CH720603A1 - ORDER PICKING SYSTEM - Google Patents

Abstract

The present disclosure relates to an order-picking system (1) for transporting and providing piece goods (S, S'), comprising a conveying device (2) comprising an overhead conveyor (21) for conveying the piece goods (S, S'), and a delivery station (22) for delivering the piece goods (S, S') from the overhead conveyor (21) to a transfer device (3) for assembling the conveyed piece goods (S, S'), which transfer device (3) has a horizontally movable transfer element (31) by means of which the piece goods (S, S') can be assembled at an assembly station (P) by gravity. The present disclosure further comprises a method for transporting and providing piece goods (S, S') by means of the order-picking system (1).

Description

AREA OF REVELATION

[0001] The present disclosure relates to an order picking system with a transfer device having a horizontally movable transfer element, as well as a method for transporting and providing piece goods by means of the order picking system.

BACKGROUND OF REVELATION

[0002] DE10346122A1 was published on April 21, 2005 in the name of Beumer Maschinenfabrik GmbH & Co. KG and discloses a device for feeding piece goods onto a sorter, with a feed conveyor from which the piece goods are preferably fed in a predetermined orientation and are to be transferred individually at its discharge end to a receiving station of a receiving conveyor immediately downstream of the feed conveyor, from which one piece goods part is to be transferred in a controlled manner to a receiving station of the sorter downstream of the receiving conveyor. An intermediate conveyor with a support plate for receiving the piece goods arranged above the conveying level of the receiving conveyor and which can be driven reversibly in the conveying direction of the feed conveyor is used to deliver the piece goods to the receiving conveyor.

[0003] CH719043A1 was published on April 14, 2023 in the name of the applicant and discloses a transfer device for transferring goods to be conveyed, such as flat goods, from a feed conveyor to conveyor positions of a removal conveyor. The transfer device forms a stationary receiving space for at least one item to be conveyed, which is limited at the bottom by a movable support member. The support member can be moved by means of a movement device between a support position in which the at least one item to be conveyed rests flat on the support member, and a delivery position in which the item to be conveyed falls downwards by gravity through an exposed transfer opening onto a conveyor position of the removal conveyor that moves past below the receiving space.

PRESENTATION OF REVELATION

[0004] While there are fewer orders in the business to business (B2B) sector but these have large volumes and the same product sequences, since companies typically order products in large quantities, in the business to customer (B2C) sector there are typically many individual orders with individual deliveries of goods or small volumes and small quantities, which can also have high seasonal fluctuations. Piece goods can be a very wide range of different products. For example, both inherently stable products such as packages, boxes or books and flexible and essentially flat piece goods such as magazines or even individual loose items of clothing packaged only in a flexible protective cover must be picked at the same time.

[0005] In the area of order picking of piece goods, particularly in business to customer (B2C) order processing or order processing, it is required to be able to process and order pick various types of piece goods in one and the same system. Furthermore, the individual orders should also be put together in the same system and these picked orders should be made available immediately at the exit of the system, packaged and ready for dispatch. In the known systems, the goods delivered are delivered in trays or similar transport containers and then usually manually packed in cardboard boxes of the appropriate size. This step is therefore very labour-intensive.

[0006] An object of the invention can be seen in providing a picking system which enables a more efficient provision of consignments of goods for packaging with a wide variety of product categories.

[0007] An order picking system according to the invention for transporting and providing piece goods usually comprises at least one conveying device. The conveying device comprises an overhead conveyor for conveying the piece goods, as well as a delivery station for delivering the piece goods from the overhead conveyor to a transfer device for assembling the conveyed piece goods. The transfer device typically has a horizontally movable transfer element by means of which the piece goods can be assembled at an assembly station by gravity. In the context of the present disclosure, horizontal is not to be understood in the geometric sense as exactly vertical to the vertical, but also includes an inclination of ± 10°.

[0008] The transfer element can serve to simply transfer the piece goods to a downstream device. Typically, the assembly station is arranged on a conveyor. Alternatively or in addition, the transfer element can also be controlled in such a way that piece goods conveyed one after the other can be stacked on an assembly station or can be transferred to a common assembly station offset from one another and/or at least partially overlapping one another.

[0009] An alternative order picking system according to the invention for transporting and providing piece goods can also be provided. This can also comprise a feed device which comprises an overhead conveyor for conveying the piece goods, as well as a delivery station for delivering the piece goods from the overhead conveyor to a transfer device. The transfer device can have a feed conveyor for assembling the piece goods delivered from the delivery station, by means of which the piece goods can be assembled at an assembly station by means of gravity. The piece goods can be taken from the delivery station by means of the feed conveyor and transported further to an assembly station. This assembly station can be arranged on a discharge conveyor, with the piece goods being transferred from the feed conveyor to the discharge conveyor by means of gravity. The piece goods cannot be transferred in an orderly manner from the feed conveyor into a pile at the assembly station.

[0010] The alternative embodiment of the order picking system is an independent concept and the applicant reserves the right to pursue this and the other technically compatible features of the disclosure in the form of a divisional application.

[0011] The piece goods are delivered to the transfer device by means of the overhead conveyor. The overhead conveyor of the delivery device typically comprises overhead conveyor receiving means in the form of pockets, baskets, bags or carrying loops, by means of which the piece goods can be conveyed in a hanging manner. The overhead conveyor receiving means in the form of pockets, baskets, bags or carrying loops for delivering the piece goods from the overhead conveyor can be emptied, in particular emptied by pivoting the overhead conveyor receiving means.

[0012] To convey the overhead conveyor receiving means, the overhead conveyor typically comprises at least one rail on which the overhead conveyor receiving means can be conveyed suspended by means of a carriage. The overhead conveyor receiving means can typically be emptied via an opening on the top or via an opening in the side. For this purpose, they can be pivoted backwards in order to empty a piece of goods received therein via the opening on the top or can be moved to the side in order to empty the piece of goods received therein via the opening in the side.

[0013] The overhead conveyor receiving means can be designed in the form of overhead conveyor pockets with a rear wall and a front wall, which are flexibly connected to one another at least via a base section such that they can be moved back and forth between a first state in which they form an open and fillable pocket, and a second state in which they lie close to one another and form a folded-up pocket.

