JP7502163B2 - Loading system, loading method and program - Google Patents

Description

The present invention relates to a stowage system, stowage method, and program, and in particular to a stowage system that removes multiple items from a storage unit and stows them on a cart.

As described in Patent Document 1, the applicant proposes a system for automatically loading multiple items onto a cart.

Patent application No. 2020-024148

Patent document 1 is for loading supplied cargo. It does not specify how the cargo is to be supplied.

For example, one idea would be to create a loading pattern by distinguishing between individual packages and performing loading calculations, and then supply the removed packages in the loading order via a higher-level conveyor. However, as the number of packages increases, the amount of calculations becomes enormous, and the workload of rearranging the packages into the loading order also becomes enormous.

Therefore, the present invention aims to provide a loading system that is suitable for increasing the efficiency of determining the order in which cargo is supplied for loading onto carts and reducing the workload of rearranging cargo.

A first aspect of the present invention is a stowage system that removes multiple pieces of luggage from a storage unit and stows them on a cart, comprising a stowage pattern calculation device that calculates a stowage pattern for stacking the multiple pieces of luggage on the cart, and a rearrangement unit that rearranges the multiple pieces of luggage removed from the storage unit using the stowage pattern, the stowage pattern calculation device comprising a grouping unit that divides the multiple pieces of luggage into groups, and a pattern selection unit that selects the stowage pattern from among stowage pattern candidates that can stack multiple pieces of luggage in a group to which the multiple pieces of luggage belong, even if the multiple pieces of luggage are supplied in different orders, and the rearrangement unit rearranges pieces of luggage belonging to different groups using the stowage pattern while maintaining the order of pieces of luggage belonging to the same group unchanged.

A second aspect of the present invention is the stowage system of the first aspect, in which the stowage pattern calculation device includes a pattern calculation unit, which calculates, for each group, a pattern for multiple packages belonging to the group that can be stowed on the cart even if they are supplied in a different order, and if the packages belonging to the group can be placed on the cart together with packages belonging to other groups, calculates a stowage pattern for at least one of the other groups using the pattern that can be stowed on the cart even if it is supplied in a different order, together with the packages belonging to the other groups, and calculates the stowage pattern candidates by combining the calculated patterns.

A third aspect of the present invention is a stowage system according to the first or second aspect, in which the pattern selection unit selects a stowage pattern from the stowage pattern candidates based on at least one of the following criteria: a pattern that reduces the number of carts, a pattern that reduces the difference in overall distribution of luggage, and a pattern that reduces the difference in distribution of luggage among each cart.

A fourth aspect of the present invention is a stowage method in a stowage system that removes multiple pieces of luggage from a storage unit and stows them on a cart, the stowage system including a stowage pattern calculation device that calculates a stowage pattern for stowage on the cart, a rearrangement unit that rearranges the multiple pieces of luggage removed from the storage unit using the stowage pattern, and a stowage unit that loads the multiple pieces of luggage on the cart using the stowage pattern, and includes a step of a grouping unit included in the stowage pattern calculation device dividing the multiple pieces of luggage into groups, a step of a pattern selection unit included in the stowage pattern calculation device selecting the stowage pattern from among stowage pattern candidates that can load multiple pieces of luggage belonging to a group onto the cart even if the multiple pieces of luggage belonging to the group are supplied in different orders, and a step of the rearrangement unit maintaining the order of pieces of luggage belonging to the same group without changing it, and rearranging pieces of luggage belonging to different groups using the stowage pattern.

The fifth aspect of the present invention is a program for causing a computer to function as a stowage pattern calculation device that calculates a stowage pattern for stacking multiple pieces of luggage taken out of a storage unit onto a cart, and causes the computer to function as a grouping unit that divides the multiple pieces of luggage into groups, and a pattern selection unit that selects the stowage pattern from among stowage pattern candidates that can stack multiple pieces of luggage in a group onto the cart even if the multiple pieces of luggage in the group are supplied in different orders.

The present invention may also be understood as a computer-readable recording medium on which the program of the fifth aspect is recorded.

According to each aspect of the present invention, by dividing the luggage to be supplied into groups and treating each group as a unit without rearranging the luggage within each group, the order in which the luggage is supplied for loading onto the cart can be determined efficiently, and the workload of rearranging the luggage can be reduced.

