A complete set of automated transportation equipment and method for warehouse containers.

Abstract

This invention discloses a complete set of automated transportation equipment and method for warehouse containers. The complete set of equipment includes containers, an inbound receiving and conveying unit, a container identification unit, a container shape detection unit, a container posture correction unit, a container weight and off-center load detection unit, an automatic docking and locking transfer unit, a multi-layer buffer storage unit, a cross-area transportation unit, an outbound docking and sorting unit, an automatic empty container return unit, and a central dispatch control system. The transportation method achieves fully automated transportation of warehouse containers from inbound to outbound and empty container return by performing identification, shape detection, posture correction, weight and off-center load detection on the containers, and using the automatic docking and locking transfer unit for floating positioning, lateral clamping, and lifting locking. The central dispatch control system then generates a transportation path based on the container and equipment status.

Description

Technical Field

[0001] This invention belongs to the technical field of automated warehousing and logistics equipment, specifically relating to a complete set of automated transportation equipment and method for warehousing containers throughout the entire process. Background Technology

[0002] With the development of smart warehousing, flexible manufacturing, and automated logistics, warehousing systems are increasingly using containers, storage cabinets, turnover cabinets, and mobile storage cabinets as material storage and transportation carriers. Containers are typically used to store parts, tools, spare parts, goods, semi-finished products, or other warehousing materials, and they have advantages such as large capacity, multiple storage units, and reusability.

[0003] In existing warehousing operations, after a container enters the warehousing system from the receiving end, it typically undergoes multiple stages, including receiving registration, container identification, transportation, temporary storage, inter-area transfer, outbound sorting, and empty container recovery. For larger or heavier containers, traditional methods often involve manual handling, forklift transfer, conventional conveyor lines, or single automated guided vehicles (AGVs). While these methods can accomplish basic transportation tasks, they still have shortcomings in terms of continuous operation, automation, and safety throughout the entire process.

[0004] Specifically, the following problems mainly exist in the existing warehousing container transportation process: First, when containers enter the automated conveyor system, there is usually a lack of comprehensive detection of the container's identity, specifications, size, posture, and door status. This can easily lead to containers without identification, containers with incorrect specifications, containers that are too tall or too wide, or containers with doors that are not closed entering the automated transport main line, thereby causing subsequent conveying jams, collisions, or shutdowns.

[0005] Secondly, before entering the conveyor line, lifting equipment, transport vehicle, or buffer position, the container may have issues such as lateral offset, angular deviation, or unstable bottom support. If posture correction is not performed, the container is prone to misalignment, jamming, collision, or slippage during the connection process between different equipment.

[0006] Third, the distribution of goods inside a container may not be uniform, especially for upright containers or containers with a high center of gravity. During transportation, starting, stopping, turning, lifting, or changing floors, there is a risk of uneven loading and tipping. Existing equipment generally only focuses on whether the container is in place, but lacks the detection and linkage of the container's total weight and center of gravity offset with transportation control.

[0007] Fourth, existing automated conveying equipment typically lacks a unified container connection benchmark and locking structure between transport vehicles, elevators, buffer racks, and outbound workstations. Containers are prone to relative displacement during conveying, transfer, transport, and lifting, affecting transport stability and connection accuracy.

[0008] Fifth, existing warehousing systems often treat inbound, conveying, buffering, outbound, and empty container return as relatively independent functional modules, lacking a complete set of automated equipment that combines container status detection, posture correction, automatic locking, path scheduling, anomaly removal, and empty container return, resulting in weak continuous operation capability of the system.

[0009] Therefore, it is necessary to develop a complete set of automated transportation equipment for warehouse containers, so that the containers can flow continuously, stably and safely automatically between receiving, identification, shape detection, posture correction, weight and off-center load detection, automatic connection and locking, cross-area transportation, multi-layer buffering, outbound connection and sorting and empty container return. Summary of the Invention

[0010] To address the aforementioned technical problems, this invention provides a complete set of automated transportation equipment and method for warehouse containers throughout the entire process. By performing identification, shape detection, posture correction, weight and off-center load detection on the containers, and by using an automatic docking and locking transfer unit to perform floating positioning, lateral clamping and lifting locking on the containers, the central dispatch control system generates a transportation path based on the container status and equipment status, thereby realizing fully automated transportation of warehouse containers from warehousing to outbound and empty container return.

[0011] To achieve the above-mentioned technical objectives, the technical solution adopted by the present invention is as follows: This invention discloses a complete set of automated transportation equipment for warehouse containers, including containers, an inbound receiving and conveying unit, a container identification unit, a container shape detection unit, a container posture correction unit, a container weight and off-center load detection unit, an automatic connection and locking transfer unit, a multi-layer buffer storage unit, an inter-area transportation unit, an outbound connection and sorting unit, an empty container automatic return unit, and a central dispatch and control system.

[0012] The container is equipped with a docking reference part for cooperation with the automatic docking and locking transfer unit. The docking reference part can be directly set on the bottom support frame of the container, or it can be set on the adapter base installed at the bottom of the container. The docking reference part includes a guide groove, a positioning hole, a locking hole, and a load-bearing contact surface.

[0013] The inbound receiving and conveying unit is used to receive containers to be transported and transport the containers to the inspection station. The inbound receiving and conveying unit includes an inbound conveyor frame, an inbound conveying mechanism, an entrance detection sensor, a guide rail, a buffer conveying section, and a blocking and positioning mechanism.

[0014] The container identification unit is used to read the container's identification tag and send the container's identification information to the central dispatch and control system. The identification tag can be a QR code, barcode, RFID tag, NFC tag, or other identifiable identifier.

[0015] The container shape detection unit is used to detect the container's external dimensions, lateral offset, and deflection angle. The container shape detection unit includes a detection door frame, a top ranging sensor, a first lateral ranging sensor, a second lateral ranging sensor, a front detection sensor, a rear detection sensor, and a door status detection component.

[0016] The container attitude correction unit is located after the container shape detection unit and is used to adjust the position and attitude of the container relative to the conveying centerline based on the lateral offset and deflection angle detected by the container shape detection unit. The container attitude correction unit includes a correction conveying platform, a lateral pushing mechanism, a rotation correction mechanism, a center positioning mechanism, and a correction re-inspection sensor.

[0017] The container weight and off-center load detection unit is used to detect the total weight of the container and the force distribution at each load-bearing position of the container, and sends the total weight and off-center load status of the container to the central dispatch control system. The container weight and off-center load detection unit includes at least three weighing sensors, preferably four weighing sensors, and the multiple weighing sensors are distributed and arranged below the load-bearing platform used to support the container.

[0018] The automatic docking and locking transfer unit is used to position, clamp, and lock the container after attitude correction and weight detection. The automatic docking and locking transfer unit includes a docking platform, a platform conveying mechanism, a floating positioning mechanism, a lateral clamping mechanism, a lifting and locking mechanism, front and rear blocking mechanisms, and a docking completion detection mechanism.

[0019] The multi-layer buffer storage unit is used to temporarily store containers awaiting warehousing, warehousing, transportation, verification, or return. The multi-layer buffer storage unit includes a buffer frame, multi-layer buffer channels, a buffer position conveying mechanism, a buffer position occupancy detection sensor, and a container limiting mechanism.

[0020] The inter-regional transport unit is used to carry containers locked by the automatic docking and locking transfer unit and transport the containers to the target area. The inter-regional transport unit can be an AGV transport vehicle, an AMR transport vehicle, a rail shuttle vehicle, or a ground automated transport vehicle. Preferably, the inter-regional transport unit includes a transport vehicle body, a driving mechanism, a navigation and positioning module, a carrying platform, an on-board conveying mechanism, an on-board locking mechanism, a safety obstacle avoidance module, and an on-board control module.

[0021] The outbound transfer and sorting unit is used to transport containers to the corresponding outbound workstation, picking workstation, or shipping workstation. The outbound transfer and sorting unit includes an outbound conveyor line, an outbound transfer platform, a container secondary positioning mechanism, an outbound locking mechanism, a sorting guide mechanism, a picking workstation, and an outbound confirmation and detection component.

[0022] The automatic empty container return unit is used to determine whether a container is empty or full after it leaves the warehouse, and to transport the empty container to the receiving end or the empty container buffer area. The automatic empty container return unit includes an empty / full detection component, an empty container return conveyor line, an empty container buffer position, and a return transfer mechanism.

[0023] The central dispatch and control system is connected to the inbound receiving and conveying unit, the container identification unit, the container shape detection unit, the container posture correction unit, the container weight and off-center load detection unit, the automatic connection and locking transfer unit, the multi-layer buffer temporary storage unit, the cross-regional transportation unit, the outbound connection and sorting unit, and the empty container automatic return unit.

[0024] The central dispatch and control system is used to generate container transportation routes based on container identity information, external dimensions, lateral offset, deflection angle, total container weight, off-center load status, equipment occupancy status, and target location information. It also controls the automatic flow of containers between inbound reception, identity recognition, shape detection, posture correction, weight and off-center load detection, automatic connection locking, cross-regional transportation, buffer storage, outbound connection sorting, and empty container return.

[0025] Preferably, the connecting reference part includes a guide groove, a positioning hole, a locking hole, and a bearing contact surface; the guide groove extends along the container transportation direction, and the entrance end of the guide groove forms a flared guide opening or an inclined guide surface; the positioning hole is used to cooperate with the floating positioning mechanism of the automatic connecting locking transfer unit; the locking hole is used for the insertion of the locking pin of the automatic connecting locking transfer unit; the bearing contact surface is used to contact the bearing components of the inbound receiving and conveying unit, the inter-area transportation unit, the multi-layer buffer temporary storage unit, or the outbound connecting sorting unit.

[0026] Preferably, the floating positioning mechanism includes a floating positioning seat, a guide ramp, an elastic reset member, and a floating limiting member; the floating positioning seat is capable of floating relative to the docking platform in both the lateral and longitudinal directions; the guide ramp is disposed on the inlet side of the floating positioning seat and is used to cooperate with the guide groove or inclined guide surface at the bottom of the container; the elastic reset member is connected between the floating positioning seat and the docking platform and is used to reset the floating positioning seat to its initial position when no external force is applied; the floating limiting member is used to limit the maximum floating displacement of the floating positioning seat relative to the docking platform.

