Method for mixed stacking of various types of boxes

Abstract

The invention relates to the technical field of intelligent logistics, in particular to a mixed stacking method for various types of boxes. Comprising the following steps: analyzing order data; each kind of materials uses boxes with the same specification, order data are grouped according to columns, the height of each column does not exceed the upper limit of the stacking height, and the loose boxes which are not filled with the materials are placed at the top ends of the columns. According to the stacking method, the good stacking effect is achieved while the stacking rule of a client is met, the stacking efficiency can be remarkably improved, the requirement for rapid operation of modern logistics is met, meanwhile, mixed stacking of multiple materials and multiple box types is achieved by accurately planning the stacking strategy, the stacking space is utilized to the maximum extent by inserting seams in the remaining height of each column, and the stacking efficiency is improved. The storage space utilization rate is effectively increased, the stack type is optimized in a multi-column height mode, it is guaranteed as much as possible that the upper surface of the stack type is smooth, stepped stacking sequence output is achieved, it is guaranteed that the stacking process of the mechanical arm is not interfered, and meanwhile the stacking stability is improved.

Description

Technical Field

[0001] The present invention relates to the field of intelligent logistics technology, and in particular to a method for mixed palletizing of multiple types of boxes. Background Art

[0002] In the modern logistics industry, with the increasing demand for palletizing and unpalletizing in the logistics and warehousing industries, many special customized palletizing and unpalletizing projects have emerged. For example, the palletized materials are standard boxes, but there are many types. The length, width and height of the boxes are different. Multiple materials are mixed and palletized. Traditional palletizing methods rely heavily on manual operation. Workers need to rely on experience to judge the order and position of the boxes. However, it is difficult to obtain a good pallet shape through manual palletizing.

[0003] In the existing technology, palletizing projects usually need to comply with certain palletizing rules. Boxes cannot exceed the boundaries of the pallet. Materials of the same type must be stacked in the same or adjacent columns. Unfilled boxes (collectively referred to as odd-lot boxes) must be placed at the top of the same material column. Box labels must all face outward. There is an upper limit on the stacking height, etc. In addition, the boxes used on different project sites also comply with certain rules. They are usually classified according to length and width. Boxes can be divided into several levels, such as large boxes and small boxes. Two or more small boxes can be combined together to form the size of a large box. Therefore, two or more small boxes can be regarded as one large box during palletizing.

[0004] Existing automated palletizing equipment is often designed only for a single or limited number of box types and has poor adaptability to mixed palletizing of multiple types of boxes. When encountering a mix of large and small boxes of different sizes, it is impossible to accurately plan the palletizing strategy, resulting in an unreasonable number of palletizing layers and the number of boxes per layer. This not only wastes storage space but also increases the risk of instability during transportation.

[0005] In summary, developing an efficient and intelligent method for mixed palletizing of multiple types of boxes is still a key issue that needs to be urgently addressed in the field of intelligent logistics technology. Summary of the Invention

[0006] In view of the problems existing in the prior art, the object of the present invention is to provide a method for mixed palletizing of multiple types of boxes.

[0007] To achieve the above object, the present invention provides the following technical solutions:

[0008] A method for mixed palletizing of multiple types of boxes comprises the following steps:

[0009] S1. Analyze order data;

[0010] S2. Use boxes of the same specification for each type of material. Group the order data by column. The height of each column shall not exceed the upper limit of the stacking height, and place the fractional boxes with unfilled materials at the top of the column.

[0011] S3. Caulking combination: When the last column of each type of material does not reach the maximum allowable stacking height, combine the last columns of two types of materials and use a numerical optimization algorithm to output the best combination method.

[0012] S4. Full-pallet stacking: According to the data of the best combination method, insert gaps with the remaining materials to obtain the optimal volume ratio, that is, the remaining height of each column is minimized. Through the position adjustment between columns, make the columns of the same material adjacent.

[0013] S5. Half-pallet stacking: When the remaining materials are not enough to stack all the columns of the pallet, make the height of each column close by equalizing the height. Through the position adjustment between columns, make the columns of the same material adjacent.

