A forklift AGV high-rise shelf storage location size measurement method and system

Abstract

The present invention belongs to the technical field of warehouse management, and specifically relates to a forklift AGV high-rise shelf storage location size measurement method and system, which uses an AGV controller to command the AGV to carry goods to the front of the target storage location and lift the fork to the target height. In this process, the single-line laser radar installed on the AGV fork collects plane point cloud data at various heights in real time, and the visual controller splices these data into a three-dimensional point cloud image and calculates the actual space size information for cargo placement. Subsequently, the size information will be passed to the AGV controller to determine whether to perform the cargo placement operation or adjust the cargo placement position deviation according to the actual space situation, thereby preventing the situation where the goods cannot be placed correctly due to insufficient space, effectively improving the safety and efficiency of warehouse management.

Description

Technical Field

[0001] The invention belongs to the technical field of warehouse management, and in particular relates to a method and system for measuring the storage location size of a forklift-type AGV high-rise shelf. Background Art

[0002] Forklift AGV is a highly automated material handling equipment, widely used in logistics, manufacturing, warehousing and other industries. It integrates advanced automatic control, laser navigation, machine vision and other technologies to realize automatic loading, unloading, handling and stacking of goods.

[0003] In the application scenario of forklift AGV placing goods on high-level shelves, the physical space of the placement location is often insufficient due to the tilt of adjacent goods, resulting in insufficient space at the pre-placement location, making it impossible to complete normal placement operations. For high-level placement application scenarios, if the AGV cannot effectively detect and avoid such problems, it may cause the goods to fall or even the shelf to collapse, which is a pain point in scenario application and a difficulty in the industry. Summary of the invention

[0004] The object of the present invention is to provide a method and system for measuring the storage location dimensions of a forklift-type AGV high-rise shelf, so as to solve the problems raised in the above-mentioned background technology.

[0005] To achieve the above-mentioned purpose, the present invention proposes a forklift-type AGV high-rise shelf storage location size measurement method, comprising the following steps: the AGV controller controls the AGV to carry the goods and move to the front of the target storage location for loading and unloading, and then the AGV lifts the fork to the target height; the vision controller obtains the plane point cloud data of each height in real time through the single-line laser radar during the lifting process, and splices the plane point cloud data into a three-dimensional point cloud image; the vision controller calculates the actual space size for loading and unloading according to the three-dimensional point cloud image, and sends the size information to the AGV controller; the AGV controller decides whether to execute the loading and unloading action according to the received information.

[0006] Preferably, the single-line laser radar is installed in the middle of the AGV fork and rises and falls with the fork to scan the surrounding contours in horizontal planes at different heights and generate point cloud data of the detection plane.

[0007] Preferably, the step of stitching the planar point cloud data into a three-dimensional point cloud image includes:

[0008] According to the plane point cloud data obtained by the AGV fork at different height positions, the point cloud is transformed using the translation matrix to form a three-dimensional point cloud model;

[0009] The point cloud translation formula is:

[0010] A h =R h A i ;

[0011]

[0012] A i For each frame of the radar point cloud obtained by the line laser, A h is the actual imaging point cloud after point cloud transformation, R h is the line laser radar point cloud transformation matrix, t z The value of is obtained according to the AGV fork height.

[0013] Preferably, the translation matrix does not include a rotation operation, and only performs translation in the z-axis direction, and the translation amount is determined by the corresponding height data.

[0014] Preferably, the three-dimensional point cloud model is constructed by accumulating single-frame point cloud data at different heights, and the formula is:

[0015] A=∑ h＝0 A h ;

[0016] A is the reconstructed 3D point cloud model of the entire shelf, which is a single frame point cloud A at different heights h. h The cumulative sum of .

[0017] On the other hand, the present invention provides a forklift-type AGV high-level shelf storage location size measurement system, comprising:

[0018] Single-line laser radar, used to output planar point cloud data in real time;

[0019] Visual controller, used to control point cloud stitching, perform 3D imaging and calculate storage location size information;

[0020] AGV controller, used for overall business decision control;

[0021] Includes a wire-pull encoder to measure and output fork height data in real time.

[0022] The industrial computer receives data from the laser radar through a network connection and receives data from the rope encoder through a CAN bus.

[0023] Preferably, the single-line laser radar is installed in the middle of the AGV fork, facing the cargo side, and can be raised and lowered with the fork, and is used for vertical scanning of the cargo storage location.

[0024] Preferably, the visual controller calculates the actual space size where goods can be placed based on the point cloud data provided by the laser radar, and sends the result to the AGV controller as a basis for decision-making.