[0014] The overhead conveyor typically connects directly to the delivery station, which usually includes an emptying device. The overhead conveyor or several overhead conveyors can connect the transfer device to devices arranged upstream. The overhead conveyor can thus be used to combine the delivery of goods with the removal of goods within a logistics facility, thereby establishing the flow of goods.

[0015] The emptying device can comprise a circulating conveyor belt for receiving piece goods transported in the overhead conveyor receiving means. At a contact section, the conveying path of the overhead conveyor and the conveying path of the conveyor belt can be arranged in relation to one another in such a way that the distance between the conveying path of the overhead conveyor and the conveying path of the conveyor belt becomes continuously smaller, so that when a overhead conveyor receiving means is conveyed along the contact section, a front side of the overhead conveyor receiving means contacts the conveyor belt and comes to rest on it and the overhead conveyor receiving means are pivoted backwards or alternatively to the side.

[0016] In a transfer section, the conveying path of the overhead conveyor and the conveying path of the conveyor belt can run substantially parallel to one another with a certain downward gradient, wherein the front side of the respective overhead conveyor receiving means continues to lie on the conveyor belt during conveying along the transfer section, so that the opening of the overhead conveyor receiving means is oriented obliquely downwards and the piece goods present in the overhead conveyor receiving means can be transferred from the overhead conveyor receiving means to the conveyor belt, preferably by gravity.

[0017] In a separating section, the distance between the conveying path of the overhead conveyor and the conveying path of the conveyor belt can become continuously larger, so that when conveying an overhead conveyor receiving means along the separating section, the emptied overhead conveyor receiving means is lifted off the conveyor belt and swings back into the freely hanging position. The conveying speeds of the conveyor belt and those of the overhead conveyor are usually the same.

[0018] The conveyor belt can have a plurality of outwardly directed transverse ribs arranged at equal distances along a circumference of the conveyor belt. The relative position of the ribs and the overhead conveyor receiving means is typically selected to one another such that in the contact section a rib catches up with the overhead conveyor receiving means, contacts the bottom section of the overhead conveyor receiving means and pushes it forward in the conveying direction until the overhead conveyor receiving means has changed to an emptying state. In the contact section, in the area in which the respective rib touches the bottom section of the overhead conveyor receiving means, the overhead conveyor and the conveyor belt can be operated at the same speed. In particular, the overhead conveyor and the conveyor belt can constantly run at the same speed.

[0019] The spacing of the ribs can be selected such that, during the conveyance of a suspended conveyor receiving means along the transfer section, a piece of goods present in the suspended conveyor receiving means slides out of the pocket onto the conveyor belt by gravity and slides further down the conveyor belt with the aid of gravity until it is caught and held by the rib preceding the suspended conveyor receiving means. The ribs of the conveyor belt can also consist of a plurality of parallel fingers.

[0020] An upper end of the chute can have slots whose position corresponds to the fingers of the ribs of the conveyor belt, so that when the conveyor belt is deflected, the fingers of the ribs and the slots of the chute interact with one another in a meshing manner. The piece goods held back behind a rib can then be released in a timed manner and then transported further on the chute by gravity. Another conveyor can take over the released piece goods units from the chute.

[0021] The piece goods delivered by the overhead conveyor at the delivery station are conveyed to the transfer device by means of the conveying device. For this purpose, the transfer device can have a conveyor adjacent to the delivery station. The conveyor can be designed as a belt or roller conveyor, for example. This can serve to convey the piece goods delivered at the delivery station, typically from the overhead conveyor receiving means of the overhead conveyor, to the transfer element. In particular, when emptying and feeding by means of a chute, the piece goods typically do not arrive at the transfer device in a precisely timed manner and at equal intervals.

[0022] For this purpose, the conveyor can be operated in stop-and-go mode in order to be able to transfer the respective piece goods to the transfer element in a precisely timed manner. The transfer element can typically be movable, in particular horizontally, between at least one receiving position for receiving a conveyed piece goods and at least one delivery position for delivering a piece goods located on the transfer element.

[0023] Alternatively or additionally, the feed conveyor can be accelerated or braked so that the respective piece goods conveyed by the feed conveyor can be transferred to the transfer element in the receiving position in such a synchronous manner that in the discharge position it can also be transferred from the transfer element to a downstream discharge conveyor in a synchronous manner. This can be particularly necessary if the discharge conveyor is designed as a tray conveyor with separate trays, for example. In this case, piece goods must be transferred to the respective tray essentially in the middle in order to prevent the piece goods from falling out or becoming jammed between two consecutive trays.

[0024] In addition to the synchronous conveying, it may be necessary not only to space the piece goods apart from one another along a conveying direction and to align them synchronously, but also to align them in their orientation parallel to the conveying direction or to transfer them centrally to the transfer element. For this purpose, the transfer device can comprise an alignment module which comprises driven alignment elements by means of which the piece goods can be aligned along and/or laterally with respect to a conveying direction. Since the piece goods are not transferred in an aligned manner, particularly in the case of conveying devices which comprise a chute for forwarding the piece goods from the delivery station to the conveyor or the transfer element, the alignment module can preferably be arranged upstream of the conveyor in order to bring the alignment to a desired alignment.

[0025] The alignment elements can be in the form of rollers, omnidirectional wheels or balls. Balls offer greater mobility and flexibility in a conveyor system application compared to rollers or omnidirectional wheels. They can rotate freely in all directions, allowing for a nearly frictionless ride through tight curves and around obstacles such as other piece goods. In addition, balls can distribute weight more evenly than rollers or wheels, resulting in less wear on the conveyor system. This in turn can lead to a longer conveyor system life and lower maintenance costs.

[0026] As a rule, each alignment module has a plurality of alignment elements. These can be driven individually and independently of one another in order to align a piece of goods along the conveying direction and/or laterally thereto when being conveyed on the alignment module. In order to convert a random alignment of a conveyed piece of goods into a target alignment, a sensor unit can be arranged above the alignment module, by means of which an alignment of the piece of goods on the alignment module can be detected.

[0027] Based on a sensor signal measured by the sensor unit and sent to a control device, the item can be aligned and/or spaced apart from an item arranged upstream or downstream by means of the control device by actively and directed driving of the alignment elements on the alignment module. The item is then preferably aligned and spaced apart and transferred to the conveyor and transferred by the conveyor to the transfer element in synchronism with the clock.

