The field of the invention is that of logistics.
More specifically, the invention relates to a system for conveying loads without sequencing, between a plurality of storage units and a plurality of preparation stations.
The storage units correspond for example to the different exits from alleys in an automated storage/removal warehouse.
The term “sequencing” (or “providing sequenced loads”), is understood to mean the providing, under a constraint of delivery, of at least one sequence comprising loads in a desired sequential order.
In the context of the present invention, it is assumed that in the outbound direction, the loads are conveyed from the storage units up to the preparation stations without being sequenced, and that the sequencing (if there is one) is done in each of the preparation stations. In other words, if a sequencing is needed, it is assumed that each preparation station is equipped for this purpose with a buffer storage and load sequencing system, for example, one of the types described in the patent applications FR1563151 dated 22 Dec. 2015 and FR1654863 dated 30 May 2016.
It is also assumed that the conveying system should be such that:
Referring now to
The management system also manages the list of customer orders associated with each shipping container (target load) and therefore the sequential order of the customer order lines forming this list, as a function of the location of the storage containers (source loads) in the automated warehouse 7, the availability of the trolleys and the elevators of the automated warehouse 7 as well as requirements in terms of items and goods of the different shipping containers to be prepared that succeed one and other at the preparation station. The purpose of this is to optimize all the movements and the preparation times for the shipping containers and ensure synchronization between the arrival, at the preparation station, of a shipping container and the corresponding storage containers (containing goods indicated in the customer order list associated with this storage container).
In the example of
A buffer storage function (also called an “accumulation function”) for buffering a determined quantity of containers upstream to the operator (or automaton) is set up in each of the first and second circuits, by the outbound column 3 and 4 (composed of classic horizontal conveyors). A storage container therefore makes the following journey: it is picked up by a trolley in the automated warehouse 7, and is then conveyed successively by one of the conveyors 9a and 9a′ (depending on whether it arrives at the alley 7a or 7a′) and by the conveyors 6 and 8 and finally by the conveyors of the forward or outbound column 2 to be presented to the operator. In the other direction (after presentation to the operator), the storage container makes the reverse journey: it is conveyed by the conveyors of the return column 3, then by the conveyors 8′ and 6′ and finally by one of the conveyors 9b and 9b′ (depending on whether it is returning to the alley 7a or the alley 7a′) and is then re-positioned in the automated warehouse 7 by means of a trolley.
As mentioned further above, the containers (source loads and target loads) has to be presented to the operator in a desired sequential order forming at least one determined sequence. Classically, this sequential order of arrival is pre-determined by the management system (i.e. it is determined, for each container, before this container reaches the preparation station) and, if necessary, recomputed during the conveying of the containers from the automated warehouse 7 exit to the preparation station (for example to cope with a malfunction of an element of the system).
In a first known implementation of the sequencing (i.e. the sequencing function), a first level of sequencing is obtained by the deposition of the pre-sequenced loads on each of the conveyors 9a and 9a′. There are therefore constraints on the automated warehouse 7. In other words, the loads deposited on the conveyor 9a are in a sequential order consistent with that of the final desired sequential order and the loads deposited on the conveyor 9a′ are also in a sequential order consistent with that of the final desired sequential order. Then, a second level of sequencing is achieved through the deposition on the conveyor 6, in the final desired sequential order, of the loads coming from the conveyors 9a and 9a′. For example, for a sequence of seven loads, if the loads of ranks 1, 2, 4 and 5 are stored in the alley 7a, they are deposited in this order on the conveyor 9a and if the loads of the ranks 3 and 6 are stored in the alley 7a′, they are deposited in this order on the conveyor 9a′; then, the seven loads are deposited on the conveyor 6 in ascending order (from 1 to 7) of their ranks.
In a second known implementation of the sequencing operation, in order to relax the constraints on the automated warehouse 7, it is accepted that the containers will not exit the automated warehouse 7 in the desired sequential order (i.e. the order in which they has to be presented to the operator). It is therefore necessary to carry out two operations, one for conveying and the other for sequencing the containers between the automated warehouse 7 and the preparation station where the operator is situated. The elimination of the sequencing constraints, which usually weigh on the automated warehouse 7, significantly increases the performance of this automated warehouse (and more generally of the different upstream devices) and therefore reduces its size and complexity and therefore its cost. In the example of
It will be noted that in a known way, the above-mentioned principle of the loop (carousel) is also used to carry out the single function of conveying loads (in
The use of a loop (carousel) to carry out the load-conveying function but not the sequencing function is not an optimum solution in terms of distance travelled by the loads or even less in terms of quantity of loads that can be conveyed simultaneously.
