Part in-factory receiving information and package empty data acquisition system based on RFID (Radio Frequency Identification Device)

Abstract

The invention provides an RFID-based part in-factory receiving information and package empty data acquisition system. The system comprises a TMS system, an ISC system, an RFID system, a CMS system, an MHS system, a JUMP system and an ADWN system. The TMS system provides a part pickup plan for the ISC system and the MHS system and further provides train number information for the MHS system, the ISC system provides part actual palletizing and engineering change information for the RFID system and provides the part pickup plan for the MHS system, and the RFID system provides part receiving data for the MHS system and provides package empty returning data for the CMS system. The MHS system provides train number information and unloading position information for the RFID system and provides part receiving data for the JUPM system. According to the invention, an RFID automatic induction mode is adopted as an incoming part delivery and packaging return-to-empty data acquisition mode, and the data acquisition efficiency and accuracy are improved.

Description

Technical Field

[0001] The present invention relates to the field of logistics technology, and in particular to an RFID-based parts incoming goods receipt information and packaging return data collection system. Background Art

[0002] Logistics, as one of the core business processes in the automotive industry, is still labor-intensive, with low labor efficiency and informationization level, so it is in urgent need of digital transformation. Figure 1 As shown, inbound logistics encompasses the entire process of parts production, stocking, shipping, transportation, intermediate storage, distribution to the OEM, and return of empty packaging. Logistics operations are largely manual, and logistics data is collected manually at multiple points, resulting in low efficiency and poor accuracy. The entire process utilizes eight systems and 10 sets of business data. Four of these sets are collected through manual counting and entry, while six are collected through manual scanning or clicking on systems. Furthermore, three of the eight systems are completely isolated, and while data connections exist between five systems, data transmission is not fully automated and often requires manual connection. This prevents data from driving automated business flows and creates data silos with low transmission efficiency.

[0003] RFID, or radio frequency identification, is a type of automatic identification technology. It has been widely applied in fields such as second-generation ID cards, access control systems, and expressway ETC systems. Currently, a small number of OEMs in the automotive industry are using RFID in specific logistics operations, such as receiving transmissions, handling parts from in-plant RDC, receiving materials, and managing the quantity of returned empty packaging. However, no OEM in China has yet to implement this technology across all incoming parts receiving and packaging operations.

[0004] Therefore, in order to address the above issues, it is urgent to carry out digital transformation of inbound logistics. Figure 1 The red-boxed part of the digital transformation business scope includes the receipt and packaging return of parts from the OEM, involving business processes, systems and data, involving 4 systems, requiring the collection of 2 sets of business data and the issuance of 1 business instruction, all of which are manually scanned or counted, with a working time of 140 seconds per pallet, and 22 people required for two shifts. Summary of the Invention

[0005] To address these issues, the present invention discloses an RFID-based data collection system for incoming parts and returned packaging. Based on the principle of data-driven business, this system connects data through system cascade and interfaces with infrastructure middleware via MQTT, CoAP, and LwM2M for real-time data collection, batch import, and logical processing. The processed data is then passed to applications for data storage and business processing, enabling efficient collaboration and cross-calling between data clusters. This system automatically analyzes and transmits data, and automatically triggers the next workflow.

[0006] The specific plan is as follows:

[0007] An RFID-based parts incoming receipt information and packaging return data collection system includes a TMS system (transportation management system), an ISC system (intelligent supply chain system), an RFID system (radio frequency identification system), a CMS system (empty container management system), an MHS system (material handling system), a JUMP system (joint user task planning system) and an ADWN system (scheduling system); the TMS system provides a parts pickup plan to the ISC system and the MHS system, and also provides train information to the MHS system; the ISC system provides actual parts palletizing and engineering change information to the RFID system, and provides a parts pickup plan to the MHS system; the RFID system provides parts receipt data to the MHS system, and provides packaging return data to the CMS system; the MHS system provides train information and unloading location information to the RFID system, and provides parts receipt data to the JUPM system.

[0008] Furthermore, the RFID system includes an RFID tag and an RFID reading device; the RFID tag is installed on the package, and two RFID tags are installed on opposite surfaces of each package (if two RFID tags are installed on the package, the reading rate can be increased by 1.23 times; if tags are installed on two adjacent surfaces of the package, the reading rate increases by only 1.08 times, while if tags are installed on two opposite surfaces, the reading rate increases by 1.38 times), wherein the packaging includes pallets, plastic boxes, material racks and storage cages, and the RFID tag types are divided into white card tags and anti-metal tags. White card tags are installed on pallets, plastic boxes and panel boxes, and anti-metal tags are installed on material racks and storage cages; the RFID reading device is installed on a forklift (making the forklift a mobile automatic identification device with high flexibility and adaptability, and the RFID reading device is installed without changing the basic structure of the forklift and without affecting the rated lifting weight and load center distance, such as a clamping installation method, so as not to block the forklift driver's operating line of sight and ensure the signal reading rate), and the forklift is equipped with 6 antennas.