[0027] Preferably, the lateral clamping mechanism includes a first clamping arm, a second clamping arm, a clamping drive, a clamping buffer pad, and a clamping position detection sensor; the first and second clamping arms are respectively disposed on the left and right sides of the docking platform and can move towards each other under the drive of the clamping drive. The lifting and locking mechanism includes a locking pin, a lifting drive, a locking guide sleeve, and a locking position detection sensor; the locking pin can be vertically lifted and lowered under the drive of the lifting drive and inserts into the locking hole at the bottom of the container when it rises.

[0028] Preferably, the central dispatch control system determines the container transportation level based on the total weight of the container and the off-center loading status; when the total weight of the container is less than or equal to the allowable load and the off-center loading degree is less than the first off-center loading threshold, the container is determined to be a normal transportation level; when the total weight of the container is less than or equal to the allowable load and the off-center loading degree is greater than the first off-center loading threshold but less than the second off-center loading threshold, the container is determined to be a speed-limited transportation level; when the total weight of the container is greater than the allowable load or the off-center loading degree is greater than the second off-center loading threshold, the container is determined to be an abnormal container.

[0029] Preferably, the present invention further includes a lifting and changing-floor conveying unit, which includes a lifting derrick, a lifting platform, a lifting drive mechanism, a platform conveying mechanism, a floor conveying mechanism, a floor positioning mechanism, a fall arrest mechanism, and a floor-to-floor interlocking mechanism; the floor positioning mechanism is used to mechanically position the lifting platform with the corresponding floor conveying mechanism after the lifting platform reaches the target floor; the floor-to-floor interlocking mechanism is used to restrict the platform conveying mechanism and the floor conveying mechanism from starting synchronously when the lifting platform has not completed the floor mechanical positioning.

[0030] This invention also provides a fully automated transportation method for warehouse containers, comprising the following steps: S1. The container to be transported enters the inbound receiving and conveying unit, which then transports the container to the identification station. S2. The container identification unit reads the container's identification mark and sends the container's identification information to the central dispatch and control system. S3, the container shape detection unit detects the container's external dimensions, lateral offset, deflection angle, and door closure status; S4. The central dispatch and control system controls the container attitude correction unit to operate according to the lateral offset and deflection angle, so that the container returns to the standard conveying center line and standard angle. S5, the container weight and off-center load detection unit detects the total weight of the container and the force distribution at each load-bearing position of the container. The central dispatch control system calculates the off-center load status of the container and determines the container transportation level based on the detection results. S6. The automatic docking and locking transfer unit performs floating positioning, lateral clamping and lifting locking on the container, and sends a locking completion signal to the central dispatch and control system after locking is in place. S7. The central dispatch and control system generates a container transportation path based on the container's identity information, target location information, shape detection results, attitude correction results, total container weight, off-center loading status, transportation level, equipment occupancy status, and buffer space status. S8. Cross-regional transportation unit, multi-layer buffer storage unit, lifting and layer-changing conveying unit or outbound connection sorting unit perform container transportation, buffering, layer-changing or outbound connection operations according to the container transportation path. S9. After the container completes the outbound operation, the empty container automatic return unit determines whether the container is empty based on the actual weight of the container after it leaves the warehouse, the detection signals inside the container, and the outbound task completion information. S10. When the container is empty, the central dispatch control system controls the automatic empty container return unit to transport the container to the inbound end or the empty container buffer area; when the container is not empty, the central dispatch control system transports the container to the multi-layer buffer temporary storage unit, the outbound connection and sorting unit or the abnormal container rejection unit.

[0031] Compared with the prior art, the present invention has at least the following beneficial effects: First, by setting up a container identification unit, a container shape detection unit, a container posture correction unit, and a container weight and off-center load detection unit, the present invention enables the container to complete comprehensive detection of its identity, size, posture, door status, weight, and off-center load status before entering the automated transport main line, which can effectively prevent abnormal containers from entering the main transport path.

[0032] Secondly, the present invention automatically corrects the lateral offset and deflection angle of the container through the container posture correction unit, so that the container is in the standard conveying center line and standard angle position before entering the automatic docking and locking transfer unit, thereby improving the reliability of subsequent docking, clamping, locking, lifting and transportation.

[0033] Third, the present invention performs secondary positioning, lateral clamping and rigid locking of the container through the floating positioning mechanism, lateral clamping mechanism and lifting locking mechanism in the automatic docking and locking transfer unit, so that the container is not prone to slipping, tilting, collision or falling during cross-equipment transfer, transportation, lifting and outbound docking.

[0034] Fourth, the present invention detects the total weight of the container and the force distribution at each load position through the container weight and off-center load detection unit, and the central dispatch control system determines the transportation level according to the off-center load status, so as to realize differentiated transportation control for normal containers, speed-limited containers and abnormal containers, thereby improving the transportation safety of containers with high center of gravity or off-center load.

[0035] Fifth, the present invention generates container transportation routes based on container status, target location, equipment occupancy status, and buffer status through a central dispatch and control system, thereby forming a continuous automated operation process between receiving, detection and correction, automatic connection, cross-regional transportation, multi-layer buffering, lifting and changing layers, outbound sorting, and empty container return.

[0036] Sixth, the present invention automatically determines whether a container is empty after the container has completed its outbound operation through an automatic empty container return unit, and returns the empty container to the inbound end or the empty container buffer area, thereby reducing manual collection of empty containers and improving the efficiency of container recycling.

[0037] Seventh, the present invention automatically exports containers that fail to be identified, exceed size limits, have doors that are not closed, fail to correct posture, exceed weight limits, have severe off-center loading, fail to automatically lock, or are deemed abnormal due to being empty or full through the abnormal container rejection unit. This can prevent abnormal containers from continuing to enter the main line and reduce the risk of system downtime and equipment damage.

[0038] Of course, any product implementing this invention does not necessarily need to achieve all of the technical effects described above at the same time. Attached Figure Description

[0039] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this invention, illustrate exemplary embodiments of the invention and are used to explain the invention, but do not constitute an undue limitation of the invention. In the drawings: Figure 1 This is a schematic diagram of the overall layout of a complete set of automated transportation equipment for warehouse containers according to the present invention; Figure 2 This is a schematic diagram of the structure of the container and the connecting reference part in this invention; Figure 3 This is a schematic diagram of the structure of the warehouse receiving and conveying unit, the container identification unit, and the container shape detection unit in this invention; Figure 4 This is a schematic diagram of the container posture correction unit in this invention; Figure 5 This is a schematic diagram of the container weight and off-center load detection unit in this invention; Figure 6 This is a schematic diagram of the automatic docking and locking transfer unit in this invention; Figure 7 This is a schematic diagram of the cross-regional transportation unit in this invention; Figure 8 This is a schematic diagram of the lifting and layer-changing conveying unit in this invention; Figure 9 This is a schematic diagram of the layout of the multi-layer buffer storage unit, the outbound connection and sorting unit, and the empty cabinet automatic return unit in this invention; Figure 10 This is a flowchart illustrating a fully automated transportation method for warehouse containers according to the present invention.

[0040] Explanation of reference numerals in the attached figures: 1. Container; 11. Container body; 12. Bottom load-bearing frame; 13. Connecting base; 131. Guide groove; 132. Positioning hole; 133. Locking hole; 134. Load-bearing contact surface; 14. Adapter base; 15. Identification mark; 2. Inbound receiving and conveying unit; 21. Inbound conveying rack; 22. Inbound conveying mechanism; 23. Entrance detection sensor; 24. Guide rail; 25. Buffer conveying section; 26. Blocking and positioning mechanism; 261. Liftable stop block; 262. Stop block drive component; 3. Container identification unit; 31. Identification bracket; 32. Identification reader; 33. Identification supplementary lighting component; 4. Container shape detection unit; 41. Detection gantry; 42. Top distance sensor; 43. First lateral distance sensor; 44. Second lateral distance sensor; 45. Front-end detection sensor; 46. Rear-end detection sensor; 47. Door status detection assembly; 5. Container posture correction unit; 51. Correction conveying platform; 52. Lateral pushing mechanism; 521. First lateral push plate; 522. Second lateral push plate; 523. Push plate drive component; 53. Rotation correction mechanism; 531. Rotation support; 532. Rotation drive component; 533. Angle detection sensor; 54. Center positioning mechanism; 55. Correction re-inspection sensor; 6. Container weight and off-center load detection unit; 61. Weighing sensor; 611. First weighing sensor; 612. Second weighing sensor; 613. Third weighing sensor; 614. Fourth weighing sensor; 62. Weighing platform; 7. Automatic docking and locking transfer unit; 71. Docking platform; 72. Platform conveying mechanism; 73. Floating positioning mechanism; 731. Floating positioning seat; 732. Guide slope; 733. Elastic reset component; 734. Floating limit component; 74. Lateral clamping mechanism; 741. First clamping arm; 742. Second clamping arm; 743. Clamping drive component; 744. Clamping buffer pad; 745. Clamping position detection sensor; 75. Lifting and locking mechanism; 751. Locking pin; 752. Lifting drive component; 753. Locking guide sleeve; 754. Locking position detection sensor; 76. Front and rear blocking mechanisms; 761. Front stop block; 762. Rear stop block; 77. Docking position detection mechanism; 8. Multi-layer buffer storage unit; 81. Buffer frame; 82. Multi-layer buffer channel; 83. Buffer position conveying mechanism; 84. Buffer position occupancy detection sensor; 85. Container limiting mechanism; 9. Cross-regional transportation unit; 91. Transport vehicle body; 92. Walking drive mechanism; 93. Navigation and positioning module; 94. Load-bearing platform; 95. Vehicle-mounted conveying mechanism; 96. Vehicle-mounted locking mechanism; 97. Safety obstacle avoidance module; 98. Vehicle-mounted control module; 10. Lifting and changing floor conveying unit; 101. Lifting derrick; 102. Lifting platform; 103. Lifting drive mechanism; 104. Platform conveying mechanism; 105. Floor conveying mechanism; 106. Floor positioning mechanism; 107. Fall arrest mechanism; 108. Floor-to-floor interlocking mechanism; 20. Outbound connecting and sorting unit; 201. Outbound conveyor line; 202. Outbound connecting platform; 203. Secondary positioning mechanism for containers; 204. Outbound locking mechanism; 205. Sorting guiding mechanism; 206. Picking workstation; 207. Outbound confirmation and detection components; 30. Automatic empty cabinet return unit; 301. Empty / full detection component; 302. Empty cabinet return conveyor line; 303. Empty cabinet buffer position; 304. Return transfer mechanism; 40. Abnormal container rejection unit; 401. Abnormal conveyor branch line; 402. Abnormal buffer position; 403. Manual verification station; 404. Alarm and prompting device; 405. Abnormal reset entrance; 50. Central Dispatch and Control System. Detailed Implementation