Thus, in the example of
In addition, certain sections of the loop are travelled by all the loads: on the outbound journey, the section situated between the connection point (on the conveyor 6 of the loop) of the exit conveyor 9a of the alley 7a and the connection point (on the conveyor 8 of the loop) of the entry conveyor 3 or 4 of the preparation station 10a; on the return journey, the section situated between the connection point (on the conveyor 8′ of the loop) of the exit conveyor 2 or 5 of the preparation station 10a and the connection point (on the conveyor 6′ of the loop) of the entry conveyor 9b of the alley 7a.
In the least favorable case, i.e. to travel the longest path (outbound or return) between one of the alleys 7a, 7a′ of the automated warehouse 7 and one of the preparation stations 10a to 10f, a load must pass before the other alley or alleys of the automated warehouse 7 and the other preparation station or stations. In the example of
One particular embodiment of the invention proposes a system for conveying loads without sequencing, between a plurality of storage units and a plurality of preparation stations. This system comprises:
The general principle of the invention consists therefore of the setting up, between the storage units and the preparation stations, of a horizontal load-routing network having a structure comprising the following elements: the first and second collecting conveyors, the storage unit entrance conveyors, the storage unit exit conveyors, the preparation station entrance conveyors, the preparation station exit conveyors, the outbound junction conveyor and the return junction conveyor. The outbound junction conveyor and the return junction conveyor provide direct junctions between the first and second collecting conveyors.
This horizontal load routing network is simple to implement because all its elements are positioned in the same horizontal plane.
In addition, it does away with the use of an endless loop (carousel) to carry out the load-conveying function. This minimizes the distance travelled by each load and increases the quantity of loads that can be conveyed (distributed) simultaneously.
According to one particular characteristic, the outbound junction conveyor is aligned with the storage unit exit conveyor and the preparation station entry conveyor, respectively associated with the storage unit and with the preparation station of said at least one couple. In addition, the return junction conveyor is aligned with the storage unit entry conveyor and the preparation station exit conveyor respectively associated with the storage unit and the preparation station for said at least one couple.
Thus, the distance travelled by each load is even further reduced.
According to one particular characteristic, the storage unit entrance conveyors, the storage unit exit conveyors, the preparation station entrance conveyors, the preparation station exit conveyors, the outbound junction conveyors and the return junction conveyors are perpendicular to the first and second collecting conveyors.
Thus, the horizontal routing network is constituted by two mutually parallel collecting conveyors and by conveyors perpendicular to these two collecting conveyors. This simple and efficient horizontal routing structure facilitates the conveying (“routing”) of the loads between the storage units and the preparation stations.
According to one particular characteristic, for a conveying of loads between N storage units and M preparation stations, K couples each comprising a storage unit and a preparation station facing each other on either side of the first and second collecting conveyors, with K=min (N, M), the system comprises a pair of junction conveyors for each of the K couples.
In this way, by maximizing the number of couples each comprising a storage unit and a preparation station facing each other, the invention optimizes (minimizes) the number of pairs of junction conveyors needed, within the horizontal routing network, for the conveying of loads from/to the storage units and the preparation stations of these pairs.
One particular characteristic of the invention relates to the case where a given load has to be conveyed from a given storage unit, of which the associated storage unit exit conveyor is connected to the first collecting conveyor at a first connection point, to a given preparation station, of which the associated preparation station entry conveyor is connected to the second collecting conveyor at a second connection point. In this case, the system comprises a unit for managing collecting conveyors and junction conveyors of said system, said management unit being configured so that, between the first and second connection points, the given load is transported in travelling through a minimum distance:
Thus, in the case of a conveying of a load from a storage unit to a preparation station, the structure of the horizontal routing network ensures that the load travels a minimum distance.
