A method and system for continuously replenishing cartons of cigarettes

Abstract

This invention discloses a continuous replenishment method and system for cigarette cartons, belonging to the field of cigarette sorting. The replenishment method includes the following steps: S1: setting up virtual stations, physical stations, and replenishment workstations with corresponding numbers according to replenishment channels numbered 1 to X; S2: establishing a replenishment task list according to actual replenishment needs; S3: sending each replenishment task to the virtual station in the order of the replenishment task list, triggering replenishment task allocation step A, and performing task allocation; then, according to the virtual station task transfer step B, merging step C, workstation transportation step D, and downstream transportation step E, multiple cartons of cigarettes are merged on the main conveyor channel according to the replenishment order in the replenishment task list, and sequentially output downstream along the direction of logistics transportation. This invention can perform continuous replenishment while ensuring the correct replenishment order, thus improving replenishment efficiency.

Description

Technical Field

[0001] This invention belongs to the field of cigarette sorting, and specifically relates to a method and system for continuous replenishment of cigarette cartons. Background Technology

[0002] In the field of cigarette sorting, high-speed sorting has become standard equipment in tobacco logistics centers, with current single-line sorting speeds reaching 20,000-35,000 cartons per hour. Such high sorting speeds also bring greater challenges to the replenishment capacity of cigarette cartons in logistics centers.

[0003] Because the brands and quantities of cigarettes replenished are closely related to orders, when replenishing cigarettes, various brands in each case need to be merged according to a specific order and rules to ensure the correct replenishment sequence. In other words, the replenishment order of cigarettes in cases must closely match the sorting order of cigarette cartons. However, due to the large variety of cigarette brands handled by tobacco logistics centers, problems such as chaotic replenishment order and brand mismatch can easily occur when dealing with large-volume replenishments, leading to sorting errors or decreased efficiency. Furthermore, in some logistics centers, cigarette replenishment still relies on manual operation, requiring replenishment personnel to manually move cigarettes according to sorting requirements. This not only results in low merging efficiency but also increases the risk of replenishment errors or delays due to human error.

[0004] To improve the accuracy of merging, a method is currently proposed as shown in the attached figure. Figure 2 The merging method described herein involves the following process: The logistics center generates a replenishment sequence for each brand of cigarettes based on replenishment needs. Then, replenishment tasks are assigned to the control center according to this sequence. The required brands of cigarettes are then transported sequentially from different replenishment channels to the main logistics transport channel, preventing sequence errors. However, to ensure accuracy, this method only allows one replenishment task to be performed at a time across multiple replenishment channels. This results in other replenishment channels being idle, leading to low overall merging efficiency. This significantly impacts the overall sorting efficiency of the logistics center and wastes substantial workstation resources, especially when the tobacco logistics center needs to handle large volumes of branded cigarettes. Therefore, a continuous cigarette replenishment method that can solve these problems is urgently needed. Summary of the Invention

[0005] The purpose of this invention is to address the aforementioned shortcomings by providing a continuous cigarette replenishment method and system, aiming to solve the problems of low efficiency and inability to perform continuous replenishment while ensuring the correct replenishment sequence in current cigarette replenishment methods. To achieve the above objective, this invention provides the following technical solution:

[0006] A continuous cigarette replenishment method is applied to a cigarette replenishment system. The cigarette replenishment system includes a main conveyor channel, several replenishment channels located to the side of the main conveyor channel, and a control mechanism. The main conveyor channel also has several first conveying mechanisms corresponding one-to-one with each replenishment channel. The method includes the following steps:

[0007] Step S1: Along the logistics transportation direction of the main conveyor channel, number each replenishment channel sequentially from 1 to X; set up a physical station at the exit of each replenishment channel with the same replenishment channel number; then, set up a virtual station corresponding one-to-one with the physical station number; then, set up several replenishment workstations on the main conveyor channel corresponding one-to-one with the physical station, and monitor in real time whether there are cigarettes at each replenishment workstation.

[0008] Step S2: When replenishment is needed, a replenishment task list is added according to the replenishment requirements. The replenishment task list includes replenishment tasks numbered 1 to N. Each replenishment task records the task sequence number, brand verification code, target replenishment channel number, and target address.

[0009] Step S3: Send each replenishment task to the virtual station in the order of the replenishment task list, triggering replenishment task allocation step A to allocate tasks; then, according to the virtual station task transfer step B, merging step C, workstation transportation step D and downstream transportation step E, merge multiple packs of cigarettes in the replenishment order in the replenishment task list on the main conveyor channel, and output them downstream in the direction of logistics transportation.

