends of each of the multiple rollers that constitute the conveyor, or by the upper surface of the belt that constitutes the conveyor.

The second transfer device 92 transfers the storage container 1 (here, the stacked container group 10) between the support section 94 and the carry-in section 50. The second transfer device 92 also transfers the storage container 1 (here, the stacked container group 10) between the support section 94 and the carry-out section 60. In Figures 1 and 3, the transfer operation of the stacked container group 10 by the second transfer device 92 is indicated by a white arrow as the second transfer operation M2. The second transfer operation M2 includes the transfer operation of the stacked container group 10 from the transport vehicle 90 (in this example, the support section 94) to the carry-in section 50 by the second transfer device 92, and the transfer operation of the stacked container group 10 from the carry-out section 60 to the transport vehicle 90 (in this example, the support section 94) by the second transfer device 92.

In this embodiment, the second transfer device 92 is configured to transfer the stacked container group 10 between the transfer target locations (here, the loading section 50 and the unloading section 60) by moving the stacked container group 10 in the vehicle width direction (a horizontal direction perpendicular to the direction of travel of the transport vehicle 90, and a direction perpendicular to the plane of the paper in Figure 2). In this example, the second transfer device 92 is equipped with a conveyor (e.g., a roller conveyor or belt conveyor) that transports the stacked container group 10 in the vehicle width direction. Alternatively, the second transfer device 92 may be a fork-type transfer device equipped with forks that support and retract the stacked container group 10. Note that in this specification, a member that supports the supported object and is retracted by a retracting device is referred to as a "fork," and the term "fork" is not limited to a specific shape.

The lifting device 95 is mounted on the running body 93 so that it can be raised and lowered. The lifting device 95 is configured to lift a storage container 1 at any level (any height) among the multiple storage containers 1 that make up the stacked container group 10 supported by the support part 94. By lifting a storage container 1 at any level using the lifting device 95 in this way, the storage container 1 at that level can be separated from the storage container 1 one level below it. Note that if one or more other storage containers 1 are stacked next to the storage container 1 being lifted by the lifting device 95, those other one or more storage containers 1 will also be lifted.

A group of storage containers 1 in multiple tiers lifted by the lifting device 95 is referred to as a target container group. In this example, the lifting device 95 is configured to be able to form a space in the Z direction between storage containers 1 in two adjacent tiers in the target container group (here, between the storage container 1 in the lowest tier and the storage container 1 one tier above). Figure 2 shows the lifting device 95 lifting a target container group consisting of a two-tier group of storage containers 1, and a space in the Z direction is formed between the bottommost storage container 1 that makes up the target container group and the storage container 1 one tier above it (here, the topmost storage container 1 that makes up the target container group). As will be described later, Figure 2 shows the first transfer device 91 moving a storage container 1 (storage container 1 marked with a circled "2") into the space thus formed.

The first transfer device 91 transfers the storage container 1 between the storage shelf 9 provided in the container storage facility 8 and the stacked container group 10 supported by the support portion 94. In FIG. 1, the transfer operation of the storage container 1 by the first transfer device 91 is indicated by a white arrow as the first transfer operation M1. The first transfer operation M1 includes the transfer operation of the storage container 1 from the storage shelf 9 to the stacked container group 10 supported by the support portion 94, and the transfer operation of the storage container 1 from the stacked container group 10 supported by the support portion 94 to the storage shelf 9.

When transferring a storage container 1 from a storage shelf 9 to a stacked container group 10 supported by a support portion 94, the first transfer device 91 removes the storage container 1 from the storage shelf 9 and adds the storage container 1 to one of the tiers of the stacked container group 10 supported by the support portion 94. The first transfer device 91 is mounted on a traveling body 93 so that it can be raised and lowered. The first transfer device 91 removes the storage container 1 while being raised and lowered to a height corresponding to the shelf tier on which the storage container 1 to be removed is stored. The first transfer device 91 then removes the storage container 1 while being raised and lowered to a height corresponding to the tier in the stacked container group 10 supported by the support portion 94 to which the storage container 1 will be added, and adds the storage container 1 to that tier. In this example, because the transport vehicle 90 is equipped with a lifting device 95, the first transfer device 91 can add the storage container 1 not only to the top tier of the stacked container group 10 supported by the support portion 94 but also to any tier (specifically, the tier below the storage container 1 lifted by the lifting device 95).

When transferring a storage container 1 from a stacked container group 10 supported by the support portion 94 to a storage shelf 9, the first transfer device 91 removes the storage container 1 from one of the levels of the stacked container group 10 supported by the support portion 94 and then stores the storage container 1 on the storage shelf 9. The first transfer device 91 removes the storage container 1 from the level of the stacked container group 10 supported by the support portion 94, while being raised or lowered to a height corresponding to the level from which the storage container 1 is to be removed. In this example, because the transport vehicle 90 is equipped with a lifting device 95, the first transfer device 91 can remove the storage container 1 not only from the top level of the stacked container group 10 supported by the support portion 94, but also from any level (specifically, the level below the storage container 1 lifted by the lifting device 95). The first transfer device 91 then removes the storage container 1 from the level, while being raised or lowered to a height corresponding to the shelf level to be stored.

In this embodiment, the first transfer device 91 is a push-pull type transfer device. The first transfer device 91 delivers the storage container 1 to the transfer target location (here, the storage shelf 9 and the stacked container group 10) by pressing on the storage container 1, and receives the storage container 1 from the transfer target location by pulling in the storage container 1. Alternatively, the first transfer device 91 may be a fork-type transfer device equipped with forks that support the storage container 1 and move forward and backward.

The first transfer device 91 is mounted on a traveling body 93 so as to be rotatable around an axis along the Z direction. By rotating the first transfer device 91 around an axis along the Z direction, the position of the first transfer device 91 can be switched between a position in which a storage container 1 is transferred between the storage shelf 9 (in this example, a position facing the width direction of the vehicle body) and a position in which a storage container 1 is transferred between a stacked container group 10 supported by a support portion 94 (in this example, a position facing the fore-and-aft direction of the vehicle body). Here, the fore-and-aft direction of the vehicle body is the horizontal direction along the direction of travel of the transport vehicle 90, and is the left-right direction in Figure 2.

In this example, the first transfer device 91 is configured to be able to transfer two storage containers 1 in parallel. Figure 2 shows how, while the lifting device 95 is lifting two storage containers 1, the first transfer device 91 simultaneously removes the storage container 1 one level below these two storage containers 1 (the storage container 1 marked with a circled "1") and adds a storage container 1 (the storage container 1 marked with a circled "2") between these two storage containers 1.

The operation of the conveying system 40 is controlled by a control system 5 (see Figure 5). The control system 5 controls the operation of the device to be controlled by controlling the drive of a drive power source (e.g., an electric motor) provided in the device. Each function of the control system 5 is realized, for example, by cooperation between hardware such as a processing unit and a program executed on the hardware. The control system 5 may be configured not as a single piece of hardware, but as a collection of multiple pieces of hardware (multiple separate pieces of hardware) that can communicate with each other. Furthermore, the device to be controlled by the control system 5 (e.g., a controller provided in the device) may constitute at least a part of the control system 5.

The various technical features of the control system 5 disclosed in this specification can also be applied to a method for controlling the conveyance system 40 and a program for controlling the conveyance system 40 (a program for causing a computer to function as the control system 5), and this specification also discloses such methods and programs, as well as storage media on which such programs are stored (e.g., computer-readable storage media such as optical disk flash memory).

Work area A is an area where sorting work is performed, in which items 4 stored in storage containers 1 are removed and sorted into multiple collection containers 2. As will be described later, in this embodiment, workers perform sorting work in work area A. For this reason, an instruction output device 6 (see FIG. 5) that outputs work instructions to the worker is located in work area A. Although the instruction output device 6 is not shown in FIGS. 3 and 4, the instruction output device 6 is, for example, a display (monitor). The control system 5 controls the instruction output device 6 in addition to the conveyance system 40. The instruction output device 6 may be a monitor on a mobile device carried by the worker, or may be smart glasses (a display device integrated with eyeglasses) if the worker is wearing them.

