Automated warehouse inloading/outloading storage controller

• US 5,568,393 A
• Filed: 01/10/1995
• Issued: 10/22/1996
• Est. Priority Date: 03/25/1992
• Status: Expired due to Fees

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Okura, Akira, Ando, Yukito, Ito, Mikio
• Primary Examiner(s): NOT, DEFINED
• Assistant Examiner(s): NOT, DEFINED
• Application Number:
  US08/370,819
• Time in Patent Office: 651 Days
• Field of Search: 364/401, 364/402, 364/403, 364/424.02, 364/424.07, 364/468, 364/478, 364/564, 414/799, 414/786, 414/927, 414/929, 414/930
• US Class Current: 700/214
• CPC Class Codes: B65G 1/1371 with data records
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders

Abstract

A picking means for picking goods from pallets removed from a storehouse, and a filling means for filling the pallets with incoming goods and storing them in the storehouse, are connected by a pallet transport means. When goods are to be delivered, the storage space created by picking goods from the pallets is detected. Pallets in which storage space is detected are transported by the transport means to the filling means, where they are filled with incoming goods of sizes which match their storage space, and are then stored in the storehouse. Goods are thereby stored in the storehouse promptly, and the filling density in the storehouse is increased.

Claims

1. An automated warehouse comprising:

a storehouse for storing pallets, said pallets storing a plurality of types of goods;

storage means for storing pallets in said storehouse;

recording means for recording the types and quantities of pallets stored in the storehouse, and the types, quantities and volumes of goods filling the pallets for each of the pallets as inventory data;

outloading means for outloading pallets from said storehouse;

picking means for picking outloaded goods from outloaded pallets, wherein said outloading means is positioned between said picking means and said storehouse;

filling means for filling incoming goods each having a predetermined volume in said outloaded pallets, said filling means including buffer means for temporarily storing outloaded pallets until an occupancy volume of incoming goods is matched with the available storage space on an outloaded pallet;

transporting means for transporting pallets from which outloaded goods have been picked by said picking means and pallets from said buffer means to said filling means; and

an inloading/outloading controller for controlling each of the aforesaid means wherein said inloading/outloading controller includes computing means for computing the occupancy volume of incoming goods based on data of the incoming goods and for computing the amount of available storage space created in a pallet for each of the pallets when outloaded goods have been picked from the pallet based on data of the goods which have been picked by said picking means, space recording means for recording the amount of available storage space in a pallet for each of the pallets computed by the computing means, and selection means for selectively specifying incoming goods having an occupancy volume that is approximately equal to or smaller than the amount of available storage space created in an outloaded pallet such that said filling means fills incoming goods in the available storage space on the outloaded pallets, wherein when a pallet suitable for accommodating incoming goods is not in the buffer means, the inloading/outloading controller searches for a suitable pallet from the pallets in the storehouse and carries the pallet to the filing means for accommodating the incoming goods.

2. An automated warehouse as defined in claim 1, wherein said computing means of said inloading/outloading controller includes a first occupancy volume computing means for computing the occupancy volume of outloaded goods removed from an outloaded pallet from a width, height and depth of said outloaded goods, and wherein said selection means specifies incoming goods based upon the computed occupancy volume of outloaded goods removed from the outloaded pallet.

3. An automated warehouse as defined in claim 2, wherein said computing means of said inloading/outloading controller comprises:

second occupancy volume computing means for computing an occupancy volume of incoming goods from a width, height, and depth of said incoming goods; and

a command controller that compares the occupancy volume computed by said first occupancy volume computing means and the occupancy volume computed by said second occupancy volume computing means, and if said occupancy volume of said incoming goods is smaller than said occupancy volume of outloaded goods, said selection means specifies that the outloaded pallet is filled by said filling means with said incoming goods.

4. An automated warehouse as defined in claim 2, wherein said computing means of said inloading/outloading controller comprises:

second occupancy volume computing means for computing an occupancy volume of incoming goods from a width, height, and depth of said incoming goods; and

a command controller that compares the occupancy volume computed by said first occupancy volume computing means and the occupancy volume computed by said second occupancy volume computing means, and if said occupancy volume of said incoming goods is approximately equal to said occupancy volume of outloaded goods, said selection means specifies that the outloaded pallet is filled by said filling means with said incoming goods.

5. An automated warehouse as defined in claim 1, further comprising planning command means, said planning command means comprising:

removal sequence recording means for providing, as data, the occupancy volume of outloaded goods and the sequence in which outloaded goods are removed from an outloaded pallet;

storage space creation sequence recording means for recording the amount of available storage space in the outloaded pallets in the sequence in which the storage space was created from the data entered by said removal sequence recording means; and

storage plan design means for deciding the sequence in which incoming goods are to be stored for optimizing the use of the available storage space on a pallet according to data entered by said storage space creation sequence recording means.

6. An automated warehouse as defined in claim 5, wherein said computing means of said inloading/outloading controller includes a first occupancy volume computing means for computing the occupancy volume of outloaded goods removed from an outloaded pallet from a width, height and depth of said outloaded goods, and wherein said selection means specifies incoming goods based upon the computed occupancy volume of outloaded goods removed from the outloaded pallet.

7. An automated warehouse as defined in claim 6, wherein said computing means of said inloading/outloading controller comprises:

second occupancy volume computing means for computing an occupancy volume of incoming goods from a width, height, and depth of said incoming goods; and

a command controller that compares the occupancy volume computed by said first occupancy volume computing means and the occupancy volume computed by said second occupancy volume computing means, and if said occupancy volume of said incoming goods is smaller than said occupancy volume of outloaded goods, said selection means specifies that the outloaded pallet is filled by said filling means with said incoming goods.

8. An automated warehouse as defined in claim 6, wherein said computing means of said inloading/outloading controller comprises:

second occupancy volume computing means for computing an occupancy volume of incoming goods from a width, height, and depth of said incoming goods; and

a command controller that compares the occupancy volume computed by said first occupancy volume computing means and the occupancy volume computed by said second occupancy volume computing means, and if said occupancy volume of said incoming goods is approximately equal to said occupancy volume of outloaded goods, said selection means specifies that the outloaded pallet is filled by said filling means with said incoming goods.