JP7840486B2 - Sorting system and sorting method - Google Patents

Description

[Cross-reference of related applications]
This invention claims priority based on the following Chinese patent applications filed with the China Patent Office on June 21, 2024, application number 202410814791.5, with the title of invention "Sorting System and Sorting Method"; the following Chinese patent applications filed with the China Patent Office on June 21, 2024, with the title of utility model "Sorting System": the following Chinese patent applications filed with the China Patent Office on June 21, 2024, with the title of invention "Sorting System and Sorting Method": the following Chinese patent applications filed with the China Patent Office on June 21, 2024, with the title of utility model "Sorting System": the following Chinese patent applications filed with the China Patent Office on December 6, 2024, with the title of utility model "Sorting System": the following Chinese patent applications claim priority based on the following Chinese patent applications filed with the China Patent Office on December 6, 2024, with the title of utility model "Sorting System": all of the contents of the following Chinese patent applications are incorporated into this application by reference.

This invention relates to the technical field of logistics warehouse storage, and more particularly to sorting systems and sorting methods.

With advancements in intelligent logistics warehouse technology, processes such as packaging and transportation can be completed entirely by intelligent robots. However, human intervention is still necessary for sorting. For example, in the sorting process, workers must retrieve full containers from the sorting equipment shelves and place them in the next stage, and also replenish empty containers in available spaces, which reduces sorting efficiency.

Currently, related technologies primarily focus on researching sorting equipment to improve sorting efficiency. However, even after the sorting equipment loads the cargo into containers, manual container exchange is still required, limiting sorting efficiency. Furthermore, the height of the sorting equipment shelves is limited by the height of the workers, resulting in low space utilization.

The objective of the embodiments of this invention is to realize automatic container exchange, improve sorting efficiency and space utilization, and provide a sorting system and sorting method. The specific technical proposal is as follows:

An embodiment of the present invention provides a sorting system. The sorting system includes a sorting device, a first robot, and a second robot. The sorting device includes a sorting mechanism, storage shelves, and a transfer shelf. The storage shelves are arranged in two rows and include multiple storage layers, each of which includes multiple container openings, each of which stores one container to be loaded. The transfer shelf is installed adjacent to the storage shelves and is for temporarily storing full containers or empty containers awaiting replenishment. The sorting mechanism is installed between the two rows of storage shelves and is configured to receive cargo to be sorted and transport the cargo into the containers on the storage shelves. The first robot is positioned between the storage shelves and the transfer shelf to load and unload full or empty containers. The second robot is positioned between the transfer shelf and the container transfer station to load and unload full or empty containers.

An embodiment of the present invention provides a sorting method. The sorting method uses a control device, which is communicated to the sorting mechanism, a first robot, and a second robot of the sorting apparatus in the sorting system described above. The sorting method includes: instructing the sorting mechanism to accept the cargo to be sorted and transporting the cargo to be sorted into an unfulfilled container on a storage shelf; instructing the first robot to move the full container on the storage shelf to a transfer shelf if a full container exists on the storage shelf, wherein the full container is a container filled with cargo or a container in which all cargo of the associated order has been sorted; instructing the second robot to move the full container on the transfer shelf to a container transfer station; instructing the second robot to move an empty container from the container transfer station to the transfer shelf if at least one container opening on the storage shelf is empty; and instructing the first robot to move the empty container from the transfer shelf to an empty container opening on the storage shelf.

The sorting system and sorting method provided in the embodiment of the present invention achieve automatic container exchange in the sorting system by having a first robot move containers in and out between storage shelves and transfer shelves, and a second robot move containers in and out between transfer shelves and a container transfer station. Compared to methods where containers are exchanged manually, sorting efficiency and accuracy are improved. Furthermore, by using the first robot for container exchange instead of manual exchange, the height of the storage shelves can exceed the height limitations imposed by the worker's height, increasing the available container openings on the storage shelves and improving the sorting performance and space utilization of the sorting system.

Embodiments of the present invention further provide a sorting system. The sorting system includes a sorting mechanism, shelves, a transport robot, and a container transfer transport line. The shelves are arranged in two rows and include a plurality of storage layers spaced vertically apart, each of which includes a plurality of container openings, each of which is for storing one container to be loaded. The sorting mechanism is positioned between the two rows of shelves and is configured to receive goods to be sorted and transport them into the containers on the shelves. The container transfer transport line is positioned adjacent to the shelves and is configured to transport empty containers to the shelves or loaded containers away from the shelves. The transport robot is configured to move loaded or empty containers between the shelves and the container transfer transport line.

An embodiment of the present invention further provides a sorting method. The sorting method uses a control device, which is communicated to the sorting mechanism, transport robot, and container transfer transport line in the sorting system. The sorting method includes: instructing and activating the container transfer transport line so that it can transport empty containers to the shelves and fully loaded containers away from the shelves; instructing the sorting mechanism to accept the cargo to be sorted and transport the cargo into empty containers on the shelves; instructing the transport robot to move the fully loaded containers on the shelves to the container transfer transport line if there are fully loaded containers on the shelves; and instructing the transport robot to move empty containers on the container transfer transport line to the empty container openings on the shelves if at least one container opening on the shelves is open.

The present invention further provides a control device. The control device includes a memory for storing a computer program, and a processor for executing the program stored in the memory to implement the sorting method described in any of the above embodiments.

An embodiment of the present invention further provides a computer-readable storage medium. A computer program is stored in the computer-readable storage medium, and when the computer program is executed by a processor, the sorting method described in any of the above embodiments is realized.

The sorting system and sorting method provided in the embodiments of the present invention achieve automatic container exchange in the sorting system by having a transport robot move containers in and out between the shelves and the container transfer transport line, improving sorting efficiency and accuracy compared to manual container exchange. Furthermore, instead of manual container exchange, container exchange by a transport robot allows the shelf height to exceed the limitations imposed by the worker's height, increasing the available container openings on the shelves and improving the sorting performance and space utilization of the sorting system. Additionally, the container transfer transport line can transport empty containers to the shelves or fully loaded containers away from the shelves, achieving automatic transport of both empty and fully loaded containers and further improving the overall operational efficiency of the sorting system.

An embodiment of the present invention further provides a sorting system. The sorting system includes at least two sorting devices, a container exchange robot, and a container transport device, wherein the at least two sorting devices are spaced apart and arranged in parallel, with a container exchange robot passage formed between the two adjacent sorting devices, each sorting device is capable of sorting received cargo into containers, each of the at least two sorting devices is provided with a storage area for storing containers and a transfer area for docking with the container transport device, the container transport device is for transporting empty containers to the transfer area of the sorting device or for transporting fully loaded containers located in the transfer area of the sorting device outside the sorting device, and the container exchange robot is installed on either of the sorting devices on either side of the container exchange robot passage and is capable of traveling along the container exchange robot passage, for each of the two sorting devices on either side of the container exchange robot passage, transporting empty containers in the transfer area of the sorting device to the storage area of the sorting device or transporting fully loaded containers in the storage area to the transfer area of the sorting device.

In the sorting system provided in the embodiment of the present invention, the container exchange robot is mounted on either of the sorting devices on either side of the container exchange robot aisle and can travel along the aisle. Its purpose is to transport empty containers from the delivery area to the storage area of each of the two sorting devices on either side of the container exchange robot aisle, or to transport full containers from the storage area to the delivery area of the sorting device. This improves the utilization rate of the container exchange robot, reduces the cost of the sorting system, enables automated container exchange in the sorting system, and improves sorting efficiency and accuracy compared to manual container exchange. Furthermore, container exchange by the container exchange robot instead of manual container exchange allows the height of the sorting device to exceed the height limitations imposed by the worker, improving the storage capacity, sorting performance, and space utilization rate of the sorting system. The container transport system is designed to transport empty containers to the sorting equipment's delivery area, or to transport fully loaded containers located in the sorting equipment's delivery area to the outside of the sorting equipment. This enables automated transport of both empty and fully loaded containers, further improving the overall operational efficiency of the sorting system.

The drawings described herein are provided for a further understanding of the present invention and constitute part of the present invention. The schematic embodiments and descriptions of the present invention are merely for interpretation purposes and do not constitute an unreasonable limitation of the present invention.

This is a schematic diagram of a perspective view of a sorting system according to the first embodiment of the present invention. Figure 1 is a schematic front view of the sorting system. Figure 1 is a schematic plan view of the sorting system shown. Figure 1 is a schematic side view of the sorting system. Figure 1 is a schematic diagram of the first robot's perspective configuration. Figure 1 is a schematic front view of the first robot. Figure 1 is a schematic plan view of the first robot. Figure 1 is a schematic side view of the first robot. Figure 1 is a schematic plan view of the transfer rack shown. Figure 1 is a schematic diagram of the second robot's perspective configuration. Figure 1 is a schematic perspective view of the configuration when the second robot lifts a container. Figure 11 is a schematic perspective view showing the configuration when the second robot, shown in Figure 11, is docked with the container relay station. Figure 12 is a schematic perspective view of the configuration after the second robot has docked with the container relay station. This is a schematic diagram of a perspective view of a sorting system according to a second embodiment of the present invention. Figure 14 is a schematic front view of the sorting system. Figure 14 is a schematic plan view of the sorting system. Figure 14 is a schematic side view of the sorting system. This is a flowchart of a first embodiment of the sorting method according to the first embodiment of the present invention. This is a flowchart of a second embodiment of the sorting method according to the first embodiment of the present invention. This is a flowchart of a third embodiment of the sorting method according to the first embodiment of the present invention. This is a flowchart of a fourth embodiment of the sorting method according to the first embodiment of the present invention. This is a configuration diagram of a control device of the first embodiment provided in the present invention. This is a schematic diagram of a perspective view of a sorting system according to the third embodiment of the present invention. Figure 23a is a schematic front view of the sorting system. Figure 23a is a schematic plan view of the sorting system. Figure 23a is a schematic side view of the sorting system. Figure 23a is a schematic diagram of the connection relationships in the container transfer and transport line. Figure 23a is a schematic diagram of the transport robot's perspective configuration. Figure 23a is a schematic front view of the transport robot. Figure 23a is a schematic plan view of the transport robot. Figure 23a is a schematic side view of the transport robot. This is a schematic plan view of a sorting system according to the fourth embodiment of the present invention. This is a flowchart of the first embodiment of the second form of sorting method provided in the present invention. This is a flowchart of a second embodiment of the sorting method of the second embodiment provided in the present invention. This is a flowchart of a third embodiment of the sorting method of the second embodiment provided in the present invention. This is a flowchart of a fourth embodiment of the sorting method of the second embodiment provided in the present invention. This is a configuration diagram of a second embodiment of the control device provided in the present invention. This is a schematic diagram of a perspective view of a sorting system according to the fifth embodiment of the present invention. Figure 32a is a schematic plan view of the sorting system. Figure 32a is a schematic front view of the sorting device. Figure 32a is a schematic plan view of the docking layer. Figure 32a is a schematic diagram of the perspective configuration of the relay robot shown. Figure 32a is a schematic diagram of the perspective configuration of the container exchange robot shown. This is a schematic diagram of a perspective view of the sixth embodiment of the sorting system of the present invention. Figure 36a is a schematic plan view of the sorting system. Figure 36a is a schematic front view of the sorting device. This is a schematic plan view of the sorting system according to the seventh embodiment of the present invention. This is a schematic plan view of the eighth embodiment of the sorting system of the present invention.

To further clarify the object, technical concept, and advantages of the present invention, the invention will be described in more detail below with reference to the drawings and examples. Clearly, the examples described are only a selection of the present invention, not all examples. All other examples obtainable by those skilled in the art based on the examples of the present invention fall within the scope of protection of the present invention.

As described in the background technology section, with the advancement of intelligent logistics warehouse storage technology, processes such as packaging and transportation can all be handled by intelligent robots. However, human intervention is still required for the sorting process. For example, in the sorting process, workers must retrieve full containers from the sorting equipment shelves and place them in the next stage, and also replenish empty containers in available spaces, which reduces sorting efficiency.

Currently, related technologies primarily focus on researching sorting equipment to improve sorting efficiency. However, even after the sorting equipment has finished loading the cargo into containers, manual container exchange is still required, limiting sorting efficiency. Furthermore, the height of the sorting equipment shelves is limited by the height of the workers, resulting in low space utilization.

To achieve automated container exchange and improve sorting efficiency and space utilization, the present invention provides several sorting systems and methods. These systems all achieve automated container exchange through the cooperation of a robot dedicated to container exchange with a transport device. Here, the transport device may be a separate robot or a transport line, and can transport containers to shelves on either side of the sorting mechanism (picking mechanism) in the system, or to a location away from the sorting mechanism. Each of these will be described in detail below.

First, a sorting system of the first embodiment provided in the embodiments of the present invention will be described in detail. In this sorting system, the robot dedicated to container exchange is the first robot 200, and the transport device capable of transporting containers to the transfer racks 130 on both sides of the sorting mechanism 110 in the system, or to a position away from the transfer racks 130, is the second robot 300.

Referring to Figures 1 to 4, Figure 1 is a schematic perspective view of the sorting system according to the first embodiment of the present invention, Figure 2 is a schematic front view of the sorting system shown in Figure 1, Figure 3 is a schematic plan view of the sorting system shown in Figure 1, and Figure 4 is a schematic side view of the sorting system shown in Figure 1.

As shown in Figures 1 to 4, the sorting system provided in the embodiment of the present invention includes a sorting device 100, a first robot 200, and a second robot 300. The sorting device 100 includes a sorting mechanism 110, a storage shelf 120, and a transfer shelf 130.

The storage rack 120 is installed in two rows and includes multiple storage layers 121, each storage layer 121 including multiple container openings 1211, each of which is for storing one container 500 to be loaded.

The transfer rack 130 is installed adjacent to the storage rack 120 and is for temporarily storing fully loaded containers 500 or empty containers 500 awaiting replenishment.

The sorting mechanism 110 is installed between two rows of storage shelves 120 and is positioned to receive the goods to be sorted and transport them into the containers 500 of the storage shelves 120.

The first robot 200 is positioned between the storage rack 120 and the transfer rack 130 to move fully loaded or empty containers 500 in and out.

The second robot 300 is positioned between the transfer rack 130 and the container transfer station 400 to move fully loaded or empty containers 500 in and out.

In this invention, the transfer shelf 130 belongs to the sorting device, but in practice, the transfer shelf 130 may be arranged independently, and may be installed independently of the sorting mechanism 110 and storage shelves 120 of the sorting device 100.

The embodiment of the present invention provides such a sorting system in which a first robot 200 moves containers 500 in and out between the storage rack 120 and the transfer rack 130, and a second robot 300 moves containers 500 in and out between the transfer rack 130 and the container relay station 400, thereby achieving automatic exchange of containers 500 in the sorting system and improving sorting efficiency and accuracy compared to the method of manually exchanging containers. Furthermore, by using the first robot 200 to exchange containers instead of manual exchange, the height of the storage rack 120 can exceed the height limit imposed by the worker's height, increasing the container opening 1211 that can be placed on the storage rack 120, and improving the sorting performance and space utilization rate of the sorting system.

In the embodiment shown in Figure 1, as shown in Figures 2 and 3, the storage rack 120 may include multiple beams 122 installed at vertical intervals, and the first robot 200 is mounted on the outside of the storage rack 120 by the beams 122. There may be multiple first robots 200, all mounted on the beams 122, and they improve transport efficiency by loading and unloading containers from the storage rack 120 and the transfer rack 130.

Specifically, the beam 122 extends from one end to the other along the longitudinal direction of the storage shelf 120, and the first robot 200 achieves horizontal movement along the storage shelf 120 by sliding along the beam 122. The specific arrangement method will be explained in detail in the following section.

In the embodiment shown in Figure 1, referring to Figures 5 to 8, Figure 5 is a schematic perspective view of the first robot shown in Figure 1, Figure 6 is a schematic front view of the first robot shown in Figure 1, Figure 7 is a schematic plan view of the first robot shown in Figure 1, and Figure 8 is a schematic side view of the first robot shown in Figure 1.

As shown in Figures 5 to 8, the first robot 200 may include a column mast 210, a transport mechanism 220, and at least one slide rail 230.

The column mast 210 is mounted along the vertical direction of the storage shelf 120.

The transport mechanism 220 is installed on the column mast 210 and is used to load and unload containers 500 located at different heights in the storage rack 120.

At least one slide rail 230 is fixedly mounted to the beam 122, and the column mast 210 is slidably connected to at least one slide rail 230. The column mast 210 and the transport mechanism 220 slide horizontally along the beam 122, allowing different containers 500 to be loaded and unloaded along the longitudinal direction of the storage rack 120.

The first robot 200 is positioned to move a fully loaded container 500 from the storage rack 120 to the transfer rack 130, or to move an empty container 500 from the transfer rack 130 to the storage rack 120.

Specifically, as shown in Figures 1 and 2, the first robot 200 is fixed to the storage shelf 120 by two slide rails 230 installed with a gap between them vertically, and the first robot 200 can move along the longitudinal direction of the storage shelf 120 by these two slide rails 230.

According to an embodiment of the present invention, the first robot 200 can move horizontally along the longitudinal direction of the storage shelf 120, thereby loading and unloading each container 500 along the longitudinal direction of the storage shelf 120. Furthermore, the pickup assembly 222 of the first robot 200 can move vertically along the height direction of the storage shelf 120, thereby loading and unloading containers 500 at different heights on the storage shelf 120. The specific method of loading and unloading cargo will be described in detail in the following description.

In the embodiment shown in Figure 1, the transport mechanism 220 may include a lifting assembly 221 and a pickup assembly 222, as shown in Figures 5 to 8.

The lifting assembly 221 is mounted on the column mast 210 and is positioned to move along the vertical direction by moving the pickup assembly 222.

The pickup assembly 222 is mounted on the lifting assembly 221 and protrudes from the column mast 210, positioned to load and unload containers 500 from the storage rack 120 or transfer rack 130.

Specifically, the column mast 210 includes two door posts 211, and the lifting assembly 221 can move up and down along the vertical direction of the storage rack 120 by moving the pickup assembly 222 via a drive motor installed on the column mast 210, driving wheels and driven wheels installed on the top and bottom of the two door posts 211, and two synchronous belts fitted to the driving and driven wheels.

The embodiments of the pickup assembly 222 include, but are not limited to, fork arm type, suction cup type, drum type, hook arm type, etc.

The pickup assembly 222 may be mounted on a synchronization belt, and may include a telescopic structure, the telescopic direction being bidirectional, and may move toward or away from the storage rack 120, extending outwards from the storage rack 120 or the transfer rack 130 by the telescopic structure to load and unload containers 500.

According to an embodiment of the present invention, the first robot 200 can move containers 500 in and out of the storage shelves 120 or transfer shelves 130 in the horizontal direction using the slide rail 230, and can move containers 500 in and out of the storage shelves 120 or transfer shelves 130 in the vertical direction using the lifting assembly 221.

In the embodiment shown in Figure 1, as shown in Figures 1 to 3, the transfer shelves 130 are installed in two rows below the storage shelves 120, corresponding to the storage shelves 120.

The transfer rack 130 may be a single-layer rack and is arranged along the longitudinal direction of the storage rack 120. Each of the two transfer racks 130 is installed beneath the two storage racks 120. The transfer rack 130 is equipped with multiple temporary storage spaces 131, arranged to temporarily hold one fully loaded container 500 or one empty container 500.

In the embodiment shown in Figure 1, referring to Figure 9, Figure 9 is a schematic plan view of the transfer shelf shown in Figure 1. The transfer shelf 130 is installed below the storage shelf 120 and may be a standalone shelf, or, as shown in Figures 1 and 9, may be installed as an integrated shelf with the storage shelf 120. The bottom layer of the shelf is the transfer shelf 130, used for temporarily placing containers 500.

As shown in Figure 9, grooves 1311 are installed at the bottom of each temporary storage area 131 of the transfer rack 130, and the second robot 300 uses the grooves 1311 to move the containers 500 in and out of the temporary storage areas 131.

Specifically, as shown in Figure 3, the process by which the second robot 300 retrieves a fully loaded container 500 from the transfer rack 130 is as follows:

The second robot 300 moves below the target temporary storage area 131, lifts the fully loaded container 500 through the groove 1311, and exits the temporary storage area 131 along the groove 1311.

The process by which the second robot 300 places an empty container onto the transfer rack 130 is as follows:

The second robot 300 moves below the target temporary storage area 131, descends through the groove 1311, places the fully loaded container 500, and exits the temporary storage area 131 along the groove 1311.

The transfer rack can be of various types. For example, it may be a transfer rack 130 with a single groove 1311 in the middle, as shown in Figure 9. In other embodiments of the present invention, the transfer rack 130 may have a comb-shaped groove in the middle. The comb-shaped groove consists of multiple spaced grooves. Accordingly, the lifting surface of the second robot 300's lift mechanism 320 is also equipped with a comb-shaped groove to allow for the loading and unloading of containers 500 while avoiding the comb-shaped groove. There are no specific limitations on the type of transfer rack 130 in the present invention.

In the embodiment shown in Figure 1, the first aisle 600 and the second aisle 700 are installed parallel to each other and spaced apart on either the side of each row of storage shelves 120 away from the sorting mechanism 110.

The first aisle 600 is closer to storage shelf 120 than the second aisle 700.

The first aisle 600 and the second aisle 700 extend from the storage racks 120 to the container transfer station 400.

The second robot 300 is arranged as follows:

The empty second robot 300 travels along the first aisle 600 to the transfer rack 130, receives a fully loaded container 500 from the transfer rack 130, travels along the second aisle 700, and transports the fully loaded container 500 to the container transfer station 400. Alternatively, the empty second robot 300 travels along the first aisle 600 to the container transfer station 400, receives an empty container 500 from the container transfer station 400, travels along the second aisle 700, and transports the empty container 500 to the transfer rack 130.

In other words, the first aisle 600 is for the second robot 300 to travel in an empty state. In the first aisle 600, the second robot 300 can receive a fully loaded container 500 toward the transfer rack 130, and can also receive an empty container 500 toward the container transfer station 400.

The second aisle 700 is for the second robot 300, which is fully loaded, to travel through. In the second aisle 700, the second robot 300 can place empty containers 500 toward the transfer rack 130, and can also place fully loaded containers 500 toward the container transfer station 400.

Here, the structure of the container transfer station 400 includes, but is not limited to, a transport line, a transfer rack, etc. The container transfer station 400 shown in Figure 3 is a transport line configuration, and includes a fully loaded container transport line 410 and an empty container replenishment line 420. The second robot 300 is positioned to move fully loaded containers 500 from the transfer rack 130 to the fully loaded container transport line 410, or to move empty containers 500 from the empty container replenishment line 420 to the transfer rack 130.

Specifically, as shown in Figure 3, the second robot 300 moves along the second aisle 700, transferring fully loaded containers 500 from the transfer rack 130 to the fully loaded container transport line 410, or transferring empty containers 500 from the empty container replenishment line 420 to the transfer rack 130.

In Figure 3, the black blocks represent fully loaded containers 500, and the white blocks represent empty containers 500. In the two second aisles 700 of this embodiment of the present invention, a second robot 300 carrying a fully loaded container 500 can pass through, and a second robot 300 carrying an empty container 500 can also pass through. Figure 3 shows only an embodiment in which a second robot 300 carrying an empty container 500 travels through one second aisle 700, and a second robot 300 carrying a fully loaded container 500 travels through the other second aisle 700.

The orientation of the first passage 600 and the second passage 700 is determined based on the position of the container transfer station 400 relative to the sorting device 100. As shown in Figure 3, if the container transfer station 400 is installed at one end of the sorting device 100, the orientation of the first passage 600 and the second passage 700 is parallel to the long side of the storage rack 120, extending from the end of the storage rack 120 away from the container transfer station 400 to the container transfer station 400. The first passage 600 and the second passage 700 may merge at the end closest to the container transfer station 400 and extend jointly to the container transfer station 400.

