A material box type automated stereoscopic warehouse stacking method and control system

Abstract

The present invention relates to a stacking method and control system for a bin-type automated three-dimensional warehouse, which relates to the field of automated warehousing. The method includes dividing shelves into sub-areas by layer, with each area containing X cargo locations, numbered according to storage distance; performing quality inspection and labeling in the incoming storage area, and packing similar and contemporaneous cargo; classifying the cargo locations in the inspection area, obtaining the total weight of each box and the pressure values ​​at the four corners of the bottom, and calculating the balance point; if the total weight is ≤ a weight threshold and the balance point falls within the safe zone, the qualified cargo location is sent to the selection area; otherwise, rework is performed; a determination is made as to whether there is an area without cargo locations; if so, X groups of cargo locations are selected in the selection area, such that the absolute value of the difference between the sum of the pressure values ​​on both sides of the shelf length within the group is ≤ a first pressure threshold, the groups are numbered and stored in corresponding cargo locations, and a mapping table of cargo locations and four-corner pressure values ​​is created; if not, based on historical pressure values ​​in the empty cargo location mapping table, the cargo locations in the unused cargo locations whose absolute value of the difference between the sum of the pressure values ​​on the same side as the historical cargo locations is ≤ a second pressure threshold are selected and stored in the corresponding empty locations, thereby achieving dynamic balanced optimization of shelf load.

Description

Technical Field

[0001] The present invention relates to the field of automated warehousing, and in particular to a stacking method and control system for a material box type automated stereoscopic warehouse. Background Art

[0002] A material box type automated warehouse is usually composed of multiple shelves arranged side by side. There are aisles reserved between adjacent shelves for stacker cranes to pass through. Each shelf has several layers of shelves, and each layer of shelves is arranged with multiple cargo spaces for storing material boxes. The material boxes are rectangular boxes. After the goods are loaded through the material boxes, they are first transported from the storage area to the stacking area via rollers, and then automatically moved to the designated cargo space for storage by the stacker crane.

[0003] At present, to ensure the stability of the shelves, a shelf design with a rated load far exceeding the actual total weight of the goods is generally adopted. Although this method is simple and reliable, it significantly increases the construction cost when there are large storage needs. In addition, due to the different densities of different goods and the different center of gravity positions of the goods in each material box, storing them together on the shelves can easily lead to uneven force on the shelves, which in turn causes local structural deformation. This deformation will not only affect the service life of the shelves, but will also directly cause interference with the operation trajectory of the stacker crane, ultimately affecting the normal operation and operating efficiency of the automated warehousing system. Summary of the Invention

[0004] The present invention provides a material box type automated stereoscopic warehouse stacking method and control system, which realizes dynamic load balancing optimization of shelves, improves shelf life, and ensures normal operation and operating efficiency of the storage system.

[0005] The present invention provides a stacking method for a material box type automated stereoscopic warehouse, comprising:

[0006] S1. Divide each shelf in the high-bay warehouse into multiple sub-areas based on the layer. Each sub-area contains X cargo locations. Sort and number the cargo locations in each sub-area according to the storage distance.

[0007] S2. Inspect the goods for quality and affix labels in the incoming warehouse area. Load the same type of goods into the same box and enter the inspection area.

[0008] S3. Classify each material box in the inspection area: obtain the total weight of each material box, obtain at least four pressure values ​​at the four corners of the bottom of each material box, and calculate the balance point of the bottom of the material box based on the four pressure values; if the total weight of a single material box is less than or equal to the weight threshold, and the balance point falls within the safe area, it is marked as a qualified material box and enters the picking area; otherwise, it is marked as a high-risk material box and returned for repacking.

[0009] S4. Determine whether there is a sub-area where no material boxes are stored:

[0010] If so, X boxes are selected from the qualified boxes in the selection area to form a box group; first, based on the pressure value of each box, the boxes are adjusted so that the absolute value of the difference between the sum of the pressure values ​​of the X boxes on both sides of the shelf length direction is ≤ the first pressure threshold; then the X boxes are numbered, and the boxes with corresponding serial numbers are stored in the corresponding serial numbered storage locations in the sub-area to be stored, and a mapping table of the four pressure values ​​of the storage locations and the boxes stored thereon is established; if so, based on the four pressure values ​​of the historical storage boxes of the empty storage locations on the mapping table, the boxes to be stored whose absolute value of the difference between the sum of the two pressure values ​​on the same side of the shelf length direction as the historical storage boxes is ≤ the second pressure threshold are selected and stored in the corresponding empty storage locations.