[0009] Among them, by setting up label inspection and installation points in three locations: the main engine factory, the intermediate storage warehouse, and the local supplier, RFID labels are installed on the packaging distributed in the main engine factory, the intermediate storage warehouse, the vehicles in transit and the parts suppliers.

[0010] Furthermore, the RFID signal reading accuracy is improved by determining the optimal reading position, determining the optimal reading power, adding data screening functions and abnormal error prevention solutions.

[0011] (1) Determine the optimal reading position. Specifically, when receiving parts, use the on-site building walls and truck doors as natural signal shielding walls. After passing through the logistics door, the forklift rotates 90 degrees to face the parts temporary storage area and then starts the identification function, which can avoid reading the signals of parts that have not been unloaded from the truck. When the package is returned empty, use the closed metal door on one side of the flying wing vehicle as a natural signal shielding wall to read the empty package data on the truck side, thereby reducing half of the package cross-read data.

[0012] (2) Determine the optimal reading power, specifically: the power of the RFID reading device is greater than 25DBM (at 25DBM, the signal can be read at a distance of about 10 meters, the signal to be read accounts for 87%, and the cross-read signal accounts for 13%. When the power is 30DBM, the signal can be read at a distance of about 15 meters, the signal to be read accounts for 75%, and the cross-read signal accounts for 25%. The cross-read signal that needs to be processed at 30DBM power is about twice that of 25DBM); and combined with the characteristics of RFID signals being reflected by metal, the RFID signal is reflected by the metal truck compartment to form signal superposition enhancement. After all the empty packages are loaded, the forklift reads the signal three times at three different positions on one side of the compartment, thereby achieving 100% reading of the empty package data at 25DBM power.

[0013] (3) Add data screening function, specifically: compare the actual delivery data of the parts supplier with the pick-up plan data, record and transmit the data within the plan range, and display abnormal delivery if it is not delivered or outside the plan range; compare the empty package return plan with the actual RFID reading data, record and transmit the data within the plan range, and automatically filter out the data outside the plan range.

[0014] (4) The specific solution for preventing abnormalities is to install a driving computer on the forklift to start the identification device and verify the data read each time, so as to prevent abnormalities such as RFID device damage, system abnormalities, network abnormalities, and reading rate from being identified in a timely manner. The driving computer is used to display the number of pallets read each time after starting automatic identification, inform the forklift driver by voice, and display various abnormalities to remind the forklift driver to deal with them in a timely manner.

[0015] Combining the above four solutions ensures that the project can achieve 100% accurate reading of RFID signals based on the implementation of network, equipment and operating standards.

[0016] Furthermore, anti-metal tags are installed on metal packaging to prevent RFID signals from being shielded by metal. Specifically, electronic tags are encapsulated with anti-magnetic wave-absorbing materials. RFID tags are sensed and identified on a pallet basis using plastic packaging parts to prevent RFID signals from being shielded by metal parts. Specifically, the order information of each box of parts on the pallet is bound to the pallet RFID, so that only the RFID tag signal on the pallet is identified when the parts are delivered, and the receipt data of the entire pallet of parts can be read.

[0017] Furthermore, the RFID tag is provided with a QR code. When the supplier ships the parts, the part information is bound to the QR code on the packaging RFID tag. This allows the supplier's existing scanning equipment to also recognize the RFID tag, eliminating the need for a dedicated RFID tag scanner and effectively avoiding additional costs. Since the packages are stacked after loading and cannot be recognized by the QR code information, to facilitate binding for the parts supplier, an iron QR code is installed on the packaging to improve binding efficiency.

[0018] The beneficial effects of the present invention are:

[0019] (1) Utilize the shielding and function of metal on RFID signals to reduce data cross-reading and improve the accuracy of RFID signal reading;

[0020] First, metal doors and walls are used to shield RFID signals to reduce data cross-reading during the parts receiving process; second, metal doors are used to shield RFID tag signals on the outside of the door to ensure the accuracy of the signals read on the truck; finally, the interference and reflection function of metal doors on RFID tag signals is used to form signal superposition, achieving 100% empty package data reading at 25DBM power.

