Material box tracking control method

Abstract

The material box tracking control method described in the present invention effectively improves the interactive response speed and timeliness of the conveying and sorting process by increasing the redundant function of the PLC for data processing, so as to meet the speed and accuracy requirements in multiple business scenarios, accordingly improve the sorting processing efficiency of the entire system, and deliver the material box to the target address in a timely manner. Before the material box applies for a sorting station from the WCS system, the material box barcode information is scanned in advance, and the WCS system determines the sorting station and conveying path in advance based on the barcode information scanning results; the sorting station and path information obtained in advance is stored in the data linked table by the WCS system for subsequent information reading and rewriting; when the material box arrives at the sorting station application point, the WCS system sends the sorting station and path information determined in advance to the conveyor line PLC; based on the data linked table, an information storage queue is established for all material boxes on the conveyor line, and an information interaction reference point and real-time sharing are formed between the WCS system and the conveyor line PLC.

Description

Technical Field

[0001] The present invention relates to a novel fast reading and writing control method based on advance data backup in a material box conveying process, belonging to the field of logistics and warehousing. Background Art

[0002] Currently, automation and intelligent control technologies are developing rapidly in the field of logistics and warehousing. In order to improve operational efficiency, light conveying systems are usually used between distribution centers and three-dimensional storage areas for food, pharmaceuticals, chemicals, express delivery, etc.

[0003] Lightweight conveyor systems utilize roller or chain conveyors to sort bins according to designated destinations. Typically, a barcode containing sorting information is affixed to the outside of the bin, allowing scanners to read the data. Before entering the sorting area, bins request addresses from the WCS system at address request points. The conveyor system then transports the bins to the designated sorting destination. The conveyor PLC typically utilizes stack queues or timed checkpoints to continuously track and sort bins.

[0004] The address application and response method of the above-mentioned existing technology is limited by the PLC information tracking logic. The interaction efficiency between the conveyor line PLC and the WCS system, and the WCS and WMS systems is low. If the target information cannot be sent within the specified time, the material box can only be sent to the abnormal port, which makes the overall conveying path prone to blockage problems and cannot meet the high-efficiency operation requirements of the interaction scenario within 100ms or even within 200ms.

[0005] In view of this, this application is hereby filed. Summary of the Invention

[0006] The material box tracking control method described in this application aims to solve the problems existing in the above-mentioned existing technologies and proposes a control method for sharing the data link between the conveyor line PLC and the WCS system. By increasing the redundant function of the PLC for data processing, the interactive response speed and timeliness of the conveying and sorting process are effectively improved, so as to meet the speed and accuracy requirements in multiple business scenarios, accordingly improve the sorting and processing efficiency of the entire system, and deliver the material boxes to the target address in a timely manner.

[0007] To achieve the above-mentioned purpose of the invention, the material box tracking control method is as follows: before the material box applies for a sorting station to the WCS system, the barcode information of the material box is scanned in advance, and the WCS system determines the sorting station and conveying path in advance based on the barcode information scanning result; the sorting station and path information planned in advance is stored in a data linked list by the WCS system for subsequent information reading and rewriting; when the material box arrives at the sorting station application point, the WCS system sends the sorting station and path information planned in advance to the conveyor line PLC; based on the data linked list, an information storage queue is established for all material boxes on the conveyor line, and an information interaction reference point and real-time sharing are formed between the WCS system and the conveyor line PLC.

[0008] Furthermore, the container tracking control method includes the following steps:

[0009] Step S1) Create a material box information table

[0010] The material box information table is set in the material box information tracking and scheduling system on the PLC side;

[0011] For the material bin information table, establish the DB address for the PLC to store the material bin, determine the data storage length, and implement subsequent data synchronization with the WCS;

[0012] Step S2) Create a data link table

[0013] Send the pre-set scanning device information to the WCS system, and the WCS system will create a corresponding data link table for each scanning device;

[0014] According to the barcode information uploaded at each scanning location, the corresponding data link table is obtained through the WMS system;

[0015] Step S3) Determine the destination address

[0016] When a bin passes through the scanning device, the barcode information obtained by scanning is uploaded to the WCS system. The WCS system analyzes the barcode data and determines the bin's sorting station and path information in advance. This information is stored in the data link table by the WCS system.

[0017] The WMS system receives information data uploaded by the WCS system to manage orders;

[0018] Step S4), Shared data storage address information

[0019] When the material box arrives at the sorting station application point, the barcode information of the material box is sent to the PLC. After receiving the barcode information, the PLC stores the data in the material box information table;

[0020] The PLC submits a request to the WCS system for the destination address of the material box and waits for the WCS system to issue the target address;

[0021] Step S5) Determine the destination address and send it

[0022] After receiving the destination address request from the PLC, the WCS system parses it and issues the command;

[0023] If the WCS system cannot send the destination address in time, the PLC will actively search for the address from the data link table shared with the WCS system;

[0024] Step S6), execute the sorting instruction.

