Automatic warehouse system

• US 5,582,497 A
• Filed: 06/27/1994
• Issued: 12/10/1996
• Est. Priority Date: 01/29/1992
• Status: Expired due to Term

• Current Assignee: Wing LABO Company Limited
• Original Assignee: Wing LABO Company Limited
• Inventors: Noguchi, Hirokazu
• Primary Examiner(s): Werner, Frank E.
• Application Number:
  US08/266,603
• Time in Patent Office: 897 Days
• Field of Search: 414/267, 414/268, 414/269, 414/270, 414/271, 414/272, 414/277, 414/286, 414/278, 414/273, 414/276, 414/331, 414/281, 414/288, 414/282, 364/478
• US Class Current: 414/281
• CPC Class Codes: B65G 1/0407 using stacker cranes constructional features of stacker cranes B66F9/06
• CPC Class Codes: B65G 1/1371 with data records
• CPC Class Codes: B65G 1/1373 for fulfilling orders in warehouses

Abstract

An automatic warehouse has a plurality of stock units. One stock unit has one replenishing rack and one picking rack arranged so as to oppose each other with their sides, leaving a corridor between. Each rack has a plurality of shelves in both heights and length and each shelf has a size which accommodates only one article. Shifting mechanisms are provided for shifting articles to be shifted from shelves in the replenishing rack onto shelves in the picking rack. Replenishing mechanisms are provided for shifting articles to be stocked onto the replenishing rack and picking mechanisms are provided for picking articles to be picked up from the picking rack. Transfer devices are provided for transferring articles from the warehousing berth to the replenishing mechanism and from the picking mechanism to the delivery berth. A controller is provided for controlling the transfer means, replenishing mechanism, shifting mechanism and picking mechanism in such a way that the present location of any article and therewith detailed information about origin, destination, type, age or the like can be recalled and changed at any time.

Claims

1. An automatic warehouse having at least one stock unit for stocking articles, each of said stock units comprising:

a replenishing rack having a plurality of first shelves in height and length directions, each of a size of only one article, for stocking articles, each of said first shelves having an inlet opening, an outlet opening, at least support means for supporting said stocking article;

a picking rack having a plurality of second shelves in height and length directions, each of the size of only one stocking article, for stocking stocking articles so as to be picked out, each of said second shelves having an inlet opening, an outlet opening, at least support means for supporting said stocking articles;

said replenishing and picking racks being substantially identical, corresponding to each other, and arranged so as to oppose the outlet opening side of the first shelves with the inlet opening side of the second shelves, leaving a corridor therebetween;

a shifting mechanism which can access substantially all of the opposed shelf openings, said shifting mechanism being disposed within said corridor for shifting the stocking articles from the replenishing rack onto the picking rack when a number of stocking articles within the picking rack is reduced below a predetermined number;

a replenishing mechanism for replenishing the shelves to be replenished in the replenishing rack;

a picking mechanism for picking the stocking articles in the picking rack;

first transfer means for transferring the stocking articles from a warehousing berth having a stage for receiving stocking articles to be stored to the replenishing mechanism, said first transfer means having first conveying means for conveying received stocking articles; and

second transfer means for transferring the stocking articles from the picking mechanism to a delivery berth having a stage for delivering stocking articles to be shipped, said second transfer means having second conveying means for conveying the stocking articles to be shipped;

whereby replenishment and delivery of the stocking articles can occur substantially at the same time.

2. The automatic warehouse according to claim 1, wherein said picking mechanism, said shifting mechanism and said replenishing mechanism are of the same type of mechanism.

3. The automatic warehouse according to claim 1, wherein said picking mechanism is provided in a center of the arrangement and two replenishing mechanisms are provided at outer sides of the racks.

4. The automatic warehouse according to claim 1, wherein said replenishing mechanism is provided in a center of the arrangement and two picking mechanisms are provided at outer sides of the racks.

5. The automatic warehouse according to claim 1, wherein which further comprises another similar stock unit being arranged such that the picking mechanisms of both units can be replaced by only one picking mechanism picking articles to be picked up from both picking racks.

6. The automatic warehouse according to claim 5, which further comprises one additional replenishing rack at each of outer sides of the unit arranged such that the replenishing mechanisms replenish both the outer replenishing rack and the inner picking rack, and shifting articles from the replenishing rack onto the picking rack.