In work area A, storage containers 1 are transported by a first conveyor 41 (e.g., a roller conveyor or belt conveyor) provided in the transport system 40. The first conveyor 41 has a transport section 70 that transports storage containers 1 from the loading section 50 to the unloading section 60. The first conveyor 41 transports storage containers 1 in one direction (transport direction T shown in Figure 3). In this embodiment, the transport section 70 does not branch, and does not have a branch section 80 or a junction section 81 (see Figures 9 and 12) described below.

3, the conveying section 70 of the first conveyor 41 includes an inlet section extending from the inlet section 50 toward the second side Y2 in the Y direction, an outlet section extending toward the first side Y1 in the Y direction toward the outlet section 60, and an intermediate section connecting the inlet section and outlet section. In this example, the outlet section 60 is located on the second side X2 in the X direction relative to the inlet section 50, and the outlet section is located on the second side X2 in the X direction relative to the inlet section. In this example, the outlet section 60 is located at the same position in the Y direction as the inlet section 50. In addition, in this example, the intermediate section includes an upstream section extending from the inlet section toward the second side X2 in the X direction, and a downstream section located on the first side Y1 in the Y direction relative to the upstream section and extending toward the first side X1 in the X direction toward the outlet section. Although details are omitted, at the point where the transport direction T on the first conveyor 41 changes, for example, a transport mechanism that transports the storage container 1 in the X direction, a transport mechanism that transports the storage container 1 in the Y direction, and a lifting mechanism that raises and lowers these two transport mechanisms relative to one another are provided.

As shown in Figures 3 and 4, work area A includes an outgoing container placement section 23 and a collection container placement section 25. In this embodiment, work area A further includes a processing item placement section 20 and an incoming container placement section 24. Note that work area A may also be configured without either or both of the processing item placement section 20 and the incoming container placement section 24. If work area A does not include the incoming container placement section 24, work area A also does not include the incoming work area A2, which will be described later.

Storage containers 1 transported from the container storage facility 8 to work area A by the transport system 40 are placed in the outgoing container placement section 23. Hereinafter, the storage container 1 placed in the outgoing container placement section 23 will be referred to as the "first container 1a" to distinguish it from other storage containers 1. The outgoing container placement section 23 is a predetermined area on the first conveyor 41. In this embodiment, the outgoing container placement section 23 is a predetermined area on the above-mentioned intermediate section (specifically, the upstream section) of the first conveyor 41. In this embodiment, this area is set to a size that allows one storage container 1 to be placed therein.

Work area A includes a removal work area A1. As described below, work area A further includes a storage work area A2, a processing work area A3, and a sorting work area A4. Each of the areas included in work area A is at least conceptually defined. Therefore, the multiple areas included in work area A do not need to be different from each other; multiple areas may partially overlap, or multiple areas may be the same area. For example, processing work area A3 and sorting work area A4 may be different from each other, but in this embodiment, processing work area A3 and sorting work area A4 are the same area, as shown in Figures 3 and 4.

In the retrieval work area A1, retrieval work (picking work) is performed to retrieve items 4 from storage containers 1 (first containers 1a) placed in the output container placement section 23. Therefore, the output container placement section 23 is a stopping position on the first conveyor 41 where the storage container 1 is stopped for retrieval work. During retrieval work, items 4 stored in the storage container 1 are retrieved through an opening in the top surface of the storage container 1. As shown in FIG. 3 , in this embodiment, retrieval work in the retrieval work area A1 is performed by one or more first workers 31. Therefore, for example, instructions for the retrieval work (e.g., information about the type of items 4 to be retrieved and information about the number of items 4 to be retrieved) are displayed on an instruction output device 6 visible to the first worker 31. Note that the retrieval work may be performed by a robot instead of the first worker 31, or the retrieval work may be performed collaboratively by the first worker 31 and the robot.

In this embodiment, the items 4 are stored in a container 3 such as a bag, which is then stored in the storage container 1. For example, the container 3 stores multiple items 4 of the same type. In the removal operation, the items 4 are removed from the storage container 1 along with the container 3 in which the items 4 are stored. In other words, in the removal operation, the items 4 are not removed piece by piece (piece picking), but rather by type (item picking).

In this embodiment, the loading section 50 receives the stacked container group 10 from the transport vehicle 90. To this end, the work area A is equipped with a de-stacking device 44 that separates the stacked container group 10 received in the loading section 50 into individual storage containers 1. The de-stacking device 44 is located downstream of the loading section 50 and upstream of the outgoing container placement section 23. In this embodiment, the de-stacking device 44 is located in the above-mentioned loading section side section of the first conveyor 41. The storage containers 1 separated from the stacked container group 10 by the de-stacking device 44 are transported sequentially to the outgoing container placement section 23. The de-stacking device 44 is configured to, for example, sequentially separate and transport out the lowest storage container 1 in the stacked container group 10. Although details are omitted, the de-stacking device 44 includes, for example, a first lifting device that holds and raises and lowers the stacked container group 10, and a second lifting device that holds and raises and lowers the storage container 1 on the lowest level of the stacked container group 10.

A plurality of collection containers 2 are placed in the collection container placement section 25. The collection container 2 is box-shaped (here, a box-shaped container with an open top). In this embodiment, the collection container placement section 25 is a shelf on which a plurality of collection containers 2 can be arranged side by side. As shown in FIG. 4 , in this embodiment, the work area A includes a plurality of collection container placement sections 25. The collection container placement sections 25 are arranged at different positions (heights) in the Z direction and are arranged so as to overlap each other when viewed in the Z direction (viewed in the direction along the Z direction, i.e., in a plan view). Here, the work area A includes two collection container placement sections 25. Specifically, as shown in FIG. 4 , the shelf portion constituting one collection container placement section 25 and the shelf portion constituting another collection container placement section 25 are arranged at different positions in the Z direction and are arranged so as to overlap each other when viewed in the Z direction.

In this embodiment, the collection container placement section 25 is configured so that multiple collection containers 2 are lined up in parallel with the conveying direction T of the storage container 1 in the outgoing container placement section 23. The conveying direction T of the storage container 1 can also be referred to as the arrangement direction of the storage containers 1. As shown in FIG. 3 , in this embodiment, the conveying direction T of the storage container 1 in the outgoing container placement section 23 is the X direction. The collection container placement section 25 is configured so that multiple collection containers 2 are lined up in parallel with the X direction. Here, the collection container placement section 25 is disposed on the second side Y2 in the Y direction relative to the outgoing container placement section 23. By configuring the collection container placement section 25 in this manner, the collection container placement section 25 can be disposed adjacent to a section of the first conveyor 41 that extends in the X direction and includes the outgoing container placement section 23 (here, the intermediate section described above, specifically the upstream section), thereby reducing the space required for installing the outgoing container placement section 23 and the collection container placement section 25. In this embodiment, the collection container arrangement section 25 is configured so that multiple collection containers 2 are lined up in parallel with the transport direction T (here, the X direction) of the storage container 1 in the receiving container arrangement section 24.

Work area A includes a processing work area A3. In processing work area A3, items 4 removed by the removal work are subjected to processing work for shipping (hereinafter simply referred to as "processing work"). Processing work is, for example, the processing of items 4, such as merchandise, to suit their shipping form (i.e., the work of performing distribution processing). Distribution processing includes, for example, packaging, subdivision, replacing identification tags (shipping labels), processing parts, assembling parts, measuring weight, and inspection.