[0041] The following will describe in detail the implementation of the present invention with reference to the accompanying drawings and embodiments, so that the process of how the present invention uses technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly. Example 1

[0042] like Figures 1 to 10 As shown, this embodiment provides a complete set of automated transportation equipment for warehouse containers, including a container 1, an inbound receiving and conveying unit 2, a container identification unit 3, a container shape detection unit 4, a container posture correction unit 5, a container weight and off-center load detection unit 6, an automatic docking and locking transfer unit 7, a multi-layer buffer temporary storage unit 8, an inter-area transportation unit 9, an lifting and layer-changing conveying unit 10, an outbound docking and sorting unit 20, an automatic empty container return unit 30, an abnormal container rejection unit 40, and a central dispatch and control system 50.

[0043] In this embodiment, container 1 serves as the unified transportation object in the warehousing system and can be a turnover container, material container, tool container, parts storage container, upright container, or mobile storage container. Container 1 can be continuously transported, buffered, transported, and returned between various units.

[0044] The central dispatch and control system 50 is communicatively connected to the inbound receiving and conveying unit 2, the container identification unit 3, the container shape detection unit 4, the container posture correction unit 5, the container weight and off-center load detection unit 6, the automatic docking and locking transfer unit 7, the multi-layer buffer storage unit 8, the inter-area transportation unit 9, the lifting and layer-changing conveying unit 10, the outbound docking and sorting unit 20, the empty container automatic return unit 30, and the abnormal container rejection unit 40. The central dispatch and control system 50 is used to collect the identity information, shape information, posture information, weight information, off-center load information, locking status, and current position of the container 1, and to control the automatic flow of the container 1 between the various units according to the warehousing task and equipment status.

[0045] like Figure 2 As shown, the container 1 includes a container body 11 and a bottom support frame 12 disposed at the bottom of the container body 11. The bottom support frame 12 is used to bear the weight of the container body 11 and the goods inside, and is used to contact conveying equipment, transport equipment or buffer equipment.

[0046] The container 1 is equipped with a docking reference unit 13. The docking reference unit 13 is used to cooperate with the automatic docking and locking transfer unit 7 to guide, position and lock the container 1 during the automatic docking process.

[0047] In one embodiment, the connecting base 13 is directly mounted on the bottom support frame 12. In another embodiment, the connecting base 13 is mounted on the adapter base 14, which is installed on the bottom of the container 1 by bolting, welding, snap-fitting, or other fixing methods. By providing the adapter base 14, existing containers can be adapted to this complete set of equipment after simple modifications.

[0048] The docking reference section 13 includes a guide groove 131, a positioning hole 132, a locking hole 133, and a bearing contact surface 134. The guide groove 131 extends along the transport direction of the container 1, and its entrance end has a flared guide opening or an inclined guide surface to guide the container 1 gradually to the docking center position when it enters the docking platform 71. The positioning hole 132 is used to cooperate with the floating positioning mechanism 73. The locking hole 133 is used for the insertion of the locking pin 751 of the lifting locking mechanism 75. The bearing contact surface 134 is used to contact the conveying mechanism or the carrying platform.

[0049] The container 1 is equipped with an identification tag 15, which can be placed on the side wall, top, bottom, or adapter base 14 of the container body 11. The identification tag 15 can be a QR code, barcode, RFID tag, or NFC tag. Through the identification tag 15, the central dispatch control system 50 can obtain information such as container number, container specifications, empty container weight, allowable load, target location, transportation task status, and outbound priority.

[0050] like Figure 3 As shown, the inbound receiving and conveying unit 2 is used to receive the container 1 to be transported and convey the container 1 to the identification and detection station. The inbound receiving and conveying unit 2 includes an inbound conveying frame 21, an inbound conveying mechanism 22, an entrance detection sensor 23, a guide rail 24, a buffer conveying section 25, and a blocking and positioning mechanism 26.

[0051] The inbound conveyor 21 is arranged along the inbound direction of the container 1. The inbound conveyor mechanism 22 is installed on the inbound conveyor 21 and is used to transport the container 1 along the inbound direction. The inbound conveyor mechanism 22 can be a roller conveyor mechanism, a chain conveyor mechanism, a synchronous belt conveyor mechanism, or a combination of the above mechanisms.

[0052] An entrance detection sensor 23 is installed on the entrance side of the inbound conveyor rack 21 to detect whether the container 1 has entered the inbound receiving and conveying unit 2. The entrance detection sensor 23 can be a photoelectric sensor, a proximity sensor, a laser sensor, or a vision sensor.

[0053] Guide rails 24 are respectively installed on both sides of the inbound conveyor frame 21 to limit the lateral deviation of the container 1 when it enters the inbound receiving conveyor unit 2. The buffer conveyor section 25 is installed after the entrance detection sensor 23 to reduce the conveying speed of the container 1 before it enters the detection station, so as to prevent the container 1 from impacting the detection equipment or blocking the positioning mechanism 26.

[0054] The blocking and positioning mechanism 26 is located at the end of the receiving and conveying unit 2 or at the front of the inspection station. The blocking and positioning mechanism 26 includes a liftable stop 261 and a stop drive 262. The stop drive 262 can be a pneumatic cylinder, an electric cylinder, a hydraulic cylinder, or a motor screw mechanism. When the container 1 is conveyed to the inspection station, the liftable stop 261 rises and abuts against the front of the container 1, stopping the container 1 at the preset inspection position; when the container 1 needs to continue to be conveyed, the liftable stop 261 descends, and the container 1 continues to be conveyed to the subsequent unit through the receiving and conveying mechanism 22.

[0055] The container identification unit 3 is used to read the identification mark 15 on the container 1 and send the reading result to the central dispatch control system 50. The container identification unit 3 includes an identification bracket 31, an identification reader 32, and an identification supplementary lighting component 33.

[0056] The identification bracket 31 is disposed on one side, above, or at the bottom of the receiving and conveying unit 2. The identification reader 32 is mounted on the identification bracket 31. The identification reader 32 can be a QR code reader, barcode scanner, RFID reader, NFC reader, or vision camera.

[0057] When container 1 enters the identification station, the central dispatch control system 50 controls the inbound conveyor 22 to stop or operate at a low speed, and the identification reader 32 reads the identification tag 15. The identification supplementary lighting component 33 is used to provide illumination during visual identification or barcode scanning identification.

[0058] When identification is successful, the central dispatch control system 50 establishes or calls up the corresponding transportation task for container 1 based on the identification result. When identification fails, identification information is missing, identification information does not match the current task, or container specifications are not within the allowable range, the central dispatch control system 50 controls container 1 to enter the abnormal container rejection unit 40.

[0059] The container shape detection unit 4 is used to detect the external dimensions, lateral offset, deflection angle, and door closing status of the container 1. For example... Figure 3 As shown, the container shape detection unit 4 includes a detection door frame 41, a top distance sensor 42, a first lateral distance sensor 43, a second lateral distance sensor 44, a front detection sensor 45, a rear detection sensor 46, and a door status detection component 47.

[0060] The detection gantry 41 is mounted above the receiving and conveying unit 2 or the detection conveying section. A top distance sensor 42 is mounted on top of the detection gantry 41 to detect the height of the container 1. A first lateral distance sensor 43 and a second lateral distance sensor 44 are respectively mounted on the left and right sides of the detection gantry 41 to detect the distance between the left and right sides of the container 1 and the detection gantry 41. A front-end detection sensor 45 and a rear-end detection sensor 46 are used to detect the front and rear boundary positions of the container 1. A door status detection assembly 47 is used to detect whether the door of the container 1 is closed properly.

[0061] During the specific inspection, container 1 passes through the inspection gantry 41. The top distance sensor 42 collects the container height data, the first lateral distance sensor 43 and the second lateral distance sensor 44 collect the distance data between the two sides of the container, and the front-end detection sensor 45 and the rear-end detection sensor 46 collect the container length boundary data. The central dispatch control system 50 determines whether container 1 is excessively tall, excessively wide, excessively long, or has an abnormal shape based on the above data.

[0062] Simultaneously, the central dispatch control system 50 calculates the lateral offset of container 1 relative to the conveying centerline based on the distance data collected by the first lateral ranging sensor 43 and the second lateral ranging sensor 44. If two sets of lateral distance values ​​are collected at the front and rear of container 1 respectively, the central dispatch control system 50 can also calculate the deflection angle of container 1 relative to the conveying direction based on the difference between the lateral distances at the front and rear of container 1.

[0063] When the external dimensions of container 1 exceed the allowable range, or when the door status detection component 47 detects that the door of container 1 is not closed properly, the central dispatch control system 50 controls container 1 to enter the abnormal container rejection unit 40. When the external dimensions of container 1 are qualified but the lateral offset or deflection angle does not meet the standard position requirements, if it is within the correctable range, the central dispatch control system 50 controls container 1 to enter the container attitude correction unit 5.

[0064] like Figure 4 As shown, the container attitude correction unit 5 is located after the container shape detection unit 4 and before the automatic docking and locking transfer unit 7. The container attitude correction unit 5 is used to automatically correct the container 1 according to the lateral offset and deflection angle.

