Production sorting scheduling system

Abstract

This invention discloses a production sorting scheduling system that enables products to be sorted according to production orders and channels, thereby improving sorting efficiency and success rate. The system includes at least two production lines, a merging and splitting device, at least two sorting areas, a loop conveyor with different loop conveyor lines, a barcode scanning and identification device including loop area barcode scanners and lane divider barcode scanners, and a scheduling control device. The scheduling control device is configured to execute barcode reading business processing logic, fault business processing logic, and congestion business processing logic. The barcode reading business processing logic includes: matching the production order based on the SN code read by the loop area barcode scanner; controlling the merging and splitting device to divert products to the corresponding loop conveyor lines according to the channel set in the production order; and matching the production order based on the SN code read by the lane divider barcode scanner; and allocating products entering a specific sorting area to the sorting lane assigned to the matched production order according to the matched production order.

Description

Technical Field

[0001] This invention relates to the field of logistics automation technology, and in particular to a production sorting and scheduling system. Background Technology

[0002] With intensifying market competition and diversified consumer demands, the production model of large white goods (such as refrigerators, washing machines, and air conditioners) is evolving towards small-batch, multi-batch, and high-frequency changes. Correspondingly, the sales channels for these products are also exhibiting a complex network structure, with the same product potentially flowing to different regional warehouses, retail outlets, or being directly delivered to customers depending on the order. Against this backdrop, the sorting system at the end of the production logistics chain, as a crucial link connecting production and delivery, directly determines order fulfillment capabilities and overall operating costs through its efficiency, accuracy, and flexibility.

[0003] Therefore, given the network structure of product production orders and distribution channels, how to achieve product sorting according to production orders and channels, and improve sorting efficiency and success rate, is a technical problem that urgently needs to be solved in this industry. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a production sorting and scheduling system that can sort products according to production orders and channels, and improve sorting efficiency and success rate.

[0005] This invention provides a production sorting and scheduling system, comprising: at least two production lines for producing products; a merging and splitting device connected to the at least two production lines for receiving products from different production lines; at least two sorting areas, each sorting area having multiple sorting access points; a circular conveyor system including different circular conveyor lines connected between the merging and splitting device and the different sorting areas for conveying products from the merging and splitting device to the corresponding sorting areas; a barcode scanning and identification device including barcode scanners located at the ends of each production line and barcode scanners located at the entrances of each sorting area for reading the product's serial number (SN) code; and a scheduling control device communicatively connected to the barcode scanning and identification device, the circular conveyor system, the merging and splitting device, and the sorting access points, configured to execute barcode reading business processing logic, fault business processing logic, and blockage business processing logic.

[0006] The code reading business processing logic includes: matching the production order with the SN code read by the ring zone scanner, and controlling the merging and splitting equipment to divert the products to the corresponding ring zone conveyor line according to the channel set in the production order; and matching the production order with the SN code read by the lane scanner, and allocating the products entering the specific sorting area to the sorting operation lane assigned to the matched production order according to the matched production order.

[0007] The aforementioned production sorting and scheduling system reads the product's serial number (SN) code to match the production order. Based on the channel set in the production order and the sorting lane assigned to the production order, it allocates the products to the corresponding sorting lane in a specific sorting area for sorting operations, thus achieving product sorting according to production order and channel. During the sorting process, the SN code is read twice for production order matching. First, products are allocated to a specific sorting area according to the channel set in the production order. Then, products entering the specific sorting area are allocated to the sorting lane assigned to the matching production order. This greatly reduces the probability of missorting and omissions, and significantly improves the sorting success rate. The system is designed with comprehensive fault handling logic and blockage handling logic, possessing strong fault tolerance capabilities. Local equipment failures or local area blockages will not cause system paralysis. Instead, tasks are automatically transferred to normal equipment or areas to continue execution, ensuring the entire operation continues and reducing the impact of abnormal line stoppages on sorting, thereby improving sorting efficiency. Attached Figure Description

[0008] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0009] Figure 1 This is a schematic diagram of a production sorting and scheduling system according to an embodiment of the present invention. Detailed Implementation

[0010] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0011] like Figure 1 As shown, in one embodiment of the present invention, the production sorting and scheduling system includes the following components:

[0012] Two production lines for manufacturing products, namely production line A and production line B;

[0013] A merging and splitting device is connected to production line A and production line B to receive products from production line A and production line B and perform initial merging.

