Automated system for preparing parcels

Translation of description of equivalent WO 2008152244 A2

AUTOMATED SYSTEM PACKAGE PREPARATION

p0002The present invention relates to an automated preparation products control package, particularly control unit readiness and a parcel preparation process using said system.

p0003These parcel preparation systems are especially used in shipping firms and distance selling small volume products. The main examples of users of automated parcel preparation are office equipment suppliers, clothing, cosmetics, tools or spare parts in the engineering industry. These systems allow to prepare with a minimum of labor, within a short time and with accurate inventory tracking, a package for a specific a customer order, said order for several products in various quantities, each products with the quantity being identified by a command line. Automated systems known parcel preparation usually consist of an automated warehouse containing products in containers of a picking station where the products are removed and placed in a package, with a conveyor bringing products store pickup station and vice versa and a central computer system management.

p0004In order picking systems by unit, each container is associated with a unique reference product. An automated storage magazine comprises a plurality of superimposed storage levels which transfer devices ensure the transport of goods, for their implementation within areas _ 9 - storage and for their withdrawal from these areas.

p0005A first known example of automated parcel preparation system and implements a store horizontal carousel. This system has the disadvantage of linking the flow of goods and storage. Moreover, it is not possible to replenish the carousel while that it is used to prepare parcels.

p0006Another known technology stores is that in which the transfer device is formed by the association of at least one transfer shuttle and elevator. The storage magazine then includes storage units, each storage unit being formed of a path serving to either side of a shelf tiered storage, said shelf being subdivided on its cell in storage length for accommodation each containing a product, the path receiving, at each storage level of the tracks for the movement of a shuttle and elevator being disposed at at least one end of the aisle. One channel is generally formed of two parallel rails and the shuttle is provided with wheels to move on these rails. Shuttles can therefore move horizontally at one level, but also be brought from one level to another by forklift according to the possibilities provided by the manufacturer of the store.

p0007Are thus known example of a parcel preparation system based on shuttles and lifting solution in which each storage level includes a shuttle that deposits the containers, which are specific bins disposed or not on trays, in elevators. In this system, the shuttles are powered by busbars. This solution is not optimal, especially from the perspective of the occupation shuttles and total cost installation because of the required amounts of conductor rails and risks of immobilization of the shuttle in case of items on the rails generating poor electrical contact between the rail and the shuttle. In another example based on the same technology, the shuttles are also fed by conductor rail but may use the elevators to move from one level to another and also circulate on the conveyor. In the last two examples, these systems require the prior transfer of products in specific containers to the system.

p0008Other embodiments of parcel preparation systems based on store solutions with shuttles and lift are given in DE 202 11 321 U and DE 201 12 328 ϋ.

p0009The first proposes a system in which the store shelves are divided into independent sub-sectors, each sub-sector with a lift associated with a shuttle and a loading buffer / unloading of containers from and to horizontal conveyors bringing the containers to picking stations. In DE 201 12 328 U, the scheduling of the containers is done at the warehouse, the products being removed in the order on the order list and headed to the picking stations as they exit the store through a system of complex distribution based on conveyors with circulation loops intersecting on different levels. These known parcel preparation systems therefore have various disadvantages related to their manufacturing costs, operating and maintenance, the time needed to prepare a package, and the complexity of managing the movements of the different elements.

p0010The present invention therefore aims to remedy these drawbacks by proposing a novel solution for automated preparation products control package that is scalable, whose storage capacity is separated from the flow of products in which the management of the different elements movements is simplified and the costs of production and operation are economically attractive. In this regard, the system of the invention comprises:

p0011- A storage magazine having at least • a set of storage, each storage unit being formed of a path serving to either side of a shelf tiered storage, said shelf being divided lengthwise into storage cells designed to accommodate each containing a product, this path receiving, at each storage level of the tracks for moving a shuttle for the introduction or extraction of said containers inside the cells and a lift being arranged at least one end of the aisle, the elevator can take a shuttle from one level to another level and having an inlet and / or outlet store for product containers, - a removal station where an operator prepares the package by placing the desired amount of product,

p0012- A main conveyor bringing all container products from the entrance / exit of the store picking station and vice versa - a central management computer system controlling the movements of each package, each shuttle and each elevator and each product containing manage the product order list associated with each package, said list consisting of control lines each indicating the product and the desired amount, the main assembly conveyor comprising means for scheduling according to their order product containers on the order list, so they appear in this order to the picking station.