[0011] When a container is stored in a storage location, the storage timestamp is associated with the corresponding storage location ID and stored in a central database. The central database supports associating multiple timestamp sequences with the same storage location ID. When replenishing, the total storage time of all containers in the history of each empty storage location is calculated. The empty storage locations are arranged in ascending order according to the total storage time to generate an empty storage location stacking priority queue. The empty storage locations to be stacked are selected in turn from the empty storage location stacking priority queue.

[0012] If there are cargo locations with the same total duration, determine whether the same cargo locations are in the same sub-area; if so, sort them in ascending order by storage distance; if not, sort them in ascending order by height based on the height of the sub-area.

[0013] If there are no X bins whose absolute value of the sum of the pressure values ​​on both sides of the shelf length direction is less than or equal to the first pressure threshold, these X bins will be temporarily stored in a designated buffer storage area, which is located in the warehousing area and will be used to form a new bin group later.

[0014] When a bin is stored in a storage location, the shelf life information is bound to the storage location ID based on the shelf life information in the cargo identification and stored in the central database. When picking up goods, all storage locations with similar goods and their associated shelf life information are retrieved based on the requested cargo type, and the remaining shelf life days of each bin are calculated. A pickup queue is generated in ascending order of the remaining shelf life days, and goods are picked up in the queue order.

[0015] Determine whether the storage locations of bins with the same remaining shelf life are in the same sub-area. If so, sort the bins in ascending order based on their storage distance. If not, sort the bins in descending order based on the height of the sub-area.

[0016] The coordinates and pressure values ​​of the four corners of the material box are: (0, 0), pressure value P1; (L, 0), pressure value P2; (0, W), pressure value P3; (L, W), pressure value P4; where L is the length of the material box and W is the width of the material box. The calculation formula for the balance point (x, y) is: .

[0017] A material box type automated three-dimensional warehouse stacking control system, comprising:

[0018] Shelf numbering module: It is configured to divide the shelf sub-areas by layer and sort and number the shelves in the area based on the storage distance.

[0019] Quality inspection and labeling module: configured to inspect and label goods, and load the same type of goods into the same container.

[0020] Classification module: This module is configured to detect the total weight of the material box and the pressure values ​​at the four corners, and calculate its bottom balance point. If the total weight is ≤ the threshold and the balance point falls within the safe area, the material box is marked as qualified. Otherwise, it is marked as a high-risk material box and returned for repacking.

[0021] The stacking module is configured as follows: (a) When there is a sub-area without any bins stored: X bins are selected from qualified bins to form a bin group, and the pressure distribution is adjusted so that the absolute value of the pressure difference on both sides of the shelf in the longitudinal direction is ≤ a first threshold. The bins are stored in the corresponding storage locations in the target sub-area according to the serial number, and the pressure values ​​of the storage locations are recorded; (b) When there is no sub-area without any bins stored: bins whose absolute value of the difference between the sum of the pressure values ​​on the same side and the sum of the pressure values ​​on the same side of the historically stored bins is ≤ a second pressure threshold are selected and stored in the corresponding empty storage locations.

[0022] The stacking module also includes a dynamic replenishment optimization module, which is configured as follows: when a material box is stored in a storage location, the storage timestamp is associated with the storage location ID and stored in the central database; when replenishing, the total historical storage time of the empty storage locations is calculated, and the empty storage locations are arranged from small to large according to the total storage time to generate an empty storage location stacking priority queue; if the total time is the same, it is determined whether the storage locations belong to the same sub-area; if they belong to the same sub-area, they are sorted in ascending order by storage distance; if they belong to different sub-areas, they are sorted in ascending order by sub-area height.

[0023] A material box type automated stereoscopic warehouse stacking control system also includes a shelf life management module, which is configured to: bind the expiration date of the material box with the storage location ID and store it in a central database; search for the storage location of similar goods when picking up goods, calculate the remaining shelf life days and generate a pickup queue in ascending order; if the remaining shelf life days are the same, determine whether the storage locations belong to the same sub-area: if they belong to the same sub-area, sort them in ascending order by storage distance; if they belong to different sub-areas, sort them in descending order by sub-area height.

[0024] Beneficial effects:

[0025] Through sub-area numbering, you can quickly locate the cargo location, reduce the time of addressing the cargo location, optimize inventory management, improve work efficiency, and lay the foundation for subsequent dynamic and balanced stacking of material boxes.

