Flexible storage sorting method and system for improving utilization of storage locations

Abstract

The application discloses a flexible storage classification method and system for improving the utilization rate of storage locations, and comprises the following steps: calculating the division of flexible single templates and mixed templates according to the size of the storage grid in the warehouse, the size of common storage goods and the capacity of conveying equipment; predicting future receiving data according to historical order data, and changing the template arrangement of the storage area of the warehouse according to the predicted data; when goods need to be stored, the category and size of the current goods are obtained, and the optimal storage location is selected from the available storage locations for recommendation; according to the allocation result, the storage task is issued, the allocated storage location coordinate points are transmitted to the conveying equipment, and the goods storage is completed. The single flexible storage location template and the mixed flexible storage location template are set, the goods with large storage quantity are put into the specified single flexible storage location template according to the same batch or the same kind of goods, and the management of the warehouse is facilitated; meanwhile, the mixed flexible storage location template is used to uniformly store the goods with small storage quantity and of multiple kinds, and the utilization rate of the storage locations is improved.

Description

Technical Field

[0001] This invention relates to the field of warehousing and logistics technology, and in particular to a flexible storage classification method and system for improving the utilization rate of storage space. Background Technology

[0002] In a containerized automated storage and retrieval system (AS / RS), various sizes of storage boxes are stored. To meet the storage needs of these different boxes, the overall design of the warehouse includes vertical storage layers of varying sizes. When goods arrive at the warehouse, they are first sorted by height to be placed on the appropriate storage layer. To maximize space utilization within each storage unit, every space is filled as much as possible, minimizing waste. In the horizontal direction of the shelving, the key to maximizing storage unit utilization lies in how to centrally store goods.

[0003] Some patents have already explored variable-size storage models, dynamically adjusting the size of storage locations based on the dimensions of incoming goods to achieve efficient use of space within the storage compartments. However, this method requires adding mechanical equipment to the shelving structure, which occupies storage space and reduces the structural stability of the shelving. Adjusting storage locations also takes time, reducing the available storage time for goods.

[0004] Therefore, this patent designs a scheme to adjust the storage space size information based on the arrival ratio of various modular goods by designing different storage templates and adjusting the correspondence between the storage compartments and the templates. When the template changes, the size, number, and left side of the storage space within different sized compartments will all change. By changing the size and arrangement of the storage spaces within the compartments, the coordinates of each storage space are adjusted to achieve a quantity of storage spaces of different sizes. The multi-level shuttle adjusts the position of the goods it grips based on the storage space changes obtained from the electronic control system, thus dynamically changing the storage space size. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings of existing technologies by proposing a flexible storage classification method that, when the storage compartment structure is fixed and the compartment size is fixed, analyzes the receiving size ratio and sets the arrangement of storage locations within the compartments according to the size of the goods when goods of different sizes are placed together.

[0006] The technical solution of the present invention is as follows:

[0007] This invention discloses a flexible storage classification method to improve the utilization rate of storage space, including calculating and generating storage templates and flexible storage arrangement;

[0008] The storage template is generated by calculating and classifying flexible single templates and hybrid templates based on warehouse storage cell dimensions, common storage goods dimensions, and conveying equipment capabilities.

[0009] Based on historical order forecasts of the arrival of goods of various sizes, single flexible storage space templates or mixed flexible storage templates are allocated to storage areas.

[0010] The flexible storage arrangement involves setting storage modules based on storage compartment sizes and common cargo packaging sizes, and developing single flexible storage templates and mixed flexible storage templates. The number of rows and columns of goods placed within a single flexible storage location template is determined. Under a single flexible template, only one size module storage location exists within the same storage compartment. Upon warehousing, goods are categorized by module, ensuring goods of the same module are placed within the same single flexible storage location template. Calculations are performed based on the cargo size and the specifications of the single flexible storage location template to place goods of multiple sizes with lower warehousing volumes into the same mixed flexible storage location template. The mixed flexible template arranges various combinations of storage location module sizes into a single row, selecting the combination that leaves the smallest remaining gap after placement within the mixed flexible storage location template. Goods are then stacked upwards based on the number of storage locations that can accommodate each size.

[0011] Furthermore, it also includes the following steps:

[0012] S1. Based on the dimensions of the storage compartments and the common packaging dimensions of goods, set the storage module, and develop single flexible storage templates and mixed flexible storage templates. Determine the number of columns and rows for storing goods in different templates, and calculate the coordinates of each storage location.

[0013] The coordinates of various storage locations in the set templates are imported into the WCS system to achieve storage location information synchronization. Future arrival information is predicted based on historical inbound / outbound and inventory information, and the warehouse storage areas are divided into single flexible storage location templates and mixed flexible storage location templates according to historical order information.

