A method for using a three-dimensional storage picking system

Abstract

The present invention proposes a method for using a three-dimensional storage and picking system, comprising the following steps: the WMS system calculates the quantity of goods, the WCS system receives the quantity, starts the equipment in the system and judges according to the number of boxes: when the number reaches the whole pallet, it is the whole pallet warehousing, and when the number is less than the whole pallet, it is the whole box warehousing; when the whole pallet is warehousing, the goods are stacked on the pallet by the depalletizing and stacking robot and stored in the whole pallet warehouse by the heavy-duty stacker; when the whole box is warehousing, the goods are transported by the box elevator and stored in the whole box warehouse by the variable-length clamp light stacker; when the replenishment task is executed, the heavy-duty stacker sends the pallet to the depalletizing station, the depalletizing robot depalletizes the pallet into whole boxes, and the pallet is transported to the whole box warehouse by the variable-length clamp light stacker, and the pallet is stored by the variable-length clamp light stacker, thereby completing the replenishment task; the variable-length clamp light stacker is combined with the heavy-duty stacker to achieve the coverage of box-type replenishment and box-type warehousing, thereby solving the problem that the stocking area in the prior art can only handle static line fixed batch sorting.

Description

Technical Field

[0001] The present invention relates to the field of warehouse management, and in particular to a method for using a three-dimensional storage and picking system. Background Art

[0002] At present, logistics distribution centers are usually composed of warehousing systems, stocking systems and sorting systems. Each system is independent of each other and exists in a plane layout. The warehousing system usually uses pallets as logistics processing units, while the sorting system usually enters the logistics processing unit in the form of full boxes. Order-type shipments are measured in boxes and single pieces. There are six types of shipment status: full pallet out, full pallet + full box out, full pallet + full box + single piece out, full box out, full box + single piece out, and single piece out. In order to solve the problem of mismatch between product specifications, efficiency requirements and real-time efficiency of pallet removal, a stocking system is usually configured to cache full boxes after pallet removal, and then sort them according to the requirements of the scheduling system and transport them to the sorting system.

[0003] This process mode mainly has the following problems: 1. The depalletized whole boxes are cached in the stocking system and then enter the sorting system, which increases the logistics links and equipment configuration; 2. There are many varieties of small-sized SKUs and low demand. The tail plates generated after depalletizing are frequently in and out of the warehouse, causing waste of equipment and seriously affecting the efficiency of entering and leaving the warehouse; 3. Due to the constraints of the equipment and site of the stocking system, the stocking system can only handle static line fixed batch sorting, and the stocking system has poor flexibility; 4. In general, the equipment layout adopts a flat layout, which increases the logistics distance; 5. During the depalletizing and picking operation, due to the many sizes and specifications of the whole box, standard plastic boxes are used as container storage and retrieval operations, and equipment specifically for container transportation and recycling is added, which makes the process route complicated and increases investment. Summary of the invention

[0004] A variable-length clamping light stacker comprises a base and a panel assembly mounted on the base, a variable-length mechanism and a hexagonal shaft assembly, wherein the panel assembly is provided in two groups, and the two groups of panel assemblies are provided with layer plates, wherein a plurality of layer plates are provided and the layer plates are slidably mounted, wherein the hexagonal shaft assembly is provided with a gear assembly for driving the sliding between the multiple layers of the panel assembly, and the hexagonal shaft assembly and the variable-length mechanism are used for controlling the movement and extension of the panel assembly.

[0005] Preferably, the panel assembly includes an outer fork panel, a rack, a pulley structure, a middle fork panel and an inner fork panel, the middle fork panel is fixedly mounted with a rack on the side, the outer fork panel is fixedly mounted on the base, the middle fork panel is slidably connected to the outer fork panel, the inner fork panel is slidably connected to the middle fork panel, the pulley structure includes a plurality of pulleys and synchronous belts, the pulleys are respectively mounted on the outer fork panel, the middle fork panel and the inner fork panel, and a synchronous belt is laid between the pulleys, the middle fork panel is provided with a photoelectric detection switch module, and the synchronous belt and pulley are mounted on the middle fork panel and the inner fork panel.

[0006] Preferably, it also includes a shift rod device, which is arranged at the end of the inner fork panel in the extension direction. The shift rod device includes a motor, a coupling, a bearing seat and a shift rod. A bearing is provided in the bearing seat. The motor and the bearing seat are fixedly mounted on the inner fork panel, and the motor is connected to the bearing in the bearing seat through a coupling, and the shift rod is connected to the bearing.