[0025] Technical effects and advantages of the present invention: Compared with the prior art, the forklift AGV high-rise shelf storage location size measurement method and system proposed by the present invention has the following advantages:

[0026] The present invention proposes a method for measuring the size of a storage location for a forklift-type AGV high-rise shelf. The method is based on vertical scanning imaging of a single-line laser radar during the AGV lifting process to reconstruct the three-dimensional point cloud of the storage location, and then calculate the actual spatial size and position information of the storage location. The AGV can then use this data to compare with the actual size and position of the stored objects to determine whether the storage location space can accommodate the goods and whether the storage location deviation needs to be adjusted, thereby avoiding the danger caused by the inability to effectively place the goods. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a flow chart of the method for measuring the storage location size of a high-rise shelf of a forklift-type AGV of the present invention;

[0028] Figure 2 This is a working principle diagram of the laser radar of the present invention;

[0029] Figure 3 It is a block diagram of the forklift-type AGV high-level shelf storage location size measurement system of the present invention. DETAILED DESCRIPTION

[0030] The following will be combined with the accompanying drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. The specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0031] The present invention provides a method for measuring the size of a high-rise shelf storage space of a forklift-type AGV. Figure 1 As shown, the following steps are included:

[0032] S1: The AGV controller controls the AGV to carry the goods to the front of the target storage location, and then the AGV lifts the fork to the target height.

[0033] In the specific implementation, the AGV controller will first dispatch the AGV to carry the specified goods from the storage area or production line according to the pre-set task plan, and drive along the planned path to the front of the target delivery location. When the AGV approaches the target location, it will accurately locate itself through its own laser navigation system or other positioning devices to ensure that the AGV's position accuracy meets the delivery requirements.

[0034] Once the AGV reaches the designated location, the AGV controller will issue a command to start lifting the forks on the AGV, and this process will continue until the forks reach the expected height for loading. To ensure accuracy, the AGV is equipped with a draw-wire encoder that can measure the height change of the forks in real time and feed the data back to the AGV controller.

[0035] By precisely controlling the lifting height of the forks, it is ensured that the goods can be placed accurately at the predetermined location, reducing the possibility of incorrect placement of goods due to inaccurate positioning. By real-time monitoring of the lifting height of the forks, any operational errors that may lead to safety hazards, such as placing the goods too high or unstable, can be discovered and corrected in a timely manner. The entire release process does not require manual intervention and is completed autonomously by the AGV, which improves the automation level of warehouse management, reduces labor costs, and also improves work efficiency. By accurately releasing goods, the location information of the goods can be better tracked, which is conducive to the realization of refined inventory management and optimization of warehouse space utilization.

[0036] S2: During the lifting process, the visual controller uses a single-line laser radar to obtain the plane point cloud data at each height in real time, and splices the plane point cloud data into a three-dimensional point cloud image;

[0037] like Figure 2 As shown in the figure, the LiDAR sensor uses a laser beam to scan the surrounding contour in a plane in a non-contact manner. If the laser beam hits an object, the position is determined in the form of distance and reverse direction. In this way, point cloud data of the detection plane can be generated to represent the spatial position relationship between the obstacle and the radar in the plane.

[0038] Furthermore, a single-line laser radar is installed in the middle of the AGV fork and rises and falls with the fork. It is used to scan the surrounding contours in horizontal planes at different heights and generate point cloud data of the detection plane.

[0039] In addition, stitching the plane point cloud data into a three-dimensional point cloud image includes:

[0040] According to the plane point cloud data obtained by the AGV fork at different height positions, the point cloud is transformed using the translation matrix to form a three-dimensional point cloud model;

[0041] The point cloud translation formula is:

[0042] A h =R h A i ;

[0043]

[0044] A i For each frame of the radar point cloud obtained by the line laser, A h is the actual imaging point cloud after point cloud transformation, R his the line laser radar point cloud transformation matrix, t z The value of is obtained according to the AGV fork height.

[0045] The translation matrix does not include rotation operations, but only performs translation in the z-axis direction, and the translation amount is determined by the corresponding height data.

[0046] S3: The visual controller calculates the actual space size where goods can be placed based on the 3D point cloud image, and sends the size information to the AGV controller; when the AGV lifts the fork, the radar height is raised synchronously. During this process, the visual controller collects the current height value and the plane point cloud data of the laser radar in real time, and splices the plane point cloud data of each height to form an overall point cloud image of one side of the goods, completing the 3D data reconstruction of the cargo space.