Since it is necessary to ensure that the pickup assembly 222 of the first robot 200 can move containers 500 in and out of the storage shelves 120 and the transfer shelves 130, the height of the column mast 210 of the first robot 200 must extend vertically from the uppermost storage layer 121 to the transfer shelf 130.

Since the height of the empty second robot 300 is lower than the height at which the first robot 200's pickup assembly 222 moves containers 500 in and out of the transfer rack 130, the first aisle 600 through which the empty second robot 300 travels can be positioned as close as possible to the storage rack 120 while ensuring smooth passage for the second robot 300. This allows for maximum conservation of the area required for the sorting device 100 without interference between the first robot 200 and the second robot 300.

As shown in Figures 1 to 3, the movement process of the unloaded second robot 300 is as follows:

The unloaded second robot 300 passes under the first robot 200 along the first aisle 600, enters the temporary storage area 131 from the side of the temporary storage area 131 closest to the first aisle 600, lifts the loaded container 500, and then returns along the trench 1311 to its original path, enters the second aisle 700, and heads toward the loaded container transport line 410.
Alternatively, an empty second robot 300 can move along the first aisle 600 toward the empty container replenishment line 420 to receive an empty container 500.

The movement process of the second robot 300 carrying container 500 is as follows:

The second robot 300, carrying an empty container 500, travels along the second aisle 700, enters the temporary storage area 131, places the empty container 500, then returns along the trench 1311 to the original path, enters the first aisle 600, and then, along the first aisle 600, enters the temporary storage area 131 where other loaded containers 500 are placed, receives the loaded container 500, and finally, travels along the second aisle 700 towards the loaded container transport line 410.
Alternatively, the second robot 300, carrying an empty container 500, travels along the second aisle 700, enters the temporary storage area 131, places the empty container 500, then returns along the trench 1311 to the original path, enters the first aisle 600, and heads towards the waiting area or the empty container replenishment line 420.

The second robot 300, carrying the fully loaded container 500, travels along the second aisle 700 and, after placing the fully loaded container 500 toward the fully loaded container transport line 410, may proceed toward the waiting area, or toward the empty container replenishment line 420 to receive empty containers, or may travel along the first aisle 600 toward the transfer rack 130 to receive the fully loaded container 500.

According to an embodiment of the present invention, the transfer racks 130 are installed in two rows below the storage racks 120, saving space in the sorting device 100's layout and improving the utilization rate of the space where the storage racks 120 reside. The travel track for the second robot 300 is divided into a first aisle 600 and a second aisle 700 for the empty second robot 300 and the second robot 300 carrying containers 500, respectively, improving the efficiency of the second robot 300's transport. The empty second robot 300 travels in the first aisle 600, avoiding interference between the first robot 200 and the second robot 300, saving space in the sorting device 100's layout, and improving space utilization. The container transfer station 400 is divided into a fully loaded container transport line 410 and an empty container replenishment line 420, allowing for the simultaneous transport of fully loaded and empty containers 500, improving the operational efficiency of the sorting system.

In the embodiment shown in Figure 1, referring to Figures 10 and 11, Figure 10 is a schematic perspective view of the second robot shown in Figure 1, and Figure 11 is a schematic perspective view of the second robot shown in Figure 1 when it lifts a container.

As shown in Figures 10 and 11, the second robot 300 includes a motion chassis 310 and a lift mechanism 320, the lift mechanism 320 being mounted on top of the motion chassis 310 and moved by the motion chassis 310, positioned vertically along the groove 1311 to lift or place the container 500.

Specifically, the lift mechanism 320 includes a lift platform 321, and the groove 1311 is positioned so that its width is smaller than the dimensions of the container 500 and larger than the dimensions of the lift platform 321, thereby allowing the lift platform 321 to lift or place the container 500 through the groove 1311, and preventing the container 500 from falling through the groove 1311.

As shown in Figures 1-3 and 9, the flow for the second robot 300 to pick up the fully loaded container 500 is as follows: After the first robot 200 places the fully loaded container on the transfer rack 130 at the temporary storage area 131, the second robot 300 moves below the temporary storage area 131, the lift platform 321 moves upward, lifts the fully loaded container 500 through the groove 1311, and then moves along the groove 1311 from the temporary storage area 131 to transport the fully loaded container 500 to the fully loaded container transport line 410.

The process by which the second robot 300 places the empty container 500 is as follows: The second robot 300 places the empty container 500 and moves to the side of the temporary storage area 131, and the lift mechanism 320 lifts the empty container 500 to a position higher than the height of the temporary storage area 131. Then, the second robot 300 moves along the groove 1311 below the temporary storage area 131, and the lift mechanism 320 moves the empty container 500 downwards until it contacts the top surface of the temporary storage area 131, and then moves downwards and exits the temporary storage area 131.

Here, the vertical movement of the lift mechanism 320 and the horizontal movement of the moving chassis 310 can be performed simultaneously. That is, as the moving chassis 310 enters or exits the temporary storage area 131, the lift mechanism can lift or lower the container 500.

According to an embodiment of the present invention, the first robot 200 can load and unload the container 500 without stopping its movement, or only with a temporary pause, thereby improving the efficiency of the second robot in loading and unloading the container 500. Furthermore, the second robot 300 loading and unloading the container 500 below the temporary storage area 131 improves the space utilization rate of the transfer rack 130.

In the embodiment shown in Figure 1, both the fully loaded container transport line 410 and the empty container replenishment line 420 consist of one handover area 401 and one transport area 402, with the handover area 401 and transport area 402 moving independently. The end portion is the handover area 401, and the other portion is the transport area 402. The handover area 401 and transport area 402 can work together to transport containers 500.

Specifically, the second robot 300 completes the process of placing a full container 500 or taking an empty container 500 by docking with the transfer area 401 of either the fully loaded container transport line 410 or the empty container replenishment line 420.

The process by which the second robot 300 transports the fully loaded container 500 is as follows:

When the second robot 300 transports a fully loaded container 500 from the transfer rack 130 to the transfer area 401 of the fully loaded container transport line 410, the transfer area 401 stops rolling. After the second robot 300 has finished placing the fully loaded container 500, rolling resumes, and in cooperation with the transport area 402, the fully loaded container 500 is transported to the next processing stage, such as outbound shipment or re-check packaging. After transporting the fully loaded container 500, the second robot 300 can wait in the waiting area, or it can move toward the empty container replenishment line 420, dock with the transfer area 401 of the empty container replenishment line 420, receive empty containers 500, and replenish the transfer rack 130, or it can continue receiving fully loaded containers 500 toward the transfer rack 130.

The process by which the second robot 300 transports the empty container 500 is as follows:

When the second robot 300 moves to the transfer area 401 of the empty container replenishment line 420, the transfer area 401 becomes stationary. After the second robot 300 picks up an empty container 500, rolling resumes, and the transport area 402 replenishes the transfer area 401 with the next empty container 500, waiting for the second robot 300 to receive it.

Having finished transporting the empty container 500, the second robot 300 can either wait in the waiting area, receive a fully loaded container 500 from the transfer rack 130 and transport it to the fully loaded container transport line 410, or continue receiving empty containers 500 towards the empty container replenishment line 420.

According to an embodiment of the present invention, the handover area 401 and the transport area 402 operate independently and in coordination with each other during transport. When the handover area 401 needs to receive a fully loaded container 500, or when the second robot 300 needs to pick up an empty container 500, the stationary state of the handover area 401 does not affect the transport area 402's ability to transport the container 500 placed on the transport area 402, thereby improving the operational efficiency of the container transfer station 400.

Referring to Figures 12 and 13, Figure 12 is a schematic perspective view of the second robot shown in Figure 11 when it is docked with the container relay station, and Figure 13 is a schematic perspective view of the second robot shown in Figure 12 after it has docked with the container relay station.

As shown in Figure 12, both the input end of the fully loaded container transport line 410 and the transfer area 401 of the empty container replenishment line 420 include two parallel conveyors 430, with a travel space provided between the two conveyors 430 for the second robot 300 to pass through.

As shown in Figures 11 to 13, when the second robot 300 docks with the transfer area 401 of the fully loaded container transport line 410 and places the loaded container 500, the conveyor 430 becomes stationary. The second robot 300 uses the lift mechanism 320 to lift the loaded container 500 to a position higher than the conveyor 430 and moves toward the travel space. After the second robot 300 enters the travel space, the lift mechanism 320 places the loaded container 500 onto the two conveyors 430. The conveyors 430 then begin to roll, and in coordination with the transport area 402, transport the loaded container 500 to the next processing stage. The second robot 300 then continues moving, exits the travel space, and performs its next task.

The container transfer station 400 further includes empty container racks, and empty containers 500 from the empty container racks are placed into the empty container replenishment line 420 by workers or automated devices such as robotic arms. The second robot 300 moves to the transfer area 401 of the empty container replenishment line 420, docks, receives the empty containers 500, and transports them to the transfer rack 130.

When the second robot 300 docks with the transfer area 401 of the empty container replenishment line 420 to receive an empty container 500, the second robot 300 moves to the transfer area 401 of the empty container replenishment line 420. After the empty container 500 moves to the transfer area 401 of the empty container replenishment line 420, the rolling of the transfer area 401 stops. After the second robot 300 takes the empty container 500 using the lift mechanism 320, the empty container replenishment line 420 continues to be replenished with new empty containers 500 by a person or automated device.

According to this embodiment of the present invention, the second robot 300 and the container transfer station 400 perform the transfer of fully loaded containers 500 and the replenishment of empty containers 500, thereby improving the work efficiency of the sorting system compared to transporting fully loaded containers 500 and replenishing empty containers 500 manually.

In the embodiment shown in Figure 1, as shown in Figures 1 to 3, the sorting device 100 further includes a lift mechanism 140 and a supply table 150, and the sorting mechanism 110 includes a guide mechanism 111 and a sorting shuttle 112.

The lift mechanism 140 is installed at both ends of the storage shelf 120 and is designed to move the sorting shuttle 112 up and down along the height of the storage shelf 120 when the sorting shuttle 112 moves to one end of the storage shelf 120.

The supply platform 150 is installed on one or both sides of the lift mechanism 140 and docks with the lift mechanism 140.

The guide mechanism 111 is installed between two rows of storage shelves 120 and includes multiple shuttle rails 1111 corresponding to the height of each storage layer 121. The shuttle rails 1111 dock with the lift mechanism 140, allowing the sorting shuttle 112 to move back and forth along the longitudinal direction of the storage shelves 120.

The sorting shuttle 112 is switched between shuttle rails 1111 of different heights by a lift mechanism 140, sorting the cargo to be sorted on the supply table 150 and placing it into containers 500 with different container openings 1211 of different heights. The guide mechanism 111 further sorts the cargo on the supply table 150 and places it into containers 500 with different container openings 1211 in the longitudinal direction.

Specifically, the supply table 150 may be docked with a cargo transport line, and the cargo to be sorted may be transported to the supply table 150 by the cargo transport line. Alternatively, workers may place the cargo to be sorted on the supply table 150 for pickup by the sorting shuttle 112.

The sorting system further includes a control device, which is connected to the sorting shuttle 112 via communication. The control device controls the sorting shuttle 112 by issuing commands, thereby placing each item to be sorted into its corresponding container 500.

The control device is connected to the lift mechanism 140 via communication. When the control device transmits a command, the lift mechanism 140 moves the sorting shuttle 112 along the height of the storage rack 120 to the height of the storage layer 121 where the corresponding container 500 is located. The sorting shuttle 112 then continues to move along the shuttle rail 1111 in the storage layer 121 where the corresponding container 500 is located, thereby placing the cargo into the container 500.

The above operations are repeated until a container 500 in storage rack 120 is fully loaded with cargo, or when all the cargo in the order associated with that container 500 has been sorted, that container 500 is considered fully loaded. The control device is connected to the first robot 200 and the second robot 300 via communication. The control device sends commands so that the first robot 200 moves the fully loaded container 500 from storage rack 120 to the transfer rack 130, the second robot 300 moves the fully loaded container 500 from the transfer rack 130 to the container transfer station 400, moves the empty container 500 from the container transfer station 400 to an empty space in the transfer rack 130, and finally, the first robot 200 can move the empty container 500 from the transfer rack 130 to an empty container opening 1211 in storage rack 120.

Each row of storage shelves 120 is assigned at least one first robot 200 and one second robot 300. Multiple first robots 200 can simultaneously move full containers 500 to the transfer shelves 130 or empty containers 500 to the open container openings 1211. Multiple second robots 300 can simultaneously move full containers 500 to the container transfer station 400 or empty containers 500 to the transfer shelves 130. This improves the efficiency of the sorting system.

According to an embodiment of the present invention, the lift mechanism 140 and the guide mechanism 111 enable the sorting shuttle 112 to move in both the height and longitudinal directions of the storage shelves 120. The sorting mechanism 110 is installed between two rows of storage shelves 120, saving space and improving space utilization. The sorting shuttle 112, via the shuttle rail 1111, allows for the simultaneous sorting of orders for containers 500 in the two rows of storage shelves 120, thereby improving the operational efficiency of the sorting system.

As described above, in the sorting system of the embodiment shown in Figure 1, the transfer shelves 130 are installed in two rows below the storage shelves 120, corresponding to the storage shelves 120 of each row. In other embodiments of the sorting system, the transfer shelves 130 may be installed in two parallel rows, spaced apart from the storage shelves 120, on the side away from the sorting mechanism 110, corresponding to the storage shelves 120 of each row.

The following describes in detail a second embodiment of the sorting system provided in the embodiments of the present invention. In this sorting system, the robot dedicated to container exchange is the first robot 200, and the transport device capable of transporting containers to the transfer racks 130 on both sides of the sorting mechanism 110 in the sorting system, or to a position away from the transfer racks 130, is the second robot 300.

Specifically, referring to Figures 14 to 17, Figure 14 is a schematic perspective view of the sorting system of the second embodiment of the present invention, Figure 15 is a schematic front view of the sorting system shown in Figure 14, Figure 16 is a schematic plan view of the sorting system shown in Figure 14, and Figure 17 is a schematic side view of the sorting system shown in Figure 14.

As shown in Figures 14 to 17, the transfer shelves 130 are installed in two parallel rows, spaced apart from the storage shelves 120, on the side away from the sorting mechanism 110, corresponding to the storage shelves 120 in each row.

A third aisle 800 is installed in the space between the transfer rack 130 and the storage rack 120 of each row, and a fourth aisle 900, parallel to the third aisle 800, is installed on the side of the transfer rack 130 of each row that is away from the storage rack 120.

The third aisle 800 and the fourth aisle 900 extend from the storage rack 120 to the container transfer station 400.

The second robot 300 is arranged as follows:

The empty second robot 300 travels along the third aisle 800 to the transfer rack 130, receives a fully loaded container 500 from the transfer rack 130, travels along the fourth aisle 900, and transports the fully loaded container 500 to the container transfer station 400. Alternatively, the empty second robot 300 travels along the third aisle 800 to the container transfer station 400, receives an empty container 500 from the container transfer station 400, travels along the fourth aisle 900, and transports the empty container 500 to the transfer rack 130.

In other words, the third aisle 800 is for the second robot 300 to travel in an empty state. The second robot 300 may receive a fully loaded container 500 toward the transfer rack 130 in the third aisle 800, or it may receive an empty container 500 toward the container transfer station 400.

The fourth aisle 900 is for the second robot 300, which is fully loaded, to travel through. The second robot 300 may place empty containers 500 toward the transfer rack 130, or it may place fully loaded containers 500 toward the container transfer station 400, within the fourth aisle 900.

Specifically, as shown in Figure 16, the second robot 300 moves along the fourth aisle 900, transferring fully loaded containers 500 from the transfer rack 130 to the fully loaded container transport line 410, or transferring empty containers 500 from the empty container replenishment line 420 to the transfer rack 130.

In Figure 16, the black blocks represent fully loaded containers 500, and the white blocks represent empty containers 500. In the two fourth aisles 900 of this embodiment, a second robot 300 carrying a fully loaded container 500 may pass through, or a second robot 300 carrying an empty container 500 may pass through. Figure 16 only shows an embodiment where a second robot 300 carrying an empty container 500 travels through one of the fourth aisles 900, and a second robot 300 carrying a fully loaded container 500 travels through the other fourth aisle 900.

The first robot 200 is installed on the outer surface of the storage rack 120, that is, the first robot 200 is positioned between the storage rack 120 and the transfer rack 130. The pickup assembly 222 of the first robot 200 can extend and retract in both directions, extending toward the storage rack 120 to receive a full container 500 or place an empty container 500, and extending toward the transfer rack 130 to place a full container 500 or receive an empty container 500.

The orientation of the third passage 800 and the fourth passage 900 is determined based on the position of the container transfer station 400 relative to the sorting device 100. As shown in Figure 16, if the container transfer station 400 is installed at one end of the sorting device 100, the orientation of the third passage 800 and the fourth passage 900 is parallel to the long side of the storage rack 120, extending from the end of the storage rack 120 away from the container transfer station 400 to the container transfer station 400. The third passage 800 and the fourth passage 900 may merge at the end closest to the container transfer station 400 and extend jointly to the container transfer station 400.

As shown in Figures 14 to 16, the movement process of the unloaded second robot 300 is as follows:

The empty second robot 300 passes under the first robot 200 along the third aisle 800, enters the temporary storage area 131 from the side of the temporary storage area 131 closest to the third aisle 800, lifts the fully loaded container 500, and then enters the fourth aisle 900 along the groove 1311, heading towards the fully loaded container transport line 410.
Alternatively, the unloaded second robot 300 can move along the third aisle 800 toward the empty container replenishment line 420 to receive an empty container 500.

The movement process of the second robot 300 carrying container 500 is as follows:

The second robot 300, carrying an empty container 500, travels along the fourth aisle 900, enters the temporary storage area 131, places the empty container 500, then travels along the groove 1311 to the third aisle 800, then travels along the third aisle 800 to the temporary storage area 131 where other loaded containers 500 are placed, receives the loaded containers 500, and finally travels along the fourth aisle 900 towards the loaded container transport line 410.
Alternatively, the second robot 300, carrying an empty container 500, travels along the fourth aisle 900, enters the temporary storage area 131, places the empty container 500, then travels along the groove 1311 to enter the third aisle 800, and proceeds to the waiting area or the empty container replenishment line 420.

The second robot 300, carrying the fully loaded container 500, travels along the fourth aisle 900 and, after placing the fully loaded container 500 toward the fully loaded container transport line 410, may proceed to the waiting area, or to receive empty containers toward the empty container replenishment line 420, or to receive the fully loaded container 500 toward the transfer rack 130 along the third aisle 800.

According to an embodiment of the present invention, the transfer racks 130 are installed in two rows on the side away from the sorting mechanism 110, corresponding to each row of storage racks 120, and more container openings 1211 are installed on the storage racks 120, improving the sorting performance of the sorting device 100. The travel track of the second robot 300 is divided into a third passage 800 and a fourth passage 900 for the second robot 300 without a load and the second robot 300 carrying a container 500, respectively, improving the efficiency of transport by the second robot 300. The first robot 200 and the second robot 300 without a load move between the storage racks 120 and the transfer racks 130 without interfering with each other, saving space in the sorting device 100's layout area, improving space utilization, and avoiding scenarios where the first robot 200 and the second robot 300 need to move out of the way of each other.

In the embodiment shown in Figure 14, the structure of the sorting mechanism 110 in the sorting device 100, the structure and mounting method of the first robot 200, the structure of the second robot 300, and the structure of the container transfer station 400 may all be exactly the same as the sorting mechanism 110, first robot 200, second robot 300, and container transfer station 400 in the first embodiment of the sorting system shown in Figure 1, and a detailed explanation is omitted here.

In other words, the main difference between the second configuration sorting system shown in Figure 14 and the first configuration sorting system shown in Figure 1 is the difference in the storage shelves 120, the transfer shelves 130, and the travel tracks of the second robot 300; other components may be installed in the same way.

In actual applications, using the sorting system of the first or second embodiment described above, or variations of the two embodiments described above, the first robot 200 can move containers 500 in and out between the storage shelf 120 and the transfer shelf 130, and the second robot 300 can move containers 500 in and out between the transfer shelf 130 and the container relay station 400. This enables automatic exchange of containers 500 in the sorting system, improving sorting efficiency and accuracy compared to manual container exchange. Furthermore, instead of manual container exchange, container exchange by the first robot 200 allows the height of the storage shelf 120 to exceed the height limit imposed by the worker, increasing the container opening 1211 that can be placed on the storage shelf 120, and improving the sorting performance and space utilization rate of the sorting system.

Next, the sorting method of the first embodiment provided in the embodiments of the present invention will be described in detail.

The sorting method provided in the embodiment of the present invention is used in a control device, and the control device is communicated to the sorting mechanism 110, the first robot 200, and the second robot 300 of the sorting device 100 in the sorting system.

Referring to Figure 18, Figure 18 is a flowchart of a first embodiment of the sorting method of the first embodiment provided in the present invention, the flowchart including the following steps.
Step S1800: The sorting mechanism is instructed to accept the cargo to be sorted and to transport the cargo to be sorted into a container on a storage shelf that is not full.
Step S1810: If there is a fully loaded container on the storage shelf, the first robot is instructed to move the fully loaded container on the storage shelf to the transfer shelf. The fully loaded container is either a container that is full of cargo or a container in which all the cargo of the associated order has been sorted.
In step S1820, the second robot is instructed to move the fully loaded container on the transfer rack to the container transfer station.
Step S1830: If at least one container opening of the storage rack is open, the second robot is instructed to move an empty container from the container transfer station to the transfer rack.
Step S1840: The first robot is instructed to move the empty container from the transfer rack to an empty container opening in the storage rack.

This embodiment is used in the sorting system described above. The method involves instructing the first robot 200 to move a fully loaded container 500 from the storage rack 120 to the transfer rack 130, and the second robot 300 to move the fully loaded container 500 from the transfer rack 130 to the container transfer station 400. It also involves instructing the second robot 300 to move an empty container 500 from the container transfer station 400 to the transfer rack 130, and the first robot 200 to move the empty container 500 from the transfer rack 130 to an empty container opening 1211 on the storage rack 120. This enables automatic exchange of containers 500 in the sorting system, improving sorting efficiency and accuracy compared to manual container exchange. Furthermore, container exchange by the first robot 200, instead of manual container exchange, allows the height of the storage rack 120 to exceed the height limit imposed by the worker, increasing the number of container openings 1211 that can be placed on the storage rack 120, and improving the sorting performance and space utilization rate of the sorting system.

In actual applications, steps S1810 and S1830 may be performed in parallel. Furthermore, if there are fully loaded containers in the storage rack, or if at least one container opening in the storage rack is open, steps S1810 and S1830 may be performed separately. The procedure for performing the steps is not limited.

In practical applications, during the initial startup of a sorting system, all container openings on the storage shelves are empty. Therefore, empty containers can be moved to the storage shelf openings first, preparing them for subsequent sorting.

Specifically, referring to Figure 19, which is a flowchart of a second embodiment of the sorting method of the first embodiment provided in the present invention, the flowchart includes the following steps.
Step S1801: The second robot is instructed to move an empty container from the container transfer station to the transfer rack.
Step S1802: The first robot is instructed to move the empty container from the transfer rack to the container opening of the storage rack.

Thus, empty containers for sorting by the sorting mechanism are present at the opening of the storage shelves.

Step S1800: The sorting mechanism is instructed to accept the cargo to be sorted and transport the cargo to be sorted into a container on the storage rack that is not full.

In practical applications, this step can be performed if there are empty containers and goods to be sorted in the container openings of the storage rack. If all container openings in the storage rack are empty, this step does not need to be started. For example, this step may be started when there are empty containers in a certain number of container openings in the storage rack. This number can be flexibly set depending on the situation and is not limited here. In other words, sorting can be done in batches, further improving sorting efficiency.

In step S1810, if a fully loaded container exists on the storage shelf, the first robot is instructed to move the fully loaded container from the storage shelf to the transfer shelf. The fully loaded container is either a container full of cargo or a container in which all the cargo of the associated order has been sorted.

Specifically, in practical applications, the control device records how much cargo has been loaded into each container. In this step, based on this record, it can be determined whether or not each container is fully loaded.

