A non-transfer material delivery prompting method and system applied to an intelligent induction rack

Abstract

This invention relates to a non-transfer material issuance prompting method and system applied to intelligent sensor racks, comprising the following steps: receiving material issuance requests from work orders; performing material issuance analysis to obtain the rack code of the material to be issued rack, the number of material trays to be issued, the unique code of each material tray, and the storage location code of the corresponding storage location on the rack; pushing the obtained information to a barcode scanning terminal device and prompting the user to scan the rack code on the rack; determining whether the rack code sent by the barcode scanning terminal device has been received within a set time; if yes, proceeding to the next step; otherwise, prompting the user to rescan the rack code and entering the rack code receiving state; significantly reducing the error risk of intelligent sensor racks in the non-transfer material issuance process, providing a solid and reliable foundation for other processes, reducing the cost of correcting errors for enterprises, and effectively filling the industry gap in this process of intelligent sensor racks.

Description

Technical Field

[0001] This invention relates to the field of intelligent sensor material rack technology, and more specifically, to a non-transfer material dispensing prompt method and system applied to intelligent sensor material racks. Background Technology

[0002] Intelligent sensor racks are a new type of rack with material sensing and detection functions for trays. Each storage location on the rack is typically assigned a location code, and a sensor is installed at each location to read the placed tray. All this information is centrally controlled by a host system. Currently, when performing non-transfer feeding operations on intelligent sensor racks (non-transfer feeding means the trays on the rack are directly fed to the production line, as opposed to transfer feeding, where the trays are fed to an intermediate rack), the prompts used are varied and lack a unified standard. Furthermore, the prompts are incomplete and too simplistic, failing to provide targeted and effective alerts for the various errors that may occur during the feeding process. The formality of the prompts far outweighs their actual effectiveness. After receiving error prompts, the rack operator still needs to follow the internally defined inspection procedures to determine the location of the error.

[0003] These types of errors include: incorrect material racks for issuing materials (this type of basic error is common and difficult to detect, especially when there are many racks and they are densely distributed), incorrect storage location for issuing materials, errors caused by unscanned trays on the racks, errors caused by illegally removed trays on the racks, and errors caused by work orders corresponding to multiple racks (this refers to situations where the trays required for one work order are on multiple racks). For these reasons, a non-transfer material issuing prompt method and system applied to intelligent sensor racks is needed. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a non-transfer material dispensing prompt method for intelligent induction material racks, and to provide a non-transfer material dispensing prompt system for intelligent induction material racks, in view of the above-mentioned defects of the prior art.

[0005] The technical solution adopted by this invention to solve its technical problem is:

[0006] A non-transfer material dispensing prompt method for intelligent sensor-operated material racks is constructed, wherein the method includes the following steps:

[0007] Receive the material issuance request from the work order, perform material issuance analysis to obtain the rack code of the material rack to be issued, the number of material trays to be issued, the unique code of each material tray to be issued, and the storage location code of the storage location on the rack corresponding to each material tray to be issued.

[0008] The obtained information is pushed to the barcode scanning terminal device, and a prompt is given to scan the barcode on the bar;

[0009] Determine whether the rack code sent by the barcode scanning terminal device has been received within the set time. If yes, proceed to the next step; otherwise, prompt the user to scan the rack code again and enter the rack code receiving state.

[0010] Receive and determine whether the rack code matches the rack code of the rack to be issued obtained from the material issuance analysis. If it matches, proceed to the next step; otherwise, prompt that the rack code is incorrect, rescan the rack code and return to the previous step.

[0011] The light corresponding to the material tray waiting to be dispensed on the control rack will light up, prompting the user to remove the material tray from the lit storage position.

[0012] Monitor and read the storage code of the storage location on the material rack whose storage location status has changed, and determine whether the storage code matches the storage code obtained from the material issuance analysis. If it matches, proceed to the next step; otherwise, proceed to the material issuance anomaly handling process.

[0013] Increment the number of issued material trays by 1 and indicate that the single tray of material has been successfully issued;

[0014] Read the unique code of the pallet corresponding to the storage location whose status has changed, and delete the read unique code from the pallet dataset of the rack storage;

[0015] Determine whether all materials in the lit storage positions on the current material rack have been removed. If yes, proceed to the next step; otherwise, jump to the monitoring step and read the storage position code of the storage position whose status on the material rack has changed.