FIG. 1 is a diagram showing an overview of an example of a luggage loading device. FIG. 1A is a block diagram showing an example of a configuration of a stowage system 1 according to an embodiment of the present invention, and FIG. 1B is a flow diagram showing an example of an operation thereof. FIG. 3 is a first diagram for explaining an example of the processing of the grouping unit 17, the pattern calculation unit 19, and the pattern selection unit 21 in FIG. 2. FIG. 3 is a second diagram for explaining an example of the processing of the grouping unit 17, the pattern calculation unit 19, and the pattern selection unit 21 in FIG. 2. FIG. 3 is a third diagram for explaining an example of the processing of the grouping unit 17, the pattern calculation unit 19, and the pattern selection unit 21 in FIG. 2. FIG. 4 is a fourth diagram for explaining an example of the processing of the grouping unit 17, the pattern calculation unit 19, and the pattern selection unit 21 in FIG.

Below, examples of the present invention will be described with reference to the drawings. Note that the embodiment of the present invention is not limited to the following examples.

Figure 1(a) is a diagram showing an outline of a luggage stacking device (see, for example, Patent Document 1). In a stacking unit 61, luggage is stacked. A control panel 51 is for controlling the entire system including the stacking unit 61. A case supply conveyor 59 is for supplying luggage to the stacking unit 61. A cart is inserted next to the case supply conveyor 59 and is transported to a luggage transport position 64 by a cart supply device 53. The luggage supplied from the case supply conveyor 59 to the stacking unit 61 is stacked on a stacking unit 67 (slide table) and organized into one cart. The luggage organized on the stacking unit 67 is transferred to a cart fixed to the luggage transport position 64 by a pusher device 55 and a slider device 65. The cart on which the luggage is loaded is automatically dispensed by the cart supply device 53. Figures 1(b) and (c) show a specific example of Figure 1(a).

Figure 2 is (a) a block diagram showing an example of the configuration of a stowage system 1 according to an embodiment of the present invention, and (b) a flow diagram showing an example of the operation.

Referring to Figure 2 (a), the stowage system 1 comprises a stowage pattern calculation device 3, N storage sections ₅₁ , ..., _5N (N is a natural number) (the subscripts to the symbols may be omitted, similarly for others), N removal sections ₇₁ , ..., _7N , a sorting section 9, a stowage section 11, and a cart 13.

The stowage pattern calculation device 3 includes a shipping data acquisition unit 15, a grouping unit 17, a pattern calculation unit 19, a pattern selection unit 21, and a master data storage unit 23.

The storage unit 5 stores the luggage. The removal unit 7 removes multiple luggage to be shipped from the storage unit 5 and supplies them to the rearrangement unit 9. The rearrangement unit 9 rearranges the multiple luggage to be shipped according to a stowage pattern selected by the pattern selection unit 21. The stowage unit 11 stows the multiple luggage to be shipped on a cart 13 according to the stowage pattern selected by the pattern selection unit 21.

An example of the operation of the stowage system 1 in FIG. 2(a) will be described with reference to FIG. 2(b).

In the stowage pattern calculation device 3, the master data storage unit 23 stores data on the cargo to be shipped. For example, the size and package classification of each cargo are set in the master data storage unit 23. Package classifications are categorized according to the contents, etc. Regarding package classifications, information such as whether cargo in a certain package classification can be loaded onto cargo in the same package classification, or whether cargo in a different package classification can be loaded onto cargo in another package classification, is also managed.

The shipping data acquisition unit 15 acquires shipping data that identifies one batch of cargo (the amount to be loaded in one transport) (step ST1). The shipping data identifies, for example, multiple cargoes to be transported to the same destination at the same time. Then, for the multiple cargoes identified by the shipping data, the master data storage unit 23 is referenced to acquire information such as case size and package classification.

The grouping unit 17 groups the multiple packages identified by the shipping data (step ST2). The grouping is performed, for example, by the package classification of each package.