Step S1820: The second robot is instructed to move the fully loaded container on the transfer rack to the container transfer station.

Step S1830: If at least one container opening of the storage rack is open, the second robot is instructed to move an empty container from the container transfer station to the transfer rack.

Specifically, in actual applications, the control device records the status of each container opening. In this step, based on this record, it is determined whether each container opening is open or not.

Step S1840: The first robot is instructed to move the empty container from the transfer rack to an empty container opening in the storage rack.

In this embodiment, as shown in Figure 19, after step S1840, empty containers are replenished in the storage rack. At this point, the process returns to step S1800, and the sorting mechanism is instructed to continue sorting. This creates a cyclical operation, further improving sorting efficiency.

In one embodiment, as shown in Figures 1 to 3, the sorting system has two rows of transfer shelves 130 installed below the storage shelves 120, corresponding to the storage shelves 120. On either side of the storage shelves 120 in each row, away from the sorting mechanism 110, a first passage 600 and a second passage 700 are installed parallel to each other, spaced apart. The first passage 600 is closer to the storage shelves 120 than the second passage 700. Both the first passage 600 and the second passage 700 extend from the storage shelves 120 to the container transfer station 400. A detailed explanation of the specific structure is omitted here. For the sorting process of this sorting system, please refer to Figure 20, which is a flowchart of a third embodiment of the sorting method of the first embodiment provided in the present invention. This flowchart includes the following steps.

Step S1801: The second robot is instructed to move an empty container from the container transfer station to the transfer rack.
Step S1802: The first robot is instructed to move the empty container from the transfer rack to the container opening of the storage rack.
Step S1800: The sorting mechanism is instructed to accept the cargo to be sorted and to transport the cargo to be sorted into a container on a storage shelf that is not full.
Step S1810: If there is a fully loaded container on the storage shelf, the first robot is instructed to move the fully loaded container on the storage shelf to the transfer shelf. The fully loaded container is either a container that is full of cargo or a container in which all the cargo of the associated order has been sorted.
Step S1821: The second robot, which is empty, is instructed to travel along the first aisle to the transfer rack, receive a fully loaded container from the transfer rack, travel along the second aisle, and transport the fully loaded container to the container transfer station.
Step S1831: If at least one container opening of the storage rack is open, the second robot, which is empty, is instructed to travel along the first aisle to the container transfer station, receive an empty container from the container transfer station, travel along the second aisle, and transport the empty container to the transfer rack.
Step S1840: The first robot is instructed to move the empty container from the transfer rack to an empty container opening in the storage rack.

In the sorting system of this embodiment, the travel track of the second robot 300 is divided into a first passage 600 and a second passage 700, for the second robot 300 without a load and for the second robot 300 carrying a container 500, respectively, thereby improving the efficiency of transport by the second robot 300.

In one embodiment, as shown in Figures 14 to 16, the sorting system has two rows of transfer shelves 130 installed on the side away from the sorting mechanism 110, corresponding to the storage shelves 120 in each row, and running parallel to the storage shelves 120 with a gap between them. A third passage 800 is installed in the space between the transfer shelves 130 and the storage shelves 120 in each row, and a fourth passage 900 is installed on the side of the transfer shelves 130 in each row away from the storage shelves 120, running parallel to the third passage 800. The third passage 800 and the fourth passage 900 extend from the storage shelves 120 to the container transfer station 400.

The sorting process of this sorting system is similar to that of the embodiment shown in Figure 20. Specifically, referring to Figure 21, which is a flowchart of a fourth embodiment of the first form of sorting method provided in the present invention, this flowchart includes the following steps.

Step S1801: The second robot is instructed to move an empty container from the container transfer station to the transfer rack.
Step S1802: The first robot is instructed to move the empty container from the transfer rack to the container opening of the storage rack.
Step S1800: The sorting mechanism is instructed to accept the cargo to be sorted and to transport the cargo to be sorted into a container on a storage shelf that is not full.
Step S1810: If there is a fully loaded container on the storage shelf, the first robot is instructed to move the fully loaded container on the storage shelf to the transfer shelf. The fully loaded container is either a container that is full of cargo or a container in which all the cargo of the associated order has been sorted.
In step S1822, the second robot, which is empty, is instructed to travel along the third aisle to the transfer rack, receive a fully loaded container from the transfer rack, travel along the fourth aisle, and transport the fully loaded container to the container transfer station.
In step S1832, if at least one container opening of the storage rack is open, the second robot, which is empty, is instructed to travel along the third aisle to the container transfer station, receive an empty container from the container transfer station, travel along the fourth aisle, and transport the empty container to the transfer rack.

Step S1840: The first robot is instructed to move the empty container from the transfer rack to an empty container opening in the storage rack.

In this sorting system, the travel track of the second robot 300 is divided into a third passage 800 and a fourth passage 900, respectively, for the second robot 300 to travel empty and the second robot 300 to travel loaded with a container 500, thereby improving the efficiency of transport by the second robot 300.

In one embodiment, referring to Figure 3, the container transfer station 400 shown in Figure 3 is in the form of a transport line, and the container transfer station 400 includes a fully loaded container transport line 410 and an empty container replenishment line 420. In this case, step S1810 shown in Figure 18 specifically instructs the second robot to move the fully loaded container from the transfer shelf to the fully loaded container transport line if there are fully loaded containers in the storage shelf. Accordingly, step S1830 specifically instructs the second robot to move an empty container from the container transfer station to the transfer shelf if at least one container opening in the storage shelf is open.

In this embodiment, the container transfer station 400 is divided into a fully loaded container transport line 410 and an empty container replenishment line 420, allowing for the simultaneous transport of fully loaded containers 500 and empty containers 500, thereby improving the operational efficiency of the sorting system.

In one embodiment, the sorting device 100 further includes a lift mechanism 140 and a supply table 150, the sorting mechanism 110 includes a guide mechanism 111 and a sorting shuttle 112, and the control device is further connected to the lift mechanism 140 and the sorting shuttle 112.

In this case, step S1800 shown in Figure 18 specifically involves, when the sorting shuttle moves to one end of the storage shelf, instructing the lift mechanism to move the sorting shuttle up and down along the height direction of the storage shelf, instructing the sorting shuttle to switch between shuttle rails of different heights using the lift mechanism, sorting the cargo to be sorted on the supply table and placing it into containers with different height openings, and using the guide mechanism to sort the cargo to be sorted on the supply table and place it into containers with different lengthwise openings.

In this embodiment, the sorting device 100 has a lift mechanism 140, a guide mechanism 111, and a sorting shuttle 112. This enables rapid sorting of cargo in both the longitudinal and vertical directions, further improving sorting efficiency.

Embodiments of the present invention further provide a control device. The control device is communicated to the sorting mechanism, first robot and second robot of the sorting device in any of the sorting systems described above. Referring to Figure 22, Figure 22 is a schematic diagram of the configuration of the first embodiment of the control device provided in the present invention. As shown in Figure 22, the control device is
A memory 2201 for storing computer programs,
When the program stored in memory 2201 is executed, it includes a processor 2202 for realizing the steps of the sorting method described above,
The aforementioned method,
The sorting mechanism is instructed to accept the cargo to be sorted, and the cargo to be sorted is transported into a container on a storage shelf that is not full.
If a fully loaded container exists in the storage rack, the first robot is instructed to move the fully loaded container from the storage rack to the transfer rack, wherein the fully loaded container is a container that is full of cargo or a container in which all the cargo of the associated order has been sorted.
The second robot is instructed to move the fully loaded containers on the transfer rack to the container transfer station,
If at least one container opening of the storage rack is open, the second robot is instructed to move an empty container from the container transfer station to the transfer rack.
This includes instructing the first robot to move an empty container from the transfer rack to an empty container opening in the storage rack.

Furthermore, the above-mentioned electronic device may further include a communication bus and/or a communication interface, and the processor 2202, the communication interface, and the memory 2201 communicate with each other via the communication bus.

Furthermore, the above control device can be implemented using a computer. The control device may also include, for example, a wired or wireless network card for communication with transport robots and sorting robots.

The following describes in detail a third embodiment of the sorting system provided in the embodiments of the present invention. In this sorting system, the robot dedicated to container exchange is a transport robot 2-300, and the transport device capable of transporting containers to shelves 2-200 on both sides of the sorting mechanism 2-100 in the system, or to a position away from shelves 2-200, is a container transfer transport line 2-400.

Referring to Figures 23a to 23d, Figure 23a is a schematic perspective view of the sorting system according to the third embodiment of the present invention, Figure 23b is a schematic front view of the sorting system shown in Figure 23a, Figure 23c is a schematic plan view of the sorting system shown in Figure 23a, and Figure 23d is a schematic side view of the sorting system shown in Figure 23a.

As shown in Figures 23a to 23d, the sorting system provided in the embodiment of the present invention includes a sorting mechanism 2-100, shelves 2-200, a transport robot 2-300, and a container transfer transport line 2-400.

The shelf 2-200 is arranged in two rows and includes multiple storage layers 2-210 spaced vertically apart. Each storage layer 2-210 includes multiple container openings 2-211, each of which is designed to accommodate one container 2-500 to be loaded.

The sorting mechanism 2-100 is installed between two rows of shelves 2-200 and is positioned to receive the goods to be sorted and transport them into containers 2-500 on shelf 2-200.

The container transfer transport line 2-400 is installed adjacent to rack 2-200 and is configured to transport empty containers 2-500 toward rack 2-200, or to transport fully loaded containers 2-500 toward rack 2-200.

The transport robot 2-300 is positioned between the shelf 2-200 and the container transfer transport line 2-400 to load and unload either a fully loaded or empty container 2-500.

The sorting system provided in this embodiment of the present invention uses a transport robot 2-300 to move containers 2-500 between shelves 2-200 and a container transfer transport line 2-400, achieving automatic container exchange in the sorting system and improving sorting efficiency and accuracy compared to manual container exchange. Furthermore, container exchange by the transport robot 2-300, instead of manual exchange, allows the shelf 2-200 height to exceed the limitations imposed by the worker's height, increasing the container opening 2-211 that can be placed on the shelf 2-200, thereby improving the sorting performance and space utilization of the sorting system. Additionally, the container transfer transport line 2-400 can transport empty containers 2-500 toward shelves 2-200 or fully loaded containers away from shelves 2-200, achieving automatic transport of both empty and fully loaded containers and further improving the overall operational efficiency of the sorting system.

In the embodiment shown in Figure 23a, as shown in Figures 23a and 23c, the container transfer transport line 2-400 is installed in two rows, and by docking each row with two rows of shelves 2-200, the transport robot 2-300 moves fully loaded or empty containers 2-500 between the shelves 2-200 and the container transfer transport line 2-400.

Specifically, Figures 23a to 23c show only a portion of the container handling line 2-400 located on shelf 2-200. However, the actual container handling line 2-400 is installed within the logistics warehouse storage system, following the container transport route, and transports containers 2-500 between the sorting system and other stages.

In one embodiment, a container transfer line 2-400 is installed at a distance from the shelves 2-200, a transport robot 2-300 is installed on the shelves 2-200, and the pickup assembly of the transport robot 2-300 loads and unloads containers 2-500 in the space between the container transfer line 2-400 and the shelves 2-200. There may be multiple transport robots 2-300, with at least one transport robot 2-300 loading and unloading containers 2-500 between each row of shelves 2-200 and the container transfer line 2-400, and each transport robot 2-300 is for transporting containers 2-500 within a preset length section of the shelves 2-200.

If the shelf 2-200 is long, two, three, or more transport robots 2-300 may be installed on each row of shelf 2-200. The shelf 2-200 is divided into multiple sections along its length, corresponding to the number of transport robots 2-300. Each transport robot 2-300 is responsible for transporting containers 2-500 within one length section of the shelf 2-200. The length sections do not need to be constant, as they are divided based on the distribution area of containers 2-500 that need to be transported on the shelf 2-200. According to this embodiment, the efficiency of transport robots 2-300 in transporting containers 2-500 can be improved.

In the embodiment shown in Figures 23a to 23c, there are two transport robots 2-300, and each transport robot 2-300 is used to coordinate a row of shelves 2-200 with a container transfer transport line 2-400.

Specifically, Figures 23a to 23c only show the case where the container transfer transport line 2-400 is arranged parallel to the longitudinal direction of the shelf 2-200. However, the actual arrangement direction of the container transfer transport line 2-400 is determined based on a specific scenario, and the present invention does not have any specific limitations on this.

According to an embodiment of the present invention, installing two container transfer transport lines 2-400, each docked with two rows of shelves 2-200, can improve the replenishment efficiency of empty containers 2-500 in the sorting system and the transport efficiency of fully loaded containers 2-500.

In the embodiment shown in Figure 23a, as shown in Figures 23a to 23c, one or more transfer areas 2-410 are installed in the container transfer transport line 2-400. Each transfer area 2-410 is installed within a section corresponding to the long side of the shelf 2-200 in the container transfer transport line 2-400. Each transfer area 2-410 may be installed adjacent to each other or spaced apart; the present invention has no restrictions on the distance between each transfer area 2-410.

The transport robot 2-300 is positioned to transport a fully loaded container 2-500 from shelf 2-200 to the transfer area 2-410 of the container transfer transport line 2-400, or to transport an empty container 2-500 from the transfer area 2-410 of the container transfer transport line 2-400 to shelf 2-200.

According to an embodiment of the present invention, one or more transfer areas 2-410 are installed in the container transfer transport line 2-400. The transport robot 2-300 does not need to move along the longitudinal direction of the container transfer transport line 2-400 to load and unload containers 2-500. Instead, it can move along the horizontal direction of the shelf 2-200 and dock with the transfer area 2-410 to complete the loading and unloading of containers 2-500. This improves the efficiency of the transport robot 2-300 in loading and unloading containers 2-500 and enhances the sorting performance of the sorting system.

In the embodiment shown in Figure 23a, referring to Figure 24, Figure 24 is a schematic perspective view of the container transfer transport line shown in Figure 23a. As shown in Figures 23c and 24, the portion of the container transfer transport line 2-400 other than the transfer area 2-410 is the transport area 2-420.
Transport area 2-420 is for transporting empty containers 2-500 to delivery area 2-410, or for transporting fully loaded containers 2-500 in delivery area 2-410 away from shelf 2-200.

Specifically, the sorting system further includes a control device, which can control the operations of the sorting mechanism 2-100, the transport robot 2-300, and the container transfer transport line 2-400.

As shown in Figure 24, the container transfer transport line 2-400 may be a roller transport line, and both the transfer area 2-410 and the transport area 2-420 include multiple rollers, enabling transport by rolling. The container transfer transport line 2-400 further includes a drive unit (not shown in the drawing), and detection devices (not shown in the drawing) are installed in both the transfer area 2-410 and the transport area 2-420. The control device can control the drive unit based on detection information fed back from the detection devices in the transfer area 2-410 and the transport area 2-420 to start or stop the rotation of the rollers in the transfer area 2-410 or the transport area 2-420. The specific transport process will be described in detail in the following section.

According to an embodiment of the present invention, the container transfer transport line 2-400 includes independent transfer areas 2-410 and transport areas 2-420. The transfer areas 2-410 and transport areas 2-420 can work together to transport containers 2-500. Even if container 2-500 is temporarily placed in the transfer area 2-410 and becomes immobile, this does not affect transport in the transport area 2-420, thereby improving the operational efficiency of the container transfer transport line 2-400.

In the embodiment shown in Figure 23a, as shown in Figure 24, when the transport robot 2-300 needs to place a fully loaded container 2-500 in the transfer area 2-410, the transfer area 2-410 stops rolling. After the placement is complete, rolling resumes, and in coordination with the transport area 2-420, the fully loaded container 2-500 is transported away.

When an empty container 2-500 is transported to the handover area 2-410, the rolling of the handover area 2-410 stops. Once the transport robot 2-300 picks up the empty container 2-500, rolling resumes and continues until the next empty container 2-500 is transported to the handover area 2-410.

When container 2-500 in transport area 2-420 is transported to an area immediately adjacent to delivery area 2-410, and delivery area 2-410 is in a stopped state, the area in transport area 2-420 on which container 2-500 is placed will stop rolling. After delivery area 2-410 begins rolling, the area on which container 2-500 is placed will also begin rolling, and transport of container 2-500 will continue.

Specifically, the sorting system's control device is connected to the transport robot 2-300 and the container transfer transport line 2-400 via communication. The control device can independently control the starting and stopping of the transfer area 2-410 of the container transfer transport line 2-400. By coordinating with the transport robot 2-300, the transport robot 2-300 can move containers 2-500 into and out of the transfer area 2-410 when the transfer area 2-410 is in a stopped state.

When the transport robot 2-300 intends to place a fully loaded container 2-500, the control device sends a command to the container transfer transport line 2-400, directing it to the transfer area 2-410 of the container transfer transport line 2-400 and stopping its rolling. The rollers in the transfer area 2-410 are stationary, and since the placement of the fully loaded container 2-500 is complete, the control device directs it to the transfer area 2-410 again and restarts rolling. In cooperation with the transport area 2-420, it sends the fully loaded container 2-500 to the next processing stage, such as a warehouse or packing plant. When an empty container 2-500 is transported to the handover area 2-410, the rollers in the handover area 2-410 stop rolling, the transport robot 2-300 picks up the empty container 2-500, and then the container handover transport line 2-400 transports the next empty container 2-500 to the handover area 2-410, waiting for the transport robot 2-300 to pick it up.

In the transport area 2-420, photoelectric sensors may be installed in the area adjacent to the downstream handover area 2-410. When the downstream handover area 2-410 is placing a fully loaded container 2-500, or when an empty container 2-500 is placed in the handover area, the rollers in the handover area 2-410 are stationary. The area in the transport area 2-420 that is away from the handover area 2-410 is kept in a rolling state. When the photoelectric sensors detect that the container 2-500 is to be transported to the area adjacent to the downstream handover area 2-410, the rolling of the adjacent area on which the container 2-500 is placed stops. After the handover area 2-410 starts rolling, the rolling of the adjacent area on which the container 2-500 is placed also starts, and the container 2-500 continues to be transported.

Furthermore, if the movement of containers in delivery area 2-410 stops, the sorting system will temporarily suspend the transport of containers 2-500 only in the area adjacent to delivery area 2-410 in the upstream transport area 2-420, and will not affect the transport of containers 2-500 in the area of transport area 2-420 that is separate from delivery area 2-410.

According to an embodiment of the present invention, while transportation in the handover area 2-410 and the transport area 2-420 is independent of each other, they also cooperate. When the handover area 2-410 needs to receive a fully loaded container 2-500, or when the transport robot 2-300 needs to retrieve an empty container 2-500, the stationary state of the handover area 2-410 does not affect the transport of the container 2-500 placed in the transport area 2-420, thereby improving the operational efficiency of the container handover transport line 2-400.

In the embodiment shown in Figure 23a, as shown in Figures 23a and 24, the container transfer transport line 2-400 includes a fully loaded container transfer transport line 2-430 and an empty container transfer transport line 2-440, which are installed at vertical intervals. The transport robot 2-300 is positioned to transport fully loaded containers 2-500 from shelf 2-200 to the fully loaded container transfer transport line 2-430, or to transport empty containers 2-500 from the empty container transfer transport line 2-440 to shelf 2-200.

Specifically, a single container transfer transport line 2-400 includes one fully loaded container transfer transport line 2-430 and one empty container transfer transport line 2-440. The specific structure of the fully loaded container transfer transport line 2-430 and the empty container transfer transport line 2-440 is identical, and both consist of one or more transfer areas 2-410 and transport areas 2-420.

The fully loaded container transfer line 2-430 may be installed above or below the empty container transfer line 2-440, and the present invention does not limit the vertical positional relationship between the fully loaded container transfer line 2-430 and the empty container transfer line 2-440. As shown in Figures 23a and 24, the fully loaded container transfer line 2-430 is installed above the empty container transfer line 2-440, with a gap between the two transport lines, providing suitable space for the empty container transfer line 2-440 to transport the empty container 2-500.

As shown in Figure 24, as the container transfer transport line 2-400 extends away from the shelf 2-200, the fully loaded container transfer transport line 2-430 and the empty container transfer transport line 2-440 separate and extend to different stations. The fully loaded container transfer transport line 2-430 transports fully loaded containers 2-500 to the packing area, while the empty container transfer transport line 2-440 extends to the empty container transfer station. The empty containers 2-500 from the empty container transfer station are transported to the transfer area 2-410 of the empty container transfer transport line 2-440, where the transport robot 2-300 takes them and replenishes the empty container opening 2-211.

According to this embodiment of the present invention, the container transfer transport line 2-400 is divided into a fully loaded container transfer transport line 2-430 and an empty container transfer transport line 2-440, which are installed at vertical intervals. By clearly defining the roles of the fully loaded and empty container transfer transport lines 2-430 and 2-440, the operation of transporting fully loaded containers 2-500 to the next processing stage and transporting empty containers 2-500 to the transfer area 2-410 can be performed simultaneously, thereby improving the operational efficiency of the container transfer transport line 2-400. The transport robot 2-300 can place the fully loaded containers 2-500 on the fully loaded container transfer transport line 2-430, and then subsequently pick up empty containers 2-500 from the empty container transfer transport line 2-440, simplifying the transport robot 2-300's movement path and improving its operational efficiency.

In the embodiment shown in Figure 23a, as shown in Figures 23a to 23d, the container transfer transport line 2-400 is installed on the side away from the sorting mechanism 2-100 on the shelf 2-200. Here, the transfer area 2-410 of the container transfer transport line 2-400 is installed at intervals parallel to the longitudinal direction of the shelf 2-200.

Specifically, as shown in Figures 23a to 23d, the two rows of container transfer lines 2-400 are installed on the outside, corresponding to the two rows of shelves 2-200, that is, on the side away from the sorting mechanism 2-100.

Figures 23a to 23d only show the case where the container transfer transport line 2-400 is arranged parallel to the longitudinal direction of the shelf 2-200. However, the actual arrangement of the container transfer transport line 2-400 needs to be set based on a specific scenario. For the transport robot 2-300 to load and unload containers 2-500 in the transfer area 2-410, the transfer area 2-410 needs to be installed parallel to the longitudinal direction of the shelf 2-200. The transport area 2-420 may be arranged based on the location of the processing stage to which the fully loaded containers 2-500 are headed and the location of the empty container replenishment station. The present invention is not specifically limited in this regard.

According to this embodiment of the present invention, the container transfer transport line 2-400 is installed outside the shelf 2-200, and the transfer area 2-410 is installed parallel to the longitudinal direction of the shelf 2-200 with a gap between them. This does not occupy the space of the shelf 2-200, allowing more container openings 2-211 to be installed on the shelf 2-200, thereby improving the sorting performance of the sorting system.

In the embodiment shown in Figure 23a, as shown in Figures 23a to 23d, the shelf 2-200 includes multiple beams 2-230 installed vertically, and the transport robot 2-300 is mounted on the outside of the shelf 2-200 by the beams 2-230.

Specifically, multiple transport robots 2-300 are each mounted on the outer beams 2-230 of two rows of shelves 2-200. By sliding along the beams 2-230, the multiple transport robots 2-300 move horizontally along the shelves 2-200. This allows the multiple transport robots 2-300 to simultaneously load and unload containers between the shelves 2-200 and the container transfer transport line 2-400, thereby improving transport efficiency. The specific arrangement method will be explained in detail in the following section.

In the embodiment shown in Figure 23a, referring to Figures 25a to 25d, Figure 25a is a schematic perspective view of the transport robot shown in Figure 23a, Figure 25b is a schematic front view of the transport robot shown in Figure 23a, Figure 25c is a schematic top view of the transport robot shown in Figure 23a, and Figure 25d is a schematic side view of the transport robot shown in Figure 23a.

As shown in Figures 25a to 25c, the transport robot 2-300 includes a column mast 2-310, a transport mechanism 2-320, and at least one slide rail 2-330.

Column mast 2-310 is mounted vertically along shelf 2-200.

