Goods shelf temporary storage space structure and automatic warehousing system and method

Abstract

The invention relates to the technical field of intelligent warehousing, and discloses a goods shelf temporary storage space structure and an automatic warehousing system and method.The goods shelf temporary storage space structure comprises a material box goods shelf area used for storing preset standard material boxes; the workbin-goods shelf mixing area is used for storing workbins borne by goods shelves; the non-standard goods shelf storage area is used for storing SKUs with irregular sizes; when the material box shelf area is of an immovable integrated structure, the arrangement sequence of the mixing area and the non-standard shelf storage area is dynamically adjusted according to the real-time commodity popularity; when the material box goods shelf area is a movable interactive goods shelf, the arrangement sequence of the three storage areas is dynamic according to the real-time commodity popularity, so that the high-frequency storage and taking goods shelf is close to a manual operation area, the storage space utilization rate is increased, and it is ensured that the storage operation process keeps efficient operation; a dispatching control system of the automatic warehousing system is combined to control various carrying robots, and automatic warehousing business operation is achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of intelligent warehousing, and particularly relates to a shelf temporary storage space structure, an automated warehousing system and a method. Background Art

[0002] In recent years, the logistics industry has developed rapidly, and the in-depth application of automation technology has become the core driving force for the industry to improve quality and efficiency. The automated warehousing solution with bins as the carrier has quickly popularized in warehousing scenarios due to its high cost performance advantage, significantly improving the storage efficiency and management accuracy of standard parts goods. However, most traditional shelves have a fixed layout and are not designed with differential partitions for standard bins, mixed-load bins and goods with irregular sizes. This results in oversized goods being difficult to fit into standard bin shelves, or forced storage causing space waste, and the three-dimensional space of the warehouse cannot be fully utilized. Especially in scenarios with diverse SKUs, the utilization rate of warehousing space is relatively low.

[0003] At the same time, the existing shelf layout is difficult to optimize the shelf position in real time according to demand changes, often relying on manual handling or temporary storage areas for processing, and automated operations cannot be achieved. The linkage between the shelf structure and automated equipment is insufficient, making it difficult to support the efficient access of non-standard goods, resulting in low overall operation efficiency and increased labor costs. Summary of the Invention

[0004] In view of this, the present invention provides a shelf temporary storage space structure, an automated warehousing system and a method, which can realize the automated operation of warehousing services for goods of multiple sizes, improve the warehousing utilization rate and operation efficiency, and reduce the operation cost.

[0005] In the first aspect, the present invention provides a shelf temporary storage space structure, including:

[0006] A bin shelf area, configured as an immovable integrated structure or a movable interactive shelf for storing preset standard bins;

[0007] A bin-shelf mixed area, configured as a movable interactive shelf for storing bins carried by the shelf;

[0008] A non-standard shelf storage area, configured as a movable interactive multi-layer shelf for storing SKUs with irregular sizes;

[0009] When the bin shelf area is an immovable integrated structure, the shelf arrangement order of the bin-shelf mixed area and the non-standard shelf storage area is dynamically adjusted according to the real-time commodity popularity, so that the high-frequency access shelves are close to the manual operation area;

[0010] When the bin rack area is a movable interactive rack, the rack arrangement order of the bin rack area, the bin-rack mixed area, and the non-standard rack storage area is dynamically adjusted according to the real-time commodity popularity, so that the high-frequency access racks are close to the manual operation area.

[0011] In the embodiment of the present invention, by dividing the bin rack area, the bin-rack mixed area, and the non-standard rack storage area, an adapted storage method is adopted for different specifications of commodities. The standardized storage in the bin rack area is combined with the flexible loading of irregular commodities in the non-standard rack storage area, avoiding space waste caused by the limitation of unified storage specifications, improving the utilization rate of the warehouse space, the design of the movable interactive rack, and the dynamic adjustment of the rack layout according to the commodity popularity, enabling the warehousing system to quickly respond to changes in business requirements. When the commodity popularity fluctuates, the rack layout can be adjusted in a timely manner to ensure that the operation process always remains efficient, avoiding inefficiencies caused by the inability of a fixed layout to adapt to demand changes. By optimizing the rack layout and storage method, the automated equipment and rack resources are more fully utilized, reducing equipment idle time and resource waste, and lowering the operating cost.

[0012] In an optional embodiment, the bin rack area includes fixed preset standard bin racks arranged vertically;

[0013] The bin-rack mixed area includes modular rack units that can move horizontally, and each unit carries a plurality of preset standard bins;

[0014] The non-standard rack storage area is configured with a detachable multi-layer rack assembly, the rack layer height is adjustable and the single-layer load-bearing is less than a preset threshold.