[0065] The container posture correction unit 5 includes a correction conveying platform 51, a lateral pushing mechanism 52, a rotation correction mechanism 53, a center positioning mechanism 54, and a correction re-inspection sensor 55.

[0066] The alignment conveyor platform 51 is used to carry the container 1 and transport the container 1 along the transport direction. The alignment conveyor platform 51 can be a roller conveyor platform, a chain conveyor platform, or a synchronous belt conveyor platform.

[0067] The lateral pushing mechanism 52 includes a first lateral push plate 521, a second lateral push plate 522, and a push plate drive member 523. The first lateral push plate 521 and the second lateral push plate 522 are respectively disposed on the left and right sides of the correction conveying platform 51, and can move towards each other or away from each other under the drive of the push plate drive member 523. The push plate drive member 523 can be a cylinder, an electric cylinder, a hydraulic cylinder, a motor screw mechanism, or a gear and rack mechanism.

[0068] When the central dispatch control system 50 determines that container 1 is shifting to the left, it controls the second lateral pusher 522 on the right to extend inward, pushing container 1 towards the conveying center line; when it determines that container 1 is shifting to the right, it controls the first lateral pusher 521 on the left to extend inward, pushing container 1 towards the conveying center line. Alternatively, the first lateral pusher 521 and the second lateral pusher 522 can be controlled to move synchronously in opposite directions, so that container 1 is clamped and conveyed to the center position.

[0069] The rotation correction mechanism 53 is located below the correction conveyor platform 51 and includes a rotation support 531, a rotation drive 532, and an angle detection sensor 533. The rotation drive 532 can drive the correction conveyor platform 51 to rotate around the vertical axis within a preset angle range to correct the deflection angle of the container 1 relative to the conveying direction. The rotation drive 532 can be a servo motor, a reducer, a gear ring mechanism, a worm gear mechanism, or an electric rotary mechanism.

[0070] The center positioning mechanism 54 is used to position the container 1 in a standard transport position after the container 1 has completed lateral pushing and rotational correction. The center positioning mechanism 54 may include a center positioning block, a guide wheel assembly, a positioning groove, or a limit guide rail.

[0071] The correction and re-inspection sensor 55 is used to re-detect the lateral offset and deflection angle of container 1 after the lateral push-up mechanism 52 and the rotation correction mechanism 53 have been activated. If the re-inspection result meets the preset requirements, the central dispatch control system 50 controls container 1 to continue to enter the subsequent inspection or connection process. If the re-inspection result is still unqualified, the central dispatch control system 50 can control the container attitude correction unit 5 to perform the correction action again; when the number of corrections reaches the preset number and is still unqualified, the central dispatch control system 50 controls container 1 to enter the abnormal container rejection unit 40.

[0072] With the above structure, the container posture correction unit 5 can ensure that the container 1 is in a standard posture suitable for docking and locking before it enters the automatic docking and locking transfer unit 7, thereby improving the success rate of subsequent automatic locking.

[0073] like Figure 5 As shown, the container weight and off-center load detection unit 6 is used to detect the total weight and off-center load status of container 1. The container weight and off-center load detection unit 6 can be installed below the correction conveyor platform 51, or below the connection platform 71 of the automatic connection locking transfer unit 7.

[0074] In this embodiment, the container weight and off-center load detection unit 6 includes a weighing platform 62 and a plurality of weighing sensors 61 disposed below the weighing platform 62. Preferably, the weighing sensors 61 include a first weighing sensor 611, a second weighing sensor 612, a third weighing sensor 613, and a fourth weighing sensor 614, which respectively correspond to the left front bearing position, right front bearing position, left rear bearing position, and right rear bearing position of the container 1.

[0075] When container 1 is placed on the weighing platform 62, the first weighing sensor 611, the second weighing sensor 612, the third weighing sensor 613 and the fourth weighing sensor 614 respectively collect the force values ​​at the corresponding positions and send the force values ​​to the central dispatch control system 50.

[0076] The central dispatch control system 50 calculates the total weight of the container based on the force values ​​collected by each weighing sensor, and calculates the direction of the center of gravity offset and the degree of off-center loading of container 1 based on the force differences between different weighing sensors. For example, if the force values ​​collected by the first weighing sensor 611, the second weighing sensor 612, the third weighing sensor 613, and the fourth weighing sensor 614 are denoted as F1, F2, F3, and F4 respectively, then the total weight W of the container can be expressed as: W = F1 + F2 + F3 + F4.

[0077] The degree of eccentric loading in the left-right direction of container 1 can be determined by the difference between the force values ​​on the left and right sides, where the force value on the left is F1+F3 and the force value on the right is F2+F4. The degree of eccentric loading in the front-rear direction of container 1 can be determined by the difference between the force values ​​on the front and rear sides, where the force value on the front is F1+F2 and the force value on the rear is F3+F4.

[0078] The central dispatch control system 50 determines the transport class of container 1 based on its total weight and degree of off-center loading. When the total weight of the container is less than or equal to the allowable load and the degree of off-center loading is less than the first off-center loading threshold, container 1 is classified as normal transport. When the total weight of the container is less than or equal to the allowable load and the degree of off-center loading is greater than the first off-center loading threshold but less than the second off-center loading threshold, container 1 is classified as speed-limited transport. When the total weight of the container exceeds the allowable load or the degree of off-center loading exceeds the second off-center loading threshold, container 1 is classified as an abnormal container.

[0079] For containers in normal transport categories, the central dispatch control system 50 allows them to be transported at standard speed, standard acceleration, and standard route. For containers in speed-limited transport categories, the central dispatch control system 50 controls the inter-regional transport unit 9 to reduce its operating speed, starting acceleration, braking deceleration, and turning radius. For abnormal containers, the central dispatch control system 50 controls container 1 to enter the abnormal container rejection unit 40.

[0080] like Figure 6 As shown, the automatic docking and locking transfer unit 7 is used to automatically dock, position, clamp, lock and release between the container 1 and the inbound receiving and conveying unit 2, the cross-area transport unit 9, the multi-layer buffer temporary storage unit 8, the lifting and changing layer conveying unit 10 or the outbound docking and sorting unit 20.

[0081] The automatic docking and locking transfer unit 7 includes a docking platform 71, a platform conveying mechanism 72, a floating positioning mechanism 73, a lateral clamping mechanism 74, a lifting and locking mechanism 75, a front and rear blocking mechanism 76, and a docking positioning detection mechanism 77.

[0082] The docking platform 71 is used to carry the container 1. The platform conveying mechanism 72 is installed on the docking platform 71 and is used to transport the container 1 to the preset docking position of the docking platform 71. The platform conveying mechanism 72 can be a roller conveyor, a chain conveyor, a synchronous belt conveyor, or a lifting and transferring mechanism.

[0083] The floating positioning mechanism 73 is disposed on the docking platform 71 and corresponds to the docking reference part 13 at the bottom of the container 1. The floating positioning mechanism 73 includes a floating positioning seat 731, a guide ramp 732, an elastic reset member 733, and a floating limit member 734.

[0084] The floating positioning seat 731 can float within a small range in both the lateral and longitudinal directions relative to the docking platform 71. A guide ramp 732 is disposed on the entrance side of the floating positioning seat 731 and is used to engage with the guide groove 131 or inclined guide surface at the bottom of the container 1. When the container 1 enters the docking platform 71, the guide ramp 732 first contacts the docking reference part 13 at the bottom of the container 1 and guides the container 1 to gradually enter the predetermined position. Because the floating positioning seat 731 has a certain floating capability, it can absorb residual deviations when the container 1 enters the docking platform 71, avoiding rigid collisions or jamming.

[0085] An elastic reset element 733 is connected between the floating positioning seat 731 and the docking platform 71, and is used to reset the floating positioning seat 731 to its initial position when no external force is applied. The elastic reset element 733 can be a spring, a rubber elastic element, a gas spring, or an elastic buffer assembly. The floating limit element 734 is used to limit the maximum floating displacement of the floating positioning seat 731 relative to the docking platform 71, so as to prevent the floating positioning seat 731 from deviating too much and affecting the positioning accuracy.

[0086] Lateral clamping mechanisms 74 are disposed on the left and right sides of the connecting platform 71. The lateral clamping mechanisms 74 include a first clamping arm 741, a second clamping arm 742, a clamping drive 743, a clamping buffer pad 744, and a clamping position detection sensor 745. The first clamping arm 741 and the second clamping arm 742 can move towards each other under the drive of the clamping drive 743, respectively abutting against the bottom support frame 12 or the sides of the adapter base 14 of the container 1, thereby clamping the container 1 at the center position of the connecting platform 71. The clamping buffer pad 744 is disposed at the contact position between the first clamping arm 741 and the second clamping arm 742 and the container 1 to prevent damage to the container 1 during clamping.

[0087] The lifting and locking mechanism 75 is located below or inside the docking platform 71. The lifting and locking mechanism 75 includes a locking pin 751, a lifting drive component 752, a locking guide sleeve 753, and a locking position detection sensor 754. The locking pin 751 can move vertically up and down under the drive of the lifting drive component 752. The lifting drive component 752 can be a pneumatic cylinder, an electric cylinder, a hydraulic cylinder, or a motor screw mechanism. The locking guide sleeve 753 guides the lifting and lowering movement of the locking pin 751. The locking position detection sensor 754 detects whether the locking pin 751 is fully inserted or fully unlocked.

[0088] The upper end of the locking pin 751 is preferably provided with a tapered head or a rounded guide head. With this structure, even if there is a slight positional deviation between the locking hole 133 and the locking pin 751, the locking pin 751 can still be smoothly guided into the locking hole 133 during the upward process, thereby improving the locking success rate.

[0089] The front and rear blocking mechanism 76 includes a front stop 761 and a rear stop 762. The front stop 761 and the rear stop 762 are capable of lifting and lowering to restrict the movement of the container 1 along the conveying direction. When the container 1 needs to stop at the docking position, the front stop 761 or the rear stop 762 rises; when the container 1 needs to continue conveying, the front stop 761 or the rear stop 762 lowers.