The transport mechanism 2-320 is installed on the column mast 2-310 and is used for loading and unloading containers 2-500 at different heights on the racks 2-200 or the container transfer transport line 2-400.

At least one slide rail 2-330 is fixedly mounted to the beam 2-230. The column mast 2-310 is slidably connected to at least one slide rail 2-330 so that different containers 2-500 along the longitudinal direction of the shelf 2-200 or the container transfer transport line 2-400 can be moved in and out by sliding the column mast 2-310 and the transport mechanism 2-320 horizontally along the beam 2-230.

Specifically, as shown in Figures 23a and 23b, the transport robot 2-300 is fixed to the shelf 2-200 by two slide rails 2-330 installed with a gap between them vertically. The transport robot 2-300 can move along the longitudinal direction of the shelf 2-200 using these two slide rails 2-330.

According to an embodiment of the present invention, the transport robot 2-300 can move horizontally along the longitudinal direction of the shelf 2-200, thereby loading and unloading each container 2-500 along the longitudinal direction of the shelf 2-200, or containers 2-500 in the handling area 2-410 of the container handling transport line 2-400. Furthermore, the pickup assembly 2-322 of the transport robot 2-300 can move vertically along the height direction of the shelf 2-200 or the container handling transport line 2-400, thereby loading and unloading containers 2-500 in storage layers 2-210 at different heights of the shelf 2-200, a fully loaded container handling transport line 2-430, or an empty container handling transport line 2-440. A specific method for loading and unloading containers 2-500 will be described in detail in the following description.

In the embodiment shown in Figure 23a, as shown in Figures 25a to 25d, the transport mechanism 2-320 of the transport robot 2-300 includes a lifting assembly 2-321 and a pickup assembly 2-322.

The lifting assembly 2-321 is mounted on the column mast 2-310 and is positioned to move along the vertical direction by moving the pickup assembly 2-322.

The pickup assembly 2-322 is mounted on the lifting assembly 2-321 and extends from the column mast 2-310 toward the rack 2-200 or the container transfer transport line 2-400, positioned to load and unload containers 2-500 from the rack 2-200 or the container transfer transport line 2-400.

Specifically, the column mast 2-310 includes two door posts 2-311, and the lifting assembly 2-321 is able to move the pickup assembly 2-322 vertically along the shelf 2-200 or container transfer transport line 2-400 by a drive motor installed on the column mast 2-310, driven wheels and driven wheels installed on the top and bottom of the two door posts 2-311, and two synchronous belts fitted onto the driven wheels and driven wheels.

The embodiments of the pickup assembly 2-322 include, but are not limited to, fork arm type, suction cup type, drum type, hook arm type, etc.

The pickup assembly 2-322 may be mounted on a synchronization belt, and may include a telescopic structure that is bidirectional, and may move toward or away from the shelf 2-200, extending outwards from the shelf 2-200 or the container transfer transport line 2-400 via the telescopic structure to load and unload container 2-500.

According to an embodiment of the present invention, the transport robot 2-300 can, by means of the slide rail 2-330, load and unload containers 2-500 from shelves 2-200 or container transfer transport lines 2-400 in the horizontal direction, and by means of the lifting assembly 2-321, it can load and unload containers 2-500 from storage layers 2-210 at different heights of shelves 2-200, a fully loaded container transfer transport line 2-430, or an empty container transfer transport line 2-440 in the vertical direction.

The following describes in detail how the transport robot 2-300 loads and unloads container 2-500, based on the embodiment shown in Figure 23a.

Specifically, the sorting system's control device can control the operations of the sorting mechanism 2-100, the transport robot 2-300, and the container transfer transport line 2-400.

The process of transporting a fully loaded container 2-500 specifically includes the following steps:

Step A: The transport robot 2-300 moves along the longitudinal direction of shelf 2-200 to the row where the target fully loaded container 2-500 is located, using the slide rail 2-330.

Step B: The lifting assembly 2-321 moves the pickup assembly 2-322 along the height direction of shelf 2-200 to the row where the target fully loaded container 2-500 is located.

Here, the order in which steps A and B are performed does not matter; step A may be performed first, followed by step B. Alternatively, step B may be performed, the pickup assembly 2-322 may move to the row where the target container 2-500 is located, and then step A may be performed, causing the transport robot 2-300 to move via the slide rail 2-330 to the row where the target fully loaded container 2-500 is located. Furthermore, steps A and B may be performed in parallel, with the vertical movement of the pickup assembly 2-322 and the horizontal movement of the transport robot 2-300 being performed concurrently.

Step C: The pickup assembly 2-322 extends outwards from the fully loaded container 2-500 via its telescopic structure and is recovered after the fully loaded container 2-500 has been picked up.

In step D, the slide rail 2-330 and the lifting assembly 2-321 move the pickup assembly 2-322, loaded with container 2-500, to the front of the transfer area 2-410 of the container transfer transport line 2-430. Here, horizontal movement by the slide rail 2-330 and vertical movement by the lifting assembly 2-321 can be performed simultaneously, thereby improving the transfer efficiency of the transport robot 2-300.

Step E: The pickup assembly 2-322, through its telescopic structure, extends into the transfer area 2-410 of the fully loaded container transfer transport line 2-430, and places the fully loaded container 2-500 into the transfer area 2-410.

The subsequent workflow for container transfer line 2-400 is as follows: The fully loaded container transfer line 2-430 transports the loaded container 2-500 to the next processing stage. Simultaneously, the control device sends a command to replenish the empty container opening 2-211 of shelf 2-200 with an empty container 2-500, and the empty container transfer line 2-440 then transports the empty container 2-500.

The process of transporting empty container 2-500 specifically includes the following steps:

Step F, slide rail 2-330, and lifting assembly 2-321 move the pickup assembly 2-322 in front of the transfer area 2-410 of the empty container transfer transport line 2-440.

Step G, the pickup assembly 2-322, extends by its telescopic structure into the transfer area 2-410 of the empty container transfer transport line 2-440, and is recovered after picking up the empty container 2-500.

Step H, slide rail 2-330, and lifting assembly 2-321 move the pickup assembly 2-322 in front of the open container opening 2-211.

Step I: The pickup assembly 2-322, through its telescopic structure, extends out into the open container opening 2-211 and is retrieved from the empty container 2-500 placed in the open container opening 2-211.

The subsequent workflow for container transfer line 2-400 is as follows: After transport robot 2-300 picks up an empty container 2-500, the control unit controls empty container transfer line 2-440 to continue transporting the next empty container 2-500 to transfer area 2-410, waiting for transport robot 2-300 to pick it up.

After the transport robot 2-300 has performed step E, the lifting assembly 2-321 may directly move the pickup assembly 2-322 in front of the transfer area 2-410 of the empty container transfer transport line 2-440. Then, steps G through I are performed, completing the loading and unloading of container 2-500.

According to this embodiment of the present invention, by simply docking the transport robot 2-300 with the shelf 2-200 and the container transfer transport line 2-400, the retrieval of fully loaded containers and the replenishment of empty containers are performed in place of a human, thereby automating the container flow of the sorting system and improving sorting efficiency and accuracy compared to the method of exchanging containers by human hands. Furthermore, by having the transport robot 2-300 exchange containers with the shelf 2-200 in place of a human, the design height of the shelf 2-200 can exceed the limitations imposed by the height of a worker, increasing the container opening 2-211 that can be placed on the shelf 2-200, and improving the sorting performance and space utilization rate of the sorting system. In addition, the container transfer transport line 2-400 can transport empty containers 2-500 toward the shelf 2-200 or fully loaded containers 2-500 away from the shelf 2-200, realizing the automated transport of empty and fully loaded containers 2-500 and further improving the overall operational efficiency of the sorting system.

In the embodiment shown in Figure 23a, the sorting mechanism 2-100 is installed between two rows of shelves 2-200, and can receive cargo to be sorted and transport the cargo into the containers 2-500 on the shelves 2-200.

Specifically, as shown in Figures 23a to 23d, the sorting mechanism 2-100 includes a supply table 2-110, a lift mechanism 2-120, a guide mechanism 2-130, and a sorting shuttle 2-140.

The lift mechanism 2-120 is installed at both ends of shelf 2-200 and is used to move the sorting shuttle 2-140 up and down along the height of shelf 2-200.

The supply platform 2-110 is installed on one or both sides of the lift mechanism 2-120 and docks with the lift mechanism 2-120.

The guide mechanism 2-130 is installed between two rows of shelves 2-200 and includes multiple shuttle rails 2-131 corresponding to the height of each storage layer 2-210. The shuttle rails 2-131 dock with the lift mechanism 2-120, causing the sorting shuttle 2-140 to reciprocate along the longitudinal direction of the shelves 2-200.

The sorting shuttle 2-140 uses a lift mechanism 2-120 to switch between shuttle rails 2-131 of different heights, thereby sorting the cargo to be sorted on the supply table 2-110 into containers 2-500 with different container openings 2-211 of different heights. The guide mechanism 2-130 further sorts the cargo to be sorted on the supply table 2-110 into containers 2-500 with different container openings 2-211 in the longitudinal direction.

Specifically, the supply table 2-110 may be docked with the cargo transport line, and the cargo to be sorted may be transported to the supply table 2-110 by the cargo transport line. Alternatively, the cargo to be sorted may be placed on the supply table 2-110 by an operator for pickup by the sorting shuttle 2-140.

The control unit is connected to the sorting shuttle 2-140 via communication. The control unit transmits commands to control the sorting shuttle 2-140, placing each item to be sorted into its corresponding container 2-500.

The control device is connected to the lift mechanism 2-120 via communication. The control device transmits commands to control the lift mechanism 2-120, causing the sorting shuttle 2-140 to move along the height of the shelf 2-200 to the height of the storage layer 2-210 where the corresponding container 2-500 is located. The sorting shuttle 2-140 then continues to move along the shuttle rail 2-131 in the storage layer 2-210 to the corresponding container 2-500, placing the cargo into the container 2-500.

The above operation is repeated until a container 2-500 on shelf 2-200 is fully loaded with cargo, or when all the cargo in the order associated with that container 2-500 has been sorted, that container 2-500 is considered fully loaded. The control device communicates with the transport robot 2-300 and controls the transport robot 2-300 to move the fully loaded container 2-500 on shelf 2-200 to the transfer area 2-410 of the fully loaded container transfer transport line 2-430. The fully loaded container transfer transport line 2-430 then transports the fully loaded container away from the sorting system. Subsequently, the transport robot 2-300 moves the empty container 2-500 from the transfer area 2-410 of the empty container transfer transport line 2-440 to the empty container opening 2-211 on shelf 2-200.

According to this embodiment of the present invention, the lift mechanism 2-120 and the guide mechanism 2-130 enable the sorting shuttle 2-140 to move in the height and longitudinal direction of the shelf 2-200. The sorting mechanism 2-100 is installed between two rows of shelves 2-200, saving space and improving space utilization. The sorting shuttle 2-140, via the shuttle rail 2-131, enables simultaneous sorting of orders for containers 2-500 on the two rows of shelves 2-200, improving the operational efficiency of the sorting system.

As described above, in the third embodiment of the sorting system shown in Figure 23a, the container transfer transport line 2-400 is installed on the side of the shelf 2-200 away from the sorting mechanism 2-100. In other embodiments of the sorting system, the container transfer transport line 2-400 may be installed at one end of the shelf 2-200 in the longitudinal direction.

The following describes in detail a fourth embodiment of the sorting system provided in the embodiments of the present invention. In this sorting system, the robot dedicated to container exchange is a transport robot 2-300, and the transport device capable of transporting containers to shelves 2-200 on both sides of the sorting mechanism 2-100 in the system, or to a position away from shelves 2-200, is a container transfer transport line 2-400.

Referring to Figure 26, which is a schematic plan view of a sorting system according to the fourth embodiment of the present invention, a container transfer transport line 2-400 is installed at one end of the shelf 2-200 in the longitudinal direction, and a storage space 2-220 is installed at the bottom of the end of the shelf 2-200 closest to the container transfer transport line 2-400. The transfer area 2-410 of the container transfer transport line 2-400 extends into the storage space 2-220.

Specifically, in this embodiment, there is one lift mechanism 2-120, and the two rows of container transfer transport lines 2-400 are each installed corresponding to the ends of the two rows of shelves 2-200 that are away from the lift mechanism 2-120. Their transfer areas 2-410 are each installed corresponding to the storage spaces 2-220 at the bottom of the two rows of shelves 2-200.

To provide storage space 2-220 for the handover area 2-410, the shelf 2-200 can be installed at a higher height to ensure sufficient height at its bottom to accommodate the handover area 2-410.

If shelf 2-200 is not raised, the length of the one or two storage layers 2-210 that might interfere with the container transfer transport line 2-400 at the bottom of shelf 2-200 may be shortened. Specifically, the bottom one or two storage layers 2-210 are shortened towards the lift mechanism 2-120, and two additional support door posts are installed at the shortened end. These two door posts, along with the two door posts on shelf 2-200 closest to the container transfer transport line 2-400, surround the storage space 2-220, thereby accommodating the transfer area 2-410.

According to an embodiment of the present invention, locating the container transfer area 2-410 of the container transfer transport line 2-400 at the bottom of the shelf 2-200 saves the transfer robot 2-300 the step required to move to the transfer area 2-410, improves the efficiency of loading and unloading containers 2-500 by the transport robot 2-300, enhances the sorting performance of the sorting system, saves space in the sorting system's layout area, and improves space utilization.

In the fourth configuration of the sorting system, the structure of the sorting mechanism 2-100, the structure and mounting method of the transport robot 2-300, and the structure of the container transport line 2-400 are all exactly the same as those in the third configuration sorting system shown in Figure 23a, except for the number of lift mechanisms 2-120, the installation location of the container transfer transport line 2-400, and the structure of the shelves 2-200. Therefore, a detailed explanation is omitted here.

In other words, the main differences between the fourth sorting system shown in Figure 26 and the third sorting system shown in Figure 23a lie in the number of lift mechanisms 2-120, the installation location of the container transfer transport line 2-400, and the structure of the shelves 2-200; other components can be installed in the same way.

In actual applications, the sorting system of the third or fourth embodiment described above, or a modified configuration of the two embodiments described above, enables the automatic exchange of containers 2-500 in the sorting system by having the transport robot 2-300 move containers 2-500 in and out between the shelf 2-200 and the container transfer transport line 2-400. This improves sorting efficiency and accuracy compared to the method of manually exchanging containers. Furthermore, instead of manual container exchange, container exchange by the transport robot 2-300 allows the height of the shelf 2-200 to exceed the height limit imposed by the worker, increasing the container opening 2-211 that can be placed on the shelf 2-200 and improving the sorting performance and space utilization rate of the sorting system. Furthermore, the container transfer transport line 2-400 can transport empty containers 2-500 toward shelf 2-200, or fully loaded containers 2-500 away from shelf 2-200, enabling automated transport of both empty and fully loaded containers 2-500 and further improving the overall operational efficiency of the sorting system.

Next, a second embodiment of the sorting method provided in the embodiments of the present invention will be described in detail.

The second embodiment of the sorting method provided in the embodiments of the present invention is used in a control device, which is communicated to the sorting mechanism 2-100, the transport robot 2-300, and the container transfer transport line 2-400 in the sorting system.

Referring to Figure 27, Figure 27 is a flowchart of a first embodiment of the second embodiment of the sorting method provided in the present invention, the flowchart including the following steps.

Step S500: The container transfer transport line is instructed and started so that it can transport empty containers to the shelves and fully loaded containers away from the shelves.

Step S510: The sorting mechanism is instructed to accept the cargo to be sorted and to transport the cargo to be sorted into a container on the shelf that is not full.

In step S520, if a fully loaded container exists on the shelf, the transport robot is instructed to move the fully loaded container from the shelf to the container transfer transport line.

Specifically, a fully loaded container 2-500 is a container 2-500 that is full of cargo or whose associated order cargo has been fully sorted. In practical applications, the control device records how much cargo has been loaded into each container 2-500. In this step, based on this record, it can be determined whether or not each container 2-500 is fully loaded.

Step S530: If at least one container opening of the shelf is open, the transport robot is instructed to move an empty container in the container transfer transport line to the open container opening of the shelf.

Specifically, in actual applications, the control device records the status of each container 2-500 and the container opening 2-211. In this step, based on this record, it can be determined whether each container opening 2-211 is open or not.

This embodiment is used in the sorting system described above. The method involves instructing the transport robot 2-300 to move fully loaded containers 2-500 from shelf 2-200 to the container transfer transport line 2-400, and then moving empty containers 2-500 from the container transfer transport line 2-400 to the empty container openings 2-211 on shelf 2-200. This enables automatic container exchange in the sorting system, improving sorting efficiency and accuracy compared to manual container exchange. Furthermore, instead of manual container exchange, container exchange by the transport robot 2-300 allows the shelf 2-200 to exceed the height limitations imposed by human workers, increasing the number of container openings 2-211 that can be placed on shelf 2-200, thus improving the sorting performance and space utilization of the sorting system. Furthermore, this method directs the container transfer transport line 2-400 to transport empty containers 2-500 toward shelf 2-200 and fully loaded containers 2-500 toward shelf 2-200, thereby achieving automated transport of both empty and fully loaded containers 2-500 and further improving the overall operational efficiency of the sorting system.

In actual applications, steps S520 and S530 can be performed in parallel. Steps S520 and S530 may be performed when there are fully loaded containers 2-500 on shelf 2-200, or when at least one container opening 2-211 of shelf 2-200 is empty. The procedure for performing the steps is not limited.

In one embodiment, the container transfer transport line 2-400, as shown in Figure 24, includes a fully loaded container transfer transport line 2-430 and an empty container transfer transport line 2-440, which are spaced vertically apart. Referring to Figure 28, Figure 28 is a flowchart of a second embodiment of the sorting method provided in the present invention, the flowchart comprising the following steps.

Step S501: The fully loaded container transfer line and the empty container transfer line are instructed and activated so that the empty container transfer line can transport empty containers to the shelves, and the fully loaded container transfer line can transport fully loaded containers away from the shelves.

Step S510: The sorting mechanism is instructed to accept the cargo to be sorted and to transport the cargo to be sorted into a container on the shelf that is not full.

Step S521: If a fully loaded container exists on the shelf, the transport robot is instructed to move the fully loaded container from the shelf to the container transfer transport line.

Step S531: If at least one container opening of the shelf is open, the transport robot is instructed to move an empty container from the empty container transfer transport line to the open container opening of the shelf.

In actual applications, steps S521 and S531 can be performed in parallel. Steps S521 and S531 may be performed when there are fully loaded containers 2-500 on shelf 2-200, or when at least one container opening 2-211 of shelf 2-200 is empty. The procedure for performing the steps is not limited.

In this embodiment, by instructing the transport robot 2-300 to move the fully loaded containers 2-500 from shelf 2-200 to the fully loaded container transfer transport line 2-430, and moving the empty containers 2-500 from the empty container transfer transport line 2-440 to the empty container opening 2-211 on shelf 2-200, the roles of the fully loaded container transfer transport line 2-430 and the empty container transfer transport line 2-440 are clearly defined. This allows for the simultaneous transport of fully loaded containers 2-500 to the next processing stage and the transport of empty containers 2-500 to the transfer area 2-410, further improving the operational efficiency of the container transfer transport line 2-400.

In one embodiment, one or more transfer areas 2-410 are provided in the container transfer transport line 2-400, and the area other than the transfer areas 2-410 is the transport area 2-420. Referring to Figure 29, Figure 29 is a flowchart of a second embodiment of the sorting method of the second embodiment provided in the present invention, and the flowchart includes the following steps.

Step S502: The container transfer transport line is instructed and started so that the transport area in the container transfer transport line can transport empty containers to the transfer area, receive fully loaded containers transported from the transfer area and transport them away from the shelves, and transport fully loaded containers from the transfer area to the transport area.

Step S510: The sorting mechanism is instructed to accept the cargo to be sorted and to transport the cargo to be sorted into a container on the shelf that is not full.

In step S522, if a fully loaded container exists on the shelf, the transport robot is instructed to move the fully loaded container from the shelf to the transfer area.

Step S532: If at least one container opening of the shelf is open, the transport robot is instructed to move an empty container in the transfer area to the open container opening of the shelf.

When implementing this system, the control device may independently control the starting and stopping of the transfer area 2-410 in coordination with the transport robot 2-300. This allows the transport robot 2-300 to load and unload containers 2-500 in the transfer area 2-410 when the transfer area 2-410 is in a stopped state.

In actual applications, steps S522 and S532 may be performed in parallel. Steps S522 and S532 may be performed, respectively, when there are fully loaded containers 2-500 on shelf 2-200, or when at least one container opening 2-211 of shelf 2-200 is empty. The procedure for performing the steps is not limited.

In this embodiment, the handover area 2-410 and the transport area 2-420 can work together to transport containers 2-500. The transport area 2-420 can transport empty containers 2-500 to the handover area 2-410, receive fully loaded containers 2-500 transported from the handover area 2-410, and transport them away from the shelf 2-200. The handover area 2-410 can transport fully loaded containers 2-500 to the transport area 2-420. The handover area 2-410 and the transport area 2-420 can also operate independently of each other, as will be explained in detail in the following description.

In one embodiment, referring to Figure 30, Figure 30 is a flowchart of a fourth embodiment of the sorting method of the second embodiment provided in the present invention, and the flowchart includes the following steps.

Step S502: The container transfer transport line is instructed and started so that the transport area in the container transfer transport line can transport empty containers to the transfer area, receive fully loaded containers transported from the transfer area and transport them away from the shelves, and transport fully loaded containers from the transfer area to the transport area.

Step S510: The sorting mechanism is instructed to accept the cargo to be sorted and to transport the cargo to be sorted into a container on the shelf that is not full.

In step S5221, when the transport robot needs to place the fully loaded container in the transfer area, it directs the robot to the transfer area and stops rolling.

In step S5222, after the transport robot places the fully loaded container in the transfer area, it directs the robot to the transfer area and starts rolling, transporting the fully loaded container away from the shelf in coordination with the transport area.

In step S5223, when a container in the transport area is transported to an area adjacent to the handover area, and the handover area is in a stopped-rolling state, a photoelectric sensor installed in the transport area triggers a stop in the handover area where the container is placed. After the handover area starts rolling again, the handover area also starts rolling, and the container continues to be transported.

Step S5321: If an empty container is placed in the transfer area, indicate the transfer area and stop the rolling motion.

Step S5322: If no empty containers exist in the delivery area, the system directs the containers to the transport area and transports them to the delivery area.

Step S5323: After the transport robot retrieves an empty container from the transfer area, it is instructed to move to the transfer area, and then instructed to transport the next empty container to the transfer area.

In this embodiment, the handover area 2-410 and the transport area 2-420 can operate independently of each other. When the handover area 2-410 needs to receive a fully loaded container 2-500, or when the transport robot 2-300 needs to pick up an empty container 2-500, the handover area 2-410 remains stationary. This does not affect the transport area 2-420's ability to transport the container 2-500 placed on it, thereby improving the operational efficiency of the container handover transport line 2-400.

In one embodiment, the sorting mechanism 2-100 includes a supply table 2-110, a lift mechanism 2-120, a guide mechanism 2-130, and a sorting shuttle 2-140, wherein the guide mechanism 2-130 includes a plurality of shuttle rails 2-131, and the control device is further communicated to the lift mechanism 2-120 and the sorting shuttle 2-140. In this case, specifically in step S510 shown in Figure 27,
When the sorting shuttle moves to one end of the shelf, the lift mechanism is instructed to move the sorting shuttle up and down along the height direction of the shelf, the sorting shuttle is instructed to switch between shuttle rails of different heights using the lift mechanism, sorts the cargo to be sorted on the supply table and places it into containers with different heights, and the guide mechanism sorts the cargo to be sorted on the supply table and places it into containers with different lengthwise widths.

In this embodiment, the sorting mechanism 2-100, which includes a lift mechanism 2-120, a guide mechanism 2-130, and a sorting shuttle 2-140, enables rapid sorting of cargo in both the longitudinal and vertical directions, further improving sorting efficiency.