[0015] In the embodiment of the present invention, the bin rack area adopts fixed preset standard bin racks arranged vertically, which can maximize the use of vertical space, form a high-density storage array, is suitable for the stable storage of a large number of bins of the same specification, reduces space waste caused by non-uniform specifications, and improves the utilization rate of the warehousing space; the modular rack units in the bin-rack mixed area can move horizontally and can flexibly adjust the storage area layout when needed, realizing the dynamic expansion or contraction of the storage capacity, effectively coping with changes in the cargo storage volume in different periods, and avoiding the problems of idleness or insufficiency of fixed racks when the space demand fluctuates; the detachable multi-layer rack assembly in the non-standard rack storage area has an adjustable layer height and limited load-bearing, which can not only meet the personalized needs of irregular-sized goods for space height, but also avoid rack damage caused by overloading through reasonable load-bearing planning, realizing the precise storage of non-standard goods and making full use of the remaining space in the warehouse. The rack structure with clear zoning and flexible functions can meet the storage requirements and improve the warehousing utilization rate.

[0016] In an alternative embodiment, a connection and separation device is provided between the modular shelf units in the bin-shelf hybrid area. When the shelf layout needs to be adjusted, the combination or disassembly of the shelf units can be automatically achieved within a short time.

[0017] For the temporarily increased storage requirements of special categories in the embodiments of the present invention, the shelf units can be flexibly disassembled or combined to quickly construct an exclusive storage area without large-scale replacement of shelves or infrastructure renovation. Only by the combination and disassembly of the shelf units can the new requirements be met, significantly reducing the cost of upgrading the warehousing system.

[0018] In a second aspect, the present invention provides an automated warehousing system, including: the shelf temporary storage space structure according to any one of the embodiments of the first aspect, handling robots, and a scheduling control system; wherein:

[0019] The handling robots include: a first robot, a second robot, and a third robot;

[0020] The scheduling control system configures the bin-shelf area to be independently accessed and retrieved by the first robot and transported to the manual operation area by the second robot, the bin-shelf hybrid area to be jointly operated by the second robot and the third robot, and the non-standard shelf storage area to be independently transported by the third robot for the entire shelf.

[0021] According to the operation characteristics and requirements of different areas, the present invention configures different types of robots for targeted operations, giving full play to the advantages of each robot, avoiding task confusion and conflicts, enabling each robot to work efficiently in its proficient field, and improving the operation efficiency.

[0022] In a third aspect, the present invention provides an automated warehousing method based on the scheduling control system of the system described in the second aspect, including:

[0023] Respond to the warehousing request and determine whether the SKU size in the warehousing request order is suitable for storage in a preset standard bin;

[0024] When the SKU size in the order is suitable for storage in a preset standard bin, send an instruction to control the first robot to retrieve the required turnover box from the bin-shelf area, and then control the second robot to transport it to the manual operation area along the optimal path. After the manual puts the SKU into the turnover box and gives feedback of completion, send an instruction to control the second robot to transport the turnover box back to the buffer rack along the optimal path, and the first robot puts the turnover box back into the bin-shelf area;

[0025] When the SKU size in the order is not suitable for storage in a preset standard bin, send an instruction to control the third robot to transport multiple-layer shelves to the manual operation area according to a preset path. After the manual puts the SKU into the shelf and gives feedback of completion, send an instruction to control the third robot to place the shelf at a designated position below the bin-shelf area.

[0026] In the embodiments of the present invention, by judging the SKU size to determine the storage and handling methods, it can flexibly cope with goods of different specifications. For SKUs suitable for standard bins, the bin turnover method is adopted; for those not suitable, multi-layer shelf handling is used, enabling the warehousing system to accommodate various types of goods, improving the versatility and adaptability of the system. The goods suitable for standard bins are stored in the bin shelf area, and the unsuitable goods are stored in the non-standard shelf storage area (the multi-layer shelves placed at the designated position below the bin shelf area also reflects the reasonable planning of space). This zoning storage method can make full use of the warehousing space according to the characteristics of the goods, avoid space waste caused by a unified storage method, and improve the utilization rate of the warehousing space; for different types of goods, the tasks of the first robot, the second robot, and the third robot are reasonably allocated, enabling each device to give full play to its functions and advantages and improving the operation efficiency.

[0027] In an alternative embodiment, when any area executes the bin handling task, the moving permission of the shelves in the adjacent area is automatically locked to ensure that at most two types of robots operate in the same area.

