A suspended sorting conveyor system and method of operation thereof

Abstract

The application provides a suspension type sorting conveying system and a running method thereof. The system is designed with three layers in the software control part, including a top layer warehouse management system software, a middle layer warehouse control system software and a bottom layer PLC equipment control software. Each layer has different functions. When sorting, a user issues a sorting task instruction in the top layer warehouse management system software. Then, the middle layer warehouse control system software receives the sorting task instruction, and transmits the sorting task instruction to the bottom layer PLC equipment control software. After receiving the decomposed sorting task instruction, the bottom layer PLC equipment control software transmits the sorting task instruction to the PLC controller, which is distributed to each mechanism in the hardware execution part. The PLC controller of the application feeds back the execution of each mechanism to the bottom layer PLC equipment control software, and then generates the execution result of the sorting task to the top layer warehouse management system software through the middle layer warehouse control system software. Therefore, the execution of the sorting task can be known in real time, and abnormalities can be found in time.

Description

Technical Field

[0001] This invention relates to the field of commodity sorting technology, and in particular to a suspended sorting and conveying system and its operation method. Background Technology

[0002] Fresh food supermarkets, a new retail business model, are currently one of the hottest sectors. The pre-warehouse operation model utilizes overhead conveyor systems for sorting and transporting goods, enabling rapid order processing and handling. While existing supermarkets generally use overhead conveyor systems for sorting goods, these systems suffer from inadequate software and hardware compatibility, leading to sorting chaos.

[0003] Therefore, existing technologies still need to be improved and developed. Summary of the Invention

[0004] The main objective of this invention is to provide a suspended sorting and conveying system with more reasonable software and hardware adaptation, which is less prone to sorting chaos.

[0005] The first aspect of the present invention provides a suspended sorting and conveying system, the suspended sorting and conveying system comprising a software control part and a hardware execution part;

[0006] The software control component includes a top-level warehouse management system software, a middle-level warehouse control system software, and a bottom-level PLC equipment control software; the hardware execution component includes a weighing and sorting module, a suspended sorting conveyor line, and a suspended basket feeding module; the bottom-level PLC equipment control software communicates with the hardware execution component through a PLC controller.

[0007] The top-level warehouse management system software is used to issue sorting task instructions. The intermediate-level warehouse control system software is used to receive the sorting task instructions, decompose them, and then pass them to the bottom-level PLC equipment control software. The bottom-level PLC equipment control software is used to receive the decomposed sorting task instructions and pass them to the PLC controller, which then distributes them to the various mechanisms in the hardware execution part for execution.

[0008] The underlying PLC device control software is also used to receive the execution status of each mechanism fed back by the PLC controller and transmit it to the intermediate warehouse control system software; the intermediate warehouse control system software is also used to receive the execution status of each mechanism fed back by the PLC controller transmitted by the underlying PLC device control software, generate the execution result of the sorting task based on the execution status of each mechanism fed back by the PLC controller, and feed back the execution result to the top-level warehouse management system software.

[0009] In an optional embodiment of the first aspect of the present invention, the suspended sorting conveyor line includes a product loading area, a product unloading area, a circular hoisting track for connecting the product loading area and the product unloading area, and a lifting device disposed on the circular hoisting track; the weighing and sorting module is disposed in the product loading area, the suspended basket throwing module is disposed in the product unloading area, and the lifting device is provided with an RFID tag.

[0010] In an optional embodiment of the first aspect of the present invention, the suspended basket module includes a storage support rod and baskets distributed on both sides of the storage support rod, the storage support rod being connected to the circular hoisting track branch.

[0011] In an optional embodiment of the first aspect of the present invention, an RFID reader and a push rod are provided at the position where the storage support rod connects to the circular hoisting track.

[0012] In one optional embodiment of the first aspect of the present invention, the product listing area is further provided with a handheld barcode scanning terminal.

[0013] In an optional embodiment of the first aspect of the present invention, in the product unloading area, the products are sorted by color manually. The sorting by color manually involves manually distinguishing different customers based on the color marks or labels on the outer packaging bags of the products inside the hanging device, and placing the products of different customers into the corresponding color mark or color block baskets.

[0014] In an optional embodiment of the first aspect of the present invention, in the product unloading area, the product is placed into the basket by means of an indicator light. The product is placed into the basket by means of an indicator light being provided on the basket. When the RFID reader identifies the customer information of the product in the hanging device, the indicator light on the basket corresponding to the customer information lights up, and the product is placed into the basket where the indicator light is lit.