[0090] The docking positioning detection mechanism 77 is used to detect the positioning status of the front end of container 1, the rear end of container 1, the lateral clamping position, and the lifting lock position. The docking positioning detection mechanism 77 may include a photoelectric sensor, a proximity sensor, a limit switch, a pressure sensor, or a displacement sensor.

[0091] The automatic connection and locking process is as follows: Container 1 enters the connecting platform 71 via the platform conveyor 72, which decelerates. When both the front and rear positions meet preset conditions, the front and rear blocking mechanisms 76 activate, stopping Container 1 at the connecting position. Subsequently, the floating positioning mechanism 73 cooperates with the connecting reference part 13 at the bottom of Container 1 to perform secondary positioning of Container 1. Afterward, the lateral clamping mechanism 74 activates, with the first clamping arm 741 and the second clamping arm 742 moving towards each other and clamping Container 1. Once clamped in place, the lifting locking mechanism 75 activates, and the locking pin 751 extends upward and inserts into the locking hole 133. After the locking position detection sensor 754 confirms that the locking pin 751 is inserted in place, the central dispatch control system 50 marks Container 1 as locked and ready for transport.

[0092] The unlocking and releasing process is the reverse of the locking process. After container 1 arrives at the target equipment, the target equipment completes the connection preparation confirmation. The lifting and locking mechanism 75 first drives the locking pin 751 to descend and exit the locking hole 133; then the lateral clamping mechanism 74 releases container 1; the front and rear blocking mechanisms 76 descend; and the platform conveying mechanism 72 starts to transport container 1 to the target equipment. When the locking pin 751 has not fully descended or the lateral clamping mechanism 74 has not fully released, the central dispatch control system 50 does not allow the platform conveying mechanism 72 to start, in order to avoid container 1 getting stuck or damaging the locking mechanism.

[0093] With the above structure, the automatic docking and locking transfer unit 7 can achieve stable docking when the container 1 is transferred between the fixed conveying equipment, the cross-zone transport unit 9, the lifting and changing layer conveying unit 10, or the outbound docking and sorting unit 20, thereby preventing the container 1 from slipping, tilting, falling or colliding during transportation.

[0094] like Figure 9 As shown, the multi-layer buffer storage unit 8 is used to temporarily store the container 1 in different task states. The multi-layer buffer storage unit 8 includes a buffer frame 81, a multi-layer buffer channel 82, a buffer position conveying mechanism 83, a buffer position occupancy detection sensor 84, and a container limiting mechanism 85.

[0095] The buffer frame 81 has multiple buffer channels 82 arranged vertically, and each buffer channel 82 has multiple buffer positions. The buffer position conveying mechanism 83 is used to transport the container 1 into the corresponding buffer position or to output the container 1 from the corresponding buffer position. The buffer position conveying mechanism 83 can be a roller, chain, synchronous belt or shuttle transfer mechanism.

[0096] The buffer position occupancy detection sensor 84 is used to detect whether the corresponding buffer position is occupied by the container 1. The container limiting mechanism 85 is used to limit the container 1 after it enters the buffer position to prevent the container 1 from sliding during the buffering process.

[0097] The central dispatch control system 50 allocates buffer spaces to container 1 based on the container's task status, transportation priority, target location, equipment occupancy status, and buffer space availability. For example, for containers awaiting shipment with high priority, the central dispatch control system 50 prioritizes allocating buffer spaces closer to the outbound connection and sorting unit 20; for empty containers, it prioritizes allocating buffer spaces closer to the inbound end or the empty container automatic return unit 30; and for abnormal containers, it prioritizes allocating abnormal buffer space 402 closer to the manual verification station 403.

[0098] By setting up multi-layered buffer storage units 8, temporary buffer space can be provided for container 1 during peak inbound and outbound periods, transportation route congestion, or temporary equipment failure, thus preventing the entire automated transportation system from shutting down due to local congestion.

[0099] like Figure 7 As shown, the inter-area transport unit 9 is used to transport container 1 between different storage areas. The inter-area transport unit 9 can be an AGV transport vehicle, an AMR transport vehicle, a rail shuttle vehicle, or a ground automated transport vehicle.

[0100] In this embodiment, the cross-regional transportation unit 9 includes a transportation vehicle body 91, a walking drive mechanism 92, a navigation and positioning module 93, a carrying platform 94, an on-board conveying mechanism 95, an on-board locking mechanism 96, a safety obstacle avoidance module 97, and an on-board control module 98.

[0101] The walking drive mechanism 92 is used to drive the transport vehicle body 91 to move. The navigation and positioning module 93 is used to realize the navigation and positioning of the transport vehicle body 91 within the storage area. The navigation and positioning method can be QR code navigation, laser navigation, visual navigation, magnetic navigation, or SLAM navigation. The carrying platform 94 is set on the transport vehicle body 91 and is used to carry the container 1. The on-board conveying mechanism 95 is used to transfer the container 1 between the transport vehicle body 91 and the fixed docking equipment. The on-board locking mechanism 96 is used to lock the container 1 during the transport of the container 1 by the transport vehicle body 91. The safety obstacle avoidance module 97 is used to detect personnel or obstacles in the transport path. The on-board control module 98 is used to receive task instructions from the central dispatch control system 50 and control the operation of the transport vehicle body 91.

[0102] When the transport vehicle 91 arrives at the receiving station, the navigation and positioning module 93 completes the positioning alignment. After the receiving station confirms the transport vehicle 91 is in place, and the transport vehicle 91 confirms the receiving platform is ready, the onboard conveyor 95 and the conveyor on the receiving platform start synchronously, smoothly transferring the container 1 to the carrying platform 94. Once the container 1 enters the carrying platform 94, the onboard locking mechanism 96 activates, locking the container 1 onto the transport vehicle 91. After locking, the transport vehicle 91 performs its transport task.

[0103] The central dispatch control system 50 controls the travel speed, starting acceleration, braking deceleration, and turning radius of the transport vehicle 91 based on the container weight and the total weight and off-center load status output by the off-center load detection unit 6. When the container 1 is in the speed-limited transport class, the transport vehicle 91 runs at a speed lower than the standard speed and prioritizes routes with more straight sections and fewer turns in the route planning.

[0104] like Figure 8 As shown, the lifting and transferring unit 10 is used to realize the vertical transfer of container 1 between different floors, platforms of different heights, or multi-level buffer racks. The lifting and transferring unit 10 includes a lifting hoist 101, a lifting platform 102, a lifting drive mechanism 103, a platform conveying mechanism 104, a floor conveying mechanism 105, a floor positioning mechanism 106, a fall arresting mechanism 107, and a floor-to-floor interlocking mechanism 108.

[0105] The lifting platform 102 can move up and down along the lifting frame 101 under the drive of the lifting drive mechanism 103. The platform conveying mechanism 104 is installed on the lifting platform 102 and is used to receive and transport the container 1. The floor conveying mechanisms 105 are respectively installed at different floor positions and are used to connect with the platform conveying mechanism 104 to connect the container 1.

[0106] The floor positioning mechanism 106 is used to mechanically position the lifting platform 102 with the corresponding floor conveying mechanism 105 after the lifting platform 102 reaches the target floor. The floor positioning mechanism 106 may include a positioning pin, a positioning hole, a locking block, a guide block, or a limit stop.

[0107] The anti-fall locking mechanism 107 is used to prevent the lifting platform 102 from falling accidentally during the lifting process. The inter-floor connection interlocking mechanism 108 is used to restrict the platform conveying mechanism 104 and the floor conveying mechanism 105 from starting synchronously when the lifting platform 102 has not completed the mechanical positioning of the floor.

[0108] Before container 1 enters the lifting platform 102, the lifting platform 102 stops at the current floor and completes floor positioning. The platform conveying mechanism 104 and the current floor conveying mechanism 105 start synchronously, transporting container 1 to the lifting platform 102. After container 1 enters the lifting platform 102, the platform conveying mechanism 104 stops, and the front and rear blocking mechanisms or locking mechanisms limit the movement of container 1. Then, the lifting platform 102 moves to the target floor. Upon reaching the target floor, the floor positioning mechanism 106 first completes mechanical positioning, and then the platform conveying mechanism 104 and the target floor conveying mechanism 105 start synchronously, transporting container 1 to the target floor.

[0109] By using the floor positioning mechanism 106 and the floor-to-floor interlocking mechanism 108, the container 1 can be forcibly transported when there is a height difference, gap difference, or misalignment between the lifting platform 102 and the floor conveying mechanism 105, thereby reducing the risk of the container 1 getting stuck, falling, or colliding.

[0110] like Figure 9 As shown, the outbound transfer and sorting unit 20 is used to transport the container 1 to the corresponding outbound workstation, picking workstation, or shipping workstation. The outbound transfer and sorting unit 20 includes an outbound conveyor line 201, an outbound transfer platform 202, a container secondary positioning mechanism 203, an outbound locking mechanism 204, a sorting guide mechanism 205, a picking workstation 206, and an outbound confirmation and detection component 207.

[0111] Outbound conveyor 201 receives containers 1 from inter-zone transport unit 9, multi-layer buffer storage unit 8, or lift-and-change conveyor unit 10. Outbound connection platform 202 transports containers 1 to the target outbound workstation. Container secondary positioning mechanism 203 positions the container 1 so that its door or picking surface faces the picking station 206. Outbound locking mechanism 204 locks containers 1 during picking or sorting to prevent movement during manual picking, robotic picking, or sorting operations.

[0112] The sorting guide mechanism 205 is used to guide the container 1 to different outbound workstations according to the outbound task. The sorting guide mechanism 205 can be a swing wheel sorting mechanism, a transfer conveyor mechanism, a pusher sorting mechanism, or a branch guide mechanism. The outbound confirmation detection component 207 is used to detect whether the container 1 has arrived at the designated outbound workstation and whether the corresponding outbound task has been completed.