[0028] By locking the moving permission of the shelves in the adjacent area, the present invention avoids the risk of path conflicts or collisions caused by multi-robot simultaneous operation. The scheduling system dynamically allocates resources according to the task urgency and device status, avoids interference between tasks in different areas, improves the overall operation fluency, meets the actual automation requirements, and improves the efficiency of the overall warehousing operation.

[0029] In an alternative embodiment, the method further includes: when controlling the first robot to take out the turnover box, according to the real-time storage status of the bin shelf area, preferentially select a storage position that is closer to the buffer shelf and has a sufficient number of turnover boxes.

[0030] The embodiments of the present invention preferentially select the turnover box storage positions close to the buffer shelf, greatly shortening the box-taking path of the first robot and the transportation path of the second robot, reducing the device operation time, and accelerating the goods turnover speed. Especially in the scenario of high-frequency inbound, the overall operation efficiency can be significantly improved; preferentially select the storage positions with sufficient turnover boxes, avoid temporary replenishment or path adjustment caused by the exhaustion of turnover boxes in a certain area, maintain the balance of resource use in each storage area, and improve the comprehensive utilization rate of warehousing space and equipment resources.

[0031] In an alternative embodiment, the method further includes: when controlling the third robot to take out the shelf, according to the real-time storage status of the bin-shelf mixed area and the non-standard shelf storage area, preferentially select a shelf that is closer to the manual operation area and stores idle SKUs.

[0032] In the embodiments of the present invention, the shelves closer to the manual operation area are preferentially selected, which can significantly shorten the travel distance and handling time of the third robot. The third robot does not need to spend a lot of time on long-distance transportation and can deliver the shelves to the manual operation area faster, enabling the manual workers to process the SKUs in a timely manner, thereby accelerating the entire warehousing process and improving the operation efficiency of the warehouse. By selecting the shelves storing idle SKUs, these idle resources can be fully utilized, avoiding the situation where a large number of idle shelves in the warehouse occupy space. By storing the new SKUs on the idle shelves, the utilization rate of the shelves can be increased, the storage space of the warehouse can be optimized, and the storage capacity of the warehouse can be improved. Selecting the shelves according to the real-time storage status can prevent the third robot from concentrating on picking goods in certain specific areas, thus making the workload of the third robot more balanced.

[0033] In an alternative embodiment, the method further includes: when the turnover boxes of multiple SKUs required by an order are distributed in multiple storage areas, the turnover boxes are centrally placed on the shelves in the non-standard shelf storage area, the first robot is controlled to carry the turnover boxes to the non-standard shelf storage area, and then the third robot is controlled to carry the entire shelf to the manual operation area at one time.

[0034] In the embodiments of the present invention, the turnover boxes scattered in different areas are centralized in the non-standard shelf storage area, and then the third robot carries the entire shelf to the manual operation area at one time, avoiding the time loss of multiple round-trip transports.

[0035] In the embodiments of the present invention, the turnover boxes scattered in different areas are centralized in the non-standard shelf storage area, and then the third robot carries the entire shelf to the manual operation area at one time, avoiding the time loss of multiple round-trip transports, greatly improving the order processing speed. At the same time, the centralized processing of turnover boxes in multiple areas reduces the coordination difficulty of the scheduling control system for multiple devices and multiple paths. For complex orders containing multiple SKUs, this strategy can quickly integrate scattered resources and avoid order processing delays caused by resource dispersion. Whether it is daily orders or a large number of mixed orders during promotional periods, it can be processed efficiently, enhancing the adaptability of the warehouse to business fluctuations.

[0036] In an alternative embodiment, the method further includes: when it is detected that the first robot, the second robot or the third robot fails, an emergency plan is immediately activated, the operations in the relevant area are suspended, and standby equipment is automatically scheduled to replace the faulty equipment to continue to complete the task, while sending a fault message to the maintenance personnel.

