Column perpendicularity real-time monitoring system and method for stereoscopic warehouse management

Abstract

The invention relates to the technical field of intelligent warehouse management and logistics automation, in particular to a stand column perpendicularity real-time monitoring system and method for stereoscopic warehouse management, and the system comprises a light reflecting column, a high-precision laser scanner and a data processing unit. The light reflecting column is arranged at the top end of the goods shelf stand column, and the high-precision laser scanner capable of emitting laser is arranged on the ceiling of the stereoscopic warehouse, can continuously rotate by 360 degrees and can capture laser point cloud data reflected by the light reflecting column. The data processing unit can receive scanning data and calculate current position information of the goods shelf stand columns and the deviation degree of the goods shelf stand columns and the ideal vertical state. According to the invention, comprehensive and real-time monitoring of the verticality of the stand column can be realized, and safe and stable operation of a stereoscopic warehouse is ensured.

Description

Technical Field

[0001] The present invention relates to the field of intelligent warehouse management and logistics automation technology, and in particular to warehouse internal structure monitoring and optimization, automated detection and early warning systems. Background Art

[0002] With the booming development of the modern logistics industry, the importance of high-bay warehouses, as key facilities for efficiently utilizing storage space and optimizing cargo storage layout, has become increasingly prominent. However, the structural safety and stability of high-bay warehouses are directly related to the warehouse's operational efficiency and the safe storage of cargo, and have become a focus of industry attention. In the structural system of high-bay warehouses, shelf columns play a vital role. They are the core components that support the entire warehouse structure. The verticality of shelf columns is a key indicator of the overall stability and load-bearing capacity of the warehouse. Once a column tilts, it is very likely to cause a series of serious consequences. At the very least, it can cause the shelf structure to deform, squeezing the cargo storage space and affecting the normal storage and retrieval of goods; at worst, it can cause damage to the goods and even cause shelf collapse accidents, posing a threat to the safety of on-site personnel and causing huge financial losses to the company.

[0003] In traditional high-bay warehouse management, monitoring the verticality of shelf columns primarily relies on regular manual inspections and simple measuring tools. Workers manually use tools such as levels and tape measures to measure and inspect each shelf column individually. This approach has numerous drawbacks. First, manual inspections are relatively inefficient, making it difficult to complete a comprehensive inspection of the numerous shelf columns in a large high-bay warehouse in a short period of time. This results in long monitoring cycles and prevents timely detection of column tilt issues. Second, the manual measurement process is labor-intensive, requiring workers to climb shelves and carry measuring equipment, resulting in high labor intensity. Furthermore, manual measurement results are susceptible to subjective factors and environmental factors, such as differences in worker experience, hand stability during measurement, and lighting conditions. These factors can lead to deviations in measurement data, affecting the accuracy and reliability of the results. This makes it difficult for warehouse managers to accurately grasp the true condition of shelf columns and effectively prevent potential safety risks.

[0004] Therefore, developing a method that can achieve continuous, real-time, and non-contact monitoring of the verticality of the columns in a three-dimensional warehouse has become an important requirement for improving warehouse management and ensuring operational safety. Summary of the Invention

[0005] The purpose of the present invention is to provide a real-time monitoring system and method for the verticality of columns for high-definition warehouse management. By introducing high-precision laser scanning technology and advanced data processing algorithms, accurate monitoring and automatic early warning of the verticality of the columns in the high-definition warehouse can be achieved, providing strong guarantees for the safe and stable operation of the high-definition warehouse.

[0006] In order to achieve the above-mentioned purpose, the technical solution of the present invention provides a real-time monitoring system for the verticality of columns for high-definition warehouse management, including a reflective column, a high-precision laser scanner and a data processing unit; the reflective column is arranged at the top of the shelf column, and the high-precision laser scanner that can emit laser is arranged on the ceiling of the high-definition warehouse and can rotate 360 degrees continuously, and can capture the laser point cloud data reflected back by the reflective column; the data processing unit can receive the scanning data and calculate the current position information of the shelf column and the degree of deviation from the ideal vertical state.

[0007] Preferably, the high-precision laser scanner is equipped with a laser transmitter, a laser receiver and a data wireless transmission device.

[0008] Preferably, the high-precision laser scanner can transmit the acquired position information of the reflective column at the top of each shelf column to a remote cloud platform. The remote cloud platform accurately judges the inclination and deformation of each shelf column, generates a two-dimensional point map, and compares and analyzes the real-time collected data with the historical data, thereby judging whether there is inclination and deformation of the shelf column in the stereoscopic warehouse.

