An automatic production line intelligent logistics system for truck-mounted cranes

Abstract

This application provides an intelligent logistics system for an automated production line of a truck-mounted crane, including a structural production line logistics module and an assembly and adjustment production line logistics module that cooperate with each other. The structural production line logistics module includes welding and machining processes, while the assembly and adjustment production line logistics module includes assembly and debugging processes. The advantages of this application are that it fully considers the flow of materials, minimizing the transportation routes between material demand and supply, reducing logistics route intersections, significantly improving the level of intelligence, reducing labor intensity, saving production costs, and improving work efficiency.

Description

Technical Field

[0001] This application relates to the field of equipment manufacturing technology, and in particular to an intelligent logistics system for an automated production line of a truck-mounted crane. Background Technology

[0002] The intelligent logistics system for truck-mounted crane automated production lines consists of an information system and automated equipment and their supporting components. The information system includes a Production Execution System (MES), a Warehouse Management System (MWS), a Logistics Execution System (LES), a Logistics Control and Scheduling System (LCS), and a Warehouse Control System (WCS / RCS). The automated equipment and its supporting components include various models of AGVs (Automated Guided Vehicles), CTU (Computer-controlled Tractor) bin-based automated storage and retrieval systems (AS / RS), stacker crane pallet AS / RS, multi-level shuttle cart bin AS / RS, intelligent light-activated picking racks, KBK (Keeper Handybox), customized vehicles, tooling, and other equipment. Currently, truck-mounted crane production line logistics systems primarily focus on equipment automation or partial system digitization, with limited integrated linkage of automated equipment, small coverage of the entire information flow, and the logistics system not yet fully automated or unmanned. The level of digitization and intelligence in the logistics system is low, resulting in weak improvements in production efficiency and minimal reductions in labor intensity. Summary of the Invention

[0003] The purpose of this application is to solve the problems of low intelligence, weak efficiency improvement, and high labor intensity in existing logistics systems. It provides an intelligent logistics system for automated production lines with truck-mounted cranes. All material transportation is fully automated and unmanned. It fully considers the flow of materials, reduces the intersection of logistics routes, improves the level of automation in production, reduces labor intensity, improves energy efficiency, saves production costs, reduces production time, and improves work efficiency.

[0004] To achieve the above objectives, the first aspect of this application provides an intelligent logistics system for an automated production line of a truck-mounted crane, comprising a structural production line logistics module and an assembly and adjustment production line logistics module that cooperate with each other. The structural production line logistics module includes welding and machining processes, and the assembly and adjustment production line logistics module includes assembly and debugging processes. The structural production line logistics module is used to perform the following steps:

[0005] Step a. After the self-made or outsourced parts are assembled in the assembly area, the LCS issues a transfer and warehousing task. The AGV takes an empty vehicle from the warehouse area and drives to the assembly and transfer area. It unloads the empty vehicle and picks up the material vehicle to be stored and returns to the corresponding warehouse area. Small materials are transported into the warehouse by the transfer rack and CTU in cooperation. Medium and large materials are directly sent into the warehouse area by the AGV for flat storage.

[0006] Step b. The LCS issues warehouse transportation and picking tasks. The AGV takes the required materials from the warehouse and sends them to the picking area or processing station. The picking station picks and pallets the materials according to the system guidance and sends them to the waiting buffer area or processing station.

[0007] Step c. The LCS issues a delivery task, and the AGV transports the required materials from the warehouse or the buffer area to the processing station;

[0008] Step d. After the workpiece assembly and welding are completed at the structural workstation, the manual assembly is followed by sending an entry instruction to the warehouse using a PDA. The LCS schedules the AGV to send the workpiece into the pre-machining buffer warehouse.

[0009] Step e. After the machining station completes the machining of the workpiece, the manual assembly is followed by sending an inbound instruction via PDA. The LCS schedules the AGV to send the workpiece into the pre-coating buffer area. The PDA sends an inbound instruction, and the LCS schedules the AGV to transport the WIP work-in-process to the coating hanging point.

[0010] The assembly and adjustment production line logistics module is used to perform the following steps:

[0011] Step a. After the purchased materials are inspected and manually palletized, LCS issues a transfer and warehousing task. The AGV travels from the warehouse area to the palletizing and transfer area, picks up the material carrier to be stored and returns to the corresponding warehouse area. Standard-sized materials are stored in the standard vertical warehouse, large materials and turntables, base frames and outrigger painting assemblies are stored in the large-item vertical warehouse, and crane booms and telescopic cylinders are stored in the extra-large-item vertical warehouse. The AGV and stacker crane are used to realize the warehousing and retrieval.