[0010] Furthermore, step A of the replenishment task allocation specifically includes:

[0011] Step A1: Set the initial task sequence N=1 for the replenishment task, and the virtual station number X=1 to accept the task, then proceed to step A2;

[0012] Step A2: Assign replenishment task N to virtual station X, and then trigger virtual station task transfer step B;

[0013] Step A3: Determine whether the current replenishment task N is the last replenishment task in the current replenishment task list; if not, set N = N + 1, X = 1, and return to step A2; if yes, exit the replenishment task assignment step A.

[0014] Furthermore, step B of the virtual platform task transfer process specifically includes:

[0015] Step B1: Determine if there is a previous replenishment task for virtual station X; if there is no previous replenishment task, proceed to step B2; if there is a previous replenishment task, the replenishment task enters a waiting state; after the previous replenishment tasks for virtual station X are cleared, proceed to step B2.

[0016] Step B2: Determine if there is a preceding transportation task for virtual station X; if there is, proceed to step B3; if not, proceed to step B4.

[0017] Step B3: Trigger workstation transport step D. After workstation transport step D is completed, proceed to step B4.

[0018] Step B4: Determine whether the target replenishment channel number recorded in replenishment task N is consistent with the target replenishment channel number of virtual station X; if the numbers are inconsistent, proceed to step B5; if the numbers are consistent, proceed to step B6.

[0019] Step B5: Let X = X + 1, pass the replenishment task N to the virtual station X, and return to step B1;

[0020] Step B6: Trigger the merging step C and exit the virtual platform task transfer step B.

[0021] Furthermore, the merging step C specifically comprises:

[0022] Step C1: Determine whether a cigarette pack is placed at replenishment station X; if so, proceed to step C2; if not, proceed to step C3.

[0023] Step C2: Trigger workstation transportation step D; after transportation step D is completed, return to step C1;

[0024] Step C3: Determine whether there is a pack of cigarettes on the actual station X corresponding to the target replenishment channel number; if there is, proceed to step C5; if not, proceed to step C4.

[0025] Step C4: Trigger step A3 and create a transportation task for replenishment station X; then, proceed to step C6 after replenishment at station X.

[0026] Step C5: Throw the cigarette packs from the physical station X and send them to the replenishment station X for merging; if the current replenishment station X has no transportation task, generate a transportation task for the replenishment station X and clear the replenishment task of the virtual station X; then, simultaneously trigger the downstream transportation steps E and A3, and exit the merging step C.

[0027] Step C6: Discard the cigarette packs on the physical station X and send them to the replenishment station X for merging; if the current replenishment station X has no transportation task, generate a transportation task for the replenishment station X and clear the replenishment task of the virtual station X; then, only trigger the downstream transportation step E and exit the merging step C.

[0028] Furthermore, the workstation transportation step D specifically includes:

[0029] Step D1: Check whether there are consecutive transportation tasks from virtual station X to the last virtual station in ascending order of numbering; if not, proceed to step D4; if so, record the replenishment station number Y where the task is interrupted, and proceed to step D2.

[0030] Step D2: Determine whether cigarettes are placed at all replenishment stations Y-1 to X; if not, wait for cigarettes to be replenished at all replenishment stations Y-1 to X, and then proceed to step D3; if so, proceed directly to step D3.

[0031] Step D3: In descending order of numbering, transport all cigarettes located between replenishment stations Y-1 and X to the next replenishment station; then, transfer the transport tasks from virtual station X to virtual station Y-1 to virtual station X+1 to virtual station Y; if replenishment station Y-1 is the last replenishment station, output the cigarettes at replenishment station Y-1 to the downstream and clear the transport task at virtual station Y-1; then, exit step D.

[0032] Step D4: Transport the cigarette pack located at the current replenishment station to the next replenishment station; then, transfer the transportation task of virtual station X to virtual station X+1 corresponding to the next replenishment station; then, exit step D.

[0033] Furthermore, it also includes a downstream transportation step E, which specifically includes:

[0034] Step E1: Determine the downstream output based on whether there is a new replenishment task list and the completion status of each current replenishment task list; if the cigarettes in the current replenishment task list have been merged in order and there is no new replenishment task list, proceed to step E2; if the cigarettes in the current replenishment task list have not been merged or there is a new replenishment task list, exit the downstream transportation step E directly.