[0014] S2. Obtain the dimensions and category of the currently inbound goods;

[0015] S3. Based on the dimensions of the goods, classify the goods according to the modular dimensions of the storage location and determine whether to place them in a single flexible storage location template or a mixed flexible storage location template.

[0016] S4. Traverse the storage locations within the specified storage area to determine the number of available storage locations and the number of vacant storage locations.

[0017] S5. Select the best storage location from the available storage locations and recommend it;

[0018] S6. Based on the allocation results, the shelving tasks and the selected storage location information are transmitted to the WMS and WCS systems. The WCS system reads the coordinates of the inbound task and controls the conveyor equipment to move the goods to the designated storage location coordinates to execute the inbound process.

[0019] S7. According to the statistics of the receiving information, when there is a deviation between the receiving size ratio and the set ratio, trigger template adjustment. Predict the packaging size and quantity of the receiving and warehousing boxes in the next receiving cycle in the future. Based on the predicted receiving quantity information and the set storage template, calculate the quantity required for different category template storage locations to ensure that all incoming goods can be warehoused normally.

[0020] Further, the specific operation steps of step S5 are as follows:

[0021] S51. According to the layout setting in step S3, prioritize filling an entire storage location with a batch of goods that can fill one storage location.

[0022] S52. Determine whether there is a storage location with the same goods but not fully filled. If not, store the remaining goods that cannot fill an entire storage location in a new storage location according to the layout in S51, leave the unfilled storage cells empty, and upload the quantity and specifications of the empty storage cells to the control system. If there is a storage location with the same goods but not fully filled, go to step S53.

[0023] S53. Determine the number K1 of remaining empty storage cells in the storage location with the same goods but not fully filled, and the number K2 of the remaining goods that cannot fill an entire storage location. If K1≥K2, fill all the remaining goods that cannot fill an entire storage location into the storage location with the same goods but not fully filled. If K1<K2, store K1 pieces of goods in the storage location with the same goods but not fully filled, and store the remaining K = K2 - K1 pieces of goods in a newly allocated storage location, leave the unfilled storage cells in the new storage location empty, and upload the quantity and specifications of the empty storage cells to the control system.

[0024] Further, in step S6, the lower left corner coordinates of the storage locations divided by each template obtained according to the allocation result are recorded in the WMS and WCS systems. When goods are warehoused, the storage location coordinates are transmitted from the WMS to the WCS system in the WMS, and the storage location template is adjusted by changing the storage coordinates of each good in the storage cell.

[0025] Further, the historical orders predict and analyze the number of arrivals of various goods sizes in the future through machine learning methods. According to the historical receiving and shipping data in the warehouse and the current inventory, through the prediction model, predict the receiving and shipping volume of goods in a future period of time, and combine the number of available empty storage location information currently to adjust the proportion of different size templates, so as to ensure that when goods arrive, enough storage locations are pre-divided in advance, and the current incoming goods are concentrated and stored in the fewest storage cells.

[0026] Further, within the single flexible storage location template, there should be a spacing between goods and between goods and the column at both ends of the storage location, and the number of storage boxes in each row within the storage location is:

[0027]

[0028] Where D is the distance between the goods and the two end posts of the storage location, d is the distance between the goods, L is the length of the storage compartment in the L direction, and l i The width of the storage location in the direction of storage compartment L; the maximum number of storage locations satisfies l min For the minimum required width of the storage space, l min The value is constrained by the conveyor line capacity;

[0029] Small-sized goods can be stored in large-sized storage spaces. However, to improve the utilization rate of storage space, goods should be allocated to storage spaces that match their size as much as possible. If the storage space utilization rate is low, the template should be cancelled and the goods should be considered for placement in a mixed flexible storage space template.

[0030] Furthermore, when the goods are put into storage, the starting coordinates of each column of goods need to be accurately obtained. If the layout is set, there are n storage locations... i If we list the storage cells, then there are n storage locations. i Given the spacing between 1 item and the spacing between 2 items and the pillars at both ends of the storage location, the X-axis coordinates of the lower left and lower right corners of each storage compartment are as follows:

[0031]

[0032]

[0033] The conveying equipment determines the placement position of each item by using the coordinates of the lower left and lower right corners of each compartment.

[0034] Furthermore, the hybrid flexible storage template has N storage compartments of different sizes. The relationship between the size of the storage compartment and the size and quantity of the stored goods in the hybrid flexible storage template is as follows:

[0035]

[0036] Where L is the length of the storage location along the X-axis, D is the distance between the goods and the columns at both ends of the storage location, d is the distance between the goods, and n j (1≤j≤N) represents the number of compartments of different sizes, l j (1≤j≤N) represents the length of goods of different sizes, and the storage space utilization rate is...