[0016] Determine if the work order has been completed. If so, prompt that the work order has been completed and end the material issuance process. Otherwise, proceed to the step of pushing the obtained information to the barcode scanning terminal device and prompt that the current rack has been completed, and proceed to the next rack for material issuance.

[0017] The non-transfer material dispensing prompt method applied to intelligent sensor material racks according to the present invention includes the following material dispensing anomaly handling process:

[0018] Determine whether there is a material tray at the storage location where the storage status has changed;

[0019] If the storage location status has changed, the storage location code is added to the unscanned placement exception dataset, indicating that there is an unscanned placement exception, and then the unscanned placement resolution process is initiated.

[0020] Otherwise, read the unique code of the associated pallet corresponding to the storage location whose storage status has changed, delete the obtained pallet's unique code from the rack storage pallet dataset, add the storage location code and the obtained pallet's unique code to the illegal retrieval dataset, indicate that there is an illegal retrieval exception, and enter the illegal retrieval exception resolution process.

[0021] The non-transfer material dispensing prompt method applied to intelligent sensor material racks according to the present invention includes the following steps for resolving the unscanned material placement process:

[0022] Receive the rack code of the current rack and read the abnormal dataset corresponding to the rack code;

[0023] Determine if the unscanned tray in the abnormal dataset is empty. If it is, indicate that there is no abnormality in the rack and end the process. Otherwise, indicate that the unscanned tray should be removed and proceed to the next step.

[0024] Monitor the status of each storage location on the material rack;

[0025] Determine whether the unscanned tray has been removed. If yes, proceed to the next step; otherwise, return to the previous step.

[0026] The message indicates that the "unscanned barcode placement" status has been removed, the color of the storage space light has been changed to the normal color, and the corresponding "unscanned barcode placement" data set has been deleted from the abnormal data set.

[0027] Determine if the "unscanned barcode placed in the abnormal dataset" is empty. If yes, proceed to the next step; otherwise, return to the step of monitoring the status of each storage location on the material rack.

[0028] The message indicates that the "unscanned QR code placed" status has been removed, ending the process of removing the "unscanned QR code placed" status.

[0029] The non-transfer material dispensing prompt method applied to intelligent sensor material racks according to the present invention includes the following steps for resolving illegal removal anomalies:

[0030] Receive the rack code of the current rack and read the abnormal dataset corresponding to the rack code;

[0031] Determine if the illegally retrieved data set in the abnormal data set is empty. If it is, indicate that the material rack is not abnormal and end the process. Otherwise, indicate that the illegally retrieved material tray should be returned and proceed to the next step.

[0032] Receive and determine whether the unique code of the returned material tray is the unique code of the illegally taken material tray. If it is, prompt the tray to be put back on the shelf and proceed to the next step; otherwise, prompt the tray return error.

[0033] Record the unique code of the material tray and start the countdown;

[0034] Before the countdown ends, determine whether the storage location code of the returned material tray has been received from the storage location on the material rack. If yes, proceed to the next step; otherwise, prompt that the racking timeout has occurred and return to the step of receiving and determining whether the unique code of the returned material tray is the unique code of the illegally retrieved material tray.

[0035] Record the storage location code of the storage location on the bound material rack where the returned material tray is placed, as well as the unique code of the returned material tray, and enter the valid material loading dataset to resolve the illegal retrieval anomaly corresponding to the returned material tray.

[0036] The non-transfer material dispensing prompt method applied to intelligent sensor material racks according to the present invention further includes the illegal removal anomaly resolution process as follows:

[0037] Check again whether the illegally retrieved dataset in the abnormal dataset is empty; otherwise, proceed to the step of receiving and checking whether the unique code of the returned material tray is the unique code of the illegally retrieved material tray. If yes, proceed to the next step.

[0038] Determine if there are any abnormalities on the material rack or in the storage location. If so, proceed with the corresponding abnormality handling process; otherwise, indicate that the abnormality has been resolved and end the illegal removal handling process.

[0039] The non-transfer material dispensing prompt method for intelligent sensor-operated material racks described in this invention, wherein determining whether all materials in the currently lit storage positions on the rack have been removed includes:

[0040] Determine if the number of issued material trays on the current material rack is equal to the number of material trays waiting to be issued on the current material rack. If yes, it is determined that all materials in the lit storage positions on the current material rack have been removed; otherwise, it is determined that all materials in the lit storage positions on the current material rack have not been removed.