[0035] Step E2: When the downstream is idle, transport all cigarettes on the current main conveyor channel to the downstream in the order of logistics direction, then clear the conveying tasks of all virtual stations, and then exit the downstream transportation step E.

[0036] Furthermore, the merging step C also includes the following steps:

[0037] Step C401: When a cigarette is thrown from any station, the replenishment station corresponding to the main conveyor channel is monitored for timing. If the replenishment station does not receive the cigarette within 1.5 seconds, all tasks are suspended and an alarm is triggered.

[0038] Furthermore, in step S2, the replenishment task names of each replenishment task list are specifically replenishment task 1, replenishment task 2, ..., replenishment task N; and the multiple replenishment task lists are sorted in ascending order of their creation time, with all replenishment tasks in the previous replenishment task list taking priority over the replenishment tasks in the next replenishment task list.

[0039] Furthermore, it also includes a target address allocation step, which specifically involves: when a cigarette is detected to be placed at the last replenishment station of the main conveyor channel, adjusting the transportation direction of the cigarette after it leaves the main conveyor channel according to the target address recorded in the corresponding replenishment task.

[0040] A cigarette replenishment system employs the continuous cigarette replenishment method described in any of the above claims, comprising a control mechanism, a main conveying channel, and a plurality of replenishment channels; the main conveying channel is provided with a plurality of first transport mechanisms and a first monitoring mechanism; the first monitoring mechanism is used to monitor the placement of cigarettes on each of the first transport mechanisms; the replenishment channels are provided with second transport mechanisms and second monitoring mechanisms; the second monitoring mechanism is used to monitor the placement of cigarettes on the second transport mechanisms; the plurality of replenishment channels are arranged laterally relative to the main conveying channel; the control mechanism is electrically connected to the plurality of first transport mechanisms and the plurality of second transport mechanisms respectively.

[0041] The beneficial effects of this invention are:

[0042] 1. This invention, through optimized control algorithms, enables multiple replenishment channels to perform multiple replenishment tasks simultaneously without adding any hardware equipment, by coordinating the replenishment channels with the main conveying channel. This maximizes the utilization of workstation resources, realizes the function of multi-channel parallel conveying, improves merging efficiency, and allows for continuous replenishment while ensuring the correct replenishment sequence. Attached Figure Description

[0043] Figure 1 This is a schematic diagram of the cigarette replenishment system provided in Embodiment 4 of the present invention;

[0044] Figure 2 This is a schematic diagram of the existing smoke confluence system;

[0045] Figure 3 This is a flowchart of step A in the continuous replenishment method for cigarettes provided by the present invention;

[0046] Figure 4 This is a flowchart of step B in the continuous cigarette replenishment method provided by the present invention;

[0047] Figure 5 This is a flowchart of step C in the continuous cigarette replenishment method provided by the present invention;

[0048] Figure 6 This is a flowchart of step D in the continuous cigarette replenishment method provided by the present invention; Detailed Implementation

[0049] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0050] In the description of this invention, "first feature" and "second feature" may include one or more of the features.

[0051] In the description of this invention, "a plurality of" means two or more.

[0052] In the description of this invention, the first feature being "above" or "below" the second feature may include the first and second features being in direct contact, or it may include the first and second features not being in direct contact but being in contact through another feature between them.

[0053] In the description of this invention, the terms "above," "over," and "on top" for the first feature and the second feature include the first feature being directly above or diagonally above the second feature, or simply indicating that the first feature is at a higher horizontal level than the second feature.

[0054] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," and "some examples" indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0055] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments, but the present invention is not limited to the following embodiments.

[0056] Example 1:

[0057] See attached Figures 1-2A continuous cigarette replenishment method is provided, applied to a cigarette replenishment system. The cigarette replenishment system includes a main conveyor channel, several replenishment channels located to the side of the main conveyor channel, and a control mechanism. The main conveyor channel is equipped with several first conveying mechanisms corresponding one-to-one with each replenishment channel. The method includes the following steps:

[0058] Step S1: Along the logistics transportation direction of the main conveyor channel, number each replenishment channel sequentially from 1 to X; set up a physical station at the exit of each replenishment channel with the same replenishment channel number; then, set up a virtual station corresponding one-to-one with the physical station number; then, set up several replenishment workstations on the main conveyor channel corresponding one-to-one with the physical station, and monitor in real time whether there are cigarettes at each replenishment workstation.

[0059] Step S2: When replenishment is needed, a replenishment task list is added according to the replenishment requirements. The replenishment task list includes replenishment tasks numbered 1 to N. Each replenishment task records the task sequence number, brand verification code, target replenishment channel number, and target address.