Embodiments of the present invention further provide a control device. The control device is communicated to the sorting mechanism, transport robot and container handling transport line in any of the sorting systems described above. Referring to Figure 31, Figure 31 is a schematic diagram of the configuration of a second embodiment of the control device provided in embodiments of the present invention. As shown in Figure 31, the control device is
A memory 901 for storing computer programs,
The method includes a processor 902 for implementing the steps of the sorting method described above, and when the program stored in memory 901 is executed,
The container transfer transport line is instructed and activated so that it can transport empty containers to the shelves and fully loaded containers away from the shelves.
The sorting mechanism is instructed to accept the cargo to be sorted, and the cargo to be sorted is transported into a container on the shelf that is not full.
If there are fully loaded containers on the shelf, the transport robot is instructed to move the fully loaded containers on the shelf to the container transfer transport line.
If at least one container opening of the shelf is open, the transport robot is instructed to move an empty container in the container transfer transport line to the open container opening of the shelf.

Furthermore, the above-mentioned electronic device may further include a communication bus and/or a communication interface, and the processor 902, the communication interface, and the memory 901 communicate with each other via the communication bus.

Furthermore, the above-described control device can be implemented using a computer and may include a communication module for connecting to the transport robot and sorting robot, such as a wired network card or a wireless network card.

In the electronic devices described above, the communication bus mentioned may be a PCI (Peripheral Component Interconnect) bus or an EISA (Extended Industry Standard Architecture) bus, etc. This communication bus may be divided into an address bus, data bus, control bus, etc. For illustrative purposes, only one thick line is shown in the diagram, but this does not mean that there is only one bus or only one type of bus.

The communication interface is used for communication between the above-mentioned electronic devices and other devices.

The memory may include random access memory (RAM) or non-volatile memory (NVM), and may be, for example, at least one disk memory. Optionally, the memory may be a storage device located away from at least one of the processors.

The above-mentioned processor may be a general-purpose processor including a Central Processing Unit (CPU), a Network Processor (NP), etc., and may also be a Digital Signal Processor (DSP), Application Specific Integrated Circuit (ASIC), Field-Programmable Gate Array (FPGA), or other programmable logic device, discrete gate or transistor logic device, or discrete hardware assembly.

Another embodiment provided by the present invention is a computer-readable storage medium in which a computer program is stored, and the computer program, when executed by a processor, realizes any of the sorting method steps described above.

Another embodiment provided by the present invention provides a computer program product containing instructions, which, when executed on a computer, cause the computer to perform one of the sorting methods described in the above embodiment.

In the above embodiments, all or part of the embodiments can be implemented by software, hardware, firmware, or any combination thereof. When implemented using software, all or part of the embodiments are implemented in the form of a computer program product. The computer program product includes one or more computer instructions. When the instructions of the computer program are loaded into a computer and executed, all or part of them implement the flow or function described in the embodiments of the present invention. The computer may be a general-purpose computer, a dedicated computer, a computer network, or other programmable device. The computer instructions may be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, the computer instructions may be transmitted from one website, computer, server, or data center to another website, computer, server, or data center by a wired (e.g., coaxial cable, optical fiber, digital subscriber line (DSL)) or wireless (e.g., infrared, radio, microwave, etc.) method. The computer-readable storage medium may be any available medium accessible to the computer, or a data storage device such as a server or data center that integrates one or more available media. The usable media may include magnetic media (e.g., floppy disks, hard disks, tapes), optical media (e.g., DVDs), or solid-state drives (Solid State Disks, SSDs).

To improve sorting efficiency, a sorting system may be equipped with multiple sorting devices. However, if one robot is responsible for container exchange in a single device, the robot's utilization rate will be low, resulting in high costs for the sorting system.

The following describes in detail a fifth embodiment of the sorting system provided in the embodiments of the present invention. In this sorting system, the robot dedicated to container exchange is the container exchange robot 3-200, and the transport device capable of transporting containers to shelves 3-120 on either side of the sorting mechanism 3-110 in the system, or to a position away from shelf 3-120, is the relay robot 3-300A.

Referring to Figures 32a to 32c, Figure 32a is a schematic perspective view of the sorting system according to the fifth embodiment of the present invention, Figure 32b is a schematic plan view of the sorting system shown in Figure 32a, and Figure 32c is a schematic front view of the sorting device shown in Figure 32a.

As shown in Figures 32a to 32c, the sorting system includes at least two sorting devices 3-100, a container exchange robot 3-200, and a container transport device 3-300.

At least two sorting devices 3-100 are installed in parallel with a gap between them, and a container exchange robot passage 3-400 is formed between two adjacent sorting devices 3-100. Each sorting device 3-100 sorts the received cargo and places it into each container 3-500.

At least two sorting devices 3-100 are equipped with a storage area for storing containers 3-500 and a transfer area 3-140 for docking with container transport devices 3-300.

The container transport device 3-300 is for transporting empty containers 3-500 to the delivery area 3-140 of the sorting device 3-100, or for transporting fully loaded containers 3-500 located in the delivery area 3-140 of the sorting device 3-100 to the outside of the sorting device 3-100.

The container exchange robot 3-200 is installed by being attached to either of the sorting devices 3-100 on either side of the container exchange robot aisle 3-400, and is capable of traveling along the container exchange robot aisle 3-400. Its purpose is to transport empty containers 3-500 from their transfer area 3-140 to the storage area of each of the two sorting devices 3-100 on either side of the container exchange robot aisle 3-400, or to transport fully loaded containers 3-500 from their storage area to the transfer area 3-140 of each sorting device 3-100.

Furthermore, if the sorting system has multiple sorting devices 3-100, it is sufficient that two sorting devices 3-100 are installed in parallel with a gap between them as described above, and that a common container exchange robot 3-200 transports the containers 3-500.

In the sorting system provided in the embodiment of the present invention, the container exchange robot 3-200 is installed on either of the sorting devices 3-100 on both sides of the container exchange robot passage 3-400, and can travel along the container exchange robot passage 3-400. Its purpose is to transport empty containers 3-500 from the delivery area 3-140 of each of the two sorting devices 3-100 on both sides of the container exchange robot passage 3-400 to the storage area of the sorting device 3-100, or to transport full containers 3-500 from the storage area to the delivery area 3-140 of the sorting device 3-100. This improves the utilization rate of the container exchange robot, reduces the cost of the sorting system, enables automatic container exchange in the sorting system, and improves sorting efficiency and sorting accuracy compared to the method of manually exchanging containers. Furthermore, replacing manual container exchange with a container exchange robot allows the sorting device's height to exceed the limitations imposed by human height, improving the sorting system's storage capacity, sorting performance, and space utilization efficiency.

The container transport device 3-300 is for transporting empty containers 3-500 to the delivery area 3-140 of the sorting device 3-100, or for transporting fully loaded containers 3-500 located in the delivery area 3-140 of the sorting device 3-100 to the outside of the sorting device 3-100. This enables the automated transport of both empty and fully loaded containers 3-500, further improving the overall operational efficiency of the sorting system.

In the embodiment shown in Figure 32a, the sorting device 3-100 includes a sorting mechanism 3-110 and a shelf 3-120, as shown in Figures 32a to 32c.

Shelves 3-120 are arranged in two rows, with the storage area located on shelves 3-120. Multiple storage layers 3-121 are spaced apart vertically, each containing a container 3-500 to be loaded. Each storage layer 3-121 is divided into multiple storage locations 3-1211, each containing one container 3-500 to be loaded.

The sorting mechanism 3-110 is installed between two rows of shelves 3-120 and is designed to receive cargo to be sorted and transport it into each container 2-500 on shelf 3-120.

The container exchange robot 3-200 is installed on either side of the container exchange robot aisle 3-400, on the side of the sorting device 3-100 on shelf 3-120 that is away from the sorting mechanism 3-110. For both shelves 3-120 on either side of the container exchange robot aisle 3-400, the container exchange robot 3-200 is used to transport empty containers 3-500 from the transfer area 3-140 to the storage layer 3-121 of shelf 3-120, or to transport fully loaded containers 3-500 from the storage layer 3-121 of shelf 3-120 to the transfer area 3-140.

In each sorting device 3-100, when one shelf 3-120 is adjacent to a container exchange robot passage 3-400, at least one container exchange robot 3-200 is installed on the side of the other shelf 3-120 that is away from the sorting mechanism 3-110.

As shown in Figure 32c, the sorting system in this embodiment of the present invention includes two sorting devices 3-100, with a container exchange robot passage 3-400 formed between the two sorting devices 3-100. A container exchange robot 3-200 is installed in the container exchange robot passage 3-400, and this robot is mounted on a shelf 3-120 of one of the sorting devices 3-100 on the container exchange robot passage 3-400. The robot is used to load and unload containers 3-500 from the shelves 3-120 on both sides of the container exchange robot passage 3-400.

In the embodiment shown in Figure 32c, only one container exchange robot 3-200 is installed in the container exchange robot passage 3-400.

Multiple container exchange robots 3-200 may be installed in the container exchange robot passage 3-400. The container exchange robots 3-200 are installed hanging on the shelves 3-120 of one of the sorting devices 3-100 on either side of the container exchange robot passage 3-400, and each is responsible for loading and unloading containers 3-500 in a portion of the two shelves 3-120, thereby improving container exchange efficiency and avoiding the need for the container exchange robots 3-200 to move between them. For example, in the container exchange robot passage 3-400 of the embodiment shown in Figure 32a, two container exchange robots 3-200 are installed, each hanging on the shelves 3-120 of two sorting devices 3-100. Each of the two sorting devices 3-100 has a shelf 3-120 located on the side away from the container exchange robot aisle 3-400, and one container exchange robot 3-200 is installed on each shelf 3-120. This container exchange robot 3-200 is responsible for loading and unloading containers 3-500 from shelf 3-120 and its transfer area 3-140.

According to an embodiment of the present invention, the sorting mechanism 3-110 is installed to perform sorting between two rows of shelves 3-120, and the container exchange robot 3-200 is installed to move containers 3-500 in and out of the container exchange robot passage 3-400, thereby improving the space utilization rate of the sorting system. The container exchange robot 3-200 installed in the container exchange robot passage 3-400 can move containers 3-500 in and out of the shelves 3-120 and the transfer area 3-140 of the two sorting devices 3-100, improving the utilization rate of the container exchange robot 3-200. The container exchange robot 3-200 is also installed on shelves 3-120 that are not adjacent to the container exchange robot passage 3-400 in the sorting device 3-100, ensuring that containers 3-500 on all shelves 3-120 in the sorting system can be automatically exchanged.

In the embodiment shown in Figure 32a, as shown in Figures 32a to 32c, the transfer area 3-140 is located below the storage layer 3-121, the lowest layer of shelf 3-120. A docking layer 3-122 is installed there, for temporarily storing full or empty containers 3-500. The docking layer 3-122 is divided into multiple docking locations 3-1221, each of which is for temporarily storing one full or empty container 3-500.

The container transport device 3-300 is a relay robot 3-300A, which is used to transport empty containers 3-500 to the docking layer 3-122, or to transport fully loaded containers 3-500 from the docking layer 3-122 to the outside of the sorting device 3-100.

The container exchange robot 3-200 is for transporting fully loaded containers 3-500 from the storage layer 3-121 of shelf 3-120 to the docking layer 3-122, or for transporting empty containers 3-500 from the docking layer 3-122 of shelf 3-120 to the storage layer 3-121.

Specifically, the container exchange robot 3-200 moves along the container exchange robot aisle 3-400 to transport a fully loaded container 3-500 from storage area 3-1211 of shelf 3-120 to an empty docking area 3-1221, or to transport an empty container 3-500 from docking area 3-1221 to an empty storage area 3-1211.

The relay robot 3-300A moves along the relay robot passage 3-700 and is intended to transport empty containers 3-500 from outside the sorting device 3-100 to an empty docking location 3-1221, or to transport fully loaded containers 3-500 from docking location 3-1221 to the outside of the sorting device 3-100.

The container exchange robot passage 3-400 is a bidirectional passage, and a portion of the relay robot passage 3-700 overlaps with the container exchange robot passage 3-400. The container exchange robot 3-200 is mounted on shelf 3-120 and has a preset distance from the ground. Therefore, the container exchange robot 3-200 and the relay robot 3-300A can move without interference in the overlapping section of the two passages and move simultaneously to load and unload container 3-500, improving the overall operational efficiency of the sorting system.

According to this embodiment of the present invention, the container exchange robot 3-200 moves the container 3-500 in and out between the storage area 3-1211 and the docking layer 3-122, and the relay robot 3-300A transports the container 3-500 between the docking layer 3-122 and the outside of the sorting device 3-100. This enables automatic exchange of the container 3-500 in the sorting system, improving sorting efficiency and accuracy compared to manual container exchange. The docking layer 3-122 is installed, and both the relay robot 3-300A and the container exchange robot 3-200 dock with the docking layer 3-122 to move the container 3-500 in and out. Compared to a direct docking between the relay robot 3-300A and the container exchange robot 3-200, this improves the transport efficiency of the container 3-500 in the sorting system, thereby improving the overall operational efficiency of the sorting system.

In the embodiment shown in Figure 32a, referring to Figures 33 and 34, Figure 33 is a schematic plan view of the docking layer shown in Figure 32a, and Figure 34 is a schematic perspective view of the relay robot shown in Figure 32a. As shown in Figures 32a, 33, and 34, a groove 3-1222 is installed at the bottom of the docking location 3-1221, and the relay robot 3-300A moves the container 3-500 in and out of the docking location 3-1221 using the groove 3-1222.

The relay robot 3-300A includes a travel mechanism 3-310 and a lift mechanism 3-320, with the lift mechanism 3-320 installed on top of the travel mechanism 3-310.

The relay robot 3-300A is designed so that after the travel mechanism 3-310 moves the lift mechanism 3-320 along the relay robot passage 3-700 to a position corresponding to the docking location 3-1221, it moves to the bottom of the docking location 3-1221, and the lift mechanism 3-320 moves vertically through the groove 3-1222 to lift or place the container 3-500.

Specifically, as shown in Figures 32a and 33, the groove 3-1222 is perpendicular to the longitudinal direction of the shelf 3-120. The width of the groove 3-1222 is smaller than the dimensions of the container 3-500 and larger than the width of the top of the lift mechanism 3-320. This allows the lift mechanism 3-320 to lift or place the container 3-500 through the groove 3-1222, while also preventing the container 3-500 from falling through the groove 3-1222.

The process by which relay robot 3-300A retrieves the fully loaded container 3-500 from docking layer 3-122 is as follows:

The travel mechanism 3-310 of the empty relay robot 3-300A moves the lift mechanism 3-320 along the relay robot passage 3-700 to a position corresponding to the docking location 3-1221, then moves to the bottom of the docking location 3-1221, where the lift mechanism 3-320 rises through the groove 3-1222 to lift the fully loaded container 3-500. The travel mechanism 3-310 then moves the lift mechanism 3-320 along the groove 3-1222 to exit the docking location 3-1221, and subsequently moves away from the sorting device 3-100 along the relay robot passage 3-700.

The process by which relay robot 3-300A places the empty container 3-500 into docking layer 3-122 is as follows:

The travel mechanism 3-310 of the relay robot 3-300A moves the lift mechanism 3-320, which is carrying an empty container 3-500, along the relay robot passage 3-700 to a position corresponding to the docking location 3-1221. Then the lift mechanism 3-320 moves upward and lifts the empty container 3-500, the travel mechanism 3-310 moves below the docking location 3-1221, the lift mechanism 3-320 descends through the groove 3-1222, and after placing the empty container 3-500 at the docking location 3-1221, the travel mechanism 3-310 moves the lift mechanism 3-320 to exit the docking location 3-1221. Subsequently, the relay robot 3-300A can move along the relay robot passage 3-700 to another docking location 3-1221 to receive a fully loaded container 3-500, or it can move along the relay robot passage 3-700 away from the sorting device 3-100 and subsequently receive an empty container 3-500.

According to an embodiment of the present invention, when the relay robot 3-300A connects to the docking layer 3-122, it is positioned at the bottom of the docking layer 3-122, improving the space utilization rate of the sorting system. The lift mechanism 3-320 of the relay robot 3-300A can lift or place the container 3-500 through the groove 3-1222 by vertical movement, allowing for the loading and unloading of the container 3-500 without stopping or temporarily pausing its movement, thereby improving the efficiency of loading and unloading the container 3-500 by the relay robot 3-300A.

In the embodiment shown in Figure 32a, the sorting system further includes a container transfer station 3-600, as shown in Figure 32c.

The relay robot 3-300A moves between shelf 3-120 and container relay station 3-600, and is used to transport empty containers 3-500 from container relay station 3-600 to docking layer 3-122 of shelf 3-120, or to transport fully loaded containers 3-500 from docking layer 3-122 to container relay station 3-600.

Here, the structural configuration of container transfer station 3-600 includes, but is not limited to, transport lines, transfer shelves, etc. The container transfer station 3-600 shown in Figure 32c is a transport line configuration.

Specifically, container transfer station 3-600 transports empty containers 3-500 along the direction toward sorting device 3-100, or receives fully loaded containers transported from transfer robot 3-300A to sorting device 3-100, and then dispatches and packs them.

The process for retrieving the fully loaded container 3-500 is as follows: Container exchange robot 3-200 transports the fully loaded container 3-500 from the storage layer 3-121 of shelf 3-120 to the docking layer 3-122 at the bottom of shelf 3-120. Relay robot 3-300A then moves to the docking layer 3-122, receives the fully loaded container 3-500, and transports it to container relay station 3-600.

The process for receiving the empty container 3-500 is as follows: Relay robot 3-300A moves to container relay station 3-600, receives the empty container 3-500, and transports the empty container 3-500 to docking layer 3-122 at the bottom of shelf 3-120 where the target empty storage location 3-1211 is located. Container exchange robot 3-200 then transports the empty container 3-500 from docking layer 3-122 to the target empty storage location 3-1211.

According to an embodiment of the present invention, the container transfer station 3-600 can transport empty containers 3-500 along the direction toward the sorting device 3-100, or receive fully loaded containers transported from the transfer robot 3-300A to the sorting device 3-100, and then dispatch and pack them. The installation of the container transfer station 3-600 reduces the length of the transfer robot 3-300A's travel path, allowing the transfer robot 3-300A to transport containers 3-500 between the container transfer station 3-600 and the sorting device 3-100. This improves the transport efficiency of the transfer robot 3-300A and enhances the overall operational efficiency of the sorting system.

In the embodiment shown in Figure 32a, as shown in Figure 32c, the container transfer station 3-600 includes a first fully loaded container transport line 3-610 and a first empty container transport line 3-620.

The relay robot 3-300A is for transporting empty containers 3-500 from the first empty container transport line 3-620 to the docking layer 3-122 of shelf 3-120, or for transporting fully loaded containers 3-500 from the docking layer 3-122 to the first fully loaded container transport line 3-610.

Specifically, as shown in Figure 32c, the first fully loaded container transport line 3-610 and the first empty container transport line 3-620 are installed in parallel outside the sorting device 3-100. The first empty container transport line 3-620 is used to place empty containers 3-500 by person or machine, dock with the relay robot 3-300A, and transport the empty containers 3-500 to the relay robot 3-300A.

The first fully loaded container transport line 3-610 is for receiving the fully loaded containers 3-500 from the sorting device 3-100, to which the relay robot 3-300A is transported, and for transporting them to the shipping area for shipping and packaging.

According to an embodiment of the present invention, the container transfer station 3-600 is equipped with two transport lines for transporting a fully loaded container 3-500 and an empty container 3-500, respectively. The transfer robot 3-300A can dock with different transport lines depending on the task it is performing, thereby improving the efficiency of container transport by the sorting system.

In the embodiment shown in Figure 32a, as shown in Figure 32c, a relay robot passage 3-700 is further installed between the container relay station 3-600 and the sorting device 3-100, and the relay robot passage 3-700 extends from the container relay station 3-600 to the sorting device 3-100.

The relay robot 3-300A moves along the relay robot aisle 3-700 and is used to transport empty containers 3-500 from container relay station 3-600 to shelf 3-120 of sorting device 3-100, or to transport fully loaded containers 3-500 from shelf 3-120 of sorting device 3-100 to container relay station 3-600.

The relay robot passage 3-700 includes the first passage 3-710, the second passage 3-720, and the third passage 3-730.

The first passageway 3-710 extends from the container transfer station 3-600 to the sorting device 3-100, and a portion of it overlaps with the container exchange robot passageway 3-400.

The first passage 3-710 is extended to the second passage 3-720 and the third passage 3-730. Of these, the second passage 3-720 is located in the transfer area 3-140, and the third passage 3-730 is located away from the container exchange robot passage 3-400 of the sorting device 3-100. Both the second passage 3-720 and the third passage 3-730 run parallel to the container exchange robot passage 3-400.

The relay robot 3-300A moves along the first passage 3-710 or the third passage 3-730 to a position corresponding to the target position in the docking layer 3-122, then moves to the second passage 3-720 at the bottom of the docking layer 3-122, docks with the docking layer 3-122 to load and unload container 3-500, and then moves back to the first passage 3-710 or the third passage 3-730 to proceed to the container relay station 3-600.

Specifically, as shown in Figure 32c, a portion of the first passage 3-710 is located between the two sorting devices 3-100, and another portion extends to the container transfer station 3-600. Multiple branch passages extend from the first passage 3-710, of which four branch passages are located in the second passage 3-720 of the transfer area 3-140, and two branch passages are located in the third passage 3-730, which is on the side away from the container exchange robot passage 3-400 of the sorting device 3-100.

The process for transporting container 3-500, fully loaded, by relay robot 3-300A is as follows:

The unloaded relay robot 3-300A moves to a position corresponding to the target docking location 3-1221 in the second aisle 3-720, lifts the fully loaded container 3-500 through groove 3-1222, and then exits along groove 3-1222 to the first aisle 3-710 or the third aisle 3-730 outside shelf 3-120, and travels towards container relay station 3-600.

The process by which relay robot 3-300A transports empty container 3-500 is as follows:

The relay robot 3-300A, having received an empty container 3-500 from container relay station 3-600, moves along the first passage 3-710 to a position close to the sorting device 3-100, and then, depending on the position of the target docking location 3-1221, travels along the corresponding first passage 3-710 or third passage 3-730 to a position corresponding to the target docking location 3-1221, lifts the container 3-500, moves to the second passage 3-720 toward the target docking location 3-1221, places the container 3-500, and then may directly move along the second passage 3-720 beneath another docking location 3-1221 to receive a fully loaded container 3-500, or it may exit outside the shelf 3-120 and proceed toward container relay station 3-600 to receive an empty container 3-500.

In the diagram, the widths of the two passages are distinguished by showing the first passage 3-710 and the container exchange robot passage 3-400, but in the actual scenario, the widths of the two passages are not limited. Similarly, the width of the third passage 3-730 is not limited; the relay robot 3-300A can travel in the space away from the container exchange robot passage 3-400 of the sorting device 3-100.

According to this embodiment of the present invention, the installation of the relay robot passage 3-700 allows for the standardization of the movement of the relay robot 3-300A, thereby facilitating the management of multiple relay robots 3-300A in the sorting system. The relay robot 3-300A switches between the first passage 3-710, the second passage 3-720, and the third passage 3-730, moving out of the way of each other to improve container transport efficiency.

In the embodiment shown in Figure 32a, referring to Figure 35, Figure 35 is a schematic perspective view of the container exchange robot shown in Figure 32a. As shown in Figures 32a, 32b, and 35, multiple horizontal rails 3-130 are installed vertically spaced apart on the side of shelf 3-120 closest to the container exchange robot passage 3-400, and the container exchange robot 3-200 is mounted on the outside of shelf 3-120 by the horizontal rails 3-130.

The container exchange robot 3-200 includes a mounting frame 3-210 and a cargo loading/unloading assembly 3-220. The mounting frame 3-210 is movably mounted on a horizontal rail 3-130, and the cargo loading/unloading assembly 3-220 is mounted on the mounting frame 3-210. The assembly can move vertically along the mounting frame 3-210 and horizontally along the horizontal rail 3-130 in conjunction with the mounting frame 3-210 to load and unload containers 3-500 from different locations in the storage layer 3-121 of shelves 3-120 on both sides of the container exchange robot aisle 3-400 and in the transfer area 3-140.