[0028] The transfer element can be designed and moved at an accelerated rate such that the piece goods received on it can be transferred to the assembly station essentially motionless, driven by gravity due to its horizontal inertia. The transfer element can be removed from under the piece goods lying on it by means of an accelerated, typically jerky movement. Due to its mass and the resulting inertia, the piece goods temporarily remain almost unchanged during a jerky movement before falling down due to gravity.

[0029] The horizontally movable transfer element of the transfer device can, for example, be at least partially plate-shaped or designed as a plate that is optionally movably mounted in lateral guides or designed as a rotating plate that is rotatably mounted for transferring the piece goods, preferably below the conveyor. The plate can be designed as an inherently stable plate or as an unstable and guided plate. The plate typically has a coefficient of friction that allows the piece goods to slide on the plate due to its inertia when the plate is abruptly accelerated.

[0030] Good results can be achieved if the plate is at least partially made of a plastic or at least partially coated with a plastic with good sliding properties. An adhesive friction coefficient µH between the items on the transfer element is, for example, less than or equal to 0.5, preferably less than or equal to 0.25. Typical materials for this can be hard cotton fabrics based on phenol or epoxy resin. Alternatively, polyamide (PA), polyterafluoroethylene (PTFE), polyterafluoroethylene (PE) or polyester terephthalate (PET) can also be used.

[0031] Alternatively, the horizontally movable transfer element of the transfer device can also be designed as a belt conveyor with a movable belt section, preferably in the form of a telescopic conveyor belt. To deliver the respective piece goods, the movable belt section can be moved at such an accelerated rate that it is retracted beneath the piece goods due to their inertia and the piece goods can thus be transferred by gravity.

[0032] In addition to simply moving back and forth between the receiving and delivery positions, the transfer element can also be moved incrementally. This makes it possible to specifically control any position in between, in addition to simply controlling the receiving position and the delivery position. The transfer element can be horizontally incrementally moved so that the piece goods can be transferred to the assembly station in a position, preferably in the middle, off-center or stacked with other piece goods, stacked next to each other or overlapping. This makes it possible for the transfer device to be used for both individual and synchronized transfer to the assembly station, for example a central transfer of a piece of goods into a transport tray of a tray conveyor. It is also possible to implement a stacked transfer while the conveyor element of the discharge conveyor continues to move, in particular continuously.

[0033] Alternatively, it is also possible to provide several piece goods in a stacked manner at an assembly station. In this way, several piece goods can be transferred to a stack within an assembly station, several piece goods can be placed on several stacks within an assembly station, or several piece goods can be offset from one another and provided at least partially overlapping.

[0034] A particularly space-saving structure can be achieved if the transfer element is arranged below the conveyor and can be moved horizontally with respect to a distal end of the conveyor. The transfer element, for example in the form of a plate or a telescopic conveyor belt as explained in more detail above, as well as the drive of the transfer element can be arranged below the conveyor, which enables a particularly compact and horizontally particularly short transfer device.

[0035] In the receiving position, the transfer element can be arranged so as to protrude from a distal end of the conveyor in order to at least partially close a transfer area. This transfer area can be designed as a window or as a physically formed shaft, for example in the form of a funnel. In the delivery position, the transfer element can be retracted under the conveyor in such a way as to free up the transfer area. The transfer area can be limited by the distal end of the conveyor and by a stop arranged at a distance from it. The stop thus limits the transfer area and ensures that a piece of goods to be transferred through the transfer area to the assembly station also ends up in the assembly station.

[0036] The assembly station is typically arranged on the conveyor so that a picking group formed thereon can be removed by means of the conveyor. In the present disclosure, a picking group is understood to mean both an ordered and a disordered collection of piece goods. Thus, one or more stacks as well as a pile or an overlapping arrangement of piece goods placed sequentially on top of one another can be understood as a picking group. Depending on the downstream system, the conveyor can be designed as a belt, roller or tray conveyor. The assembly station can be designed in the form of a virtual assembly station or as a physical frame that is arranged on the conveyor. Alternatively, the assembly station can also be arranged within a receiving container that is arranged on the conveyor. The receiving container can be designed as a box, carton, tray or tub. Alternatively, a frame, for example a U-shaped frame, can also be used.

[0037] In order to achieve the most efficient packaging possible, keeping the number of work steps to a minimum and at the same time producing the smallest possible packages, which saves volume and thus shipping costs, the packages can be formed directly around the picking group. The picking group is placed on a flat cardboard box, which is cut to size after the picking group has been measured, folded around the picking group and then glued. In order to avoid repeated handovers, the picking group can be formed directly on a plate-shaped piece of cardboard, which is placed on the conveyor.

[0038] Films, bags, or preferably rectangular or square flat cardboard webs can be provided as the starting material for the packaging. Alternatively, an endless belt of cardboard can also be provided on the conveyor. Packaging in the form of a shipping bag, a wrap made of film or a cardboard box can be formed around the picking group. The picking groups can be transferred to the cardboard web using the transfer element. Packaging can then be formed around the picking group assembled at the assembly station using the transfer element, preferably in the form of a cardboard box that is folded around the picking group. This does not simply mean packing in a cardboard box, but rather forming a cardboard box in the form of a package. Based on the recorded dimensions, length, width and height, a package can be formed by mechanically cutting, folding and gluing the flat starting material. During shipping, additional inserts can be added to the picking group in a further step before the packaging is formed. For example, in the form of delivery notes, invoices, brochures or advertising materials. Important information for shipping can be attached to the packaging, for example in the form of shipping labels.

[0039] A sensor unit can be arranged at the distal end of the conveyor, by means of which the arrival of a piece of goods conveyed by the conveyor can be detected and based on a first sensor signal measured by the sensor unit and sent to a control device, the transfer element can be moved from the delivery position to the receiving position by means of the control device in order to receive the piece of goods conveyed and detected by the sensor. The receiving position can also be movable, so the transfer element can be moved together with the conveyor in order to improve the transfer to the transfer element. This can be relevant in particular for loosely packaged piece goods, such as clothing.

[0040] The sensor unit can ensure the synchronous transfer by allowing the control device to control either the travel path of the transfer element and/or the acceleration of the transfer element based on the sensor signal. If, for example, a central transfer to a passing assembly station is desired, the control device can adjust the transfer element based on the first sensor signal in such a way that the central transfer is ensured.