[0060] Step S3: Send each replenishment task to the virtual station in the order of the replenishment task list, triggering replenishment task allocation step A to allocate tasks; then, according to the virtual station task transfer step B, merging step C, workstation transportation step D and downstream transportation step E, merge multiple packs of cigarettes in the replenishment order in the replenishment task list on the main conveyor channel, and output them downstream in the direction of logistics transportation.

[0061] The replenishment method provided by this invention enables multiple replenishment channels to perform multiple replenishment tasks simultaneously without adding any hardware. This is achieved by coordinating replenishment channels with the main conveyor channel, maximizing the utilization of workstation resources, realizing multi-channel parallel conveying, improving merging efficiency, and ensuring continuous replenishment while maintaining the correct replenishment sequence. In step S1, the replenishment workstation refers to the physical location on the main conveyor channel where the cigarette is received after being ejected from the corresponding replenishment channel. Furthermore, since one of the virtual stations must correspond to the target replenishment channel number, and task transmission starts from virtual station 1, the virtual station corresponding to the replenishment task will eventually be found as the replenishment task is transmitted. Each replenishment task includes several task information items, including at least a task sequence number, a brand verification code, a target replenishment channel number, and a target address. The brand verification code is used for verification after the cigarettes are merged and transported downstream, and the target address is the receiving address.

[0062] Example 2:

[0063] See attached Figures 1-6 Based on Example 1, step A of the replenishment task allocation is specifically as follows:

[0064] Step A1: Set the initial task sequence N=1 for the replenishment task, and the virtual station number X=1 to accept the task, then proceed to step A2;

[0065] Step A2: Assign replenishment task N to virtual station X, and then trigger virtual station task transfer step B;

[0066] Step A3: Determine whether the current replenishment task N is the last replenishment task in the current replenishment task list; if not, set N = N + 1, X = 1, and return to step A2; if yes, exit the replenishment task assignment step A.

[0067] In step A3, if replenishment task N is the last replenishment task in the current replenishment task list, it means that the transfer of all virtual station task information in the current replenishment task list has been completed, and the replenishment task allocation step A is exited. Step A is triggered again after the next replenishment task list is added.

[0068] The specific steps of virtual platform task transfer step B are as follows:

[0069] Step B1: Determine if there is a previous replenishment task for virtual station X; if there is no previous replenishment task, proceed to step B2; if there is a previous replenishment task, the replenishment task enters a waiting state; after the previous replenishment tasks for virtual station X are cleared, proceed to step B2.

[0070] Step B2: Determine if there is a preceding transportation task for virtual station X; if there is, proceed to step B3; if not, proceed to step B4.

[0071] Step B3: Trigger workstation transport step D. After workstation transport step D is completed, proceed to step B4.

[0072] Step B4: Determine whether the target replenishment channel number recorded in replenishment task N is consistent with the target replenishment channel number of virtual station X; if the numbers are inconsistent, proceed to step B5; if the numbers are consistent, proceed to step B6.

[0073] Step B5: Let X = X + 1, pass the replenishment task N to the virtual station X, and return to step B1;

[0074] Step B6: Trigger the merging step C and exit the virtual platform task transfer step B.

[0075] The merging step C specifically involves:

[0076] Step C1: Determine whether a cigarette pack is placed at replenishment station X; if so, proceed to step C2; if not, proceed to step C3.

[0077] Step C2: Trigger workstation transportation step D; after transportation step D is completed, return to step C1;

[0078] Step C3: Determine whether there is a pack of cigarettes on the actual station X corresponding to the target replenishment channel number; if there is, proceed to step C5; if not, proceed to step C4.

[0079] Step C4: Trigger step A3 and create a transportation task for replenishment station X; then, proceed to step C6 after replenishment at station X.

[0080] Step C5: Throw the cigarette packs from the physical station X and send them to the replenishment station X for merging; if the current replenishment station X has no transportation task, generate a transportation task for the replenishment station X and clear the replenishment task of the virtual station X; then, simultaneously trigger the downstream transportation steps E and A3, and exit the merging step C.

[0081] Step C6: Discard the cigarette packs on the physical station X and send them to the replenishment station X for merging; if the current replenishment station X has no transportation task, generate a transportation task for the replenishment station X and clear the replenishment task of the virtual station X; then, only trigger the downstream transportation step E and exit the merging step C.