One particular characteristic of the invention is related to the case where a given load has to be conveyed from a first given storage unit, of which the associated storage unit exit conveyor is connected to the first collecting conveyor at a first connection point, to a second given storage unit, of which the associated storage unit entry conveyor s connected to the first collecting conveyor at a third connection point. In this case, the system comprises a management unit for managing the collecting conveyors and the junction conveyors of said system, said management unit being configured so that between the first and third connection points, the given load is transported in travelling through a minimum distance:
Thus, in the case of a conveying of a load from a first storage unit to a second storage unit, the horizontal network routing structure ensures that the load travels through a minimum distance.
According to one particular characteristic, the invention is situated in the case where a given load has to be conveyed from a given preparation station, of which the associated preparation station exit conveyor is connected to the second collecting conveyor at a fourth connection point, to a given storage unit, of which the associated storage unit entry conveyor is connected to the first collecting conveyor at a fifth connection point. In this case, the system comprises a management unit for managing the collecting conveyors and the junction conveyors of said system, said management unit being configured so that, between the fourth and fifth connection points, the given load is transported in travelling a minimum distance:
Thus, in the case of a conveying of a load from a preparation station to a storage unit, the horizontal routing network structure ensures that the load will travel a minimum distance.
One particular characteristic of the invention relates to the case where a given load has to be conveyed from a first given preparation station, of which the associated preparation station exit conveyor is connected to the second collecting conveyor at a fourth connection point, to a second given preparation station, of which the associated given preparation station entry conveyor is connected to the second collecting conveyor at a sixth connection point. In this case, the system comprises a management unit for managing the collecting conveyors and junction conveyors of said system, said management unit being configured so that, between the fourth and sixth connection points, the given load is transported in travelling a minimum distance:
Thus, in the case of a conveying of a load from a first preparation station to a second preparation station, the structure of the horizontal routing network ensures that the load will travel a minimum distance.
According to one particular characteristic, for at least one storage unit that does not face a preparation station and is situated in the direction of movement of the first collecting conveyor, upstream to the first other storage unit facing a preparation station, the system comprises a single junction conveyor which is a return junction conveyor interconnecting the first and second collecting conveyors in the direction going from the first to the second collecting conveyor, and is preferably aligned with the entry conveyor of the storage unit associated with said at least one storage unit.
Thus, for such a storage unit (not coupled with a preparation station and upstream—in the direction of forward feed of the loads on the first collecting conveyor—to the first other storage unit facing a preparation station), a return junction conveyor is sufficient (there is no need for an outbound junction conveyor).
According to one particular characteristic, for at least one storage unit that is not facing a preparation station and is situated along the direction of movement of the first collecting conveyor, downstream to the last other storage unit facing a preparation station, the system comprises a single junction conveyor which is an outbound junction conveyor interconnecting the first and second collecting conveyors in the direction going from the first collecting conveyor to the second collecting conveyor and which is preferably aligned with the storage unit exit conveyor associated with said at least one storage unit.
Thus, for such a storage unit (not coupled with a preparation station and downstream (in the direction of forward feed of the loads on the first collecting conveyor) to the last other storage unit facing a preparation station), an outbound junction conveyor is sufficient (there is no need for a return junction conveyor).
According to one particular characteristic, for at least one storage unit that is not facing a preparation station and is situated along the direction of movement of the first collecting conveyor, between two other storage units each facing a preparation station, the system comprises a pair of junction conveyors interconnecting the first and second collecting conveyors in opposite directions of movement and comprising an outbound junction conveyor having a direction of movement from the first to the second collecting conveyor and preferably aligned with the storage unit exit conveyor associated with said at least one storage unit, and a return junction conveyor, having a direction of movement from the second to the first collecting conveyor, and preferably aligned with the entry conveyor of the storage unit associated with said at least one storage unit.
Thus, for such a storage unit (not coupled with a preparation station and situated between two other storage units each facing a preparation station), a return junction conveyor and an outbound junction conveyor are needed.
According to one particular characteristic, for at least one preparation station that does not face a storage unit and is situated, in the direction of movement of the second collecting conveyor, upstream to the first other preparation station, facing a storage unit, the system comprises a single junction conveyor which is an outbound junction conveyor interconnecting the first and second collecting conveyors in the direction going from the first to the second collecting conveyor, and which is preferably aligned with the preparation station entry conveyor associated with said at least one preparation station.