[0009] Preferably, the high-precision laser scanner is mounted on a pan-tilt platform at the end of a hanging column on the ceiling of the stereoscopic warehouse, which can rotate continuously 360 degrees.

[0010] Preferably, a plurality of the high-precision laser scanners are provided, each of which is responsible for detecting the shelf columns in its own area, and they work together to obtain the position information of the top ends of the shelf columns in the entire area.

[0011] The technical solution of the present invention also provides a real-time monitoring method for verticality of columns for stereoscopic warehouse management, comprising the following steps:

[0012] 1) Installing a reflective column with high reflectivity on the top of each shelf column;

[0013] 2) Using the high-precision laser scanner installed on the ceiling of the stereoscopic warehouse to perform 360-degree continuous scanning to accurately capture the laser point cloud data reflected back by the reflective column;

[0014] 3) The data processing unit receives the scanned data and calculates the current position information of the shelf column and the degree of deviation from the ideal vertical state by using an image processing algorithm;

[0015] 4) When it is detected that the shelf column deviates from the vertical position beyond a preset threshold range, an alarm is issued.

[0016] Preferably, the data wireless sending device can be externally connected to transmit the acquired position information of the reflective column at the top of each shelf column to the remote cloud platform through the industrial Internet. Based on the monitoring principle, the remote cloud platform accurately judges the inclination and deformation of each shelf column, generates a two-dimensional point map, and compares and analyzes the real-time collected data with the historical data, thereby judging whether there is any inclination and deformation of the shelf column in the stereoscopic warehouse.

[0017] Preferably, when there are multiple high-precision laser scanners, each of the high-precision laser scanners is responsible for detecting the shelf columns in its respective area, and they work together to obtain the position information of the top ends of the shelf columns in the entire area, and this information is obtained through the reflective column at the top end of each column.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] 1. This method uses high-precision laser scanning technology to achieve real-time monitoring of shelf tilt angles. Compared to traditional manual inspections and wired sensor monitoring, this method requires no human intervention and provides 24-hour, uninterrupted monitoring of shelf status, significantly improving monitoring efficiency. Wireless communication technologies, such as NB-IoT, enable wireless data transmission, eliminating the complexity and maintenance costs of cabling, reducing data transmission latency, and improving real-time monitoring.

[0020] 2. This method utilizes advanced high-precision laser scanning technology to achieve high-precision measurement of shelf tilt and deformation. Compared to traditional measurement tools such as pendulums, this method can more accurately reflect the tilt state of the shelf.

[0021] 3. By analyzing the collected tilt data, we can understand the changing trends of the shelf structure in real time and infer the cause of the tilt. At the same time, the monitoring system can also predict the stress response of different load capacities, providing a scientific basis for shelf safety assessment and management.

[0022] 4. When the shelf's tilt angle exceeds a preset threshold, the system immediately triggers an alarm, alerting management personnel to take emergency measures through various means, including audible and visual alarms and text message notifications. The entire monitoring process requires no human intervention, achieving automated monitoring. This not only reduces staff workload but also mitigates errors and risks caused by human error.

[0023] 5. This method can also be linked with other environmental monitoring sensors (such as temperature, humidity, and illumination) to achieve comprehensive monitoring of the warehouse environment. Furthermore, with the development of IoT technology, the system can also be integrated with cloud platforms to achieve higher-level data analysis and intelligent management. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a schematic diagram of the three-dimensional warehouse site.

[0025] Figure 2 This is a partial schematic diagram of the top of the three-dimensional warehouse shelf.

[0026] Figure 3 Schematic diagram of the laser scanner scanning the obscured area.

[0027] Figure 4 Schematic diagram for improving the layout of laser scanners in high-bay warehouses.

[0028] Figure 5 Schematic diagram for monitoring, processing and judging the tilt and deformation of columns.

[0029] Figure numerals: 1. High-precision laser scanner; 2. Stereoscopic warehouse ceiling; 3. Reflective column; 3-1. Reflective column one; 3-2. Reflective column two; 4. Shelf column. DETAILED DESCRIPTION

[0030] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0031] This invention provides a real-time monitoring system and method for column verticality in high-bay warehouse management. The system aims to improve the stability and safety of warehouse storage structures, effectively prevent shelf collapse risks, and ensure the normal operation of the warehouse and the stability of cargo storage. Compared to traditional manual inspection or simple sensor-based monitoring methods, this invention also enables continuous, real-time, and non-contact monitoring of column verticality, improving monitoring accuracy and efficiency.