[0014] There are two sorting areas, namely Area A and Area B;

[0015] A single-loop conveyor system includes two loop conveyor lines, namely the A-zone conveyor line and the B-zone conveyor line;

[0016] A barcode scanning and identification device, comprising 4 barcode scanners, numbered 01-04;

[0017] A scheduling and control device is communicatively connected to the barcode scanning and identification device, the loop conveyor device, and the sorting operation gate, and is configured to execute barcode reading business processing logic, fault business processing logic, and blockage business processing logic.

[0018] The classification and definition of the various components and business processes of the production sorting and scheduling system in this embodiment of the invention are as follows:

[0019] Production Line A: Consists of N production units. Products from each production unit are transported to the merging and splitting equipment via Production Line A, with a maximum flow rate of 1000 boxes / hour.

[0020] Production Line B: Consists of N production units. Products from each production unit are transported to the merging and splitting equipment via Production Line B, with a maximum flow rate of 2000 boxes / hour.

[0021] Area A: Includes 25 sorting stations, numbered 01-25, mainly handling products from channels such as engineering, general, strategic retail, and strategic engineering.

[0022] Zone B: Includes 23 sorting stations, numbered 26-48, mainly handling products from channels such as e-commerce available, e-commerce not available, overseas, and specific brands.

[0023] Area A conveyor line: Connected between the merging and separating equipment and Area A, it is used to transport products from the merging and separating equipment to the corresponding sorting lane in Area A, with a maximum flow rate of 1500 boxes / hour.

[0024] B-zone conveyor line: Connected between the merging and separating equipment and Zone B, it is used to transport products from the merging and separating equipment to the corresponding sorting lane in Zone B, with a maximum flow rate of 1500 boxes / hour.

[0025] Barcode Scanners: The entire production sorting and scheduling system is equipped with four barcode scanners (numbered 01-04) to identify the product's SN (Serial Number) code and transmit it to the scheduling control device for diversion and sorting operations. Among them, barcode scanners 01 and 03 are loop zone barcode scanners, respectively located at the end of production line A and the end of production line B; barcode scanners 02 and 04 are lane entrance barcode scanners, respectively located at the entrance of zone A and the entrance of zone B.

[0026] Sorting operation gates: Each picking line has one sorting operation gate. There are a total of 48 sorting operation gates in Zones A and B. The sorting operation gate will be assigned a production order during the sorting operation. Each sorting operation gate can only process one production order at a time.

[0027] Box-type exception ports: Sorting lane 25 in Zone A and sorting lanes 26 and 48 in Zone B are designated as box-type exception ports. Sorting lanes 25 and 48 are used to handle products that fail to read the serial number (SN) code, cannot be sorted normally after the sorting lane is used up, or cannot be sorted normally after the sorting lane is assigned. In other words, sorting lanes 25 and 48 are used to handle products that fail to identify the identity information or fail to be sorted. Sorting lane 26 only handles products that fail to read the SN code. In other words, sorting lane 26 only handles products that fail to identify the identity information.

[0028] Pallet Abnormal Location: This is the destination given when the robot requests a task from the system after normal product palletizing operations have been completed, but the information matching fails. This location is in the blank space between areas A and B (e.g.,...). Figure 1 (As shown).

[0029] Production order: This refers to a document issued by a higher-level system (such as an order management system). Each production unit can only have one production order at a time. The document contains information such as the quantity of products to be produced, channel type, and serial number (SN).

[0030] Setting up a sorting lane: This refers to the process initiated by the system at the start of the sorting operation, in which the corresponding equipment responds by setting a unique production order information for the sorting lane. After successful setting up, the sorting lane can only handle the sorting operation of the corresponding production order.