[0026] By implementing quality inspection and labeling management at the warehousing stage, the traceability and storage safety of goods are ensured; loading similar and contemporaneous goods into the same material box not only reduces the weight distribution difference inside the material box, but also facilitates subsequent outbound optimization based on shelf life, preliminarily controls the homogeneity of goods in the material box from the source, reduces the risk of large imbalance caused by mixing of goods, and provides a data basis for subsequent pressure detection and balance point calculation.

[0027] By detecting the total weight of the material box and the pressure values ​​at the four corners and calculating the balance point, a quantitative assessment of the material box stability is achieved. The setting of the weight threshold and the safety area effectively filters out high-risk material boxes that are overweight or have an unstable center of gravity, and prevents unqualified material boxes from causing local overload on the shelves after being put on the shelves. Combined with pressure sensing technology, it improves the detection accuracy of the material box balance point, significantly reduces the risk of shelf deformation due to uneven force, and provides reliable data support for subsequent material box stacking.

[0028] By adjusting the material box groups, the pressure difference on both sides of the shelf is controlled within the safety threshold. Combined with the historical data reference of the cargo position pressure value mapping table, the load distribution is continuously optimized during the stacking and replenishment process, thereby improving the uniformity of the bending moment distribution in the length direction of the shelf and reducing shelf deformation. DETAILED DESCRIPTION

[0029] The technical solutions of the present invention are as follows:

[0030] First, the three-dimensional warehouse for stacking material boxes of the present invention has been described in the background technology. The three-dimensional warehouse is usually composed of a plurality of shelves arranged side by side, and aisles for stackers to pass through are reserved between adjacent shelves. Each shelf is provided with several layers of shelves, and each layer of shelves is arranged with a plurality of cargo spaces for storing material boxes.

[0031] Specifically, the shelf includes a plurality of column groups arranged vertically and parallelly along the length direction, each column group includes two columns arranged opposite to each other along the width direction and a support beam connecting the two columns, and the adjacent columns on both sides of the length direction of the shelf are connected by a cross beam, and two supports are provided opposite to each other between the two adjacent column groups, and the two supports are connected to the columns of the adjacent column groups on opposite sides.

[0032] Based on the above description, it can be seen that the shelf layer is arranged in multiple layers along the height direction of the shelf, each shelf layer is arranged with X cargo spaces along its own length direction, and the two supports between any two adjacent column groups correspond to an independent cargo space for storing material boxes.

[0033] The following describes a material box type automated three-dimensional warehouse stacking method and control system provided by this embodiment in conjunction with a three-dimensional warehouse.

[0034] The present invention provides a stacking method for a material box type automated stereoscopic warehouse, comprising:

[0035] S1. Divide each shelf in the high-bay warehouse into multiple sub-areas based on the layer. Each sub-area contains X cargo locations. Sort and number the cargo locations in each sub-area according to the storage distance.

[0036] According to the location of the shelf, the working distance of the stacker from obtaining the material box at the picking station to placing the material box on each cargo location in each sub-area is calculated as the storage distance. The cargo locations in each sub-area are prioritized and numbered in ascending order of storage distance. A conveyor channel is set parallel to one side of the length direction of each shelf in the three-dimensional warehouse. The material box is transported to one side of the corresponding shelf by the conveyor channel, and the picking station is set on the end of the conveyor channel close to the corresponding shelf.

[0037] Through sub-area numbering, the stacker crane can quickly locate the cargo location, reduce the cargo location addressing time, optimize inventory management, improve work efficiency, and lay the foundation for subsequent dynamic and balanced stacking of material boxes.

[0038] S2. Inspect the goods for quality and affix labels in the incoming warehouse area. Load the same type of goods into the same box and enter the inspection area.

[0039] By implementing quality inspection and labeling management at the warehousing stage, the traceability and storage safety of goods are ensured; loading similar and contemporaneous goods into the same material box not only reduces the weight distribution difference inside the material box, but also facilitates subsequent outbound optimization based on shelf life, preliminarily controls the homogeneity of goods in the material box from the source, reduces the risk of large imbalance caused by mixing of goods, and provides a data basis for subsequent pressure detection and balance point calculation.

[0040] S3. Classify each material box in the inspection area: obtain the total weight of each material box, obtain at least four pressure values ​​at the four corners of the bottom of each material box, and determine the balance point of the material box bottom based on the four pressure values;

[0041] If the total weight of a single box is less than or equal to the weight threshold, and the balance point falls within the safe area, it is marked as a qualified box and enters the picking area; otherwise, it is marked as a high-risk box and returned for repacking.