[0007] Preferably, the hexagonal shaft assembly includes a servo motor, and the gear assembly includes a hexagonal shaft and a gear sleeved on the hexagonal shaft, the hexagonal shaft is connected to the servo motor, the servo motor is connected to the outer fork panel, the hexagonal shaft crosses and is rotatably connected to the left-right symmetrical middle fork panel, and the middle fork panel is also provided with a driven wheel, the driven wheel is meshed with the gear, and the driven wheel is meshed with the rack.

[0008] Preferably, the amplitude varying mechanism comprises an amplitude varying motor and a nut, a guide rail and a mounting plate, the guide rail is mounted on the nut, the mounting plate is mounted on the guide rail, limit blocks are arranged at both ends of the guide rail, and the amplitude varying motor is connected to a bidirectional lead screw.

[0009] On the other hand, the three-dimensional storage and picking system includes a variable-length clamping light stacker, a whole-pallet warehouse, and a whole-box warehouse. The whole-pallet warehouse is directly above the whole-box warehouse and is arranged with double layers. The whole-pallet warehouse is provided with a depalletizing robot, which is used to palletize cartons. The whole-box warehouse includes a variable-length clamping light stacker, and the depalletizing robot is arranged at the outbound end of the whole-pallet warehouse. The whole-box warehouse includes a number of box-type elevators, which are distributed on both sides of the outbound end and the inbound end of the whole-box warehouse. The box-type elevators are used to transport whole pallets to complete the inbound and outbound operations.

[0010] Preferably, it also includes a full-case incoming conveyor line, a full-case return conveyor line, a full-pallet incoming conveyor line, a full-pallet outgoing conveyor line and a full-case outgoing conveyor line, the full-pallet outgoing conveyor line is arranged at the outgoing end, the full-pallet incoming conveyor line is arranged at the incoming end of the full-pallet warehouse, and the full-case incoming conveyor line is arranged at the incoming end of the full-case warehouse.

[0011] Preferably, the full-container warehouse further comprises a light-duty container stacker warehouse, the variable-length clamp light-duty stacker is installed on the light-duty container stacker warehouse, and the full-container return conveyor line is arranged at the entrance end of the light-duty container stacker warehouse.

[0012] Preferably, the whole pallet warehouse also includes a heavy-duty stacker warehouse, a heavy-duty stacker, a whole pallet unpacking station, a whole case replenishment conveyor line, a whole pallet picking return port, and an empty pallet return port. The heavy-duty stacker is installed on the heavy-duty stacker warehouse, and the whole pallet picking return port, the empty pallet return port, the whole pallet unpacking station and the whole case replenishment conveyor line are arranged at the entrance end of the heavy-duty stacker warehouse. An abnormality handling port is provided on one side of the exit end of the heavy-duty stacker warehouse, a whole pallet exit port is provided on the whole pallet exit conveyor line, and a whole case exit port and a whole case destocking exit port are provided on the whole case exit conveyor line.

[0013] On the other hand, a method for using a three-dimensional storage and picking system is provided, comprising the following steps:

[0014] In the first step, the WMS system issues a warehousing instruction. The WMS transfers the big data order to the WCS system. The WCS system classifies the goods and transports the classified goods to the full pallet warehousing conveyor line and the full box warehousing conveyor line respectively. At the same time, the WCS system starts all equipment.

[0015] In the second step, when the goods are palletized by the palletizing robot, they are transported to the pallet warehouse through the pallet storage conveyor line, and the goods are stored in the form of pallets by the heavy-duty stacker.

[0016] The third step is that when the full-container goods are transported to the full-container warehouse through the full-container warehouse line, they are stored in the full-container warehouse in the form of boxes by the box-type elevator and the variable-luffing clamp light stacker;

[0017] Step 4: If the outbound instruction is full pallet outbound, the heavy stacker will transport the full pallet of goods to the full pallet outbound conveyor line and finally flow into the full pallet outbound port; if the outbound instruction is full box outbound, the variable-luffing clamp light stacker will transport the goods to the box elevator, and the box elevator will send them to the full box outbound conveyor line and finally flow into the full box outbound port;

[0018] Step 5: If the outbound instruction is comprehensive outbound, the goods will be shipped from the full pallet warehouse and the full container warehouse to the same logistics port respectively to complete the combined outbound;