[0025] Furthermore, the data linked list includes the following fields:

[0026] Cyclic monitoring is used to implement communication detection, that is, content is updated every time information is exchanged;

[0027] Storage address, pointing to the PLC's DB address to store the starting address of the material box;

[0028] Task number, which tracks the serial number of the bin sorting task;

[0029] Task type, used to mark when the WCS system changes the address multiple times or when the container needs to be intercepted;

[0030] The starting address refers to the address where the bin arrives at the sorting station application point;

[0031] The current address refers to the real-time address of the container when it is running, and is used for verification when the WCS system changes the destination address of the container;

[0032] Destination address, pointing to the final address of the bin sorting station;

[0033] Encoder value, pointing to the encoder value corresponding to the destination address, used for verification before sorting;

[0034] Cargo barcode, which refers to the barcode on the box for information tracking;

[0035] Sorting results refer to the bin sorting results uploaded by PLC, which are used to close tasks and analyze problems.

[0036] Furthermore, in step S4), when the first material box arrives at the sorting station application point, the PLC traverses and searches the material box information table in the DB block to confirm the first free address bit, and stores the barcode information of the first material box in the first free address bit; according to the above operation, the barcode information of multiple material boxes is stored in the material box information table in the DB block in sequence, and the destination address requests of multiple material boxes are submitted to the WCS system one by one in sequence.

[0037] Furthermore, in step S4), during the bin tracking control process, the storage address in the bin information table does not change, and at the same time, the PLC submits a request data for the destination address to the WCS system containing the storage address information, so that the WCS system can parse the storage address information and subsequently update the storage address information.

[0038] Furthermore, in the steps S4) and S5), the PLC and the WCS system interact with each other in terms of barcode and data storage address information via a communication mechanism such as Socket or OPC.

[0039] In summary, the advantages of the material box tracking control method are:

[0040] 1. This application can solve the problem of information interaction delay between the existing WCS and WMS systems. By realizing real-time sharing of data links between PLC and WCS, the timeliness and response speed of information sent by WCS can be significantly improved. The sorting address can be obtained in a sufficiently long time, the sorting success rate is high, and the path congestion is less likely to occur.

[0041] 2. This application can meet the requirements of high efficiency and timeliness in material box transportation, and the transportation and sorting efficiency is relatively high.

[0042] 3. This application solves the drawbacks of the existing control method, which is beneficial to subsequent system upgrades. For example, when adding new business equipment or new information flow processing, there is no need to redevelop the PLC program before sorting. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The present invention will now be further described with reference to the following drawings;

[0044] Figure 1 It is a storage list of sorting stations and path information based on the interactive response mechanism between PLC and WCS;

[0045] Figure 2 It is the flow chart of the interaction between PLC and WCS; DETAILED DESCRIPTION

[0046] Example 1, as Figures 1 to 2 As shown, this application proposes a novel bin tracking control method. Before the bin applies to the WCS system for a sorting station, a pre-processing step is added to scan the bin barcode information. The WCS system determines the sorting station in advance based on the barcode information scanning results and plans the bin's conveying path.

[0047] Before the bin applies for a sorting station from the WCS system, the sorting station and path information planned in advance is stored by the WCS system in the following ways: Figure 1 In the data linked list shown, information reading and rewriting are subsequently implemented;

[0048] When the bin arrives at the sorting station application point, the WCS system will immediately send the pre-planned sorting station and route information to the conveyor line PLC;

[0049] Based on the above data linked list, an information storage queue is established for all material boxes on the conveyor line. An information exchange reference point and real-time sharing are formed between the WCS system and the conveyor line PLC, thereby effectively shortening the information exchange delay between the two.

[0050] The data linked list includes the following fields:

[0051] Cyclic monitoring is used to implement communication detection, that is, content is updated every time information is exchanged;

[0052] Storage address, pointing to the PLC's DB address to store the starting address of the material box;

[0053] Task number, which tracks the serial number of the bin sorting task;

[0054] Task type, used to mark when the WCS system changes the address multiple times or when the container needs to be intercepted;

[0055] The starting address refers to the address where the bin arrives at the sorting station application point;

[0056] The current address refers to the real-time address of the container when it is running, and is used for verification when the WCS system changes the destination address of the container;

[0057] Destination address, pointing to the final address of the bin sorting station;

[0058] Encoder value, pointing to the encoder value corresponding to the destination address, used for verification before sorting;

[0059] Cargo barcode, which refers to the barcode on the box for information tracking;

[0060] Sorting results refer to the bin sorting results uploaded by PLC, which are used to close tasks and analyze problems.