[0021] (2) Packaging is the smallest intelligent unit in the field of inbound logistics;

[0022] Each package is given two RFID tags, making the package the smallest intelligent unit in the supply chain process, and realizing the Internet of Things in the logistics process with packaging as the carrier.

[0023] (3) Forklift as a mobile automatic identification device;

[0024] Transforming a forklift into a mobile RFID automatic identification device is more flexible and adaptable than the RFID logistics door solution, and is also less expensive.

[0025] (4) Open up data links and maximize the value of data;

[0026] Through RFID hardware modules and equipment, multiple data interfaces, computer technology, and visualization technology, we have realized a visual supervision system for inbound logistics operations, as well as automatic calculation and processing of inventory, vehicles, tasks, and data in all areas, and real-time visual tracking and early warning of risks, so as to achieve closer control over the supply chain, ensure stable supply, reduce personnel input, and rationally allocate resources to reduce operating costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 This is a flowchart of parts entering the factory and packaging and returning empty parts before the implementation of this invention, where the red box represents the scope of digital transformation.

[0028] Figure 2 It is a system diagram of the present invention.

[0029] Figure 3 This is a flowchart of parts entering the factory and packaging and returning empty after the implementation of this invention, where the red box represents the scope of digital transformation.

[0030] Figure 4 Schematic diagram of the installation of RFID tags on packaging.

[0031] Figure 5 Schematic diagram of installing an RFID reading device on a forklift.

[0032] Figure 6 A diagram to prevent data cross-reading when receiving parts.

[0033] Figure 7 A diagram showing a solution to reduce data cross-reading when packaging is returned empty.

[0034] Figure 8 Figure 1. RFID tag signal enhancement for metal carriage reflection. DETAILED DESCRIPTION

[0035] The present invention will be further explained below in conjunction with specific embodiments. It should be understood that the following specific embodiments are only used to illustrate the present invention and are not used to limit the scope of the present invention.

[0036] like Figure 2 and 3As shown, the present invention provides an RFID-based parts incoming receipt information and packaging return data collection system, including a TMS system, an ISC system, an RFID system, a CMS system, an MHS system, a JUMP system and an ADWN system; the TMS system provides a parts pickup plan to the ISC system and the MHS system, and also provides train information to the MHS system; the ISC system provides actual parts palletizing and engineering change information to the RFID system, and provides a parts pickup plan to the MHS system; the RFID system provides parts receipt data to the MHS system, and provides packaging return data to the CMS system; the MHS system provides train information and unloading location information to the RFID system, and provides parts receipt data to the JUMP system.

[0037] like Figure 4 As shown, the RFID system includes an RFID tag and an RFID reading device; the RFID tag is installed on the package, and two RFID tags are installed on opposite sides of each package (installing two RFID tags on the package can increase the reading rate by 1.23 times; if the tags are installed on two adjacent sides of the package, the reading rate increases by only 1.08 times, while if the tags are installed on two opposite sides, the reading rate increases by 1.38 times). The package includes plastic boxes, material racks and storage cages; Figure 5 As shown, the RFID reading device is installed on a forklift (making the forklift a mobile automatic identification device with high flexibility and adaptability, and the RFID reading device is installed without changing the basic structure of the forklift and without affecting the rated lifting capacity and load center distance, such as a clamping installation method, which neither blocks the forklift driver's operating line of sight nor ensures the signal reading rate), and the forklift is equipped with 6 antennas.

[0038] In this embodiment, by setting up label inspection and installation points in the OEM, intermediate storage warehouse, and local suppliers, RFID labels are installed on the packaging distributed in the OEM, intermediate storage warehouse, in-transit vehicles, and parts suppliers.

[0039] In this embodiment, the RFID signal reading accuracy is improved by determining the optimal reading position, determining the optimal reading power, adding a data screening function, and an abnormality prevention scheme.

[0040] (1) The optimal reading position is determined as follows: when receiving parts, the on-site building walls and truck doors are used as natural signal shielding walls. After passing through the logistics door, the forklift rotates 90 degrees to face the parts temporary storage area and then starts the recognition function, which can avoid reading the signal of the parts that have not been unloaded from the truck ( Figure 6 When the package is returned empty, the closed metal door on one side of the flying wing vehicle is used as a natural signal shielding wall to read the empty package data on the truck side, thereby reducing the cross-reading data of the package by half ( Figure 7 ).