In this embodiment, the items 4 removed by the removal operation are placed in the processing item placement section 20 for the processing operation. In this embodiment, the processing item placement section 20 is a workbench for performing the processing operation. In the example shown in FIG. 3, the items 4 removed by the removal operation are placed on a cart 7 together with the container 3 containing the items 4 and transported from the removal operation area A1 to the processing operation area A3, and then the container 3 is placed in the processing item placement section 20. The processing operation is then performed on the items 4 removed from the container 3. In this way, in this embodiment, the items 4 are removed piece by piece (piece picking) during the processing operation.

As shown in FIG. 3, in this embodiment, processing work in the processing work area A3 is performed by one or more second workers 32. Therefore, for example, instructions for the processing work (e.g., specific details of the processing work) are displayed on an instruction output device 6 that is visible to the second workers 32. Note that it is also possible to configure the processing work to be performed by a robot instead of the second workers 32, or to configure the processing work to be performed collaboratively by the second workers 32 and the robot.

Work area A includes a sorting area A4. In sorting area A4, sorting work is performed to place items 4 after processing into collection containers 2. The sorting work involves placing the number of items 4 of the type specified in the order into each of the multiple collection containers 2 arranged in the collection container placement unit 25. That is, an order specifying the number of items 4 of each type is assigned to each of the multiple collection containers 2. For example, the control system 5 or another control system that can communicate with the control system 5 (e.g., a higher-level control system) generates orders based on orders from destinations for the items 4 and manages the generated orders by correlating them with the destinations. The control system 5 then controls the transport system 40 to transport storage containers 1 containing items 4 of the type specified in the order (i.e., storage containers 1 required for the sorting work) to the output container placement unit 23.

As shown in FIG. 3, in this embodiment, sorting work in the sorting work area A4 is performed by one or more second workers 32. Therefore, for example, sorting instructions (e.g., information on the type and number of items 4 specified in the order for each collection container 2) are displayed on an instruction output device 6 that is visible to the second workers 32. Note that the sorting work can also be performed by a robot instead of the second workers 32, or by the second workers 32 and the robot working together to perform the sorting work.

In this embodiment, both the processing work and the sorting work are performed by the same worker (worker or robot). In the example shown in Figure 3, the second worker 32 performs both the processing work and the sorting work. That is, the second worker 32 performs the processing work on the items 4, and then performs the sorting work of placing the items 4 into the collection container 2. Alternatively, the processing work and the sorting work can be performed by different workers.

As shown in FIG. 4, in this embodiment, the collection container placement section 25 is positioned above the processing item placement section 20 in the Z1 direction. The processing item placement section 20 and the collection container placement section 25 are positioned so that they overlap when viewed in the Z direction. In the example shown in FIGS. 3 and 4, the direction perpendicular to the arrangement direction of the multiple storage containers 1 in the collection container placement section 25 when viewed in the Z direction is defined as the target direction (in this example, the Y direction), and the processing item placement section 20 is formed with a larger dimension in the target direction than the collection container placement section 25. The processing item placement section 20 is positioned so that it protrudes on both sides of the target direction relative to the collection container placement section 25 when viewed in the Z direction. This allows multiple second workers 32 to be separated into two groups on both sides of the target direction relative to the processing item placement section 20 and the collection container placement section 25, making it easier to perform processing and sorting tasks, as shown in FIG. 3.

The incoming container placement section 24 is where storage containers 1 scheduled to be transported from work area A to the container storage facility 8 by the transport system 40 are placed. Hereinafter, the storage container 1 placed in the incoming container placement section 24 is referred to as the "second container 1b" to distinguish it from other storage containers 1. The incoming container placement section 24 is a predetermined area on the first conveyor 41. The incoming container placement section 24 is a predetermined area downstream of the outgoing container placement section 23 in the transport section 70 (specifically, the intermediate section described above, more specifically, the upstream section described above). In this embodiment, this area is set to a size that allows one storage container 1 to be placed therein. In the example shown in Figures 3 and 4, between the first container 1a placed in the outgoing container placement section 23 and the second container 1b placed in the incoming container placement section 24, storage containers 1 other than the first container 1a and the second container 1b (here, four storage containers 1) can be placed.

Work area A includes a receiving work area A2. In the receiving work area A2, receiving work is carried out. The receiving work involves placing items 4 to be stored into a storage container 1 (second container 1b) placed in the receiving container placement section 24, or placing a storage container 1 containing items 4 to be stored in the receiving container placement section 24. Therefore, the receiving container placement section 24 is a stop/placement position on the first conveyor 41 where the storage container 1 is stopped or placed for receiving work.

In this embodiment, the storing operation of placing items 4 to be stored into second container 1b involves placing a container 3 (container 3 with remaining items 4) from which items 4 have been removed through processing into second container 1b. In the example shown in FIG. 3, the container 3 from which items 4 have been removed through processing is placed on a cart 7 and transported from processing work area A3 to receiving work area A2, where it is then placed into second container 1b. Note that the second container 1b into which the container 3 is placed may be the same storage container 1 from which the container 3 was removed through removal work, or a different storage container 1. In this embodiment, the storing operation of placing items 4 to be stored into second container 1b also involves placing a container 3 containing replenishment items 4 or a container 3 containing new items 4 to be stored (container 3 indicated by a two-dot chain line in FIG. 3) into second container 1b.

In addition, in this embodiment, the receiving operation of placing the storage container 1 containing the items 4 to be stored in the incoming container placement section 24 involves loading the storage container 1, which contains items 4 to be replenished or newly stored items 4, from outside the first conveyor 41 onto the incoming container placement section 24.

As shown in FIG. 3, in this embodiment, the warehousing work in the warehousing work area A2 is performed by one or more third workers 33. Note that it is also possible to configure the warehousing work to be performed by a robot instead of the third workers 33, or for the third workers 33 and a robot to work together to perform the warehousing work. Also, in the example shown in FIG. 3, the processing work and sorting work are performed by the same worker (worker or robot), but any two or more of the retrieval work, processing work, sorting work, and warehousing work may be performed by the same worker. For example, it is possible to configure the retrieval work and warehousing work to be performed by the same worker.

In this embodiment, the discharge section 60 delivers the stacked container group 10 to the transport vehicle 90. Therefore, the work area A is equipped with a stacking device 45 that stacks multiple storage containers 1 (in this embodiment, a set number of storage containers 1, as described below) to create the stacked container group 10. The stacking device 45 is located downstream of the outgoing container placement section 23 and the incoming container placement section 24, but upstream of the discharge section 60. In this embodiment, the stacking device 45 is located in the above-mentioned discharge section of the first conveyor 41. The stacked container group 10, created by sequentially stacking multiple storage containers 1 in the stacking device 45, is transported to the discharge section 60. The stacking device 45 is configured, for example, to sequentially add storage containers 1 to be stacked to the stacked container group 10 as the lowest storage container 1. For example, the destacking device 44 and the stacking device 45 can be devices with a common configuration.

Although not limited to this configuration, in this embodiment, the control system 5 is configured to cause the conveyance system 40 to execute batch loading processing. The sorting operations for a predetermined number of collection containers 2 are grouped into one batch, and the batch loading processing involves loading the storage containers 1 required for the sorting operations contained in each of the multiple batches into work area A in the order in which the multiple batches are processed. As described above, in this embodiment, work area A includes multiple collection container placement sections 25 in which collection containers 2 are placed. Each of the multiple collection container placement sections 25 contains collection containers 2 belonging to different batches. Therefore, sorting operations for multiple batches (specifically, the same number of batches as the number of collection container placement sections 25) can be performed in parallel. The maximum number of collection containers 2 that can be placed in each collection container placement section 25 (6 in the example shown in Figures 3 and 4) is set to the same number as the maximum number of collection containers 2 belonging to a single batch. Note that "collection container 2 belonging to a batch" refers to the collection container 2 into which items 4 are sorted during the sorting work included in the batch.