[0015] A second aspect of the present invention provides an operation method for a suspended sorting and conveying system, the suspended sorting and conveying system comprising a software control part and a hardware execution part; the software control part comprising a top-level warehouse management system software, a middle-level warehouse control system software, and a bottom-level PLC equipment control software; the hardware execution part comprising a weighing and sorting module, a suspended sorting and conveying line, and a suspended bin-feeding module, the operation method comprising:

[0016] Receive user input from the interactive interface of the top-level warehouse management system software in the software control section, and generate sorting task instructions;

[0017] The sorting task instruction is sent to the intermediate-level warehouse control system software for instruction decomposition.

[0018] The decomposed sorting task instructions are sent to the underlying PLC device control software.

[0019] The underlying PLC device control software then sends the decomposed sorting task instructions to the PLC controller, which controls the various mechanisms in the hardware execution part to perform the tasks.

[0020] The PLC controller acquires the execution status of each mechanism and transmits it to the intermediate warehouse control system software through the underlying PLC equipment control software to generate the execution results of the sorting task;

[0021] The intermediate-layer warehouse control system software feeds back the execution results to the top-layer warehouse management system software for display.

[0022] In an optional embodiment of the second aspect of the present invention, the step of receiving user operations from the interactive interface of the top-level warehouse management system software in the software control section and generating sorting task instructions includes:

[0023] The system acquires the goods to be sorted, weighs and sorts them, and scans the product tags on the goods using a handheld terminal. After entering the product information, it is transmitted to the database of the top-level warehouse management system software, and the product information is bound to the lifting device on the circular hoisting track of the suspended sorting conveyor line.

[0024] In an optional embodiment of the second aspect of the present invention, the step of binding the product information to the lifting device on the circular hoisting track of the suspended sorting conveyor includes: writing the product information into the RFID tag of the lifting device on the circular hoisting track of the suspended sorting conveyor.

[0025] Beneficial Effects: This invention provides a suspended sorting and conveying system and its operation method. The system is designed with three layers in the software control part, including a top-level warehouse management system software, a middle-level warehouse control system software, and a bottom-level PLC equipment control software. Each layer has different functions. During sorting, the user issues a sorting task instruction through the top-level warehouse management system software. Then, the middle-level warehouse control system software receives and decomposes the sorting task instruction and passes it to the bottom-level PLC equipment control software. The bottom-level PLC equipment control software receives the decomposed sorting task instruction and passes it to the PLC controller for distribution to various mechanisms in the hardware execution part for execution. Furthermore, the PLC controller of this invention also feeds back the execution status of each mechanism to the bottom-level PLC equipment control software, which then generates the sorting task execution result and sends it to the top-level warehouse management system software through the middle-level warehouse control system software. This allows for real-time monitoring of the sorting task execution status and timely detection of anomalies. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of a suspended sorting and conveying system according to the present invention;

[0027] Figure 2 This is a top view of a suspended sorting conveyor line according to the present invention;

[0028] Figure 3 This is a side view of a suspended sorting conveyor line according to the present invention;

[0029] Figure 4 for Figure 3 Enlarged view of area A in the middle;

[0030] Figure 5 This is a flowchart of the operation method of a suspended sorting and conveying system according to the present invention. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] See Figure 1 The first aspect of the present invention provides a suspended sorting and conveying system, the suspended sorting and conveying system comprising a software control part and a hardware execution part;

[0033] The software control part includes a top-level warehouse management system software 10, a middle-level warehouse control system software 20, and a bottom-level PLC equipment control software 30; the hardware execution part includes a weighing and sorting module 40, a suspended sorting conveyor line 50, and a suspended basket feeding module 60; the bottom-level PLC equipment control software communicates with the hardware execution part through a PLC controller 70.

[0034] The top-level warehouse management system software 10 is used to issue sorting task instructions. The intermediate-level warehouse control system software 20 is used to receive the sorting task instructions, decompose them, and then pass them to the bottom-level PLC equipment control software 30. The bottom-level PLC equipment control software 30 is used to receive the decomposed sorting task instructions and pass them to the PLC controller 70. The PLC controller 70 then distributes the instructions to the various mechanisms in the hardware execution section (i.e., the weighing and sorting module 40, the suspended sorting conveyor line 50, and the suspended basket throwing module 60) for execution.