p0013This system is remarkable in that the scheduling means comprise a first conveyor strand, said input / output bit, a second strand conveying said strand storage, parallel and adjacent to the first strand and attached to the post collection, said conveying strands being situated horizontally at the same level, and an intermediate buffer zone between the output of the store and the first conveyor strand, the product containers being transposed between the strands at transfer zones by organs of transfer and the direction of travel of the two strands being opposite, so that the flow of goods containers between the input / output of the store and picking station is done repeatedly. One understands that this system allows more freedom in managing the movement of the shuttles and elevators for the final scheduling is provided outside the store. In addition and advantageously, this system simplifies the preparation of packages by the operator because different product containers are presented to it in a given order and in coincidence with the successive arrivals of packages to prepare for the picking station.

p0014Other features and advantages become apparent from the following description of an embodiment given by way of example, the automated parcel preparation system with reference to the accompanying figures in which:

p0015- Figure 1 is a top view of a schematic representation of the system according to the invention; S _ -

p0016- Figure 2 is a partial sectional view along the axis II-II 'of Figure 1, storage magazine forming part of the system according to the invention.

p0017Referring to Figures 1 and 2, the automated system for preparing one package 100 includes a storage magazine 2 shown here in a configuration with four storage assemblies 3. Each of the storage units 3 is formed of a path serving to 4 hand and the other a storage shelf 5 at several levels, said shelves 5 are subdivided along their length into 6 storage cells intended to each receive a container 7 products.

p0018At each level, the path receives a path 8 comprising two parallel rails for moving a transfer shuttle 9. Each storage assembly 3 has an associated elevator 10 disposed at the same end of the aisle 4, for 9 transport a shuttle from one level to another level and having an input level and / or exit from the store 2 for containers 7 products. The input and output containers 7 can be at the same level or at different levels, depending on the system configuration.

p0019The system 1 of the invention also includes a picking station 11, a main conveyor assembly 12 and a computer system for central management 13.

p0020This is the picking station 11 an operator prepares a package 100 by placing the desired amount of product, determined by the control list associated with the package. The sampling station includes for this purpose visual or sound signaling means, such as a screen indicating to the operator the amount of product to be taken into the container 7 in this picking station 11. It is clear the advantage brought by this device that simplifies the task of the operator and enables saving time to prepare the package.

p0021The main conveyor assembly 12 brings the containers 7 products since the input / output tray 2 at the sampling station 11 and vice versa. The central management computer system 13 controls the movements of each package 100, each shuttle 9, each elevator 10 and each containing 7 products. The central management computer system 13 also manages the control list for each package and therefore the order of the command lines based on the location of storage containers 7 product, the availability of shuttles and elevators as well products to the needs of different packages to prepare succeeding in picking station 11 in order to optimize all trips and packages of preparation time and to ensure synchronization between the arrival of a package in preparation and containers corresponding products to pickup station 11. of course, the computer system of central management 13 may be divided into several units and communicating hierarchical layers together by known architectures of Man Art.

p0022According to an essential feature of the invention, the main assembly conveyor 12 comprises means for scheduling containers 7 products according to their order on the order list, so that they appear in this order to the post sampling 11.

p0023Referring to Figure 1, the sequencing means include an intermediate buffer area between the exit of the store 2 and a first conveying strand 14, said input / output strand.

p0024According to the embodiment of the invention shown in Figure 1, the intermediate buffer area consists of pairs of intermediate respectively input conveyors 15 and outlet 16, disposed on either of side of each of the elevators 10 and transversely to the strand input / output 14. The scheduling means also comprise a second conveying strand 17, said strand storage, parallel and adjacent to the first strand 14 and adjacent to the pickup station 11. preferably, the two conveyor strands 14,17 are situated horizontally at the same level. Containers 7 products are transposed between the strands 14, 17 at transfer areas 18 by transfer members and the direction of travel of the two strands 14, 17 opposed, so that the movement of products between containers inputs / outputs of the store 2 and the removal station 11 is done in a loop in one direction or the other. Referring to Figure 1, the flow direction represented containers on conveyor strands 14, 17 takes place here in the anticlockwise direction. Further conveying the containers 7 will be preferably carried out by steps, one step being slightly longer than the predetermined maximum length of the containers 7.

p0025The transfer of containers 7 at the input / output of a forklift 10, from a shuttle 9 to the intermediate output conveyor 16 or vice versa from the input via conveyor 15 to a shuttle 9, is accompanied by a mechanical device also monitored by the central computer system 13. This system is necessary to release or to approach the container 7 of the shuttle 9 so that the vertical movement of the elevator 10 is performed safely and without discomfort can originate from a problem of loading or unloading of a container 7 to or from said shuttle 9. the conveying on conveyors intermediate 15, 16 can be achieved by free rolls can be driven at will by driving rollers, through the use of bracelets between two rollers, step by step. transfer mechanisms containers 7 between the input bit / 14 output and intermediate conveyors 15, 16 are types known to the skilled artisan.