[0047] Furthermore, the 3D point cloud model is constructed by accumulating single-frame point cloud data at different heights, and the formula is:

[0048] A=∑ h＝0 A h ;

[0049] A is the reconstructed 3D point cloud model of the entire shelf, which is a single frame point cloud A at different heights h. h The cumulative sum of .

[0050] S4: The AGV controller decides whether to release the goods based on the information received. After the visual controller completes the measurement of the actual size of the storage space for the goods to be released and sends this information to the AGV controller, the AGV controller will compare and analyze the actual size of the goods to be stored based on the received data. If the storage space is large enough to accommodate the goods to be stored without affecting the safety of the surrounding environment, the AGV controller will decide to release the goods; otherwise, if the storage space is insufficient or there are factors that may cause risks, the AGV controller will not release the goods, but will choose to find a new storage location or take other measures to solve the problem of releasing the goods.

[0051] By pre-evaluating whether the space for placing goods is suitable, we can effectively prevent problems such as goods falling or shelf structure damage caused by insufficient space, thereby improving the safety factor of warehouse operations. The automated dimension measurement and evaluation process saves the time required for traditional manual inspections, speeds up the storage and retrieval of goods, and thus improves the efficiency of the entire warehouse management system. Automated decision-making reduces the potential risks caused by human misjudgment and makes the placing process more reliable. Through accurate measurement and evaluation, warehouse space can be planned more reasonably, making more efficient use of limited storage space.

[0052] On the other hand, the present invention proposes a forklift AGV high-level shelf storage location size measurement system, such as Figure 3 As shown, it mainly includes the following key components:

[0053] Single-line laser radar: Installed at the appropriate position of the AGV fork, as the fork rises and falls, the laser radar can scan the contour of the storage location at different heights and output plane point cloud data in real time. This data contains the contour information of each height of the storage location and is the basis for building a 3D model.

[0054] Vision controller: responsible for controlling the work of the single-line laser radar, and splicing the collected plane point cloud data to form a three-dimensional point cloud image. The actual size information of the storage location is calculated through the algorithm to provide a basis for subsequent release decisions.

[0055] AGV controller: As the "brain" of the entire system, it is responsible for receiving the storage location size information provided by the vision controller, and making decisions on whether to release the goods or how to adjust the placement of the goods based on this information and the actual size of the goods.

[0056] Wire-pull encoder: Installed on the AGV, it is used to monitor the lifting height of the fork in real time and transmit the height data to the vision controller and other control systems through the CAN bus to ensure that the fork reaches the preset height position accurately.

[0057] Industrial computer: As the data processing center, it receives point cloud data from the single-line LiDAR through a network connection and receives height data from the cable encoder through the CAN bus. The industrial computer processes this data and forwards it to the vision controller and other necessary control system components.

[0058] Through the multi-height scanning of the single-line laser radar and the three-dimensional stitching of the plane point cloud data, the precise measurement of the space size of the storage space is achieved, ensuring that the goods can be placed accurately. Based on the accurate storage space size information, the AGV controller can make intelligent decisions on the release of goods, improve the success rate of the release of goods, and reduce the probability of wrong release of goods. The pull rope encoder monitors the height change of the fork in real time and quickly feeds back to the control system through the CAN bus, ensuring the dynamic monitoring and adjustment capabilities of the release process. As the data processing center, the industrial computer efficiently coordinates the data exchange between various components to ensure the smooth operation of the entire measurement system.

[0059] Furthermore, a single-line laser radar is installed in the middle of the AGV fork, facing the side of the goods, and can be raised and lowered with the fork to vertically scan the storage location for placing goods. In addition, the visual controller calculates the actual space size for placing goods based on the point cloud data provided by the laser radar, and sends the result to the AGV controller as a basis for decision-making.

[0060] Specifically, in order to accurately measure the size of high-level shelf storage locations, the single-line laser radar is designed to be installed in the middle of the AGV fork, and its detection direction faces the side of the goods. This installation method allows the laser radar to rise or fall with the fork when the AGV lifts the fork, thereby vertically scanning the storage location at different heights. The single-line laser radar outputs plane point cloud data on each height level, which records the contour information of the storage location at each height.

[0061] The visual controller receives the plane point cloud data from the single-line laser radar and controls the stitching of the point cloud data, combining multiple plane point cloud data at different heights into a complete three-dimensional point cloud image. Based on this three-dimensional image, the visual controller can calculate the actual spatial dimensions of the storage location through algorithms, including key parameters such as width, depth, and height. These calculation results will be sent to the AGV controller as the basis for its decision-making.