For example, in the example shown in Figures 3 and 4, the sorting work for six collection containers 2 placed in one collection container placement section 25 is collectively considered to be one batch. Then, each of the two collection container placement sections 25 is placed with collection containers 2 belonging to two different batches (specifically, one batch and the batch to be processed after the first batch). When the sorting work included in one of the two batches is completed, the collection containers 2 belonging to that batch (in this example, six collection containers 2) are carried out of the collection container placement section 25, and collection containers 2 belonging to the batch to be processed after the first batch are placed in that collection container placement section 25.

In this embodiment, the conveying system 40 is configured to create stacked container groups 10 by stacking a predetermined number of storage containers 1 (eight in the example shown in FIG. 4 ), and to transport these stacked container groups 10 to work area A. When transporting stacked container groups 10 to work area A in this way, it is possible to create one stacked container group 10 containing only storage containers 1 belonging to the same batch, rather than creating stacked container groups 10 containing a mixture of storage containers 1 belonging to different batches (i.e., creating only stacked container groups 10 separated by batch). However, in this case, it may become necessary to create stacked container groups 10 with fewer layers than the set number, which may reduce the efficiency with which the conveying system 40 transports the storage containers 1. Note that "storage containers 1 belonging to a batch" refers to storage containers 1 required for the sorting work included in that batch.

In consideration of the above, in this embodiment, rather than only transporting stacked container groups 10 divided into batches into work area A, as described below, stacked container groups 10 containing a mixture of storage containers 1 belonging to multiple batches in which the processing order is reversed (consecutive) are also transported into work area A. This reduces the need to create stacked container groups 10 with fewer layers than the set number, making it easier to improve the efficiency of transporting storage containers 1 by the transport system 40. Note that, while this embodiment assumes that the "set number" is always a fixed number, the set number may also be configured to be changeable depending on the situation.

When the control system 5 causes the conveyance system 40 to execute the batch loading process, it controls the conveyance system 40 as follows. One of the batches is designated the first batch, and the batch processed after the first batch is designated the second batch. Between the first loading process, which causes a stacked container group 10, some or all of which are storage containers 1 belonging to the first batch, to be loaded into the work area A, and the third loading process, which causes a stacked container group 10, some of which are storage containers 1 belonging to the second batch, to be loaded into the work area A, the control system 5 causes the conveyance system 40 to execute a second loading process, which causes a stacked container group 10, some of which are storage containers 1 belonging to the first batch and the remainder of which are storage containers 1 belonging to the second batch, to be loaded into the work area A.

If the stacked container group 10 brought into work area A in the first carrying-in process is a stacked container group 10 in which some of the storage containers 1 belong to the first batch, the remaining storage containers 1 will be considered to be storage containers 1 that belong to the batch that will be processed before the first batch, for example. In other words, the remaining storage containers 1 in this case will not generally be considered to be storage containers 1 that belong to the second batch. Also, if the stacked container group 10 brought into work area A in the third carrying-in process is a stacked container group 10 in which some of the storage containers 1 belong to the second batch, the remaining storage containers 1 will be considered to be storage containers 1 that belong to the batch that will be processed next after the second batch, for example. In other words, the remaining storage containers 1 in this case will not generally be considered to be storage containers 1 that belong to the first batch.

Figure 6 is an explanatory diagram of the first, second, and third loading processes. As shown in Figure 6(a), a situation is assumed in which there are 13 storage containers 1 (storage containers 1 marked with a circled "1") belonging to the first batch and 11 storage containers 1 (storage containers 1 marked with a circled "2") belonging to the second batch. In Figure 6(b), the first stacked container group 11 is the stacked container group 10 that is loaded into work area A by the first loading process, the second stacked container group 12 is the stacked container group 10 that is loaded into work area A by the second loading process, and the third stacked container group 13 is the stacked container group 10 that is loaded into work area A by the third loading process. Here, an example is shown in which all of the storage containers 1 belonging to the first batch are lined up consecutively in the Z direction in the second stacked container group 12, and all of the storage containers 1 belonging to the second batch are lined up consecutively in the Z direction. However, as described above, in this embodiment, sorting operations for multiple batches (two batches in the example shown in FIG. 4) can be performed in parallel. Therefore, in the second stacked container group 12, one or more storage containers 1 belonging to the first batch and one or more storage containers 1 belonging to the second batch may be lined up alternately in the Z direction.

6(b) 。 If the configuration shown in FIG. 6 were to produce only stacked container groups 10 divided by batch, two stacked container groups 10 with fewer tiers than the set number would be produced instead of the second stacked container group 12: one stacked with five storage containers 1 belonging to the first batch, and one stacked with three storage containers 1 belonging to the second batch. In this case, the stacked container groups 10 would need to be transferred from the transport vehicle 90 to the loading section 50 four times, one more than the three times required in the case shown in FIG. 6(b), which could reduce the efficiency of transporting the storage containers 1 by the transport system 40. In contrast, by producing not only stacked container groups 10 divided by batch, but also stacked container groups 10 containing a mixture of storage containers 1 belonging to different batches, the number of times the stacked container groups 10 need to be transferred from the transport vehicle 90 to the loading section 50 can be reduced, improving the efficiency of transporting the storage containers 1 by the transport system 40.

When the control system 5 causes the transport system 40 to execute the batch loading process, it is not necessary for the control system 5 to cause the transport system 40 to execute the first loading process, the second loading process, and the third loading process in that order, but the control system 5 may cause the transport system 40 to execute other loading processes. For example, if one of the batches is the third batch, the batch processed after the third batch is the fourth batch, and the batch processed after the fourth batch is the fifth batch, the control system 5 can be configured to control the transport system 40 as follows when the number of storage containers 1 belonging to the fourth batch is equal to or less than the set number minus 2: Between a fourth carry-in process for carrying into work area A a stacked container group 10, some of which are storage containers 1 belonging entirely or partially to the third batch, and a sixth carry-in process for carrying into work area A a stacked container group 10, some of which are storage containers 1 belonging entirely or partially to the fifth batch, the control system 5 causes the transport system 40 to execute a fifth carry-in process for carrying into work area A a stacked container group 10, some of which are storage containers 1 belonging to the third batch, some of which are storage containers 1 belonging to the fourth batch, and the remainder of which are storage containers 1 belonging to the fifth batch.

If the stacked container group 10 brought into work area A in the fourth carrying-in process is a stacked container group 10 in which some storage containers 1 belong to the third batch, the remaining storage containers 1 will be considered to be storage containers 1 that belong to the batch processed before the third batch, for example. In other words, the remaining storage containers 1 in this case will not generally be considered to be storage containers 1 that belong to the fourth or fifth batch. Also, if the stacked container group 10 brought into work area A in the sixth carrying-in process is a stacked container group 10 in which some storage containers 1 belong to the fifth batch, the remaining storage containers 1 will be considered to be storage containers 1 that belong to the batch processed next after the fifth batch, for example. In other words, the remaining storage containers 1 in this case will not generally be considered to be storage containers 1 that belong to the third or fourth batch.

Figure 7 is an explanatory diagram of the fourth, fifth, and sixth loading processes. As shown in Figure 7(a), a situation is assumed in which there are 10 storage containers 1 (storage containers 1 marked with a circled "3") belonging to the third batch, 5 storage containers 1 (storage containers 1 marked with a circled "4") belonging to the fourth batch, and 9 storage containers 1 (storage containers 1 marked with a circled "5") belonging to the fifth batch. In other words, in Figure 7, the number of storage containers 1 belonging to the fourth batch is 5, and the number obtained by subtracting 2 from the set number is 6, satisfying the condition that the number of storage containers 1 belonging to the fourth batch is equal to or less than the number obtained by subtracting 2 from the set number. In FIG. 7(b), the fourth stacked container group 14 is a stacked container group 10 that is carried into work area A by the fourth carry-in process, the fifth stacked container group 15 is a stacked container group 10 that is carried into work area A by the fifth carry-in process, and the sixth stacked container group 16 is a stacked container group 10 that is carried into work area A by the sixth carry-in process.