The pattern calculation unit 19 calculates a group unit stowage pattern for each group (step ST3). The pattern calculation unit 19 calculates a candidate stowage pattern for the cart by combining the group unit stowage patterns calculated in the previous stage (step ST4). The pattern selection unit 21 selects a stowage pattern for finally stowed in the cart from the candidate stowage patterns (step ST5). The pattern calculation unit 19 and the pattern selection unit 21 perform processing using, for example, case size. This will be described in detail later with reference to Figure 3 onwards.

The removal unit 7 removes the multiple packages identified by the shipping data from the storage unit 5 and supplies them to the sorting unit 9 (step ST6). This process may be performed in parallel with the process by the stowage pattern calculation device 3.

The sorting unit 9 rearranges the multiple pieces of luggage according to the stowage pattern (step ST7). In the present invention, the sorting unit 9 supplies multiple pieces of luggage belonging to the same group to the stowage unit 11 while maintaining the order in which they were supplied from the removal unit and arrived at the sorting unit 9. The sorting unit 9 only rearranges pieces of luggage belonging to different groups. Therefore, the amount of processing required for rearrangement in the sorting unit 9 is significantly reduced compared to rearranging all pieces of luggage.

The stacking unit 11 stacks the luggage supplied from the sorting unit 9 onto the cart 13 according to the stacking pattern (step ST8).

An example of a stacking section 11 is the luggage stacking device shown in FIG. 1. In the following, for simplicity of explanation, a case will be described in which luggage is stacked on top of one another on a cart in two rows in the front-to-back direction, and height restrictions are mainly taken into consideration when creating a stacking pattern. Note that the present invention is not limited to such a case, and can also be applied to cases in which luggage is stacked in more rows in the front-to-back direction, in the left-to-right direction, luggage is placed on top of multiple luggage, or multiple luggage is placed side-by-side on top of luggage.

An example of the processing of the grouping unit 17, the pattern calculation unit 19, and the pattern selection unit 21 will be specifically described with reference to Figure 3 and subsequent figures.

In this example, each piece of luggage has the same width W and length L, but different heights H. The height limit _HMAX is the maximum height that can be placed on the cart, and is 39 cm. Note that the present invention may be applied to luggage with different widths W and lengths L.

The multiple packages identified by the shipping data are divided into four package classifications. The grouping unit 17 groups the multiple packages according to the package classifications.

Package 1 contains six packages. The heights H of the packages are 8 cm, 8 cm, 8 cm, 9 cm, 10 cm, and 10 cm. They are called packages 1-1, 1-2, 1-3, 1-4, 1-5, and 1-6, respectively. Each package in package 1 can be placed on top of other packages in package 1, but cannot be placed on top of packages in other packages.

There are four packages in package 2. The heights H of the packages are 7 cm, 8 cm, 9 cm, and 9 cm. They are called packages 2-1, 2-2, 2-3, and 2-4, respectively. Each package in package 2 can be placed on top of other packages in package 2 and each package in package 1, but cannot be placed on top of packages 3 and 4.

There are two packages in package 3. The height H of each package is 8 cm and 9 cm. They are called packages 3-1 and 3-2, respectively. Each package in package 3 can be placed on top of other packages in package 3 and each package in package 1, but cannot be placed on top of packages 2 and 4.

Package 4 contains one package. The package height H is 15 cm. This package is called package 4-1. Package 4-1 can be placed on top of each package in packages 1, 2, and 3.

An example of processing by the pattern calculation unit 19 for packages in package 1 will be described with reference to FIG. 3. In the present invention, multiple packages in the same group are not rearranged. Even if packages of different heights are supplied in various orders, the height limit must be satisfied. Therefore, a pattern is considered focusing on the worst case (when stacked at the lowest height) for the number of packages that satisfies the height limit even if they are supplied in any order.

3A shows the case where six items in package 1 are stacked in a straight line. In this case, the height is 53 cm, which exceeds the height limit _HMAX of 39 cm. Therefore, six items cannot be stacked in a straight line for package 1.

3(b), (c), and (d) show cases where five of the six packages contained in package 1 are stacked in a straight line. Combinations with the same height are omitted. In these cases, the heights are 43 cm, 44 cm, and 45 cm, respectively, which exceed the height limit _HMAX of 39 cm. Therefore, five packages cannot be stacked in a straight line for package 1.

