JPH0321442B2 - - Google Patents

Description

[Detailed description of the invention] [Table of contents] - Overview - Industrial application field - Conventional technology - Problems to be solved by the invention - Means for solving the problems - Effects - Examples - Effects [Summary] When loading and unloading packaging boxes into and out of the goods storage means of an automated warehouse, picking is carried out separately and separately from shipping, and re-stocking is carried out, and at the time of shipping, all packaging boxes in ready-to-ship condition in the goods storage means are picked. We will ship more.
Thereby, picking and shipping operations can be performed efficiently and without errors.

[Industrial application field]

The present invention relates to a control method and apparatus for an automatic warehouse that automatically performs loading and unloading operations of articles, and particularly to an automatic warehouse control method and apparatus suitable for cases where picking operations are required.

[Conventional technology]

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

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

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

As shown in FIG. 10, each horizontal rotating shelf 220 is
Rubber roller 222 placed on frame 221
The tray 223 is connected to the top and rotates. Each horizontal rotating shelf 220 is independently controlled to rotate.

As shown in FIG. 10, each tray 223 has a single storage compartment configuration of one stage and one row for storing one storage box. Each horizontal rotating shelf 220 is rotationally controlled using this single storage compartment as one unit of movement.

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

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

Each transfer table 250 and 270 has a horizontal rotary shelf 22
A plurality of transfer shelves are provided corresponding to each stage of 0.
The transfer table 250 on the warehousing side is a buffer for temporarily holding the storage boxes entering the horizontal rotating shelf 220, and the outgoing transfer table 270 temporarily holds the storage boxes taken out from the horizontal rotating shelf 220. It's a buffer to keep it there.

Each transfer machine 240 and 260 is equipped with one lifting platform (not shown). The warehousing transfer machine 240 transports the storage boxes conveyed from the warehousing line 230 to a predetermined transfer shelf on the warehousing transfer table 250. The outgoing transfer machine 260 receives the storage box taken out from the horizontal rotary shelf 220 and placed on the transfer shelf of the outgoing transfer table 270, transports it up and down, and carries it out to the outgoing line (not shown).

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

The storage boxes are moved between the transfer table 250 and the horizontal rotating shelf 220 by pushers (not shown) provided at each stage of the transfer table.

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

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

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

(A) Warehousing operation The storage boxes transported to the automated warehouse are transported to the warehousing transfer machine 240 by the warehousing line 230.

When the warehousing transfer machine 240 transports the storage box to the transfer shelf of the warehousing transfer platform 250 that corresponds to the horizontal rotating shelf 220 of the scheduled storage stage using a lifting platform (not shown), a belt conveyor (not shown) moves the storage box is sent to the transfer shelf.

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

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

The warehousing transfer machine 240 transfers the storage boxes to the warehousing transfer table 25.
When it is sent to the transfer rack 0, it is released and the work moves on to transporting the next storage box. Thereby, the work of storing the storage boxes on the horizontal rotating shelf 220 can be performed efficiently.

(B) Unloading operation The horizontal rotary shelf 220 in which the storage box containing the desired item to be unloaded is stored is controlled to rotate, and the tray 223 on which the storage box is mounted is moved to the position of the unloading transfer table 270. move it. After that, the storage box is moved to the horizontal rotating shelf 220 by a pusher (not shown).
from the tray 223 to the transfer shelf of the shipping transfer table 270.

When the elevating platform (not shown) of the warehousing transfer machine 260 reaches the transfer shelf, the storage box is moved to the elevating platform by a pusher (not shown), and then the storage box is moved to the elevating platform by the warehousing transfer machine 26.
0, and is conveyed by an exit line (not shown) and exited from the warehouse.

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

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

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

[Problem that the invention seeks to solve]

As described above, the conventional control system for an automatic warehouse equipped with multi-level horizontal rotating shelves manages the storage, storage, and storage in one moving unit and one storage box.

This control method has the advantage that it can be applied to any type of product without being affected by the size, weight, etc. of the product, but on the other hand, it has the following problems, especially when dealing with a wide variety of small, lightweight parts. This becomes a problem in some cases.

When several types of items are mixed in one storage box, picking work is required when entering and exiting the warehouse, making it easy for errors to occur.

Since sorting and picking operations are performed in parallel during shipping, not only are errors likely to occur, but the picking operation takes a lot of time, which delays the overall shipping operation.