[0037] When a device failure is detected in the embodiments of the present invention, an emergency plan is immediately activated, and standby devices are automatically scheduled to replace the faulty devices to continue to complete tasks, which can minimize the impact of device failures on warehouse operations, ensure that tasks such as order processing and goods handling can continue, avoid operation interruptions caused by device failures, and improve the operation efficiency of the warehouse; suspending operations in relevant areas can prevent the accumulation of goods around the faulty device, prevent excessive occupation of storage space due to long-term detention of goods, affect the normal inbound and outbound of other goods, and thus reduce the costs and risks of warehouse operations. By means of automatically pushing alarm fault information, the process of equipment maintenance is standardized, making the maintenance work more timely and orderly, which helps enterprises establish a perfect equipment maintenance management system and improve the overall equipment management level. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following will briefly introduce the drawings required for use in the description of the specific embodiments or the prior art. Obviously, the drawings in the following description are some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0039] Figure 1 is the layout diagram of the shelf temporary storage space structure according to the embodiments of the present invention;

[0040] Figure 2 is the schematic diagram of the automated warehousing system according to the embodiments of the present invention;

[0041] Figure 3 is the flow schematic diagram of the automated warehousing method according to the embodiments of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0042] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts fall within the scope of protection of the present invention.

[0043] To overcome the problems of traditional warehouse storage shelves with fixed layouts, lack of dynamic adjustment capabilities, resulting in low automation, poor operation efficiency, and high labor costs. The embodiments of the present invention provide a shelf temporary storage space structure, as Figure 1 shown in the shelf temporary storage space structure, including:

[0044] The bin rack area is configured as an immovable integrated structure or a movable interactive rack for storing preset standard bins; the bin-rack mixed area is configured as a movable interactive rack for storing bins carried by the rack; the non-standard rack storage area is configured as a movable interactive multi-layer rack for storing SKUs of irregular sizes. When the bin rack area is an immovable integrated structure, the rack arrangement order of the bin-rack mixed area and the non-standard rack storage area is dynamically adjusted according to the real-time commodity popularity, so that the high-frequency access racks are close to the manual operation area. When the bin rack area is a movable interactive rack, the rack arrangement order of the bin rack area, the bin-rack mixed area and the non-standard rack storage area is dynamically adjusted according to the real-time commodity popularity, so that the high-frequency access racks are close to the manual operation area.

[0045] Specifically, an SKU is the smallest unit for an enterprise to conduct inventory management and control. Different commodities can be accurately distinguished and managed through SKUs. In the embodiments of the present invention, the preset standard bin is a material storage container with unified specifications, dimensions, materials, load-bearing capacities, etc. preset according to business requirements and specifications, so as to facilitate unified storage and handling in logistics facilities such as racks and conveying equipment. Non-standard goods refer to goods that do not conform to unified specifications such as preset standard specifications, dimensions, shapes or weights, and cannot be stored through the turnover bins in the bin rack area.

[0046] In the embodiments of the present invention, by dividing the bin rack area, the bin-rack mixed area and the non-standard rack storage area, appropriate storage methods are adopted for different specifications of commodities. The standardized storage in the bin rack area is combined with the flexible loading of irregular commodities in the non-standard rack storage area, avoiding space waste caused by the limitation of unified storage specifications, and improving the utilization rate of the warehouse space. According to the commodity popularity, the rack arrangement order is dynamically adjusted, and the high-frequency access racks are close to the manual operation area, reducing the idle space between the racks, optimizing the layout of the storage space, and making more efficient use of the warehouse space.

[0047] In addition, by placing the high-frequency access racks close to the manual operation area, whether it is manual picking or automated equipment for accessing goods, the handling distance of the goods can be effectively shortened and the operation time can be reduced. For example, when manually picking high-frequency commodities, there is no need to make long-distance round trips in the warehouse, reducing the labor intensity and improving the picking efficiency; the automated equipment can also complete the tasks of accessing goods faster, improving the overall operation efficiency.

[0048] There are two configuration methods for the immovable integrated structure and the movable interactive shelves in the bin rack area. Combining with the movable interactive shelf configuration in the bin-rack mixed area and the non-standard rack storage area, it provides diversified storage solutions for different types of goods. The immovable integrated structure is suitable for stably storing a large number of standard bins, while the movable interactive shelves provide the possibility of flexibly adjusting the storage layout, meeting the storage needs of goods in different scenarios and improving the adaptability of the equipment to different types of goods. Through reasonable rack layout and dynamic adjustment strategies, it promotes the collaborative operation of automated equipment and manual operations. In the layout where the high-frequency access racks are close to the manual operation area, the automated equipment can quickly transport the goods to the appropriate position, and the manual workers can conveniently carry out subsequent operations, realizing the complementary advantages of automation and manual work and enhancing the overall efficiency of warehousing operations.

[0049] Furthermore, the bin rack area includes fixed preset standard bin racks arranged vertically. Through this arrangement, the vertical space can be maximally utilized to form a high-density storage array, which is suitable for the stable storage of a large number of bins of the same specification, reducing space waste caused by inconsistent specifications and improving the utilization rate of warehousing space.