[0037] Furthermore, the number of single flexible storage space templates and hybrid flexible storage space templates placed in the Y-axis direction is: In the arrangement of storage locations within storage compartments, the shorter side of the storage location corresponds to the longer side of the storage compartment along the L direction, and the longer side of the storage location corresponds to the shorter side of the storage compartment along the W direction. The storage location arrangement is perpendicular to the storage compartment arrangement direction. Within different modules, the length range of the storage location is affected by its width, and the relationship between the two is as follows: The dimensions of the storage location in the W direction are constrained by both the conveyor equipment and the width in the L direction. For example, based on the conveyor equipment design parameters, the length of the storage location in the W direction can be set to two levels, l1 and l2. The length value is determined based on the width of the storage location, taking into account the length-to-width ratio. Once the first row of layout in the X-axis direction is set, each subsequent row only needs to be aligned with the first row. The X-axis coordinates of the bottom left and bottom right corners of each storage location in each column are the same, and the Y-axis coordinates of the bottom left and bottom right corners of each storage location in each column are the Y-axis coordinate of the goods below them plus the width of the goods.

[0038] This invention also discloses a flexible storage and classification system for improving warehouse space utilization, comprising:

[0039] The cargo volume forecasting module is used to predict the cargo volume for a future period based on historical shipping and receiving data and current inventory levels. It provides a basis and support for the division of the quantity and proportion of various storage location templates, and rationally formulates the storage location templates within each storage compartment.

[0040] Cargo identification module, used to identify cargo dimensions;

[0041] The intelligent allocation and calculation unit is used to calculate the required storage location templates and quantities based on the size and quantity of the goods, select the optimal storage location for recommendation, and locate the position of the required storage location and the coordinates of the goods placed within the storage location.

[0042] Conveying equipment is used to move goods to designated locations for storage based on the results of intelligent allocation of cargo locations calculation units.

[0043] Compared with existing technologies, the advantages of this invention are:

[0044] 1. This invention divides warehouse storage into single flexible storage location templates and mixed flexible storage location templates based on common and uncommon goods. It determines the required quantity and specifications of each type of single and mixed flexible storage location template by using historical order data, and sets the storage layout based on the size of the goods to be stored. This allows for the simulation of storage methods that meet the optimal storage location utilization rate in advance, thereby improving the utilization rate of warehouse storage areas and enabling flexible storage of goods.

[0045] 2. This invention pre-arranges the positions of goods in designated storage locations based on the size of the goods and the specifications of the storage locations. By arranging the storage locations, the specific positioning coordinates of each storage location are calculated. Based on these coordinates, instructions can be directly sent to control the conveying equipment to place the goods in the pre-arranged order and position, making the entire storage process faster and more accurate.

[0046] 3. This invention, through the setting of single flexible storage location templates and mixed flexible storage location templates, allows goods with large inbound volumes to be placed in designated single flexible storage location templates according to the same batch or the same type of goods, facilitating warehouse management. At the same time, various less common goods with small inbound volumes can be placed in mixed flexible storage location templates, improving storage location utilization. Within the single and mixed flexible storage location templates, the matching relationship between each storage location and the template can be dynamically adjusted according to the proportion of various storage locations. It can flexibly configure the size and quantity of storage compartments within each storage location to match the storage of goods of different sizes. Under the premise of meeting the needs of inbound goods, it divides as many empty storage compartments in the warehouse area as possible into storage locations, so that more storage locations can be stored, thereby improving warehouse utilization. Attached Figure Description

[0047] Figure 1 This is a flowchart of the flexible storage classification method for improving warehouse space utilization according to the present invention;

[0048] Figure 2 This is a flowchart illustrating the present invention's prediction and analysis of the future arrival quantities of goods of various sizes based on historical orders;

[0049] Figure 3 This invention provides a flowchart for recommending the optimal storage location.

[0050] Figure 4 This is a schematic diagram of the storage arrangement structure of goods in each storage location in this invention;

[0051] Figure 5 This is a schematic diagram of the structure from the basic template to the multi-type change template in this invention;

[0052] Figure 6 This is a schematic diagram illustrating the working principle of the present invention;

[0053] Figure 7 This is a schematic diagram illustrating the different template arrangements for the same storage compartment. Detailed Implementation

[0054] It should be noted that relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0055] The technical solution of the present invention will be further described in detail below with reference to the embodiments.