[0019] Step 6: When the whole case needs to be split and picked, the variable-luffing clamp light stacker transports the whole pallet of goods to the whole case warehouse, and the box elevator delivers the whole case of goods to the whole case split and picked out warehouse port in sequence through the whole pallet outbound conveyor line. After the manual picking is completed, the cartons that meet the return requirements are manually resealed / resealed at the return warehouse port for material replacement, and then returned to the whole pallet picking return warehouse port via the box elevator and variable-luffing clamp light stacker;

[0020] In the seventh step, when the system needs a replenishment task, the whole pallet of goods in the whole pallet warehouse is transported by the heavy-duty stacker to the whole box replenishment conveyor line, and the whole box replenishment conveyor line is transmitted to the whole pallet depalletizing station. The depalletizing robot completes the depalletizing and sorting of the whole pallet into whole boxes of goods. The whole boxes of goods enter the box elevator, and the variable-length clamp light stacker is put on the shelf to store them in the whole box warehouse in the form of whole boxes, completing the replenishment task.

[0021] The beneficial effects of the present invention are:

[0022] For goods of different specifications, large quantities are stored in pallets to improve storage density and warehousing efficiency; small quantities are stored in whole boxes to reduce the number of unpacking and stacking operations and improve system flexibility.

[0023] Adopting variable-luffing clamp light stacker to realize the coexistence of cartons or material boxes of various specifications, which can maximize storage, reduce investment, reduce personnel, and optimize the effect of logistics process line;

[0024] By combining a variable-length clamp light stacker with a heavy-duty stacker, box-type replenishment and box-type warehousing can be covered, solving the problem in the prior art that the stocking area can only handle static line fixed batch sorting. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a flow chart of a method for using a three-dimensional storage and picking system;

[0026] Figure 2 It is a schematic diagram of the overall structure of the three-dimensional storage and picking system;

[0027] Figure 3 This is a schematic diagram of the whole pallet warehouse structure of the three-dimensional storage and picking system;

[0028] Figure 4 This is a schematic diagram of the structure of the full-case warehouse of the three-dimensional storage and picking system;

[0029] Figure 5 It is a schematic diagram of the overall structure of a variable-luffing clamp light stacker;

[0030] Figure 6 It is a three-dimensional diagram of a variable-luffing clamp light stacker;

[0031] Figure 7 is a schematic structural diagram of a gear lever device;

[0032] Figure 8 Schematic diagram of the cooperation between the mounting plate and the guide rail.

[0033] In the figure: 1-base; 2-panel assembly; 21-middle fork panel; 22-inner fork panel; 221-motor; 222-coupling; 223-bearing seat; 224-shift lever; 23-rack; 3-amplitude-changing mechanism; 31-bidirectional screw rod; 32-slider; 321-guide rail; 322-mounting plate; 4-hexagonal shaft assembly; 41-servo motor; 42-hexagonal shaft; 43-gear; 5-pallet warehouse; 501-palletizing and stacking robot; 51-heavy-duty stacker warehouse; 52-heavy-duty stacker ; 53-Pallet unpacking station; 54-Container replenishment conveyor line; 55-Pallet picking return port; 56-Empty pallet return port; 6-Container warehouse; 601-Box elevator; 61-Luffing clamp light stacker; 62-Light material box stacker warehouse; 7-Container entry conveyor line; 8-Container return conveyor line; 9-Pallet entry conveyor line; 10-Pallet outbound conveyor line; 101-Pallet outbound port; 11-Container outbound conveyor line; 111-Container outbound port; 112-Container unpacking outbound port. DETAILED DESCRIPTION

[0034] The following is a detailed description of an embodiment of the present invention in conjunction with the accompanying drawings. This embodiment is implemented on the premise of the technical solution of the present invention, and a detailed implementation method and a specific operation process are given, but the protection scope of the present invention is not limited to the following embodiment.

[0035] like Figure 1 As shown, the present invention proposes a method for using a three-dimensional storage picking system based on a variable-luffing fork light stacker combined with a heavy stacker 52 and a box lift 601, which includes:

[0036] In the first step, the WMS system issues a warehousing instruction. The WMS transfers the big data order to the WCS system. The WCS system classifies the goods and transports the classified goods to the full pallet warehousing line and the full case warehousing line respectively.