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

[Means for solving problems]

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

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

120 is a warehousing line, 130 is an article storage means 1
This is a warehousing transfer device that connects the warehousing line 10 and the warehousing line 120. These constitute the warehousing means of the second invention,
The warehousing process of the first invention, that is, the process of storing the articles in packaging boxes in the article storage means 110 is performed.

140 is a re-stocking line, and a warehousing transfer device 130
Together with this, it constitutes the re-warehousing means of the second invention, and performs the re-warehousing step of the first invention, that is, the step of re-warehousing the shipping packaging boxes created by picking into the article storage means 110.

160 is a picking line where packaging boxes are carried out during picking; 150 is an article storage means 1;
10 and the pickup line 160. These constitute the picking and dispensing means of the second invention, and perform the picking and dispensing step of the first invention, that is, the step of dispensing only the packaging boxes necessary for picking independently of the shipping process.

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

Note that the configuration of the second invention is not limited to the configuration shown in FIG. For example, the warehousing transfer device 13
0 may be provided separately for the warehousing means and the re-warehousing means instead of being shared. At the same time, the shipping transfer device 15
0 may be provided separately for the picking and dispensing means and the retrieval means instead of being shared. Furthermore, the article storage means 110 is not limited to a horizontal rotating shelf configuration.

[Effect]

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

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

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

At the time of shipment, the goods storage means 11 is stored by the unloading means.
Shipping is carried out from the shipping packaging box that is stored in the storage area 0 and ready for shipping.

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

〔Example〕

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

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

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

Single packaging box: A packaging box that stores items of the same type. The type is the type of item or product name.

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

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

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

Reserved fractional boxes: Fractional boxes that have been allocated for shipping.

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

Shipping packaging box: Reserved box with shipping instructions.

(A) Configuration of the embodiment In FIG.
40, unloading transfer device 150, picking line 1
60 and the shipping line 165 are as described in FIG.

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

FIG. 3 shows the configuration of each horizontal rotating shelf used in this embodiment. In Figure 3,
170 is a horizontal rotating shelf, 171 is a frame, 172
173 is a rubber roller, and 173 is a tray. Tray 1
73 is divided into n x m storage compartments with n stages x m columns, and each storage compartment stores a single packaging box, that is, one packaging box containing the same type of product. Ru. FIG. 3 illustrates six storage compartments arranged in two rows and three rows, forming one overall movement unit. The size of the tray 173 is the same as or slightly larger than the tray 223 in FIG. 10, and is large enough to smoothly rotate around the semicircular portion of the horizontal rotating shelf 170.

Each horizontal rotating shelf has the structure shown in Fig. 3 and the structure shown in Fig. 10.
Although it is possible to use the structure shown in the figure as appropriate, in this embodiment, each horizontal rotating shelf is
Suppose that it has the structure shown in the figure. Therefore, hereinafter, the reference numerals in FIG. 3 will be used in the explanation regarding the horizontal rotating shelf. In addition, the packaging box refers to a single packaging box.

By using the horizontal rotating shelf 170 of FIG. 3 having multiple storage compartments in one moving unit, storage efficiency can be improved more than the horizontal rotating shelf of FIG. 10, and the cost of the horizontal rotating shelf can be reduced.
In addition, since each of the n×m storage compartments can carry out loading and unloading operations and management of packaging boxes, each operation and management at the time of warehousing, picking, and shipping can be performed efficiently and rationally.

The warehousing transfer device 130 is composed of a warehousing transfer machine 131 and a warehousing transfer table 135 similar to those shown in FIG. It is composed of a stand 155. The warehousing transfer machine 131 and the warehousing transfer machine 151 are each equipped with a lifting platform (not shown), and the warehousing transfer table 135 and the warehousing transfer table 155 are equipped with a transfer shelf (not shown) corresponding to each horizontal rotating shelf 170. (not shown), and their configurations are also the same as in the case of FIG. The movement of packaging boxes between each transfer machine, transfer table, and horizontal rotating shelf is carried out by a belt conveyor or pusher method in the case of warehousing, and by the pusher method in the case of unloading.