[0042] Among them, the total weight of the material box is obtained through the weighing module integrated in the starting section of the conveyor roller in the detection area, and the four pressure values ​​at the four corners of the material box are obtained through the pressure sensing tray set in the middle section of the conveyor line. The pressure sensing tray contains four pressure sensors distributed in a rectangular shape. During detection, the material box is placed stationary in the center area of ​​the tray.

[0043] If the coordinates and pressure values ​​of the four corners of the material box are:

[0044] (0, 0), pressure value P1;

[0045] (L, 0), pressure value P2;

[0046] (0, W), pressure value P3;

[0047] (L, W), pressure value P4;

[0048] Where L is the length of the box, W is the width of the box, and the calculation formula for the balance point (x, y) is: .

[0049] For example, when the length of the material box is L = 0.5m, the width of the material box is W = 0.5m, P1 = 14, P2 = 15, P3 = 16, and P4 = 17, the equilibrium point (x, y) = (0.258, 0.266).

[0050] It should be noted that the length and width of the material box here are defined according to the length and width directions of the shelf after the material box is stacked on the shelf. Specifically, after the material box is stacked on the shelf, the dimension along the length direction of the shelf is the length dimension of the material box, and the dimension along the width direction of the shelf is the width dimension of the material box.

[0051] For example, the weight threshold can be set to be equal to the rated load per cargo space × 80%.

[0052] For example, the safety area can be set as a circular area with a radius r and a geometric center of the bottom surface of the qualified material box as the center, where r = min (L / 2, W / 2).

[0053] By detecting the total weight of the material box and the pressure values ​​at the four corners and calculating the balance point, a quantitative assessment of the material box stability is achieved. The setting of the weight threshold and the safety area effectively filters out high-risk material boxes that are overweight or have an unstable center of gravity, and prevents unqualified material boxes from causing local overload on the shelves after being put on the shelves. Combined with pressure sensing technology, it improves the detection accuracy of the material box balance point, significantly reduces the risk of shelf deformation due to uneven force, and provides reliable data support for subsequent material box stacking.

[0054] S4. Determine whether there is a sub-area where no material boxes are stored:

[0055] If there are sub-areas with no bins stored, X bins are selected from the qualified bins in the selection area to form a bin group. First, based on the pressure values ​​of each bin, the bins are adjusted so that the absolute value of the difference between the sum of the pressure values ​​of the X bins on both sides of the shelf length is ≤ the first pressure threshold. Then, the X bins are numbered and the bins with corresponding serial numbers are stored in the corresponding serial numbered locations of the sub-area to be stored. A mapping table of the four pressure values ​​of the locations and the bins stored thereon is established.

[0056] When groups of bins are stored in the same shelf, they are stored first in the lower sub-areas.

[0057] If there is no sub-area where no boxes are stored, then based on the four pressure values ​​of the historical storage boxes at the empty storage location in the mapping table, a box is selected from the boxes to be stored whose absolute value of the difference between the sum of the two pressure values ​​on the same side of the shelf length direction as the historical storage box is ≤ the second pressure threshold and is stored at the corresponding empty storage location.

[0058] The first pressure threshold is the initial storage of the bin group, and is based on the dynamic balance tolerance of the sum of the pressures on both sides of the shelf length. For example, the first pressure threshold can be set to the total pressure value of the bin group / 2×30%;

[0059] The purpose of the second pressure threshold is to ensure that when a new material box is added to a cargo location with an existing historical load, the pressure of the new material box on the same side of the shelf in the longitudinal direction and the difference from the historical load are controlled within a safe range to avoid local uneven force. Since the shelf already has a historical load, the interference of the new material box needs to be more strictly limited. For example, the second pressure threshold is set to the sum of the two pressure values ​​on the same side of the historical storage material box × (10% to 20%). The second pressure threshold can be preferably set to the sum of the two pressure values ​​on the same side of the historical storage material box × 15%, and it can be relaxed to 20% for the bottom cargo location.

[0060] By adjusting the material box groups, the pressure difference on both sides of the shelf is controlled within the safety threshold. Combined with the historical data reference of the cargo position pressure value mapping table, the load distribution is continuously optimized during the stacking and replenishment process, thereby improving the uniformity of the bending moment distribution in the length direction of the shelf and reducing shelf deformation. It is suitable for the long-term stable operation of high-density automated warehouses.

[0061] If there are no X bins whose absolute value of the sum of the pressure values ​​on both sides of the shelf in the length direction is less than or equal to the first pressure threshold, then these X bins are temporarily stored in a designated buffer storage area. The buffer storage area can be set in the warehousing area for subsequent formation of new bin groups. When subsequently forming a bin group, the bins in the buffer storage area are selected first.