[0035] The underlying PLC device control software 30 is also used to receive the execution status of each mechanism fed back by the PLC controller 70 and transmit it to the intermediate warehouse control system software 20; the intermediate warehouse control system software 20 is also used to receive the execution status of each mechanism fed back by the PLC controller 70 transmitted by the underlying PLC device control software 30, generate the execution result of the sorting task based on the execution status of each mechanism fed back by the PLC controller 70, and feed back the execution result to the top-level warehouse management system software 10.

[0036] Specifically, the suspended intelligent sorting and conveying system for fresh produce distribution in the agricultural product supply chain disclosed in this utility model comprises two parts: a software control system and a hardware execution system. The software control system includes three layers: a top-level warehouse management system (WMS), a middle-level warehouse control system (WCS), and a bottom-level PLC automated equipment control system. The hardware mainly consists of a weighing and sorting module, a suspended basket-feeding module, and a main suspended intelligent sorting and conveying line, integrating RFID radio frequency identification technology, color-coding technology, and illuminated basket-feeding technology.

[0037] The suspended intelligent sorting and conveying system consists of a top-level warehouse management system (WMS) that implements various warehouse management functions: receiving, inventory management, task processing, sorting, and distribution control, and is responsible for handling warehouse business logic. The bottom level consists of specific logistics equipment (PLC controllers and hardware execution parts) that execute the business processes of the warehouse system. In this example, weighing and sorting, PDA scanning and binding of goods, RFID conveying and diversion, and color-coded lighting for basket placement are all performed according to the pre-set program flow.

[0038] The intermediate warehouse control system software (WCS) is a management and control layer situated between the top-level warehouse management system software (WMS) and the PLC automation equipment control system software. On one hand, it interacts with the top-level warehouse management system software (WMS), receiving instructions from it and sending them to the PLC automation equipment control system software to drive the production line to produce corresponding mechanical actions. On the other hand, it reflects the status and data of the PLC automation equipment control system software in real time on the interface and provides a manual debugging interface for both the PLC automation equipment control system software and the production line.

[0039] See Figure 2 and Figure 3In an optional embodiment of the first aspect of the present invention, the suspended sorting conveyor line 50 includes a product loading area 80, a product unloading area 90, a circular hoisting track 100 connecting the product loading area 80 and the product unloading area 90, and a lifting device 110 disposed on the circular hoisting track 100; the weighing and sorting module 40 is disposed in the product loading area 80, the suspended basket-throwing module 40 is disposed in the product unloading area 90, and the lifting device 110 is equipped with an RFID tag. The suspended basket-throwing module 40 includes a storage support rod 120 and baskets 130 distributed on both sides of the storage support rod, the storage support rod 120 being connected to a branch of the circular hoisting track 100. An RFID reader 140 and a push rod 150 are disposed at the connection position between the storage support rod 120 and the circular hoisting track 100. The product loading area 80 is also equipped with a handheld barcode scanning terminal.

[0040] In one exemplary embodiment of the present invention, the height of the circular hoisting track 100 in the product loading area 80 of the suspended sorting conveyor line 50 is 1.5 meters, and it is generally staffed with no more than 10 people, as too many people concentrated on the line would affect efficiency. Here, workers manually load and weigh the sorted products, affix electronic tags, onto the line, ensuring the product weight is controlled within 20 kg. The loaded products are transported along the main line of the circular hoisting track 100, which is 3 meters high, while the product hanging bag running height is 2.2 meters. Normal production operations can be carried out in the suspended conveyor section.

[0041] In the product loading area, each of the 80 workstations is equipped with one workstation screen connected to an RFID card writer and one PDA for scanning and identifying product information. This product information is then linked to the hanging conveyor. The workstation screen displays product weighing and sorting information, and confirms the information after being linked to the hanging conveyor. After the product is transported along the main line of the circular hoisting track 100 to the product unloading area, the RFID reader reads the current product information at each unloading point. If it is the product at the current location, a push rod pushes out the hanging conveyor and the product, which slides down with the conveyor and is temporarily stored on a storage support rod; otherwise, the product continues to be transported along the main line until it reaches its designated location.