[0056] like Figure 1 , 2 As shown, this invention discloses a flexible storage classification method to improve the utilization rate of storage locations, including the generation of storage templates and flexible storage arrangement. The generation of storage templates involves: firstly, analyzing the dimensions of goods arriving in the warehouse, combining the constraints of the conveying equipment and the dimensions of the storage compartments, and setting storage location modules of varying sizes; then, developing different types of storage templates based on the dimensions of the storage compartments and the storage location modules. Based on historical orders, the arrival of goods of various sizes is predicted, and the storage area is divided into at least one single flexible storage location template and at least one mixed flexible storage location template. The flexible storage arrangement involves: placing goods of the same size with high arrival volumes into the same single flexible storage location template, arranging the number of rows and columns within the single flexible storage location template; placing goods of various sizes with low arrival volumes into the same mixed flexible storage location template, arranging them into multiple combinations based on the different sizes, selecting the combination with the smallest remaining gap after placement within the mixed flexible storage location template, and stacking them upwards based on the number of rows that can accommodate each size.

[0057] With fixed storage compartment sizes, the arrangement of goods of different sizes will change depending on their dimensions when they are grouped together. To ensure that outer storage compartments are not affected by inner storage compartments and to facilitate storage management, each row of storage compartments should be the same size. Based on storage compartment sizes and forklift access safety distances, the storage layout is adjusted to change the size of individual storage compartments, thus defining the storage range. The specific steps include:

[0058] S1. Based on the dimensions of the storage compartments and the common packaging dimensions of goods, set the storage module, and develop single flexible storage templates and mixed flexible storage templates. Determine the number of columns and rows for storing goods in different templates, and calculate the coordinates of each storage location.

[0059] Transfer various location coordinate information in the set template to the WCS system to achieve location information synchronization. Forecast future arrival information based on historical inbound and outbound information and inventory information, and divide the storage area of the warehouse into a single flexible location template and a mixed flexible location template according to historical order information;

[0060] S2. Obtain the size and category of the currently incoming goods;

[0061] S3. Classify the goods according to the location module size based on the goods size, and determine whether to place them in a single flexible location template or a mixed flexible location template;

[0062] S4. Traverse the locations in the specified storage area, and determine the number of available locations and the number of vacant locations;

[0063] S5. Select the optimal location from the available locations for recommendation;

[0064] S6. According to the allocation result, transfer the shelving task and the selected location information to the WCS system. The WCS system controls the conveying equipment to move the goods to the specified location to complete the goods inbound;

[0065] According to historical information, predict the packaging size and quantity of the incoming receiving boxes in the next receiving cycle in the future. Combine the predicted receiving quantity information with the set storage template to calculate the quantity required for different types of template locations under the condition that all inbound locations can be normally received.

[0066] As Figure 3 shown, the specific operation steps of step S5 are: S51. According to the arrangement setting in step S3, preferentially fill an entire location with a batch of goods that can fill one location;

[0067] S52. Determine whether there is a location where the same goods are stored but the storage location is not full. If not, store the remaining goods that cannot fill an entire location in a new location according to the arrangement of S51, leave the unfilled storage cells empty, and upload the quantity and specifications of the empty storage cells to the control system; if there is a location where the same goods are stored but the storage location is not full, go to step S53;

[0068] S53. Determine the number K1 of remaining empty storage cells in the location where the same goods are stored but the storage location is not full, and the number K2 of the remaining goods that cannot fill an entire location. If K1≥K2, fill all the remaining goods that cannot fill an entire location into the location where the same goods are stored but the storage location is not full; if K1<K2, store K1 pieces of goods in the location where the same goods are stored but the storage location is not full, and the remaining K = K2 - K1 pieces of goods are reallocated to a new location for storage. Leave the unfilled storage cells in the new location empty and upload the quantity and specifications of the empty storage cells to the control system.

[0069] For the calculation of the layout of shelves and storage compartments, such as Figure 4-7 As shown:

[0070] When using automated storage and retrieval systems (AS / RS) to centrally store boxed goods, sufficient spacing must be maintained between storage locations and pillars, and between goods themselves, to ensure storage safety and the operational range of the storage equipment. This requires considering the spacing D between the pillars at both ends and the goods, as well as the interval d between the goods. Let L be the dimension of the storage cell parallel to the multi-lane aisle, and W be the dimension perpendicular to the aisle. Changes in the width of the storage locations within a cell will affect the storage layout and the number of items stored within that cell.

[0071] To facilitate storage location management, all storage locations within the same storage cell are of the same size. Assuming the storage location template has a width dimension of w, the relationship between the cell's width dimension (L) and the number of cells (n) stored in each row is as follows:

[0072] L≥nw+(n-1)d+2D (5)

[0073] From the above formula, we can obtain the relationship between the size of n and the width of the storage location.