[0041] In addition to detecting the arrival of the respective piece goods by means of the sensor unit, the control device can also be used to monitor the transport of the piece goods conveyed by the conveyor. When leaving the sensor area of the sensor unit, a second sensor signal can be sent from the sensor unit to the control device and, based on the second sensor signal, the transfer element can be moved by the control device from the pick-up position back to the delivery position in order to transfer the picked-up piece goods to the assembly station by gravity.

[0042] The transfer device can define a transfer area, wherein the transfer element at least partially closes the transfer area and a piece of goods conveyed by the conveyor can be received on the transfer element. By means of the movement starting from the delivery position, the transfer element can at least release the transfer area in such a way that a piece of goods received on it can be transferred through the transfer area to the assembly station by gravity. The transfer device can comprise a detection device by means of which the layout of the picking group can be monitored in a top view and/or the outline or height of the picking group in a side view.

[0043] Preferably, the transfer area is monitored by means of this detection device. To limit the area, the transfer device can comprise a stop for positioning the piece goods, the transfer area typically being limited by the stop and the distal end of the conveyor, through which the piece goods can be transferred to the assembly area by gravity.

[0044] The order picking system can be part of a logistics system. In addition to the order picking system, the logistics system typically also includes a storage device and/or a sorting device and/or a storage device. The piece goods are typically delivered to the entrance of the logistics system, for example by means of a truck. After unloading, the piece goods are typically transported through the following areas of the logistics system: delivery, goods receipt, storage, packaging and labeling, buffering, storage, sorting, distribution, packaging, removal, which is also typically carried out by truck.

[0045] To transport the goods from loading points through the logistics system, they can be transported using overhead conveyors. To fill the overhead conveyors, the logistics system can have a device for filling the overhead conveyors. In the unfilled state, the overhead conveyors are already arranged on the overhead conveyor in a waiting position using carriages. The carriages are mounted on a guide rail so that they can move in the direction of the guide rail, and the overhead conveyors are arranged hanging downwards on the carriage to receive piece goods.

[0046] During transport in the filling device, the overhead conveyor receiving means can be transported hanging on a guide rail piece, which corresponds to a section of the guide rail and which can optionally be connected to one end of the first guide rail or the second guide rail. In the filling device, the overhead conveyor receiving means are typically rotated for filling. For this purpose, an operating arrangement is advantageously provided with which the transport elements can be rotated by a certain angle of rotation at a certain point on the conveyor path, whereby a suspension hook on the suspension of the overhead conveyor receiving means can typically be transferred from the first position to a second position or from the second position to the first position. The overhead conveyor receiving means are advantageously repositioned by rotating the overhead conveyor receiving means themselves, advantageously around a central axis. A brush arrangement or mechanical, electrical, magnetic or pneumatic actuating means are particularly advantageously provided as the operating arrangement.

[0047] In an alternative filling device, the overhead conveyor receiving means are separated in a transfer area by means of a separation mechanism, for example by means of a conveyor screw. The piece goods to be fed in are fed in by means of a feed device, which typically comprises several conveyor units arranged one behind the other, each with a conveyor belt. The feed device can have a final conveyor unit in the form of a roller conveyor in the transfer area, over which the piece goods can roll and slide or slip from above into the overhead conveyor receiving means.

[0048] During filling, a single overhead conveyor receiving means is moved along a feed conveyor path in the conveying direction with the receiving compartment running ahead in the conveying direction into the transfer area. The overhead conveyor receiving means is actively opened before or in the transfer area by means of an opening mechanism. In the transfer area, the overhead conveyor receiving means typically rests with a first side on the final conveyor unit of the feed device, which consequently forms a support. As soon as the overhead conveyor receiving means has reached the transfer area, the conveying of the overhead conveyor receiving means is stopped for the purpose of transferring a piece of goods. The overhead conveyor receiving means is therefore not in a conveying movement when the piece of goods is being transferred in the overhead conveyor receiving means.

[0049] A piece of goods resting on the conveying surface of the conveyor units is conveyed to the transfer area via the feed device. The piece of goods slides over the roller conveyor of the final conveyor unit in a transfer direction through the receiving opening into the overhead conveyor receiving means. After the piece of goods have been transferred to the overhead conveyor receiving means, the latter is moved out of the transfer area with the piece of goods by means of the carrier conveyor from the horizontal conveyor. During this process, the overhead conveyor receiving means rolls with one side on the roller conveyor of the final conveyor unit.

[0050] The final conveyor unit with the roller conveyor can be pivoted away from its conveying position to clear the conveying path for the overhead conveyor receiving means loaded with the piece goods. As soon as the overhead conveyor receiving means loaded with the piece goods has been conveyed upwards out of the transfer area, a subsequent overhead conveyor receiving means can be conveyed into the transfer area.

[0051] For storing and sorting the piece goods within the logistics system, a batch buffer for providing groups of goods can also be provided. These groups of goods can be provided in the form of batches. The logistics system can also comprise one or more matrix sorters for sorting the goods in batches. A plurality of overhead conveyor receiving means, each of which comprises a receiving unit, preferably in the form of an overhead conveyor receiving means, can be fed to a matrix sorter for sorting the goods. A matrix sorter can also have several sorting stages.

[0052] If the matrix sorter is arranged within the logistics system downstream of the batch buffer and/or the filling device, it can take over the already filled overhead conveyor receiving means from the batch buffer and/or from the filling device. The matrix sorter typically comprises at least one circulating conveyor for conveying the overhead conveyor receiving means, as well as branches extending therefrom for sorting the overhead conveyor receiving means, wherein the logistics system has a control system which is designed to control the conveying speed of the circulating conveyor.

[0053] The batch buffer can also have branches which are branched off from a further conveyor, preferably a circulating conveyor. The circulating conveyor is usually designed to convey the overhead conveyor receiving means at a constant conveying speed. The control can be designed to control the conveying speed of the circulating conveyor such that the conveying speed of the circulating conveyor in at least one batch is higher than the constant conveying speed of the further conveyors.

[0054] The circulating conveyor is typically designed to guide the overhead conveyor receiving means to and/or away from a sorting stage. A sorting stage of the matrix sorter can have a plurality of linear buffer sections which are connected to the circulating conveyor by switches. The buffer sections are preferably designed as branches and can be designed as gravitational sections with a gradient such that the overhead conveyor receiving means can be conveyed in the gravitational sections due to gravity. The batch buffer can also have a plurality of branches in the form of linear storage sections, in each of which one batch or several batches can preferably be stored.