[0042] Each slot at the product drop-off point can be equipped with 1 to 4 pallets, and the storage rack can temporarily hold 10 to 20 items. The storage rack is 1.7 meters high. If the illuminated basket dropping technology is used, an RFID reader will be installed at the rack to read the product information, separate the hanging device from the product, and drop the product into the basket below the illuminated light.

[0043] In an optional embodiment of the first aspect of the present invention, in the product off-line area 90, the products are sorted by color manually. The sorting by color manually involves manually distinguishing different customers based on the color mark or label block on the outer packaging bag of the product inside the hanging device 110, and placing the products of different customers into the corresponding color mark or color block bins.

[0044] In another optional embodiment of the first aspect of the present invention, in the product unloading area, the product is placed into the basket by lighting up an indicator light. The product is placed into the basket by lighting up an indicator light. When the RFID reader identifies the customer information of the product in the hanging device, the indicator light corresponding to the customer information lights up on the basket, and the product is placed into the basket where the indicator light is lit.

[0045] Specifically, this invention provides a solution for the end-of-line sorting and conveying system of the suspended intelligent sorting conveyor – basket placement. When the number of baskets to be placed is two or more, it employs manual intervention for color-coded and illuminated basket placement technology. First, color-coded basket placement: This is a low-cost solution that distinguishes customers based on color codes or labels on the outer packaging of the goods, assigning them to baskets with the same color code or color block. In the illustration, color codes and color blocks are represented by large letters, making it simple and easy to implement. Second, illuminated basket placement: This solution uses RFID technology to quickly identify the goods to be placed and simultaneously illuminate the corresponding basket, prompting the customer to place the basket according to the illuminated indicator.

[0046] See Figure 5 The second aspect of the present invention provides an operation method for a suspended sorting and conveying system, the suspended sorting and conveying system comprising a software control part and a hardware execution part; the software control part comprising a top-level warehouse management system software, a middle-level warehouse control system software, and a bottom-level PLC equipment control software; the hardware execution part comprising a weighing and sorting module, a suspended sorting and conveying line, and a suspended bin-feeding module, the operation method comprising:

[0047] S100: Receive user operations from the interactive interface of the top-level warehouse management system software in the software control section, and generate sorting task instructions;

[0048] S200: Send the sorting task instruction to the intermediate warehouse control system software for instruction decomposition.

[0049] S300: Send the decomposed sorting task instructions to the underlying PLC device control software;

[0050] S400, the underlying PLC device control software then sends the decomposed sorting task instructions to the PLC controller, which controls the various mechanisms in the hardware execution part to perform the task.

[0051] S500: The PLC controller acquires the execution status of each mechanism and transmits it to the intermediate warehouse control system software through the underlying PLC equipment control software to generate the execution result of the sorting task.

[0052] S600, the intermediate-level warehouse control system software feeds back the execution result to the top-level warehouse management system software for display.

[0053] In an optional embodiment of the second aspect of the present invention, the step of receiving user operations from the interactive interface of the top-level warehouse management system software in the software control section and generating sorting task instructions includes:

[0054] The system acquires the goods to be sorted, weighs and sorts them, and scans the product tags on the goods using a handheld terminal. After entering the product information, it is transmitted to the database of the top-level warehouse management system software, and the product information is bound to the lifting device on the circular hoisting track of the suspended sorting conveyor line.

[0055] In an optional embodiment of the second aspect of the present invention, the step of binding the product information to the lifting device on the circular hoisting track of the suspended sorting conveyor includes: writing the product information into the RFID tag of the lifting device on the circular hoisting track of the suspended sorting conveyor.

[0056] In summary, this invention provides a suspended sorting and conveying system and its operation method. The system of this invention is designed with three layers in the software control part, including a top-level warehouse management system software, a middle-level warehouse control system software, and a bottom-level PLC equipment control software. Each layer has different functions. During sorting, the user issues sorting task instructions through the top-level warehouse management system software. Then, the middle-level warehouse control system software receives and decomposes the sorting task instructions and passes them to the bottom-level PLC equipment control software. The bottom-level PLC equipment control software receives the decomposed sorting task instructions and passes them to the PLC controller for distribution to various mechanisms in the hardware execution part for execution. Furthermore, the PLC controller of this invention also feeds back the execution status of each mechanism to the bottom-level PLC equipment control software, and then the middle-level warehouse control system software generates the execution result of the sorting task and sends it back to the top-level warehouse management system software. This allows for real-time awareness of the sorting task execution status and timely detection of anomalies.