[0012] Step b. Small items are transported by a AGV in pallet form from the receiving area to the palletizing area at the front of the multi-passage vertical warehouse. After manual palletizing, the items are transported into the warehouse by a conveyor line, elevator, and shuttle car. The required items are delivered to the picking area or workstation by the CTU.

[0013] Step c. The LCS issues warehouse transportation and picking tasks. The AGV and CTU take the required materials from the warehouse and send them to the picking area or processing station. The picking station picks and pallets the materials according to the system guidance and sends them to the waiting-to-go temporary storage area or processing station by the AGV.

[0014] Step d. The LCS issues a delivery task, and the AGV transports the required materials from the warehouse or the temporary storage area to the processing station;

[0015] Step e. After the final assembly is disassembled and manually reassembled, a warehousing instruction is sent using a PDA. The LCS dispatches a hidden AGV to deliver the workpiece to the disassembled assembly warehouse area, where an overhead crane lifts the disassembled assembly and places it into the designated warehouse location.

[0016] Furthermore, the structured production line logistics module includes nine areas, which are in turn the following: the first purchased parts receiving and receiving area, the unloading line receiving and receiving area, the small parts CTU automated storage area, the medium and large parts floor storage area, the first centralized picking and palletizing area, the first waiting-to-go-on temporary storage area, the first AGV charging and rest area, the first line-side temporary storage area, and the WIP product temporary storage area.

[0017] Furthermore, the assembly and adjustment production line logistics module includes ten areas, which are, in order, the second externally purchased parts receiving and receiving area, the hanging point receiving and receiving area, the small parts multi-layer shuttle car material box automated storage area, the medium and large parts pallet stacker automated storage area, the irregular parts floor storage area, the second centralized picking and palletizing area, the second waiting-to-go-on temporary storage area, the second AGV charging and rest area, the second line-side temporary storage area, and the finished product temporary storage area.

[0018] Furthermore, the first purchased parts receiving and receiving area and the unloading line receiving and receiving area consist of KBK, transfer stations, and transfer equipment.

[0019] Furthermore, the small-item CTU automated storage area consists of CTUs and light-duty shelving for automated three-dimensional storage of small items.

[0020] Furthermore, the medium and large component storage area, the WIP product temporary storage area, the second purchased component receiving and transfer area and the hanging point receiving and transfer area, and the finished product temporary storage area are all composed of storage sites and transfer equipment.

[0021] Furthermore, both the first centralized picking and palletizing area and the second centralized picking and palletizing area consist of KBK, intelligent Andon picking racks, and transfer racks, for picking materials and palletizing them.

[0022] Furthermore, both the first and second AGV charging rest areas consist of charging stations and guardrails, used for AGV charging and task waiting.

[0023] Furthermore, the automated storage area for small parts multi-layer shuttle carts consists of high-level multi-pass racks, shuttle carts, material hoists, layer-changing hoists, and front and rear conveyor lines, for the three-dimensional automated storage of small parts.

[0024] Furthermore, the automated storage and retrieval area for medium and large palletized goods consists of pallet racks, stacker cranes, front and rear conveyor lines, and fixed platforms, and is used for the automated storage of medium and large sized purchased materials and work-in-process semi-finished products.

[0025] The technical solution of this application implements an automated intelligent logistics system for production lines. This system automates the entire process of material transportation: automated material handling and warehousing of raw materials and purchased components from the material unloading line; automated outbound picking and returning to the warehouse; automated material supply to the welding production line; automated inbound and outbound transportation of semi-finished products; automated material supply to the machining production line; automated transportation of top-coating components; automated warehousing and transportation of bottom-coating components and purchased components; automated warehousing and storage of semi-finished products and purchased components; automated outbound and transportation of materials for picking; automated transportation of materials to the assembly production line; automated transportation of materials through workstations; and automated warehousing and transportation of finished products. This system achieves automation and unmanned operation of all material transportation. Work tasks are issued by the upper-level system, allocated and scheduled by the task management system, and executed by the equipment execution system. Simultaneously, it fully considers the flow of materials, minimizing the transportation routes for each material demand and supply, and reducing logistics route overlap. This logistics system significantly improves the level of production automation, reduces labor intensity, increases energy efficiency, saves production costs, greatly reduces production time, and improves work efficiency.

