Full-automatic classified storage and automatic loading system for 24-hour production line based on vertical warehouse
Through the fully automatic classification storage and automatic loading system based on the vertical warehouse, the problems of high labor intensity and high management difficulty in chemical production have been solved, 24-hour automatic storage and efficient loading have been achieved, reducing costs and improving safety factors.
Patent Information
- Application Number
- CN202511163135.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-19
- Publication Date
- 2025-09-16
AI Technical Summary
Traditional chemical production requires 24-hour output, but it is labor-intensive, has high storage and shipping costs, is difficult to manage manually, and is prone to misdelivery. Furthermore, the high shelf life requirements for chemical products make it easy for manual inventory management to miss shipments, resulting in overdue losses.
The design is based on a 24-hour production line with fully automatic classification storage and automatic loading system for vertical warehouses, including a palletizing warehousing unit, a palletizing replenishment unit, a loading and unloading unit, and a stacking and returning unit. Automated storage and loading of materials are achieved through RGV and aisle stacker cranes. Combined with packaging machines, belt conveyors, high-position palletizers and other equipment, automatic material calibration, bagging, palletizing and depalletizing operations are achieved.
It realizes the automated storage and outbound delivery of 24-hour production lines, reduces labor intensity, lowers operation and maintenance costs, improves storage and loading efficiency, and avoids losses caused by wrong shipments and overdue shipments.
Smart Images
Figure CN120646434A_ABST
Abstract
Description
Technical Field
[0001] The present invention belongs to the technical field of stereoscopic warehouses, and in particular relates to a 24-hour production line fully automatic classification storage and automatic loading system based on a stereoscopic warehouse. Background Art
[0002] With the rapid development of modern industry and logistics, the importance of automated and intelligent equipment in the production process has become increasingly prominent. Among them, high-bay warehouses, as an important component of automated production lines and logistics systems, have been widely used in the manufacturing, logistics, and warehousing industries. The requirements for high-bay warehouses' access efficiency, as well as their intelligence, unmanned operation, and reliability are becoming increasingly higher. Currently, in the chemical production sector, production processes require 24-hour production every day of the year. Traditional production operations require three shifts around the clock, which is labor-intensive and results in high storage and shipping costs. Furthermore, because the quality and selling price of products produced at different times vary, manual forklift storage and management are difficult, and errors can easily occur during loading and unloading. Furthermore, because chemical products have high shelf life requirements, manual inventory management can easily lead to missed shipments, resulting in overdue losses. Summary of the Invention
[0003] In order to solve the above technical problems, the present invention provides a 24-hour production line fully automatic classification storage and automatic loading system based on a vertical warehouse.
[0004] The specific plan is as follows: The 24-hour production line based on the vertical warehouse is fully automatic in-storage and loading system, including the palletizing storage unit, the palletizing replenishment unit, the loading and unloading unit and the stacking return unit. The palletizing and warehousing unit is used to calibrate the material quality and bag the materials. At the same time, the bagged materials are palletized on empty pallets and then sent to the vertical warehouse for storage; The palletizing and replenishing unit is used to transport the empty pallets in the vertical warehouse to the palletizing and warehousing unit; The loading and unloading unit is used to send the pallets of the type that need to be loaded out of the vertical warehouse, and to separate the materials from the pallets into bags for loading. The remaining empty pallets are stacked and returned to the warehouse unit; The stacking tray return unit stacks multiple empty pallets into a group of empty pallet stacks, and transports the empty pallet stacks to the vertical warehouse for storage.
[0005] The vertical warehouse includes at least two storage areas, and different storage areas work simultaneously. Each storage area includes an aisle stacker, at least one RGV and at least three aisles. The RGV receives the palletized materials from the palletizing storage unit and transports the palletized materials to the aisle stacker. The aisle stacker places the palletized materials on the corresponding shelves through the aisle.
[0006] The palletizing and warehousing unit is set at the entrance of the vertical warehouse. The palletizing and warehousing unit includes a packaging machine, a belt conveyor, a high-position palletizer and a conveyor in front of the vertical warehouse. The packaging machine is connected to the material production line and bags the materials. The weight of each bag of material is 50KG. The belt conveyor transports the bagged materials to the high-position palletizer. The high-position palletizer stacks the bagged materials on the pallet as full pallet materials. The conveyor in front of the vertical warehouse is used to transport full pallet materials into the warehouse or transfer empty pallets from the vertical warehouse to the high-position palletizer.