[0074]

[0075] When developing a storage location template, the first step is to determine the size *l* of a single storage location in the L direction, calculate the number of items stored per row under the current storage location size, and then determine the storage layout. When designing the overall warehouse plan, the dimensions of equipment and conveyor lines limit the maximum size *w* that can be stored within the warehouse. max and minimum size w min To increase the number of storage units, the width of the storage location *w* needs to be reduced to use smaller boxes. Assuming that when storing the largest box, each column in the storage cell can hold *n0* boxes, the number of boxes in the remaining templates will increase sequentially from *n0* until the storage size approaches the minimum storage size *w*. min Therefore, the number of storage rows n1 for the second type of template is n1 = n0 + 1. According to formula (5), the calculation method for the maximum storable storage space width w1 of the second type of template is as follows:

[0076]

[0077] Corresponding to the original parameters, the maximum value that can be stored in the second type of template is:

[0078]

[0079] w1 is also the minimum value stored in the first type of template, and the storage size range of the first type of template is [w1, w0]. Following this logic, the maximum value that can be stored in the third type of template can be obtained.

[0080]

[0081] The storage location size range for the second type of template is [w2, w1]. Similarly, the number of storage columns for the i-th type of template is n. i =n0+i, storage limit is,

[0082]

[0083] In this mode, small-sized goods can be stored in large-sized storage locations. However, to improve the utilization rate of storage space, goods should be stored in the corresponding storage location templates based on their size. If the upper limit of the template is less than the minimum size that can be stored, i.e., w... i+1 <w min Stop template division; only i storage location templates can be divided under this storage space size.

[0084] The storage range for each type of template was calculated using the above formula. When goods are received into the warehouse, the starting coordinates of each column of goods need to be accurately obtained. Analysis of the warehouse location distribution diagram shows that if a certain warehouse location template is calculated to have n... i The column of storage locations will simultaneously have n i -1 bay and 2 pillars for storage space. Then the bottom left corner of the first column of storage locations (x) 1,1 The coordinates are D, and the coordinates of the lower right corner are x. 1,2 For D+w i The coordinates of the bottom left corner of the second column of storage locations (x) 2,1 For D+w i +d, bottom right corner coordinates x 2,2 D+2w i +d. Therefore, the X-axis coordinate of a storage location is related to its column number and width, as shown in the following formula:

[0085]

[0086]

[0087] This is used to determine the start and end coordinates of the operation for each cargo position, making it easier for the clamping multi-level shuttle car to determine the operation location.

[0088] The number of single flexible storage space templates and mixed flexible storage space templates placed in the Y-axis direction is: For the Y-axis direction, there is no need to leave gaps between the goods and the columns at both ends of the storage location, or between the goods themselves. Once the first row of the layout in the X-axis direction is set, each of the remaining rows only needs to be set in accordance with the layout of the first row. The X-axis coordinates of the lower left and lower right corners of each storage cell in each column are the same, and the Y-axis coordinates of the lower left and lower right corners of each storage cell in each column are the Y-axis coordinates of the goods below them plus the width of the goods.

[0089] When designing warehouse location templates, the utilization rate of the storage space is an important consideration. The calculation method for the storage space utilization rate is as follows:

[0090]

[0091] If it is calculated that a certain storage space template has a low utilization rate of storage space, consider canceling the template or combining it with other templates with low storage space utilization to form a mixed template storage.

[0092] During the warehousing process, when there are few remaining goods that cannot fill a single storage space, a mixed storage template can be implemented to store the remaining goods using the fewest possible spaces. This template stores multiple storage space modules of different sizes within the same storage space. Furthermore, the mixed template can combine multiple storage space modules with low utilization rates. Depending on demand, low-utilization modules can be mixed with high-utilization modules, effectively utilizing the remaining space that would otherwise be unusable with a single template and improving storage space utilization.

[0093] Assuming that under the current storage location size W, N size modules are calculated based on a single storage location template, w i Let n be the width dimension of the module i. In the hybrid template, the module n is selected. i The following requirements should be met for the mixed template settings to be obtained.

[0094]

[0095] The method for calculating the utilization rate of storage space is as follows:

[0096]

[0097] The rationality and usability of the hybrid flexible template are determined based on actual needs and the utilization rate of storage space.

[0098] Based on historical receiving and shipping data and current inventory levels in the warehouse, a data prediction model is used to predict the volume of goods received and shipped in the future. The basic table of goods packaging specifications in the warehouse management system is read to obtain the size specifications of cardboard boxes for various types of goods and the storage quantity of boxes of various sizes.

[0099] Based on the above data, the number of cardboard boxes to be received in the future is calculated, along with the future demand for cardboard boxes of various sizes. After the templates are defined, the system can calculate the storage quantity of each type of template in a single storage cell. Combining this with the cardboard box storage demand, the number of storage cells required for each type of template is further calculated.