[0031] Clearing the sorting channel: This refers to the process initiated by the system after the sorting operation is completed, and the corresponding equipment responds by clearing the production order information of the sorting operation channel. After the list is successfully cleared, the information of the sorting operation channel will be empty, and the next channel setting process can be carried out.

[0032] It should be noted that, in other embodiments, the number of production lines used for product manufacturing can be set according to actual needs, and can be 3, 4, or other numbers. Different sorting areas handle products of different channel types, and the number of sorting areas and the number of ring conveyor lines are consistent. In other embodiments, the number of sorting areas and the number of ring conveyor lines can be 3, 4, or other numbers. The specific locations of box-type and pallet-type defect ports can also be adjusted accordingly based on actual conditions.

[0033] During the operation of the production sorting and scheduling system, the scheduling control device executes the code reading business processing logic to sort products according to production orders and channels; and executes fault business processing logic and blockage business processing logic to handle abnormal situations such as equipment failures and blockages that occur during the sorting operation, ensuring that the entire operation continues, so as to minimize the impact of abnormal line stoppages on sorting.

[0034] (a) Code reading business processing logic

[0035] The scheduling and control device executes code reading service processing logic, including executing ring zone logic and executing level crossing logic:

[0036] (1) Execute the ring zone logic: Based on the SN code read by the ring zone scanner, match the production order, and control the diversion and merging equipment to divert the products to the corresponding ring zone conveyor line according to the channel set in the production order.

[0037] 1.1 If the ring-area scanner successfully reads the SN code, the scheduling control device performs a match in the database based on the SN code read by the ring-area scanner:

[0038] a. If a production order is matched, the merging and splitting equipment is controlled to divert the products to the corresponding ring conveyor line according to the channel set in the production order. For example, when the channel set in the production order belongs to the channel type processed in Zone A (such as engineering, general, strategic retail, strategic engineering, etc.), the merging and splitting equipment is controlled to divert the products to the Zone A conveyor line.

[0039] b. If no production order is matched, a temporary production order is created, and the diversion and merging equipment is controlled to divert the products to the corresponding ring conveyor line according to the channel set in the temporary production order. For example, when the channel set in the temporary production order belongs to the channel type processed in Zone B (such as e-commerce available, e-commerce not available, overseas, specific brand, etc.), the diversion and merging equipment is controlled to divert the products to the Zone B conveyor line.

[0040] 1.2 If the ring area barcode scanner fails to read the SN code, the scheduling control device controls the product to continue to be transported in the original transport direction.

[0041] It should be noted that each product has one and only one SN code. If the ring area barcode scanner reads multiple SN codes or does not read any SN code, it is considered an invalid read and will be treated as a failed SN code reading. When the product is being transported, the SN code must be oriented in the same direction as the direction of travel. If the SN code is oriented incorrectly or deviates from its direction, it will be treated as a failed SN code reading.

[0042] (2) Execute sorting logic: Based on the SN code read by the sorting barcode scanner, match the production order, and allocate the products entering the specific sorting area to the sorting operation gate assigned to the matched production order according to the matched production order.

[0043] 2.1 If the lane divider barcode scanner successfully reads the SN code, the scheduling control device performs a match in the database based on the SN code read by the lane divider barcode scanner:

[0044] a. If a production order is matched, the products entering the specific sorting area will be assigned to the sorting lanes assigned to the matched production order.

[0045] (a-1) If a production order is matched and the corresponding production order has been assigned a sorting lane, the products entering the specific sorting area will be assigned to the sorting lane assigned to the matched production order. For example, when the barcode scanner (02 barcode scanner) at the entrance of area A successfully reads the SN code and matches the production order, and the corresponding production order has been assigned a sorting lane (such as sorting lane 23), the scheduling control device will assign the products entering area A to sorting lane 23 for sorting.

[0046] (a-2) If a production order is matched, but the corresponding production order has not been assigned a sorting lane and there is an available sorting lane, then a sorting lane is assigned to the corresponding production order, and the products entering the specific sorting area are assigned to the newly assigned sorting lane for sorting.