181 to 184 are barcode readers (BCR)
It is. 191 is warehousing buffer storage, 19
2 is a fixed shelf line, 195 is an acceptance inspection area where receiving inspection is performed, 196 is a picking area where picking work is performed, 197 is a re-stocking area where each fractional box after picking is inspected and re-stocked, and 198 is a shipping packing operation. This is a shipping and packaging facility where Fixed shelf line 19
2 is a line for temporarily storing packaging boxes to be stored on fixed shelves (not shown).

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

(B) Operation of the Example Each operation such as warehousing, picking, and shipping performed in Figure 2 can be explained in the processing order (by the numbers in the circles) by referring to the process flowchart in Figure 4. (shown).

In Fig. 4, the communication management block, the actual inventory management block, the location management block, the shipping priority management block, the picking work management block, and the shipping/output management block surrounded by a rectangle in the center, are all executed by the host computer. Each management function is Storing, picking and discharging, re-storing, and restocking enclosed by parallelograms are operations performed by the automated warehouse system of FIG. 2. The process control system, acceptance inspection, and order/shipment management system enclosed in an oval are management functions or operations performed by separate systems. VDT ₁ is a terminal with a display to which a pick-out request is input, and VDT ₂ is a terminal with a display to which a shipping-out request is input. The arrows indicate the flow of control, and the encircled numbers indicate the general processing sequence from warehousing to warehousing.

(a) Warehousing instruction processing Information regarding goods that are scheduled to be warehoused from the process management system (warehousing schedule information) is
The communication is sent to the communication management block of the host computer.

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

The actual item inventory management block is equipped with an actual item inventory management file and manages the articles and packaging boxes stored on the horizontal rotating shelf 170, and records the warehousing schedule information in the actual item inventory management file.

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

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

(b) Warehousing operations Before warehousing operations, the products transported from the factory are subjected to sampling inspections, destructive tests, etc. on a lot-by-lot basis, and the packaging boxes of products that pass are marked with label classification, EDP number, box serial number, etc. A label with a bar code and printed text indicating the warehouse classification, check date, etc. is attached, and the product is sent to the acceptance inspection area 195 in FIG. 2.

(b ₁ ) Acceptance inspection When the packaging box is delivered to the acceptance inspection site 195,
Workers at the acceptance inspection site 195 read the labels affixed to the packaging boxes, open the packaging boxes, and inspect the actual items to see if the product name, quantity, etc. of the items stored in the packaging boxes match the information on the labels. (4th
figure acceptance inspection).

The barcode data of the label on the packaging box that has passed the inspection is input using a barcode reader (not shown) and transferred to the actual product inventory management block (FIG. 4).

(b ₂ ) Based on the input barcode information, the actual inventory management block moves the information on full boxes from the warehousing schedule information group in the actual inventory management file to the full box inventory information group, and transfers the information on fractional boxes. It is moved to the fractional box inventory information group.

In addition, the actual inventory management block creates warehousing transaction information based on the input barcode information, and sends it via the communication management block to the order receiving and shipping management system, which is in charge of inventory management at all shipping centers, including other factories. Figure 4).

(b ₃ ) Packaging boxes that have passed the acceptance inspection are transported to the receiving buffer storage 191 in lots.
Pause in front of BCR181.

The actual inventory management block rechecks whether the packaging box is scheduled to be stocked based on the barcode information read by the BCR 181, and also checks whether the packaging box is fixed to the horizontal rotating shelf 170 based on the warehouse classification information. The control device 200 of the automated warehouse is instructed as to which shelf it is.
By performing this recheck, it is possible to reliably prevent packaging boxes other than those that have undergone acceptance inspection from being erroneously stocked.

The control device 200 switches the warehousing line according to the instruction, and the packaging boxes stored on the horizontal rotating shelves 170 are carried into the warehousing line 120, and the packaging boxes stored on the fixed shelves are carried into the fixed shelf line 192.

(b ₄ ) Packaging boxes that are stored on the horizontal rotating shelf 170 are transported on the storage line 120, and are transferred to the storage transfer machine 1.
Stop in front of 31. The BCR 182 on the warehousing line side in front of the warehousing transfer machine 131 reads the barcode on the label on the stopped packaging box,
Send that information to the actual inventory management block (4th
Figure) The actual inventory management block checks whether the packaging box can be accepted based on this barcode information, and if the packaging box is acceptable, requests the location management block to determine the storage location (4th step). ( _b5 ) Location determination processing The location pipe block is equipped with a storage status file illustrated in FIG.
All locations (addresses of storage sections) are managed whether they are free or in use, and based on storage location determination requests from the inventory management block,
The location where the packaging box should be stored is determined and notified using a predetermined algorithm (Figure 4).