[0007] The high-position palletizer can stack 40 bags of bagged materials on an empty pallet. The high-position palletizer outlet is equipped with a weight and size inspection device. When the weight and size inspection device reads that the goods are overweight or out of shape, it will control the RGV to send the pallet to the inspection station in the front area of the warehouse. After manual correction of the shape of the goods, the pallet is put back into the warehouse.
[0008] The stacking and replenishing unit takes out a group of empty pallets from the vertical warehouse each time and sends them to the stacking and warehousing unit. A group of empty pallets includes seven empty pallets, and the seven empty pallets are stacked in sequence.
[0009] The loading and unloading unit includes a loading sensing device, a rear-end conveyor, a depalletizer and a transfer belt conveyor line. The loading sensing device is a camera or a card reader. The camera performs license plate recognition. The card reader is used to swipe the card to start loading and unloading. The rear-end conveyor transports full pallets from the vertical warehouse to the depalletizer or transports a group of empty pallet stacks into the vertical warehouse. The depalletizer splits the transported full pallets into bags and loads them through the transfer belt conveyor line. The remaining empty pallets are sent to the stacking return unit.
[0010] The stacking and returning unit includes a stacking machine, which stacks the empty pallets delivered by the loading and unloading unit into empty pallet stacks of seven pallets, and allocates them to the target aisle for return according to the number of empty pallet stacks remaining in each aisle in the warehouse and the available status of the aisle stacker. The empty pallets are sent to the entrance of the aisle rear area via the rear conveyor line, and the aisle stacker returns the empty pallet stacks to the three-dimensional shelf for storage. The present invention discloses a 24-hour production line fully automatic classification storage and automatic loading system based on a vertical warehouse, comprising a palletizing warehousing unit, a palletizing replenishment unit, a loading and unloading unit and a stacking and returning unit. The system automatically calibrates the material quality and classifies the material according to the production process parameters transmitted from the upstream by the palletizing warehousing unit. When loading and unloading, the loading and unloading unit carries out the material out of the warehouse, and at the same time, the pallets after being shipped out are stacked by the stacking and returning unit and then stored in the warehouse again, thereby improving the 24-hour production line's automated storage and outbound efficiency, canceling nighttime work and concentrating on loading and unloading during the day, thereby improving the production line's safety factor, reducing labor intensity, and reducing the production line's operation and maintenance costs. BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Figure 1 It is a schematic diagram of the overall layout of the vertical warehouse.
[0012] Figure 2 This is a model diagram of empty tray stacking.
[0013] Figure 3 This is a full-service model diagram.
[0014] Figure 4 This is a schematic diagram of the palletizing warehousing process.
[0015] Figure 5 This is a schematic diagram of the depalletizing and outbound delivery process.
[0016] Figure 6 This is a schematic diagram of the loading process.
[0017] Figure 7 This is a schematic diagram of pallet flow.
[0018] The accompanying drawings are described as follows: 1. High-position palletizer, 2. Belt conveyor, 3. Palletizing and replenishing unit, 4. Shelves, 5. Aisles, 6. Parking area, 7. Depalletizer, 8. Pallet stacker, 9. Empty pallets, 10. Empty pallet stacking, 11. Full pallet materials, 12. Bag materials, 13. Palletizing and warehousing unit, 14. Conveyor in front of vertical warehouse, 15. Conveyor line at the back of warehouse, 16. Transfer belt conveyor line. DETAILED DESCRIPTION
[0019] 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 implementation of the present invention, not the entire implementation. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of the present invention.
[0020] like Figures 1 to 7 As shown, the 24-hour production line based on the vertical warehouse is fully automatic in-storage and loading system, including the palletizing storage unit, the palletizing replenishment unit, the loading and unloading unit and the stacking return unit. The palletizing and warehousing unit is used to calibrate the material quality and bag the materials. At the same time, the bagged materials are palletized on empty pallets and then sent to the vertical warehouse for storage; The palletizing and replenishing unit is used to transport the empty pallets in the vertical warehouse to the palletizing and warehousing unit; The loading and unloading unit is used to send the pallets of the type that need to be loaded out of the vertical warehouse, and to separate the materials from the pallets into bags for loading. The remaining empty pallets are stacked and returned to the warehouse unit; The stacking tray return unit stacks multiple empty pallets into a group of empty pallet stacks, and transports the empty pallet stacks to the vertical warehouse for storage.