7. The automatic warehouse according to claim 1, which further comprises another similar stock unit arranged such that the replenishing mechanisms of both units can be replaced by only one replenishing mechanism for replenishing both replenishing racks.

8. An automatic warehouse having at least one stock unit for stocking articles, each of said stock units comprising:

a replenishing rack having a plurality of first shelves in height and length directions, each of said first shelves being of a size of only one stocking article, for stocking stocking articles to be replenished, each of said first shelves having an inlet opening, outlet opening, at least one support means for supporting said stocking article;

a picking rack having a plurality of second shelves in height and length directions, each of said second shelves being of the size of only one stocking article, for stocking stocking articles so as to be picked out, each of said second shelves having an inlet opening, outlet opening, at least support means for supporting said article, said second shelves being allocated for the stocking articles in response to respective shipping requirement priorities;

said replenishing and picking racks being substantially identical, corresponding to each other, and arranged so as to oppose the outlet opening side of the first shelves with the inlet opening side of the second shelves, defining a corridor therebetween;

a shifting mechanism which can access substantially all of the opposed shelf openings, said shifting mechanism being located within said corridor for shifting the stocking articles from the replenishing rack onto the picking rack when a number of the stocking articles within the picking rack is reduced below a predetermined number;

a replenishing mechanism for replenishing the shelves to be replenished in the replenishing rack;

a picking mechanism for picking stocking articles in the picking rack;

first transfer means for transferring the stocking articles from a warehousing berth having a stage for receiving the stocking articles to be stored to the replenishing mechanism, said first transfer means having first conveying means for conveying received stocking articles;

second transfer means for transferring the stocking articles from the picking mechanism to a delivery berth having a stage for delivering the stocking articles to be shipped, said second transfer means having second conveying means for conveying the stocking articles to be shipped, and

control means for controlling said replenishing mechanism, said picking mechanism and said shifting mechanism to sort stocking articles having high priority to shelves located near said delivery berth and to pick up the stocking articles;

whereby replenishment and delivery of the stocking articles can occur substantially at the same time.

9. The automatic warehouse according to claim 8, wherein said priority is based on delivery quantity of articles.

10. The automatic warehouse according to claim 8, wherein said priority is based on perishability of articles.

11. An automatic warehouse for stock management of a plurality of discrete articles, comprising:

a replenishing rack defining a selected height and length having a first side and a second side;

a picking rack having a height and length corresponding to that of said replenishing rack and being substantially identical thereto, said picking rack having a first side and a second side, said second side of said replenishing rack facing said first side of said picking rack with a corridor defined therebetween,

said replenishing rack including a plurality of first shelves extending in height and length directions, each of said first shelves being spaced apart and dimensioned to receive, support and store one discrete article, and each of said first shelves being accessible from said first and second sides;

said picking rack for the discrete articles including a plurality of second shelves extending in height and length directions, each of said second shelves being dimensioned to receive and support said one discrete article from said corresponding replenishing shelf, and each of said second shelves being accessible from said first and second sides where the second side of said first shelves is spaced apart from, opposed to and corresponds with the first side of said second shelves;

a shifting mechanism which can access substantially all of the opposed shelves, said shifting mechanism being located within said corridor for shifting the discrete articles from the second side of said first shelves of the replenishing rack to the first side of the corresponding second shelf of the picking rack when a number of the discrete articles contained on said the picking rack is reduced below a predetermined number;

a replenishing mechanism for replenishing the first shelves of the replenishing rack from which the discrete articles have been shifted by said shifting mechanism, said replenishing mechanism replenishing said first shelves from said first side of said replenishing rack;

a picking mechanism for replenishing the second shelves of the picking rack from which the discrete articles have been shifted by said shifting mechanism, said replenishing mechanism replenishing said first shelves from said first side of said replenishing rack the shelves to be replenished in the picking rack where replenishment and delivery of the discrete articles can occur substantially at the same time;

first transfer means for transferring the discrete articles to the replenishing mechanism from a warehousing berth, said first transfer means having first conveying means for conveying the discrete articles; and

second transfer means for transferring the discrete articles from the picking mechanism to a delivery berth, said second transfer means having second conveying means for conveying the discrete articles to be shipped.

12. The automatic warehouse for stock management according to claim 11 where the shifting mechanism, the replenishing mechanism and the picking mechanism are cranes.

13. The automatic warehouse for stock management according to claim 12 where said transfer means are automatic carts.

14. The automatic warehouse for stock management according to claim 11 where said transfer means are conveyors.