[0100] The cargo volume forecasting module provides a basis and support for dividing the quantity and proportion of various cargo location templates, reasonably specifying the cargo location templates in each cargo compartment, and ensuring that the proportion of cargo locations of various sizes can meet the needs of cargo storage in the future.

[0101] The working principle is as follows: Figure 4-7 As shown: The storage compartments are designed for standard 600mm*400mm cardboard boxes, with compartment dimensions of 2700mm long and 1350mm wide. Based on the design requirements of the multi-level shuttle system for storage and retrieval, and to facilitate forklift access, the distance between goods and uprights is 150mm, and the spacing between adjacent goods is 100mm. When storing standard 600mm*400mm cardboard boxes, the storage arrangement within the compartment is 5 rows and 3 columns, with each compartment capable of storing 15 goods. As the size of the receiving boxes decreases, the number of items that can be stored increases, and the arrangement will change accordingly.

[0102] To ensure centralized storage of goods and reduce the difficulty of warehouse location screening and management, the size of stored goods will be divided into different modules based on the dimensions of the storage compartments and the goods themselves. Goods of similar sizes will be placed in warehouse locations designated with the same module, according to the module range. In the length direction of the goods, two sizes, 600mm and 400mm, will be used based on the design parameters of the multi-level shuttle. When storing 600mm goods in the W direction, two rows can be arranged; when storing 400mm goods, three rows can be arranged.

[0103] In the width direction of the goods, based on the length of the storage space in the L direction, the number of items stored in each column is increased incrementally, considering the spacing between goods and the spacing between goods and the column, to calculate the dividing line of the module. The module increases from the maximum single storage location size of 600*400mm, meaning a minimum of 5 items can be stored. Combining the proposed calculation method, the storage space length L, the goods spacing d, and the goods-column spacing D are substituted into the formula to calculate the number of storage columns. For ease of calculation, the necessary spacing between storage locations will be considered for each storage location. The minimum spacing between two storage locations is 100mm, which can be simplified to 50mm on the left and 50mm on the right for each storage location. Therefore, the 150mm between the column and the first column of goods is simplified to the column needing to occupy 100mm of space for fixing, and 50mm being the space occupied by the first column of goods. Thus, the allocatable width of the entire storage location becomes 2700mm - 100mm * 2 = 2500mm. The width of the storage location in the W direction calculated using the allocatable width includes the spacing, so the actual usable storage location width needs to be reduced by 100mm. For example, when the template can store 6 columns, the maximum width is 2500 / 6 = 416.67 mm, and the actual usable width of the goods is 316.67 mm. When the template can store 7 columns, the maximum width is 2500 / 7 = 357.14 mm, and the actual usable width of the goods is 257.14 mm. For ease of management, different storage location templates are spaced 50 mm apart. When the calculated result is not an integer, or when two intervals are greater than 50 mm, the module setting is adjusted. Therefore, when the width of the goods is between 350 mm and 400 mm, the goods should be stored in a storage location 400 mm away in the W direction. Based on the constraints of the transportation equipment and the actual dimensions of the storage space, after the above steps, the storage spaces are divided into the following storage location modules: 600*400 mm, 600*350 mm, 600*315 mm, 400*400 mm, 400*350 mm, 400*315 mm, and 400*255 mm. To evaluate the utilization rate of each type of storage space, the ratio of the total storage space area within a space to the total area of ​​the storage space is used as the utilization rate. The storage space area is calculated as 2700mm² * 1350mm² = 3645000mm². 2 The details are shown in the table below:

[0104] Table 1. Information on Single Flexible Cargo Location Modules and Templates

[0105]

[0106] Analysis of the utilization rate of various pallet templates revealed that some pallet sizes have low utilization rates. The larger the area of ​​a single pallet, the higher the utilization rate. However, this results in fewer equipment access bays and a larger usable storage area. Pallet sizes of 600*350mm, 400*350mm, and 400*255mm have low utilization rates, and these two sizes are less common. Therefore, it is considered to mix these two sizes with other pallet modules to create a hybrid template, thereby improving pallet utilization. Based on the existing modules, the hybrid template modules are adjusted to integrate and utilize remaining area, resulting in a hybrid flexible template that combines different module types and pallet sizes.

[0107] Table 1. Information on Hybrid Flexible Cargo Location Modularity and Template

[0108]

[0109]

[0110] When there are goods with low storage space utilization rates in storage modules of 600*350mm, 400*350mm, 400*300mm, and 400*250mm that need to be stored, consider using mixed module storage to maximize storage space utilization and achieve centralized storage.