[0041] The non-transfer material issuance prompt method applied to intelligent sensor material racks according to the present invention, wherein determining whether the work order has been issued includes:

[0042] Determine if the total number of issued material trays is equal to the number of material trays required by the work order. If yes, the material issuance for the work order is considered complete; otherwise, the material issuance for the work order is considered incomplete.

[0043] The non-transfer material dispensing prompt method applied to an intelligent sensor-operated material rack according to the present invention further includes:

[0044] When the rack code is first received on the rack, the current rack is locked;

[0045] When determining whether all materials in the lit storage positions on the current material rack have been removed, if the material trays on the current material rack have not been completely dispensed, the current material rack will remain locked; otherwise, the current material rack will be unlocked.

[0046] The non-transfer material dispensing prompt method applied to intelligent sensor material racks according to the present invention includes one or more of the following prompting methods: voice prompts from the material rack, tower lights from the material rack, storage position lights from the material rack, voice prompts from the PDA, and text prompts on the PDA screen.

[0047] A non-transfer material dispensing prompt system for an intelligent induction material rack, the system comprising: a system host, a material rack, and a barcode scanning terminal device; the material rack is provided with multiple storage positions, each storage position being provided with a sensing device for an induction material tray; the barcode scanning terminal device is used for selecting and inputting processing items, and is also used for scanning the unique code of the material tray and the material rack code;

[0048] The system host is used to receive data information from the material rack and the barcode scanning terminal device, and execute the barcode scanning and shelving prompt method applied to the intelligent sensing material rack as described above.

[0049] The beneficial effects of this invention are as follows: By applying the methods and procedures of this application and employing reasonable operation steps and reminder designs, the intelligent sensor rack can smoothly issue materials without transferring them, while avoiding a series of hidden errors such as racking errors, storage errors, errors caused by unscanned trays on the rack, errors caused by illegally removed trays on the rack, and errors caused by multiple racks corresponding to a work order. This allows the rack reminders to truly provide accurate and targeted guidance, significantly reducing the risk of errors in the non-transfer material issuance process of the intelligent sensor rack, providing a solid and reliable foundation for other processes, reducing the cost of correcting errors for enterprises, and effectively filling the industry gap in this process stage of the intelligent sensor rack. Attached Figure Description

[0050] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the present invention will be further described below in conjunction with the accompanying drawings and embodiments. The drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort:

[0051] Figure 1 This is a flowchart of a preferred embodiment of the non-transfer material dispensing prompt method applied to an intelligent sensor material rack according to the present invention;

[0052] Figure 2 This is a flowchart illustrating the non-transfer material dispensing prompt method for a smart sensor material rack, according to a preferred embodiment of the present invention, to resolve the issue of materials not being scanned and placed in the rack.

[0053] Figure 3 This is a supplementary flowchart illustrating the process of canceling the non-transfer material dispensing prompt method for intelligent sensor material racks according to a preferred embodiment of the present invention (followed by...). Figure 2 );

[0054] Figure 4 This is a flowchart illustrating the logic for resolving illegal material removal in a non-transfer material dispensing prompt method for an intelligent sensor material rack, according to a preferred embodiment of the present invention.

[0055] Figure 5 This is a supplementary flowchart of the logic for resolving illegal material removal in a non-transfer material dispensing prompt method for an intelligent sensor material rack, according to a preferred embodiment of the present invention (continued). Figure 4 );

[0056] Figure 6 This is a flowchart of the non-transfer material dispensing prompt method for a smart sensor material rack according to a preferred embodiment of the present invention, which includes illegal removal and unscanned barcode placement judgments. Figure 7 This is a block diagram illustrating the principle of a non-transfer material dispensing prompting system applied to an intelligent sensor material rack, according to a preferred embodiment of the present invention. Detailed Implementation

[0057] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, a clear and complete description will be provided below in conjunction with the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the protection scope of the present invention.

[0058] A preferred embodiment of the present invention is a non-transfer material dispensing prompt method applied to an intelligent sensor-operated material rack, such as... Figure 1 As shown, see also Figures 2-6 This includes the following steps:

[0059] S01: Receive the material issuance request from the work order, perform material issuance analysis to obtain the rack code of the material rack to be issued, the number of material trays to be issued, the unique code of each material tray to be issued, and the storage location code of the storage location on the rack corresponding to each material tray to be issued.

[0060] S02: Push the obtained information to the barcode scanning terminal device and prompt the user to scan the barcode on the bar;

[0061] S03: Determine whether the rack code sent by the barcode scanning terminal device has been received within the set time. If yes, proceed to the next step; otherwise, prompt to scan the rack code again and enter the rack code receiving state.