[0047] (a-3) If a production order is matched, but the corresponding production order has not been assigned a sorting access point and there is no available sorting access point, then the products entering the specific sorting area will be assigned to the box-type exception port of the corresponding sorting area.

[0048] b. If no production order is matched, the products entering the specific sorting area will be assigned to the corresponding sorting area's box-type exception port.

[0049] 2.2 If the barcode scanner at the sorting lane fails to read the SN code, the scheduling control device will allocate the products entering the specific sorting area to the corresponding box-type exception port of the sorting area. For example, when the barcode scanner (02 scanner) at the entrance of area A fails to read the SN code, the scheduling control device will allocate the products entering area A to the box-type exception port of area A (sorting operation port No. 25).

[0050] It should be noted that each product has one and only one SN code. If the ring area barcode scanner reads multiple SN codes or does not read any SN code, it is considered an invalid read and will be treated as a failed SN code reading. When the product is being transported, the SN code must be oriented in the same direction as the direction of travel. If the SN code is oriented incorrectly or deviates from its direction, it will be treated as a failed SN code reading.

[0051] (ii) Fault handling logic

[0052] (1) When the barcode scanner malfunctions, the scheduling control device executes the following logic:

[0053] a. If the barcode scanner in the ring zone malfunctions, the product will continue to be conveyed in the original conveying direction.

[0054] b. If the barcode scanner at the sorting point malfunctions, control the product to be conveyed to the box-type fault port in the corresponding sorting area.

[0055] For example, when the barcode scanner (01 barcode scanner) at the end of production line A malfunctions, the fault information is uploaded to the scheduling control device. The scheduling control device does not perform any processing to achieve fault tolerance and controls the products of production line A to continue to be transported into the A area conveyor line in the original conveying direction, and then the barcode scanner (03 barcode scanner) at the entrance of A area is used for barcode processing. When the barcode scanner (03 barcode scanner) at the entrance of A area malfunctions, the scheduling control device controls the products to be transported to the box-type abnormal port (25 sorting operation port) of A area.

[0056] (2) When a fault occurs in the ring conveyor line, the dispatch control device executes the following logic:

[0057] a. If a single loop conveyor line (area A or area B) malfunctions, all products subsequently destined for the malfunctioning loop conveyor line will be automatically reassigned to another functioning loop conveyor line. For example, when area A conveyor line malfunctions, the dispatch control device receives the malfunction information from area A conveyor line and automatically reassigns all products subsequently destined for area A conveyor line to area B conveyor line; when area A conveyor line recovers from the malfunction, the dispatch control device automatically restores the products reassigned to area B conveyor line to area A conveyor line for operation.

[0058] b. If all conveyor lines in the ring area fail, control the entire production sorting and scheduling system to stop operation and wait for the failure to be resolved.

[0059] (3) When a sorting operation gate fails, the scheduling control device executes the following logic: if a sorting operation gate fails, the sorting operation gate is set to unavailable, and the production order originally assigned to the sorting operation gate is reassigned to other available sorting operation gates; if there are no available sorting operation gates, the relevant products of the production order are transported to the box-type abnormal port of the corresponding sorting area.

[0060] Specifically, when a sorting lane malfunctions, the scheduling control device obtains equipment feedback information and first sets the malfunctioning sorting lane to unavailable. If there are production orders operating at the malfunctioning sorting lane and there are remaining sorting lanes available for allocation in the same sorting area, the production orders originally assigned to that sorting lane are reassigned to other available sorting lanes. If there are no available sorting lanes, the relevant products of the production order are transported to the box-type fault port in the corresponding sorting area (Area A or Area B).

[0061] When the sorting lane is restored from failure, the scheduling control device will prioritize assigning the production order to the sorting lane closest to the full pallet quantity (based on comparison of the palletized quantity to determine the closest full pallet quantity) when the sorting lane closest to the full pallet quantity continues to operate and meets the clearing conditions (such as the completed palletized quantity being a full pallet, i.e., full pallet). This clearing process prevents a single production order from occupying multiple sorting lanes.