Specifically, the structure of the mounting frame 3-210 can vary; it may be a single door post or a column mast consisting of two door posts, and the present invention does not have any specific limitations on this. In a specific embodiment, as shown in Figures 32a, 32b, and 35, the mounting frame 3-210 is a column mast and includes two door posts 3-211 installed opposite each other. The cargo loading/unloading assembly 3-220 is installed between the two door posts 3-211 of the mounting frame 3-210, and both sides of the assembly are movably connected to one door post 3-211 each.

The cargo loading/unloading assembly 3-220 includes, but is not limited to, fork arm type, suction cup type, drum type, hook arm type, etc. In a specific embodiment, as shown in Figures 32a and 32b, the cargo loading/unloading assembly 3-220 can extend from the mounting frame 3-210 toward the storage layer 3-121 of the shelves 3-120 on both sides of the container exchange robot passage 3-400 or toward the docking layer 3-122 at the bottom of the shelves 3-120, in order to load and unload the container 3-500.

The process by which container exchange robot 3-200 transports a fully loaded container 3-500 is as follows:

The mounting frame 3-210 moves the cargo loading/unloading assembly 3-220 horizontally along the horizontal rail 3-130 to the row where the target storage area 3-1211, containing the fully loaded container 3-500, is located. The cargo loading/unloading assembly 3-220 then moves vertically along the mounting frame 3-210 to the row where the target storage area 3-1211 is located. The cargo loading/unloading assembly 3-220 then extends into the target storage area 3-1211, receives the fully loaded container 3-500, and is retrieved. The cargo loading/unloading assembly 3-220 then moves horizontally along the horizontal rail 3-130 together with the mounting frame 3-210, and vertically moves downward along the mounting frame 3-210 to the empty docking area 3-1221. The cargo loading/unloading assembly 3-220 then extends into the empty docking area 3-1221 and places the fully loaded container 3-500.

The process by which container exchange robot 3-200 transports an empty container 3-500 is as follows:

The mounting frame 3-210 moves the cargo loading/unloading assembly 3-220 horizontally along the horizontal rail 3-130, and the cargo loading/unloading assembly 3-220 moves vertically along the mounting frame 3-210, so that the cargo loading/unloading assembly 3-220 moves to the target docking location 3-1221 where the empty container 3-500 is temporarily placed, and the cargo loading/unloading assembly 3-220 extends out to the target docking location 3-1221, receives the empty container 3-500, and is then retrieved, and the mounting frame 3-210 moves the cargo loading/unloading assembly 3-220 horizontally along the horizontal rail 3-130, and the cargo loading/unloading assembly 3-220 moves vertically along the mounting frame 3-210, so that the cargo loading/unloading assembly 3-220 moves to the empty storage location 3-1211, and the cargo loading/unloading assembly 3-220 extends out to the empty storage location 3-1211, where the empty container 3-500 is placed.

In the process of the container exchange robot 3-200 transporting container 3-500, the order in which the mounting frame 3-210 moves the cargo loading/unloading assembly 3-220 horizontally along the horizontal rail 3-130 and the order in which the cargo loading/unloading assembly 3-220 moves vertically along the mounting frame 3-210 is not fixed. The vertical movement may precede the horizontal movement, or the horizontal movement may precede the vertical movement, or the horizontal and vertical movements may be performed in parallel. This improves the container exchange efficiency of the container exchange robot 3-200.

According to an embodiment of the present invention, the container exchange robot 3-200 can, by means of the horizontal rail 3-130, enable the loading and unloading of containers 3-500 into the storage layer 3-121 or docking layer 3-122 of the shelves 3-120 on both sides of the container exchange robot passage 3-400 in the horizontal direction. Furthermore, by the vertical movement of the cargo loading/unloading assembly 3-220 along the mounting frame 3-210, it can enable the loading and unloading of containers 3-500 into storage layers 3-121 or docking layer 3-122 of the shelves 3-120 at different heights in the vertical direction.

In the embodiment shown in Figure 32a, the sorting mechanism 3-110 shown in Figures 32a to 32c includes a supply table 3-111, a lift mechanism 3-112, a guide mechanism 3-113, and a sorting shuttle 3-114.

The lift mechanism 3-112 is installed at one or both ends of shelf 3-120 and is used to move the sorting shuttle 3-114 up and down along the height direction of shelf 3-120.

The supply platform 3-111 is installed on one or both sides of the lift mechanism 3-112 and docks with the lift mechanism 3-112.

The guide mechanism 3-113 is installed between two rows of shelves 3-120 and includes multiple shuttle rails 3-1131 corresponding to the height of each storage layer 3-121. The shuttle rails 3-1131 dock with the lift mechanism 3-112 to allow the sorting shuttle 3-114 to reciprocate along the longitudinal direction of the shelves 3-120.

The sorting shuttle 3-114 is used by a lift mechanism 3-112 to switch between shuttle rails 3-1131 of different heights, sorting the cargo to be sorted on the supply table 3-111 and placing it into containers 3-500 at storage locations 3-1211 of different heights, and by a guide mechanism 3-113 to sort the cargo to be sorted on the supply table 3-111 and place it into containers 3-500 at storage locations 3-1211 of different lengthwise directions.

Specifically, the supply table 3-111 may be docked with the cargo transport line, and the cargo to be sorted may be transported to the supply table 3-111 by the cargo transport line, or workers may place the cargo to be sorted on the supply table 3-111 and supply it to the sorting shuttle 3-114 for pickup.

The sorting system further includes a control device. The control device is connected to the sorting shuttle 3-114 via communication, and by issuing commands, the control device controls the sorting shuttle 3-114 to place each item to be sorted into its corresponding container 500.

The control device is connected to the lift mechanism 3-112 via communication. The control device transmits commands to control the lift mechanism 3-112, moving the sorting shuttle 3-114 along the height of the shelf 3-120 to the height of the storage layer 3-121 where the corresponding container 3-500 is located. The sorting shuttle 3-114 then moves along the shuttle rail 3-1131 in the storage layer 3-121 to the corresponding container 3-500, and subsequently places the cargo into the container 3-500.

Repeating the above operation, if a container 3-500 on shelf 3-120 is fully loaded with cargo, or if all the cargo in the order associated with that container 3-500 has been sorted, that container 3-500 is considered a fully loaded container 3-500. The control device communicates with the container exchange robot 3-200, which moves the fully loaded container 3-500 from storage layer 3-121 to docking layer 3-122. The relay robot 3-300A then transports the fully loaded container 3-500 away from sorting device 3-100. Subsequently, the container exchange robot 3-200 moves the empty container 3-500 from docking layer 3-122 to an empty storage location 3-1211 in storage layer 3-121.

According to an embodiment of the present invention, the lift mechanism 3-112 and the guide mechanism 3-113 enable the sorting shuttle 3-114 to move in both the height and longitudinal directions of the shelf 3-120. The sorting shuttle 3-114, via the shuttle rail 3-1131, can simultaneously sort orders of containers 3-500 on the two rows of shelves 3-120 of the sorting device 3-100, thereby improving the operational efficiency of the sorting system.

As described above, in the fifth embodiment of the sorting system shown in Figure 32a, the container transport device 3-300 is a relay robot 3-300A, which transports empty containers 3-500 to the docking layer 3-122 of shelves 3-120 on both sides of the container exchange robot passage 3-400, or transports fully loaded containers 3-500 from the docking layer 3-122 to the outside of the sorting device 3-100. In other embodiments of the sorting system, the container transport device 3-300 may be a first container transport line 3-300B or a second container transport line 3-300C.

The following describes in detail a sixth configuration of the sorting system in which the container transport device 3-300 is the first container transport line 3-300B. In this sorting system, the robot dedicated to container exchange is the container exchange robot 3-200, and the transport device capable of transporting containers to the shelves 3-120 on both sides of the sorting mechanism 3-110 in the system, or to a position away from the shelves 3-120, is the first container transport line 3-300B.

Referring to Figures 36a to 36c, Figure 36a is a schematic perspective view of the sorting system according to the sixth embodiment of the present invention, Figure 36b is a schematic plan view of the sorting system shown in Figure 36a, and Figure 36c is a schematic front view of the sorting device shown in Figure 36a.

As shown in Figures 36a to 36c, the handover area 3-140 is located outside one end of the shelf 3-120 in the longitudinal direction.

Container transport equipment 3-300 is the first container transport line 3-300B. The first container transport line 3-300B is installed in two rows, and a portion of each row of the first container transport line 3-300B is located in the delivery area 3-140.

The container exchange robot 3-200 travels along the container exchange robot aisle 3-400, moving between the shelf 3-120 and the handover area 3-140. The container exchange robot 3-200 transports empty containers 3-500 from the first container transport line 3-300B located in the handover area 3-140 to the storage layer 3-121 of shelf 3-120, or transports fully loaded containers 3-500 from the storage layer 3-121 of shelf 3-120 to the first container transport line 3-300B located in the handover area 3-140.

Specifically, Figures 36a to 36c only show the case where the orientation of the first container transport line 3-300B is parallel to the longitudinal direction of the shelf 3-120. However, the actual arrangement of the first container transport line 3-300B needs to be set based on a specific scenario. The first container transport line 3-300B located in the handover area 3-140 needs to be installed parallel to the longitudinal direction of the shelf 3-120 so that the container exchange robot 3-200 can load and unload containers 3-500 on the first container transport line 3-300B. The portion not located in the handover area 3-140 may be arranged based on the source position of empty containers 3-500 and the destination position of fully loaded containers 3-500. The present invention does not have any specific limitations on this.

According to this embodiment of the present invention, the first container transport line 3-300B directly provides empty containers 3-500 to the shelves 3-120, and transports the fully loaded containers 3-500 from shelves 3-120 to the outside of the sorting device 3-100. This eliminates the need to install multiple relay robots 3-300A, reducing the cost of the sorting system. Furthermore, since one row of shelves 3-120 corresponds to one row of the first container transport line 3-300B, the number of container transport devices 3-300 is reduced, making control simpler and maintenance easier. Additionally, by positioning the transfer area 3-140 outside one longitudinal end of shelf 3-120, there is no need to retain space at the bottom of shelf 3-120, allowing for the installation of more storage layers 3-121. This improves the storage density of shelf 3-120 and enhances the storage capacity of the sorting system.

In the embodiment shown in Figure 36a, as shown in Figures 36a to 36c, the horizontal rail 3-130 extends into the transfer area 3-140, allowing the container exchange robot 3-200 to move along the horizontal rail 3-130 between the shelves 3-120 and the transfer area 3-140 in order to load and unload containers 3-500 at different locations on the storage layer 3-121 of the shelves 3-120 on both sides of the container exchange robot passage 3-400 and the first container transport line 3-300B.

In this embodiment, each sorting device 3-100 has one lift mechanism 3-112 in the sorting mechanism 3-110, and the two rows of the first container transport line 3-300B of the sorting device 3-100 are installed corresponding to the ends of the two rows of shelves 3-120 of the sorting device 3-100 that are away from the lift mechanism 3-112.

Except for the number of lift mechanisms 3-112, the structure of the container transport device 3-300, the shelves 3-120 and horizontal rails 3-130, and the location of the transfer area 3-140, the structure of the sorting mechanism 3-110 and the container exchange robot 3-200 in the sorting device 3-100 of this embodiment may be the same as that of the fifth embodiment sorting system shown in Figure 32a, and a detailed explanation is omitted here.

In the embodiment shown in Figure 36a, as shown in Figure 36c, the portion of the first container transport line 3-300B located in the transfer area 3-140 is equipped with one or multiple transfer areas 3-330 spaced apart, and the portion of the first container transport line 3-300B other than the transfer areas 3-330 is the transport area 3-340.

The handover area 3-330 docks with the container exchange robot 3-200, receives the fully loaded container 3-500 transported from the container exchange robot 3-200, and transports it to the transport area 3-340, or receives the empty container 3-500 transported from the transport area 3-340 and provides it for the container exchange robot 3-200 to receive.

Transport area 3-340 is for transporting empty containers 3-500 to delivery area 3-330, or for receiving fully loaded containers 3-500 transported from delivery area 3-330, and for transporting them away from shelf 3-120.

Specifically, the first container transport line 3-300B may be a roller transport line, and both the handover area 3-330 and the transport area 3-340 include multiple rollers, enabling rolling transport by rollers. The first container transport line 3-300B further includes a drive unit (not shown in the drawings), and detection devices (not shown in the drawings) are installed in both the handover area 3-330 and the transport area 3-340. The control device can control the drive unit based on detection information fed back from the detection devices in the handover area 3-330 and the transport area 3-340 to start or stop the rotation of the rollers in the handover area 3-330 or the transport area 3-340.

The transportation process via the first container transport line, 3-300B, is specifically as follows:

When the container exchange robot 3-200 intends to place a fully loaded container 3-500, the control device sends a command to the first container transport line 3-300B, directing it to the transfer area 3-330 of the first container transport line 3-300B and stopping its rolling. Once the rollers in the transfer area 3-330 are stationary and the placement of the fully loaded container 3-500 is complete, the control device directs it to the transfer area 3-330 to resume rolling, and in cooperation with the transport area 3-340, sends the fully loaded container 3-500 to the next processing stage, such as a warehouse or packing plant. When an empty container 3-500 is transported to the transfer area 3-330, the rollers in the transfer area 3-330 stop rolling, the container exchange robot 3-200 picks up the empty container 3-500, and then the first container transport line 3-300B transports the next empty container 3-500 to the transfer area 3-330, waiting for the container exchange robot 3-200 to receive it.

In transport area 3-340, photoelectric sensors may be installed in the area adjacent to the downstream handover area 3-330. When a fully loaded container 3-500 is being placed in the downstream handover area 3-330, or when an empty container 3-500 is placed in the handover area 3-330, the rollers in handover area 3-330 remain stationary. The area in transport area 3-340 away from handover area 3-330 remains in a rolling state. When the photoelectric sensors detect that a container 3-500 is being transported to the area adjacent to the downstream handover area 3-330, the rolling of the adjacent area carrying the container 3-500 stops. After handover area 3-330 begins rolling, the rolling of the adjacent area carrying the container 3-500 also begins, continuing to transport the container 3-500.

Furthermore, if the movement of containers in delivery area 3-330 stops, the sorting system will temporarily suspend the transport of containers 3-500 only in the area adjacent to delivery area 3-330 in the upstream transport area 3-340, and will not affect the transport of containers 2-500 in the area of transport area 3-340 that is separate from delivery area 3-330.

According to this embodiment of the present invention, the transportation in the handover area 3-330 and the transport area 3-340 of the first container transport line 3-300B is independent of each other but also coordinated. The handover area 3-330 and the transport area 3-340 can work together to transport container 3-500. Even if container 3-500 is temporarily placed in the handover area 3-330 and cannot be moved, this does not affect the transportation in the transport area 3-340, improving the operational efficiency of the first container transport line 3-300B. The container exchange robot 3-200 moves along the longitudinal direction of the first container transport line 3-300B, eliminating the need to manually load and unload container 3-500. Simply moving to the handover area 3-330 and docking completes the loading and unloading of container 3-500, improving the efficiency of container 3-500 loading and unloading by the container exchange robot 3-200 and enhancing the sorting efficiency of the sorting system.

In the embodiment shown in Figure 36a, as shown in Figures 36a and 36b, each of the first container transport lines 3-300B in each row includes a second fully loaded container transport line 3-350 and a second empty container transport line 3-360, which are spaced vertically apart.

The container exchange robot 3-200 travels along the container exchange robot aisle 3-400, moving between the shelf 3-120 and the handover area 3-140. The container exchange robot 3-200 transports empty containers 3-500 from the second empty container transport line 3-360 located in the handover area 3-140 to the storage layer 3-121 of shelf 3-120, or transports fully loaded containers 3-500 from the storage layer 3-121 of shelf 3-120 to the second fully loaded container transport line 3-350 located in the handover area 3-140.

Specifically, the concrete structure of the second fully loaded container transport line 3-350 and the second empty container transport line 3-360 is the same, and both consist of one or more transfer areas 3-330 and transport areas 3-340. The second fully loaded container transport line 3-350 may be installed above or below the second empty container transport line 3-360, and the present invention does not limit the vertical positional relationship between the second fully loaded container transport line 3-350 and the second empty container transport line 3-360. As shown in Figures 36a and 36b, the second fully loaded container transport line 3-350 is installed below the second empty container transport line 3-360, and a gap remains between the two transport lines to provide a suitable space for the second fully loaded container transport line 3-350 to transport a fully loaded container 3-500.

In the embodiment shown in Figures 36a and 36b, the arrangement direction of the second empty container transport line 3-360 and the second fully loaded container transport line 3-350 is parallel to the longitudinal direction of shelf 3-120, and the second empty container transport line 3-360 is short, while the second fully loaded container transport line 3-350 is long. In actual applications, the arrangement of the first container transport line 3-300B needs to be set based on a specific scenario, and the present invention does not restrict the length of the second empty container transport line 3-360 and the second fully loaded container transport line 3-350, or their orientation after extending from the delivery area 3-140.

The process for transporting a fully loaded container 3-500 is as follows:

The mounting frame 3-210 moves the cargo loading/unloading assembly 3-220 horizontally along the horizontal rail 3-130 to the row where the target storage area 3-1211, which houses the fully loaded container 3-500, is located. The cargo loading/unloading assembly 3-220 moves vertically along the mounting frame 3-210 to the row where the target storage area 3-1211 is located. The cargo loading/unloading assembly 3-220 extends into the target storage area 3-1211, receives the fully loaded container 3-500, and is then retrieved. The 3-220, together with the mounting frame 3-210, moves horizontally along the horizontal rail 3-130, then vertically along the mounting frame 3-210 to the delivery area 3-330 of the second fully loaded container transport line 3-350 in the delivery area 3-140. The cargo loading/unloading assembly 3-220 then extends into the delivery area 3-330, places the fully loaded container 3-500, and the delivery area 3-330, in conjunction with the transport area 3-340, sends the fully loaded container 3-500 to the next processing stage, such as a warehousing or packing facility.

The process for transporting an empty container 3-500 is as follows:

The mounting frame 3-210 moves the cargo loading/unloading assembly 3-220 horizontally along the horizontal rail 3-130, and the cargo loading/unloading assembly 3-220 moves vertically along the mounting frame 3-210, so that the cargo loading/unloading assembly 3-220 moves to the handover area 3-330 of the second empty container transport line 3-360 where an empty container 3-500 is temporarily placed. The cargo loading/unloading assembly 3-220 extends into the handover area 3-330, receives the empty container 3-500, and is then retrieved. The mounting frame 3-210 moves the cargo loading/unloading assembly 3-220 horizontally along the horizontal rail 3-130, and the cargo loading/unloading assembly 3-220 moves vertically along the mounting frame 3-210, so that the cargo loading/unloading assembly 3-220 moves to the empty storage area 3-1211, so that the cargo loading/unloading assembly 3-220 extends into the empty storage area 3-1211 and places the empty container 3-500.

According to this embodiment of the present invention, the first container transport line 3-300B is divided into a second fully loaded container transport line 3-350 and a second empty container transport line 3-360, which are installed vertically spaced apart. This clarifies the roles of the second fully loaded container transport line 3-350 and the second empty container transport line 3-360, allowing the transport of fully loaded containers 3-500 to the outside of the sorting device 3-100 and the transport of empty containers 3-500 to the transfer area 3-330 to be performed simultaneously, thereby improving the operational efficiency of the first container transport line 3-300B. After the container exchange robot 3-200 places a fully loaded container 3-500 on the second fully loaded container transport line 3-350, it can then retrieve an empty container 3-500 from the second empty container transport line 3-360, simplifying the movement path of the container exchange robot 3-200 and improving its operational efficiency.

The following describes in detail a seventh embodiment of the sorting system in which the container transport device 3-300 is the second container transport line 3-300C. In this sorting system, the robot dedicated to container exchange is the container exchange robot 3-200, and the transport device capable of transporting containers to the shelves 3-120 on both sides of the sorting mechanism 3-110 in the system, or to a position away from the shelves 3-120, is the second container transport line 3-300C.

Referring to Figure 37, which is a schematic plan view of the seventh embodiment of the sorting system of the present invention, the receiving area 3-140 is located below the storage layer 3-121, which is the bottom layer of the shelf 3-120.

Container transport equipment 3-300 is the second container transport line 3-300C.

The second container transport line 3-300C is installed in two rows. Each row of the second container transport line 3-300C is installed at one end of the longitudinal direction of a single rack 3-120 and extends into the delivery area 3-140.

The container exchange robot 3-200 travels along the container exchange robot aisle 3-400 and transports empty containers 3-500 from the second container transport line 3-300C located in the handover area 3-140 to the storage layer 3-121 of the shelves 3-120, or transports fully loaded containers 3-500 from the storage layer 3-121 of the shelves 3-120 to the second container transport line 3-300C located in the handover area 3-140, to the two shelves 3-120 on either side of the container exchange robot aisle 3-400.

Specifically, the difference between the second container transport line 3-300C of this embodiment and the first container transport line 3-300B of the sixth configuration sorting system shown in Figure 36a lies in their installation locations; the structure may be the same. In the portion of the second container transport line 3-300C located in the handover area 3-140, one or more handover areas are installed at intervals. The area outside the handover areas is the transport area, and each row of the second container transport line 3-300C includes a third fully loaded container transport line and a third empty container transport line, installed at vertical intervals. The present invention omits a detailed explanation of the specific structure of the second container transport line 3-300C.

In this embodiment, shelf 3-120 may be made tall enough to accommodate the second container transport line 3-300C at its bottom, in order to provide sufficient height space for the second container transport line 3-300C.

If shelf 3-120 is not raised, the length of one or two storage layers 3-121 that might interfere with the second container transport line 3-300C at the bottom of shelf 3-120 may be shortened. That is, the bottom one or two storage layers 3-121 are shortened towards the lift mechanism 3-112, and two additional door posts are installed and supported at the shortened end. These two door posts, along with two door posts on shelf 3-120 that move away from the lift mechanism 3-112, surround the transfer area 3-140, thereby accommodating the transfer area of the second container transport line 3-300C.

According to this embodiment of the present invention, the second container transport line 3-300C directly provides empty containers 3-500 to shelf 3-120, transporting the fully loaded containers 3-500 from shelf 3-120 to the outside of the sorting device 3-100. This eliminates the need to install a relay robot 3-300A, reducing the cost of the sorting system. Furthermore, the second container transport line 3-300C extends to the bottom of shelf 3-120, improving the space utilization rate of the sorting system. Additionally, the container exchange robot 3-200 can complete the exchange of containers 3-500 simply by moving within the length of shelf 3-120, improving the transport efficiency of the container exchange robot 3-200 and enhancing the overall operational efficiency of the sorting system.

In this embodiment, the sorting mechanism 3-110 of the sorting device 3-100 has only one lift mechanism 3-112. The structure of the sorting mechanism 3-110 and the container exchange robot 3-200 in the sorting device 3-100 of this embodiment may be the same as that of the fifth embodiment of the sorting system shown in Figure 32a. The process of transporting a fully loaded or empty container 3-500 in this embodiment may be the same as that of the sixth embodiment of the sorting system shown in Figure 36a, and a detailed explanation is omitted here.

The eighth embodiment of the sorting system of the present invention will be described in detail below. In this sorting system, the robot dedicated to container exchange is the container exchange robot 3-200. The transport device capable of transporting containers to the auxiliary transfer shelves 3-810 on both sides of the sorting mechanism 3-110 in the system, or to a position away from the auxiliary transfer shelves 3-810, is the relay robot 3-300A of the second container transport line. The transport device capable of transporting containers to the shelves 3-120 on both sides of the sorting mechanism 3-110 in the system, or to a position away from the shelves 3-120, is the auxiliary transport line 3-820.