[0026] Other features and advantages of the embodiments of this application will be described in detail in the following detailed description section. Attached Figure Description

[0027] The accompanying drawings are provided to further illustrate the embodiments of this application and form part of the specification. They are used together with the following detailed description to explain the embodiments of this application, but do not constitute a limitation on the embodiments of this application. In the drawings:

[0028] Figure 1 This is a layout diagram of the structural workshop and warehouse area in the intelligent logistics system of the truck-mounted crane automated production line of this application;

[0029] Figure 2 This is a layout diagram of the loading and unloading workshop warehouse area in the intelligent logistics system of the truck-mounted crane automated production line of this application. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are only for illustration and explanation of the embodiments of this application and are not intended to limit the embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0031] An intelligent logistics system for an automated production line of a truck-mounted crane includes a structural production line logistics module and an assembly and adjustment production line logistics module that cooperate with each other. The structural production line logistics module includes welding and machining processes, and the assembly and adjustment production line logistics module includes assembly and debugging processes.

[0032] See Figure 1 The structural production line logistics system module 1 comprises nine areas: the first purchased parts receiving and receiving area 11, the unloading line receiving and receiving area 12, the small parts CTU automated storage area 13, the medium and large parts floor-stacking storage area 14, the first centralized picking and palletizing area 15, the first waiting-to-go temporary storage area 16, the first AGV charging and rest area 17, the first line-side temporary storage area, and the WIP product temporary storage area 18. The area layout is as follows... Figure 1 As shown, the first purchased parts receiving and receiving area 11 and the unloading line receiving and receiving area 12 consist of KBK (Built-in Keyboard) units, transfer stations, and transfer equipment, used for the inspection, palletizing, and warehousing of purchased materials and self-made materials from the unloading line. The small-item CTU automated storage area 13 consists of CTU units and light-duty shelving, used for automated three-dimensional storage of small items. The medium-to-large-item floor-stacking storage area 14 consists of storage stations and transfer equipment, used for automated planar storage of medium-to-large-item materials. The first centralized picking and palletizing area 15 consists of KBK units, intelligent Andon picking racks, and transfer racks, used for material picking and palletizing. The first waiting-to-go-on temporary storage area 16 is used for the temporary storage and transportation of empty vehicles and picked materials before they go online. The first AGV charging and rest area 17 consists of a charging station and guardrails, used for AGV charging and task waiting. The first line-side temporary storage area is used for the storage and transportation of materials to be delivered to the production line. The line-side temporary storage area is distributed in various workstations. There are dozens of workstations in the entire factory area, which are numerous and scattered, so they are not marked in the figure. The WIP product temporary storage area 18 consists of storage stations and transfer equipment, and is used for the temporary storage and inbound / outbound picking of various work-in-process semi-finished products.

[0033] See Figure 2 The assembly and adjustment production line logistics module 2 includes ten areas: a second purchased parts receiving and receiving area 21, a hanging point receiving and receiving area 22, a small parts multi-layer shuttle car material box automated storage area 23, a medium and large parts pallet stacker crane automated storage area 24, an irregularly shaped parts floor stacking storage area 25, a second centralized picking and palletizing area 26, a second waiting-to-go temporary storage area 27, a second AGV charging and rest area 28, a second line-side temporary storage area, and a finished product temporary storage area 29. The area layout is as follows: Figure 2As shown, the second purchased parts receiving and transfer area 21 and the hanging point receiving and transfer area 22 consist of transfer stations and transfer equipment, used for incoming material inspection and palletizing of purchased materials, palletizing of painted hanging WIP, and inbound transportation. The small-item multi-layer shuttle cart automated storage area 23 consists of high-level multi-pass racks, shuttle carts, material hoists, layer-changing hoists, and front and rear conveyor lines, used for automated storage of small items. The medium and large-item pallet stacker automated storage area 24 consists of pallet racks, stacker cranes, front and rear conveyor lines, and fixed platforms, used for automated storage of medium and large-sized purchased materials and work-in-process semi-finished products. The irregular-shaped parts floor storage area 25 is used for flat storage of irregularly sized materials. The second centralized picking and palletizing area 26 consists of KBK (Kinetic Picker), intelligent Andon picking racks, and transfer racks, used for material picking and kitting. The second pre-line storage area 27 is used for the temporary storage and transportation of empty vehicles and picked materials before they are put into service. The second AGV charging and rest area 28 consists of a charging station and guardrails, used for AGV charging and task waiting. The second line-side storage area is used for the storage and transportation of materials to be delivered. The finished product storage area 29 consists of storage stations and transfer equipment, used for the temporary storage and inbound / outbound picking of finished products.