[0062] S04: Receive and determine whether the rack code matches the rack code of the rack to be issued obtained from the material issuance analysis. If yes, proceed to the next step; otherwise, prompt that the rack code is incorrect, rescan the rack code and return to the previous step.

[0063] S05: The storage position light corresponding to the material tray waiting to be issued on the control rack will light up, prompting the material tray in the lit storage position to be removed.

[0064] S06: Monitor and read the storage code of the storage location whose status has changed on the material rack, and determine whether the storage code matches the storage code obtained from the material issuance analysis. If yes, proceed to the next step; otherwise, proceed to the material issuance anomaly handling process.

[0065] S07: Increment the number of issued reels by 1 and indicate that the single reel of material has been successfully issued;

[0066] S08: Read the unique code of the pallet corresponding to the storage location whose storage location status has changed, and delete the read unique code from the pallet data set of the rack storage;

[0067] S09: Determine whether all materials in the lit storage positions on the current material rack have been removed. If yes, proceed to the next step; otherwise, jump to the monitoring step and read the storage position code of the storage position whose status on the material rack has changed.

[0068] To determine whether all materials in the lit storage positions on the current material rack have been removed, the following method is used: check whether the number of issued material trays on the current material rack is equal to the number of material trays waiting to be issued on the current material rack. If they are equal, it is determined that all materials in the lit storage positions on the current material rack have been removed; otherwise, it is determined that all materials in the lit storage positions on the current material rack have not been removed.

[0069] S10: Determine whether the work order has been completed. If yes, prompt that the work order has been completed and end the material issuance. Otherwise, proceed to the step of pushing the obtained information to the barcode scanning terminal device and prompt that the current material rack has been completed and proceed to the next material rack for material issuance.

[0070] The method for determining whether a work order has been completed is as follows: check if the total number of issued material trays is equal to the number of material trays required by the work order. If so, the work order is considered to have been completed; otherwise, the work order is considered to have not been completed.

[0071] By employing the methods and procedures outlined in this application, and through the design of reasonable operational steps and reminders, the intelligent sensor rack can smoothly issue materials without transferring them. This avoids a series of hidden errors, including racking errors during issuance, incorrect storage locations, errors caused by unscanned trays, errors caused by illegally removed trays, and errors arising from multiple racks corresponding to a single work order. The rack reminders provide accurate and targeted guidance, significantly reducing the risk of errors in the non-transfer material issuance process. This provides a solid and reliable foundation for other processes, reduces the cost of correcting errors for enterprises, and effectively fills a gap in the industry for intelligent sensor racks in this process.

[0072] See Figure 6 The material feeding anomaly handling process includes the unscanned barcode insertion judgment and resolution process and the illegal removal anomaly judgment and resolution process, specifically adopting:

[0073] Determine whether there is a material tray at the storage location where the storage status has changed;

[0074] If the storage location status has changed, the storage location code is added to the unscanned placement exception dataset, indicating that there is an unscanned placement exception, and then the unscanned placement resolution process is initiated.

[0075] Otherwise, read the unique code of the associated pallet corresponding to the storage location whose storage status has changed, delete the obtained pallet's unique code from the rack storage pallet dataset, add the storage location code and the obtained pallet's unique code to the illegal retrieval dataset, indicate that there is an illegal retrieval exception, and enter the illegal retrieval exception resolution process.

[0076] Among them, such as Figure 2 and Figure 3 As shown, the process for removing items placed without scanning the code includes:

[0077] Receive the rack code of the current rack and read the abnormal dataset corresponding to the rack code;

[0078] Determine if the unscanned tray in the abnormal dataset is empty. If it is, indicate that there is no abnormality in the rack and end the process. Otherwise, indicate that the unscanned tray should be removed and proceed to the next step.

[0079] Monitor the status of each storage location on the material rack;

[0080] Determine whether the unscanned tray has been removed. If yes, proceed to the next step; otherwise, return to the previous step.

[0081] The message indicates that the "unscanned barcode placement" status has been removed, the color of the storage space light has been changed to the normal color, and the corresponding "unscanned barcode placement" data set has been deleted from the abnormal data set.

[0082] Determine if the "unscanned barcode placed in the abnormal dataset" is empty. If yes, proceed to the next step; otherwise, return to the step of monitoring the status of each storage location on the material rack.