7(b) , if the configuration were to produce only stacked container groups 10 divided by batch, three stacked container groups 10 with fewer tiers than the set number would be produced: a stacked container group 10 consisting of two storage containers 1 belonging to the third batch, a stacked container group 10 consisting of five storage containers 1 belonging to the fourth batch, and a stacked container group 10 consisting of one storage container 1 belonging to the fifth batch. Note that a single storage container 1 is also referred to as a stacked container group 10. In this case, the stacked container group 10 would need to be transferred five times from the transport vehicle 90 to the loading section 50, two more than the three times shown in FIG. 7(b), which could reduce the efficiency of transporting the storage containers 1 by the transport system 40. In contrast, by configuring the system to generate not only stacked container groups 10 divided into batches, but also stacked container groups 10 containing a mixture of storage containers 1 belonging to different batches, the number of times stacked container groups 10 are transferred from the transport vehicle 90 to the loading section 50 can be reduced, improving the efficiency with which the transport system 40 transports storage containers 1.

When the number of storage containers 1 belonging to the fourth batch is equal to or less than the set number minus two, the control system 5 does not necessarily cause the transport system 40 to execute the fourth, fifth, and sixth carry-in processes in sequence, as described above. Specifically, when not all of the storage containers 1 belonging to the third batch can be brought into work area A in the fourth carry-in process, and the sum of the remaining number of storage containers 1 belonging to the third batch and the number of storage containers 1 belonging to the fourth batch is less than the set number, the control system 5 causes the transport system 40 to execute the fourth, fifth, and sixth carry-in processes in sequence, as described above. On the other hand, when the sum of the remaining number of storage containers 1 belonging to the third batch and the number of storage containers 1 belonging to the fourth batch is equal to or greater than the set number, instead of the fifth carry-in process, a carry-in process is executed to bring into work area A a stacked container group 10, some of which are storage containers 1 belonging to the third batch and the remainder are storage containers 1 belonging to the fourth batch. Furthermore, if all of the storage containers 1 belonging to the third batch can be brought into work area A in the fourth carry-in process, then instead of the fifth carry-in process, a carry-in process is executed in which a stacked container group 10, some of which are storage containers 1 belonging to the fourth batch and some or the remainder of which are storage containers 1 belonging to the fifth batch, is brought into work area A.

Second Embodiment
A second embodiment of the article sorting equipment will be described with reference to the drawing ( FIG. 8 ). The following description will focus on differences from the first embodiment. Points that are not specifically mentioned are the same as those in the first embodiment, and the same reference numerals will be used, and detailed descriptions will be omitted.

As shown in FIG. 8, in this embodiment, the transport system 40 includes a first conveyor 41 and a second conveyor 42 as conveyors for transporting storage containers 1 within the work area A. In the example shown in FIG. 8, the second conveyor 42 is positioned adjacent to the first conveyor 41 on the second side X2 in the X direction.

The first conveyor 41 includes a first loading section 51 that receives storage containers 1 (here, stacked container groups 10) that have been loaded into the work area A from the container storage facility 8, a first unloading section 61 that unloads storage containers 1 (here, stacked container groups 10) bound for the container storage facility 8 from the work area A, and a first transport section 71 that transports the storage containers 1 from the first loading section 51 to the first unloading section 61. The first loading section 51, first unloading section 61, and first transport section 71 correspond to the loading section 50, unloading section 60, and transport section 70 in the first embodiment, respectively. In this example, the first conveying section 71 includes a first input section extending from the first input section 51 toward the second side Y2 in the Y direction, a first output section extending toward the first side Y1 in the Y direction toward the first output section 61, and a first intermediate section extending from the first input section toward the second side X2 in the X direction and connecting the first input section and the first output section. Unlike the intermediate section in the first embodiment, the first intermediate section is arranged in a straight line along the X direction.

The second conveyor 42 includes a second loading section 52 that receives storage containers 1 (here, stacked container groups 10) that have been transported from the container storage facility 8 to the work area A, a second unloading section 62 that unloads storage containers 1 (here, stacked container groups 10) bound for the container storage facility 8 from the work area A, and a second transport section 72 that transports the storage containers 1 from the second loading section 52 to the second unloading section 62. The second loading section 52 receives, for example, empty storage containers 1 that do not contain any items 4. In this example, the second conveying section 72 includes a second input section extending from the second input section 52 toward the second side Y2 in the Y direction, a second output section extending toward the first side Y1 in the Y direction toward the second output section 62, and a second intermediate section extending from the second input section toward the second side X2 in the X direction and connecting the second input section and the second output section. In the example shown in FIG. 8 , the second conveyor 42 has the same configuration as the first conveyor 41. Therefore, the second input section 52, the second output section 62, the second conveying section 72, the second input section, the second output section, and the second intermediate section correspond to the first input section 51, the first output section 61, the first conveying section 71, the first input section, the first output section, and the first intermediate section, respectively.

In this embodiment, the outgoing container placement section 23 is a predetermined section in the first conveying section 71 (here, the first intermediate section), and the incoming container placement section 24 is a predetermined section in the second conveying section 72 (here, the second intermediate section). In the example shown in FIG. 8, work area A is equipped with a de-staging device 44 downstream of the first carrying-in section 51 and upstream of the outgoing container placement section 23 (here, in the first carrying-in section), and is equipped with a stacking device 45 downstream of the outgoing container placement section 23 and upstream of the first carrying-out section 61 (here, in the first carrying-out section). In the example shown in FIG. 8, work area A is equipped with a de-stacking device 44 downstream of the second loading section 52 and upstream of the incoming container placement section 24 (here, in the second loading section side section), and is equipped with a stacking device 45 downstream of the incoming container placement section 24 and upstream of the second unloading section 62 (here, in the second unloading section side section).

Third Embodiment
A third embodiment of the article sorting equipment will be described with reference to the drawings (FIGS. 9 to 11). FIG. 9 is a plan view of the work area A, omitting the third conveyor 43 shown in FIG. 10. The following description will focus on differences from the first embodiment. Points that are not specifically mentioned are the same as those in the first embodiment, and the same reference numerals will be used, and detailed descriptions will be omitted.

In this embodiment, as shown in FIG. 9, the conveying section 70 of the first conveyor 41 includes a branching section 80 located downstream of the inlet section 50, multiple branch sections 82 branching off at the branching section 80, and a junction section 81 located upstream of the outlet section 60 where the multiple branch sections 82 converge. The number of branching sections 80 and junction sections 81 is not limited to one, and the number of branch sections 82 is not limited to two, but in this embodiment, the conveying section 70 includes one branching section 80, two branch sections 82, and one junction section 81.

In the example shown in Figures 9 to 11, the conveying section 70 of the first conveyor 41 includes an inlet section extending from the inlet section 50 toward the second side Y2 in the Y direction, an outlet section extending toward the first side Y1 in the Y direction toward the outlet section 60, and an intermediate section extending from the inlet section toward the second side X2 in the X direction and connecting the inlet section and outlet section. The section of the intermediate section on the first side X1 in the X direction is composed of two branch sections 82 parallel to the X direction, and the section of the intermediate section on the second side X2 in the X direction is composed of a single section formed after the two branch sections 82 join at the junction 81.