[0082] The specific steps of the workstation transportation process D are as follows:

[0083] Step D1: Check whether there are consecutive transportation tasks from virtual station X to the last virtual station in ascending order of numbering; if not, proceed to step D4; if so, record the replenishment station number Y where the task is interrupted, and proceed to step D2.

[0084] Step D2: Determine whether cigarettes are placed at all replenishment stations Y-1 to X; if not, wait for cigarettes to be replenished at all replenishment stations Y-1 to X, and then proceed to step D3; if so, proceed directly to step D3.

[0085] Step D3: In descending order of numbering, transport all cigarettes located between replenishment stations Y-1 and X to the next replenishment station; then, transfer the transport tasks from virtual station X to virtual station Y-1 to virtual station X+1 to virtual station Y; if replenishment station Y-1 is the last replenishment station, output the cigarettes at replenishment station Y-1 to the downstream and clear the transport task at virtual station Y-1; then, exit step D.

[0086] Step D4: Transport the cigarette pack located at the current replenishment station to the next replenishment station; then, transfer the transportation task of virtual station X to virtual station X+1 corresponding to the next replenishment station; then, exit step D.

[0087] It also includes downstream transportation step E, which specifically includes:

[0088] Step E1: Determine the downstream output based on whether there is a new replenishment task list and the completion status of each current replenishment task list; if the cigarettes in the current replenishment task list have been merged in order and there is no new replenishment task list, proceed to step E2; if the cigarettes in the current replenishment task list have not been merged or there is a new replenishment task list, exit the downstream transportation step E directly.

[0089] Step E2: When the downstream is idle, transport all cigarettes on the current main conveyor channel to the downstream in the order of logistics direction, then clear the conveying tasks of all virtual stations, and then exit the downstream transportation step E.

[0090] Preferably, the merging step C further includes step C401: when a cigarette is thrown from any station, the replenishment station corresponding to the main conveying channel is monitored for timing. If it is found that the replenishment station has not received the cigarette within 1.5 seconds, all tasks are suspended and an alarm is triggered.

[0091] Preferably, in step S2, the replenishment task name of each replenishment task list is specifically replenishment task 1, replenishment task 2, ..., replenishment task N; and the multiple replenishment task lists are sorted in ascending order according to their creation time, with all replenishment tasks in the previous replenishment task list taking priority over the replenishment tasks in the next replenishment task list.

[0092] Preferably, the method further includes a target address allocation step, which specifically involves: when a cigarette is detected to be placed at the last replenishment station of the main conveying channel, adjusting the transportation direction of the cigarette after it leaves the main conveying channel according to the target address recorded in the corresponding replenishment task, so as to facilitate the delivery of the cigarette to the receiving target address.

[0093] Example 3:

[0094] See attached Figures 1-6 The present invention also provides a cigarette replenishment system, employing the continuous cigarette replenishment method described in Embodiment 2, comprising a control mechanism, a main conveying channel, and a plurality of replenishment channels; the main conveying channel is provided with a plurality of first transport mechanisms and a first monitoring mechanism; the first monitoring mechanism is used to monitor the placement of cigarettes on each of the first transport mechanisms; the replenishment channels are provided with second transport mechanisms and second monitoring mechanisms; the second monitoring mechanism is used to monitor the placement of cigarettes on the second transport mechanisms; the plurality of replenishment channels are arranged laterally relative to the main conveying channel; the control mechanism is electrically connected to the plurality of first transport mechanisms and the plurality of second transport mechanisms respectively.

[0095] As described above, each first transport mechanism is used to receive and transport cigarettes of different brands. The first monitoring mechanism includes multiple monitors for real-time monitoring of the cigarette placement at each replenishment station. Specifically, both the first and second transport mechanisms can include transport components and driving components. The transport component can be a conveyor belt, and the driving component can be a power roller. The second transport mechanism is arranged laterally relative to the main conveyor channel, used to receive cigarettes of different brands and throw them out to the corresponding first transport mechanism on the main conveyor channel for merging. The second monitoring mechanism is located at the exit of the replenishment channel to monitor in real-time whether cigarettes are placed at the exit. Specifically, the first monitoring mechanism can include several photoelectric sensors, with one photoelectric sensor installed at each replenishment station and the exit of the main conveyor channel to monitor cigarette placement. Similarly, the second monitoring mechanism can also use photoelectric sensors to monitor the cigarette placement at the exit of the replenishment channel. The control mechanism has a built-in continuous replenishment method and can adjust and control the operating status of the first transport mechanism and several second transport mechanisms in real time according to replenishment needs. When the cigarette packs at the replenishment station need to be transported backward along the logistics direction, the power roller corresponding to the first transport mechanism is driven to drive the conveyor belt to transport backward along the logistics direction.