[0062] (4) When the palletizing robot fails, the scheduling control device executes the following logic: If the palletizing robot fails, all sorting operation lanes associated with the failed palletizing robot are set to unavailable, and the production orders originally assigned to the sorting operation lanes associated with the failed palletizing robot are reassigned to other available sorting operation lanes. If there are no available sorting operation lanes, the relevant products of the production order are transported to the box-type abnormal port of the corresponding sorting area.

[0063] Specifically, when a palletizing robot malfunctions, the scheduling and control device obtains equipment feedback information and first sets all sorting operation lanes associated with the malfunctioning palletizing robot to unavailable. If there are production orders operating at the sorting operation lanes associated with the malfunctioning palletizing robot, and there are remaining sorting operation lanes available for allocation in the same sorting area, then the production orders originally allocated to the sorting operation lanes associated with the malfunctioning palletizing robot are reassigned to other available sorting operation lanes. If there are no available sorting operation lanes, then the relevant products of the production orders are transported to the box-type abnormal port of the corresponding sorting area (Area A or Area B).

[0064] When the palletizing robot recovers from its malfunction, all sorting lanes associated with that palletizing robot will be set to available. When the scheduling control device receives a production order with multiple sorting lanes operating simultaneously, it will prioritize assigning the production order to the sorting lane closest to the full pallet quantity (determined by comparing the pallet quantity to the full pallet quantity). When the sorting lane closest to the full pallet quantity continues to operate and meets the clearing conditions (such as the completed pallet quantity being a full pallet), the sorting lane will be cleared to prevent a single production order from occupying multiple sorting lanes.

[0065] (5) When the clearing or setting operation fails, the scheduling control device executes the following logic: If the clearing or setting operation fails, the corresponding sorting access point is set to unavailable, and the production order pre-assigned to that sorting access point is reassigned to other available sorting access points. If there are no available sorting access points, the relevant products of the production order pre-assigned to that sorting access point are transported to the box-type exception port of the corresponding sorting area. During the sorting process, when assigning sorting access points to production orders, the selected sorting access point must first be cleared, and then the cleared sorting access point must be set up to complete the sorting access point assignment for the production order. If the clearing or setting operation fails, it means that the selected sorting access point cannot be used normally, and the production order must be reassigned to other available sorting access points, or the relevant products of the production order must be transported to the box-type exception port of the corresponding sorting area.

[0066] (6) When a palletizing error occurs, the scheduling control device executes the following logic: if the information matching fails after palletizing, the entire pallet of products will be transported to the pallet error port.

[0067] Specifically, after the palletizing robot completes the palletizing operation normally, it will report all the serial numbers (SNs) and quantities to the scheduling and control device. Based on the production order information, the scheduling and control device will verify the reported SNs and quantities. If the match is successful, it will assign a delivery task to put the entire pallet of products into the warehouse; otherwise, it will assign the entire pallet of products to the pallet exception port and deliver the entire pallet of products to the pallet exception port.

[0068] (iii) Blocking business processing logic

[0069] (1) When a sorting area is blocked, the scheduling control device executes the following logic: If a sorting area is blocked, the production order of that sorting area is automatically transferred to another sorting area for operation.

[0070] a. If a sorting area malfunctions and causes a blockage, the production orders from that sorting area will be automatically transferred to another normal sorting area. Once the sorting area returns to normal operation, the transferred production orders will be automatically switched back to their original sorting area. For example, if a blockage occurs in area A, the scheduling control device will automatically transfer the production orders from area A to the normally operating area B. Once area A returns to normal operation, the scheduling control device will automatically switch the transferred production orders back to area A.

[0071] b. If the flow rate in the sorting area exceeds the threshold, causing congestion, the excess products will be automatically reassigned to another sorting area. For example, due to an imbalance in production orders, products from production lines A and B are diverted by the merging and splitting equipment. If the flow rate of products heading to area A exceeds the processing capacity of area A (maximum flow rate 1500 boxes / hour), the scheduling control device will automatically reassign the excess products to area B. These excess products will not be switched back to area A.