[0050] The bin-rack mixed area includes modular rack units that can move horizontally, and each unit carries multiple preset standard bins. The modular rack units can move horizontally and can flexibly adjust the storage area layout when needed, realizing the dynamic expansion or contraction of storage capacity, effectively coping with the changes in the quantity of goods stored in different periods, and avoiding the problems of idleness or insufficiency of fixed racks when the space demand fluctuates.

[0051] In one embodiment, connection and separation devices are equipped between the modular rack units in the bin-rack mixed area. When the rack layout needs to be adjusted, the combination or disassembly of the rack units can be automatically achieved in a short time. For the temporary increased storage requirements of special categories, the rack units can be flexibly disassembled or combined to quickly build a dedicated storage area. For example, during an e-commerce promotion, some rack units can be combined into a temporary goods collection area and then disassembled and restored to the original state after the event, without the need to transform the overall warehousing structure. At the same time, the automatic connection and separation device can complete the layout adjustment without human intervention, avoiding human operation errors and equipment downtime, and ensuring the continuity of warehousing operations.

[0052] The non-standard rack storage area is configured with detachable multi-layer rack components. The height of each layer of the rack is adjustable and the single-layer load-bearing is less than a preset threshold (reasonably set according to the actual rack material and height). The height of the detachable multi-layer rack components is adjustable and the load-bearing is limited. It can not only meet the personalized space height requirements of irregular-sized goods but also avoid rack damage caused by overloading through reasonable load-bearing planning, realizing the precise storage of non-standard goods and making full use of the remaining space in the warehouse.

[0053] The standardized bin rack in the embodiments of the present invention can be highly adapted to automated warehousing equipment, ensuring the stable and efficient operation of the automated equipment. The design of modular rack units facilitates docking with various conveying equipment to achieve automated handling of goods. The load-bearing limit and flexible structure of the non-standard rack storage area can prevent damage to the rack caused by overweight or improper-sized goods, extend the service life of the rack, and reduce maintenance costs. This rack structure with clear zoning and flexible functions provides a good foundation for the future business expansion of the warehouse. As the business scope expands and the variety of commodities increases, there is no need to carry out large-scale transformation of the entire warehousing system. Instead, new storage requirements can be met by adjusting the layout of modular racks and changing the structure of non-standard racks, reducing the threshold and cost of business expansion.

[0054] The embodiments of the present invention also provide an automated warehousing system, as Figure 2 shown, including: the rack temporary storage space structure, handling robots, and scheduling control system in the above embodiments, where: the handling robots include: the first robot, the second robot, and the third robot; the scheduling control system configures that the bin rack area is independently accessed and stored by the first robot and transported to the manual operation area by the second robot, the bin-rack mixed area is jointly operated by the second robot and the third robot, and the non-standard rack storage area is independently transported by the third robot for the entire rack. When any area executes the bin handling task, the moving permission of the adjacent area's rack is automatically locked to ensure that at most two types of robots operate in the same area.

[0055] It should be noted that the first robot is mainly used for the rapid handling and storage of bins. It can accurately grasp the bins and quickly shuttle between the racks to place the bins in the designated positions, improving the handling efficiency of the bins. It is suitable for the bin rack area with high-density storage and can realize the automated inbound and outbound operations of bins. For example, it is a flying box robot; the second robot is mainly used for the flexible handling of different types and weights of materials. It can select appropriate grasping methods and handling paths according to the characteristics of the materials and is suitable for various shapes and sizes of goods, including small parts, packaged products, etc. It plays an important role in material transfer. For example, it is a small type of latent AGV (Automated Guided Vehicle); the third robot is mainly used for the handling and storage of pallet goods. It can lurk under the pallet, lift the pallet through an automatic lifting device, and then transport the pallet to the designated position to achieve the automated transfer of pallet goods. For example, it is a latent AGV.

[0056] In the embodiments of the present invention, dedicated robots are matched according to the characteristics of goods in different regions. The first robot uses the vertical space to quickly access and store standard goods in the bin-shelf area, and the first robot flexibly connects and transports them to the manual area; in the bin-shelf mixed area, the second robot and the third robot are combined. The former is responsible for fine picking, and the latter undertakes long-distance transportation; the non-standard shelf storage area is transported by the third robot as a whole shelf, avoiding frequent loading and unloading losses of irregular goods. This division of labor gives full play to the advantages of each device and improves the operation efficiency; by locking the moving permissions of the shelves in adjacent areas, the risk of path conflicts or collisions caused by multiple robots operating simultaneously is avoided. For example, when the third robot in the bin-shelf mixed area transports the shelf, the movement of the shelves in the surrounding areas is automatically paused to ensure unobstructed passages; the operation of two types of robots is restricted in the same area, simplifying the scheduling logic and reducing the control complexity.