[0062] When a bin is stored in a cargo location, the storage timestamp is associated with the corresponding cargo location ID and stored in a central database. The central database supports associating multiple timestamp sequences with the same cargo location ID; a mapping table between cargo locations and pressure values ​​is also part of the central database.

[0063] When replenishing, calculate the total storage time of all containers in each empty location in history;

[0064] Arrange the empty storage locations in ascending order of their total storage time to generate an empty storage location stacking priority queue;

[0065] Select the empty storage locations to be stacked from the empty storage location stacking priority queue in turn.

[0066] By dynamically rotating the frequency of use of storage locations, long-term local pressure can be avoided, making the overall force on the shelf more evenly distributed.

[0067] If there are locations with the same total duration, determine whether they are in the same sub-area. If so, sort them in ascending order of storage distance, prioritizing locations closer to the stacker to improve efficiency. If not, sort them in ascending order of height based on the height of their sub-area. Lower-level locations have greater load-bearing capacity and are used first, reducing long-term stress accumulation on higher-level racks.

[0068] When a container is deposited into a storage location, the expiration date information in the cargo identification is bound to the storage location ID and stored in a central database. When picking up the goods, all storage locations storing similar goods and their associated expiration dates are searched based on the requested goods type. The remaining expiration date for each container is calculated. A pickup queue is generated in ascending order of remaining expiration date, and the goods are picked up in the queue order. Bins with fewer remaining expiration dates are prioritized for removal to prevent expired goods.

[0069] When picking up items, it's also important to determine whether bins with the same remaining shelf life are located in the same sub-area. If so, the bins are sorted in ascending order of distance, prioritizing bins closer to the stacker to improve efficiency. If not, the bins are sorted in descending order based on the height of the sub-area. High-rise shelves are prone to deformation due to prolonged pressure, so prioritizing the removal of high-rise bins can reduce accumulated stress.

[0070] When picking up goods, the number of storage times and storage durations of the material boxes stored at the same cargo location within the time window D are queried from the central database. When the total number of storage times is ≤ the number threshold N, and the total storage duration is ≥ the total duration threshold T, the material box currently stored at the cargo location is extracted to the top of the current pickup queue, thereby avoiding long-term stress on the same cargo location and reducing the risk of local deformation of the shelf due to continuous pressure.

[0071] Among them, the time window D is the inventory monitoring period;

[0072] The calculation formula is: D = average inventory turnover days × kd;

[0073] Average inventory turnover days = total warehouse inventory / average daily outbound volume (calculated based on historical operating data from the central database);

[0074] kd is the adjustment factor, ranging from 0.8 to 1.2, with a default value of 1.0 (indicating that the average inventory turnover days are used directly);

[0075] If warehouse data is insufficient, D can be set to a fixed value. The default value is D = 30 days (based on a typical warehouse operation cycle);

[0076] For example, if the total warehouse inventory = 100,000 boxes, the average daily outbound volume = 500 boxes, and kd = 1.0, then D = 200 days.

[0077] N is the threshold value of the number of storage times, which is used to determine the access frequency of the loading box at location A within time D;

[0078] The calculation formula is: N = max(1, round up (average daily access frequency × D × fn));

[0079] Average daily access frequency = total number of warehouse storage locations / average inventory turnover days (based on central database data);

[0080] The safety factor fn ranges from 0.1 to 0.3 (default value 0.2), indicating that N should be much lower than the average access frequency to identify infrequent accesses.

[0081] For example, fn=0.1, the total number of warehouse storage spaces = 3000, the average daily access frequency = 3000 / 200 = 15 times / day, N=max(1, round(15×200×0.1))=max(1, round(300))=300 times.

[0082] T is the threshold of the total storage time, which is used to determine whether there are boxes stored in location A for a long time within time D.

[0083] The calculation formula is: T = min (D, average shelf life days × kt) × ft

[0084] Average shelf life in days = average shelf life of all goods (based on incoming quality inspection data);

[0085] The value range of the shelf life adjustment coefficient kt is: 0.5~0.7 (default value 0.6);

[0086] ft is the safety load factor, ranging from 0.7 to 0.9 (default value 0.8). A high ratio of T to D or shelf life ensures that long-term storage is recognized;

[0087] For example, D = 200 days, average shelf life = 180 days, kt = 0.6, ft = 0.8, then T = min (200, 180 × 0.6) × 0.8 ≈ 86 days.