[0072] c. If a sorting access point malfunctions and causes congestion in the sorting area, the production orders for that sorting area will be transferred to another sorting area with processing capacity. Specifically, if a sorting access point malfunctions and becomes unusable, causing a decrease in the processing flow of the sorting area and resulting in congestion, the scheduling control device will automatically transfer the production orders for that sorting area to a sorting area with processing capacity. Once the sorting access point returns to normal operation, the scheduling control device will not restore the transferred production orders to the original sorting area's sorting access point.

[0073] (2) When the sorting operation channel is blocked, the scheduling control device executes the following logic: if the sorting operation channel is blocked, the products that need to enter the sorting operation channel will be scheduled to other available sorting operation channels for operation.

[0074] a. If a sorting lane is blocked and there is an available sorting lane in the current sorting area, products that need to enter that sorting lane will be reassigned to other available sorting lanes in the current sorting area for processing.

[0075] b. If the sorting access point is blocked and there is no available sorting access point in the current sorting area, the products that need to enter the sorting access point will be reassigned to an available sorting access point in another sorting area for processing.

[0076] Specifically, if a sorting lane becomes unusable due to a malfunction or abnormality in other management equipment, causing products to remain stuck at the sorting lane, the scheduling control device will prioritize rescheduling subsequent products that need to enter that sorting lane to other available sorting lanes within the current sorting area. If no other sorting lanes are available in the current sorting area, the scheduling control device will rescheduling subsequent products that need to enter that sorting lane to an available sorting lane in another sorting area with processing capacity. Once the sorting lane returns to normal operation, the scheduling control device will not restore the transferred production orders to the original sorting lane.

[0077] (3) When the box-type abnormal port is blocked, the dispatch control device executes the following logic:

[0078] a. If too many abnormal products in the box-type abnormality port cause a blockage in the circular conveyor line of the sorting area, all subsequent products that need to enter the blocked circular conveyor line will be reassigned to another normal circular conveyor line for processing. For example, when too many abnormal products are in the box-type abnormality port of area A, occupying the circular conveyor line of area A (area A conveyor line) and causing a blockage, the scheduling control device receives the blockage information from the area A conveyor line and automatically reassigns all subsequent products that need to enter the area A conveyor line to the area B conveyor line for processing; when the blockage in the area A conveyor line is cleared, the scheduling control device automatically restores the products reassigned to the area B conveyor line to the area A conveyor line for processing.

[0079] b. If there are too many abnormal product information but the abnormal products do not occupy the entire loop conveyor line position in the sorting area, the abnormal product information will be cleared periodically to restore the flow limit of the sorting area. During the abnormal product information clearing period, if the flow of the sorting area exceeds the flow limit, the excess products will be automatically dispatched to another sorting area for operation.

[0080] c. If multiple work orders at a single sorting lane cause congestion at that lane, and no one is available to handle the situation, products that subsequently need to enter that sorting lane will be reassigned to other available sorting lanes within the current sorting area. Specifically, if a sorting lane is congested and there is an available sorting lane in the current sorting area, products that subsequently need to enter that sorting lane will be reassigned to other available sorting lanes within the current sorting area; if a sorting lane is congested and there is no available sorting lane in the current sorting area, products that subsequently need to enter that sorting lane will be reassigned to an available sorting lane in another sorting area.

[0081] d. If multiple production orders are placed on a single pallet, guide the pallet to the pallet exception port.

[0082] The production sorting and scheduling system provided by this invention has the following beneficial technical effects:

[0083] (1) By reading the product's SN code to match the production order, the product is assigned to the corresponding sorting operation gate in the specific sorting area according to the channel set in the production order and the sorting operation gate assigned to the production order, so as to realize the sorting of products according to the production order and the channel. During the sorting process, the SN code is read twice to match the production order. First, the product is assigned to the specific sorting area according to the channel set in the production order. Then, the product entering the specific sorting area is assigned to the sorting operation gate assigned to the matching production order. This greatly reduces the probability of missorting and omission and significantly improves the sorting success rate.