[0041] (2) The optimal reading power is determined as follows: the power of the RFID reading device is greater than 25DBM (at 25DBM, the signal can be read at a distance of about 10 meters, the signal to be read accounts for 87%, and the cross-read signal accounts for 13%. When the power is 30DBM, the signal can be read at a distance of about 15 meters, the signal to be read accounts for 75%, and the cross-read signal accounts for 25%. The cross-read signal that needs to be processed with a power of 30DBM is about twice that of 25DBM); and combined with the characteristics of RFID signals being reflected by metal, the metal truck compartment is used to reflect the RFID signal to form signal superposition enhancement (such as Figure 8 ), after all the empty packages are loaded, the forklift reads the signal three times at three different positions on one side of the carriage, thereby achieving 100% reading of the empty package data at 25DBM power.

[0042] (3) The added data screening function specifically compares the actual delivery data of the parts supplier and the empty packaging return plan with the actual RFID reading data. Data within the planned range is recorded and transmitted, and data outside the planned range is automatically filtered out by the system. This effectively avoids the impact of RFID signal crosstalk on reading accuracy. See the table below:

[0043] System data screening logic diagram

[0044] Plan to read the number of Actual reading of the number of System Logic 1 1 Match, accept 2 1 Not delivered yet, received none 1 Read data in series and filter

[0045] (4) The specific solution for preventing abnormalities is to install a driving computer on the forklift to start the identification device and review the data read each time to prevent abnormalities such as RFID device damage, system abnormalities, network abnormalities, and reading rate from being identified in a timely manner. The driving computer is used to display the number of pallets read each time after starting automatic identification, inform the forklift driver by voice, and display various abnormalities to remind the forklift driver to deal with them in a timely manner.

[0046] Combining the above four solutions ensures that the project can achieve 100% accurate reading of RFID signals based on the implementation of network, equipment and operating standards.

[0047] In this embodiment, anti-metal tags are installed on metal packaging to prevent RFID signals from being shielded by metal. Specifically, electronic tags are encapsulated with anti-magnetic wave-absorbing materials. RFID tags are sensed and identified on a pallet basis using plastic packaging parts to prevent RFID signals from being shielded by metal parts. Specifically, the order information of each box of parts on the pallet is bound to the pallet RFID, so that only the RFID tag signal on the pallet is identified when the parts are delivered, thereby completing the reading of the receipt data of the entire pallet of parts.

[0048] In this embodiment, a QR code is set on the RFID tag. When the supplier ships the parts, the part information is bound to the QR code on the packaging RFID tag, so that the supplier's original scanning equipment can also recognize the RFID tag. There is no need to add a dedicated RFID tag scanner, which effectively avoids additional costs.

[0049] The present invention achieves the following effects:

[0050] (1) Automatically collect data from parts logistics processes to improve efficiency and reduce costs

[0051] The time required to collect data for receiving and collecting empty boxes per pallet decreased from 140 seconds to 12 seconds, increasing operational efficiency by 91%. The process was controlled through data transmission, reducing labor hours and optimizing 14 employees across two shifts, saving 1.4 million yuan in labor costs annually. This achieved the goal of increasing efficiency and reducing costs.

[0052] Because the packaging unit has become intelligent, its continued application and development will become even more convenient in the future. For example, by deploying RFID identification equipment at Zhongchu warehouses and parts suppliers' inbound and outbound processes, parts and packaging can be automatically identified, enabling expanded applications in the supply chain.

[0053] (2) Realize cross-system data connection and data-driven business

[0054] The system collects, transmits, processes, and provides notifications for parts receipt and empty packaging data. This interconnected system forms a business-driven data system, enabling data-driven business in this area. Currently, parts receipt and empty packaging data are automatically identified, analyzed, and transmitted via RFID. This data is used for parts receipt financial settlement and precise packaging resource allocation, significantly improving efficiency and reducing costs.

[0055] (3) Digital talent training

[0056] By establishing a digital team for the enterprise, the business team gradually acquires a digital mindset and cultivates talent with digital thinking and skills. This lays a solid foundation for the enterprise to support business development through digital transformation technologies such as data connectivity, analysis, and application in the future.

[0057] The present invention realizes the data collection method of incoming parts delivery and packaging return using RFID automatic sensing, which improves the efficiency and accuracy of data collection. At the same time, an RFID system was developed for connection with RFID hardware equipment and data transmission, and 6 systems were modified, so that 106 data fields can be connected in series between 7 systems. The information flow of parts receipt and packaging return business is opened up, and through data transmission and system development logic settings, the processes are automatically linked without manual transmission. The data collection working time is 12 seconds per pallet, and it runs simultaneously at 22 unloading ports of welding and assembly. 14 people are optimized in two shifts, reducing labor costs by 1.4 million per year and alleviating the workload of front-line operators.