[0055] At least one measuring device can be arranged in front of the matrix sorter, which is designed to determine the parameters, preferably the weight and/or the size, of the overhead conveyor receiving means and/or goods entering the matrix sorter and to transmit them to the control system.

[0056] The logistics system can have a database in which the parameters, preferably the weight and/or size, of the overhead conveyor receiving means and/or goods entering the matrix sorter are stored. The matrix sorter can comprise a plurality of sorting stages and a plurality of sorting steps, each of which is assigned to one sorting stage or two sorting stages. The control is typically designed to control the conveying speed of each matrix conveyor individually.

[0057] In addition to the matrix sorter, the logistics system can also include an intermediate storage unit. This is usually arranged before or after the batch buffer. The at least one intermediate storage unit typically has a dynamic storage unit for temporarily storing the goods/unit goods provided for order picking and a retrieval storage unit downstream of the dynamic storage unit for storing goods retrieved from the dynamic storage unit and pre-sorted in the process. The dynamic storage unit and the retrieval storage unit can be arranged within a common circulating conveyor and can be connected to one another via the common circulating conveyor.

[0058] The circulating conveyor is typically a conveyor with which the goods can be conveyed in a closed circuit or circuit. Actuable or switchable switches can be provided at various points on the circulating conveyor. The switches enable new goods to be brought into the circuit in a targeted manner or goods circulating in the circuit to be taken out. The goods are divided into the overhead conveyor receiving means, preferably in the form of overhead conveyor pockets, which can each be moved individually and added to or removed from the circuit.

[0059] The goods circulating in circulation and stored in the dynamic storage are in a specific order, which is usually based on the staggered removal of the goods from the warehouse, but does not correspond to the batches of goods determined by the orders. By pre-sorting the goods in the retrieval storage, the goods are already grouped together in a batch that corresponds to the orders, so that a subsequent matrix sorter or order-picking system is relieved of sorting work and can be dimensioned accordingly smaller or eliminated entirely.

[0060] The piece goods are then transferred to the order picking system according to the invention for packaging. A method according to the invention for transporting and providing piece goods comprises at least the following method steps: • Providing a picking system according to the invention, comprising a conveying device comprising an overhead conveyor, a delivery station, and a transfer device with a horizontally movable transfer element; • Conveying the piece goods by means of the overhead conveyor and delivering the piece goods from the overhead conveyor to the transfer device by means of the delivery station; • Transferring the conveyed piece goods by means of the transfer device and assembling them at an assembly station.

[0061] The transfer device can have a conveyor adjacent to the delivery station of the conveyor device and the transfer element for assembling can be moved horizontally between a receiving position for receiving a piece of goods and a delivery position for delivering the piece of goods.

[0062] By means of a driven alignment element of an alignment module, the piece goods can be aligned along and/or laterally with respect to a conveying direction and/or spaced apart from a piece goods arranged upstream or downstream.

[0063] The transfer element can be moved horizontally with respect to a distal end of the conveyor at the same time as the conveying in order to take over a piece of goods conveyed by the conveyor from the conveyor. The transfer element can be moved back with respect to the distal end of the conveyor in order to assemble the piece of goods already on the transfer element, so that the piece of goods are transferred to the assembly station by gravity through the transfer area.

[0064] The transfer element is preferably accelerated, particularly preferably retracted abruptly, so that the piece goods received thereon remain essentially motionless in the horizontal due to its inertia and then fall down to the assembly point driven by gravity.

[0065] The transfer element for assembling the conveyor is moved in such a way that • the piece goods are transferred essentially centrally to the assembly station to form a picking group, or • the piece goods are transferred off-center to the assembly station to form several picking groups, or • the transfer element is moved further incrementally so that a subsequent piece goods are transferred to the assembly station in an overlapping manner onto a previous piece goods.

REPRESENTATION OF THE FIGURES

[0066] Aspects of the invention are explained in more detail with reference to the embodiments shown in the following figures and the associated description. They show: Fig. 1 a first embodiment of the order picking system when forming order picking groups; Fig. 2 the first embodiment of the order picking system when forming order picking groups in the form of stacks; Fig. 3 a second embodiment of the order picking system with an alignment module when forming order picking groups; Fig. 4 a third embodiment of the order picking system when transferring a first piece of goods to an assembly station; Fig. 5 the third embodiment of the order picking system when transferring the first piece of goods and simultaneously delivering another piece of goods; Fig. 6 the third embodiment of the order picking system when transferring the other piece of goods onto the first piece of goods to form a stack; Fig. 7 shows a variant of the alignment module for aligning the piece goods, in Fig. 7a and 7b an alignment, in Fig. 7c a spacing and in Fig. 7d a rotation; Fig. 8 is a flow chart of a logistics system which includes an order picking system.

DESCRIPTION OF THE EMBODIMENTS

[0067] Figure 1 shows a first embodiment of the order picking system 1 when forming order picking groups KG. The order picking system 1 shown for transporting and providing piece goods S, S' comprises a conveying device 2 which comprises an overhead conveyor 21 for conveying the piece goods S, S'. The overhead conveyor 21 shown comprises overhead conveyor receiving means 211 in the form of overhead conveyor pockets, by means of which the piece goods S, S' can be conveyed in a hanging manner. The overhead conveyor pockets 211 are guided by means of carriages 212 on a rail 213 of the overhead conveyor 21. To empty the overhead conveyor pockets 211, these are pivoted as shown.

[0068] Adjacent to the overhead conveyor 21, the conveying device 2 shown has a delivery station 22 for delivering the piece goods S, S' from the overhead conveyor 2.1 to a transfer device 3. For assembling the conveyed piece goods S, S', the transfer device 3 has a horizontally movable transfer element 31, by means of which the piece goods S, S' can be assembled by gravity at an assembly station P. The transfer device 3 is arranged adjacent to the delivery station 22 of the conveying device 2 and has a conveyor 32. The transfer element 31 can be horizontally movable for transfer at least between one receiving position P1 for receiving a conveyed piece good S and at least one delivery position P2 for delivering a piece good S located on the transfer element 31.