[0014] S6. Calculate coordinate information: According to the label orientation information of each camera, calculate the angle with the label facing outwards.

[0015] S7. Output by layer: Stack the boxes with the robotic arm. The algorithm outputs the data of the stepped stacking order by layer to the robotic arm, making the column farthest from the robotic arm the highest and the column closest to the robotic arm the lowest.

[0016] The present invention is further configured as follows: In step S1, analyze the material information that determines the key factors of the stacking pattern in the order. The material information includes the length, width, height, weight of the box corresponding to each type of material, and whether there is a fractional box. After analyzing the order data, verify whether the information is compliant. After verification, classify the materials according to the material numbers.

[0017] The present invention is further configured as follows: In step S1, the information of the nth single-box material is represented by f(n), and the full-pallet material is represented by F(n). The specific formulas are as follows:

[0018] f(n) = a*(L + W + H) + b*w + c*M1

[0019]

[0020] In the formula: L is the length of the box, W is the width of the box, H is the height of the box, w is the weight of the box, and M1 represents the fractional box.

[0021] The present invention is further configured as follows: In step S2, if it is a large box, group it by column. If it is a small box, combine two or more small boxes into a large box and then group it by column.

[0022] The present invention is further configured such that: in step S2, when two small boxes can be combined into a large box and a pallet can stack up to eight columns at most, if the total number of small boxes is odd, there will be one small box remaining after combination. The remaining small box, i.e., the odd box, is placed at the top of the same material column.

[0023] The present invention is further configured such that: in step S3, after combining the last columns of the two materials, it is necessary to sort the data, and the material with the largest number of columns is preferably stacked first. According to the number of columns of the material and the number of columns that the pallet can allow to stack, it is determined whether the materials of the current order can be stacked on a full pallet.

[0024] The present invention is further configured such that: in step S6, taking the upper left corner as the 0 point, calculate the x, y, and z coordinate values of the center point of the upper surface of each box in each column. The specific calculation formula is as follows:

[0025]

[0026] The present invention is further configured such that: when the width W of the box is parallel to the x-axis of the pallet, the value of a is 1 and the value of b is 0; when the length L of the box is parallel to the x-axis of the pallet, the value of a is 0 and the value of b is 1; when two small boxes are placed side by side, the value of c of the second small box is 0 and is not included in the accumulation of the z value.

[0027] Advantageous Effects

[0028] Adopting the technical solution provided by the present invention, compared with the known public technology, it has the following

[0029] Advantageous Effects:

[0030] (1) In the present invention, through the palletizing method of the present invention, while meeting the customer's palletizing rules, a good palletizing effect can be obtained, which can significantly improve the palletizing efficiency, meet the requirements of modern logistics for rapid operation. At the same time, through full-pallet stacking, half-pallet stacking, and the layer-by-layer stepped palletizing sequence data output by the algorithm to the robotic arm, the palletizing strategy is accurately planned, realizing mixed stacking of multiple materials and multiple box types. By inserting gaps at the remaining height of each column, the palletizing space is maximally utilized, and the multi-column equal height optimizes the stack shape, ensuring that the upper surface of the stack shape is as flat as possible. At the same time, the algorithm outputs data in a layer-by-layer stepped palletizing sequence, ensuring that the robotic arm is not interfered during the palletizing process, and making the number of palletizing layers and the number of boxes in each layer more reasonable when multiple types of boxes are mixedly arranged, improving the palletizing stability, reducing the risk of collapse during handling, reducing cargo damage, and ensuring the safety of logistics transportation.