[0111] To accurately and dynamically adjust the storage location templates so that the adjusted storage location plan can meet the subsequent storage requirements of the storage location, it is first necessary to analyze the size of the incoming boxes in advance, and then dynamically adjust the current storage plan for each storage location in conjunction with the planned storage location templates.

[0112] Upon receiving the receiving and shipping plan from the WMS, this system predicts and analyzes the future arrival quantities of various goods of different sizes. Based on the number of different receiving goods of different sizes and the number of currently available empty storage locations, it adjusts the proportion of templates for different sizes. For each storage space, a unique storage template is selected and matched to ensure that enough storage locations are pre-allocated when goods arrive, with the optimization goal of maximizing the total number of available storage locations in the entire warehouse.

[0113] The coordinates of the lower left corner of the storage location divided by each template are calculated and recorded in the equipment system. When goods are stored in the warehouse, the storage location coordinates are transmitted to the multi-level shuttle car in the control layer. The storage location template is adjusted by changing the storage coordinates of each item in the storage cell.

[0114] This invention also discloses a flexible storage and classification system for improving warehouse space utilization, comprising:

[0115] The cargo volume forecasting module is used to predict the cargo volume for a future period based on historical shipping and receiving data and current inventory levels. It provides a basis and support for the division of the quantity and proportion of various storage location templates, and rationally formulates the storage location templates within each storage compartment.

[0116] Cargo identification module, used to identify cargo size and quantity;

[0117] The intelligent allocation and calculation unit is used to calculate the required storage location templates and quantities based on the size and quantity of the goods, select the optimal storage location for recommendation, and locate the position of the required storage location and the coordinates of the goods placed within the storage location.

[0118] Conveying equipment is used to move goods to designated locations for storage based on the results of intelligent allocation of cargo locations calculation units.

[0119] The specific embodiments described in this application are quite detailed, but they should not be construed as limiting the scope of protection of this application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the technical solution of this application, and these modifications and improvements all fall within the scope of protection of this application.

Claims

1. A flexible storage classification method for improving warehouse space utilization, characterized in that, This includes calculating and generating storage templates and flexible storage arrangements; The calculation generates storage templates by dividing single flexible storage location templates and mixed flexible storage location templates based on the dimensions of storage compartments in the warehouse, the dimensions of common stored goods, and the capacity of conveying equipment. Based on historical orders, the arrival of goods of various sizes is predicted, and single flexible storage templates or mixed flexible storage templates are allocated to the storage areas. The flexible storage arrangement involves setting storage modules based on storage compartment sizes and common cargo packaging sizes, and developing single flexible storage templates and mixed flexible storage templates. The number of rows and columns for goods placed within a single flexible storage compartment template is determined. Under a single flexible storage compartment template, only one size module storage location exists within the same compartment. Upon warehousing, goods are categorized by module, ensuring goods of the same module are placed within the same single flexible storage compartment template. Calculations are performed based on the cargo size and the specifications of the single flexible storage compartment template, placing goods of multiple sizes with smaller warehousing volumes into the same mixed flexible storage compartment template. The mixed flexible storage compartment template arranges various combinations of storage compartment module sizes into a single row, selecting the combination that leaves the smallest remaining gap after placement within the mixed flexible storage compartment template. The goods are then stacked upwards based on the number of storage locations that can accommodate each size.

2. The flexible storage classification method for improving warehouse space utilization according to claim 1, characterized in that, It also includes the following specific steps: S1. Set the storage module according to the size of the storage compartment and the common packaging size of goods, and formulate a single flexible storage template and a mixed flexible storage template. Determine the number of columns and rows of goods to be stored in different templates, and calculate the coordinates of each storage location. The coordinate information of various storage locations in the set template is transmitted to the WCS system to realize the synchronization of storage location information. The future arrival information is predicted by historical inbound and outbound information and inventory information. The storage area of ​​the warehouse is divided into single flexible storage location templates and mixed flexible storage location templates according to historical order information. S2. Obtain the dimensions and category of the currently inbound goods; S3. Based on the dimensions of the goods, classify the goods according to the modular dimensions of the storage location and determine whether to place them in a single flexible storage location template or a mixed flexible storage location template. S4. Traverse the storage locations within the specified storage area to determine the number of available storage locations and the number of vacant storage locations. S5. Select the best storage location from the available storage locations and recommend it; S6. Based on the allocation results, the shelving task and the selected storage location information are transmitted to the WMS and WCS systems. The WCS system reads the coordinates of the inbound task and controls the conveyor equipment to move the goods to the designated storage location coordinates to execute the inbound process. S7. Based on the receiving information statistics, when the receiving size ratio deviates from the set ratio, the template adjustment is triggered; predict the packaging size and quantity of receiving boxes in the next receiving cycle, and calculate the quantity of different types of template locations required to ensure that all goods can be stored normally by combining the predicted receiving quantity information with the set storage template.