[0069] In the embodiment shown, the transfer element 31 is moved further incrementally horizontally in the delivery position P2 when another piece of goods S is transferred, so that the piece of goods S is transferred in a positioned manner to the assembly station P. In the embodiment shown, the piece of goods S, S' are transferred in an overlapping manner. Figure 2 shows the second embodiment of the order picking system 1 when forming order picking groups KG in the form of stacks. For this purpose, several piece of goods S, S' are transferred one after the other essentially in the middle to the assembly station P. For this purpose, the piece of goods S, S' are all positioned on top of one another.

[0070] Figure 3 shows a second embodiment of the order picking system 1 with an alignment module 35 when forming order picking groups KG. The embodiment of the order picking system 1 shown also comprises a conveying device 2 comprising an overhead conveyor 21 for conveying the piece goods S, S' and a delivery station 22 for delivering the piece goods S, S' from the overhead conveyor 21 to a transfer device 3 for assembling the conveyed piece goods S, S', which transfer device 3 has a horizontally movable transfer element 31, by means of which the piece goods S, S' can be assembled at an assembly station P by gravity.

[0071] Figures 4 to 6 show a third embodiment of the order picking system 1. The embodiment of the order picking system 1 shown also comprises a conveying device 2, comprising an overhead conveyor 21 for conveying the piece goods S, S' and a delivery station 22 for delivering the piece goods S, S' from the overhead conveyor 2.1 to a transfer device 3 for assembling the conveyed piece goods S, S', which transfer device 3 has a horizontally movable transfer element 31, by means of which the piece goods S, S' can be assembled by gravity at an assembly station P. In this embodiment, a chute 23 is provided for transferring the piece goods S, S' from the delivery station 22 to the conveyor 32.

[0072] The transfer element 31 shown is arranged below the conveyor 32 and can be moved horizontally with respect to a distal end 321 of the conveyor 32. In the receiving position P1 shown, the transfer element 31 is arranged protruding with respect to the distal end 321 in order to at least partially close the transfer area Z. A sensor unit 322 is arranged at the distal end 321 of the conveyor 32, by means of which the arrival of one of the piece goods S conveyed by the conveyor 32 can be detected and, based on a first sensor signal measured by the sensor unit 322 and sent to a control device 4, the transfer element 31 can be moved from the delivery position P2 to the receiving position P1 by means of the control device 4 in order to receive the piece goods S conveyed and detected by the sensor unit 322.

[0073] Figure 5 shows the third embodiment of the order picking system 1 during transfer of the first piece of goods S and simultaneous delivery of a further piece of goods S'. In the delivery position P2 shown, the transfer element 31 releases the transfer area Ü in such a way that the piece of goods S received on the transfer element 31 is transferred by gravity through the transfer area Ü to the assembly station P.

[0074] Figure 6 shows the third embodiment of the order picking system 1 when the further piece goods S' are transferred to the first piece goods S to form a stack. As shown, several piece goods S, S' are transferred one after the other essentially in the middle to the assembly station P. For this purpose, the piece goods S, S' are positioned one above the other and placed on top of one another.

[0075] Figure 7 shows a variant of the alignment module 35. The alignment module 35 shown has driven alignment elements 351, by means of which the piece goods S can be aligned along and/or laterally with respect to a conveying direction X. The piece goods S, S' conveyed via the chute 23 of the conveyor device 2 do not arrive aligned. The alignment module 35, which in the embodiment shown is arranged upstream of the conveyor 32, has alignment elements 351 in the form of rollers, omnidirectional wheels or balls. Balls offer greater mobility and flexibility in a conveyor system application compared to rollers or omnidirectional wheels. The alignment elements 351 are driven individually and independently of one another in order to align the piece goods S, S' along the conveying direction X and/or laterally thereto when conveyed on the alignment module 35.

[0076] Figures 7a and 7b show an alignment of piece goods S, S' with respect to the conveying direction X. Figure 7c shows a spacing of piece goods S, S' from one another along the conveying direction X and Figure 7d shows a rotation of piece goods S. In order to convert an alignment of a conveyed piece goods S into a desired alignment, a sensor unit 352 is arranged above the alignment module 35, by means of which an alignment of the piece goods S on the alignment module 35 can be detected. Based on a sensor signal measured by the sensor unit 352 and sent to a control device 4, the piece goods S is aligned by means of the control device 4 by actively and directed driving of the alignment elements 351 on the alignment module 35 and can also be spaced apart from a piece goods S' arranged upstream or downstream. The piece goods S are then transferred to the conveyor 32 in an aligned and spaced manner as shown and from there to the transfer element 31.

[0077] Figure 8 shows a flow chart of a logistics system which includes an embodiment of the order picking system. In addition to the order picking system, the logistics system also includes a storage device and a sorting device, as well as a storage device. The piece goods are delivered to the input side of the logistics system, for example by means of a truck.

[0078] To transport the goods from loading points through the logistics system, they can be transported using overhead conveyors. To fill the overhead conveyors, the logistics system can have a device for filling (S1) the overhead conveyors. In the unfilled state, the overhead conveyors are already arranged on the overhead conveyor by means of carriages and are kept ready in a waiting position. The carriages are mounted on a guide rail so that they can move in the direction of the guide rail, and the overhead conveyors are arranged hanging downwards to receive piece goods.

[0079] During transport in the filling device, the overhead conveyor receiving means can be transported hanging on a guide rail piece, which corresponds to a section of the guide rail and which can optionally be connected to one end of the first guide rail or the second guide rail. In the filling device, the overhead conveyor receiving means are typically rotated or pivoted for filling. For this purpose, an operating arrangement is advantageously provided with which the transport elements can be rotated at a specific point on the conveyor path by a specific angle of rotation to the vertical center axis of the overhead conveyor receiving means, wherein typically a suspension hook on the suspension of the overhead conveyor receiving means can be transferred from the first position to a second position or from the second position to the first position. Alternatively, pivoted overhead conveyor receiving means can be filled by means of a feed device.

[0080] For storing (S2) the piece goods within the logistics system, a batch buffer for providing groups of goods can also be provided. The logistics system can also comprise one or more matrix sorters for sorting the goods in batches (S3). A plurality of overhead conveyor receiving means, each of which comprises a receiving unit, preferably in the form of an overhead conveyor receiving means, can be provided for receiving the goods in the matrix sorter. A matrix sorter can also have several sorting stages.