[0037] In the second step, when the goods are palletized onto the pallet by the palletizing robot 501, they are transported to the pallet warehouse 5 through the pallet warehousing line, and the goods are put on the shelves by the heavy-duty stacker 52 and stored in the form of pallets;

[0038] In the third step, when the full-box goods are transported to the full-box warehouse 6 through the full-box warehouse line, they are stored in the full-box warehouse 6 in the form of boxes by the box elevator 601 and the variable-luffing fork light stacker;

[0039] Step 4: If the outbound instruction is full pallet outbound, the heavy stacker 52 transports the full pallet of goods to the full pallet outbound line and finally flows into the full pallet outbound port 101; if the outbound instruction is full box outbound, the light stacker with variable amplitude fork is transmitted to the box elevator 601, and the box elevator 601 is sent to the full box outbound line and finally flows into the full box outbound port 111;

[0040] Step 5: If the outbound instruction is comprehensive outbound, the goods are respectively outbound from the full pallet warehouse 5 and the full container warehouse 6 to the same logistics port to complete the combined outbound;

[0041] Step 6: When the whole box needs to be split and picked, the variable-length fork light stacker transports the whole pallet of goods to the whole box warehouse 6, and the box elevator 601 delivers the whole box of goods to the whole box split and picked outlet 112 in sequence through the whole pallet outbound line. After the manual picking is completed, the cartons that meet the return requirements are manually resealed / resealed at the return port for the replacement box, and then returned to the whole box return line, and returned to the warehouse through the box elevator 601 and the variable-length fork light stacker. The cartons that do not meet the return requirements are replaced with plastic boxes and returned to the warehouse again through the above-mentioned return method;

[0042] In the seventh step, when the system needs a replenishment task, the whole pallet of goods in the whole pallet warehouse 5 is transported to the whole pallet unpacking and delivery port by the heavy-duty stacker 52, and the whole pallet is unpacked and sorted into whole boxes of goods by the depalletizing and stacking robot 501. The whole boxes of goods enter the box elevator 601, and the variable-length fork light stacker is put on the shelf and stored in the whole box warehouse 6 in the form of whole boxes, completing the replenishment task.

[0043] Based on the analysis of big order data, the WMS system first classifies the items into A (items with short circulation cycles), B (items with ordinary circulation cycles), and C (items with long circulation cycles). Secondly, the length, width, height, and weight of the outer packaging dimensions of categories A, B, and C are counted, and the maximum number of stackings of each category (sku) on a single pallet is calculated based on the standard pallet as the basic unit (including height restrictions). Secondly, based on the analysis of order data, the value of the entire pallet and the value of the single box are calculated when entering the warehouse. Then, according to the variable amplitude stacking The length, width and height unit dimensions of the palletizer rack are used to calculate the maximum number of storage boxes for a single category (SKU) in each cargo compartment; finally, the above four types of data are stored in the three basic databases of WMS and WCS respectively. When a single SKU passes through the inbound conveyor line during warehousing, the barcode reader on the conveyor line reads the barcode of the single box. The WMS system retrieves the basic database data based on the total number of scheduled inbound items and the read barcode information, determines the single box flow rate and single box inbound flow rate of the whole pallet stacking, and the conveying equipment transports the single box to the corresponding docking equipment port.

[0044] like Figure 2-4 As shown, on the other hand, the present invention also proposes a three-dimensional storage picking system, such as Figure 2-4As shown, it includes a whole pallet warehouse 5, a whole box warehouse 6, a whole box warehousing conveyor line 7, a whole box return warehouse conveyor line 8, a whole pallet warehousing conveyor line 9, a whole pallet outgoing warehouse conveyor line 10 and a whole box outgoing warehouse conveyor line 11. The whole pallet warehouse 5 is directly above the whole box warehouse 6 and is arranged with a double layer. A depalletizing and stacking robot 501 is provided in the whole pallet warehouse 5. The depalletizing and stacking robot 501 is used to palletize cartons. The whole pallet outgoing warehouse conveyor line 10 and the depalletizing and stacking robot 501 are arranged on the left side of the whole pallet warehouse 5. The whole pallet warehousing conveyor line 9 is arranged at the warehousing end of the whole pallet warehouse 5. The whole box warehousing conveyor line 7 is arranged at the warehousing end of the whole box warehouse 6. The whole box warehouse 6 includes a plurality of box-type elevators 601. The plurality of box-type elevators 601 are distributed on the left and right sides of the whole box warehouse 6. The box-type elevators 601 are used to transport the whole pallet to complete the warehousing and outgoing operations.