Referring to Figure 38, which is a schematic plan view of an eighth embodiment of the sorting system of the present invention, the sorting system further includes an auxiliary transfer rack 3-810 or an auxiliary transport line 3-820, as shown in Figure 38.

The auxiliary transfer rack 3-810 or auxiliary transport line 3-820 is installed on the side of the sorting device 3-100 away from the container exchange robot passage 3-400, and is for temporarily storing fully loaded and empty containers 3-500.

The auxiliary transfer rack 3-810 or auxiliary transport line 3-820 can dock with the container exchange robot 3-200 on rack 3-120, which is separated from the container exchange robot passage 3-400 of the sorting device 3-100, in order for the container exchange robot 3-200 to load and unload containers 3-500.

Specifically, as shown in Figure 38, the container transport device 3-300 is a relay robot 3-300A, and an auxiliary transfer rack 3-810 is installed on the side of one sorting device 3-100 away from the container exchange robot passage 3-400, while an auxiliary transport line 3-820 is installed on the side of the other sorting device 3-100 away from the container exchange robot passage 3-400. In other embodiments of the present invention, either the auxiliary transfer rack 3-810 or the auxiliary transport line 3-820 may be installed, and the present invention does not specifically limit this.

According to an embodiment of the present invention, by installing an auxiliary transfer shelf 3-810 or an auxiliary transport line 3-820, it is not necessary to install a transfer area 3-140 at the bottom of the adjacent shelf 3-120, allowing for the installation of more storage layers 3-121 and improving the storage density of shelf 3-120.

If the auxiliary transfer rack 3-810 is installed on the side of the sorting device 3-100 away from the container exchange robot passage 3-400, the container transport device 3-300 becomes the relay robot 3-300A, and there is no need to install the docking layer 3-122 on the rack 3-120 adjacent to the auxiliary transfer rack 3-810.

The specific structure for placing container 3-500 on the auxiliary transfer rack 3-810 may be the same as that of the docking layer 3-122. By dividing it into multiple docking locations 3-1221 and installing grooves 3-1222 at each docking location 3-1221, the relay robot 3-300A can connect to the auxiliary transfer rack 3-810, rise, and load or unload container 3-500.

If the top surface of the lift mechanism 3-320 of the relay robot 3-300A is comb-shaped, comb-shaped grooves corresponding to the above shape may be installed at the docking locations of the auxiliary transfer shelf 3-810 and the docking layer 3-122. The present invention does not have any specific limitations on this, as long as the shape of the grooves corresponds to the shape of the top surface of the lift mechanism 3-320, and the lift mechanism 3-320 can pass through the grooves.

The method by which the relay robot 3-300A docks with the auxiliary transfer shelf 3-810 to load and unload container 3-500 is the same as the method described above for loading and unloading container 3-500 by docking with the docking layer 3-122, and therefore, the explanation is omitted here.

In other embodiments of the present invention, the container transport device 3-300 may be of a different type, or the container transport device 3-300 may not be installed at all, and the container 3-500 on the auxiliary transfer rack 3-810 may be transported by hand. The present invention does not specifically limit these aspects.

If an auxiliary transport line 3-820 is installed on either side of the two sorting devices 3-100 away from the container exchange robot passage 3-400, the container exchange robot 3-200 can work in conjunction with the auxiliary transport line 3-820 to complete the transport of container 3-500. Therefore, the container transport device 3-300 may be of a different type than the relay robot 3-300A, or the container transport device 3-300 may not be installed at all, with the container 3-500 being transported independently by the auxiliary transport line 3-820. The present invention does not have any specific limitations on these arrangements.

The distinction between the auxiliary transport line 3-820 in this embodiment and the first container transport line 3-300B in the sixth configuration sorting system shown in Figure 36a is that while their installation locations differ, their structures are the same. They may include one fully loaded container transport line and one empty container transport line; however, a detailed explanation is omitted here.

In actual applications, whether using the fifth, sixth, seventh, or eighth embodiment described above, or any of the four embodiments described above, the container exchange robot 3-200 is installed on either of the sorting devices 3-100 on either side of the container exchange robot passage 3-400 and can travel along the container exchange robot passage 3-400. For each of the two sorting devices 3-100 on either side of the container exchange robot passage 3-400, the robot is used to transport empty containers 3-500 from their transfer area 3-140 to the storage area of the sorting device 3-100, or to transport full containers 3-500 from their storage area to the transfer area 3-140 of the sorting device 3-100. This improves the utilization rate of the container exchange robot, reduces the cost of the sorting system, enables automated container exchange in the sorting system, and improves sorting efficiency and accuracy compared to manual container exchange. Furthermore, instead of manual container exchange, container exchange by a container exchange robot allows the sorting device's height to exceed the limitations imposed by the worker's height, improving the sorting system's storage capacity, sorting performance, and space utilization. Container transport device 3-300 is used to transport empty containers 3-500 to the delivery area 3-140 of sorting device 3-100, or to transport fully loaded containers 3-500 located in the delivery area 3-140 of sorting device 3-100 to the outside of sorting device 3-100. This enables automated transport of both empty and fully loaded containers 3-500, further improving the overall operational efficiency of the sorting system.

The eight sorting systems described above all utilize two types of devices to automate container exchange, improving sorting efficiency and accuracy compared to manual container exchange. They represent a comprehensive inventive concept in the field of warehouse technology. The first type of device is the first robot (transport robot/container exchange robot), while the second type of device consists of the second robot (relay robot), a container transfer transport line (auxiliary transport line), and either the first or second container transport line. Instead of manual container exchange, container exchange by the first robot (transport robot/container exchange robot) allows the storage shelf height to exceed the limitations imposed by the worker's height, increasing the available container openings on the shelves and improving the sorting performance and space utilization of the sorting system.

The above description represents preferred embodiments of the present invention and is not intended to limit it. Modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the invention should be considered within the scope of protection of the present invention.

In Figures 1 to 22,
Sorting device: 100, Sorting mechanism: 110, Guide mechanism: 111, Shuttle rail: 1111, Sorting shuttle: 112, Storage shelf: 120, Storage layer: 121, Container opening: 1211, Beam: 122; Transfer shelf: 130, Temporary storage area: 131, Groove: 1311, Lift mechanism: 140, Supply table: 150,
First robot: 200, column mast: 210, door post: 211, transport mechanism: 220, lifting assembly: 221, pickup assembly: 222, slide rail: 230,
Second robot: 300, motion chassis: 310, lift mechanism: 320, lift platform: 321,
Container transfer station: 400, Delivery area: 401, Transportation area: 402, Fully loaded container transport line: 410, Empty container replenishment line: 420, Conveyor: 430,
Containers: 500
1st passage: 600, 2nd passage: 700, 3rd passage: 800, 4th passage: 900.
In Figures 23a to 31,
Sorting mechanism: 2-100, Supply table: 2-110, Lift mechanism: 2-120, Guide mechanism: 2-130, Shuttle rail: 2-131, Sorting shuttle: 2-140,
Shelves: 2-200, Storage layer: 2-210, Container opening: 2-211, Storage space: 2-220, Beam: 2-230
Transport robot: 2-300, Column mast: 2-310, Door post: 2-311, Transport mechanism: 2-320, Lifting assembly: 2-321, Pickup assembly: 2-322, Slide rail: 2-330,
Container handover transport line: 2-400, Handover area: 2-410, Transport area: 2-420, Fully loaded container handover transport line: 2-430, Empty container handover transport line: 2-440
Containers: 2-500.
In Figures 32a to 38,
Sorting device: 3-100, Sorting mechanism: 3-110, Supply table: 3-111, Lift mechanism: 3-112, Guide mechanism: 3-113, Shuttle rail: 3-1131, Sorting shuttle: 3-114, Shelf: 3-120, Storage layer: 3-121, Storage area: 3-1211, Docking layer: 3-122, Docking area: 3-1221, Groove: 3-1222, Horizontal rail: 3-130, Transfer area: 3-140,
Container exchange robot: 3-200, mounting frame: 3-210, door post: 3-211, cargo loading/unloading assembly: 3-220,
Container transport equipment: 3-300, relay robot: 3-300A, traveling mechanism: 3-310, lift mechanism: 3-320, first container transport line: 3-300B, handover area: 3-330, transport area: 3-340, second fully loaded container transport line: 3-350, second empty container transport line: 3-360, second container transport line 3-300C,
Container exchange robot aisle: 3-400,
Container: 3-500,
Container transfer station: 3-600, 1st fully loaded container transport line: 3-610, 1st empty container transport line: 3-620
Relay robot passage: 3-700, 1st passage: 3-710, 2nd passage: 3-720, 3rd passage: 3-730,
Auxiliary transfer rack: 3-810, Auxiliary transport line: 3-820.

Claims (55)