[0081] If the matrix sorter is arranged within the logistics system downstream of the batch buffer and/or the filling device, it can take over the already filled overhead conveyor receiving means of the batch buffer and/or the filling device. The matrix sorter typically comprises at least one circulating conveyor for conveying the overhead conveyor receiving means, wherein the logistics system has a control which is designed to dynamically control the conveying speed of the circulating conveyor such that the conveying speed depends on at least one parameter, for example size and/or weight, of the conveyed overhead conveyor receiving means and/or goods.

[0082] After sorting, the overhead conveyor receiving means are typically buffered (S4). In addition to the matrix conveyor, the batch buffer can have further conveyors, preferably further circulating conveyors, which are designed to convey the overhead conveyor receiving means at a constant conveying speed. The control can be designed to control the conveying speed of the matrix conveyor such that the conveying speed of the matrix conveyor in at least one batch is higher than the constant conveying speed of the further conveyors.

[0083] The circulating conveyor is typically designed to guide the overhead conveyor receiving means to and/or away from a sorting stage. A sorting stage of the matrix sorter can have a plurality of linear buffer sections in the form of branches, which are connected to the matrix conveyor by switches. The buffer sections are preferably designed as gravity sections with a gradient such that the overhead conveyor receiving means can be conveyed in the gravity sections due to gravity. The branches can be designed as a plurality of linear storage sections, in each of which one batch or two batches can preferably be stored. The logistics system can also have a database in which the parameters, preferably the weight and/or size, of the overhead conveyor receiving means and/or goods entering the matrix sorter are stored. The matrix sorter can comprise a plurality of sorting stages and a plurality of matrix conveyors, each of which is assigned to one sorting stage or two sorting stages. The control system is typically designed to control the conveying speed of each circulating conveyor individually.

[0084] In addition to the matrix sorter, the logistics system can also include an intermediate storage unit. This is usually arranged before or after the batch buffer. The at least one intermediate storage unit typically has a dynamic storage unit for temporarily storing the goods/unit goods provided for order picking and a retrieval storage unit downstream of the dynamic storage unit for storing goods retrieved from the dynamic storage unit and pre-sorted in the process. The dynamic storage unit and the retrieval storage unit can be arranged within a common circulating conveyor or can be connected to one another via the common circulating conveyor.

[0085] The circulating conveyor is typically a conveyor with which the goods can be conveyed in a closed circuit or circuit. Actuable or switchable switches can be provided at various points on the circulating conveyor. The switches enable new goods to be brought into the circuit in a targeted manner or goods circulating in the circuit to be taken out. The goods are divided into the overhead conveyor receiving means, preferably in the form of overhead conveyor pockets, which can each be moved individually and added to or removed from the circuit.

[0086] The goods circulating in circulation and stored in the dynamic storage are in a specific order, which is usually based on the staggered removal of the goods from the warehouse, but does not correspond to the batches of goods determined by the orders. By pre-sorting the goods in the retrieval storage, the goods are already grouped together in a composition corresponding to the orders, so that a subsequent matrix sorter or an order-picking system is relieved of sorting work and can be dimensioned accordingly smaller or eliminated entirely.

[0087] The goods consignments pre-sorted in this way and prepared for shipping are then conveyed to the order-picking system (S7), in which the piece goods are transferred from the overhead conveyor means (S8) and, after the formation of order-picking groups (S9), are fed to the removal device for packaging (S10) and shipping (S11). The steps S7 - S9 are carried out by means of an order-picking system according to Figures 1 to 6.

[0088] Rectangular or square flat cardboard webs are usually provided as the starting material for the packaging (S10). Alternatively, an endless belt of cardboard can also be provided on the conveyor. The picking groups can be transferred to the cardboard web using the transfer element. A package can be formed around the picking group assembled at the assembly station using the transfer element, preferably in the form of a box that is folded around the picking group. This does not simply mean packing in a box, but rather forming a box in the form of a package. Based on the recorded dimensions, length, width and height, a package can be formed by mechanically cutting, folding and gluing the flat starting material. The picking groups packaged in this way are then shipped (S11).

Claims (24)