As shown in Figure 9, in this embodiment, an output container placement section 23 where removal work is performed is set up for each of the multiple branch line sections 82. As shown in Figure 10, work area A has the same number of removal work areas A1 as the number of branch line sections 82. Note that the multiple removal work areas A1 may be grouped together as a single area, but in this example, two removal work areas A1, the same number as the number of branch line sections 82, are set up on opposite sides in the Y direction, sandwiched between the two branch line sections 82. Removal work in the removal work area A1 is performed on a storage container 1 (first container 1a) placed in the output container placement section 23 corresponding to the removal work area A1. In the example shown in Figures 9 and 10, a first worker 31 located in the removal work area A1 on the first side Y1 in the Y direction performs removal work on a first container 1a located in the outgoing container placement section 23 on the first side Y1 in the Y direction, and a first worker 31 located in the removal work area A1 on the second side Y2 in the Y direction performs removal work on a first container 1a located in the outgoing container placement section 23 on the second side Y2 in the Y direction.

In this embodiment, the removal operation involves removing items 4 piece by piece (piece picking). Therefore, in this embodiment, unlike the first embodiment, piece picking is not performed in the processing operation. The removal operation is, for example, an operation in which a container 3 is removed from a storage container 1, an item 4 is removed from the container 3, and then the container 3 (the container 3 with the item 4 remaining) is placed back into the same storage container 1. In the removal operation, the item 4 may be removed from the container 3 without removing the container 3 from the storage container 1.

In the example shown in Figures 9 and 10, a first worker 31 performing removal work places the items 4 removed by the removal work in the processing item placement section 20. Then, a second worker 32 performing processing and sorting work performs processing work on the items 4 placed in the processing item placement section 20, and then places the items 4 in a collection container 2. In this example, two processing work areas A3 (in other words, two sorting work areas A4), the same number as the number of branch sections 82, are set on opposite sides in the Y direction, sandwiched between the transport section 70 of the first conveyor 41 (specifically, the intermediate section described above). In addition, two processing item placement sections 20 are set on opposite sides in the Y direction, sandwiched between the transport section 70 of the first conveyor 41 (specifically, the intermediate section described above).

In this embodiment, the collection container placement section 25 is also configured so that multiple collection containers 2 are lined up in parallel with the transport direction T of the storage container 1 in the output container placement section 23. As shown in FIG. 9, in this embodiment, the transport direction of the storage container 1 into the output container placement section 23 is toward the second side X2 in the X direction, and the transport direction of the storage container 1 from the output container placement section 23 is toward the first side Y1 in the Y direction or the second side Y2 in the Y direction. Therefore, the transport direction T of the storage container 1 in the output container placement section 23 includes both the X direction and the Y direction. As shown in FIG. 10, in this embodiment, the collection container placement section 25 is configured so that the transport direction T of the storage container 1 in the output container placement section 23 is the X direction, and multiple collection containers 2 are lined up in parallel with the X direction. By configuring the collection container placement section 25 in this manner, it becomes easier to position the collection container placement section 25 adjacent to the section of the first conveyor 41 that is arranged to extend in the X direction and includes the output container placement section 23 (here, the section on the first side X1 in the X direction of the intermediate section described above, specifically the section that transports storage containers 1 to the second side X2 in the X direction toward the output container placement section 23).

10 and 11, in this embodiment, the article sorting equipment 100 (specifically, the conveying system 40) is equipped with a third conveyor 43. The third conveyor 43 is a conveyor (e.g., a roller conveyor or belt conveyor) that transports empty collection containers 2 into the collection container placement section 25 and transports collection containers 2 for which sorting has been completed from the collection container placement section 25. The third conveyor 43 is configured, for example, to continuously transport multiple collection containers 2. The collection container placement section 25 is a predetermined area on the third conveyor 43. In the example shown in FIGS. 10 and 11, this area is set to a size that allows four collection containers 2 to be arranged side by side. In the example shown in FIG. 11, the article sorting equipment 100 is equipped with two third conveyors 43 at different positions in the Z direction, and these two third conveyors 43 are arranged to overlap each other when viewed in the Z direction. As a result, similar to the first embodiment, the two collection container placement sections 25 are arranged at different positions in the Z direction and overlap each other when viewed in the Z direction.

In this embodiment, the processing item placement section 20 and the collection container placement section 25 are positioned at horizontally offset positions so as not to overlap when viewed in the Z direction. In this embodiment, as shown in FIG. 11, the collection container placement section 25 is positioned above Z1 the conveying section 70 of the first conveyor 41. Then, as shown in FIGS. 9 and 10, the conveying section 70 (specifically, the intermediate section described above) and the collection container placement section 25 are positioned so as to overlap when viewed in the Z direction.

In this embodiment, unlike the first embodiment, work area A does not have an incoming container placement section 24 or an incoming work area A2. However, in order to make it easier to replenish items 4 or add new items 4 to be stored, work area A in this embodiment may also be configured to have an incoming container placement section 24 and an incoming work area A2.

Fourth Embodiment
A fourth embodiment of the article sorting equipment will be described with reference to the drawings (FIGS. 12 and 13). The following description will focus on differences from the first embodiment. Points that are not specifically mentioned are the same as those in the first embodiment, and the same reference numerals will be used, and detailed descriptions will be omitted.

In this embodiment, as shown in FIG. 12, the conveying section 70 of the first conveyor 41 includes a branching section 80 located downstream of the inlet section 50, multiple branch sections 82 branching off at the branching section 80, and a junction section 81 located upstream of the outlet section 60 and where the multiple branch sections 82 converge. In this embodiment, the conveying section 70 includes three branching sections 80, four branch sections 82, and three junction sections 81.

In the example shown in Figures 12 and 13, the conveying section 70 of the first conveyor 41 includes an inlet section extending from the inlet section 50 toward the second side Y2 in the Y direction, an outlet section extending toward the first side Y1 in the Y direction toward the outlet section 60, and an intermediate section extending from the inlet section toward the second side X2 in the X direction and connecting the inlet section and outlet section. The intermediate section is made up of four branch sections 82 that are parallel to each other in the X direction.

As shown in Figure 12, in this embodiment, an outgoing container placement section 23 where removal work is performed is set up for each of the multiple branch line sections 82. As shown in Figure 12, work area A has the same number of removal work areas A1 as the number of branch line sections 82. In the example shown in Figures 12 and 13, of the four removal work areas A1 set up to be lined up in the Y direction, the two removal work areas A1 on the first side Y1 in the Y direction are grouped together as one area, and the two removal work areas A1 on the second side Y2 in the Y direction are grouped together as one area.

Removal work in the removal work area A1 is performed on the storage container 1 (first container 1a) placed in the output container placement section 23 corresponding to the removal work area A1. In this example, the first worker 31 placed in the removal work area A1 closest to the first side Y1 in the Y direction performs removal work on the first container 1a placed in the output container placement section 23 closest to the first side Y1 in the Y direction, and the first worker 31 placed in the removal work area A1 second from the first side Y1 in the Y direction performs removal work on the first container 1a placed in the output container placement section 23 second from the first side Y1 in the Y direction. Furthermore, the first worker 31 positioned in the removal work area A1 closest to the second side Y2 in the Y direction performs removal work on the first container 1a positioned in the output container placement section 23 closest to the second side Y2 in the Y direction, and the first worker 31 positioned in the removal work area A1 second from the second side Y2 in the Y direction performs removal work on the first container 1a positioned in the output container placement section 23 second from the second side Y2 in the Y direction.

As this is the same as the third embodiment, details are omitted, but the removal operation involves removing items 4 piece by piece (piece picking). In the example shown in Figures 12 and 13, the processing item placement section 20 includes a first item placement section 21 and a second item placement section 22. The first item placement section 21 is located above the transport section 70 (specifically, the aforementioned loading section side section) of the first conveyor 41 on the Z1 side, and is arranged so as to overlap with the transport section 70 when viewed in the Z direction. The collection container placement section 25 is located on the first side X1 in the X direction relative to the first conveyor 41, and the second item placement section 22 is located adjacent to the collection container placement section 25 on the second side X2 in the X direction. In the example shown in Figures 12 and 13, the first worker 31 performing the removal operation places the items 4 removed during the removal operation in the first item placement section 21. Then, a second worker 32 who performs processing and sorting work performs processing work on the items 4 placed in the first item placement section 21 in the first item placement section 21 or the second item placement section 22, and then places the items 4 in the collection container 2.