[0113] When container 1 enters the outbound sorting unit 20, the central dispatch control system 50 determines the target outbound workstation based on the container's identity information and outbound task information. The sorting guide mechanism 205 guides container 1 to the corresponding workstation. After container 1 arrives at its position, the container secondary positioning mechanism 203 and the outbound locking mechanism 204 activate to maintain the container 1 in a predetermined relative position with the picking workstation 206. After the outbound task is completed, the outbound confirmation detection component 207 sends a completion signal to the central dispatch control system 50.

[0114] The automatic empty container return unit 30 is used to determine whether container 1 is empty after the container 1 has completed the outbound, picking or shipping operation, and to return the empty container to the inbound end or the empty container buffer area. The automatic empty container return unit 30 includes an empty / full detection component 301, an empty container return conveyor line 302, an empty container buffer position 303 and a return transfer mechanism 304.

[0115] The empty / full detection component 301 may include a weighing detection component, a vision detection component, an in-cabinet photoelectric detection component, and a task verification module. The weighing detection component detects the actual weight of container 1 after it leaves the container and compares it with the weight of the corresponding empty container. The vision detection component identifies whether there are still items inside container 1. The in-cabinet photoelectric detection component detects whether the storage compartments inside the container are occupied. The task verification module determines whether all outbound tasks corresponding to container 1 have been completed.

[0116] The central dispatch control system 50 determines whether container 1 is empty based on its actual weight after leaving the warehouse, the weight of the empty container corresponding to container 1, the detection signals inside the container, and the information on the completion of the outbound task. When the actual weight of container 1 is close to the weight of an empty container, the detection signals inside the container show that there are no goods occupying the container, and the outbound task has been completed, the central dispatch control system 50 determines that container 1 is empty and controls the empty container return conveyor line 302 and the return transfer mechanism 304 to transport container 1 to the inbound end or the empty container buffer position 303.

[0117] When there are still remaining items in container 1 or the outbound task is not completed, the central dispatch control system 50 will transport container 1 to the multi-layer buffer temporary storage unit 8, the outbound connection and sorting unit 20 or the abnormal container rejection unit 40 according to the task requirements.

[0118] The abnormal container rejection unit 40 is used to receive containers 1 that are determined to be abnormal during the fully automated transportation process. The abnormal container rejection unit 40 includes an abnormal conveyor branch line 401, an abnormal buffer position 402, a manual review station 403, an alarm prompting device 404, and an abnormal reset entrance 405.

[0119] When container 1 experiences issues such as identity recognition failure, container specifications not matching the task, external dimensions exceeding limits, door not closing properly, posture deviation exceeding the correctable range, posture correction failure, total weight exceeding limits, off-center load exceeding the safety threshold, automatic connection lock failure, connection failure, or empty / full judgment abnormality, the central dispatch control system 50 controls container 1 to enter the abnormal transport branch line 401 and transport it to the abnormal buffer position 402 or the manual verification workstation 403.

[0120] The alarm notification device 404 is used to output the anomaly type, anomaly location, and handling prompts. After manual verification, the container 1 can be re-sent to the receiving and conveying unit 2 or the designated inspection station through the anomaly reset inlet 405, so that the container 1 can re-execute the identification, shape inspection, posture correction, and weight inspection processes.

[0121] The central dispatch and control system 50 includes a task management module, a container status management module, a route planning module, an equipment status monitoring module, a safety interlock module, an anomaly handling module, and a data recording module.

[0122] The task management module receives inbound, outbound, return, and verification tasks. The container status management module records the identity, specifications, current location, target location, weight, off-center loading status, attitude status, locking status, transport class, and task status of each container. The route planning module generates a transport route based on the target location, equipment occupancy status, buffer position status, transport vehicle location, lifting and level-changing conveyor unit status, and container transport class. The equipment status monitoring module monitors the real-time operating status of the conveyor line, transport vehicle, lifting platform, buffer position, and connecting station. The safety interlock module controls the interlocking of actions between various devices. The anomaly handling module generates anomaly handling strategies when identification failure, detection failure, correction failure, locking failure, connecting failure, or route blockage occurs. The data logging module records detection data, action data, and anomaly data during the transport of container 1.

[0123] When generating a transportation route, the central dispatch control system 50 considers at least the following information: container identity, container specifications, container target location, container transportation priority, container total weight, container off-center loading status, container attitude correction result, automatic connection locking status, conveyor line occupancy status, current location of cross-regional transportation unit 9, occupancy status of lifting and changing layer conveyor unit 10, idle status of multi-layer buffer temporary storage unit 8, occupancy status of outbound connection sorting unit 20, and availability status of abnormal container rejection unit 40.

[0124] For containers of normal transport grade, the central dispatch control system 50 prioritizes transport routes with shorter distances or shorter travel times. For containers of speed-limited transport grade, the central dispatch control system 50 prioritizes transport routes with more straight conveyor sections, fewer turns, or no need for lifting or changing layers. For containers corresponding to high-priority outbound tasks, the central dispatch control system 50 prioritizes allocating buffer spaces or transport resources close to the outbound connection and sorting unit 20. For empty containers, the central dispatch control system 50 prioritizes allocating buffer spaces close to the inbound receiving conveyor unit 2 or the empty container automatic return unit 30. For abnormal containers, the central dispatch control system 50 prioritizes allocating abnormal buffer space 402 close to the manual verification station 403.

[0125] To ensure the safety of the fully automated transportation of container 1, this embodiment sets up multi-level safety interlock control logic.

[0126] When the container identification unit 3 fails to identify container 1, container 1 shall not enter the main transportation route.

[0127] When the container shape detection unit 4 detects that the container 1 has unqualified external dimensions, the door is not closed properly, or the posture deviation exceeds the correctable range, the container 1 shall not enter the automatic docking and locking transfer unit 7.

[0128] When the container posture correction unit 5 has not completed the correction re-inspection, the automatic connection locking transfer unit 7 shall not perform the locking action.

[0129] When the container weight and off-center load detection unit 6 detects that the total weight of container 1 exceeds the limit or the off-center load exceeds the safety threshold, container 1 shall not enter the inter-zone transportation unit 9 or the lifting and changing layer conveying unit 10.

[0130] When the automatic docking and locking transfer unit 7 fails to detect the signals of the front end of the container being in place, the rear end of the container being in place, the side clamping being in place, and the lifting lock being in place, the cross-regional transport unit 9 shall not start the transport operation.

[0131] When the cross-regional transport unit 9 has not completed the location confirmation with the connecting platform 71, the platform conveying mechanism 72 and the vehicle-mounted conveying mechanism 95 shall not perform the container transfer action.

[0132] When the lifting and changing conveyor unit 10 has not completed the mechanical positioning of the floor station, the platform conveyor mechanism 104 and the floor station conveyor mechanism 105 shall not be started simultaneously.

[0133] If the target buffer position is not detected as empty, container 1 shall not enter the buffer position.

[0134] When the lifting locking mechanism 75 has not completed the unlocking and release action, the platform conveying mechanism 72 shall not forcibly convey the container 1.

[0135] When the safety obstacle avoidance module 97 detects personnel or obstacles in the transportation path, the cross-regional transportation unit 9 slows down or stops and reports the obstacle avoidance status to the central dispatch control system 50.

[0136] like Figure 10 As shown, based on the above-mentioned automated transportation equipment for the entire process of warehouse containers, this embodiment also provides a method for automated transportation of warehouse containers throughout the entire process, including the following steps.

[0137] S1. The container to be transported 1 enters the receiving and conveying unit 2. After the entrance detection sensor 23 detects the container 1, the inbound conveying mechanism 22 starts and transports the container 1 to the identification station. The liftable stop 261 of the blocking and positioning mechanism 26 rises, stopping the container 1 at the preset detection position.

[0138] S2. The container identification unit 3 reads the identification tag 15 on container 1 and sends the container identification information to the central dispatch control system 50. The central dispatch control system 50 obtains the container number, specifications, target location, and task information based on the identification result. If identification fails, it controls container 1 to enter the abnormal container rejection unit 40.

[0139] S3. The container shape detection unit 4 detects the external dimensions, lateral offset, deflection angle, and door closure status of container 1. If the external dimensions of container 1 exceed the limit or the door is not closed properly, container 1 is controlled to enter the abnormal container rejection unit 40. If the dimensions of container 1 are qualified but the posture is deviated, the posture correction process is initiated.

[0140] S4. The central dispatch control system 50 controls the container attitude correction unit 5 to operate based on the lateral offset and deflection angle, so that container 1 returns to the standard conveying centerline and standard angle. After correction is completed, the correction re-inspection sensor 55 re-inspects the lateral offset and deflection angle of container 1. If the re-inspection is qualified, the process proceeds to the next step; if the re-inspection is unqualified, correction is performed again or the container enters the abnormal container rejection unit 40.

[0141] S5, the container weight and off-center load detection unit 6 detects the total weight of container 1 and the force distribution at each load-bearing position of container 1. The central dispatch control system 50 calculates the off-center load status of container 1 and determines the container transportation level based on the detection results. If the total weight of container 1 exceeds the limit or the off-center load exceeds the safety threshold, it enters the abnormal container rejection unit 40; if container 1 is suitable for transportation, it enters the automatic connection locking process.

[0142] S6. The automatic docking and locking transfer unit 7 performs floating positioning, lateral clamping, and lifting locking on the container 1. Specifically, after the container 1 enters the docking platform 71, the floating positioning mechanism 73 cooperates with the docking reference unit 13 to perform secondary positioning of the container 1; the lateral clamping mechanism 74 clamps the container 1; the lifting locking mechanism 75 drives the locking pin 751 to rise and insert into the locking hole 133; the docking positioning detection mechanism 77 detects the front end positioning status, rear end positioning status, lateral clamping positioning status, and lifting locking positioning status of the container. When all the above states meet the preset conditions, the central dispatch control system 50 allows the next transportation action to be executed.

[0143] S7, the central dispatch and control system 50 generates a container transportation path based on the container's identity information, target location information, shape detection results, attitude correction results, total container weight, off-center loading status, transportation level, equipment occupancy status, and buffer space status.