[0062] The single-line laser radar can vertically scan the storage location at different heights, providing detailed contour information and ensuring the accuracy of the storage location size measurement. Since the laser radar moves with the lifting and lowering of the fork, it can flexibly respond to the needs of releasing goods at different heights, improving the adaptability of the system. The visual controller provides a reliable decision-making basis for the AGV controller by calculating the actual space size of the storage location, making the release operation more intelligent and accurate. By measuring the size of the storage location space in advance, it is possible to effectively prevent safety hazards caused by failed release due to insufficient space or improper placement of goods. The automated measurement and decision-making process reduces the number of unnecessary release attempts and improves the overall efficiency of warehouse management. Accurate storage location size information helps to better plan the storage location of goods and make full use of warehouse space.

[0063] In summary, the AGV controller commands the AGV to carry the goods to the front of the target storage location and raise the fork to the target height. During this process, the single-line laser radar installed on the AGV fork collects plane point cloud data at various heights in real time. The visual controller splices these data into a three-dimensional point cloud image and calculates the actual space size information for placing goods. Subsequently, the size information will be passed to the AGV controller to determine whether to perform the placement operation or adjust the placement position deviation based on the actual space conditions, thereby preventing the situation where the goods cannot be placed correctly due to insufficient space, effectively improving the safety and efficiency of warehouse management.

[0064] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for measuring the size of a high-rise shelf using a forklift AGV, characterized in that: The following steps are involved: The AGV controller controls the AGV to carry the goods to the front of the target delivery location, and then lifts the fork to the target height through the AGV; during the lifting process, the visual controller uses the single-line laser radar to obtain the plane point cloud data of each height in real time, and splices the plane point cloud data into a three-dimensional point cloud image; the visual controller calculates the actual space size for delivery based on the three-dimensional point cloud image, and sends the size information to the AGV controller; the AGV controller decides whether to execute the delivery action based on the received information.

2. A forklift AGV high-rise shelf location size measurement method according to claim 1, characterized in that: The single-line laser radar is installed in the middle of the AGV fork and rises and falls with the fork. It is used to scan the surrounding contours in horizontal planes at different heights and generate point cloud data of the detection plane.

3. A forklift AGV high-rise shelf location size measurement method according to claim 1, characterized in that: The step of stitching the plane point cloud data into a three-dimensional point cloud image comprises: According to the plane point cloud data obtained by the AGV fork at different height positions, the point cloud is transformed using the translation matrix to form a three-dimensional point cloud model; The point cloud translation formula is: A h =R h A i ; A i For each frame of the radar point cloud obtained by the line laser, A h is the actual imaging point cloud after point cloud transformation, R h is the line laser radar point cloud transformation matrix, t z The value of is obtained according to the AGV fork height.

4. A forklift AGV high-rise shelf location size measurement method according to claim 3, characterized in that: The translation matrix does not include a rotation operation, and only performs translation in the z-axis direction, and the translation amount is determined by the corresponding height data.

5. The method for measuring the storage location size of a forklift AGV high-rise shelf according to claim 3 is characterized in that: The three-dimensional point cloud model is constructed by accumulating single-frame point cloud data at different heights, and the formula is: A=∑ h＝0 A h ; A is the reconstructed 3D point cloud model of the entire shelf, which is a single frame point cloud A at different heights h. h The cumulative sum of .

6. A forklift AGV high-rise shelf storage location size measurement system, characterized in that: include: Single-line laser radar, used to output planar point cloud data in real time; Visual controller, used to control point cloud stitching, perform 3D imaging and calculate storage location size information; AGV controller, used for overall business decision control.

7. A forklift AGV high-rise shelf storage location size measurement system according to claim 6, characterized in that: Also included is a wire-drawn encoder that measures and outputs fork height data in real time.

8. The forklift AGV high-rise shelf storage location size measurement system according to claim 7 is characterized in that: It also includes an industrial computer, which receives data from the laser radar through a network connection and receives data from the rope encoder through a CAN bus.

9. A forklift AGV high-rise shelf storage location size measurement system according to claim 8, characterized in that: The single-line laser radar is installed in the middle of the AGV fork, facing the cargo side, and can be raised and lowered with the fork to vertically scan the cargo storage location.

10. A forklift AGV high-rise shelf storage location size measurement system according to claim 9, characterized in that: The visual controller calculates the actual space size where goods can be placed based on the point cloud data provided by the laser radar, and sends the result to the AGV controller as a basis for decision-making.

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