[0058] 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. The RFID-based parts incoming goods receipt information and packaging return data collection system is characterized by: It includes TMS system, ISC system, RFID system, CMS system, MHS system, JUMP system and ADWN system; the TMS system provides parts picking plan to ISC system and MHS system, and also provides train number information to MHS system; the ISC system provides actual parts palletizing and engineering change information to RFID system, and provides parts picking plan to MHS system; the RFID system provides parts receiving data to MHS system, and provides empty packaging return data to CMS system; the MHS system provides train number information and unloading location information to RFID system, and provides parts receiving data to JUMP system.

2. The RFID-based parts incoming goods receipt information and packaging return data collection system according to claim 1 is characterized in that: The RFID system includes RFID tags and RFID reading devices; the RFID tags are installed on the packaging, and two RFID tags are installed on opposite sides of each package. The RFID tag types are divided into white card tags and anti-metal tags. Among them, pallets, plastic boxes, and panel boxes are installed with white card tags, and material racks and storage cages are installed with anti-metal tags; the RFID reading device is installed on a forklift, and the forklift is equipped with 6 antennas.

3. The RFID-based parts incoming goods receipt information and packaging return data collection system according to claim 2 is characterized in that: By setting up label inspection and installation points in three locations: the OEM, the Sinopec warehouse, and the parts supplier, RFID labels are installed on the packaging distributed in the OEM, Sinopec warehouse, in-transit vehicles, and parts suppliers.

4. The RFID-based parts incoming goods receipt information and packaging return data collection system according to claim 1 is characterized in that: The RFID signal reading accuracy in the RFID system is improved by determining the optimal reading position, determining the optimal reading power, adding a data screening function and an abnormality prevention scheme.

5. The RFID-based parts incoming goods receipt information and packaging return data collection system according to claim 4 is characterized in that: The optimal reading position is determined as follows: when receiving parts, the on-site building walls and truck doors are used as natural signal shielding walls. After passing through the logistics door, the forklift rotates 90 degrees to face the parts temporary storage area and then starts the identification function, which can avoid reading the signals of parts that have not been unloaded from the truck; when the package is returned empty, the closed metal door on one side of the flying wing vehicle is used as a natural signal shielding wall, and the empty package data is read on the truck side to reduce half of the package cross-read data.

6. The RFID-based parts incoming goods receipt information and packaging return data collection system according to claim 4 is characterized in that: The optimal reading power is determined by ensuring that the RFID reader power is greater than 25 dBM. Furthermore, the metal truck compartment is used to reflect the RFID signal, thereby enhancing the signal. After all empty packages are loaded, the forklift reads the signal three times at three different locations on one side of the compartment.

7. The RFID-based parts incoming goods receipt information and packaging return data collection system according to claim 4 is characterized in that: The added data screening function specifically compares the actual delivery data of the parts supplier with the pick-up plan data, records and transmits the data within the planned range, and displays abnormal delivery if it is not delivered or outside the planned range; The return plan for empty packages is compared with the actual RFID reading data. Data within the planned range is recorded and transmitted, and data outside the planned range is automatically screened out by the system.

8. The RFID-based parts incoming goods receipt information and packaging return data collection system according to claim 1 is characterized in that: The specific abnormality prevention plan is: installing an on-board computer on the forklift to start the identification device and review the data read each time. After starting the automatic identification, the on-board computer is used to display the number of pallets read each time, inform the forklift driver by voice, and display various abnormalities to remind the forklift driver to deal with them in time.

9. The RFID-based parts incoming goods receipt information and packaging return data collection system according to claim 2 is characterized in that: In the RFID system, anti-metal tags are installed on metal packaging to prevent RFID signals from being shielded by metal. Specifically, the electronic tags are encapsulated with anti-magnetic wave-absorbing materials. RFID tags are sensed and identified on a pallet basis using plastic packaging parts to prevent RFID signals from being shielded by metal parts. Specifically, the order information of each box of parts on the pallet is bound to the pallet RFID. When the parts are delivered, only the RFID tag signal on the pallet is recognized, and the receipt data of the entire pallet of parts can be read.

10. The RFID-based parts incoming goods receipt information and packaging return data collection system according to claim 2 is characterized in that: A QR code is set on the RFID tag in the RFID system. When the supplier ships the parts, the part information is bound to the QR code on the packaging RFID tag. Since the packaging is in a stacking state after loading, the QR code information cannot be identified. In order to facilitate binding for the parts supplier, an iron QR code is installed on the packaging to improve binding efficiency.

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