[0045] The full-box warehouse 6 also includes a light-duty box stacker warehouse 62, a variable-length clamp light-duty stacker 61 and a full-box return warehouse conveyor line 8. The variable-length clamp light-duty stacker 61 is installed on the light-duty box stacker warehouse 62, and the full-box return warehouse conveyor line 8 is arranged on the left side of the light-duty box stacker.

[0046] The whole pallet warehouse 5 also includes a heavy-duty stacker warehouse 51, a heavy-duty stacker 52, a whole pallet unpacking station 53, a whole case replenishment conveyor line 54, a whole pallet picking return port 55, an empty pallet return port and an exception handling port. The empty pallet return port is used to replenish spare pallets. The heavy-duty stacker 52 is installed on the heavy-duty stacker warehouse 51. The whole pallet picking return port 55, the empty pallet return port, the whole pallet unpacking station 53 and the whole case replenishment conveyor line 54 are arranged on the left side of the heavy-duty stacker warehouse 51. The exception handling port is arranged at the entrance end of the heavy-duty stacker warehouse 51. The whole pallet outbound conveyor line 10 is provided with a whole pallet outbound port 101, and the whole case outbound conveyor line 11 is provided with a whole case outbound port 111 and a whole case destocking outbound port 112.

[0047] like Figure 5-8 As shown, a variable-length clamping light stacker 61 includes a base 1 assembly and a panel assembly 2 installed on the base 1 assembly, a variable-length mechanism 3 and a hexagonal shaft assembly 4. The variable-length mechanism 3 adopts a screw structure and is connected to the panel assembly 2 for driving the panel assembly 2. The panel assembly 2 adopts a telescopic rack 23 structure, and one panel assembly 2 is provided on each side. The hexagonal shaft assembly 4 is provided with a gear 43 and meshes with the panel assembly 2 for controlling the extension and retraction of the panel assembly 2.

[0048] Specifically, the photoelectric detection switch module detects whether there are goods. When the presence of goods is detected, another set of photoelectric switches detects the size of the cargo box. The variable amplitude mechanism 3 controls the movement of the driving panel assembly 2 according to the size of the box, and drives the variable amplitude mechanism 3 at the same time, driving the panel assemblies 2 on the left and right sides through the screw rod. The panel assembly 2 is driven by the hexagonal shaft assembly 4 through the gear 43 rack 23 structure, which is used to control the extension and retraction of the dough fork to drive the goods. When delivering goods, the opposite process is performed.

[0049] The shift lever device is arranged at the end of the extension direction of the inner fork panel 22, and the shift lever device includes a motor 221, a coupling 222, a bearing seat 223 and a shift lever 224. A bearing is provided in the bearing seat 223. The motor 221 and the bearing seat 223 are fixedly installed on the inner fork panel 22, and the motor 221 is connected to the bearing in the bearing seat 223 through the coupling 222, and the shift lever 224 is connected to the bearing.

[0050] Specifically, the gear lever 224 is driven by the motor 221 to prevent the cargo from falling.

[0051] In this embodiment, the hexagonal shaft assembly 4 includes a hexagonal shaft 42 and a servo motor 41 , and the hexagonal shaft 42 crosses the panel assembly 2 and is rotatably connected.

[0052] The panel assembly 2 includes an inner fork panel 22, a pulley, a synchronous belt and a middle fork panel 21. A nut is provided at the bottom of the middle fork panel 21. A driven wheel is provided on the middle fork panel 21, and the driven wheel is meshed with a gear 43. A slide rail structure is provided on the inner fork panel 22. A rail structure is provided on the middle fork panel 21. The inner fork panel 22 is mounted on the middle fork panel 21. A rack 23 is provided on the middle fork panel 21, and the rack 23 is meshed with the driven wheel. The synchronous belt and the pulley are installed on the middle fork panel 21 and the inner fork panel 22. The inner fork panel 22 is slidably connected to the outer fork panel.

[0053] The device also includes a shift rod 224 device, which is arranged at the end of the extension direction of the inner fork panel 22. The shift rod 224 device includes a motor, a coupling 222, a bearing seat 223 and a shift rod 224. A bearing is provided in the bearing seat 223. The motor and the bearing seat 223 are fixedly installed on the inner fork panel 22, and the motor is connected to the bearing in the bearing seat 223 through the coupling 222, and the shift rod 224 is connected to the bearing.