As shown in FIG. 6, the storage status file corresponds to the configuration of the horizontal rotating shelf 170 and is divided into areas of i columns and j stages. That is, the j stage corresponds to the total number of stages of the horizontal carousel 170, and the i column corresponds to all the storage sections in one horizontal carousel. Note that the total number of stages j and the total storage compartments i of the horizontal rotating shelf 170 are 1
When the horizontal rotating shelf 170 uses trays 173 having n stages and m rows as shown in FIG. 3, each of the trays 173 has one stage and one row. As a result, one storage section, that is, one packaging box corresponds to one location, and it is possible to manage each packaging box. The location is 2 rows and 2 rows.
The value is determined and l(i,j) is the jth value of the i-th column.
shall indicate the location of the stage. a~
g is an example of a location where the packaging box is stored. In this way, the storage location is represented by (row, column), and the lowercase letters in FIG. 6 indicate that one packaging box is stored.

Hereinafter, with reference to the location determination flowchart of FIG. 7, the location determination processing performed in the location determination block will be explained according to the steps thereof. This location determination process allows the storage section of the packaging box to be determined using a completely free location method. In addition, Buf(j) in Fig. 7 indicates the j-th stage transfer buffer, and
indicates the location within one stage.

(1) Total number of stages of Step S ₁ horizontal rotating shelf 170 (assumed to be jmax)
and the position of the lifting platform of the warehousing transfer machine 131 at the time of starting the operation (given by the number of stages of the horizontal rotating shelf)
Initialize.

(2) Step _S2 location management block is Read
When there is a storage location determination request (FIG. 4) from the actual inventory management block, the location is determined in the following steps.

(3) Steps S ₃ and S ₄ Check whether there is a recommendation to terminate the location determination process (Step S ₃ ), and stop the location determination process when a termination recommendation has been received (Step S ₄ ). After completing daily work,
Performed when the system is closed.

(4) If there is no recommendation to end step S ₅ , the warehousing transfer machine 131
Save the position of the lifting platform (jsave). Other than when the operation starts, the lifting platform is stopped at the position when the packaging box was placed in the warehouse last time, so that value is saved as jsave.

(5) Steps S ₆ , S ₇ Count up a counter (not shown) for counting the number of stages of the horizontal rotating shelf 170 by “1” (Step S ₆ ), and check whether the count value is equal to jsave. (Step _S7 ). Since the count value j does not become equal to jsave until the counter counts up and returns to the jsave value, the process moves to the next step _S8 .

(6) Step S ₈ It is checked whether the count value j has reached jmax. In the case of j>jmax, the search for empty locations from the (jsave+1) stage to the jmax stage of the horizontal rotating shelf 170 has been completed, so the count value j is set to "0", and the process returns to step _S6 to save the horizontal rotating shelf 170. Search for empty locations between the 1st and (jsave-1) stages.

If j<jmax, the next step _S9 is performed.

(7) Step S Check whether the transfer shelf of the warehousing transfer table 135 corresponding to the j-th stage of the _9th horizontal rotating shelf is vacant or not by referring to the storage status file shown in FIG. If there is no vacancy, return to step _S6 ,
Performs a vacant search for the next stage. If the transfer shelf is empty, the horizontal rotating shelf at that level is selected as a candidate for storing the packaging box, and the processes from the next step _S10 onwards are performed.

(8) Steps S ₁₀ , S ₁₁ , S ₁₂ Referring to the storage status file shown in FIG. 6, search for empty locations in order from the beginning of stage j (step S ₁₀ ).

If there is no vacant location, the process returns to step _S6 and a vacant search for the next stage is performed.

If an empty location is detected, the first empty location detected will be used as the packaging box storage location.
(i, j) is set in use (step S ₁₂ ), and the next step S ₁₃ is processed.

(9) Step S ₁₃ Location (determined location) that specifies the storage compartment for storing the requested packaging box.
(i, j) is notified to the actual inventory management block (Fig. 4). When this notification ends, the step
Return to _S2 and wait for a storage location determination request for the next packaging box.