[0032] The system consists of key components such as shelf columns 4, reflective columns 3, high-precision laser scanners 1, and data processing units. Specifically, a reflective column 3 with high reflectivity is installed on the top of each shelf column 4. Its unique design can evenly reflect laser signals from all directions. The high-precision laser scanner 1 installed on the ceiling 2 of the stereoscopic warehouse performs a 360-degree continuous scan to accurately capture the laser point cloud data reflected back by the reflective column 3. Subsequently, the data processing unit receives these scan data and, with the help of advanced image processing algorithms, accurately calculates the current position information of the shelf column 4 and the degree of deviation from the ideal vertical state. Once it is detected that the shelf column 4 deviates from the vertical position beyond the preset threshold range, the system will quickly issue an alarm to remind relevant personnel to take timely measures.

[0033] In the monitoring method of the present invention, the object to be detected is a cargo rack in an actual application scenario, and the deformation of the rack is mainly concentrated in the individual columns arranged in parallel. Assuming that the shelf columns 4 are arranged along the Z axis, deformation may cause the shelf columns 4 to tilt in the X and Y directions. The present invention determines whether the shelf columns 4 are deformed by monitoring the tilt at the top of each shelf column 4. Specifically, in a top-down plane, it determines whether the top point of each column has changed relative to its normal position, thereby reflecting the deformation status of the column.

[0034] like Figure 1 As shown, the high-precision laser scanner 1 is equipped with a laser transmitter, a laser receiver, and a wireless data transmitter, which can be connected externally. A reflective column 3 is installed on the top of each shelf column in the three-dimensional warehouse. A hanging column extends downward from the top of the warehouse. The end of the hanging column is equipped with a pan-tilt head that can rotate 360 degrees around the Z axis. The pan-tilt head is mounted on the high-precision laser scanner 1 to detect whether the reflective column 3 moves, as its movement directly reflects the movement of the shelf column 4. Sufficient rigidity should be ensured on the ceiling 2 of the three-dimensional warehouse or the fixed end of the high-precision laser scanner 1 to prevent detection deviations caused by the movement of the high-precision laser scanner 1 itself.

[0035] like Figure 5 The figure shows a top view of the top of a three-dimensional warehouse shelf, where the circle at the center of the coordinate represents the high-precision laser scanner 1, and the dotted line emanating from the center of the circle represents the laser pointer. The laser scanning is used to locate the position of each reflective column 3. By processing, analyzing, and comparing the position information of the two shelf columns 4, it is possible to determine whether the shelf columns 4 remain vertical. Specifically, the first scan marked is the position information of the shelf columns 4 obtained by the high-precision laser scanner 1 before, and the second scan is the position information of the shelf columns 4 obtained by the high-precision laser scanner 1 after. By processing, analyzing, and comparing the position information of the two shelf columns 4, it is possible to determine whether the shelf columns 4 are vertical.

[0036] However, in actual application, using only one high-precision laser scanner 1 may result in a scanning blind area. Figure 3 As shown, when the laser beam emitted by the high-precision laser scanner 1 is scanning, the reflective column 3 on the right may be blocked by the reflective column 3 on the left, resulting in the high-precision laser scanner 1 being unable to obtain the position information of the blocked reflective column 3. Specifically, the thin solid line emitted by the high-precision laser scanner 1 represents the laser beam scanning process. For example, the thin solid arrow and the thin dashed arrow on the right side of the high-precision laser scanner 1 represent two laser beams, which need to be emitted to the two reflective columns 3 respectively. However, the reflective column 2 3-2 on the right will be blocked by the reflective column 1 3-1 on the left, resulting in the high-precision laser scanner 1 being unable to obtain the position information of the blocked reflective column 2 3-2.