[0054] Specifically, when the servo motor 41 drives the gear 43 on the hexagonal shaft 42 to drive the driven wheel to rotate, it drives the rack 23 to move the middle fork panel 21. At the same time, the synchronous belt is extended and tensioned to achieve the extension of the inner fork panel 22 to an appropriate size. The motor rotation of the gear lever 224 drives the gear lever 224 to fall down to block the cargo.

[0055] In this embodiment, the base 1 assembly includes a base 1, a guide rail and a mounting plate. The guide rail is mounted on the base 1, and the mounting plate is mounted on the guide rail. A stainless steel bending part is installed at the center of the mounting plate.

[0056] The amplitude varying mechanism 3 comprises a bidirectional lead screw 31 and an amplitude varying motor. A slider 32 is sleeved on the bidirectional lead screw 31. The amplitude varying motor is connected to the bidirectional lead screw 31. The slider 32 comprises a nut, a guide rail 321 and a mounting plate 322. The guide rail 321 is mounted on the nut. The mounting plate 322 is mounted on the guide rail 321. Limit blocks are arranged at both ends of the guide rail 321.

[0057] Specifically, the mounting plate is used to place goods, the stainless steel bending parts are used to initially fix the goods, and the bidirectional screw rod 31 drives the nut to move, thereby driving the outer fork panel to reciprocate.

[0058] Example:

[0059] The length, width and height dimensions of a certain category are: 300MM*400mm*250MM, weight 20KG, the length, width and height dimensions of the pallet are 1000mm*1200mm*160MM, the load limit is 1000KG, the height limit is 1500MM, then the maximum stacking quantity is 43 boxes, 860KG / pallet; the length, width and height dimensions of the variable amplitude clamp fork stacking hangar are 2000mm*500MM*300MM, then the maximum number of boxes stored in this cargo compartment is 4 boxes;

[0060] According to long-term analysis of order data, when such products are issued in waves, the total number of cartons shipped out of the whole pallet accounts for about 70%, and the number of cartons shipped out of the picking accounts for 30%. The total number of cartons booked for this warehousing is 2,000 cartons, and the system allocation logic is that the total number of cartons entering the warehouse is 2,000*0.7 / 43≌32 pallets, 1,376 cartons; the number of cartons entering the warehouse is 2,000-1,376=624 cartons. When a single carton enters the whole carton warehouse 6, the WCS system transmits the length, width and height dimensions of the incoming carton to the stacker through the barcode reader, and the fork of the variable-length clamp light stacker 61 is adjusted to the right height and moves to the pickup port; when the incoming carton arrives at the pickup end of the variable-length clamp light stacker 61, the visual system above the pickup end automatically measures the length and width dimensions of the incoming carton, and compares the measured dimensions with the dimensions in the database. If the size of the range is within the specified range, the variable-luffing clamp light stacker 61 is allowed to pick up the goods; otherwise, an alarm is triggered and the variable-luffing clamp light stacker 61 is prohibited from running; after picking up the goods, the variable-luffing clamp light stacker 61 sends the incoming boxes to the designated storage location of the system, and sends the coordinate values ​​to the WCS system for retention. When the wave is issued (tentatively 8 orders are merged, namely 45 boxes, 50 boxes, 55 boxes, 60 boxes, 65 boxes, 70 boxes, 75 boxes, and 80 boxes) and the total number of boxes shipped out is 500, the system calculates the full pallet shipment quantity as 500*0.7 / 43≌8 pallets, 344 boxes; the single box shipment quantity is 500-43*8=156 boxes; after the system issues the instruction, the logistics equipment sends out 8 full pallets from the storage locations corresponding to the pallet warehouse, and then sends out 156 single boxes from the storage locations corresponding to the variable-luffing clamp warehouse. After arriving at the delivery logistics port, the physical status of the corresponding 8 order quantities is: 1 full pallet + 3 single boxes; 1 full pallet + 7 single boxes; 1 full pallet + 12 single boxes; 1 full pallet + 17 single boxes; 1 full pallet + 22 single boxes; 1 full pallet + 27 single boxes; 1 full pallet + 32 single boxes; 1 full pallet + 37 single boxes;

[0061] An example of splitting: an order requires 8 pieces of a certain category, and the packaging of this category is 60 pieces / box. The WMS system will first find a split box with less than 60 pieces / box (if there is none, it will find a full box). After the system issues an instruction, the logistics equipment will take out 1 split box (or a full box) from the corresponding storage location of the full box warehouse 6. After arriving at the picking port, they are manually unpacked, 8 single pieces are picked out, and put into the order box. The order box automatically runs to the shipping logistics port; the remaining pieces are manually repacked, and the logistics equipment will send the repacked single boxes back to the full box warehouse 6.