3. The flexible storage classification method for improving warehouse space utilization according to claim 2, characterized in that, The specific operation steps of step S5 are as follows: S51. According to the layout settings in step S3, prioritize filling the entire storage location if a batch of goods can fill one storage location. S52. Determine whether there is a storage location with the same goods but not full. If not, store the remaining goods that cannot fill the entire storage location into a new storage location according to the arrangement in S51, empty the unfilled storage location, and upload the number and specifications of the empty storage locations to the control system. If there is a storage location with the same goods but not full, proceed to step S53. S53. Determine the number of empty storage spaces remaining in storage locations that contain the same goods but are not full. The remaining quantity of goods that cannot fill an entire storage space ,like If the remaining goods that cannot fill an entire storage space are not filled, then all the goods will be placed into storage spaces that already contain the same goods but are not full; if Then The remaining items will be stored in storage locations that already contain the same goods but are not yet full. The goods are reassigned to a new storage location, and any unfilled storage locations in the new location are vacated. The number and specifications of the vacant storage locations are then uploaded to the control system.

4. The flexible storage classification method for improving warehouse space utilization according to claim 2, characterized in that, In step S6, the coordinates of the lower left corner of each storage location divided by each template are calculated based on the allocation results and recorded in the equipment system. When goods are stored in the warehouse, the storage location coordinates are transmitted to the conveying equipment in the control layer. The storage location template is adjusted by changing the storage coordinates of each item in the storage compartment.

5. The flexible storage classification method for improving warehouse space utilization according to claim 1, characterized in that, The historical orders are analyzed and predicted using machine learning methods to predict the future arrival quantity of goods of various sizes. Based on the historical receipt and delivery data in the warehouse and the current inventory, the prediction model predicts the amount of goods received and delivered and the arrival quantity of goods of different sizes in the future period. Combined with the number of available empty storage spaces, the proportion of templates of different sizes is adjusted to ensure that when the goods arrive, enough storage spaces are allocated in advance to centrally store the goods that are currently entering the warehouse with the fewest possible storage spaces.

6. The flexible storage classification method for improving warehouse space utilization according to claim 1, characterized in that, Within the single flexible storage location template, spacing must be maintained between goods and between goods and the columns at both ends of the storage location, and the number of boxes stored in each row within the storage location is: in, The distance between the goods and the columns at both ends of the storage location. The distance between goods. For goods Length in the direction, For the location of the goods in the storage compartment Width in the direction; maximum number of storage items satisfies , The minimum width of the storage space. The value is constrained by the conveyor line capacity; Small-sized goods can be stored in large-sized storage spaces. However, to improve the utilization rate of storage space, goods should be allocated to storage spaces that match their size as much as possible. If the storage space utilization rate is low, the template should be cancelled and the goods should be considered for placement in a mixed flexible storage space template.

7. The flexible storage classification method for improving warehouse space utilization according to claim 2, characterized in that, When the goods are put into storage, the starting coordinates of each column of goods need to be accurately obtained. If the layout is set, there are storage locations... If the storage space is listed, then the storage location contains... The distance between each item and the distance between each item and the pillars at both ends of the storage location are given. Therefore, the X-axis coordinates of the lower left and lower right corners of each storage compartment are: The conveying equipment determines the placement position of each item by using the coordinates of the lower left and lower right corners of each compartment.

8. The flexible storage classification method for improving warehouse space utilization according to claim 1, characterized in that, The hybrid flexible storage template is provided with Given several storage compartments of different sizes, the relationship between the size of the storage compartment and the size and quantity of the stored goods in the hybrid flexible storage template is as follows: Where W is the length of the storage location along the X-axis. The distance between the goods and the columns at both ends of the storage location. The distance between goods. For the quantity of different sized compartments, For goods of different sizes, the storage space utilization rate is... .

9. A flexible storage and sorting system for improving warehouse space utilization, characterized in that, The flexible storage classification method for improving warehouse space utilization as described in claim 1 includes: The cargo volume forecasting module is used to predict the cargo volume for a future period based on historical shipping and receiving data and current inventory levels. It provides a basis and support for the division of the quantity and proportion of various storage location templates, and rationally formulates the storage location templates within each storage compartment. Cargo identification module, used to identify cargo type and size; The intelligent allocation and calculation unit is used to calculate the required storage location templates and quantities based on the size and quantity of the goods, select the optimal storage location for recommendation, and locate the position of the required storage location and the coordinates of the goods placed within the storage location. Conveying equipment is used to move goods to designated locations for storage based on the results of intelligent allocation of cargo locations calculation units.

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