[0061] The described bin tracking control method sets up a barcode scanner before the bin applies to the WCS system for a sorting station. The scanner is pre-installed on one side of the conveyor line and is used to scan the one-dimensional or two-dimensional code labels on the bin. Based on the scanned barcode information, a data sharing and interaction process is established between the WCS system and the conveyor line PLC to achieve control and tracking of the bin sorting status and information.

[0062] The container tracking control method includes the following steps:

[0063] Step S1) Create a material box information table

[0064] The material box information table can be set in the material box information tracking and scheduling system on the PLC side;

[0065] For the above data linked table, establish the DB address of the PLC storage bin and determine the data storage length to achieve subsequent data synchronization with the WCS. The data storage length determines the subsequent bin data storage cycle, that is, the maximum value of the current stored bin data.

[0066] The bin information table includes all fields in the data linked table and is equivalent to the data linked table. The PLC and WCS systems simultaneously back up and store the contents of the same fields. If the WCS system fails to deliver the destination address in a timely manner, the PLC can proactively address and obtain the corresponding information from the bin information table shared with the WCS system.

[0067] Step S2) Create a data link table

[0068] Send the pre-set scanning device information (including location, number, etc.) to the WCS system, and the WCS system will create a corresponding data link table for each scanning device;

[0069] According to the barcode information uploaded at each scanning location, the corresponding data link table is obtained through the WMS system;

[0070] The data link table includes but is not limited to the following fields: cycle monitoring, storage address, task number, task type, start address, current address, destination address, encoder value, cargo barcode, and sorting result;

[0071] Step S3) Determine the destination address

[0072] When a bin passes through the scanning device, the barcode information obtained by scanning is uploaded to the WCS system. The WCS system analyzes the barcode data and determines the bin's sorting station and path information in advance. This information is stored in the data link table by the WCS system.

[0073] The WMS system receives information data uploaded by the WCS system to manage orders;

[0074] Order management includes but is not limited to bin stock keeping units (SKUs) and quantities. The WMS system matches and outputs the destination address for bin sorting based on order information. The WMS system then sends the destination address to the WCS system for storage.

[0075] Step S4), shared data storage address information

[0076] When the material box arrives at the sorting station application point, the barcode information of the material box is sent to the PLC. After receiving the barcode information, the PLC stores the data in the material box information table;

[0077] The PLC submits a request to the WCS system for the destination address of the material box and waits for the WCS system to issue the target address;

[0078] In this step, when the first bin arrives at the sorting station application point, the PLC traverses and searches the bin information table in the DB block to confirm the first free address, such as A; and stores the barcode information of the first bin in the address A;

[0079] During the bin tracking control process, the storage address in the bin information table does not change. At the same time, the PLC sends a request for the destination address to the WCS system, which includes the storage address information. The WCS system then parses the storage address information and subsequently updates the storage address information.

[0080] When the WCS system lags behind in sending the target address, the WCS system and PLC can still share data based on the fixed storage address information. As long as the current address of the material box does not exceed the target address, the material box and sorting address information can be bound and the sorting operation can be completed according to the instructions.

[0081] According to the above operations, the barcode information of multiple boxes is stored in the box information table in the DB block in sequence, and the destination address requests of multiple boxes are submitted to the WCS system one by one in sequence;

[0082] Step S5) Determine the destination address and send it

[0083] After receiving the destination address request from the PLC, the WCS system parses it and issues the command;

[0084] If the WCS system fails to issue the destination address in a timely manner, the PLC proactively searches for the address from the data link table shared with the WCS system. If the WCS fails to issue the destination address in a timely manner, the PLC issues the initial destination address for the bin according to the configured exception threshold. If the WCS changes the destination address of the bin before it reaches the destination due to the link during transport, the PLC immediately corrects the bin's destination address to the one issued by the WCS, and the bin can still be sorted normally.

[0085] In the above steps S4) and S5), the PLC and the WCS system interact with the barcode and data storage address information through a communication mechanism such as Socket or OPC;

[0086] Since the WCS system already knows the PLC's data storage address when receiving the request, it can directly modify the target address of the bin sorting by command rewriting to complete the data link interaction between the WCS system and the PLC. In other words, the main information interaction such as the bin destination address request, command issuance and modification, and sorting result feedback is completed through data sharing.

[0087] During the sorting process of a bin sent by the WCS, if the destination address of the bin needs to be modified due to changes in customer order information, or if the system adds security inspection functions and needs to be intercepted when the security inspection fails, the security inspection results cannot be included in the initial destination address of the bin due to the delay in the security inspection system's own information processing results. Therefore, the destination address sent by the WCS system to the PLC is the initial destination address.