[0084] (2) During the sorting process, fault tolerance was implemented for abnormal code reading. Products that failed to read the code by the front-end ring area barcode scanner could be left to be read and identified again by the back-end lane barcode scanner. Moreover, a strict abnormal product handling mechanism was set up to guide products that failed to identify the identity information or failed to be sorted and assigned to the box-type abnormal port. The abnormality was handled after the sorting was completed, which reduced the impact of abnormal line stoppage on sorting and thus improved sorting efficiency.

[0085] (3) Comprehensive fault handling logic and blocking business handling logic are designed, which has strong fault tolerance. The failure of local equipment (such as barcode scanner, single sorting operation gate, single ring conveyor line) and the blockage of local areas (such as blockage of a single sorting area, blockage of sorting operation gate) will not cause the system to be paralyzed. Instead, the task will be transferred to normal equipment and area through automatic scheduling to continue execution, ensuring that the entire operation continues and reducing the impact of abnormal line stoppage on sorting to almost zero, further improving sorting efficiency.

[0086] (4) The scheduling and control device can optimize the allocation of system resources based on real-time traffic and equipment status. When a single device or some devices in the sorting area are under maintenance or have a fault, the remaining devices can still work together to meet the sorting operation requirements and improve the overall utilization rate of the system.

[0087] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be included within the protection scope of the present invention.

Claims

1. A production sorting dispatch system, characterized by, The application relates to a production line system, comprising: at least two production lines for producing products; a split-merge device connected to the at least two production lines for receiving products from different production lines; at least two sorting areas, each of which is provided with a plurality of sorting operation channels; a loop line conveying device comprising different loop area conveying lines connected between the split-merge device and different sorting areas, for conveying products from the split-merge device to corresponding sorting areas; a code scanning and identifying device comprising a sub-loop area code scanner arranged at the end of each production line and a sub-channel code scanner arranged at the entrance of each sorting area, for reading the SN code of the products; a scheduling control device in communication connection with the code scanning and identifying device, the loop line conveying device, the split-merge device and the sorting operation channels, and configured to execute code reading business processing logic, fault business processing logic and blockage business processing logic; wherein the code reading business processing logic comprises: controlling the split-merge device to split the products to corresponding loop area conveying lines according to the channel set in the production order based on the SN code read by the sub-loop area code scanner matching the production order; and allocating the products entering a specific sorting area to the sorting operation channel allocated for the matched production order according to the SN code read by the sub-channel code scanner matching the production order; the step of controlling the split-merge device to split the products to corresponding loop area conveying lines according to the channel set in the production order based on the SN code read by the sub-loop area code scanner matching the production order comprises: if the SN code is successfully read by the sub-loop area code scanner and the production order is matched, then controlling the split-merge device to split the products to corresponding loop area conveying lines according to the channel set in the production order; if the SN code is successfully read by the sub-loop area code scanner but the production order is not matched, then creating a temporary production order and controlling the split-merge device to split the products to corresponding loop area conveying lines according to the channel set in the temporary production order; if the SN code is not read by the sub-loop area code scanner, then controlling the products to continue conveying in the original conveying direction.

2. The production sorting dispatch system of claim 1, wherein, the step of allocating the products entering a specific sorting area to the sorting operation channel allocated for the matched production order according to the SN code read by the sub-channel code scanner matching the production order comprises: if the SN code is successfully read by the sub-channel code scanner and the production order is matched, then allocating the products entering a specific sorting area to the sorting operation channel allocated for the matched production order; if the SN code is successfully read by the sub-channel code scanner but the production order is not matched, then allocating the products entering a specific sorting area to the box type abnormal port of the corresponding sorting area; if the SN code is not read by the sub-channel code scanner, then allocating the products entering a specific sorting area to the box type abnormal port of the corresponding sorting area.