[0031] (2) In the present invention, through the palletizing method of the present invention, the utilization rate of the storage space is effectively improved. Through precise dimension adaptation calculation and palletizing scheme optimization, the storage space can be fully utilized, saving storage costs for enterprises. Brief Description of the Drawings

[0032] Figure 1 Dimension diagrams of large and small boxes for a method of mixed palletizing of multiple types of boxes

[0033] Figure 2 Schematic diagram of stacking 8 columns on one pallet for a method of mixed palletizing of multiple types of boxes

[0034] Figure 3 Flowchart of step one for a method of mixed palletizing of multiple types of boxes

[0035] Figure 4 Schematic diagram of the placement of odd-numbered boxes in step two of a method of mixed palletizing of multiple types of boxes

[0036] Figure 5 Schematic diagram of the combination result of two materials in step three of a method of mixed palletizing of multiple types of boxes

[0037] Figure 6 Schematic diagram of the exchange between columns in step four of a method of mixed palletizing of multiple types of boxes

[0038] Figure 7 Schematic diagram of the equal-height effect in step five of a method of mixed palletizing of multiple types of boxes

[0039] Figure 8 Schematic diagram of calculating coordinate values in step six of a method of mixed palletizing of multiple types of boxes

[0040] Figure 9 Schematic diagram of the palletizing process of the robotic arm for a method of mixed palletizing of multiple types of boxes

[0041] Figure 10 Overall flowchart of a method of mixed palletizing of multiple types of boxes Detailed implementation manner

[0042] To make the objectives, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the scope of protection of the present invention.

[0043] The present invention will be further described below in conjunction with the embodiments.

[0044] In this embodiment, as Figure 1 shown, taking the combination of two small boxes into the size of a large box as an example, according to the size of the large box, it is possible to calculate the maximum number of columns that can be stacked on one pallet. As Figure 2 shown, calculated according to the maximum stacking of 8 columns on one pallet, please refer toFigures 1 - 10 As shown in the figure, a method for mixed palletizing of multiple types of boxes includes the following steps:

[0045] Step 1: Analyze the order data. By analyzing the material information that is the key factor determining the palletizing pattern in the order, the material information includes the length, width, height, weight of the box corresponding to each material, and whether there is a fractional box. After analyzing the order data, verify whether the information is compliant. There may be cases where there are problems with the order information itself. For example, if the box specifications used for the same material are the same, and if boxes of other specifications appear, it means there is a problem with the order information. As Figure 3 shown, after verification, classify the materials according to the material numbers.

[0046] Among them, the information of the nth single-box material is represented by f(n), and the full-pallet material is represented by F(n). The specific formula is as follows:

[0047] f(n) = a*(L + W + H) + b*w + c*M1

[0048]

[0049] In the formula: L is the length of the box (len), W is the width of the box (width), H is the height of the box (height), w is the weight of the box (weight), and M1 represents the fractional box.

[0050] Step 2: In Step 1, the data has been grouped by material numbers. Each material uses boxes with the same specifications. Group the order data by column. The height of each column shall not exceed the upper limit of the palletizing height, and place the fractional boxes that are not full of materials at the top of the column.

[0051] Among them, if it is a large box, group it by column. If it is a small box, combine two or more small boxes into a large box and then group it by column. As Figure 4 shown, when two small boxes can be combined into a large box and a maximum of 8 columns can be palletized on one pallet, if the total number of small boxes is odd, there will be one small box remaining after combination. This remaining small box is collectively called an odd box. Each material has at most one odd box. If an odd box appears, place the remaining odd box at the top of the column of the same material.

[0052] Step 3: Caulking combination: After grouping by column in Step 2, the last column of each material may not reach the maximum allowable stacking height. When the last column of each material does not reach the maximum allowable stacking height, combine the last columns of two materials and use a numerical optimization algorithm to output the best combination method to maximize the use of the remaining space. As Figure 5As shown, the column pointed to by the square brackets is the combined result of two materials. After combination, considering that the quantity of some materials is large and a single type of material may be able to fill an entire pallet, after combining the last column of the two materials, it is necessary to sort the data and prioritize placing the material with the largest number of columns. According to the number of columns of the material and the number of columns that the pallet can allow (8 columns), determine whether the materials in the current order can be palletized into full pallets.

[0053] Step 4, Full-pallet stacking: From the data output in Step 3, take out the eight-column material data. According to the best combination data, insert the remaining materials into the gaps to obtain the optimal volume ratio, that is, the remaining height of each column is the smallest. By swapping the positions between columns, make the columns of the same material adjacent, as Figure 6 shown. It is necessary to swap the positions of columns 2 and 3, and columns 6 and 7.