A sorting system including a sorting device (100), a first robot (200), and a second robot (300),
The sorting device (100) includes a sorting mechanism (110), a storage shelf (120), and a transfer shelf (130).
The storage rack (120) is installed in two rows and includes multiple storage layers (121), each of which includes multiple container openings (1211), each of which is for storing one container (500) to be loaded.
The aforementioned transfer rack (130) is installed adjacent to the storage rack (120) and is for temporarily placing fully loaded containers (500) or empty containers (500) awaiting replenishment.
The sorting mechanism (110) is installed between two rows of storage shelves (120) and is positioned to receive cargo to be sorted and to transport the cargo to be sorted into the containers (500) of the storage shelves (120).
The first robot (200) is positioned to move a fully loaded container (500) or an empty container (500) between the storage rack (120) and the transfer rack (130).
The second robot (300) is positioned to move a fully loaded container (500) or an empty container (500) between the transfer rack (130) and the container transfer station (400) .
The storage rack (120) includes a plurality of beams (122) installed at intervals in the vertical direction, and the first robot (200) is mounted on the outside of the storage rack (120) by the beams (122).
A sorting system characterized by the following features. The first robot (200) includes a column mast (210), a transport mechanism (220), and at least one slide rail (230),
The column mast (210) is mounted along the vertical direction of the storage shelf (120),
The transport mechanism (220) is installed on the column mast (210) and is for loading and unloading containers (500) at different heights of the storage rack (120).
The at least one slide rail (230) is fixedly mounted to the beam (122), and the column mast (210) is slidably connected to the at least one slide rail (230) so that different containers (500) in the longitudinal direction of the storage rack (120) can be moved in and out by sliding the column mast (210) and transport mechanism (220) horizontally along the beam (122).
The first robot (200) is positioned to move a fully loaded container (500) from a storage shelf (120) to a transfer shelf (130), or to move an empty container (500) from a transfer shelf (130) to a storage shelf (120).
The sorting system according to feature 1 . The transport mechanism (220) includes a lifting assembly (221) and a pickup assembly (222),
The lifting assembly (221) is installed on the column mast (210) and is positioned to move the pickup assembly (222) along the vertical direction.
The pickup assembly (222) is mounted on the lifting assembly (221), protrudes from the column mast (210), and is positioned to load and unload containers (500) from the storage rack (120) or transfer rack (130).
The sorting system according to feature 2 . The transfer rack (130) is a single-layer rack and is arranged along the longitudinal direction of the storage rack (120). The transfer rack (130) is equipped with a plurality of temporary storage spaces (131), each of which is for temporarily storing one fully loaded container (500) or one empty container (500).
The sorting system according to feature 1. A groove (1311) is installed at the bottom of each temporary storage area (131), and the second robot (300) moves the container (500) in and out of the temporary storage area (131) using the groove (1311).
The sorting system according to feature 4 . The second robot (300) includes a motion chassis (310) and a lift mechanism (320), the lift mechanism (320) being installed on top of the motion chassis (310),
The lift mechanism (320) is moved by the moving chassis (310) and is positioned to lift or place the container (500) through the groove (1311) in the vertical direction.
The sorting system according to feature 5 . The transfer shelves (130) are installed in two rows below the storage shelves (120) in correspondence with them, or the transfer shelves (130) are installed in two rows on the side away from the sorting mechanism (110) in correspondence with the storage shelves (120) in each row, and are parallel to the storage shelves (120) with a gap between them.
A sorting system according to claim 1 or 4 . The transfer rack (130) is installed in two rows below the storage rack (120), corresponding to the storage rack (120).
On either side of the storage shelf (120) in each row that is away from the sorting mechanism (110), a first aisle (600) and a second aisle (700) are installed parallel to each other at intervals.
The first passage (600) is closer to the storage shelf (120) than the second passage (700).
The first passage (600) and the second passage (700) extend from the storage rack (120) to the container transfer station (400).
The second robot (300) is configured such that an empty second robot (300) travels along a first aisle (600) to a transfer rack (130), receives a fully loaded container (500) from the transfer rack (130), travels along a second aisle (700) and transports the fully loaded container (500) to a container transfer station (400), or an empty second robot (300) travels along a first aisle (600) to a container transfer station (400), receives an empty container (500) from the container transfer station (400), travels along a second aisle (700) and transports the empty container (500) to the transfer rack (130).
The sorting system according to feature 7 . The transfer shelves (130) are installed in two rows on the side away from the sorting mechanism (110), corresponding to the storage shelves (120) in each row, and are parallel to the storage shelves (120) with a gap between them.
A third passage (800) is provided in the space between the transfer rack (130) and the storage rack (120) in each row, and a fourth passage (900) parallel to the third passage (800) is provided on the side of the transfer rack (130) in each row that is away from the storage rack (120).
The third passage (800) and the fourth passage (900) extend from the storage rack (120) to the container transfer station (400).
The second robot (300) is
An empty second robot (300) is arranged to travel along the third aisle (800) to the transfer rack (130), receive a fully loaded container (500) from the transfer rack (130), travel along the fourth aisle (900) and transport the fully loaded container (500) to the container transfer station (400), or an empty second robot (300) is arranged to travel along the third aisle (800) to the container transfer station (400), receive an empty container (500) from the container transfer station (400), travel along the fourth aisle (900) and transport the empty container (500) to the transfer rack (130).
The sorting system according to feature 7 . The container transfer station (400) includes a fully loaded container transport line (410) and an empty container replenishment line (420),
The second robot (300) is positioned to move a fully loaded container (500) from the transfer rack (130) to the fully loaded container transport line (410), or to move an empty container (500) from the empty container replenishment line (420) to the transfer rack (130).
The sorting system according to feature 1. The sorting device (100) further includes a lift mechanism (140) and a supply table (150), and the sorting mechanism (110) includes a guide mechanism (111) and a sorting shuttle (112).
The lift mechanism (140) is installed at both ends of the storage shelf (120) and, when the sorting shuttle (112) moves to one end of the storage shelf (120), moves the sorting shuttle (112) up and down along the height direction of the storage shelf (120).
The supply platform (150) is installed on one or both sides of the lift mechanism (140) and docks with the lift mechanism (140).
The guide mechanism (111) is installed between two rows of the storage shelves (120) and includes a plurality of shuttle rails (1111) corresponding to the height of each storage layer (121), the shuttle rails (1111) dock with the lift mechanism (140) so that the sorting shuttle (112) moves back and forth along the longitudinal direction of the storage shelves (120).
The sorting shuttle (112) is used by the lift mechanism (140) to switch between shuttle rails (1111) of different heights, sort the cargo to be sorted on the supply table (150) and place it into containers (500) with container openings (1211) of different heights, and by the guide mechanism (111) to sort the cargo to be sorted on the supply table (150) and place it into containers (500) with container openings (1211) of different longitudinal directions.
The sorting system according to feature 1. The sorting system further includes a control device,
The control device is connected via communication to the sorting mechanism (110), the first robot (200), and the second robot (300), and is used to instruct the sorting mechanism (110) to accept the cargo to be sorted, to transport the cargo to be sorted into the containers (500) on the storage rack (120), to instruct the first robot (200) to move a full or empty container (500) between the storage rack (120) and the transfer rack (130), and to instruct the second robot (300) to move a full or empty container (500) between the transfer rack (130) and the container transfer station (400).
The sorting system according to feature 1. A sorting method using a control device, wherein the control device is communicated to the sorting mechanism (110), first robot (200), and second robot (300) of the sorting device (100) in the sorting system described in claim 1, and the sorting method is
The sorting mechanism (110) is instructed to accept the cargo to be sorted, and the cargo to be sorted is transported into a container (500) that is not full in the storage rack (120).
If there is a fully loaded container (500) in the storage rack (120), the first robot (200) is instructed to move the fully loaded container (500) in the storage rack (120) to the transfer rack (130), wherein the fully loaded container (500) is a container that is full of cargo or a container (500) in which all the cargo of the associated order has been sorted.
The second robot (300) is instructed to move the fully loaded container (500) on the transfer rack (130) to the container transfer station (400),
If at least one container opening (1211) in the storage rack (120) is empty, the second robot (300) is instructed to move an empty container (500) from the container transfer station (400) to the transfer rack (130),
This includes instructing the first robot (200) to move an empty container (500) from the transfer rack (130) to an empty container opening (1211) of the storage rack (120),
The transfer rack (130) is installed in two rows below the storage rack (120), and a first passage (600) and a second passage (700) are installed parallel to each other at intervals on either side of the storage rack (120) away from the sorting mechanism (110), the first passage (600) is closer to the storage rack (120) than the second passage (700), and both the first passage (600) and the second passage (700) extend from the storage rack (120) to the container transfer station (400).
To instruct the second robot (300) to move the fully loaded container (500) on the transfer rack (130) to the container transfer station (400) is:
This includes directing an empty second robot (300) to travel along the first aisle (600) to the transfer rack (130), receiving a fully loaded container (500) from the transfer rack (130), traveling along the second aisle (700), and transporting the fully loaded container (500) to the container transfer station (400),
Instructing the second robot (300) to move an empty container (500) from the container transfer station (400) to the transfer rack (130) is:
This includes directing an empty second robot (300) to travel along the first aisle (600) to the container transfer station (400), receiving an empty container (500) from the container transfer station (400), traveling along the second aisle (700), and transporting the empty container (500) to the transfer rack (130),
A sorting method characterized by the following. The transfer racks (130) are installed in two rows on the side away from the sorting mechanism (110) corresponding to the storage racks (120) in each row, and are parallel to the storage racks (120) with a gap between them, and a third passage (800) is installed in the space between the transfer racks (130) and the storage racks (120) in each row, and a fourth passage (900) is installed on the side of the transfer racks (130) in each row away from the storage racks (120) parallel to the third passage (800), and the third passage (800) and the fourth passage (900) extend from the storage racks (120) to the container transfer station (400),
To instruct the second robot (300) to move the fully loaded container (500) on the transfer rack (130) to the container transfer station (400) is:
This includes directing an empty second robot (300) to travel along the third passage (800) to the transfer rack (130), receiving a fully loaded container (500) from the transfer rack (130), traveling along the fourth passage (900), and transporting the fully loaded container (500) to the container transfer station (400),
Instructing the second robot (300) to move an empty container (500) from the container transfer station (400) to the transfer rack (130) is:
This includes directing an empty second robot (300) to travel along the third passage (800) to the container transfer station (400), receiving an empty container (500) from the container transfer station (400), traveling along the fourth passage (900), and transporting the empty container (500) to the transfer rack (130),
The sorting method according to feature 13 . The container transfer station (400) includes a fully loaded container transport line (410) and an empty container replenishment line (420),
To instruct the second robot (300) to move the fully loaded container (500) on the transfer rack (130) to the container transfer station (400) is:
This includes instructing the second robot (300) to move the fully loaded containers (500) on the transfer rack (130) to the fully loaded container transport line (410),
Instructing the second robot (300) to move an empty container (500) from the container transfer station (400) to the transfer rack (130) is:
This includes instructing the second robot (300) to move empty containers (500) in the empty container replenishment line (420) to the transfer rack (130),
The sorting method according to feature 13 . The sorting device (100) further includes a lift mechanism (140) and a supply table (150), the sorting mechanism (110) includes a guide mechanism (111) and a sorting shuttle (112), and the control device is further connected to the lift mechanism (140) and the sorting shuttle (112) via communication.
The sorting mechanism (110) is instructed to receive the cargo to be sorted, and the cargo to be sorted is transported into a container (500) that is not full in the storage rack (120).
The sorting shuttle (112) moves to one end of the storage shelf (120), and the lift mechanism (140) is instructed to move the sorting shuttle (112) up and down along the height direction of the storage shelf (120),
The sorting shuttle (112) is directed and switched between shuttle rails (1111) of different heights by the lift mechanism (140), sorting the cargo to be sorted on the supply table (150) and placing it into containers (500) with container openings (1211) of different heights, and the guide mechanism (111) sorts the cargo to be sorted on the supply table (150) and places it into containers (500) with container openings (1211) of different lengthwise directions.
The sorting method according to feature 13 . A sorting system comprising a sorting mechanism (2-100), shelves (2-200), transport robots (2-300), and a container transfer transport line (2-400),
The shelf (2-200) is arranged in two rows and includes a plurality of storage layers (2-210) spaced vertically apart, each of which includes a plurality of container openings (2-211), each of which is for storing one container (2-500) to be loaded.
The sorting mechanism (2-100) is installed between two rows of shelves (2-200) and is positioned to receive cargo to be sorted and to transport the cargo to be sorted into the containers (2-500) on the shelves (2-200).
The container transfer transport line (2-400) is installed adjacent to the rack (2-200) and is configured to transport empty containers (2-500) toward the rack (2-200) or to transport fully loaded containers (2-500) away from the rack (2-200).
The transport robot (2-300) is positioned between the shelf (2-200) and the container transfer transport line (2-400) to load and unload fully loaded containers (2-500) or empty containers (2-500).
A sorting system characterized by the following features. The container transfer transport line (2-400) is installed in two rows, and each row is docked with the two rows of shelves (2-200), so that the transport robot (2-300) can move loaded containers (2-500) or empty containers (2-500) between the shelves (2-200) and the container transfer transport line (2-400).
The sorting system according to feature 17 . The container transfer transport line (2-400) is equipped with one or more transfer areas (2-410).
The transport robot (2-300) is configured to transport a fully loaded container (2-500) from the shelf (2-200) to the transfer area (2-410) of the container transfer transport line (2-400), or to transport an empty container (2-500) from the transfer area (2-410) of the container transfer transport line (2-400) to the shelf (2-200).
The sorting system according to feature 18 . The portion of the container delivery and transport line (2-400) other than the delivery area (2-410) is the transport area (2-420),
The transport area (2-420) is for transporting empty containers (2-500) to the delivery area (2-410), or for receiving fully loaded containers (2-500) transported from the delivery area (2-410) and transporting them away from the shelves (2-200).
The sorting system according to feature 19 . When the transport robot (2-300) needs to place the fully loaded container (2-500) in the transfer area (2-410), the transfer area (2-410) stops rolling, and when the placement is complete, it resumes rolling and, in cooperation with the transport area (2-420), transports the fully loaded container (2-500) and moves away.
When an empty container (2-500) is transported to the transfer area (2-410), the rolling of the transfer area (2-410) stops, and the rolling resumes once the transport robot (2-300) has picked up the empty container (2-500), and continues rolling until the next empty container (2-500) is transported to the transfer area (2-410).
When a container (2-500) in the transport area (2-420) is transported to an area adjacent to the delivery area (2-410), and the delivery area (2-410) is in a stopped state, the area in the transport area (2-420) on which the container (2-500) is placed stops rolling, and after the delivery area (2-410) starts rolling, the area on which the container (2-500) is placed also starts rolling, and the container (2-500) continues to be transported.
The sorting system according to claim 20 . The container transfer transport line (2-400) is installed on the side of the shelf (2-200) away from the sorting mechanism (2-100), and the transfer area (2-410) of the container transfer transport line (2-400) is installed at intervals parallel to the longitudinal direction of the shelf (2-200).
The sorting system according to feature 19 . The container transfer transport line (2-400) is installed at one end of the shelf (2-200) in the longitudinal direction, and a storage space (2-220) is installed at the bottom of the end of the shelf (2-200) closest to the container transfer transport line (2-400), and the transfer area (2-410) of the container transfer transport line (2-400) extends into the storage space (2-220).
The sorting system according to feature 19 . Each of the container transfer lines (2-400) includes a fully loaded container transfer line (2-430) and an empty container transfer line (2-440) installed at vertical intervals, and the transport robot (2-300) is arranged to transport fully loaded containers (2-500) from the shelves (2-200) to the fully loaded container transfer line (2-430), or to transport empty containers (2-500) from the empty container transfer line (2-440) to the shelves (2-200).
The sorting system according to feature 18 . The shelf (2-200) includes a plurality of beams (2-230) installed at intervals in the vertical direction, and the transport robot (2-300) is mounted on the outside of the shelf (2-200) by the beams (2-230).
The sorting system according to feature 18 . The transport robot (2-300) includes a column mast (2-310), a transport mechanism (2-320), and at least one slide rail (2-330).
The column mast (2-310) is mounted along the vertical direction of the shelf (2-200),
The transport mechanism (2-320) is installed on the column mast (2-310) and is for loading and unloading containers (2-500) at different heights of the shelves (2-200) or the container transfer transport line (2-400).
The at least one slide rail (2-330) is fixedly mounted to the beam (2-230), and the column mast (2-310) is slidably connected to the at least one slide rail (2-330) so as to slide the column mast (2-310) and the transport mechanism (2-320) horizontally along the beam (2-230) to load and unload different containers (2-500) along the longitudinal direction of the shelf (2-200) or the container transfer transport line (2-400).
The sorting system according to claim 25 , characterized in that it is the same as described in claim 25. The transport mechanism (2-320) includes a lifting assembly (2-321) and a pickup assembly (2-322).
The lifting assembly (2-321) is installed on the column mast (2-310) and is positioned to move the pickup assembly (2-322) along the vertical direction.
The pickup assembly (2-322) is mounted on the lifting assembly (2-321) and protrudes from the column mast (2-310) toward the rack (2-200) or the container transfer transport line (2-400), and is positioned to load and unload containers (2-500) from the rack (2-200) or the container transfer transport line (2-400).
The sorting system according to feature 26 . The transport robots (2-300) are multiple, and there is at least one transport robot (2-300) that moves containers (2-500) between the shelves (2-200) in each row and the container transfer transport line (2-400), and each transport robot (2-300) is for transporting containers (2-500) within a preset length section of the shelves (2-200).
The sorting system according to feature 17 . The sorting mechanism (2-100) includes a supply table (2-110), a lift mechanism (2-120), a guide mechanism (2-130), and a sorting shuttle (2-140).
The lift mechanism (2-120) is installed at both ends of the shelf (2-200) and is used to move the sorting shuttle (2-140) up and down along the height direction of the shelf (2-200).
The supply platform (2-110) is installed on one or both sides of the lift mechanism (2-120) and docks with the lift mechanism (2-120).
The guide mechanism (2-130) is installed between two rows of shelves (2-200) and includes a plurality of shuttle rails (2-131) corresponding to the height of each storage layer (2-210), the shuttle rails (2-131) dock with the lift mechanism (2-120) so that the sorting shuttle (2-140) moves back and forth along the longitudinal direction of the shelves (2-200),
The sorting shuttle (2-140) is used by the lift mechanism (2-120) to switch between shuttle rails (2-131) of different heights, sort the cargo to be sorted on the supply table (2-110) and place it into containers (2-500) with different height container openings (2-211), and by the guide mechanism (2-130) to sort the cargo to be sorted on the supply table (2-110) and place it into containers (2-500) with different longitudinal container openings (2-211).
The sorting system according to feature 17 . The sorting system further includes a control device,
The control device is connected via communication to the sorting mechanism (2-100), the transport robot (2-300), and the container transfer transport line (2-400), and is used to instruct the sorting mechanism (2-100) to accept cargo to be sorted, to transport the cargo to be sorted into the container (2-500) on the shelf (2-200), to instruct the transport robot (2-300) to move a fully loaded container (2-500) or an empty container (2-500) between the shelf (2-200) and the container transfer transport line (2-400), and to instruct the container transfer transport line (2-400) to transport an empty container (2-500) toward the shelf (2-200), or to transport a fully loaded container (2-500) toward the shelf (2-200).
The sorting system according to any one of claims 17 to 29 . A sorting method using a control device, wherein the control device is connected to a sorting mechanism (2-100), a transport robot (2-300), and a container transfer transport line (2-400) in the sorting system described in claim 17 , and the sorting method is
The container transfer transport line (2-400) is instructed to start up so that it can transport empty containers (2-500) toward the shelves (2-200) and fully loaded containers (2-500) toward the shelves (2-200).
The sorting mechanism (2-100) is instructed to accept the cargo to be sorted, and the cargo to be sorted is transported into a container (2-500) on the shelf (2-200) that is not full.
If there is a fully loaded container (2-500) on the shelf (2-200), the transport robot (2-300) is instructed to move the fully loaded container (2-500) on the shelf (2-200) to the container transfer transport line (2-400),
The system includes, if at least one container opening (2-211) is available on the shelf (2-200), instructing the transport robot (2-300) to move an empty container (2-500) from the container transfer transport line (2-400) to the available container opening (2-211) on the shelf (2-200),
A sorting method characterized by the following. The container transfer transport line (2-400) includes a fully loaded container transfer transport line (2-430) and an empty container transfer transport line (2-440) that are spaced apart in the vertical direction.
To instruct and activate the container transfer transport line (2-400) so that it can transport empty containers (2-500) toward the shelves (2-200) and fully loaded containers (2-500) toward the shelves (2-200),
This includes instructing and activating the fully loaded container transfer line (2-430) and the empty container transfer line (2-440) in the container transfer line (2-400) so that the empty container transfer line (2-440) can transport empty containers (2-500) toward the shelves (2-200), and the fully loaded container transfer line (2-430) can transport fully loaded containers (2-500) toward the shelves (2-200),
If there is a fully loaded container (2-500) on the shelf (2-200), the transport robot (2-300) is instructed to move the fully loaded container (2-500) on the shelf (2-200) to the container transfer transport line (2-400).
If there is a fully loaded container (2-500) on the shelf (2-200), the transport robot (2-300) is instructed to move the fully loaded container (2-500) on the shelf (2-200) to the container transfer transport line (2-430),
If at least one container opening (2-211) is available on the shelf (2-200), the transport robot (2-300) is instructed to move an empty container (2-500) from the container transfer transport line (2-400) to the available container opening (2-211) on the shelf (2-200).
This includes, if at least one container opening (2-211) is available on the shelf (2-200), instructing the transport robot (2-300) to move an empty container (2-500) from the empty container transfer transport line (2-440) to the available container opening (2-211) on the shelf (2-200),
The sorting method according to feature 31 . The container transfer transport line (2-400) is provided with one or more transfer areas (2-410), and the area other than the transfer areas (2-410) is a transport area (2-420).
To instruct and activate the container transfer transport line (2-400) so that it can transport empty containers (2-500) toward the shelves (2-200) and fully loaded containers (2-500) toward the shelves (2-200),
This includes instructing and activating the container transfer transport line (2-400) so that the transport area (2-420) in the container transfer transport line (2-400) can transport empty containers (2-500) to the transfer area (2-410), receive fully loaded containers (2-500) transported from the transfer area (2-410) and transport them away from the shelves (2-200), and so that the transfer area (2-410) can transport fully loaded containers (2-500) to the transport area (2-420),
If there is a fully loaded container (2-500) on the shelf (2-200), the transport robot (2-300) is instructed to move the fully loaded container (2-500) on the shelf (2-200) to the container transfer transport line (2-400).
If a fully loaded container (2-500) is found on the shelf (2-200), the transport robot (2-300) is instructed to move the fully loaded container (2-500) on the shelf (2-200) to the transfer area (2-410), including the following:
If at least one container opening (2-211) is available on the shelf (2-200), the transport robot (2-300) is instructed to move an empty container (2-500) from the container transfer transport line (2-400) to the available container opening (2-211) on the shelf (2-200).
This includes, if at least one container opening (2-211) is available on the shelf (2-200), instructing the transport robot (2-300) to move an empty container (2-500) in the transfer area (2-410) to the available container opening (2-211) on the shelf (2-200),
The sorting method according to feature 31 . If there is a fully loaded container (2-500) on the shelf (2-200), the transport robot (2-300) is instructed to move the fully loaded container (2-500) on the shelf (2-200) to the transfer area (2-410), further,
When it is necessary to place the container (2-500) fully loaded by the transport robot (2-300) into the transfer area (2-410), the robot will indicate the transfer area (2-410) and stop rolling.
After the transport robot (2-300) places the fully loaded container (2-500) in the transfer area (2-410), it instructs the transfer area (2-410) to begin rolling, and in cooperation with the transport area (2-420), transports the fully loaded container (2-500) away from the shelf (2-200).
The system includes the following: when a container (2-500) in the transport area (2-420) is transported to an area adjacent to the delivery area (2-410), and the delivery area (2-410) is in a stopped state, a photoelectric sensor installed in the transport area (2-420) triggers the stopping of the area in the transport area (2-420) on which the container (2-500) is placed, and after the delivery area (2-410) starts to move, the area on which the container (2-500) is placed also starts to move, and the transport of the container (2-500) continues.
If at least one container opening (2-211) is available on the shelf (2-200), instructing the transport robot (2-300) to move an empty container (2-500) in the transfer area (2-410) to the available container opening (2-211) on the shelf (2-200) is further,
If an empty container (2-500) is placed in the handover area (2-410), the handover area (2-410) will be indicated and the rolling will be stopped.
If there are no empty containers (2-500) in the delivery area (2-410), the transport area (2-420) will be instructed to transport the empty containers (2-500) to the delivery area (2-410),
This includes the transport robot (2-300) taking an empty container (2-500) from the handover area (2-410), then directing the handover area (2-410) to begin rolling, and then directing the transport area (2-420) to transport the next empty container (2-500) to the handover area (2-410),
The sorting method according to feature 33 . The sorting mechanism (2-100) includes a supply table (2-110), a lift mechanism (2-120), a guide mechanism (2-130), and a sorting shuttle (2-140), the guide mechanism (2-130) including a plurality of shuttle rails (2-131), and the control device is further connected to the lift mechanism (2-120) and the sorting shuttle (2-140) via communication.
The sorting mechanism (2-100) is instructed to accept the cargo to be sorted, and the cargo to be sorted is transported into the empty container (2-500) on the shelf (2-200).
When the sorting shuttle (2-140) moves to one end of the shelf (2-200), the lift mechanism (2-120) is instructed to move the sorting shuttle (2-140) up and down along the height direction of the shelf (2-200),
This includes: directing the sorting shuttle (2-140) and switching it between shuttle rails (2-131) of different heights using the lift mechanism (2-120); sorting the cargo to be sorted on the supply table (2-110) and placing it into containers (2-500) with different height container openings (2-211); and sorting the cargo to be sorted on the supply table (2-110) and placing it into containers (2-500) with different longitudinal container openings (2-211);
The sorting method according to feature 31 . A control device,
Memory for running computer programs,
When a program stored in memory is executed, a processor for realizing the sorting method described in any one of claims 13 to 16 and 31 to 35 is included,
A control device characterized by the following features. A computer-readable storage medium, wherein a computer program is stored in the computer-readable storage medium, and when the computer program is executed by a processor, the sorting method described in any one of claims 13 to 16 and 31 to 35 is realized.
A computer-readable storage medium characterized by the following features. A sorting system comprising at least two sorting devices (3-100), a container exchange robot (3-200), and a container transport device (3-300),
The at least two sorting devices (3-100) are installed in parallel with a gap between them, and a container exchange robot passage (3-400) is formed between two adjacent sorting devices (3-100) in parallel, and each of the sorting devices (3-100) sorts the received cargo to be sorted and places it into each container (3-500).
The aforementioned two sorting devices (3-100) are equipped with a storage area for storing containers (3-500) and a transfer area (3-140) for docking with a container transport device (3-300).
The container transport device (3-300) is for transporting empty containers (3-500) to the delivery area (3-140) of the sorting device (3-100), or for transporting fully loaded containers (3-500) located in the delivery area (3-140) of the sorting device (3-100) to the outside of the sorting device (3-100).
The container exchange robot (3-200) is installed by hanging on either of the sorting devices (3-100) on either side of the container exchange robot passage (3-400), and is capable of traveling along the container exchange robot passage (3-400). Its purpose is to transport empty containers (3-500) from the transfer area (3-140) of each of the two sorting devices (3-100) on either side of the container exchange robot passage (3-400) to the storage area of the sorting device (3-100), or to transport fully loaded containers (3-500) from the storage area to the transfer area (3-140) of the sorting device (3-100).
A sorting system characterized by the following features. The sorting device (3-100) includes a sorting mechanism (3-110) and shelves (3-120),
The shelves (3-120) are arranged in two rows, the storage area is located on the shelves (3-120), and multiple storage layers (3-121) are installed at intervals along the vertical direction.
The sorting mechanism (3-110) is installed between two rows of shelves (3-120) and is for receiving cargo to be sorted and transporting the cargo to be sorted into each container (3-500) on the shelves (3-120).
The container exchange robot (3-200) is installed on the side of the sorting mechanism (3-110) away from the sorting device (3-100) on either side of the container exchange robot aisle (3-400), and the container exchange robot (3-200) is used to transport empty containers (3-500) from the transfer area (3-140) to the storage layer (3-121) of the shelf (3-120), or to transport fully loaded containers (3-500) from the storage layer (3-121) of the shelf (3-120) to the transfer area (3-140).
The sorting system according to claim 38 , characterized in that way. The sorting system according to claim 39, characterized in that, in each of the two shelves (3-120) of the sorting device (3-100), if only one shelf (3-120) is adjacent to a container exchange robot passage (3-400), at least one container exchange robot (3-200) is installed on the side of the other shelf (3-120) that is away from the sorting mechanism (3-110) . The aforementioned transfer area (3-140) is located below the storage layer (3-121) of the bottom layer of the shelf (3-120), and a docking layer (3-122) is installed there for temporarily storing fully loaded containers (3-500) or empty containers (3-500).
The container transport device (3-300) is a relay robot (3-300A), and the relay robot (3-300A) is for transporting empty containers (3-500) to the docking layer (3-122), or for transporting fully loaded containers (3-500) from the docking layer (3-122) to the outside of the sorting device (3-100).
The container exchange robot (3-200) is for transporting a fully loaded container (3-500) from the storage layer (3-121) of the shelf (3-120) to the docking layer (3-122), or for transporting an empty container (3-500) from the docking layer (3-122) of the shelf (3-120) to the storage layer (3-121).
The sorting system according to feature 40 . The sorting system further includes a container transfer station (3-600),
The relay robot (3-300A) moves between the shelf (3-120) and the container relay station (3-600) and transports empty containers (3-500) from the container relay station (3-600) to the docking layer (3-122) of the shelf (3-120), or transports fully loaded containers (3-500) from the docking layer (3-122) to the container relay station (3-600).
The sorting system according to feature 41 . The container transfer station (3-600) includes a first fully loaded container transport line (3-610) and a first empty container transport line (3-620),
The relay robot (3-300A) is for transporting empty containers (3-500) from the first empty container transport line (3-620) to the docking layer (3-122) of the shelf (3-120), or for transporting fully loaded containers (3-500) from the docking layer (3-122) to the first fully loaded container transport line (3-610).
The sorting system according to feature 42 . Between the container transfer station (3-600) and the sorting device (3-100), a transfer robot passage (3-700) is further installed.
The relay robot passage (3-700) extends from the container relay station (3-600) to the sorting device (3-100),
The relay robot (3-300A) moves along the relay robot passage (3-700) and transports empty containers (3-500) from the container relay station (3-600) to the shelves (3-120) of the sorting device (3-100), or transports fully loaded containers (3-500) from the shelves (3-120) of the sorting device (3-100) to the container relay station (3-600).
The sorting system according to feature 42 . The relay robot passage (3-700) includes a first passage (3-710), a second passage (3-720), and a third passage (3-730).
The first passage (3-710) extends from the container transfer station (3-600) to the sorting device (3-100), and a portion of it overlaps with the container exchange robot passage (3-400).
The first passage (3-710) is extended to the second passage (3-720) and the third passage (3-730),
The second passage (3-720) is located in the transfer area (3-140), the third passage (3-730) is located away from the container exchange robot passage (3-400) of the sorting device (3-100), and both the second passage (3-720) and the third passage (3-730) are parallel to the container exchange robot passage (3-400).
The relay robot (3-300A) moves along the first passage (3-710) or the third passage (3-730) to a position corresponding to the target position on the docking layer (3-122), then moves to the second passage (3-720) at the bottom of the docking layer (3-122), docks with the docking layer (3-122), loads and unloads containers (3-500), then moves to the first passage (3-710) or the third passage (3-730) to proceed to the container relay station (3-600).
The sorting system according to feature 44 . The docking layer (3-122) is divided into multiple docking locations (3-1221), and each of the docking locations (3-1221) is for temporarily placing one fully loaded container (3-500) or an empty container (3-500).
A groove (3-1222) is installed at the bottom of the docking location (3-1221), and the relay robot (3-300A) moves the container (3-500) in and out of the docking location (3-1221) using the groove (3-1222).
The sorting system according to feature 41 . The relay robot (3-300A) includes a travel mechanism (3-310) and a lift mechanism (3-320), the lift mechanism (3-320) being installed on top of the travel mechanism (3-310),
The relay robot (3-300A) is configured such that the traveling mechanism (3-310) moves the lift mechanism (3-320) along the container exchange robot passage (3-400) to a position corresponding to the docking location (3-1221), then moves to the bottom of the docking location (3-1221), and the lift mechanism (3-320) moves vertically through the groove (3-1222) to lift or place the container (3-500).
The sorting system according to claim 46 . The sorting system further includes an auxiliary transfer rack (3-810) or an auxiliary transport line (3-820),
The auxiliary transfer rack (3-810) or auxiliary transport line (3-820) is installed on the side of the sorting device (3-100) away from the container exchange robot passage (3-400) and is for temporarily storing fully loaded containers (3-500) and empty containers (3-500).
The auxiliary transfer rack (3-810) or auxiliary transport line (3-820) can dock with the container exchange robot (3-200) at a rack (3-120) away from the container exchange robot passage (3-400) of the sorting device (3-100) in order for the container exchange robot (3-200) to load and unload containers (3-500).
The sorting system according to feature 40 . The aforementioned handover area (3-140) is located outside one end of the shelf (3-120) in the longitudinal direction.
The container transport device (3-300) is a first container transport line (3-300B), and the first container transport line (3-300B) is installed in two rows, with a portion of each row of the first container transport line (3-300B) installed in the delivery area (3-140).
The container exchange robot (3-200) moves along the container exchange robot aisle (3-400) to move between the shelves (3-120) and the handover area (3-140), and for the two shelves (3-120) on both sides of the container exchange robot aisle (3-400), the container exchange robot (3-200) is used to transport empty containers (3-500) from the first container transport line (3-300B) located in the handover area (3-140) to the storage layer (3-121) of the shelves (3-120), or to transport fully loaded containers (3-500) from the storage layer (3-121) of the shelves (3-120) to the first container transport line (3-300B) located in the handover area (3-140).
The sorting system according to feature 39 . In the portion of the first container transport line (3-300B) located in the handover area (3-140), one or more handover areas (3-330) are installed at intervals, and the portion of the first container transport line (3-300B) other than the handover areas (3-330) is the transport area (3-340).
The aforementioned transfer area (3-330) is for docking with the container exchange robot (3-200), receiving fully loaded containers (3-500) transported from the container exchange robot (3-200) and transporting them to the transport area (3-340), or for receiving empty containers (3-500) transported from the transport area (3-340) to be provided for the container exchange robot (3-200) to receive.
The transport area (3-340) is for transporting empty containers (3-500) to the delivery area (3-330), or for receiving fully loaded containers (3-500) transported from the delivery area (3-330) and transporting them away from the shelves (3-120).
The sorting system according to feature 49 . Each row of the first container transport line (3-300B) includes a second fully loaded container transport line (3-350) and a second empty container transport line (3-360) that are spaced apart in the vertical direction.
The container exchange robot (3-200) moves along the container exchange robot aisle (3-400) to move between the shelves (3-120) and the handover area (3-140), and for the two shelves (3-120) on both sides of the container exchange robot aisle (3-400), the container exchange robot (3-200) transports empty containers (3-500) from the second empty container transport line (3-360) located in the handover area (3-140) to the storage layer (3-121) of the shelves (3-120), or transports fully loaded containers (3-500) from the storage layer (3-121) of the shelves (3-120) to the second fully loaded container transport line (3-350) located in the handover area (3-140).
The sorting system according to feature 49 . The aforementioned handover area (3-140) is located below the storage layer (3-121) of the bottom layer of the shelf (3-120).
The container transport device (3-300) is the second container transport line (3-300C),
The second container transport line (3-300C) is installed in two rows, and each row of the second container transport line (3-300C) is installed at one end of the longitudinal direction of one of the shelves (3-120) and extends into the delivery area (3-140).
The container exchange robot (3-200) travels along the container exchange robot aisle (3-400) and transports empty containers (3-500) from the second container transport line (3-300C) located in the handover area (3-140) to the storage layer (3-121) of the shelves (3-120), or transports fully loaded containers (3-500) from the storage layer (3-121) of the shelves (3-120) to the second container transport line (3-300C) located in the handover area (3-140), to the two shelves (3-120) on both sides of the container exchange robot aisle (3-400).
The sorting system according to feature 39 . On the side of the shelf (3-120) closest to the container exchange robot passage (3-400), multiple horizontal rails (3-130) are installed at vertical intervals, and the container exchange robot (3-200) is mounted on the outside of the shelf (3-120) by the horizontal rails (3-130).
The container exchange robot (3-200) includes a mounting frame (3-210) and a cargo loading/unloading assembly (3-220), and the mounting frame (3-210) is movably mounted on the horizontal rail (3-130) to load and unload containers (3-500) from different locations in the storage layer (3-121) and the handover area (3-140) of the shelves (3-120) on both sides of the container exchange robot aisle (3-400), and the cargo loading/unloading assembly (3-220) is installed on the mounting frame (3-210) and can move vertically along the mounting frame (3-210) and horizontally along the horizontal rail (3-130) together with the mounting frame (3-210).
The sorting system according to feature 39 . The aforementioned handover area (3-140) is located outside one end of the shelf (3-120) in the longitudinal direction.
The container transport device (3-300) is a first container transport line (3-300B), and the first container transport line (3-300B) is installed in two rows, with a portion of each row of the first container transport line (3-300B) installed in the delivery area (3-140).
The horizontal rail (3-130) extends into the delivery area (3-140) so that the container exchange robot (3-200) moves along the horizontal rail (3-130) between the shelves (3-120) and the handover area (3-140), thereby allowing the container exchange robot (3-200) to move in and out of the storage layer (3-121) of the shelves (3-120) on both sides of the container exchange robot passage (3-400) and containers (3-500) at different positions in the first container transport line (3-300B).
The sorting system according to claim 53 . The sorting mechanism (3-110) includes a supply table (3-111), a lift mechanism (3-112), a guide mechanism (3-113), and a sorting shuttle (3-114).
The lift mechanism (3-112) is installed at one or both ends of the shelf (3-120) and is used to move the sorting shuttle (3-114) up and down along the height direction of the shelf (3-120).
The supply platform (3-111) is installed on one or both sides of the lift mechanism (3-112) and docks with the lift mechanism (3-112).
The guide mechanism (3-113) is installed between two rows of shelves (3-120) and includes a plurality of shuttle rails (3-1131) corresponding to the height of each storage layer (3-121), the shuttle rails (3-1131) dock with the lift mechanism (3-112) so that the sorting shuttle (3-114) moves back and forth along the longitudinal direction of the shelves (3-120),
The sorting shuttle (3-114) is used by the lift mechanism (3-112) to switch between shuttle rails (3-1131) of different heights, sort the cargo to be sorted on the supply table (3-111) and place it into containers (3-500) in storage locations (3-1211) of different heights, and by the guide mechanism (3-113) to sort the cargo to be sorted on the supply table (3-111) and place it into containers (3-500) in storage locations (3-1211) of different lengths.
The sorting system according to feature 39 .