[0021] The vertical warehouse includes at least two storage areas, and different storage areas work simultaneously. Each storage area includes an aisle stacker, at least one RGV and at least three aisles 5. The RGV receives the palletized materials from the palletizing storage unit and transports the palletized materials to the aisle stacker. The aisle stacker places the palletized materials on the corresponding shelves through the aisle 5.
[0022] The palletizing and warehousing unit is arranged at the entrance of the vertical warehouse. The palletizing and warehousing unit includes a packaging machine, a belt conveyor 2, a high-position palletizer 1 and a conveyor 14 in front of the vertical warehouse. The packaging machine is connected to the material production line and bags the materials. The weight of each bag of material is 50KG. The belt conveyor 2 transports the bagged materials to the high-position palletizer 1. The high-position palletizer 1 stacks the bagged materials on the pallet as full pallet materials 11. The conveyor 14 in front of the vertical warehouse is used to transport the full pallet materials 11 into the warehouse or transfer the empty pallet 9 from the vertical warehouse to the high-position palletizer 1.
[0023] The high-position palletizer 1 stacks 40 bags of bagged materials on the empty pallet 9. The outlet of the high-position palletizer 1 is equipped with a weight and size inspection device. When the weight and size inspection device reads that the goods are overweight or out of shape, it will control the RGV to send the pallet to the inspection station in the front area of the warehouse. After manual correction of the shape of the goods, the pallet is put back into the warehouse.
[0024] The stacking and replenishing unit 3 takes out a group of empty pallet stacks 10 from the vertical warehouse each time and sends them to the stacking and warehousing unit. A group of empty pallet stacks 10 includes seven empty pallets 9, and the seven empty pallets 9 are stacked in sequence.
[0025] The loading and unloading unit includes a loading sensing device, a rear-end conveyor 15, a depalletizer 7 and a transfer belt conveyor line 16. The loading sensing device is a camera or a card reader. The camera performs license plate recognition. The card reader is used to swipe the card to start loading and unloading. The rear-end conveyor 15 transports the full pallet 11 from the vertical warehouse to the depalletizer 7 or transports a group of empty pallet stacks 10 into the vertical warehouse. The depalletizer 7 depalletizes the transported full pallet 11 into bags and loads them through the transfer belt conveyor line 16. The remaining empty pallets 9 are sent to the stack return unit.
[0026] The stacking and returning unit includes a stacking machine 8, which stacks the empty pallets 9 delivered by the loading and unloading unit into empty pallet stacks 10 in groups of seven pallets, and allocates them to the target aisle for return according to the number of empty pallet stacks 10 remaining in each aisle in the warehouse and the available status of the aisle stacker. The empty pallet stacks 10 are sent to the entrance of the aisle warehouse rear area via the rear conveyor line 15, and the aisle stacker returns the empty pallet stacks 10 to the three-dimensional shelf for storage. To achieve the above purpose, this embodiment is designed with a palletizing storage unit, a palletizing replenishment unit, a loading and unloading unit, and a stacked pallet return unit. In the front area of the warehouse, two sets of packaging machines, a belt conveyor 2, and a high-position palletizer 1 are designed based on the principle of one backup and one use; the vertical warehouse is divided into two warehouse areas, the south and the north. Figure 1 As shown, Figure 1 The dotted line in the figure is the dividing line between the two storage areas. Each storage area has one RGV and three lanes 5. The north and south storage areas can work simultaneously.
[0027] like Figure 1 As shown, the warehouse mainly consists of three parts. Figure 1 From left to right, the image shows the front area, the three-dimensional storage area, and the back area. The front area houses the palletizing and loading unit, connecting the production line and the storage area. The three-dimensional storage area stores full pallets 11 and empty pallet stacks 10. The back area is where equipment is used to depalletize and load pallets.