[0034] In this embodiment, during specific operation, regarding the structural production line logistics module, after self-made or outsourced parts are assembled in the palletizing area, the LCS issues a receiving and warehousing task. AGVs retrieve empty vehicles from the warehouse area, drive to the palletizing and receiving area, unload the empty vehicles, and retrieve the material vehicles to be stored, returning to the corresponding warehouse area. Small materials are transported into the warehouse by transfer racks in cooperation with CTUs, while medium and large materials are directly delivered to the warehouse area by AGVs for planar storage. The LCS issues outbound transportation and picking tasks, and AGVs retrieve the required materials from the warehouse and deliver them to the picking area or processing station. The picking station picks and pallets the materials according to system guidance and delivers them to the waiting-to-go buffer area or processing station. The LCS issues delivery tasks, and AGVs transport the required materials from the warehouse or the waiting-to-go buffer area to the processing station. After the structural station completes the workpiece assembly and welding, manual palletizing is performed, and a warehousing instruction is sent using a PDA. The LCS schedules AGVs to deliver the workpieces to the pre-machining buffer area. After the machining station completes the machining of the workpiece, the manual assembly is followed by sending an inbound instruction via PDA. The LCS then dispatches the AGV to send the workpiece to the pre-coating buffer area. The PDA sends an inbound instruction, and the LCS dispatches the AGV to transport the WIP (Work in Process) to the coating hanging point.

[0035] In terms of the logistics module of the assembly and adjustment production line, after the purchased materials in this application are inspected and manually palletized, the LCS issues a transfer and warehousing task. The AGV travels from the warehouse area to the palletizing and transfer area, picks up the material carrier to be stored and returns to the corresponding warehouse area. Standard-sized materials are stored in the standard vertical warehouse, large materials and turntables, base frames, and outrigger painting assemblies are stored in the large-item vertical warehouse, and crane booms and telescopic cylinders are stored in the extra-large-item vertical warehouse. The AGV and stacker crane are used to realize the warehousing and retrieval. Small materials are transported by the AGV in whole pallets from the transfer area to the flipping and palletizing area at the front of the multi-pass vertical warehouse. After manual flipping and palletizing, the materials are transported into the warehouse by the conveyor line, elevator and shuttle car. The CTU delivers the required materials to the picking area or workstation for retrieval. When the LCS issues outbound transportation and picking tasks, AGVs and CTUs retrieve the required materials from the warehouse and deliver them to the picking area or processing station. At the picking station, materials are picked and palletized according to system guidance, and then transported by AGVs to the waiting-to-go temporary storage area or processing station. When the LCS issues delivery tasks, AGVs transport the required materials from the warehouse or waiting-to-go temporary storage area to the processing station. After the final assembled product is disassembled and manually palletized, an inbound instruction is sent using a PDA. The LCS dispatches AGVs to deliver the workpiece to the disassembled assembly storage area, where an overhead crane lifts the disassembled assembly and places it in the designated storage location.

[0036] In this logistics system, all material transportation is fully automated and unmanned. AGVs are used for transfers between workstations, while stacker cranes / shuttle cars / CTUs / AGVs are used for transfers within the warehouse. Work tasks are issued by the upper-level system, allocated and scheduled by the task management system, and executed by the equipment execution system. Furthermore, this logistics system fully considers the flow of materials, minimizing the transportation routes between material demand and supply, reducing route overlaps, significantly improving the level of intelligence, reducing labor intensity, saving production costs, and increasing work efficiency.

[0037] In addition to the embodiments described above, this application may have other implementation methods. All technical solutions formed by equivalent substitution or equivalent transformation fall within the protection scope claimed by this application.

[0038] It should also be noted that 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 process, method, article, or apparatus. Unless otherwise specified, 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 that element.