[0088] Among them, the coefficients kd / ft / kt / fn support flexible adjustment according to warehouse characteristics to adapt to the needs of multiple scenarios.

[0089] That is, assuming N=300 times, T=86 days, and the remaining shelf life of the material box stored on location A is 150 days, the historical records within D=200 days are: the number of storage times is 280 times, and the total storage time of 280 times is 87 days. Even if the remaining shelf life of the material box stored on location A is 150 days, the material box currently stored on location A must be taken out first.

[0090] During the storage period of the material box, if the remaining shelf life days are lower than the validity threshold, it will be marked as an expiring material box and an alarm will be issued.

[0091] Based on the above design, the stacking method of a material box-type automated three-dimensional warehouse of the present invention adopts a triple filtering mechanism: quality inspection and packing, weight and balance point detection, and stacking pressure adjustment. By reducing the risk of shelf deformation layer by layer, the overall force distribution of the shelf is more uniform, thereby extending the service life.

[0092] The present invention also provides a material box type automated stereoscopic warehouse stacking control system, comprising:

[0093] Shelf numbering module: configured to divide shelf sub-areas by layer and sort and number the shelves in the area based on storage distance;

[0094] Quality inspection and labeling module: configured to inspect and label goods, and load the same type of goods into the same container;

[0095] Classification module: This module is configured to detect the total weight of the material box and the pressure values ​​at the four corners, and calculate its bottom balance point. If the total weight is less than or equal to the threshold and the balance point falls within the safe area, the material box is marked as qualified. Otherwise, it is marked as a high-risk material box and returned for repacking.

[0096] Stacking module, configured as:

[0097] (a) When there are sub-areas with no bins stored: select X qualified bins to form a bin group, adjust the pressure distribution so that the absolute value of the pressure difference on both sides of the shelf length is ≤ the first threshold, and store them in the target sub-area storage locations according to their serial numbers, and record the pressure values ​​of the storage locations;

[0098] (b) When there is no sub-area where no boxes are stored: select the boxes to be stored whose absolute value of the difference between the sum of the two pressure values ​​on the same side of the shelf length direction as the historically stored boxes is less than or equal to the second pressure threshold and store them in the corresponding empty storage location.

[0099] The stacking module also includes a dynamic replenishment optimization module, which is configured as follows:

[0100] When a container is stored in a storage location, the storage timestamp is associated with the storage location ID and stored in the central database;

[0101] When replenishing, calculate the total historical storage time of empty storage locations, and sort the empty storage locations in ascending order of storage time to create an empty storage location stacking priority queue;

[0102] If the total duration is the same, determine whether the storage locations belong to the same sub-area:

[0103] If they belong to the same sub-area, they are sorted in ascending order by storage distance;

[0104] If they belong to different sub-areas, they are sorted in ascending order by sub-area height.

[0105] A material box type automated three-dimensional warehouse stacking control system also includes a shelf life management module, which is configured as follows:

[0106] Bind the expiration date of the container to the location ID and store it in the central database;

[0107] When picking up goods, search for the same type of goods in the same location, calculate the remaining shelf life and generate a pickup queue in ascending order;

[0108] If the remaining shelf life is the same, determine whether the storage location belongs to the same sub-area:

[0109] If they belong to the same sub-area, they are sorted in ascending order by storage distance;

[0110] If they belong to different sub-areas, they are sorted in descending order of sub-area height.

[0111] A material box type automated stereoscopic warehouse stacking control system also includes a deformation monitoring module, which detects the micro-deformation of the shelf through a laser rangefinder installed on the side column of the lane;

[0112] The calculation module uses the data of the largest deformation among the columns as feedback input and dynamically adjusts the following parameters:

[0113] a) When the maximum value of the vertical displacements of the tops of the columns exceeds the vertical displacement threshold of the tops of the columns, the weight threshold and the first pressure threshold are adjusted synchronously;

[0114] The adjustment rule is: new weight threshold = original weight threshold × (1 − kv);

[0115] New first pressure threshold = original first pressure threshold × (1 − 0.5 kV).

[0116] b) When the maximum value of the horizontal displacement of the top of each column exceeds the horizontal displacement threshold of the top of the column, the radius of the safety zone and the second pressure threshold are adjusted synchronously;

[0117] The adjustment rule is: new safety radius = original new safety radius × (1 − kh);

[0118] New second pressure threshold = original second pressure threshold × (1 − 0.7 kh).