[0054] Step 5, Half-pallet stacking: When the remaining materials are not enough to fill all the columns of the pallet, make the height of each column close by equalizing the height. The equalizing effect is as Figure 7 shown, to prevent the situation where a certain column is too high, and make the height of each column as close as possible. By swapping the positions between columns, make the columns of the same material adjacent, as Figure 6 shown. It is necessary to swap the positions of columns 2 and 3, and columns 6 and 7.

[0055] Step 6, Calculate coordinate information: Before this step, the data of materials with less than or equal to eight columns has been obtained. According to the label orientation information of each camera, calculate the angle of the label facing outwards, as Figure 8 shown in the numbering. Regarding the upper left corner as the 0 point, calculate the x, y, and z coordinate values of the center point on the upper surface of each box in each column. The specific calculation formula is as follows:

[0056]

[0057] Among them, when the width W of the box is parallel to the x-axis of the pallet, the value of a is 1 and the value of b is 0; when the length L of the box is parallel to the x-axis of the pallet, the value of a is 0 and the value of b is 1; when two small boxes are placed side by side, the value of c of the second small box is 0 and is not included in the accumulation of the z value.

[0058] Step 7, Output by layer: During the process of the robotic arm stacking boxes, as Figure 8 shown, it is necessary to ensure that the column farthest from the robotic arm is the highest, that is, the height of column 1 should always be higher than that of column 3, and the height of column 4 should always be higher than that of column 6. If the situation occurs where the height of column 3 is higher than that of column 1, then when placing boxes on column 1, there will be interference with column 3; therefore, the data of the stepped stacking order by layer output by the algorithm to the robotic arm is as Figure 9 shown, from Figure 8 (a) to Figure 8 (b), and then toFigure 8 (c), and finally Figure 8 (d) The palletizing process is completed, with the column farthest from the robot arm being the highest and the column close to the robot arm being the lowest. At this point, the palletizing step is completed.

[0059] In the present invention, when stacking multiple types of boxes together, the material information contained in the order, which is a key factor in determining the stacking type, is first parsed. After parsing the order data, the information is verified to be compliant. After verification, the materials are classified according to the material numbers. Boxes of the same specifications are used for each material, and the order data are grouped by columns. The height of each column must not exceed the upper limit of the stacking height, and the leftover boxes that are not fully filled with materials are placed at the top of the column. When the last column of each material does not reach the maximum allowable stacking height, the last columns of the two materials are combined, and a numerical optimization algorithm is used to output the best combination method to maximize the use of the remaining space. Based on the best combination method data, the remaining materials are inserted to obtain the optimal volume ratio, that is, the remaining height of each column is minimized, and the columns of the same material are placed adjacently by swapping the positions of the columns.

[0060] When the remaining material is insufficient to stack all the columns of a pallet, the height of each column is equalized to prevent any one column from being too high. The columns are kept as close as possible and the positions of the columns are swapped to make the columns of the same material adjacent. The outward angle of the label is calculated based on the label orientation information of each camera. The mixed code algorithm outputs the layered stepped stacking sequence data to the robot arm, making the column farthest from the robot arm the highest and the column close to the robot arm the lowest. At this point, the stacking process is completed.

[0061] The palletizing method of the present invention can achieve a good palletizing effect while meeting the customer's palletizing rules, significantly improving the palletizing efficiency. Through information collection and intelligent solution planning, the palletizing efficiency can be increased several times compared with manual palletizing, meeting the needs of fast operations in modern logistics. At the same time, through full pallet stacking, half pallet stacking, and layer-by-layer ladder-type palletizing sequence data output by the algorithm to the robot arm, based on scientific large box / small box distribution and adaptation planning, the number of palletizing layers and the number of boxes per layer when multiple types of boxes are mixed are more reasonable, making the palletizing structure more stable, improving the palletizing stability, reducing the risk of collapse during transportation, reducing cargo damage, and ensuring logistics and transportation safety. It effectively improves the utilization rate of storage space. Through accurate size adaptation calculation and palletizing solution optimization, the storage space can be fully utilized, saving storage costs for enterprises.