Thus, for a preparation station of this kind (not coupled with a storage unit and upstream—in the direction of forward feed of the loads on the second collecting conveyor—to the first other preparation station facing a storage unit), an outbound junction conveyor suffices (there is no need for a return junction conveyor).
According to one particular characteristic, for at least one preparation station that does not face a storage unit and is situated in the direction of movement of the second collecting conveyor, downstream to the last other preparation station facing a storage unit, the system comprises a single junction conveyor that is a return junction conveyor interconnecting the first and second collecting conveyors in the direction going from the second to the first collecting conveyor, and which is preferably aligned with the associated preparation station exit conveyor associated with said at least one preparation station.
Thus, for such a preparation station (not coupled to a storage unit downstream—in the direction of forward feed of the loads on the second collecting conveyor—to the last other preparation station facing a storage unit), a return junction conveyor suffices (there is no need for an outbound junction conveyor).
According to one particular characteristic, for at least one preparation station that does not face a storage unit and is situated, in the direction of movement of the second collecting conveyor, between two other preparation stations each facing a storage unit, the system comprises a pair of junction conveyors interconnecting the first and second collecting conveyors in opposite directions of movement and comprising an outbound junction conveyor, having a direction of movement from the first to the second collecting conveyor and being preferably aligned with the entry conveyor of the preparation station, associated with said at least one preparation station, and a return junction conveyor, having a direction of movement from the second to the first collecting conveyor and being preferably aligned with the preparation station exit conveyor associated with at least one preparation station.
Thus, for such a preparation station (not coupled to a storage unit and situated between two other preparation stations each facing a storage unit), a return junction conveyor and an outbound junction conveyor are necessary.
Other features and advantages of the invention shall appear from the following description, given by way of a non-exhaustive and indicatory example and from the appended drawings of which:
In all the figures of the present document, identical elements and steps are designated by a same numerical reference.
As already mentioned further above, if a sequencing is necessary, it is assumed that each preparation station is equipped to this effect with a buffer storage and load sequencing system (for example one of the types described in the patent applications FR1563151 dated 22 Dec. 2015 and FR1654863 dated 30 May 2016).
The system comprises two collectors (i.e. collecting conveyors), a plurality of conveyors and a managing unit. All these elements are described in detail here below.
In general, the direction of movement of each collector or conveyor (i.e. the direction of movement of the loads on this conveyor) is illustrated in the figures by the direction of the arrow schematically representing this collector or conveyor.
One of the collectors, called a “first collector” is referenced C1. The other, called “second collector”, is referenced C2. They are positioned on a same plane. They are rectilinear and parallel. They have opposite directions of movement. In
Each storage unit A1 to A4 is connected to the first collector C1 by a pair of conveyors comprising a storage unit entry conveyor ia1 to ia4 and a storage unit exit conveyor oa1 to oa4.
Each preparation station P1 to P4 is connected to the second collector C2 by a pair of conveyors comprising a preparation station entry conveyor ip1 to ip4 and a preparation station exit conveyor op1 to op4.
The four storage units A1 to A4 and the four preparation stations P1 to P4 form four pairs (A1, P1), (A2, P2), (A3, P3), (A4, P4) each comprising a storage unit and a preparation station facing each other on either side of the first and second collectors C1, C2. For each of these pairs, the system comprises a pair of a junction conveyors interconnecting the first and second collectors C1, C2 and comprising:
For example, for the couple (A1, P1), the system comprises the following pair of junction conveyors:
In one variant, for a couple comprising a storage unit and a preparation station facing each other on either side of the first and second collectors, the outbound junction conveyor ja1 to ja4 is not aligned with the storage unit exit conveyor oa1 to oa4 nor is it aligned with the preparation station entry conveyor ip1 to ip4, and the return junction conveyor jr1 to jr4 is not aligned with the storage unit entrance conveyors ia1 to ia4, nor is it aligned with the preparation station exit conveyors op1 to op4.