[0119] c) when the maximum value of the horizontal displacement of the middle part of each column exceeds the horizontal displacement threshold of the middle part of the column, adjusting the second pressure threshold;

[0120] The adjustment rule is: new second pressure threshold = current value × (1 − 0.9 km).

[0121] Among them, the vertical displacement exceeding the threshold in a) directly reflects that the vertical load-bearing capacity of the shelf exceeds the limit. It is necessary to reduce the maximum allowable weight of a single material box and reduce the pressure difference during the initial stacking on both sides of the shelf to avoid the bending moment aggravating the compression deformation of the column.

[0122] b) limits the displacement of the center of gravity of the material box, reduces the pulling of the lateral moment on the top of the column, suppresses the cumulative effect of the pressure on the same side of the length direction of the shelf, and reduces the lateral deformation. It is particularly suitable for structures where no lateral pull rods are set on the top of the shelf.

[0123] c) The horizontal displacement of the middle part of the center column reflects that the shelf’s anti-lateral stiffness is insufficient, and the pressure difference on both sides of the shelf length needs to be more strictly controlled.

[0124] If the maximum values ​​of the top vertical displacement and horizontal displacement exceed the threshold at the same time, the weight threshold and the safety zone radius are reduced at the same time; the new weight threshold = original value × (1-1.2kv); the new safety radius = original value × (1-1.2kh).

[0125] Among them, kv, kh, and km are the corresponding deformation adjustment ratios, which are calculated by the corresponding conversion coefficient × (measured displacement / maximum allowable displacement). For example, if the vertical displacement of the top of a single column exceeds the limit, if the maximum allowable displacement is 5 cm, the measured displacement is 6 cm, and the conversion coefficient is 0.2, then:

[0126] New weight threshold = original weight threshold × (1 − 0.24) = 76% of original weight threshold;

[0127] New first pressure threshold = original first pressure threshold × (1 − 0.5 × 0.24) = 88% of the original first pressure threshold.

[0128] If the displacement of multiple columns exceeds the threshold, the first pressure thresholds of all sub-areas will be uniformly lowered. For example, the first pressure thresholds of all sub-areas will be lowered to: original value × (1-max (kv, kh, km)).

[0129] The laser rangefinder can be installed on the top and middle of each group of shelves close to the side columns of the aisle, and each shelf is provided with at least 6 detection points.

[0130] A stacking control system for a bin-type automated high-bay warehouse also includes an alarm module. When it detects shelf deformation exceeding a threshold of 80%, the system automatically issues an alarm, adjusts the stacker crane's path to avoid areas of significant deformation, and prompts for manual intervention for repairs. Early deformation intervention reduces the risk of irreversible shelf deformation and prevents losses caused by mechanical collisions.

Claims

1. A stacking method for a material box type automated three-dimensional warehouse, characterized in that: include: S1. Divide each shelf in the high-bay warehouse into multiple sub-areas on a layer-by-layer basis. Each sub-area contains X cargo locations. Sort and number the cargo locations in each sub-area according to storage distance. S2. Inspect the goods in the incoming warehouse and label them. Load the same type of goods into the same container and enter the inspection area. S3. Classify each material box in the detection area; Obtain the total weight of a single material box, obtain at least four pressure values ​​at the four corners of the bottom of each material box, and determine the balance point of the bottom of the material box based on the four pressure values; If the total weight of a single box is less than or equal to the weight threshold, and the balance point falls within the safe area, it is marked as a qualified box and enters the picking area; Otherwise, it is marked as a high-risk container and returned for repacking; S4. Determine whether there is a sub-area where no material boxes are stored; If so, select X bins from the qualified bins in the selection area to form a bin group; First, based on the pressure values ​​of each bin, adjust the bins so that the absolute value of the difference between the sum of the pressure values ​​of X bins on one side of the shelf length and the sum of the pressure values ​​on the other side is less than or equal to the first pressure threshold. Then, number X boxes and place them in the corresponding numbered cargo locations in the storage sub-area. A mapping table is created between the cargo locations and the four pressure values ​​of the boxes stored thereon. If it does not exist, then based on the four pressure values ​​of the historical storage boxes at the empty storage location in the mapping table, select the box to be stored whose two pressure values ​​on the same side of the shelf length direction and the absolute value of the difference between the two pressure values ​​of the historical storage box on the same side of the shelf length direction is ≤ the second pressure threshold and store it at the corresponding empty storage location.