[0096] Example 4:

[0097] See attached Figures 1-6 According to Embodiment 3, preferably, the cigarette replenishment system of the present invention has one main conveying channel and three replenishment channels, and each replenishment station of the main conveying channel is provided with a power roller for driving the conveyor belt to move along the conveying direction.

[0098] The following example illustrates the continuous replenishment method and the cigarette replenishment system scheme described above. Suppose that none of the virtual stations 1 to 3 have any preceding replenishment tasks, none of the replenishment stations 1 to 3 have any cigarettes placed on them, and currently, station 1 has cigarettes placed on it, station 2 has no cigarettes placed on it, and station 3 has cigarettes placed on it. Furthermore, the cigarette brands corresponding to stations 1, 2, and 3 are brand a, brand b, and brand c, respectively. Then, the replenishment method for this example is as follows:

[0099] A new replenishment task list has been added, which includes Replenishment Task 1, Replenishment Task 2, and Replenishment Task 3. Among them, Replenishment Task 1 requires replenishment of cigarettes of brand b; Replenishment Task 2 requires replenishment of cigarettes of brand a; and Replenishment Task 3 requires replenishment of cigarettes of brand c.

[0100] According to the replenishment task list and the set initial task sequence, replenishment task 1 is assigned to virtual station 1, triggering step B. Since virtual station 1 has no preceding replenishment or transport tasks, it is determined that the target replenishment channel number of virtual station 1 is different from that of replenishment task 1. Replenishment task 1 is then passed to virtual station 2, and it is determined that virtual station 2 also has no preceding replenishment or transport tasks. Then, it is determined that the target replenishment channel number of virtual station 2 is the same as that of replenishment task 1, triggering step C. It is determined that no cigarettes are placed at replenishment station 2, and no cigarettes are placed at physical station 2 either, so it enters the waiting state for replenishment. Then, the transport task for replenishment station 2 is formed, and step A3 is triggered, entering the transfer of replenishment task 2.

[0101] Assign replenishment task 2 to virtual station 1; and trigger step B. Since there are no preceding replenishment tasks and transport tasks in virtual station 1, and the target replenishment channel number of virtual station 1 is the same as that of replenishment task 1, trigger step C. If no cigarettes are placed in replenishment station 1, and cigarettes are present in physical station 1, then throw the cigarettes of brand a in physical station 1 to replenishment station 1, and then form a transport task for replenishment station 1. Clear the replenishment task of virtual station 1, and trigger step A3 and downstream transport step E at the same time. On the one hand, the transfer of replenishment task 3 begins, and on the other hand, it is determined that the current replenishment task list is not completed, so downstream transport is not carried out.

[0102] Replenishment task 3 is assigned to virtual station 1. Since virtual station 1 has a preceding transport task, step D is triggered. It is found that although virtual station 1 and virtual station 2 have consecutive transport tasks, the replenishment station 2 does not have any cigarettes placed, so it enters the waiting state.

[0103] As can be seen, due to the lack of merging of brand b cigarettes, replenishment task 3 cannot be passed on, and cigarettes cannot be transported downstream. Only after station 2 replenishes brand b cigarettes, are the cigarettes thrown to replenishment station 2 for merging. Then, the cigarettes from replenishment stations 2 and 1 are sequentially transported to replenishment stations 3 and 2, clearing the replenishment task of virtual station 1 and passing the transport task to virtual stations 3 and 2. On one hand, step E is triggered, indicating that the current replenishment task list is incomplete, and downstream transport is not carried out; on the other hand, returning to step B4, it is determined that the target replenishment channel number of virtual station 1 is different from that of replenishment task 3, so replenishment task 3 is passed to virtual station 2; however, virtual station 2 already has a transport task at this time, so... Continue triggering step D, transporting the cigarettes from replenishment station 3 and replenishment station 2 downstream. Since replenishment station 3 is the last replenishment station, and the subsequent position is downstream, only virtual station 3 currently has a transportation task. Return to step B4. Virtual station 2 has no preceding replenishment task or transportation task, but it is determined that the target replenishment channel number of virtual station 2 is different from that of replenishment task 3, so replenishment task 3 is passed to virtual station 3. At this time, virtual station 3 has no preceding replenishment task, but has a transportation task, so continue triggering step D, transporting the cigarettes from replenishment station 3 downstream, and clearing the transportation task of virtual station 3.