3(e), (f), (g), (h) and (i) show the case where four of the six packages contained in package 1 are stacked in a straight line. Packages with the same height are omitted. In this case, the heights are 33 cm, 34 cm, 35 cm, 36 cm and 37 cm, respectively, which do not exceed the height limit H _MAX of 39 cm. Therefore, for package 1, the four packages can be stacked in a straight line no matter what order they are supplied in. Among these, the worst case is FIG. 3(e), where packages 1-1, 1-2, 1-3 and 1-4 are stacked on top of each other. In this case, even if the remaining packages 1-5 and 1-6 are stacked in a straight line, the height limit H _MAX will not be exceeded.

The pattern calculation unit 19 determines the group stowage pattern for package 1 to be a pattern in which packages 1-1, 1-2, 1-3, and 1-4 are stowed in a straight line, and packages 1-5 and 1-6 are stowed in a straight line, as shown in FIG. 3(j).

Package 1 packages cannot be stacked on top of packages from other packages. Therefore, there is no need to consider group combination patterns that stack packages on top of packages from other groups.

With reference to Figures 4(a) to (f), an example of processing by the pattern calculation unit 19 for the cargo of package 2 will be described.

4(a) shows a case where the four packages contained in package 2 are stowed in a random order. In this case, the height is 33 cm, which does not exceed the height limit _HMAX of 39 cm. Therefore, for package 2, the four packages can be stowed in a random order regardless of the order in which they are supplied. The pattern calculation unit 19 sets the group stowage pattern for package 2 to a pattern in which packages 2-1, 2-2, 2-3, and 2-4 are stowed in a random order.

The luggage contained in package 2 can be added to the luggage contained in package 1. The pattern calculation unit 19 considers group combination patterns to consider combinations between groups.

No additional packages contained in package 2 may be placed on top of packages 1-1, 1-2, 1-3, and 1-4.

Three packages in package 2 cannot be stacked on top of packages 1-5 and 1-6, but two packages can be stacked on top of them as shown in Figures 4(b), (c), (d), and (e). Packages of the same height are omitted. The heights are 35 cm, 36 cm, 37 cm, and 38 cm, respectively, and do not exceed the height limit H _MAX of 39 cm. Of these, the worst case scenario is when packages 2-1 and 2-2 are stacked on top of packages 1-5 and 1-6.

As shown in FIG. 4(f), the pattern calculation unit 19 determines the group combination pattern for package 2 relative to package 1 by stacking packages 2-1 and 2-2 on top of packages 1-5 and 1-6, and stacking packages 2-3 and 2-4 separately.

With reference to Figures 4(g) and (h), an example of processing by the pattern calculation unit 19 for package 3 cargo will be described.

4(g) shows a case where two packages included in package 3 are stowed in a straight line. In this case, the height is 17 cm, which does not exceed the height limit _HMAX of 39 cm. Therefore, two packages can be stowed in a straight line for package 3. The pattern calculation unit 19 sets the group stowage pattern for package 3 to a pattern in which packages 3-1 and 3-2 are stowed in a straight line.

The luggage contained in package 3 can be added to the luggage contained in package 1. The pattern calculation unit 19 considers group combination patterns to consider combinations between groups.

The cargo contained in package 3 cannot be placed on top of cargo 1-1, 1-2, 1-3, and 1-4.

On top of the packages 1-5 and 1-6 stacked together, two packages included in package 3 can be stacked on top of each other as shown in Figure 4(h). The height is 37 cm, which does not exceed the height limit _HMAX of 39 cm.

As shown in FIG. 4(h), the pattern calculation unit 19 determines that the group combination pattern for package 3 with respect to package 1 is a combination of packages 3-1 and 3-2 stacked on top of packages 1-5 and 1-6.

With reference to Figures 4(i) to (l), an example of processing by the pattern calculation unit 19 for package 4 cargo will be described.

4(i) shows a case where one unit included in package 4 is stowed uniformly. In this case, the height is 15 cm, which does not exceed the height limit _HMAX of 39 cm. Therefore, one unit can be stowed uniformly for package 4. The pattern calculation unit 19 sets the group stowage pattern for package 4 to a pattern in which unit 4-1 is stowed uniformly.