(10) The value when the step S ₇ counter is counted up is
If equal to jsave, horizontal rotating shelf 17
Even if the number of stages of 0 (1 to jmax) is searched, there is no vacancy or there is no vacancy on the transfer table, so the waiting process from the next step _S14 is performed.

(11) Steps S ₁₄ , S ₁₅ , and S ₁₆ location tube blocks store the count value of another counter (not shown) when j=jsave.
Count up CNT by "1" (step _S14 ). This counter counts the number of times that no vacancy was detected in the vacancy location search process performed in steps _S6 to _S11 .

In the next step _S15 , it is checked whether the count value CNT has reached a predetermined value (for example, 10 times).

If the count value CNT is less than 10, after waiting for a certain period of time (step _S16 ), the process returns to step _S6 and repeats the above-mentioned vacant location search process.

If vacancies are not detected 10 times or more in a row (step _S15 ), an alarm display is instructed to indicate that the warehousing operation will not be performed (step _S17 ). Based on this alarm display instruction, an alarm is displayed on the control device 200 of the automated warehouse system and in the section where the warehousing work is performed, notifying the worker that the warehousing work is in a waiting state and at the same time prompting the worker to carry out the shipping work.

( _b6 ) When the actual inventory management block receives the location decision notification from the location management block, it sends it to the automated warehouse control device 200 (FIG. 4).

( _b7 ) The control device 200 controls the warehousing transfer machine 131 to transport the packaging boxes to the height of the horizontal rotating shelves 170 of the number of stages specified by the location determination notification,
A belt conveyor (not shown) sends it to the transfer shelf of the warehousing transfer table 135 corresponding to that stage.

Next, the horizontal rotating shelf 170 is rotated,
When the storage compartment specified by the location decision notification comes to the position of the transfer rack, the pusher (not shown)
stores the packaging box in its storage compartment.

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

(c) Common shipping and picking operations (c ₁ ) When shipping the packaging boxes stored in the horizontal rotating rack 170, the order shipping management system issues shipping instructions including the shipping destination, shipping item name, shipping quantity, etc. Information is sent to the host copier (Figure 4).

( _c2 ) The host computer receives the shipping instruction information through the communication management block and transfers the contents to the shipping priority management block (FIG. 4).

( _c3 ) The shipping priority management block calculates the number of fully loaded boxes required for shipping from the number of shipped items in the transferred shipping instruction information, and sends the allocation account switching information to the actual inventory management block (Figure 4).

When the actual inventory management block receives this allocation port switching information, it moves each full box indicated by the allocation port switching information from the full box inventory information group of the actual inventory management file shown in FIG. 5 to the reserved box information group. Processing is performed, and the shipping priority management block is notified that the allocation account has been switched (FIG. 4').

The shipping priority management block instructs picking if the predetermined number of shipped items cannot be obtained with only the number of fully loaded boxes and a fractional number occurs. This picking instruction is sent to the automated warehouse control device 200. Since picking is typically performed on multiple items, the pickings are registered in a picking queue (not shown). The exception is when no picking is done; picking is usually done.

Next, the picking operation will be explained.

(d) Picking operation (d ₁ ) When the worker at the picking workshop 196 receives a picking instruction and is ready for picking, he notifies the picking work management block of a picking delivery request from the terminal VDT ₁ (FIG. 4).

( _d2 ) When the picking operation management block receives this notification, it issues a picking request to the delivery priority management block (FIG. 4).

( _d3 ) Upon receiving a picking request, the delivery priority management block extracts the location information of the fractional boxes for the specified quantity from the picking queue of the fractional boxes of the type to be picked, and
A picking task request including this fractional box location information is sent to the picking task management block (FIG. 4').

( _d4 ) Based on this picking work request, the picking work management block sends a picking delivery request to the actual item inventory management block (FIG. 4).

( _d5 ) Based on the location information of the fractional boxes to be picked in the picking issue request, the actual inventory management block retrieves information on the fractional boxes to be picked from the fractional boxes inventory information group in the actual inventory management file (Figure 5). Move to the picking work disbursing information group.

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

On the other hand, information regarding the type, quantity, storage location, etc. of the fractional boxes for shipping (already reserved fractional boxes) newly created by the picking operation and scheduled to be restocked is created, and the information is scheduled to be restored after the picking. Recorded in information group.