2. A stacking method for a material box type automated high-bay warehouse according to claim 1, characterized in that: When a container is stored in a cargo location, the storage timestamp is associated with the corresponding cargo location ID and stored in a central database. The central database supports associating multiple timestamp sequences with the same cargo location ID. When replenishing, calculate the total storage time of all containers in each empty location in history; Arrange the empty storage locations in ascending order of their total storage time to generate an empty storage location stacking priority queue; Select the empty storage locations to be stacked from the empty storage location stacking priority queue in turn.

3. A stacking method for a material box type automated warehouse according to claim 2, characterized in that: If there are cargo locations with the same total duration, determine whether the same cargo locations are in the same sub-area; If yes, sort them in ascending order according to the storage distance of the cargo location; If not, sort in ascending order based on the height of the sub-area it is in.

4. A stacking method for a material box type automated warehouse according to claim 1, characterized in that: If the absolute value of the difference between the sum of the pressure values ​​of X boxes on both sides of the shelf in the length direction does not exist and is less than the first pressure threshold, the X boxes are temporarily stored in a designated buffer storage area, which is located in the warehousing area and is used to form a box group later.

5. The stacking method of a material box type automated high-bay warehouse according to claim 1, characterized in that: When the container is stored in the cargo location, the expiration date information is bound to the cargo location ID according to the expiration date information in the cargo identification and stored in the central database; When picking up goods, based on the requested goods type, all storage locations with similar goods and their associated shelf life information are retrieved, and the remaining shelf life days of each container are calculated; Generate a pickup queue in ascending order of the remaining shelf life days, and pick up the goods in the order of the queue.

6. A stacking method for a material box type automated high-bay warehouse according to claim 5, characterized in that: Determine whether the storage locations of the boxes with the same remaining shelf life are in the same sub-area; If so, sort in ascending order by the storage distance of the bins; If not, sort in descending order based on the height of the sub-area it is in.

7. A stacking method for a material box type automated high-bay warehouse according to claim 1, characterized in that: The coordinates and pressure values ​​of the four corners of the material box are: (0, 0), pressure value P1; (L, 0), pressure value P2; (0, W), pressure value P3; (L, W), pressure value P4; Wherein, L and W are the length and width of the container respectively. The calculation formula of the balance point (x, y) is: .

8. A material box type automated three-dimensional warehouse stacking control system, characterized in that: include: Shelf numbering module: configured to divide shelf sub-areas by layer and sort and number the shelves in the area based on storage distance; Quality inspection and labeling module: configured to inspect and label goods, and load the same type of goods into the same container; Classification module: This module is configured to detect the total weight of the material box and the pressure values ​​at the four corners, and calculate its bottom balance point. If the total weight is less than or equal to the weight threshold and the balance point falls within the safe area, the material box is marked as qualified. Otherwise, it is marked as a high-risk material box and returned for repacking. Stacking module, configured as: (a) When there are sub-areas with no bins stored: select X bins from the qualified bins to form a bin group. Adjust the pressure distribution so that the absolute difference between the sum of the pressure values ​​on one side of the shelf and the sum of the pressure values ​​on the other side is less than or equal to the first pressure threshold. Store the bins in the target sub-area storage locations according to their serial numbers, and record the pressure values ​​of the storage locations. (b) When there is no sub-area without a container: a container whose absolute value of the difference between the sum of the pressure values ​​on the same side and the sum of the pressure values ​​on the same side of the historically stored containers is less than or equal to the second pressure threshold is selected and stored in the corresponding empty storage location.

9. A material box type automated warehouse stacking control system according to claim 8, characterized in that: The stacking module also includes a dynamic replenishment optimization module configured as follows: When a container is stored in a storage location, the storage timestamp is associated with the storage location ID and stored in the central database; When replenishing, calculate the total historical storage time of empty storage locations, and sort the empty storage locations in ascending order of storage time to create an empty storage location stacking priority queue; If the total duration is the same, determine whether the storage locations belong to the same sub-area: If they belong to the same sub-area, they are sorted in ascending order by storage distance; If they belong to different sub-areas, they are sorted in ascending order by sub-area height.

10. The stacking control system of a material box type automated high-bay warehouse according to claim 8, characterized in that: It also includes a shelf life management module, which is configured as follows: Bind the expiration date of the container to the location ID and store it in the central database; When picking up goods, search for the same type of goods in the same location, calculate the remaining shelf life and generate a pickup queue in ascending order; If the remaining shelf life is the same, determine whether the storage location belongs to the same sub-area: If they belong to the same sub-area, they are sorted in ascending order by storage distance; If they belong to different sub-areas, they are sorted in descending order of sub-area height.

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