[0028] Palletizing storage unit control process: Figure 4 As shown in the figure, the materials produced by the production line are first packaged into 50kg bags 12 by the packaging machine. The palletizing and warehousing unit automatically reads the process parameters of the upstream system and preliminarily calibrates the material quality. The materials are sent to the high-level palletizer 1 via the belt conveyor 2. The high-level palletizer 1 fills the empty pallet 9 with 40 bags to form a full pallet 11. Figure 3 and Figure 4 As shown; then, the palletizing and warehousing unit automatically allocates cargo locations according to the goods and stores them on the shelves.
[0029] like Figure 3 The single empty pallet 9 in (d) is used to receive the bagged materials 12 that are brought into the warehouse through the conveyor belt of the production and packaging line. Figure 3 (c) shows a full pallet of material 11. The high-level palletizer 1 is stacking 40 bags of bagged material 12 from the packaging line onto an empty pallet 9. The dimensions of the full pallet 11 are 1700 mm long, 1450 mm wide, and 1660 mm high.
[0030] When there are vacant storage spaces in the north and south warehouses and the aisle stacker cranes are available, the palletizing and warehousing units take turns to allocate the RGVs in the north and south warehouses to receive the pallets, that is, the RGV receives the full pallet of materials 11 from the conveyor 14 in front of the vertical warehouse. After the RGV receives the pallet, it controls the RGV in the front area of the warehouse to deliver the full pallet of materials 11 to the aisle entrance based on the inventory level of each aisle in the warehouse area. After the full pallet of materials 11 stops at the entrance of the vertical warehouse, the control system in the vertical warehouse allocates the storage space according to the goods, and then operates the aisle stacker crane to place the full pallet of materials 11 on the corresponding shelf 4.
[0031] A weight and size inspection device is installed at the exit of the palletizer. The weight and size inspection device includes a weight sensor and an infrared measuring ruler. When the weight and size inspection device reads that the goods are overweight or out of shape, it controls the RGV to send the pallet to the inspection station in the front area of the warehouse. After manual correction of the shape of the goods, the pallet is put back into the warehouse.
[0032] In this embodiment, the goods that have been put into storage cannot be shipped out within four hours. If there is no need to modify the quality, they will be automatically marked as available. If the inspection department conducts sampling inspection at the production end and determines that the quality is other than the original, they must be marked as available after the correct quality is determined.
[0033] The palletizing and replenishment unit controls the following process: Empty pallets 9 for the high-level palletizer 1 are also provided by the vertical warehouse. Seven empty pallets are stacked into a stack 10 and evenly stored in each aisle of the vertical warehouse. When needed, the palletizing and replenishment unit controls the aisle stacker to automatically remove pallets from the warehouse. The north and south warehouses prioritize replenishment from their respective aisles. If no pallets are available in their own aisle, replenishment can be performed across multiple aisles.
[0034] The process of loading and unloading unit: the driver parks the truck at the automatic loader, and the loading task is started by license plate recognition or the driver swipes the loading card. The loading and unloading unit retrieves the full pallet of materials 11 of the available loading type in the warehouse, and the aisle stacker delivers the full pallet of materials 11 to the aisle exit of the rear area of the warehouse, and then sends it to the depalletizer 7 used by the loader via the rear conveyor line 15. The depalletizer 7 depalletizes the materials into bags and loads them through the transfer belt conveyor line 16. The remaining empty pallets are sent to the stacking machine 8.
[0035] The control process of the stacking return unit: after the depalletizer 7 completes the depalletizing, the remaining empty pallets 9 are sent to the stacking machine 8, which stacks the empty pallets 9 into a group of empty pallet stacks 10. Figure 2 As shown in (a) to (b), (a) is a single empty pallet 9, and (b) is an empty pallet stack 10, that is, seven empty pallets 9 are placed together. Usually, the empty pallet stack 10 is stored in the vertical warehouse.
[0036] Figure 2 Figure (a) shows an empty pallet 9. The length of an empty pallet 9 is 1600 mm, the width is 1400 mm, and the height is 220 mm. Figure 2 Figure (b) shows a set of empty tray stacks 10, which have a length of 1600 mm, a width of 1400 mm, and a height of 1540 mm.