When the above-mentioned processes are completed, the inventory management block notifies the picking operation management block of the delivery location and instructs the location of the fractional box to be picked (FIG. 4).

(d ₆ ) When the picking work management block receives this delivery location notification, it instructs the control device 200 of the automated warehouse system shown in FIG. 2 to perform picking delivery (FIG. 4).

The picking operation management block further sends picking payout information to the location management block (FIG. 4).

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

(d ₇ ) When the control device 200 receives the picking dispensing instruction, it controls the horizontal rotating shelf 170, the unloading transfer table 155, and the warehousing transfer machine 151, and based on the location information in the picking dispensing instruction, The fraction box is placed on the horizontal rotating shelf 17
Work to pay out from 0. This dispensing operation is the reverse of the warehousing operation previously explained in (b ₇ ), and is obvious from the warehousing operation, so the explanation will be omitted.

(d ₈ ) When the fraction box for picking is delivered to the picking line 160, the BCR 183 reads the barcode on the label on the fraction box and sends the contents to the control device 200.

Since the work location for picking differs depending on the model of the article, the control device 200
Based on the barcode information sent from 183,
When the fractional box is conveyed to a predetermined work location in the picking area 196, a pusher (not shown) is controlled to send the fractional box to a workbench at the predetermined work location, and a picking label is printed out. When sorting for multiple users from one fractional box, a picking label for each user is printed out. Each picking label has a barcode printed with the model number, quantity, etc.

The worker performs the prescribed picking operation according to the instructions on the picking label, and places the picks into the newly created fraction boxes for each shipment and the original fraction boxes in which the remaining quantities are stored. Attach the label.

While the worker is picking, the host computer delivers the next packaging box to be picked to the work location in the same manner. This eliminates the waiting time of the worker between picks and greatly improves picking work efficiency.

When the picking operation is completed, each fractional box is sent to the re-stocking area 197, and an operator inspects whether the contents of each fractional box match the contents of the picking label.

Each fractional box that passes the inspection is transferred to restocking line 1.
Sent to 40. Each fractional box is transported to the front of the automatic warehousing transfer device 130 by the re-warehousing line 140. When the first fractional box reaches the warehousing automatic transfer device 130, the BCR on the re-warehousing line side
184 reads the bar code on the label on the fraction box and sends the information to the picking work management block as a restorage request that also serves as a picking work completion report (FIG. 4).

Note that since the number of fractional boxes to be dispensed for the picking operation is known in advance, the control device 200 of the automated warehouse system counts the number of fractional boxes that have been dispensed and determines when all the fractional boxes have been transferred to the workbench. When it is determined, a notification of completion of dispensing is sent to the picking work management block. When the picking work management block receives this completion notification,
Requests the shipping priority management block to issue the next picking work request.

( _d9 ) The picking operation management block notifies the actual item inventory management block of the re-storage request (FIG. 4).

When the actual inventory management block receives this restorage request, it sends a message to the location management block.
A request is made to determine the storage location of the fraction box.

The location management block determines the storage location of the fractional boxes in accordance with the same procedure as the storage location determination procedure at the time of warehousing, and notifies the actual product inventory management block. Note that for each fractional box to be re-stored after picking, empty locations corresponding to the number of fractional boxes are reserved in advance, so there will be no situation where re-storage cannot be performed due to a lack of free locations. This is to prioritize shipping work.

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

The actual item inventory management block further transfers the fractional boxes for shipping to be stored again from the post-picking restorage schedule information group of the actual item inventory management file as allocated fractional boxes to the allocated box information group. Therefore, the reserved box information group stores information on reserved full boxes and reserved fractional boxes that are ready for shipping.

( _d10 ) The picking operation management block notifies the shipping priority management block of the completion of picking for the re-stored fraction boxes (FIG. 4).

(e) Shipping operation ( _e1 ) The shipping priority management block performs the following based on the notification that the allocation account has been switched from the actual inventory management block (Figure 4') and the picking completion notification from the picking operation management block (Figure 4). , informs the shipping/output management block of information regarding the shipping destination user and reserved full boxes and fractional boxes that can be shipped.

( _e2 ) The shipping/output management block is equipped with a shipping/output management file and manages shipping/output.

FIG. 8 shows an example of the shipping and issue management file, which has a hierarchical structure as shown. Level 0 is the entry level, and entries for the entire shipping and issue management file are defined.