[0057] In practice, the scheduling system can dynamically allocate resources according to the urgency of tasks and the status of devices. For example, during peak hours, the third robot is preferentially scheduled to process urgent orders in the non-standard shelf area, and at the same time, the first robot is coordinated to ensure the regular operation in the bin area, avoiding interference between tasks in different regions and improving the overall operation fluency. The embodiments of the present invention also provide an automated warehousing method, which is applied to the above scheduling control system, as Figure 3 shown, and includes the following steps:

[0058] S1. Respond to the warehousing request and determine whether the SKU size in the warehousing request order is suitable for storage in a preset standard bin;

[0059] S2. When the SKU size in the order is suitable for storage in a preset standard bin, send an instruction to control the first robot to take the required turnover box from the bin-shelf area, and then control the second robot to transport it to the manual operation area according to the optimal path. After the manual puts the SKU into the turnover box and gives feedback that it is completed, send an instruction to control the second robot to transport the turnover box back to the buffer rack according to the optimal path, and the first robot puts the turnover box back into the bin-shelf area;

[0060] S3. When the SKU size in the order is not suitable for storage in a preset standard bin, send an instruction to control the third robot to transport the multi-layer shelf to the manual operation area according to the preset path. After the manual puts the SKU into the shelf and gives feedback that it is completed, send an instruction to control the third robot to place the shelf at a specified position below the bin-shelf area.

[0061] In the embodiment of the present invention, during warehousing, it is first necessary to determine the SKU size in the order to determine which storage area to place it in. When it is determined that it is suitable to be stored in a preset standard bin, the first robot is triggered to pick up the bin, and the second robot is used for transportation, forming a closed-loop automated process of "bin picking - bin delivery - bin return". Workers only need to focus on the SKU packing operation, reducing time-consuming and laborious basic links such as searching for turnover bins and handling, and greatly improving the warehousing efficiency; by reasonably allocating equipment tasks, avoiding overuse of a single device, ensuring the load balance of each device, and improving the overall operation stability and reliability of the equipment; when it is determined that the SKU size in the order is large and suitable to be stored on the shelf, the third robot directly transports the multi-layer shelf to the manual operation area, avoiding the cumbersome processes of single-piece splitting, handling, and assembling of large-size SKUs, and is especially suitable for the rapid warehousing of a large batch of large-size goods. Through the preset handling path, the third robot can avoid complex routes and potential congestion areas in the warehouse, reducing ineffective movement and waiting time caused by chaotic path planning, ensuring the rapid and accurate delivery of the shelf to the operation area, and improving the overall warehousing efficiency.

[0062] In the embodiment of the present invention, the shelf loaded with large-size SKUs is placed below the bin shelf area, making full use of the idle area of the vertical space to achieve three-dimensional mixed storage of large and small goods. This layout avoids the space waste caused by separately opening a storage area for large-size goods, and improves the warehouse volume ratio. In addition, the storage position of the shelf is flexibly adjusted according to the real-time warehousing demand. For example, during the peak period, the storage volume of large-size goods below the bin shelf area can be increased, and the space in this area is released for other operations during the off-season, enhancing the dynamic adaptability of the storage space. The fixed "handling - shelving - returning to the warehouse" process is combined with the manual feedback mechanism to ensure that each operation is traceable, avoiding problems such as misplacement and omission of goods caused by random operation, and improving the accuracy and standardization of inventory management.

[0063] In one embodiment, when controlling the first robot to take out the turnover bin, according to the real-time storage status of the bin shelf area, a storage position that is closer to the buffer shelf and has a sufficient number of turnover bins is preferentially selected.

[0064] In the embodiment of the present invention, a turnover bin storage position close to the buffer shelf is preferentially selected, greatly shortening the bin picking path of the first robot and the transportation path of the second robot. For example, in a large three-dimensional warehouse, the single-bin picking and handling distance can be greatly reduced, the equipment operation time can be reduced, and the goods turnover speed can be accelerated. Especially in the scenario of high-frequency warehousing, the overall operation efficiency can be significantly improved. Combining the dynamic selection of the path according to the real-time storage status can avoid equipment congestion caused by the centralized use of a certain area. When the storage position in a certain area is busy, the system automatically switches to the sub-optimal path to ensure the continuous and efficient operation of the equipment and reduce the waiting time.