The parcel contained in package 4 can be added to the parcels contained in packages 1, 2, and 3. The pattern calculation unit 19 considers group combination patterns to consider combinations between groups.

Regarding the packages contained in package 1, packages 1-1, 1-2, 1-3, and 1-4 stacked randomly, packages contained in package 4 cannot be stacked on top of them. Packages 1-5 and 1-6 stacked randomly, packages contained in package 4 can be stacked on top of them as shown in Figure 4(j). The height is 35 cm, which does not exceed the height limit H _MAX of 39 cm.

Regarding the packages contained in package 2, packages 2-1, 2-2, 2-3, and 2-4 stacked randomly, packages contained in package 4 cannot be placed on top of them. Packages 2-1, 2-2, 1-5, and 1-6 stacked randomly, packages contained in package 4 cannot be placed on top of them. Packages 2-3 and 2-4 stacked randomly, packages contained in package 4 can be placed on top of them as shown in FIG. 4(k). The height is 33 cm, which does not exceed the height limit H _MAX of 39 cm.

Regarding the packages contained in package 3, packages 1-5, 1-6, 3-1, and 3-2 are stacked randomly, and packages contained in package 4 cannot be placed on top of them. Packages 3-1 and 3-2 are stacked randomly, and packages contained in package 4 can be placed on top of them as shown in Figure 4(l). The height is 32 cm, which does not exceed the height limit _HMAX of 39 cm.

As shown in Figures 4(j), (k), and (l), the pattern calculation unit 19 determines that the group combination pattern for package 4 is a random combination of packages 1-5, 1-6, and 4-1 for package 1, a random combination of packages 2-3, 2-4, and 4-1 for package 2, and a random combination of packages 3-1, 3-2, and 4-1 for package 3.

With reference to Figure 5, an example of the processing of the pattern calculation unit 19 will be specifically described.

The pattern calculation unit 19 refers to the group stowage pattern and group combination pattern to consider the one that requires the fewest number of carts. In this case, it is not possible to transport all the luggage using one cart. The case where there are two carts (i.e., two rows per cart, for a total of four rows) is considered.

When the height limit _HMAX is satisfied and the number of carts is two, there are five patterns as shown in Figure 5 (a) to (e). In each pattern, the stowage pattern candidates are obtained by distributing four rows to two carts.

When transporting by cart, it is desirable that the height of the stacking of each cart is similar. Therefore, for the five patterns in Figures 5(a) to (e), the average standard deviation of the rows included in each cart is calculated when the four rows are divided into two carts, and the one with the smallest standard deviation is selected. Here, for example, processing may be performed to make the packing as low as possible without increasing the number of carts. In Figure 5, (a), (b), (d), and (e), one row is lower than the other rows and has a large standard deviation. On the other hand, in Figure 5(c), there is no extremely low row, and it can be divided into two rows of approximately the same height. Therefore, as shown in Figure 5(f), the division into two carts based on Figure 5(c) is selected as the stowage pattern.

For example, as shown in Figure 6, if each case is considered separately, it is possible that a more appropriate method of classification may exist. However, classification like that in Figure 6 requires a huge amount of calculation to compare each piece of luggage, and furthermore, the sorting unit needs to rearrange all the luggage in the appropriate order, which places too much of a load on the overall processing.

The present invention does not rearrange within a group, which can significantly reduce the rearrangement work by the rearrangement unit 9. Furthermore, the stowage pattern calculation device 3 also divides into groups, calculates the stowage for each group and the stowage between groups separately, combines them to find stowage pattern candidates, and compares them to select the appropriate one, which can significantly reduce the calculation load.

The criteria for selecting a stowage pattern from the candidate stowage patterns can be any or all of the following: a small number of carts (i.e., a large amount of luggage loaded on each cart), a small number of rows (i.e., a large amount of luggage loaded on each row), a small number of rows for the last cart, a low last row, small unevenness (small average standard deviation of the height of each row, small average standard deviation of the height of each row per cart, etc.; taking into consideration workability with carts), small number of groups added on (small number of groups added on), small total stowage length (sum of W dimensions of each row), etc.