[0037] The stacked pallet return unit allocates the target aisle for return according to the number of empty pallet stacks 10 remaining in each aisle in the warehouse and the available status of the aisle stacker, and sends them to the aisle warehouse rear area entrance via the rear conveyor line 15, where the aisle stacker sends the empty pallet stacks 10 back to the three-dimensional shelf for storage. The specific working process of the 24-hour production line fully automatic classification storage and automatic loading system based on the vertical warehouse is as follows: Figure 4 As shown, the palletizing and warehousing process is as follows: the materials produced by the production line are automatically packaged into bagged materials 12 and then sent to the palletizing and warehousing unit 13 via a belt conveyor line. The palletizing and warehousing unit 13 stacks the bagged materials 12 into a full pallet of 40 bags (12) and then takes them out. After passing the inspection port, the system automatically reads the pallet number, weight, and shape of the goods, and sets the goods according to the parameters pushed by the upstream system. After passing the inspection, the palletizing and warehousing task is generated.
[0038] When both the north and south storage areas are ready for storage, the RGVs in the north and south storage areas are called in turn to receive the pallets. The pallets are transported to the vertical storage lane entrances of their respective storage areas through the front-of-store conveyor system 14 by the RGV rail transport vehicle. The system then allocates storage locations based on the goods and calls the stacker crane to store the pallets on the shelves.
[0039] The system also provides the empty pallets (10) needed for palletizing by the high-level palletizer. When the palletizer's buffer becomes vacant, the system generates a pallet replenishment task. Empty pallets (10) from the vertical warehouse are delivered to the palletizer's buffer, with priority given to empty pallets from the lanes of the same storage area. If there are no available pallets or stackers in the current storage area, pallets can be replenished across storage areas via the RGV transfer station in the middle of the storage area. If the incoming pallets fail inspection for shape or weight, an abnormal outbound task is generated and the pallets are sent to an inspection station for manual processing before being put back into storage.
[0040] like Figure 5 and Figure 6 As shown, the loading and unloading process is as follows: the upper system pushes the loading task to this system, and this system Generate a loading task based on the vehicle's license plate number or loading card number. After the driver parks the vehicle at the loading machine, he taps the loading button and the system automatically reads the license plate number or swipes the loading card to initiate the loading task.
[0041] Figure 6 Parking areas 6 are located on the north (top), east, and south sides of the building. The north (top) side accommodates large trucks, while the east (right) and south (bottom) sides accommodate medium-sized trucks. The two destackers in the north warehouse supply the loaders on the north and east sides, while the two destackers in the south warehouse supply the loaders on the east and south sides.
[0042] According to the goods required for the task, the system finds the corresponding pallet in the warehouse and calls its aisle stacker to unload the pallet, which is then sent to the depalletizer 7 used by the loader via the rear conveyor line 15. The pallet is then depalletized into individual bagged materials 12 and sent to the depalletizer 7 via the transfer belt conveyor line 16. The manipulator of the depalletizer 7 completes the grabbing and packing of the pallets. After depalletizing, the remaining empty pallets are sent to the stacker 8 via the conveyor line and stacked into groups of seven empty pallets 10. The system allocates the aisle according to the number of remaining empty pallets in the aisle in the warehouse and whether the aisle stacker is available. The pallets are sent to the aisle entrance of the rear area of the warehouse via the rear conveyor line 15 and are put on the shelves for storage by the stacker.
[0043] In addition to automatically loading standard-shaped materials, the system also supports manual loading and unloading of non-standard-shaped materials, as well as random inspection of pallets within the warehouse. This invention is ready for use in the Shanxi Lingshi Zhongcoal Chemical Automated Three-Dimensional Storage Equipment Project.
[0044] The technical means disclosed in the solutions of the present invention are not limited to those disclosed in the above-mentioned embodiments, but also include technical solutions composed of any combination of the above-mentioned technical features. It should be noted that those skilled in the art may make various improvements and modifications without departing from the principles of the present invention, and such improvements and modifications are also considered to be within the scope of protection of the present invention.