In the first to third embodiments, the collection container placement section 25 was configured so that multiple collection containers 2 were lined up parallel to the transport direction T of the storage container 1 in the outgoing container placement section 23. However, in this embodiment, the collection container placement section 25 is configured so that multiple outgoing container placement sections 23 are set up and multiple collection containers 2 are lined up parallel to the arrangement direction of the multiple outgoing container placement sections 23. Specifically, as shown in Figures 12 and 13, in this embodiment, four outgoing container placement sections 23 are set up, and the arrangement direction of these four outgoing container placement sections 23 is the Y direction. The collection container placement section 25 is configured so that multiple collection containers 2 are lined up parallel to the Y direction. Here, the collection container placement section 25 is arranged on the first side X1 in the X direction relative to the four outgoing container placement sections 23. By configuring the collection container placement section 25 in this manner, the collection container placement section 25 can be positioned adjacent to and parallel to the section (here, the above-mentioned inlet section) that is arranged to extend in the Y direction on the first conveyor 41 and connects multiple output container placement sections 23 (in other words, multiple branch sections 82), thereby reducing the space required to install the output container placement section 23 and collection container placement section 25.

In addition, unlike the examples shown in Figures 12 and 13, the collection container placement section 25 may be configured so that multiple collection containers 2 are lined up in parallel in the Y direction on the second side X2 in the X direction relative to the four output container placement sections 23. In this case, the collection container placement section 25 can be arranged adjacent to and in parallel with the section of the first conveyor 41 that is arranged to extend in the Y direction and connects the multiple output container placement sections 23 (here, the aforementioned output section side section).

In this embodiment, unlike the first embodiment, work area A does not have an incoming container placement section 24 or an incoming work area A2. However, in order to make it easier to replenish items 4 or add new items 4 to be stored, work area A in this embodiment may also be configured to have an incoming container placement section 24 and an incoming work area A2.

Other Embodiments
(1) In the above embodiments, an example has been described in which the items 4 are stored in a container 3 such as a bag and then stored in the storage container 1. However, the present disclosure is not limited to such a configuration, and the items 4 may be stored in the storage container 1 without being stored in a container 3. In the first and second embodiments, when such a configuration is used, the items 4 are removed piece by piece (piece picking) in the removal operation, and the storage operation of placing the container 3 into the second container 1b after the items 4 have been removed in the processing operation is not performed. Therefore, in this case, the operation area A may be configured not to include the receiving container placement unit 24 and the receiving operation area A2.

(2) In each of the above embodiments, an example has been described in which the container storage equipment 8 stores multiple storage containers 1 in a separated state. However, the present disclosure is not limited to such a configuration, and the container storage equipment 8 may also be configured to store stacked container groups 10. Furthermore, the container storage equipment 8 may also be configured to include both an area in which multiple storage containers 1 are stored in a separated state, and an area in which stacked container groups 10 are stored.

(3) In each of the above embodiments, an example has been described in which the container storage facility 8 includes a storage shelf 9 for storing the storage containers 1. However, the present disclosure is not limited to such a configuration, and the container storage facility 8 may not include a storage shelf 9, and the storage containers 1 may be stored in the container storage facility 8 by being placed on the floor or the like.

(4) In the above embodiments, the transport system 40 includes a transport vehicle 90 that transports storage containers 1 outside the work area A. However, the present disclosure is not limited to such a configuration. The transport system 40 may also include a container transport device of a different configuration than the transport vehicle 90, instead of or in addition to the transport vehicle 90. In this case, the container transport device may be configured to carry out at least one of the following: loading the storage container 1 or stacked container group 10 into the loading section 50; and unloading the storage container 1 or stacked container group 10 from the unloading section 60. For example, a container transport device of a different configuration than the transport vehicle 90 may include a gripping unit that grips the storage container 1 or stacked container group 10, an elevating unit that raises and lowers the gripping unit, and a horizontal moving unit that moves the gripping unit in two horizontal directions that are perpendicular to each other. It is preferable that this container transport device be configured to be able to change the combination of storage containers 1 that make up the stacked container group 10.

(5) In the above embodiments, the working area A is described as having a destacking device 44 and a stacking device 45 as an example. However, the present disclosure is not limited to such a configuration. The working area A may not have a destacking device 44, and the task of separating the stacked container group 10 into individual storage containers 1 may be performed manually by a worker or the like. The working area A may also not have a stacking device 45, and the task of stacking multiple storage containers 1 to create the stacked container group 10 may be performed manually by a worker or the like. If the working area A does not have a stacking device 45, the storage containers 1 may be transported one by one from the transport section 60.

(6) In the above embodiments, a configuration has been described in which the collection container placement section 25 is positioned above the processing item placement section 20 in the Z1 direction. However, the present disclosure is not limited to such a configuration, and the collection container placement section 25 may also be positioned below the processing item placement section 20 in the Z2 direction. Furthermore, in the first and second embodiments, a configuration has been described in which the processing item placement section 20 and the collection container placement section 25 are positioned so as to overlap when viewed in the Z direction. However, in the first and second embodiments, as in the third and fourth embodiments, the processing item placement section 20 and the collection container placement section 25 may also be positioned so as to be horizontally offset so as not to overlap when viewed in the Z direction.

(7) In the above embodiments, an example configuration has been described in which work area A includes multiple collection container placement sections 25, and the multiple collection container placement sections 25 are arranged at different positions (heights) in the Z direction and are arranged so as to overlap each other when viewed in the Z direction. However, the present disclosure is not limited to such a configuration, and the multiple collection container placement sections 25 may also be arranged at horizontally offset positions so as not to overlap each other when viewed in the Z direction. In this case, the multiple collection container placement sections 25 may be arranged at the same position in the Z direction. Furthermore, work area A may also be configured to include only one collection container placement section 25.

(8) In the first to third embodiments, an example was described in which the collection container placement section 25 is configured so that multiple collection containers 2 are lined up in parallel with the conveying direction T of the storage container 1 in the outgoing container placement section 23. In the fourth embodiment, an example was described in which the collection container placement section 25 is configured so that multiple outgoing container placement sections 23 are set and multiple collection containers 2 are lined up in parallel with the arrangement direction of the multiple outgoing container placement sections 23. However, the present disclosure is not limited to such a configuration, and the configuration of the collection container placement section 25 may be different from either of these two cases.

(9) Note that the configurations disclosed in the above-described embodiments may be applied in combination with configurations disclosed in other embodiments (including combinations of embodiments described as other embodiments) as long as no contradictions arise. Regarding other configurations, the embodiments disclosed in this specification are merely examples in all respects. Therefore, various modifications may be made as appropriate within the scope of the present disclosure.

[Summary of this embodiment]
The embodiment of the article sorting equipment described above will be summarized below.

The item sorting equipment comprises a container storage facility in which multiple storage containers are stored, a work area in which sorting work is performed in which items contained in the storage containers are removed and sorted into multiple collection containers, a transport system that transports the storage containers from the container storage facility to the work area and transports the storage containers from the work area to the container storage facility, and a control system that controls the transport system. The storage containers are configured to be stackable in the vertical direction, and the transport system is configured to create a stacked container group in which a predetermined number of the storage containers are stacked and transport them to the work area. The control system groups the sorting work for the predetermined number of collection containers into one batch and controls the sorting of multiple batches. When the transport system is caused to execute a batch delivery process in which the storage containers required for the sorting operation included in each of the batches are delivered to the work area in the order in which the multiple batches are processed, one of the batches is designated as a first batch, and the batch processed after the first batch is designated as a second batch, the transport system is caused to execute a second delivery process in which the stacked container group, some of which are storage containers belonging to the first batch and the remainder are storage containers belonging to the second batch, delivered to the work area between a first delivery process in which the stacked container group, some of which are storage containers belonging to the first batch and the remainder are storage containers belonging to the second batch, is delivered to the work area, and a third delivery process in which the stacked container group, some of which are storage containers belonging to the first batch and the remainder are storage containers belonging to the second batch, is delivered to the work area.