[0088] Step S6), execute the sorting instruction.

[0089] Based on the material box tracking control method proposed in this application, the PLC can not only accurately track the material boxes but also share data with the WCS system. The two can also realize the writing and reading of batch data, which simplifies the corresponding requirements for the response time of the WCS and PLC in the material box conveying and sorting process. At the same time, it meets the large-scale, high-SKU, and block-based business operation requirements in normal and abnormal material box sorting scenarios, which can significantly improve the efficiency of information interaction, ensure the fast and accurate delivery of material boxes, and improve the efficiency and accuracy of sorting.

[0090] The embodiments described above, in conjunction with the accompanying drawings, are merely preferred solutions for achieving the objectives of the present invention. Those skilled in the art will readily be able to derive alternative structures consistent with the design concepts of the present invention based on these insights. Other structural features derived from these alternatives are also intended to fall within the scope of the present invention.

Claims

1. A material box tracking control method, characterized in that: Before the material box applies for a sorting station to the WCS system, the barcode information of the material box is scanned in advance. The WCS system determines the sorting station and conveying path in advance based on the barcode information scanning results; The sorting station and route information planned in advance is stored in the data link table by the WCS system for subsequent reading and rewriting of information; When the bin arrives at the sorting station application point, the WCS system sends the pre-planned sorting station and path information to the conveyor line PLC; Based on the data linked list, an information storage queue is established for all material boxes on the conveyor line, forming an information exchange reference point and real-time sharing between the WCS system and the conveyor line PLC; The following steps are included: Step S1) Create a material box information table The material box information table is set in the material box information tracking and scheduling system on the PLC side; For the material bin information table, establish the DB address for the PLC to store the material bin, determine the data storage length, and implement subsequent data synchronization with the WCS; Step S2) Create a data link table Send the pre-set scanning device information to the WCS system, and the WCS system will create a corresponding data link table for each scanning device; According to the barcode information uploaded at each scanning location, the corresponding data link table is obtained through the WMS system; Step S3) Determine the destination address When a bin passes through the scanning device, the barcode information obtained by scanning is uploaded to the WCS system. The WCS system analyzes the barcode data and determines the bin's sorting station and path information in advance. This information is stored in the data link table by the WCS system. The WMS system receives information data uploaded by the WCS system to manage orders; Step S4), Shared data storage address information When the material box arrives at the sorting station application point, the barcode information of the material box is sent to the PLC. After receiving the barcode information, the PLC stores the data in the material box information table; The PLC submits a request to the WCS system for the destination address of the material box and waits for the WCS system to issue the target address; Step S5) Determine the destination address and send it After receiving the destination address request from the PLC, the WCS system parses it and issues the command; If the WCS system cannot send the destination address in time, the PLC will actively search for the address from the data link table shared with the WCS system; Step S6), execute the sorting instruction.

2. The container tracking control method according to claim 1, characterized in that: The data linked list includes the following fields: Cyclic monitoring is used to implement communication detection, that is, content is updated every time information is exchanged; Storage address, pointing to the PLC's DB address to store the starting address of the material box; Task number, which tracks the serial number of the bin sorting task; Task type, used to mark when the WCS system changes the address multiple times or when the container needs to be intercepted; The starting address refers to the address where the bin arrives at the sorting station application point; The current address refers to the real-time address of the container when it is running, and is used for verification when the WCS system changes the destination address of the container; Destination address, pointing to the final address of the bin sorting station; Encoder value, pointing to the encoder value corresponding to the destination address, used for verification before sorting; Cargo barcode, which refers to the barcode on the box for information tracking; Sorting results refer to the bin sorting results uploaded by PLC, which are used to close tasks and analyze problems.

3. The container tracking control method according to claim 1, characterized in that: In the step S4), when the first bin arrives at the sorting station application point, the PLC searches the bin information table in the DB block to confirm the first free address bit and stores the barcode information of the first bin in the first free address bit; According to the above operations, the barcode information of multiple material boxes is stored in the material box information table in the DB block in sequence, and the destination address requests of multiple material boxes are submitted to the WCS system one by one in sequence.

4. The container tracking control method according to claim 3, characterized in that: In step S4), during the bin tracking control process, the storage address in the bin information table does not change. At the same time, the PLC submits a request for the destination address to the WCS system, which includes the storage address information, so that the WCS system can parse the storage address information and subsequently update the storage address information.

5. The container tracking control method according to claim 4, characterized in that: In the steps S4) and S5), the PLC and the WCS system interact with each other through the Socket or OPC communication mechanism to perform barcode and data storage address information.

Images