Claims

1. An intelligent logistics system for an automated production line with a truck-mounted crane, characterized in that, The system includes a structural production line logistics module and an assembly and adjustment production line logistics module that cooperate with each other. The assembly and adjustment production line logistics module includes, in sequence, a second purchased parts receiving and receiving area (21), a hanging point receiving and receiving area (22), a small parts multi-layer shuttle car material box automated storage area (23), a medium and large parts pallet stacker automated storage area (24), an irregular parts floor storage area (25), a second centralized picking and palletizing area (26), a second waiting-to-go-on temporary storage area (27), a second AGV charging and rest area (28), a second line-side temporary storage area, and a finished product temporary storage area (29). The logistics module includes, in sequence, a first externally purchased parts receiving and receiving area (11), a material unloading line receiving and receiving area (12), a small CTU automated storage area (13), a medium and large parts floor storage area (14), a first centralized picking and palletizing area (15), a first waiting-to-go temporary storage area (16), a first AGV charging and rest area (17), a first line-side temporary storage area, and a WIP product temporary storage area (18). Among them, the structural production line logistics module includes welding and machining processes, and the assembly and debugging production line logistics module includes assembly and debugging processes. The structural production line logistics module is used to perform the following steps: Step a. After the self-made or outsourced parts are assembled in the assembly area, the LCS issues a transfer and warehousing task. The AGV takes an empty vehicle from the warehouse area and drives to the assembly and transfer area. It unloads the empty vehicle and picks up the material vehicle to be stored and returns to the corresponding warehouse area. Small materials are transported into the warehouse by the transfer rack and CTU in cooperation. Medium and large materials are directly sent into the warehouse area by the AGV for flat storage. Step b. The LCS issues out the warehouse transportation and picking tasks. The AGV takes the required materials from the warehouse and sends them to the picking area or processing station. The picking station picks and pallets the materials according to the system guidance and sends them to the waiting buffer area or processing station. Step c. The LCS issues a delivery task, and the AGV transports the required materials from the warehouse or the buffer area to the processing station; Step d. After the structural workstation completes the workpiece assembly and welding, the manual assembly is followed by sending an entry instruction to the warehouse using a PDA. The LCS schedules the AGV to send the workpiece into the pre-machining buffer warehouse. Step e. After the machining station completes the machining of the workpiece, the manual assembly is followed by sending an inbound instruction via PDA. The LCS schedules the AGV to send the workpiece into the pre-coating buffer area. The PDA sends an inbound instruction, and the LCS schedules the AGV to transport the WIP work-in-process to the coating hanging point. The assembly and adjustment production line logistics module is used to perform the following steps: Step a. After the purchased materials are manually inspected and palletized, LCS issues a transfer and warehousing task. The AGV travels from the warehouse area to the palletizing and transfer area, picks up the material carrier to be stored and returns to the corresponding warehouse area. Standard-sized materials are stored in the standard vertical warehouse, large materials and turntables, base frames and outrigger painting assemblies are stored in the large-item vertical warehouse, and crane booms and telescopic cylinders are stored in the extra-large-item vertical warehouse. The AGV and stacker crane are used to realize the warehousing and retrieval. Step b. Small items are transported by a AGV in pallet form from the receiving area to the palletizing area at the front of the multi-passage vertical warehouse. After manual palletizing, the items are transported into the warehouse by a conveyor line, elevator, and shuttle car. The required items are delivered to the picking area or workstation by the CTU. Step c. The LCS issues warehouse transportation and picking tasks. AGV and CTU take the required materials from the warehouse and send them to the picking area or processing station. The picking station picks and pallets the materials according to the system guidance and sends them to the waiting storage area or processing station by the AGV. Step d. The LCS issues a delivery task, and the AGV transports the required materials from the warehouse or the temporary storage area to the processing station; Step e. After the final assembly is disassembled and manually reassembled, a warehousing instruction is sent using a PDA. The LCS dispatches a hidden AGV to deliver the workpiece to the disassembled assembly warehouse area, where an overhead crane lifts the disassembled assembly and places it into the designated warehouse location.

2. The intelligent logistics system for automated production lines with truck-mounted cranes according to claim 1, characterized in that, The first purchased parts receiving and receiving area (11) and the unloading line receiving and receiving area (12) consist of KBK, transfer station and transfer equipment.

3. The intelligent logistics system for automated production lines with truck-mounted cranes according to claim 1, characterized in that, The small CTU automated storage area (13) consists of CTUs and light-duty shelving.

4. The intelligent logistics system for automated production lines with truck-mounted cranes according to claim 1, characterized in that, The medium and large parts storage area (14), the WIP product temporary storage area (18), the second purchased parts receiving and transfer area (21) and the hanging point receiving and transfer area (22), and the finished product temporary storage area (29) are all composed of storage sites and transfer equipment.

5. The intelligent logistics system for automated production lines with truck-mounted cranes according to claim 1, characterized in that, Both the first centralized picking and palletizing area (15) and the second centralized picking and palletizing area (26) consist of KBK, intelligent Andon picking rack, and transfer rack.

6. The intelligent logistics system for automated production lines with truck-mounted cranes according to claim 1, characterized in that, Both the first AGV charging rest area (17) and the second AGV charging rest area (28) consist of a charging station and a guardrail.

7. The intelligent logistics system for automated production lines with truck-mounted cranes according to claim 1, characterized in that, The automated storage area (23) for small multi-level shuttle carts consists of a high-level multi-level rack, shuttle carts, material hoists, layer-changing hoists, and front and rear conveyor lines.

8. The intelligent logistics system for automated production lines with truck-mounted cranes according to claim 1, characterized in that, The automated storage and retrieval area (24) for medium and large pallet stackers consists of pallet racks, stackers, front and rear conveyor lines and fixed platforms.

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