3. The production sorting dispatch system of claim 2, wherein, the step of allocating the products entering a specific sorting area to the sorting operation channel allocated for the matched production order according to the SN code read by the sub-channel code scanner matching the production order comprises: if the SN code is successfully read by the sub-channel code scanner and the production order is matched, and the sorting operation channel allocated for the matched production order is matched, then allocating the products entering a specific sorting area to the sorting operation channel allocated for the matched production order. If the SN code is successfully read by the passageway scanner and the production order is matched, but the corresponding production order is not assigned to a sorting job passageway and there is an available sorting job passageway, the sorting job passageway corresponding to the production order is assigned, and the product entering the specific sorting area is assigned to the newly assigned sorting job passageway for sorting.

4. The production sorting dispatch system of claim 3, wherein, If the SN code is successfully read by the passageway scanner and the production order is matched, the product entering the specific sorting area is assigned to the sorting job passageway assigned to the matched production order, and the method further comprises: If the production order is matched, but the corresponding production order is not assigned to a sorting job passageway and there is no available sorting job passageway, the product entering the specific sorting area is assigned to the box abnormal passageway of the corresponding sorting area.

5. The production sorting dispatch system of claim 1, wherein, The fault business processing logic is executed, including: If the ring area scanner fails, the product is controlled to continue conveying in the original conveying direction; If the passageway scanner fails, the product is controlled to be conveyed to the box abnormal passageway of the corresponding sorting area; If the single ring area conveying line fails, all subsequent products that need to enter the failed ring area conveying line are automatically scheduled to another normal ring area conveying line for operation; If the sorting job passageway fails, the sorting job passageway is set as unavailable, and the production order originally assigned to the sorting job passageway is reassigned to other available sorting job passageways; If the stacking manipulator fails, all sorting job passageways associated with the failed stacking manipulator are set as unavailable, and the production order originally assigned to the sorting job passageway associated with the failed stacking manipulator is reassigned to other available sorting job passageways.

6. The production sorting dispatch system of claim 1, wherein, The blocking business processing logic is executed, including: If the sorting area is blocked, the production order of the sorting area is automatically transferred to another sorting area for operation; If the sorting job passageway is blocked, the product that needs to enter the sorting job passageway is scheduled to other available sorting job passageways for operation; If the abnormal product information is too much but the abnormal product does not occupy the entire ring area conveying line position of the sorting area, the abnormal product information is cleaned up in time to restore the upper limit of the flow of the sorting area; If the single sorting job passageway multi-order operation causes the sorting job passageway to be blocked, the product that needs to enter the sorting job passageway is scheduled to other available sorting job passageways for operation without human processing; If a single tray stores multiple production order products, the tray is guided to the whole tray abnormal passageway.

7. The production sorting dispatch system of claim 6, wherein, If the sorting area is blocked, the production order of the sorting area is automatically transferred to another sorting area for operation, including: If the sorting area fails to cause blocking, the production order of the sorting area is automatically transferred to another normal sorting area for operation; If the flow of the sorting area exceeds the threshold to cause blocking, the excess product is automatically scheduled to another sorting area for operation; If the sorting job passageway fails to cause the sorting area to be blocked, the production order of the sorting area is transferred to a sorting area with processing capacity for operation.

8. The production sorting dispatch system of claim 6, wherein, If the sorting job passageway is blocked, the product that needs to enter the sorting job passageway is scheduled to other available sorting job passageways for operation, including: If the sorting operation portal is blocked and there is a sorting operation portal available in the current sorting area, the products that need to enter the sorting operation portal subsequently are dispatched to other available sorting operation portals in the current sorting area for operation; If the sorting operation portal is blocked and there is no available sorting operation portal in the current sorting area, the products that need to enter the sorting operation portal subsequently are dispatched to the available sorting operation portal of another sorting area for operation.

9. The production dispatching system according to any one of claims 1 to 8, characterized in that, Each sorting operation portal is only assigned to process the products of one production order at the same time point, and the dispatching control device assigns the sorting operation portal to the production order through the portal setting operation and unbinds the sorting operation portal from the production order through the portal clearing operation.

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