[0062] An example of the replenishment process: WMS regularly scans the categories and corresponding quantities stored in the full-case warehouse 6. When the quantity is less than the warning threshold, the replenishment process is started in a specific time period. First, the pallets are unpacked from the full-case warehouse 5, and the depalletizing robot 501 grabs the number of boxes to be replenished and puts them on the full-case replenishment conveyor line 54, and then transports them to the designated storage location of the full-case warehouse 6.

[0063] The specific implementation methods described above further illustrate the objectives, technical solutions and beneficial effects of the present invention in detail. It should be understood that the above description is only a specific implementation method of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A method for using a three-dimensional storage and picking system, based on the three-dimensional storage and picking system, including a variable-luffing clamp light stacker, characterized in that: The variable-length clamping light stacker comprises a base (1), a panel assembly (2) mounted on the base (1), a variable-length mechanism (3) and a hexagonal shaft assembly (4); the panel assembly (2) is provided with two groups, the two groups of panel assemblies (2) are provided with layer plates, the layer plates are provided with a plurality of layer plates, and the layer plates are slidably mounted; the hexagonal shaft assembly (4) is provided with a gear assembly for driving the sliding between the plurality of layers of the panel assembly (2); the hexagonal shaft assembly (4) and the variable-length mechanism (3) are used to control the movement and extension of the panel assembly (2); The panel assembly (2) comprises an outer fork panel, a rack, a pulley structure, a middle fork panel (21) and an inner fork panel (22); a rack is fixedly mounted on the side of the middle fork panel (21); the outer fork panel is fixedly mounted on the base (1); the middle fork panel (21) is slidably connected to the outer fork panel; the inner fork panel (22) is slidably connected to the middle fork panel (21); the pulley structure comprises a plurality of pulleys and a synchronous belt; the pulleys are respectively mounted on the outer fork panel, the middle fork panel (21) and the inner fork panel (22); a synchronous belt is laid between the pulleys; a photoelectric detection switch module is provided on the middle fork panel (21); and the synchronous belt and pulley are mounted on the middle fork panel (21) and the inner fork panel (22); The inner fork panel (22) further comprises a shift lever device, the shift lever device being arranged at the end of the inner fork panel (22) in the extension direction, the shift lever device comprising a motor (221), a coupling (222), a bearing seat (223) and a shift lever (224), a bearing being arranged in the bearing seat (223), the motor (221) and the bearing seat (223) being fixedly mounted on the inner fork panel (22), the motor (221) and the bearing in the bearing seat (223) being connected via the coupling (222), and the shift lever (224) being connected to the bearing; The hexagonal shaft assembly (4) comprises a servo motor (41), the gear assembly comprises a hexagonal shaft (42) and a gear (43) sleeved on the hexagonal shaft (42), the hexagonal shaft (42) is connected to the servo motor, the servo motor is connected to the outer fork panel, the hexagonal shaft (42) crosses and is rotatably connected to the left-right symmetrical middle fork panel (21), the middle fork panel (21) is also provided with a driven wheel, the driven wheel is meshed with the gear (43), and the driven wheel is meshed with the rack (23); The amplitude variation mechanism (3) comprises an amplitude variation motor and a nut, a guide rail (321) and a mounting plate (322), wherein the guide rail (321) is mounted on the nut, and the mounting plate (322) is mounted on the guide rail (321). Limiting blocks are provided at both ends of the guide rail (321), and the amplitude variation motor is connected to the bidirectional lead screw (31); The three-dimensional storage and picking system also includes a whole-pallet warehouse (5) and a whole-box warehouse (6). The whole-pallet warehouse (5) is provided with a palletizing robot (501), and the palletizing robot (501) is used to palletize cartons. The whole-box warehouse (6) includes a variable-length clamping light stacker (61). The palletizing robot (501) is arranged at the outbound end of the whole-pallet warehouse (5). The whole-box warehouse (6) includes a plurality of box-type elevators (601), and the plurality of box-type elevators (601) are distributed on both sides of the outbound end and the inbound end of the whole-box warehouse (6). The box-type elevators (601) are used to transport the whole-pallet pallet to complete the inbound and outbound operations. It also includes a full-box inbound conveyor