[0062] Through the palletizing method of the present invention, the palletizing strategy can be accurately planned to achieve mixed palletizing of multiple materials and multiple box types. The optimization points include inserting gaps at the remaining height of each column to maximize the utilization of the palletizing space, optimizing the pallet shape with equal height for multiple columns, ensuring as flat a top surface of the pallet shape as possible, and at the same time, the algorithm outputs data in a layer-by-layer stepped palletizing order, making the columns farther from the robotic arm the highest and the columns closer to the robotic arm the lowest, ensuring that the robotic arm is not interfered during the palletizing process.

[0063] The above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions recorded in the foregoing embodiments or perform equivalent replacements for some of the technical features; and these modifications or replacements will not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for mixed palletizing of multiple types of boxes, characterized in that, It includes the following steps: S1. Analyze the order data; S2. Use boxes with the same specifications for each material. Group the order data by column, and the height of each column shall not exceed the upper limit of the stacking height. Place the fractional boxes that are not full of materials at the top of the column; S3. Caulking combination: When the last column of each material does not reach the maximum allowable stacking height, combine the last columns of two materials and use a numerical optimization algorithm to output the best combination method; S4. Full pallet stacking: According to the data of the best combination method, insert gaps with the remaining materials to obtain the optimal volume ratio, that is, the remaining height of each column is the smallest. Through the position adjustment between columns, make the columns of the same material adjacent; S5. Half pallet stacking: When the remaining materials are not enough to stack all the columns of the pallet, make the height of each column close by equalizing the height. Through the position adjustment between columns, make the columns of the same material adjacent; S6. Calculate the coordinate information: According to the label orientation information of each camera, calculate the angle with the label facing outwards; S7. Output by layer: Stack the boxes with the robotic arm. The algorithm outputs the layer-by-layer stepped stacking order data given to the robotic arm, making the columns farthest from the robotic arm the highest and the columns closest to the robotic arm the lowest.

2. The method for mixed palletizing of various types of boxes according to claim 1, characterized in that In step S1, analyze the material information that is a key factor determining the stacking pattern in the order. The material information includes the length, width, height, weight of the box corresponding to each material, and whether there is a fractional box. After analyzing the order data, verify whether the information is compliant. After verification, classify the materials according to the material numbers.

3. The method for mixed palletizing of multiple types of boxes according to claim 1, characterized in that In step S1, the information of the nth single-box material is represented by f(n), and the full-pallet material is represented by F(n). The specific formula is as follows: f(n) = a*(L + W + H) + b*w + c*M1 In the formula: L is the length of the box, W is the width of the box, H is the height of the box, w is the weight of the box, and M1 represents the fractional box.

4. The method for mixed palletizing of multiple types of boxes according to claim 1, characterized in that, In step S2, if it is a large box, group it by column. If it is a small box, combine two or more small boxes into a large box and then group it by column.

5. The method for mixed palletizing of various types of boxes according to claim 1, characterized in that, In step S2, when two small boxes can be combined into a large box and a maximum of eight columns can be stacked on one pallet, if the total number of small boxes is odd, there will be one remaining small box after combination. Place the remaining small box, that is, the odd box, at the top of the column of the same material.

6. The method for mixed palletizing of various types of boxes according to claim 1, characterized in that, In step S3, after combining the last columns of two materials, it is necessary to sort the data. Prioritize stacking the material with the largest number of columns. According to the number of columns of the material and the number of columns that can be stacked on the pallet, determine whether the materials in the current order can be stacked into a full pallet.

7. The method for mixed palletizing of various types of boxes according to claim 1, characterized in that In step S6, regard the upper left corner as the 0 point and calculate the x, y, and z coordinate values of the center point on the upper surface of each box in each column. The specific calculation formula is as follows:

8. The method for mixed palletizing of multiple types of boxes according to claim 7, characterized in that, When the width W of the box is parallel to the x-axis of the pallet, the value of a is 1 and the value of b is 0; when the length L of the box is parallel to the x-axis of the pallet, the value of a is 0 and the value of b is 1; when two small boxes are placed side by side, the value of c of the second small box is v, and it is not included in the accumulation of the z value.

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