[0065] Meanwhile, prioritize storage locations with an adequate number of turnover boxes to avoid temporary replenishment or path adjustment due to the exhaustion of turnover boxes in a certain area, maintain the balance of resource utilization in each storage area, and improve the comprehensive utilization rate of warehousing space and equipment resources. Additionally, perform path planning based on the real-time storage status of the bin rack area to ensure a high degree of synchronization between system data and the actual inventory status. For example, update the storage location information by recording each box retrieval operation to provide accurate data support for subsequent inventory counts and replenishment plans, and improve the refinement level of inventory management.

[0066] In one embodiment, when controlling the third robot to retrieve the shelf, according to the real-time storage status of the bin-shelf mixed area and the non-standard shelf storage area, preferentially select the shelf that is closer to the manual operation area and stores idle SKUs.

[0067] In the embodiments of the present invention, preferentially selecting the shelf closer to the manual operation area can significantly shorten the travel distance and handling time of the third robot. The third robot does not need to spend a lot of time on long-distance transportation and can deliver the shelf to the manual operation area faster, enabling the manual worker to process the SKUs in a timely manner, thereby accelerating the entire inbound process and improving the operation efficiency of the warehouse. Selecting the shelf that stores idle SKUs can make full use of these idle resources and avoid the situation where a large number of idle shelves in the warehouse occupy space. By storing the new SKUs on these idle shelves, the utilization rate of the shelves can be increased, the storage space of the warehouse can be optimized, enabling the warehouse to accommodate more goods and improving the storage capacity of the warehouse.

[0068] In the embodiments of the present invention, by considering the storage status of the bin-shelf mixed area and the non-standard shelf storage area in real time, the scheduling control system can flexibly adjust the picking strategy according to the actual situation. When the storage layout of the warehouse changes or the business volume suddenly increases, the system can quickly adapt to these changes, preferentially select the appropriate shelf, ensure that the inbound process is not affected, and maintain the stability and high efficiency of the warehouse operation.

[0069] In one embodiment, when the turnover boxes of multiple SKUs required by an order are distributed in multiple storage areas, the scheduling control system centrally places the turnover boxes on the shelves in the non-standard shelf storage area, controls the first robot to transport the turnover boxes to the non-standard shelf storage area, and then controls the third robot to transport the shelf to the manual operation area at one time.

[0070] In the embodiment of the present invention, the turnover boxes scattered in different areas are centralized to the non-standard shelf storage area, and then the third robot transports the entire shelf to the manual operation area at one time, avoiding the time loss of multiple round-trip transports. For example, if an order requires turnover boxes in 5 scattered areas, the traditional method requires multiple transports, while this strategy can reduce the number of transports to 1 time, significantly improving the order processing speed. For complex orders containing multiple SKUs, this strategy can quickly integrate scattered resources and avoid order processing delays caused by resource dispersion. Whether it is daily orders or a large number of mixed orders during promotional periods, it can be efficiently processed, enhancing the warehouse's adaptability to business fluctuations. The non-standard shelf storage area serves as a temporary goods collection point, which can flexibly utilize the idle space to store turnover boxes, avoiding space waste caused by scattered storage and improving the warehouse space utilization rate. At the same time, the entire shelf transportation mode facilitates subsequent adjustment of the shelf layout according to needs, enhancing the flexibility of warehousing.

[0071] In one embodiment, when the scheduling control system detects a failure of the first robot, the second robot, or the third robot, it immediately activates the emergency plan, suspends the operations in the relevant area, and automatically schedules standby equipment to replace the faulty equipment to continue to complete the task. At the same time, it sends a failure message to the maintenance personnel.

[0072] In the embodiment of the present invention, when a device failure is detected, the system immediately activates the emergency plan and automatically schedules standby equipment to replace the faulty equipment to continue to complete the task, which can minimize the impact of device failures on warehouse operations, ensure the continuous progress of order processing, goods handling, etc., avoid operation interruptions caused by device failures, improve the operational efficiency of the warehouse, and prevent delays in customer order processing due to device failures, thus guaranteeing the service quality for customers.

[0073] By suspending the operations in the relevant area, it is possible to avoid the backlog of goods around the faulty equipment, prevent excessive occupation of warehouse space due to long-term detention of goods, and affect the normal inbound and outbound of other goods, thereby reducing the costs and risks of warehouse operations; by sending detailed failure messages to the maintenance personnel, the maintenance personnel can have a preliminary understanding of the failure before arriving at the scene, clarify the location of the faulty equipment and the possible causes of the failure, and thus can prepare repair tools and spare parts in advance, improve the repair efficiency, shorten the equipment repair time, make the maintenance work more timely and orderly, contribute to the enterprise's establishment of a perfect equipment maintenance management system, and enhance the overall equipment management level.