p0026According to a v ariant preferred embodiment, the conveying strands 14, 17 are constituted by free rollers with horizontal axis can be driven in rotation at will, for example by friction of a lapping belt, said belt being disengaged, or by rolls engines through the use of bracelets between two rollers, step by step. The roller conveyor strands can be restrained. Of course, the skilled in the art can implement any other known conveying system, such as single-belt systems, multi-band or modular belt, within the scope of the present invention. Referring to Figure 1, the main conveyor assembly 12 includes at least at each of its ends a transfer region 18. Preferably and advantageously, it will include more transfer zones 18, at least by a storage unit 3 except for all that is right in front of the pickup station 11 to avoid congestion containers 7 at the pickup station 11. in these transfer areas 18 operate transfer members to translate the containers 7 products of one strand to another. Ideally, each transfer zone will be located on the site of a step on each of the input strands / outlet 14 and accumulation 17.

p0027According to a preferred embodiment of the invention, the conveying strands 14, 17 are located horizontally at the same level and the transfer members are formed by transfer tables with drive belts containers, along an axis perpendicular to the feed direction on the strands 14, 17, said belts being disposed between the rollers of the strands conveyor 14, 17 and can be contacted at will with the underside of the containers 7 products to transpose or absence of a strand to another. It goes without saying that the nature of the transfer members is in no way limiting of the invention and the skilled in the art can implement other mechanical systems performing the same functions, such as systems push or gripper.

p0028Preferably, as shown in Figure 1, it will place the sample station 11 along the conveyor accumulation 17 so that 1 'sampling operation is not performed on the last step of the accumulation conveyor where the main strand lies the transfer zone 181 between the strand accumulation and the input bit / output, but not the last, with the aim to optimize transfer time. Indeed, a straight transfer being faster than a transverse transfer from one strand to another, the transverse transfer is then advantageously carried out during the sampling time in the given container.

p0029Referring to Figure 1, the system 1 according to the invention also comprises an auxiliary conveyor 19 for the replenishment of the store 2 and the evacuation of containers 7 empty or optionally in default. This conveyor Annex 19 can be placed at the upstream end of the inlet conveyor strand / exit 14, downstream from the pickup station 11. Of course, the system can be topped up by other means, for example by providing a elevator at the other end of the paths, which would lift in connection with a replenishing conveyor.

p0030According to another advantageous characteristic of the invention, the container 7 of products is disposed on a tray. This tray comprises cooperating means with the shuttle gripper system 9 and the mechanical transfer device between said shuttle 9 and the intermediate conveyors 15, 16 to the input level and / or exit lift 10. An example detailed embodiments of said means of cooperation and the shuttle gripper system is described in another patent application concurrently filed on behalf of the plaintiff and which specifically addresses this aspect. The length of not moving on conveyor strands will be slightly longer than the length of a plateau.

p0031The tray further comprises means for stabilizing the container adaptable to different sizes of container. Thus, the system according to one invention can equally accommodate containers of products made by a cardboard packing, that is-to-say, the bulk packaging of cardboard or ordered products as delivered by their manufacturer or distributor, tray standard commercially available or a specific tray, that is to say whose shapes and dimensions have been specifically designed for use in an automated warehouse, where the products were transferred bins. In the case where the products are packed in their carton packing, advantageously saves costs in time and labor of a transfer step in specific bins.

p0032Of course, the system according to the invention may also be implemented without plateau, with specific bins whose bottom contains the special features of the plateau to cooperate with the special gripper system of the shuttle. According to another characteristic of the invention, the shuttle is stand alone type with embedded energy supply means of propulsion means. In a particularly preferred embodiment, the supply means of the shuttle are the electric type and include a means for storing electrical energy electrostatic. In particular and advantageously, the storage means comprises a battery of supercapacitors. In this preferred variant, as shown in Figure 2, the risers 10 and the ends of the channels 8 in the vicinity of said elevators include sections of track conductors, 20 and 21 respectively, arranged in recharge zone shuttles; these track sections 20, 21 are connected to a common power supply 22 per lane. It understands the significant economic advantage of this technological choice, to minimize the necessary lengths of conductor rails for charging the supply shuttles over shuttles powered directly from a conductor rail and the simplicity and increased reliability of the mode of operation of said shuttle relative to a feeding system on batteries. The detail of the shuttle powered by electrostatic storage is the subject of another simultaneously filed application on behalf of the applicant, to which reference will advantageously for a detailed description of the characteristics of the shuttle according to variant a preferred embodiment of the present invention.