1. Order picking system (1) for transporting and providing piece goods (S, S'), comprising: a. a conveying device (2) comprising an overhead conveyor (21) for conveying the piece goods (S, S'), and a delivery station (22) for delivering the piece goods (S, S') from the overhead conveyor (2.1) to b. a transfer device (3) for assembling the conveyed piece goods (S, S'), which transfer device (3) has a horizontally movable transfer element (31) by means of which the piece goods (S, S') can be assembled at an assembly station (P) by gravity. 2. Order picking system (1) according to claim 1, wherein the transfer device (3) has a conveyor (32) adjacent to the delivery station (22) of the conveying device (2) and the transfer element (31) is movable, in particular horizontally, at least between one receiving position (P1) for receiving a conveyed piece of goods (S) and at least one delivery position (P2) for delivering a piece of goods (S) located on the transfer element (31). 3. Order picking system (1) according to claim 2, wherein the feed conveyor (32) can be accelerated or braked so that the respective piece goods (S) conveyed by the feed conveyor (2) can already be transferred to the transfer element (31) in a clock-synchronized manner in the receiving position (P1) such that it can also be transferred from the transfer element (31) to a downstream discharge conveyor (33) in a clock-synchronized manner in the delivery position (P2). 4. Order picking system (1) according to claim 2 or 3, wherein the transfer element (31) is horizontally incrementally movable, so that the piece goods (S) can be transferred to the assembly station (P) in a positioned manner, preferably centrally, off-center or depending on other piece goods (S'), in particular stacked or overlapping. 5. Order picking system (1) according to one of the preceding claims, wherein the transfer device (3) comprises an alignment module (35) which comprises driven alignment elements (351) by means of which the piece goods (S) can be aligned along and/or laterally with respect to a conveying direction (X), wherein the alignment module (35) is preferably arranged upstream of the conveyor (32). 6. Order picking system (1) according to claim 5, wherein a sensor unit (352) is arranged above the alignment module (35), by means of which an alignment of the piece goods (S) on the alignment module (35) can be detected and based on a sensor signal measured by the sensor unit (352) and sent to a control device (4), by means of the control device (4) the piece goods (S) can be aligned by actively and directed driving of the alignment elements (351) on the alignment module (35) and/or can be spaced apart from a piece goods (S) arranged upstream or downstream. 7. Order picking system (1) according to one of claims 2 to 6, wherein a sensor unit (322) is arranged at the distal end (321) of the conveyor (32), by means of which the arrival of a piece of goods (S) conveyed by the conveyor (32) can be detected and based on a first sensor signal measured by the sensor unit (322) and sent to the control device (4), the transfer element (31) can be moved by means of the control device (4), in particular from the delivery position (P2) to the receiving position (P1), in order to receive the piece of goods (S) conveyed and detected by the sensor unit (322). 8. Order picking system (1) according to claim 7, wherein the control device (4) can also be used to monitor the transport of the piece goods (S) conveyed by the conveyor (32), wherein when leaving the sensor area of the sensor unit (322) a second sensor signal is sent to the control device (4) and based on the second sensor signal the transfer element (31) can be moved by the control device (4) from the pick-up position (P1) back to the delivery position (P2) in order to transfer the picked-up piece goods (S) to the assembly station (P) by gravity. 9. Order picking system (1) according to one of the preceding claims, wherein the transfer element (31) is designed and can be moved in an accelerated manner such that the piece goods (S) received thereon can be transferred to the assembly station (P) essentially motionless due to its horizontal inertia, driven by gravity. 10. Order picking system (1) according to one of the preceding claims, wherein the assembly station (S) is arranged on the discharge conveyor (33) so that a picking group (KG) formed thereon can be conveyed away by means of the discharge conveyor (33), wherein the assembly station (P) is designed in the form of a virtual assembly station (V) or as a physical frame (R) which is arranged on the discharge conveyor (33) or within a receiving container (A) which is arranged on the discharge conveyor (33). 11. Order picking system (1) according to one of the preceding claims, wherein the transfer element (31) is arranged below the conveyor (32) and is horizontally movable with respect to a distal end (321) of the conveyor (32), wherein in the receiving position (P1) it is arranged protruding with respect to the distal end (321) in order to at least partially close the transfer area (Ü) and in the delivery position (P2) it is retracted under the conveyor (32) in such a way as to release the transfer area (Ü). 12. Order picking system (1) according to one of the preceding claims, wherein the horizontally movable transfer element (31) of the transfer device (3) is designed as a plate (311) which is optionally movably mounted in lateral guides (312) or is designed as a rotatable plate which is rotatably mounted preferably below the conveyor (32) for the transfer of the piece goods (S). 13. Order picking system (1) according to one of claims 1 to 11, wherein the horizontally movable transfer element (31) of the transfer device (3) is designed as a belt conveyor (313) with a movable belt section (314), preferably in the form of a telescopic conveyor belt. 14. Order picking system (1) according to one of the preceding claims, wherein the transfer device (3) comprises a stop (34) for positioning the piece goods (S, S'), wherein the transfer area (Ü) is delimited by the stop (34) and the distal end (321) of the conveyor (32), through which the piece goods (S) can be transferred to the assembly station (P) by gravity. 15. Order picking system (1) according to one of the preceding claims, wherein the transfer device (3) comprises a recognition device (6) by means of which the floor plan (G) of the order picking group (KG) can be determined in a top view and/or the outline (U) or the height (H) of the order picking group (KG) in a side view for controlling the order picking system (1). 16. Order picking system (1) according to one of the preceding claims, wherein the overhead conveyor (21) comprises overhead conveyor receiving means (211) in the form of pockets, baskets, bags or carrying loops by means of which the piece goods (S, S') can be conveyed in a hanging manner and the overhead conveyor receiving means (211) in the form of pockets, baskets, bags or carrying loops can be emptied from the overhead conveyor (21) for delivering the piece goods (S, S'), in particular can be emptied by pivoting. 17. Method for transporting and providing piece goods (S, S') comprising at least the following method steps: a. Providing (S0) a picking system (1) according to one of the preceding claims, comprising a conveying device (2) which comprises an overhead conveyor (21), as well as a delivery station (22), and a transfer device (3) with a horizontally movable transfer element (31); b. Conveying (S5) the piece goods (S, S') by means of the overhead conveyor (21) and delivering (S6) the piece goods (S, S') from the overhead conveyor (21) to the transfer device (3) by means of the delivery station (22); c. Transferring (S8) the conveyed piece goods (S, S') by means of the transfer device (3) and assembling (S9) them at an assembly station (P). 18. Method according to claim 17, wherein the transfer device (3) has a conveyor (32) adjacent to the delivery station (22) of the conveying device (2) and the transfer element (31) for assembling (S9) is moved horizontally between a receiving position (P1) for receiving a piece of goods (S) and a delivery position (P2) for delivering the piece of goods (S). 19. Method according to claim 17 or 18, wherein by means of driven alignment elements (351) of an alignment module (35) the piece goods (S) are aligned along and/or laterally with respect to a conveying direction (X) and/or are spaced apart from a piece goods (S) arranged upstream or downstream. 20. Method according to one of claims 17 to 19, wherein the transfer element (31) for assembling (S9) is moved horizontally with respect to a distal end (321) of the conveyor (32) at the same time as the conveying (S2) in order to take over a piece of goods (S) conveyed by the conveyor (32) from the conveyor (32). 21. Method according to one of claims 17 to 20, wherein the transfer element (31) for assembling (S9) the piece goods (S) already located on the transfer element (31) is simultaneously moved back with respect to the distal end (321) of the conveyor (32), so that the piece goods (S) are transferred by gravity through the transfer area (Ü) to the assembly station (P), in particular in an aligned manner for transfer. 22. Method according to claim 21, wherein the transfer element (31) is accelerated, preferably jerkily, and is moved back so that the piece goods (S) received thereon fall essentially motionless in the horizontal due to its inertia and then, driven by gravity, onto the assembly station (P). 23. Method according to one of claims 17 to 22, wherein the transfer element (31) is moved for assembling so that a. the piece goods (S) are transferred essentially centrally to the assembly station (P) to form a picking group (KG), or b. the piece goods (S) are transferred off-center to the assembly station (P) to form several picking groups (KG) to the assembly station (ST), or c. the transfer element (31) is moved further incrementally so that a subsequent piece goods (S) are transferred to the assembly station (P) in an overlapping manner onto a preceding piece goods (S). 24. Method according to one of claims 17 to 23, wherein a packaging is formed around the order-picking group (KG) assembled on the assembly station (P), preferably in the form of a box which is folded around the order-picking group (KG).