[0057] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A suspended sortation conveyor system, characterized by, The hanging type sorting conveying system comprises a software control part and a hardware execution part; The software control part comprises top warehouse management system software, intermediate warehouse control system software and bottom PLC device control software; the hardware execution part comprises a weighing and sorting module, a hanging type sorting conveying line and a hanging type basket throwing module; the bottom PLC device control software is in communication connection with the hardware execution part through a PLC controller; The top warehouse management system software is used to issue sorting task instructions, the intermediate warehouse control system software is used to receive the sorting task instructions, decompose the sorting task instructions and then transmit the decomposed sorting task instructions to the bottom PLC device control software, and the bottom PLC device control software is used to receive the decomposed sorting task instructions from the intermediate warehouse control system software and transmit the decomposed sorting task instructions to the PLC controller, which distributes the decomposed sorting task instructions to each mechanism in the hardware execution part for execution; The bottom PLC device control software is also used to receive the execution conditions of each mechanism fed back by the PLC controller and transmit the execution conditions to the intermediate warehouse control system software; the intermediate warehouse control system software is also used to receive the execution conditions of each mechanism fed back by the PLC controller from the bottom PLC device control software, generate an execution result of the sorting task based on the execution conditions of each mechanism fed back by the PLC controller, and feed back the execution result to the top warehouse management system software; The hanging type sorting conveying line comprises a commodity upline area, a commodity downline area, a loop track for connecting the commodity upline area and the commodity downline area, and a lifting tool arranged on the loop track; the weighing and sorting module is arranged in the commodity upline area, the hanging type basket throwing module is arranged in the commodity downline area, and the lifting tool is provided with an RFID tag; The hanging type basket throwing module comprises a storage support rod and baskets distributed on both sides of the storage support rod; the storage support rod is connected with a branch of the loop track; An RFID card reader and a push rod are arranged at a position where the storage support rod is connected with the loop track.

2. The overhead sortation conveyor system of claim 1, wherein, The commodity upline area is also provided with a handheld code scanning terminal.

3. The overhead sortation conveyor system of claim 1, wherein, In the commodity downline area, the baskets are thrown by a manual color distinguishing method; in the manual color distinguishing method, different customers are distinguished according to color marks or label color blocks on outer packaging bags of commodities in the lifting tool, and commodities of different customers are thrown into baskets corresponding to the color marks or color blocks.

4. The overhead sortation conveyor system of claim 1, wherein, In the commodity downline area, the baskets are thrown by a light-on method; in the light-on method, indicator lights are arranged on the baskets; when customer information of commodities in the lifting tool is identified by the RFID card reader, the customer information corresponds to the indicator lights on the baskets, the indicator lights are turned on, and the commodities are thrown into the baskets in which the indicator lights are turned on.

5. A method of operating a suspended sorting conveyor system, characterized in that, The hanging type sorting conveying system comprises a software control part and a hardware execution part; the software control part comprises top warehouse management system software, intermediate warehouse control system software and bottom PLC device control software; The hardware execution part includes a weighing sorting module, a suspension sorting conveying line and a suspension basket throwing module, and the operation method includes: Receiving user operation on the interactive interface of the top-level warehouse management system software of the software control part to generate a sorting task instruction; Sending the sorting task instruction to the intermediate-level warehouse control system software for instruction decomposition; Sending the decomposed sorting task instruction to the bottom-level PLC device control software; Sending the decomposed sorting task instruction to the PLC controller by the bottom-level PLC device control software to control each mechanism in the hardware execution part to execute; The PLC controller obtains the execution of each mechanism and transmits it to the intermediate-level warehouse control system software through the bottom-level PLC device control software to generate the execution result of the sorting task; The intermediate-level warehouse control system software feeds back the execution result to the top-level warehouse management system software for display; Before the receiving user operation on the interactive interface of the top-level warehouse management system software of the software control part to generate a sorting task instruction, it includes: Obtaining goods to be sorted, weighing and sorting, and scanning the product label on the goods by a handheld terminal to input product information into the database of the top-level warehouse management system software, and binding the product information with the lifting tool on the loop lifting rail of the suspension sorting conveying line; The binding of the product information with the lifting tool on the loop lifting rail of the suspension sorting conveying line includes writing the product information into the RFID tag of the lifting tool on the loop lifting rail of the suspension sorting conveying line.

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