With this configuration, when storage containers required for sorting work contained in each of multiple batches are brought into the work area in a stacked container group with a set number of tiers in the order in which the multiple batches are processed, it is possible to create stacked container groups that contain a mixture of storage containers belonging to two batches that are processed in different (consecutive) orders, rather than just creating stacked container groups separated by batch. This reduces the need to create stacked container groups with fewer tiers than the set number, making it easier to increase the efficiency with which the transport system transports storage containers. As described above, with this configuration, it is easier to increase the efficiency with which the transport system transports storage containers when the control system transports stacked container groups into the work area.

Here, one of the batches is designated the third batch, the batch processed after the third batch is designated the fourth batch, and the batch processed after the fourth batch is designated the fifth batch. When the number of storage containers belonging to the fourth batch is equal to or less than the set number minus 2, the control system preferably causes the transport system to execute a fifth carry-in process to carry into the work area a stacked container group some of which are storage containers belonging to the third batch, some of which are storage containers belonging to the fourth batch, and the remainder of which are storage containers belonging to the fifth batch, between a fourth carry-in process to carry into the work area a stacked container group some of which are storage containers belonging to the third batch, some of which are storage containers belonging to the fourth batch, and the remainder of which are storage containers belonging to the fifth batch, and a sixth carry-in process to carry into the work area a stacked container group some of which are storage containers belonging to the third batch, some of which are storage containers belonging to the fourth batch, and the remainder of which are storage containers belonging to the fifth batch.

With this configuration, when storage containers required for sorting work contained in each of multiple batches are brought into the work area in the order in which the multiple batches are processed in a stacked container group with a set number of tiers, if the number of storage containers belonging to a certain batch is small, a stacked container group containing a mixture of storage containers belonging to three batches that are processed in different orders can be created. This makes it easier to increase the efficiency with which the transport system transports storage containers, regardless of the number of storage containers belonging to each batch.

Furthermore, it is preferable that the work area includes a plurality of collection container placement sections in which the collection containers are placed, and that each of the plurality of collection container placement sections is placed with a collection container belonging to a different batch.

This configuration allows sorting tasks for multiple batches to be performed in parallel in the work area, making it easier to improve the efficiency of sorting tasks.

The transport system preferably includes a conveyor that transports the storage containers within the work area and a transport vehicle that transports the storage containers outside the work area, the conveyor including an input section that receives the stacked container group transported from the container storage facility to the work area, the work area including a de-stacking device that separates the stacked container group received at the input section into individual storage containers, and the transport vehicle including a traveling vehicle, a support section mounted on the traveling vehicle and supporting the stacked container group, a first transfer device mounted on the traveling vehicle and transferring the storage containers between a storage shelf provided in the container storage facility and the stacked container group supported on the support section, and a second transfer device mounted on the traveling vehicle and transferring the stacked container group between the support section and the input section.

With this configuration, the transport vehicle can remove the necessary storage containers from the storage shelves of the container storage facility, create a stacked container group, and transport them to the work area. Then, in the work area, the stacked container group can be separated into individual storage containers for sorting. Therefore, multiple storage containers can be transported efficiently by the transport vehicle, while the sorting work can be performed appropriately in the work area.

In the above configuration, the conveyor preferably further includes a carry-out section through which the stacked container group is transported from the work area to the container storage facility, the second transfer device transfers the stacked container group between the support section and the carry-out section, and the work area preferably further includes a stacking device that is located upstream of the carry-out section and stacks the set number of storage containers to create the stacked container group.

With this configuration, after sorting work is completed, the storage containers can be stacked again and handed over to the transport vehicle. Therefore, when returning the storage containers after sorting work to the storage shelves provided in the container storage facility, multiple storage containers can be transported efficiently by the transport vehicle.

The article sorting equipment disclosed herein should be able to achieve at least one of the above-mentioned effects.

1: Storage container 2: Collection container 4: Item 5: Control system 8: Container storage equipment 9: Storage shelf 10: Stacked container group 25: Collection container arrangement unit 40: Transport system 41: First conveyor (conveyor)
42: Second conveyor (conveyor)
44: De-stacking device 45: Stacking device 50: Loading section 60: Loading section 90: Transport vehicle 91: First transfer device 92: Second transfer device 93: Traveling body 94: Support section 100: Article sorting equipment A: Work area Z: Z direction (vertical direction)

Claims (5)

An item sorting facility comprising: a container storage facility in which a plurality of storage containers are stored; a work area in which sorting work is performed in which items contained in the storage containers are removed and sorted into a plurality of collection containers; a transport system that transports the storage containers from the container storage facility to the work area and transports the storage containers from the work area to the container storage facility; and a control system that controls the transport system,
The storage container is configured to be stackable in the vertical direction,
the transport system is configured to create a stacked container group in which a predetermined number of the storage containers are stacked, and transport the stacked container group to the work area;
The control system includes:
When the sorting work for a predetermined number of the collection containers is grouped into one batch and the transport system is caused to execute a batch carrying-in process in which the storage containers necessary for the sorting work included in each of the plurality of batches are carried into the work area in the processing order of the plurality of batches,
An item sorting facility in which, between a first delivery process in which a group of stacked containers, some or all of which are storage containers belonging to the first batch, are delivered to the work area, with one of the batches designated as a first batch and the batch processed next after the first batch designated as a second batch, and a third delivery process in which a group of stacked containers, some of which are storage containers belonging to the second batch, are delivered to the work area, a second delivery process in which a group of stacked containers, some of which are storage containers belonging to the first batch and the remainder are storage containers belonging to the second batch, is carried out by the conveying system. one of the batches is designated as a third batch, the batch processed next after the third batch is designated as a fourth batch, and the batch processed next after the fourth batch is designated as a fifth batch;
2. The item sorting equipment of claim 1, wherein the control system causes the conveying system to execute a fifth delivery process to deliver to the work area a group of stacked containers, some of which are storage containers belonging to the third batch, some of which are storage containers belonging to the fourth batch, and the remainder of which are storage containers belonging to the fifth batch, between a fourth delivery process to deliver to the work area a group of stacked containers, some of which are storage containers belonging to the third batch, and a sixth delivery process to deliver to the work area a group of stacked containers, some of which are storage containers belonging to the fifth batch, when the number of storage containers belonging to the fourth batch is equal to or less than the set number minus 2. the work area includes a plurality of collection container placement units in which the collection containers are placed,
The article sorting facility according to claim 1 or 2, wherein the collection containers belonging to different batches are placed in each of the plurality of collection container placement sections. the transport system includes a conveyor that transports the storage container within the work area and a transport vehicle that transports the storage container outside the work area;
the conveyor includes a loading section that receives the stacked container group that has been carried into the work area from the container storage facility,
the work area is equipped with a de-stacking device that separates the stacked container group received in the loading section into individual storage containers,
The transport vehicle is
A traveling vehicle;
a support portion mounted on the traveling body and supporting the stacked container group;
a first transfer device mounted on the traveling body and configured to transfer the storage container between a storage shelf provided in the container storage facility and the stacked container group supported by the support section;
a second transfer device mounted on the traveling body and configured to transfer the stacked container group between the support section and the loading section;
The article sorting equipment according to claim 1 or 2, comprising: The conveyor further includes a discharge section through which the stacked container group is transported from the work area to the container storage facility,
the second transfer device transfers the stacked container group between the support unit and the unloading unit,
5. The article sorting equipment according to claim 4, wherein the work area is arranged upstream of the discharge section, and further comprises a stacking device that stacks the set number of storage containers to generate the stacked container group.