Level 1 is the shipping area level, which divides the country into multiple shipping areas and files information regarding each shipping area.

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

Level 3 is a user internal type rating level, and shipping type information (type name, number of items shipped, shippable state indication flag, etc.) is filed for each user.

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

Assuming that an item of type (1) is to be shipped to user 1, the shipping priority management block will notify the shipping user name (user 1) and information regarding the full shipping box and fractional boxes of type (1). 1 of direction i according to the above-mentioned levels 0 to 4.
Among the users, information regarding full boxes and fractional boxes reserved for shipping is stored in the shipping packaging box information group ((1)-a) to ((1) to (c)) in shipping type information (1). be done.

When the information regarding the reserved fractional boxes for shipping is finally filed in the shipping packaging box information ((1)-c),
Since all the required number of items for the model number (1) are ready for shipment, the ready-to-ship status indication flag in the level 3 shipping model number information (1) is set to ON.
Wait for shipping instructions.

( _e3 ) When shipping and leaving the warehouse, the shipping and leaving instruction information is notified from the terminal VDT ₂ to the shipping and leaving management block (Fig. 4).

( _e4 ) Based on the shipping/shipping instruction information, the shipping/distributing management block refers to the destination-specific user, shipping type/class information, and shipping packaging box information in the shipping/distributing management file, and makes the item ready for shipping. The location information of a certain shipping packaging box, that is, a full box and a fractional box that have been reserved for shipping, is summarized by type for each user, and the automated warehouse system is instructed to take it out (FIG. 4).

At the same time, send the destination label, shipping slip, and delivery note to the shipping packing area 198 of the automated warehouse system.
Print it out at each work location.

( _e5 ) In the automated warehouse system, in the same manner as in the above-mentioned warehousing operation or picking operation, the location shipping packaging boxes for which the outgoing instruction has been received are sequentially carried out from the horizontal rotating rack 170 to the shipping line 165, and then transported to the shipping packing area. Send to 198.

(e ₆ ) At the shipping packing area 198, after inspecting whether the contents of the shipping packaging boxes that have been transported match the contents of the shipping slip, a predetermined number of shipping packaging boxes ( For example, 4 pieces)
Store and pack everything together. A destination label is affixed to each shipping cardboard box, and the shipping slip and delivery note are grouped together for each user and placed in the final shipping cardboard box.

( _e7 ) The shipping/output management block instructs the outgoing item and also notifies the actual inventory control block of the completion of the outgoing item (Fig. 4).

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

(e ₈ ) The dispatch/output management block also notifies the location management block of the completion of the outbound delivery (Fig. 4).

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

In the above manner, warehousing work, picking work,
Shipping work can be carried out efficiently.

(C) Control System The automatic warehouse system of the present invention is an online real-time system. Therefore, even if the system goes down for a short period of time, it is fatal, so in the present invention, the entire system is divided into host blocks and LAN (Local
It is divided into two blocks (area network). This creates a completely tolerant system.

(1) Host block The host block includes a communication management block, an inventory management block, a location management block, a shipping priority management block, as shown in Figure 4.
The contents include a picking work management block and a shipping/output management block. The functions and processing contents of each block are as already explained.

(2) LAN block The LAN block controls each operation of storage, picking and discharging, re-storage, and restocking shown by the parallelogram block in Fig. 4, that is, each operation in the automated warehouse system shown in Fig. 2. , is performed by the control device 200. Their control operations are as already explained.

Host block and LAN in the present invention
The block is structured as follows.

(1) Host block The price of the host computer accounts for a considerable amount of the cost of the entire system, and if it were to be made dual or duplex, it would incur enormous costs and result in extremely poor cost performance. In addition, with the recent rapid development of hardware reliability technology (RAS), MTBF (Mean
Time Between Failures) is getting longer, and MTTR (Mean Time To Repair)
As the time period has been shortened, the effect of redundant investment has almost disappeared.

However, of course, there is no guarantee that it will never go down, so in this system, even if a host goes down, we have a fail-soft configuration to prevent it from affecting the LAN block, so that the entire system can be maintained without reducing cost or performance.
Avoiding going down.

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

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

The logs of each personal computer (functioning as a Workstation) are stored on the shared DASD within the LAN (inside the file server and personal computer).
Since data is written, only this device is dual.