Claims
1. A 24-hour production line fully automatic classification storage and automatic loading system based on a vertical warehouse, characterized by: It includes palletizing warehousing unit, palletizing replenishment unit, loading and unloading unit and stacking and returning unit, among which: The palletizing and warehousing unit is used to calibrate the material quality and bag the materials. At the same time, the bagged materials are palletized on empty pallets and then sent to the vertical warehouse for storage; The palletizing and replenishing unit is used to transport the empty pallets in the vertical warehouse to the palletizing and warehousing unit; The loading and unloading unit is used to send the pallets of the type that need to be loaded out of the vertical warehouse, and to separate the materials from the pallets into bags for loading. The remaining empty pallets are stacked and returned to the warehouse unit; The stacking tray return unit stacks multiple empty pallets into a group of empty pallet stacks, and transports the empty pallet stacks to the vertical warehouse for storage.
2. The 24-hour production line fully automatic classification storage and automatic loading system based on a vertical warehouse according to claim 1 is characterized by: The vertical warehouse includes at least two storage areas, and different storage areas work simultaneously. Each storage area includes an aisle stacker, at least one RGV and at least three aisles (5). The RGV receives the palletized materials from the palletizing storage unit and transports the palletized materials to the aisle stacker. The aisle stacker places the palletized materials on the corresponding shelves through the aisle (5).
3. The 24-hour production line fully automatic classification storage and automatic loading system based on a vertical warehouse according to claim 1 is characterized by: The stacking and warehousing unit is arranged at the entrance of the vertical warehouse, and the stacking and warehousing unit comprises a packaging machine, a belt conveyor (2), a high-position palletizer (1) and a front conveyor (14) of the vertical warehouse. The packaging machine is connected to the material production line and bags the materials. The weight of each bag of materials is 50 kg. The belt conveyor (2) transports the bagged materials to the high-position palletizer (1). The high-position palletizer (1) stacks the bagged materials on a pallet as full pallet materials (11). The front conveyor (14) of the vertical warehouse is used to transport the full pallet materials (11) into the warehouse or to transport the empty pallet (9) from the vertical warehouse to the high-position palletizer (1).
4. The 24-hour production line fully automatic classification storage and automatic loading system based on a vertical warehouse according to claim 3 is characterized by: The number of bagged materials stacked by the high-position palletizer (1) on the empty pallet (9) is 40 bags. The outlet of the high-position palletizer (1) is provided with a weight and size inspection device. When the weight and size inspection device reads that the goods are overweight or out of shape, it will control the RGV to send the pallet to the inspection station in the front area of the warehouse. After the shape of the goods is manually corrected, the pallet is put back into the warehouse.
5. The 24-hour production line fully automatic classification storage and automatic loading system based on a vertical warehouse according to claim 1 is characterized by: The stacking and replenishing unit takes out a group of empty pallet stacks (10) from the vertical warehouse each time and sends them to the stacking and warehousing unit. A group of empty pallet stacks (10) includes seven empty pallets (9), and the seven empty pallets (9) are stacked in sequence.
6. The 24-hour production line fully automatic classification storage and automatic loading system based on a vertical warehouse according to claim 1 is characterized by: The loading and unloading unit includes a loading sensing device, a rear-end conveyor (15), a depalletizer (7) and a transfer belt conveyor line (16). The loading sensing device is a camera or a card reader. The camera performs license plate recognition. The card reader is used to swipe a card to start loading and unloading. The rear-end conveyor (15) transports full pallets (11) from the vertical warehouse to the depalletizer (7) or transports a group of empty pallet stacks (10) into the vertical warehouse. The depalletizer (7) depalletizes the transported full pallets (11) into bags and loads them onto vehicles through the transfer belt conveyor line (16). The remaining empty pallets (9) are sent to the stack return unit.
7. The 24-hour production line fully automatic classification storage and automatic loading system based on a vertical warehouse according to claim 6 is characterized by: The stacking and returning unit includes a stacking machine (8), which stacks the empty pallets (9) delivered by the loading and unloading unit into empty pallet stacks (10) of seven pallets each, and allocates the empty pallet stacks (10) to the target lanes for returning to the warehouse according to the number of empty pallet stacks (10) remaining in each lane in the warehouse and the available status of the lane stacker. The empty pallet stacks (10) are sent to the lane rear area entrance via the rear conveyor line (15), and the lane stacker returns the empty pallet stacks (10) to the three-dimensional shelf for storage.