[0144] S8, the inter-zone transport unit 9, the multi-layer buffer storage unit 8, the lifting and layer-changing conveyor unit 10, or the outbound connection and sorting unit 20 perform container transport, buffering, layer-changing, or outbound connection operations according to the container transport route. When container 1 is in a speed-limited transport class, the central dispatch control system 50 controls the inter-zone transport unit 9 to reduce its travel speed, reduce its starting acceleration, reduce its braking deceleration, and increase its turning radius. When the transport route is congested or the target equipment is occupied, the central dispatch control system 50 transports container 1 to the nearest available buffer position and regenerates the container transport route according to the updated equipment status.

[0145] S9. After container 1 completes the outbound operation, the empty container automatic return unit 30 determines whether container 1 is empty based on the actual weight of container 1 after it leaves the warehouse, the detection signal inside the container, and the outbound task completion information.

[0146] S10. When container 1 is empty, the central dispatch control system 50 controls the empty container automatic return unit 30 to transport container 1 to the inbound end or the empty container buffer area; when container 1 is not empty, the central dispatch control system 50 transports container 1 to the multi-layer buffer temporary storage unit 8, the outbound connection and sorting unit 20 or the abnormal container rejection unit 40.

[0147] S11. When container 1 experiences an abnormality during the process of identity recognition, shape detection, posture correction, weight and off-center load detection, automatic connection locking, cross-regional transportation, lifting and changing layers, outbound connection, or empty / full judgment, the central dispatch control system 50 controls container 1 to enter the abnormal container rejection unit 40 and records the abnormality type, the location of the abnormality, and the container identity information.

[0148] In an alternative embodiment, the lifting locking mechanism 75 in the automatic docking and locking transfer unit 7 can be replaced by a side locking mechanism. The side locking mechanism extends from the side of the docking platform 71 and inserts into the side locking groove of the bottom support frame 12 or the adapter base 14 of the container 1 to lock the container 1.

[0149] In one alternative implementation, the container attitude correction unit 5 may only have a lateral push-up mechanism 52, without a rotation correction mechanism 53. This approach is suitable for storage scenarios where the container 1 mainly exhibits lateral offset and a small deflection angle.

[0150] In one alternative implementation, the inter-regional transport unit 9 may employ a rail shuttle, which runs along a fixed track and transfers the container 1 to a fixed docking platform via an onboard transport mechanism 95.

[0151] In one optional implementation, the empty / full detection component 301 can employ only weighing detection, or it can combine weighing detection, visual detection, in-cabinet photoelectric detection, and task verification. Using a combination of multiple detection methods can improve the accuracy of empty / full detection.

[0152] The foregoing description illustrates and describes several preferred embodiments of the present invention. However, as previously stated, it should be understood that the present invention is not limited to the forms disclosed herein and should not be construed as excluding other embodiments. It can be used in various other combinations, modifications, and environments, and can be altered within the scope of the inventive concept described herein through the foregoing teachings or techniques or knowledge in related fields. Any modifications and variations made by those skilled in the art that do not depart from the spirit and scope of the present invention should be within the protection scope of the appended claims.

Claims

1. A complete set of automated transportation equipment for warehouse containers, characterized in that, It includes containers, inbound receiving and conveying units, container identification units, container shape detection units, container posture correction units, container weight and off-center load detection units, automatic docking and locking transfer units, multi-layer buffer storage units, cross-regional transportation units, outbound docking and sorting units, empty container automatic return units, and a central dispatch and control system. The container is equipped with a docking reference section for use with an automatic docking and locking transfer unit; The receiving and conveying unit is used to receive containers to be transported and convey the containers to the inspection station; The container identification unit is used to read the container's identification mark and send the container's identification information to the central dispatch and control system; The container shape detection unit is used to detect the container's external dimensions, lateral offset, and deflection angle. The container attitude correction unit is located after the container shape detection unit and is used to adjust the position and attitude of the container relative to the conveying centerline according to the lateral offset and deflection angle. The container weight and off-center load detection unit is used to detect the total weight of the container and the force distribution at each load-bearing position of the container, and sends the total weight of the container and the off-center load status to the central dispatch and control system. The automatic docking and locking transfer unit is used to position, clamp and lock the container after the attitude correction and weight detection have been completed. The inter-regional transport unit is used to carry containers locked by the automatic docking and locking transfer unit and transport the containers to the target area; The multi-layer buffer storage unit is used to temporarily store containers that are to be received, shipped, transported, verified, or returned. The outbound connection and sorting unit is used to transport the container to the corresponding outbound workstation, picking workstation or shipping workstation. The automatic empty container return unit is used to determine whether the container is empty or full after it leaves the warehouse, and to transport the empty container to the receiving end or the empty container buffer area. The central dispatch and control system is connected to the inbound receiving and conveying unit, the container identification unit, the container shape detection unit, the container posture correction unit, the container weight and off-center load detection unit, the automatic connection locking and transfer unit, the multi-layer buffer temporary storage unit, the cross-regional transportation unit, the outbound connection and sorting unit, and the empty container automatic return unit. The central dispatch and control system is used to generate container transportation routes based on container identity information, external dimensions, lateral offset, deflection angle, total container weight, off-center load status, equipment occupancy status, and target location information. It also controls the automatic flow of containers between inbound reception, identity recognition, shape detection, posture correction, weight and off-center load detection, automatic connection locking, cross-regional transportation, buffer storage, outbound connection sorting, and empty container return.

2. The complete set of automated transportation equipment for warehouse containers according to claim 1, characterized in that, The connecting reference part is set on the bottom support frame of the container, or on the adapter base installed at the bottom of the container; The connecting reference part includes a guide groove, a positioning hole, a locking hole, and a bearing contact surface; The guide channel extends along the container transport direction, and the inlet end of the guide channel forms a trumpet-shaped guide opening or an inclined guide surface. The positioning hole is used to cooperate with the floating positioning mechanism of the automatic docking and locking transfer unit; The locking hole is used for the insertion of the locking pin of the automatic docking locking and transfer unit; The bearing contact surface is used to contact the bearing components of the inbound receiving and conveying unit, the cross-regional transportation unit, the multi-layer buffer temporary storage unit, or the outbound connecting and sorting unit.

3. The fully automated transportation system for warehouse containers according to claim 1, characterized in that, The inbound receiving and conveying unit includes an inbound conveying rack, an inbound conveying mechanism, an entrance detection sensor, a guide rail, a buffer conveying section, and a blocking and positioning mechanism; The inbound conveying mechanism is installed on the inbound conveying frame and is used to convey containers along the inbound direction; The entrance detection sensor is installed on the entrance side of the inbound conveyor rack and is used to detect whether the container has entered the inbound receiving and conveying unit. The guide rails are respectively installed on both sides of the inbound conveyor rack to limit the lateral deviation of the container when it enters the inbound receiving and conveying unit. The buffer conveyor section is located after the inlet detection sensor and is used to reduce the conveying speed of the container before it enters the detection station. The blocking and positioning mechanism includes a liftable block and a block drive component. The liftable block is used to abut against the front end of the container, so that the container stops at a preset detection position. The container shape detection unit includes a detection door frame, a top distance sensor, a first lateral distance sensor, a second lateral distance sensor, a front detection sensor, a rear detection sensor, and a door status detection component; The inspection gantry is positioned above the inbound receiving and conveying unit or the inspection conveying section; The top ranging sensor is installed on the top of the detection gantry and is used to detect the height of the container; The first lateral ranging sensor and the second lateral ranging sensor are respectively disposed on the left and right sides of the detection gantry, and are used to detect the distance between the left and right sides of the container and the detection gantry; The front-end and rear-end detection sensors are used to detect the front and rear boundary positions of the container; The door status detection component is used to detect whether the container door is closed properly. The central dispatch control system calculates the lateral offset of the container relative to the conveying centerline based on the distance data collected by the first lateral ranging sensor and the second lateral ranging sensor, and calculates the deflection angle of the container relative to the conveying direction based on the lateral distance difference between the front and rear of the container. The container attitude correction unit includes a correction conveying platform, a lateral pushing mechanism, a rotation correction mechanism, a center positioning mechanism, and a correction re-inspection sensor; The alignment and conveying platform is used to carry and transport containers; The lateral pushing mechanism includes a first lateral push plate and a second lateral push plate respectively disposed on the left and right sides of the correction conveyor platform. The first lateral push plate and the second lateral push plate can move towards each other to push the container to the conveyor center line position. The rotation correction mechanism is located below the correction conveyor platform. The rotation correction mechanism is used to drive the correction conveyor platform to rotate around the vertical axis in order to correct the deflection angle of the container relative to the conveying direction. The central positioning mechanism is used to confine the container to the standard transport position after the correction is completed; The correction and re-inspection sensor is used to re-detect the lateral offset and deflection angle of the container after the lateral push-up mechanism and the rotation correction mechanism have been activated. The container weight and off-center load detection unit includes at least three weighing sensors, which are distributed and arranged below the support platform used to support the container; The central dispatch and control system calculates the total weight of the container based on the force values ​​collected by each weighing sensor, and calculates the direction of the container's center of gravity offset and the degree of off-center loading based on the force difference between different weighing sensors. When the total weight of the container is less than or equal to the allowable load and the degree of off-center loading is less than the first off-center loading threshold, the central dispatch and control system will determine the container as a normal transportation level. When the total weight of the container is less than or equal to the allowable load and the degree of off-center loading is greater than the first off-center loading threshold but less than the second off-center loading threshold, the central dispatch control system will determine the container to be transported at a speed-limited level. When the total weight of the container exceeds the allowable load or the degree of off-center loading exceeds the second off-center loading threshold, the central dispatch control system will identify the container as an abnormal container.