By adopting this method, even when the host is stopped (due to regular maintenance, failure, etc.), the LAN can be maintained.
It is configured so that only the blocks can carry out the minimum required amount of receiving and shipping operations.

That is, (i) Every morning from the host's database, the horizontal carousel storage status (stored information for each location: model number, lot number, box serial number, etc.) before the start of operation is transferred to the hard disk in the file server. Forward.

(ii) All loading and unloading of files into and out of the horizontal carousel
Logging (recording) is done on the server.

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

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

〔Effect of the invention〕

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

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

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

(b) At the time of shipping, the products are shipped from packaging boxes that are already ready for shipping (full boxes and fractional boxes that have been allocated), so shipping work can be carried out without errors and efficiently.

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

[Brief explanation of the drawing]

Fig. 1...Explanatory diagram of the principles of each invention of the present application, Fig. 2...Explanatory diagram of the embodiment of each invention, Fig. 3...Explanatory diagram of the horizontal rotary shelf used in the embodiment, Fig. 4...Explanatory diagram of the same embodiment Example system flowchart, FIG. 5: An explanatory diagram of the actual inventory management block used in the example,
Fig. 6...Explanatory diagram of the storage status file used in the same embodiment, Fig. 7...Location determination flowchart of the same embodiment, Fig. 8...Explanatory diagram of the shipping/output management file used in the same embodiment, Fig. 9 FIG. 10: An explanatory diagram of the basic configuration of a conventional automated warehouse. FIG. 10: An explanatory diagram of a conventional horizontal rotating shelf. In FIGS. ...Receiving transfer device, 140... Re-receiving line, 150...
Delivery transfer device, 160... Picking line, 1
65...Shipping line, 170...Horizontal rotating shelf, 2
00...control device.

Claims (1)

[Scope of Claims] 1. A control method for an automatic warehouse that automatically carries out loading and unloading of articles into and out of the article storage means 110, which includes: (a) a warehousing step in which articles are warehoused in the article storage means 110 in packaging boxes; , (b) a picking and discharging process of discharging only the packaging boxes necessary for picking independently of the shipping process, and (c) re-stocking the shipping packaging boxes created by picking into the article storage means 110. A method for controlling an automated warehouse, comprising: a re-warehousing step; and (d) a shipping step for shipping from a shipping packaging box that is stored in the article storage means 110 and ready for shipping. 2. The automatic warehouse control method according to claim 1, wherein the packaging box is a single packaging box. 3. Scope of Claims characterized in that the warehousing process involves searching for an empty location in the article storage means 110 before warehousing, determining the storage location using a free location method, and then warehousing the packaging boxes. The method for controlling an automated warehouse according to paragraph 1. 4 The control of the automated warehouse is performed by the host/host that performs the management function.
A method for controlling an automated warehouse according to claim 1, characterized in that the method is divided into two parts: a block and a local area network block that directly controls the operation of the automated warehouse. . 5. In an automatic warehouse that automatically carries out loading and unloading of articles into and out of the article storage means 110, (a) warehousing means 120 and 130 for storing articles in packaging boxes in the article storage means 110, and (b) processing during picking. Picking dispensing means 150,1 for dispensing only the packaging boxes necessary for picking
(c) re-stocking means 1 for re-stocking the shipping packaging boxes created by picking into the article storage means 110;
30, 140; and (d) unloading means 150, 165 for unloading shipping packaging boxes from the article storage means 110 at the time of shipment. 6. The automatic warehouse according to claim 5, wherein the article storage means 110 includes at least one horizontal rotating shelf 170. 7. The automatic warehouse according to claim 6, wherein the horizontal rotating shelf 170 is provided with a tray 173 provided with a plurality of single packaging box storage compartments. 8. The automatic warehouse according to claim 5 or 6, wherein the warehousing means and the re-warehousing means are provided with a common warehousing transfer device 130. 9. The automatic warehouse according to claim 5 or 6, wherein the picking and discharging means and the unloading means are provided with a common unloading transfer device 150. 10 The warehousing transfer device 130 is the warehousing transfer machine 131
9. The automatic warehouse according to claim 8, further comprising a storage transfer table 135. 11 The outgoing transfer device 150 is the outgoing transfer device 151
The automatic warehouse according to claim 9, characterized in that the automated warehouse is provided with a warehouse transfer table 155.