[0074] Although the embodiments of the present invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the present invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A temporary storage space structure for a shelf, characterized in that, Comprising: A bin rack area, configured as an immovable integrated structure or a movable interactive rack for storing preset standard bins; A bin-rack mixed area, configured as a movable interactive rack for storing bins carried by the rack; A non-standard rack storage area, configured as a movable interactive multi-layer rack for storing SKUs of irregular sizes; When the bin rack area is an immovable integrated structure, dynamically adjust the rack arrangement order of the bin-rack mixed area and the non-standard rack storage area according to the real-time product popularity, so that the high-frequency access rack is close to the manual operation area; When the bin rack area is a movable interactive rack, dynamically adjust the rack arrangement order of the bin rack area, the bin-rack mixed area and the non-standard rack storage area according to the real-time product popularity, so that the high-frequency access rack is close to the manual operation area.

2. The rack temporary storage space according to claim 1, wherein The bin rack area includes fixed preset standard bin racks arranged vertically; The bin-rack mixed area includes modular rack units that can move horizontally, and each unit carries multiple preset standard bins; The non-standard rack storage area is configured with detachable multi-layer rack components, the rack layer height is adjustable and the single-layer load-bearing is less than a preset threshold.

3. The shelving temporary storage space according to claim 1, wherein Connection and separation devices are provided between the modular rack units in the bin-rack mixed area. When the rack layout needs to be adjusted, the combination or splitting of the rack units can be automatically realized in a short time.

4. An automated warehousing system, characterized in that, Comprising: The rack temporary storage space structure, handling robot and scheduling control system according to any one of claims 1-3; wherein: The handling robot includes: a first robot, a second robot, and a third robot; The scheduling control system configures the bin rack area to be independently accessed by the first robot and transported to the manual operation area by the second robot, the bin-rack mixed area to be jointly operated by the second robot and the third robot, and the non-standard rack storage area to be independently transported by the third robot for the entire rack.

5. An automated warehousing method, based on the scheduling control system of the automated warehousing system described in claim 4, characterized in that, Comprising: Respond to the inbound request and judge whether the size of the SKU in the inbound request order is suitable for storage in the preset standard bin; When the size of the SKU in the order is suitable for storage in the preset standard bin, send an instruction to control the first robot to take the required turnover box from the bin rack area, and then control the second robot to transport it to the manual operation area according to the optimal path. After the manual puts the SKU into the turnover box and gives feedback to complete, send an instruction to control the second robot to transport the turnover box back to the buffer rack according to the optimal path, and the first robot puts the turnover box back into the bin rack area; When the size of the SKU in the order is not suitable for storage in the preset standard bin, send an instruction to control the third robot to transport the multi-layer rack to the manual operation area according to the preset path. After the manual puts the SKU into the rack and gives feedback to complete, send an instruction to control the third robot to place the rack at the specified position below the bin rack area.

6. The automated warehousing method according to claim 5, characterized in that, Further comprising: When any area executes the bin handling task, automatically lock the rack movement permission of the adjacent area to ensure that at most two robots operate in the same area.

7. The automated warehousing method according to claim 5, characterized in that, Further comprising: When controlling the first robot to pick up the turnover box, according to the real-time storage status of the bin rack area, preferentially select the storage location that is closer to the buffer rack and has a sufficient number of turnover boxes.

8. The automated warehousing method according to claim 5, wherein It also includes: When controlling the third robot to pick up the shelf, according to the real-time storage status of the bin-shelf mixed area and the non-standard shelf storage area, preferentially select the shelf that is closer to the manual operation area and stores idle SKUs.

9. The automated warehousing method according to claim 6, wherein It also includes: When the turnover boxes of multiple SKUs required by the order are distributed in multiple storage areas, concentrate the turnover boxes on the shelves in the non-standard shelf storage area, control the first robot to transport the turnover boxes to the non-standard shelf storage area, and then control the third robot to transport the shelf to the manual operation area at one time.

10. The automated warehousing method according to any one of claims 5-9, characterized in that, When it is detected that the first robot, the second robot or the third robot fails, immediately start the emergency plan, suspend the operations in the relevant area, automatically dispatch the standby equipment to replace the faulty equipment to continue to complete the task, and at the same time send the fault information to the maintenance personnel.

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