In the particular embodiment of
The managing unit UP manages the collectors and conveyors described here above, to enable different types of load transfer that are described in detail here below:
Transfer of a Load from a Storage Unit to a Preparation Station
Let us consider the case of a load that has to be conveyed:
In this case, the managing unit UP is configured to manage the first and second collectors C1, C2, the outbound junction connectors ja1 to ja4 and the return junction connectors jr1 to jr4 so that between the first and second connection points (oai/C1 and C2/ipi), the loads are transported in travelling a minimum distance. It is possible to distinguish between the following three situations:
Transfer of a Load between Two Storage Units
Let us consider the case of a load that has to be conveyed:
In this case, the managing unit UP is configured to manage the first and second collectors C1, C2, the outbound junction conveyors ja1 to ja4 and the return junction conveyors jr1 to jr4, so that between the first and third connection points (oai/C1 and C1/iaj), the load is transported in travelling a minimum distance. The following two situations can be distinguished:
Transfer of a Load from a Preparation Station to a Storage Unit
Let us consider the case of a load that has to be conveyed:
In this case, the driving unit UP is configured to drive the first and second collectors C1, C2, the outbound junction conveyors ja1 to ja4 and the return junction conveyors jr1 to jr4, so that between the fourth and fifth connection points (opi′/C2 and C1/iaj′), the load is transported in travelling a minimum distance. The following three situations can be distinguished:
Transfer of a Load between Two Preparation Stations
Let us consider the case of a load to be conveyed:
In this case, the managing unit UP is configured to manage the first and second collectors C1, C2, the outbound junction conveyors ja1 to ja4 and the return junction conveyors jr1 to jr4, so that between the fourth and fifth connection points (opi/C2 and C2/ipj), the load is transported in travelling a minimum distance. The following two situations can be distinguished:
In this case, the system enables a conveying of loads between N storage units and M preparation stations, with N=5 and M=4. There are K couples each comprising a storage unit and a preparation station facing each other on either side of the first and second collectors, with K=min (N, M)=4. For each of the K couples, the system comprises a pair of junction conveyors (ja, jr).
The storage unit A5 is connected to the first collector C1 by a pair of conveyors comprising storage entry conveyor ia5 and a storage unit exit conveyor oa5. For the storage unit A5, the system comprises a single junction conveyor which is a return junction conveyor jr5 interconnecting the first and second collectors C1, C2 in the direction going from the second to the first collector. This return junction conveyor jr5 is aligned with the storage unit entry conveyor ia5. For the storage (return path), the return junction conveyor jr5 makes it possible for a load coming from one of the preparation stations P1 to P4 to go to the storage unit A5. For the removal of loads (on the outbound path) from the storage unit A5, the operation is identical to the one described further above with
In this case, the system makes it possible to convey loads between N storage units and M preparation stations, with N=7 and M=4. There are K couples each comprising a storage unit and a preparation station, facing each other on either side of the first and second collectors, with K=min (N, M)=4. For each of the K couples, the system comprises a pair of junction conveyors (ja, jr).
The storage unit A0 is connected to the first collector C1 by a pair of conveyors comprising a storage unit entry conveyor ia0 and a storage unit exit conveyor oa0. For the storage unit A0, the system comprises a single junction conveyor, which is an outbound junction conveyor ja0 interconnecting the first and second collectors C1, C2 in the direction going from the first to the second collector. This outbound junction conveyor ja0 is aligned with the storage unit exit conveyor oa0. For the removal of loads (outbound path) from the storage unit A0, the outbound junction conveyor ja0 makes it possible, for a load coming from the outbound storage unit A0, to go to one of the preparation stations P1 to P4. For the storage (return path) in the storage unit A0, the operation is identical to the one described further above with
The storage unit A3′ is connected to the first collector C1 by a pair of conveyors comprising a storage unit entry conveyor ia3′ and a storage unit exit conveyor oa3′. For the storage unit A3′, the system comprises a pair of junction conveyors (ja3′, jr3′) interconnecting the first and second collectors C1, C2 along opposite directions of movement and comprising an outbound junction conveyor ja3′, having a direction of movement from the first to the second collector and being aligned with the storage unit exit conveyor oa3′, and a return junction conveyor jr3′, having a direction of movement from the second to the first collector and being aligned with the storage unit entry conveyor ia3′. For the removal (outbound path) from the storage unit A3′, the cases 2 and 3 for the outbound path, described further above with
In this case, the system enables a conveying of loads between N storage units and M preparation stations, with N=4 and M=5. There are K couples each comprising a storage unit and the preparation station facing each other on either side of the first and second collectors, with K=min (N, M)=4. For each of the K couples, the system comprises a pair of junction conveyors (ja, jr).