[0104] Only then can step C be triggered via step B6, by ejecting the cigarette packs from physical station 3 and merging them at replenishment station 3, generating a transport task for replenishment station 3, and clearing the replenishment task for virtual station 3. Finally, cigarette packs of brands b, a, and c are output in the order of logistics transport direction. Then, steps E and A3 are triggered. For step A3, since replenishment task 3 is the last replenishment task, step A is exited. For step E, since the cigarette packs in the current replenishment task list have been merged in sequence and there are no new replenishment task lists, when the downstream is idle, all cigarette packs on the current main conveyor channel are transported downstream in the logistics direction, then all transport tasks of virtual stations are cleared, and step E is exited.

[0105] As can be seen from the above method, this invention, through the control and joint judgment of replenishment and transportation tasks, can, on the one hand, continue to allocate replenishment tasks while waiting for replenishment, thus improving task allocation efficiency; on the other hand, the preceding transportation tasks can also be processed in a timely manner, ensuring that multiple cases of cigarettes that have been merged are transported downstream in a timely manner, guaranteeing the efficiency of merged transportation. Furthermore, the continuous replenishment method provided by this invention, through strict control of the replenishment sequence, also ensures the accuracy of the replenishment sequence while improving merging efficiency.

[0106] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A method for continuous replenishment of cigarettes, characterized in that, This invention is applied to a cigarette replenishment system. The cigarette replenishment system includes a main conveyor channel, several replenishment channels located to the side of the main conveyor channel, and a control mechanism. The main conveyor channel also has several first conveying mechanisms corresponding to each replenishment channel. The invention includes the following steps: Step S1: Along the logistics transportation direction of the main conveyor channel, number each replenishment channel sequentially from 1 to X; set up a physical station at the exit of each replenishment channel with the same replenishment channel number; then, set up a virtual station corresponding one-to-one with the physical station number; then, set up several replenishment workstations on the main conveyor channel corresponding one-to-one with the physical station, and monitor in real time whether there are cigarettes at each replenishment workstation. Step S2: When replenishment is needed, a replenishment task list is added according to the replenishment requirements. The replenishment task list includes replenishment tasks numbered 1 to N. Each replenishment task records the task sequence number, brand verification code, target replenishment channel number, and target address. Step S3: Send each replenishment task to the virtual station in the order of the replenishment task list, triggering replenishment task allocation step A to allocate tasks; then, according to the virtual station task transfer step B, merging step C, workstation transportation step D and downstream transportation step E, merge multiple cigarette packs in the replenishment order in the replenishment task list on the main conveyor channel and output them downstream in the direction of logistics transportation. The specific steps of virtual platform task transfer step B are as follows: Step B1: Determine if there is a previous replenishment task for virtual station X; if there is no previous replenishment task, proceed to step B2; if there is a previous replenishment task, the replenishment task enters a waiting state; after the previous replenishment tasks for virtual station X are cleared, proceed to step B2. Step B2: Determine if there is a preceding transportation task for virtual station X; if there is, proceed to step B3; if not, proceed to step B4. Step B3: Trigger workstation transport step D. After workstation transport step D is completed, proceed to step B4. Step B4: Determine whether the target replenishment channel number recorded in replenishment task N is consistent with the target replenishment channel number of virtual station X; if the numbers are inconsistent, proceed to step B5; if the numbers are consistent, proceed to step B6. Step B5: Let X = X + 1, pass the replenishment task N to the virtual station X, and return to step B1; Step B6: Trigger the merging step C and exit the virtual platform task transfer step B.

2. The method for continuous replenishment of cigarettes according to claim 1, characterized in that, The specific steps A for assigning replenishment tasks are as follows: Step A1: Set the initial task sequence N=1 for the replenishment task, and the virtual station number X=1 to accept the task, then proceed to step A2; Step A2: Assign replenishment task N to virtual station X, and then trigger virtual station task transfer step B; Step A3: Determine whether the current replenishment task N is the last replenishment task in the current replenishment task list; if not, set N=N+1, X=1, and return to step A2; if yes, exit the replenishment task assignment step A.