p0033The invention also relates to a method of preparation package implementing the system described above.

p0034This method comprises a first step of charging a transfer shuttle 9 of the container 7 products corresponding to a given command line, followed by the shuttle moving step loaded on channels 8 of the driveway 4 of storage unit 3 in which it operates, the shuttle 9 is then fed by the elevator 10 to the lower level of input / output of the storage room 2. then, a successive step of transferring the container from the shuttle 9 to the intermediate buffer zone, a scheduling step the various containers on the strand of the accumulation conveyor 17, a removal step by an operator of the products in the container according to the desired amount and setting package said products. Finally, the method comprises a step of returning the container in the warehouse.

p0035In a first variant, the step of scheduling the strand accumulation 17 is to maintain the p containing a command given line in the intermediate buffer area until the containing p-1 of the line previous control is located downstream of the circulation loop of the input / output strand 14 and strand 17 of the accumulation and transfer p containing the input / output strand 14 and to move on said strand up 'to the first transfer zone 18 wherein the containing p-1 is located downstream of said zone, then transpose p containing the strand from the input / output 14 to the strand storage 17 so that the containers P. -1 p succeed in picking station 11.

p0036According to another embodiment, the step of ordering the accumulation strand 17 is to maintain the p containing a given command line maintain the given p containing a command line in the intermediate buffer zone until the container p-1 of the previous command line is located on the storage strand 17 other than its most end away from the pickup station 11, and the path to the next transfer area 18 is free, then transfer p containing the strand input / output 14 and to move it to said strand to the first transfer zone 18 wherein the containing p-1 is located downstream of said zone, then transpose p containing the strand from the input / output 14 to the strand storage 17 so that p-1 and p containers succeed in picking station 11.

p0037Of course, both variants of the process described above are given by way of example and skilled in the art can design for this step of ordering other travel management modes parcels on 12 main assembly conveyor 1 according to the invention. We will now describe the system operating principle. When a new order list is triggered by the central computer system 13 to the arrival of a package 100 prepared at the picking station, mission orders are transmitted to the shuttle 9 that will, in parallel, each sample in the cells 6 container 7 corresponding to the first control lines. The shuttle then charged back to the 10 elevators that will take over as their availability and their order of priority, each said shuttle 9. The management of the elevator wait cycles is ensured by the central computer system 13, which takes also into account the level of electric charge of each of the shuttles.

p0038At exit 10 elevators, the shuttle 9 fulfills its mission, that is to say that it files containing 7 on the intermediate output conveyor 16. Then the elevator 10 takes the shuttle 9, empty or loaded with a container return removal station 11 and was waiting on the input via conveyor 15 near the elevator 10, to a level where it will take a new container 7 after depositing in a storage cell containing 7 6 available to store, where appropriate. 7 containers deposited on the intermediate conveyors output 16 are progressively transferred to the input / output strand 14 and the storage strand 17 of the main assembly conveyor 12 as the ordering principle of the method described above, so the containers are presented in order of command lines to pickup station 11. in addition, the central computer system synchronizes arrival at pickup station of the first containers of a command with that of the parcel to prepare. In this position, the operator picks the desired quantity of products and places them in the package 100 in preparation. Then, the container 7 returns to the input / output strand 14 and on intermediate input conveyor 15 of the store, waiting to be taken over by a shuttle 9 that comes fulfill previous load its mission.

p0039After moving to the picking station 11, if a container 7 is emptied or if the amount of product it contains has reached a predefined threshold of renewal, it will be directed to the Annex conveyor 19 that will ensure his evacuation system 1 and introduce the system in a new container full of reference of concerned products.

p0040Of course, each containing or carrying tray of these containers include means of identification of like bar code or RFID tag allows the central management system to precisely locate each container. Readers of these forms of identification are placed on conveyors to transfer intersections and just upstream of the picking station and can optionally equip the transfer shuttles.

p0041Note that the number of shuttles driveway can be freely selected between 1 and n, where n is the number of levels of storage racks of the driveway, depending on the intended application, including parameters such as speed stock rotation, the maximum access time to a desired object, the cost of installation, etc.

p0042Preferably, to maximize the occupancy rate of the shuttles and the overall cost of the installation, we will select a number of shuttles per aisle between one and five, preferably one to three, for shelves with eight fifteen levels.

p0043It is understandable that, in general, the system storage magazine according to the invention may comprise only a single aisle and that every avenue be associated only one or two storage shelves without departing from the scope of the present invention.

p0044Finally, it goes without saying that the examples that have just given are therefore particular illustrations by no means limiting the areas of application of 1 invention.