4. The complete set of automated transportation equipment for warehouse containers according to claim 1, characterized in that, The automatic docking and locking transfer unit includes a docking platform, a platform conveying mechanism, a floating positioning mechanism, a lateral clamping mechanism, a lifting and locking mechanism, a front and rear blocking mechanism, and a docking completion detection mechanism. The platform conveying mechanism is set on the docking platform and is used to convey the container to the preset docking position of the docking platform; The floating positioning mechanism is set on the docking platform and is used to cooperate with the docking reference part at the bottom of the container to perform secondary positioning of the container; The lateral clamping mechanism is located on the left and right sides of the docking platform and is used to clamp the bottom support frame or the adapter base of the container. The lifting and locking mechanism is located below or inside the docking platform and is used to insert into the locking hole at the bottom of the container. The front and rear blocking mechanisms are used to restrict the movement of the container along the conveying direction; The docking positioning detection mechanism is used to detect the positioning status of the front end of the container, the positioning status of the rear end of the container, the positioning status of the lateral clamping, and the positioning status of the lifting lock. The floating positioning mechanism includes a floating positioning seat, a guide ramp, an elastic reset component, and a floating limiting component. The floating positioning seat is capable of floating relative to the docking platform in both the horizontal and vertical directions. The guide ramp is located on the entrance side of the floating positioning seat and is used to cooperate with the guide groove or inclined guide surface at the bottom of the container. The elastic reset component is connected between the floating positioning seat and the docking platform, and is used to reset the floating positioning seat to its initial position when no external force is applied. The floating limiter is used to limit the maximum floating displacement of the floating positioning seat relative to the docking platform; The lateral clamping mechanism includes a first clamping arm, a second clamping arm, a clamping drive, a clamping buffer pad, and a clamping position detection sensor. The first clamping arm and the second clamping arm are respectively disposed on the left and right sides of the docking platform and can move towards each other under the drive of the clamping drive component; The clamping buffer pad is located at the position where the first clamping arm and the second clamping arm contact the container; The lifting and locking mechanism includes a locking pin, a lifting drive component, a locking guide sleeve, and a locking position detection sensor; The locking pin can be vertically raised and lowered under the drive of the lifting drive component, and is inserted into the locking hole at the bottom of the container when it rises. The upper end of the locking pin is provided with a tapered head or a rounded guide head.

5. The complete set of automated transportation equipment for warehouse containers according to claim 1, characterized in that, The cross-regional transportation unit includes a transportation vehicle body, a walking drive mechanism, a navigation and positioning module, a carrying platform, an on-board conveying mechanism, an on-board locking mechanism, a safety obstacle avoidance module, and an on-board control module. The navigation and positioning module is used to align the transport vehicle with the automatic docking and locking transfer unit, the outbound docking and sorting unit, or the multi-layer buffer temporary storage unit. The vehicle-mounted conveying mechanism is used to transfer containers between the transport vehicle body and the fixed docking equipment; The vehicle-mounted locking mechanism is used to lock the container during the transportation of the container by the transport vehicle body; The central dispatch and control system controls the vehicle's speed, acceleration, deceleration, and turning radius based on the container weight and the total weight and off-center load status output by the off-center load detection unit.

6. The complete set of automated transportation equipment for warehouse containers according to claim 1, characterized in that, It also includes a lift-up and layer-changing conveyor unit and an abnormal container rejection unit; The lifting and conveying unit includes a lifting derrick, a lifting platform, a lifting drive mechanism, a platform conveying mechanism, a floor conveying mechanism, a floor positioning mechanism, a fall arrest mechanism, and a floor-to-floor interlocking mechanism. The lifting platform can move up and down along the lifting derrick under the drive of the lifting drive mechanism. The platform conveying mechanism is mounted on the lifting platform and is used to receive and convey containers. The floor conveying mechanism is located at different floor heights and is used to connect with the platform conveying mechanism for container transfer. The floor positioning mechanism is used to mechanically position the lifting platform with the corresponding floor conveying mechanism after the lifting platform reaches the target floor. The floor-to-floor interlocking mechanism prevents the platform conveying mechanism and the floor conveying mechanism from starting synchronously before the lifting platform completes the mechanical positioning of the floor. The abnormal container rejection unit includes an abnormal conveyor branch line, an abnormal buffer position, a manual verification position, an alarm prompting device, and an abnormal reset entrance. When the container experiences issues such as identity recognition failure, exceeding size limits, door not closing properly, posture deviation exceeding the correctable range, posture correction failure, total weight exceeding limits, off-center loading exceeding the safety threshold, automatic connection locking failure, connection failure, or an abnormal empty / full judgment, the central dispatch control system controls the container to enter the abnormal conveyor branch line and convey it to the abnormal buffer position or the manual verification position.

7. The fully automated transportation system for warehouse containers according to claim 1, characterized in that, The multi-layer buffer temporary storage unit includes a buffer frame, a multi-layer buffer channel, a buffer position conveying mechanism, a buffer position occupancy detection sensor, and a container limiting mechanism; The cache frame is vertically arranged with multiple cache channels, and each cache channel is provided with multiple cache bits; The buffer position conveying mechanism is used to convey the container into the corresponding buffer position or to output the container from the corresponding buffer position; The cache slot occupancy detection sensor is used to detect whether the corresponding cache slot is occupied by the container. The central dispatch and control system allocates buffer slots to containers based on their task status, transportation priority, target location, equipment occupancy status, and buffer slot availability.

8. The fully automated transportation system for warehouse containers according to claim 1, characterized in that, The automatic empty cabinet return unit includes an empty / full detection component, an empty cabinet return conveyor line, an empty cabinet buffer position, and a return transfer mechanism. The empty / full detection component includes a weighing detection component, a vision detection component, an in-cabinet photoelectric detection component, and a task verification module. The central dispatch and control system determines whether a container is empty based on its actual weight after it leaves the warehouse, the weight of the empty container corresponding to the container, the detection signals inside the container, and the information on the completion of the outbound task. When a container is determined to be empty, the central dispatch control system controls the empty container return conveyor line and return transfer mechanism to transport the container to the warehouse end or empty container buffer position. When a container is determined to be non-empty, the central dispatch control system will transport the container to a multi-level buffer storage unit, an outbound transfer and sorting unit, or an abnormal container rejection unit.

9. A fully automated transportation method for warehouse containers, characterized in that, Includes the following steps: S1. The container to be transported enters the inbound receiving and conveying unit, which then transports the container to the identification station. S2. The container identification unit reads the container's identification mark and sends the container's identification information to the central dispatch and control system. S3, the container shape detection unit detects the container's external dimensions, lateral offset, deflection angle, and door closure status; S4. The central dispatch and control system controls the container attitude correction unit to operate according to the lateral offset and deflection angle, so that the container returns to the standard conveying center line and standard angle. S5, the container weight and off-center load detection unit detects the total weight of the container and the force distribution at each load-bearing position of the container. The central dispatch control system calculates the off-center load status of the container and determines the container transportation level based on the detection results. S6. The automatic docking and locking transfer unit performs floating positioning, lateral clamping and lifting locking on the container, and sends a locking completion signal to the central dispatch and control system after locking is in place. S7. The central dispatch and control system generates a container transportation path based on the container's identity information, target location information, shape detection results, attitude correction results, total container weight, off-center loading status, transportation level, equipment occupancy status, and buffer space status. S8. Cross-regional transportation unit, multi-layer buffer storage unit, lifting and layer-changing conveying unit or outbound connection sorting unit perform container transportation, buffering, layer-changing or outbound connection operations according to the container transportation path. S9. After the container completes the outbound operation, the empty container automatic return unit determines whether the container is empty based on the actual weight of the container after it leaves the warehouse, the detection signals inside the container, and the outbound task completion information. S10. When the container is empty, the central dispatch control system controls the automatic empty container return unit to transport the container to the inbound end or the empty container buffer area; when the container is not empty, the central dispatch control system transports the container to the multi-layer buffer temporary storage unit, the outbound connection and sorting unit or the abnormal container rejection unit.

10. The fully automated transportation method for warehouse containers according to claim 9, characterized in that, In step S5, the central dispatch and control system determines the container transportation level based on the total weight of the container and the off-center loading status. When the total weight of the container is less than or equal to the allowable load and the degree of off-center loading is less than the first off-center loading threshold, the container is classified as a normal transport class. When the total weight of the container is less than or equal to the allowable load and the degree of off-center loading is greater than the first off-center loading threshold but less than the second off-center loading threshold, the container will be classified as a speed-limited transport class. When the total weight of the container exceeds the allowable load or the degree of off-center loading exceeds the second off-center loading threshold, the container is identified as an abnormal container and the container is controlled to enter the abnormal container rejection unit. In step S6, the automatic connection locking transfer unit performs the following actions: After the container enters the docking platform, the floating positioning mechanism works with the docking reference part at the bottom of the container to perform secondary positioning of the container; The lateral clamping mechanism clamps the bottom support frame or adapter base of the container; The lifting and locking mechanism drives the locking pin to rise and insert it into the locking hole at the bottom of the container; The docking inspection agency detects the docking status of the front end of the container, the rear end of the container, the side clamping status, and the lifting lock status. When the front end of the container is in place, the rear end of the container is in place, the side clamping is in place, and the lifting lock is in place, all of the preset conditions are met, the central dispatch control system allows the cross-regional transportation unit, the lifting and layer-changing conveying unit, or the outbound connection and sorting unit to execute the next transportation action. In step S8, when the container is determined to be a speed-limited transport class, the central dispatch control system controls the inter-regional transport unit to reduce its driving speed, reduce its starting acceleration, reduce its braking deceleration, and increase its turning radius. When the transport route becomes congested or the target equipment is occupied, the central dispatch and control system will transport the container to the nearest available buffer location and regenerate the container transport route based on the updated equipment status. In step S7, when the central dispatch and control system generates the container transportation route, it follows these rules: For containers of normal transport class, the transport route with the shortest distance or the shortest travel time should be selected first. For containers with speed-limited transport levels, priority should be given to transport routes with more straight conveyor sections, fewer turns, or no need for lifting and changing layers. For containers corresponding to high-priority outbound tasks, prioritize the allocation of buffer spaces or transportation resources that are close to the outbound connection and sorting unit; For empty cabinets, prioritize allocating buffer positions close to the inbound receiving and conveying unit or the empty cabinet automatic return unit; For abnormal containers, priority should be given to allocating abnormal buffer slots close to the manual verification workstations.

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