[0037] In order to solve this problem, a plurality of high-precision laser scanners 1 can be used to scan simultaneously. Each high-precision laser scanner 1 is responsible for detecting the shelf columns 4 in its own area, such as Figure 4 As shown in the figure, multiple high-precision laser scanners 1 work together to acquire the positional information of the tops of shelf columns 4 throughout the entire area. This information is obtained using reflective posts 3 attached to the top of each column and transmitted to a remote cloud platform via a wireless data transmission device. Based on monitoring principles, the remote cloud platform accurately determines the tilt and deformation of each shelf column 4. After acquiring the positional information of the reflective posts 3 at the top of each shelf column 4, the high-precision laser scanners 1 transmit the information to the remote cloud platform via the Industrial Internet. Upon receiving the data, the remote cloud platform generates a two-dimensional point map and compares and analyzes the real-time data with historical data to determine whether any tilt or deformation exists in the three-dimensional warehouse shelf columns 4. By installing high-precision laser scanners 1 on the ceiling 2 of the three-dimensional warehouse and reflective posts 3 at the top of each shelf column in the three-dimensional warehouse, the high-precision laser scanners 1 can transmit and receive laser light. The reflective posts 3 reflect the laser light back to the high-precision laser scanners 1, which then receive the reflected laser light to determine the position of each column top. This enables real-time monitoring of the verticality of the columns, effectively ensuring the safe operation of the three-dimensional warehouse.

[0038] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A real-time monitoring system for verticality of columns used in stereoscopic warehouse management, characterized in that: The invention comprises a reflective column (3), a high-precision laser scanner (1) and a data processing unit; the reflective column (3) is arranged at the top of a shelf column (4); the high-precision laser scanner (1) capable of emitting laser light is arranged on the ceiling (2) of a three-dimensional warehouse and can rotate continuously 360 degrees to capture the laser point cloud data reflected back by the reflective column (3); the data processing unit can receive the scanning data and calculate the current position information of the shelf column (4) and the degree of deviation from the ideal vertical state.

2. A real-time monitoring system for verticality of columns for high-bay warehouse management according to claim 1, characterized in that: The high-precision laser scanner (1) is equipped with a laser transmitter, a laser receiver and a data wireless transmitting device.

3. A real-time monitoring system for verticality of columns for high-bay warehouse management according to claim 2, characterized in that: The high-precision laser scanner (1) can transmit the acquired position information of the reflective column (3) at the top of each shelf column (4) to a remote cloud platform. The remote cloud platform accurately determines the tilt deformation of each shelf column (4), generates a two-dimensional point map, and compares and analyzes the real-time collected data with historical data, thereby determining whether the shelf column (4) in the stereoscopic warehouse has tilt deformation.

4. A real-time monitoring system for verticality of columns for high-bay warehouse management according to claim 3, characterized in that: The high-precision laser scanner (1) is mounted on a platform at the end of a hanging column of the ceiling (2) of the stereoscopic warehouse, which platform can rotate continuously 360 degrees.

5. A real-time monitoring system for verticality of columns for high-bay warehouse management according to claim 4, characterized in that: A plurality of high-precision laser scanners (1) are provided, each of the high-precision laser scanners (1) is responsible for detecting the shelf columns (4) within its own area, and the high-precision laser scanners (1) work together to obtain position information of the top ends of the shelf columns (4) in the entire area.

6. A monitoring method using the real-time monitoring system for verticality of columns for high-bay warehouse management according to any one of claims 1 to 5, characterized in that: The following steps are involved: 1) Installing the reflective column (3) with high reflectivity on the top of each shelf column (4); 2) using the high-precision laser scanner (1) installed on the ceiling (2) of the stereoscopic warehouse to perform 360-degree continuous scanning to accurately capture the laser point cloud data reflected back by the reflective column (3); 3) The data processing unit receives the scanned data and calculates the current position information of the shelf column (4) and the degree of deviation from the ideal vertical state by means of an image processing algorithm; 4) When it is detected that the shelf column (4) deviates from the vertical position beyond a preset threshold range, an alarm is issued.

7. A real-time monitoring method for verticality of columns for high-bay warehouse management according to claim 6, characterized in that: The data wireless transmission device can be externally connected to transmit the acquired position information of the reflective column (3) at the top of each shelf column (4) to the remote cloud platform via the industrial Internet. The remote cloud platform accurately judges the tilt deformation of each shelf column (4) based on the monitoring principle, generates a two-dimensional point map, and compares and analyzes the real-time collected data with historical data, thereby judging whether the shelf column (4) in the stereoscopic warehouse has tilt deformation.

8. A real-time monitoring method for verticality of columns for high-bay warehouse management according to claim 7, characterized in that: When there are multiple high-precision laser scanners (1), each high-precision laser scanner (1) is responsible for detecting the shelf columns (4) in its own area, and works together to obtain position information of the top ends of the shelf columns (4) in the entire area. This information is obtained through the reflective columns (3) at the top ends of each column.

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