The preparation station A5 is connected to the second collector C2 by a pair of conveyors comprising a preparation station entry conveyor ip5 and a preparation station outbound conveyor op5. For the preparation station P5, the system comprises a single junction conveyor which is a return junction conveyor jr5 interconnecting the first and second collectors C1, C2 in the direction going from the second to the first collector. This return junction conveyor jr5 is aligned with the preparation station exit conveyor op5. For the storage (return path), the return junction conveyor jr5 enables a load coming from the preparation station P5 to go to one of the storage units A1 to A4. For the load removal (outbound path) from one of the storage units A1 to A4, the operation is identical to the one described further above with reference to
The system in this case enables a conveying of loads between N storage units and M preparation stations, with N=4 and M=7. There are K couples each comprising a storage unit and a preparation station facing each other on either side of the first and second collectors, with K=min (N, M)=4. For each of the K couples, the system comprises a pair of junction conveyors (ja, jr).
The preparation station P0 is connected to the second collector C2 by a pair of conveyors comprising a preparation station entry conveyor ip0 and a preparation station exit conveyor op0. For the preparation station P0, the system comprises a single junction conveyor which is an outbound junction conveyor ja0 interconnecting the first and second collectors C1, C2 in the direction going from the first collector to the second collector. This outbound junction conveyor ja0 is aligned with the preparation station entry conveyor ip0. For the removal of loads (outbound path), the outbound junction conveyor ja0 enables a load coming from one of the storage units A1 to A4 to go to the preparation station P0. For the storage (return path) from the preparation station P0 to one of the storage units A1 to A4, the operation is identical to the one described further above with
The preparation station P3′ is connected to the second collector C2 by a pair of conveyors comprising a preparation station entry conveyor ip3′ and a preparation station exit conveyor op3′. For the preparation station P3′, the system comprises a pair of junction conveyors (ja3′, jr3′) interconnecting the first and second collectors C1, C2 along opposite directions of movement and comprising an outbound junction conveyor ja3′, having a direction of movement from the first to the second collector and aligned with the preparation station entry conveyor ip3′, and a return junction conveyor jr3′, having a direction of movement from the first to the second collector and being aligned with the preparation station exit conveyor op3′. For the load removal (the outbound path) to the preparation station P3′, the cases 2 and 3 for the outbound path described further above with
The input signals 104 comprise various pieces of information on the operating of the general system (comprising especially the storage units, the preparation stations, the collectors, the storage unit entry conveyors, the storage unit exit conveyors, the preparation station entry conveyors, the preparation station exit conveyors, the outbound junction conveyors, the return junction conveyors), especially the load identifiers read (by barcode or RFID label types of reader devices, etc.) on the loads when they pass by different places in the general system (for example, at the extremities of the different conveyors).
The output signal 105 comprises various pieces of control information for the management of the devices of the general system in order to manage the movements of the loads in the general system.
This
It is clear that many other embodiments of the invention can be envisaged without departing from the framework of the present invention, especially as a function of the values taken by the number N of storage units and the number M of preparation stations (as described further above, through several examples, three cases are possible: N=M, N<M and N>M).
An exemplary embodiment of the present disclosure overcomes the different drawbacks of the prior art.
More specifically, an exemplary embodiment provides a system for conveying loads without sequencing, between a plurality of storage units and a plurality of preparation stations, the system not having the drawbacks related to the use of a loop (carousel).
An exemplary embodiment provides a system of this kind to minimize the distances travelled by the loads and to increase the quality of loads that can be conveyed simultaneously.
An exemplary embodiment provides a system of this kind that has a multiplier effect on the use of the devices that constitute it (in particular collectors and conveyors).
An exemplary embodiment provides a system of this kind that is simple to implement and costs little.
Number | Date | Country | Kind |
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1756449 | Jul 2017 | FR | national |
This Application is a Section 371 National Stage Application of International Application No. PCT/EP2018/068213, filed Jul. 5, 2018, the content of which is incorporated herein by reference in its entirety, and published as WO 2019/008084 on Jan. 10, 2019, not in English.
Filing Document | Filing Date | Country | Kind |
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PCT/EP2018/068213 | 7/5/2018 | WO | 00 |