line (7), a full-box return conveyor line (8), a full-pallet inbound conveyor line (9), a full-pallet outbound conveyor line (10) and a full-box outbound conveyor line (11), wherein the full-pallet outbound conveyor line (10) is arranged at the outbound end, the full-pallet inbound conveyor line (9) is arranged at the inbound end of the full-pallet warehouse (5), and the full-box inbound conveyor line (7) is arranged at the inbound end of the full-box warehouse (6); The full-box warehouse (6) also includes a light-duty material box stacker warehouse (62), the variable-length clamp light-duty stacker (61) is installed on the light-duty material box stacker warehouse (62), and the full-box return warehouse conveyor line (8) is arranged at the warehouse entrance end of the light-duty material box stacker warehouse (62); The whole pallet warehouse (5) further comprises a heavy-duty stacker warehouse (51), a heavy-duty stacker (52), a whole pallet unpacking station (53), a whole case replenishment conveyor line (54), a whole pallet picking return warehouse port (55), and an empty pallet return warehouse port (56); the heavy-duty stacker (52) is installed on the heavy-duty stacker warehouse (51); the whole pallet picking return warehouse port (55), the empty pallet return warehouse port (56), the whole pallet unpacking station (53), and the whole case replenishment conveyor line (54) are arranged at the entrance of the heavy-duty stacker warehouse (51); an abnormality handling port is arranged on one side of the exit of the heavy-duty stacker warehouse (51); a whole pallet exit warehouse port (101) is arranged on the whole pallet exit conveyor line (10); and a whole case exit warehouse port (111) and a whole case unpacking exit warehouse port (112) are arranged on the whole case exit conveyor line (11); The following steps are included: In the first step, the WMS system issues a warehousing instruction. The WMS transfers the big data order to the WCS system. The WCS system classifies the goods and transports the classified goods to the full pallet warehousing conveyor line (9) and the full case warehousing conveyor line (7). At the same time, the WCS system starts all equipment. In the second step, when the goods are palletized onto pallets by the palletizing robot (501), they are then transported to the pallet warehouse (5) via the palletizing conveyor line (9), and the goods are put on the shelves by the heavy-duty stacker (52) and stored in the form of pallets; In the third step, when the full-box goods are transported to the full-box warehouse (6) through the full-box warehouse line, they are stored in the full-box warehouse (6) in the form of boxes via the box-type elevator (601) and the variable-luffing clamp light stacker (61); In the fourth step, the outbound instruction is to send out a whole pallet of goods, and the heavy stacker (52) transports the whole pallet of goods to the whole pallet outbound conveyor line (10), and finally flows into the whole pallet outbound port (101); the outbound instruction is to send out a whole box of goods, and the light stacker (61) with variable amplitude clamping is transmitted to the box-type elevator (601), and the box-type elevator (601) sends it to the whole box outbound conveyor line (11), and finally flows into the whole box outbound port (111); Step 5: If the outbound instruction is a comprehensive outbound, the goods are respectively outbound from the full pallet warehouse (5) and the full container warehouse (6) to the same logistics port to complete the combined outbound delivery; Step 6: When the whole case needs to be disassembled and picked, the variable-length clamp light stacker (61) transports the whole case of goods to the whole case warehouse (6), and the whole case of goods is sent to the whole case disassembly and picking outlet (112) in sequence through the whole case outbound conveyor line (10) via the box-type elevator (601). After the manual picking is completed, the cartons that meet the requirements for returning to the warehouse are returned to the whole case picking return outlet (55) after being manually resealed / re-sealed at the material replacement box return outlet, and then returned to the warehouse via the box-type elevator (601) and the variable-length clamp light stacker (61); In the seventh step, when the system needs a replenishment task, the whole pallet of goods in the whole pallet warehouse is transported by the heavy stacker (52) to the whole box replenishment conveyor line (54), and the whole box replenishment conveyor line (54) is transmitted to the whole pallet depalletizing station (53), and the depalletizing robot (501) completes the depalletizing and sorting of the whole pallet into whole boxes of goods. The whole boxes of goods enter the box elevator (601), and the variable amplitude clamp light stacker (61) is put on the shelf and stored in the whole box warehouse (6) in the form of whole boxes, completing the replenishment task.

Images