3. The method for continuous replenishment of cigarettes according to claim 1, characterized in that, The merging step C specifically involves: Step C1: Determine whether a cigarette pack is placed at replenishment station X; if so, proceed to step C2; if not, proceed to step C3. Step C2: Trigger workstation transportation step D; after transportation step D is completed, return to step C1; Step C3: Determine whether there is a pack of cigarettes on the actual station X corresponding to the target replenishment channel number; if there is, proceed to step C5; if not, proceed to step C4. Step C4: Trigger step A3 and create a transportation task for replenishment station X; Then, after the actual station X is replenished, proceed to step C6; Step C5: Throw the cigarette packs from the physical station X and send them to the replenishment station X for merging; if the current replenishment station X has no transportation task, generate a transportation task for the replenishment station X and clear the replenishment task of the virtual station X; then, simultaneously trigger the downstream transportation steps E and A3, and exit the merging step C. Step C6: Discard the cigarette packs on the physical station X and send them to the replenishment station X for merging; if the current replenishment station X has no transportation task, generate a transportation task for the replenishment station X and clear the replenishment task of the virtual station X; then, only trigger the downstream transportation step E and exit the merging step C.

4. The method for continuous replenishment of cigarettes according to claim 3, characterized in that, The specific steps of the workstation transportation process D are as follows: Step D1: Check whether there are consecutive transportation tasks from virtual station X to the last virtual station in ascending order of numbering; if not, proceed to step D4; if so, record the replenishment station number Y where the task is interrupted, and proceed to step D2. Step D2: Determine whether cigarettes are placed at all replenishment stations Y-1 to X; if not, wait for cigarettes to be replenished at all replenishment stations Y-1 to X, and then proceed to step D3; if so, proceed directly to step D3. Step D3: In descending order of numbering, transport all cigarettes located between replenishment stations Y-1 and X to the next replenishment station; then, transfer the transport tasks from virtual station X to virtual station Y-1 to virtual station X+1 to virtual station Y; if replenishment station Y-1 is the last replenishment station, output the cigarettes at replenishment station Y-1 to the downstream and clear the transport task at virtual station Y-1; then, exit step D. Step D4: Transport the cigarette pack located at the current replenishment station to the next replenishment station; then, transfer the transportation task of virtual station X to virtual station X+1 corresponding to the next replenishment station; then, exit step D.

5. The method for continuous replenishment of cigarettes according to claim 3, characterized in that, It also includes downstream transportation step E, which specifically includes: Step E1: Determine the downstream output based on whether there is a new replenishment task list and the completion status of each current replenishment task list; if the cigarettes in the current replenishment task list have been merged in order and there is no new replenishment task list, proceed to step E2; if the cigarettes in the current replenishment task list have not been merged or there is a new replenishment task list, exit the downstream transportation step E directly. Step E2: When the downstream is idle, transport all cigarettes on the current main conveyor channel to the downstream in the order of logistics direction, then clear the conveying tasks of all virtual stations, and then exit the downstream transportation step E.

6. The method for continuous replenishment of cigarettes according to claim 3, characterized in that, The merging step C further includes the following steps: Step C401: When a cigarette is thrown from any station, the replenishment station corresponding to the main conveyor channel is monitored for timing. If the replenishment station does not receive the cigarette within 1.5 seconds, all tasks are suspended and an alarm is triggered.

7. The method for continuous replenishment of cigarettes according to claim 1, characterized in that, In step S2, the replenishment task names of each replenishment task list are specifically replenishment task 1, replenishment task 2, ..., replenishment task N; and the multiple replenishment task lists are sorted in ascending order of their creation time, with all replenishment tasks in the previous replenishment task list taking priority over replenishment tasks in the next replenishment task list.

8. The method for continuous replenishment of cigarettes according to claim 1, characterized in that, It also includes a target address allocation step, which specifically involves: when a cigarette is detected to be placed at the last replenishment station of the main conveyor channel, the transport direction of the cigarette after leaving the main conveyor channel is adjusted according to the target address recorded in the corresponding replenishment task.

9. A cigarette replenishment system, employing the continuous cigarette replenishment method as described in any one of claims 1-8, characterized in that: It includes a control mechanism, a main conveying channel, and several replenishment channels; the main conveying channel is equipped with several first transport mechanisms and a first monitoring mechanism; the first monitoring mechanism is used to monitor the placement of cigarettes on each first transport mechanism; the replenishment channels are equipped with second transport mechanisms and second monitoring mechanisms; the second monitoring mechanism is used to monitor the placement of cigarettes on the second transport mechanism; the several replenishment channels are arranged laterally relative to the main conveying channel; the control mechanism is electrically connected to several first transport mechanisms and several second transport mechanisms respectively.

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