In addition, when there are two or more carts, the maximum height that can be loaded can be calculated, and the calculation can be repeated using the same method. If the number of carts decreases as a result, a new loading pattern can be determined, and if the number of carts remains the same, the original pattern can be determined as the loading pattern. In addition, in order to level out the height of the rows, the height can be gradually subtracted from the upper limit and recalculated to determine the loading pattern just before the number of carts increases.

In addition, in the present invention, for example, the pattern selection unit 21 may select a plurality of stowage patterns, and the rearrangement unit 9 and the stowage unit 11 may detect the position of the luggage supplied from the removal unit 7 to the rearrangement unit 9, and rearrange and stow the luggage using a stowage pattern that minimizes rearrangement in the rearrangement unit 9.

In addition, in the present invention, the loading work may be performed manually.

1 Stacking system, 3 Stacking pattern calculation device, 5 Storage unit, 7 Removal unit, 9 Rearrangement unit, 11 Stacking unit, 13 Cart, 15 Shipping data acquisition unit, 17 Grouping unit, 19 Pattern calculation unit, 21 Pattern selection unit, 23 Master data storage unit, 51 Control panel, 53 Cart supply device, 55 Pusher device, 59 Case supply conveyor, 61 Stacking unit, 64 Baggage transport position, 65 Slider device, 67 Stacking unit

Claims (5)

A loading system for taking out a plurality of packages from a storage unit and loading them onto a cart,
a loading pattern calculation device that calculates a loading pattern for loading the plurality of cargo items onto the cart;
a rearrangement unit that rearranges the plurality of packages taken out from the storage unit using the stowage pattern,
The stowage pattern calculation device comprises:
A grouping unit that divides the plurality of packages into groups;
a pattern selection unit that selects a stowage pattern from stowage pattern candidates that can stow the plurality of packages belonging to a group on the cart even if the plurality of packages belonging to the group are supplied in different orders,
The rearrangement unit maintains the order of luggage belonging to the same group without changing it, and rearranges luggage belonging to different groups using the stowage pattern. The stowage pattern calculation device includes a pattern calculation unit,
The pattern calculation unit
In each group,
A pattern is calculated that allows the plurality of packages belonging to the group to be loaded onto the cart even if they are supplied in different orders;
If the luggage belonging to the group can be placed on a cart together with luggage belonging to other groups, a loading pattern is calculated for at least one of the other groups, using a pattern that allows the luggage to be loaded onto the cart even if it is supplied in the different order, together with the luggage belonging to the other groups;
The stowage system according to claim 1 , wherein the stowage pattern candidates are calculated by combining the calculated patterns. The stowage system according to claim 1 or 2, wherein the pattern selection unit selects a stowage pattern from the stowage pattern candidates based on at least one of the following criteria: a pattern that reduces the number of carts, a pattern that reduces the difference in overall distribution of luggage, and a pattern that reduces the difference in distribution of luggage among each cart. A stowage method for a stowage system that takes out a plurality of packages from a storage unit and stows them on a cart, comprising the steps of:
The stowage system comprises:
a loading pattern calculation device that calculates a loading pattern for loading the plurality of cargo items onto the cart;
a rearrangement unit that rearranges the plurality of packages taken out from the storage unit using the stowage pattern;
a loading unit that loads the plurality of packages onto the cart using the loading pattern,
A grouping unit included in the stowage pattern calculation device divides the plurality of luggage into groups;
a pattern selection unit of the stowage pattern calculation device selecting the stowage pattern from stowage pattern candidates that allow multiple units to be loaded onto the cart even if the multiple units belong to a group and are supplied in different orders;
The stowage method includes a step in which the rearrangement unit maintains the order of luggage belonging to the same group without changing it, and rearranges luggage belonging to different groups using the stowage pattern. A program for causing a computer to function as a stowage pattern calculation device that calculates a stowage pattern for stowage of a plurality of packages taken out of a storage unit onto a cart, the program comprising:
The computer,
A grouping unit that divides the plurality of packages into groups;
The program functions as a pattern selection unit that selects a stowage pattern from candidate stowage patterns that can load multiple packages belonging to a group onto the cart even if the multiple packages are supplied in different orders to the group.

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