[0083] The message indicates that the "unscanned QR code placed" status has been removed, ending the process of removing the "unscanned QR code placed" status.

[0084] Among them, such as Figure 4 and Figure 5 As shown, the process for resolving illegal retrieval issues includes:

[0085] Receive the rack code of the current rack and read the abnormal dataset corresponding to the rack code;

[0086] Determine if the illegally retrieved data set in the abnormal data set is empty. If it is, indicate that the material rack is not abnormal and end the process. Otherwise, indicate that the illegally retrieved material tray should be returned and proceed to the next step.

[0087] Receive and determine whether the unique code of the returned material tray is the unique code of the illegally taken material tray. If it is, prompt the tray to be put back on the shelf and proceed to the next step; otherwise, prompt the tray return error.

[0088] Record the unique code of the material tray and start the countdown;

[0089] Before the countdown ends, determine whether the storage location code of the returned material tray has been received from the storage location on the material rack. If yes, proceed to the next step; otherwise, prompt that the racking timeout has occurred and return to the step of receiving and determining whether the unique code of the returned material tray is the unique code of the illegally retrieved material tray.

[0090] Record the storage location code of the storage location on the bound material rack where the returned material tray is placed, as well as the unique code of the returned material tray, and enter the valid material loading dataset to resolve the illegal retrieval anomaly corresponding to the returned material tray;

[0091] Check again whether the illegally retrieved dataset in the abnormal dataset is empty; otherwise, proceed to the step of receiving and checking whether the unique code of the returned material tray is the unique code of the illegally retrieved material tray. If yes, proceed to the next step.

[0092] Determine if there are any abnormalities on the material rack or in the storage location. If so, proceed with the corresponding abnormality handling process; otherwise, indicate that the abnormality has been resolved and end the illegal removal handling process.

[0093] It should be noted that:

[0094] The prompting methods involved in this application include: voice prompts for the material rack, tower lights for the material rack, storage position lights for the material rack, voice prompts for the PDA, and text prompts for the PDA; specific settings can be made according to the specific content of each of the above steps.

[0095] During the material transfer process, if not all the material trays on the current rack have been issued, the current rack will be locked, and material issuance to other racks will not be allowed, in order to prevent employees from missing or under-issuing materials.

[0096] A barcode scanning and shelving notification system for intelligent sensor-operated material racks, such as Figure 7 As shown, the system includes: a system host 10, a material rack 11 (only one material rack is shown in the figure for example, but in actual operation there can be one or more material racks) and a barcode scanning terminal device 12; the material rack 11 is provided with multiple storage positions 110, and each storage position is provided with a sensing device 111 for sensing the material tray; the barcode scanning terminal device 12 is used for selecting and inputting processing items, and is also used to scan the unique code of the material tray 13 and the material rack code of the material rack 11;

[0097] The system host 10 is used to receive data information from the material rack 11 and the barcode scanning terminal device 12, and execute the barcode scanning and shelving prompt method applied to the intelligent sensing material rack as described above.

[0098] The system applied in this application employs a reasonable design of operating procedures and reminders to ensure that the intelligent sensor rack can smoothly issue materials without transferring them. This avoids a series of hidden errors, such as racking errors during issuance, incorrect storage locations, errors caused by unscanned trays on the rack, errors caused by illegally removed trays, and errors arising from multiple racks corresponding to a work order. The rack reminders provide accurate and targeted guidance, significantly reducing the risk of errors in the non-transfer material issuance process. This provides a solid and reliable foundation for other processes, reduces the cost of correcting errors for enterprises, and effectively fills a gap in the industry for intelligent sensor racks in this process.

[0099] It should be understood that those skilled in the art can make improvements or modifications based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims.

Claims

1. A non-transfer material dispensing prompt method applied to an intelligent sensor-operated material rack, characterized in that, The method includes the following steps: Receive the material issuance request from the work order, perform material issuance analysis to obtain the rack code of the material rack to be issued, the number of material trays to be issued, the unique code of each material tray to be issued, and the storage location code of the storage location on the rack corresponding to each material tray to be issued. The obtained information is pushed to the barcode scanning terminal device, and a prompt is given to scan the barcode on the bar; Determine whether the rack code sent by the barcode scanning terminal device has been received within the set time. If yes, proceed to the next step; otherwise, prompt the user to scan the rack code again and enter the rack code receiving state. Receive and determine whether the rack code matches the rack code of the rack to be issued obtained from the material issuance analysis. If it matches, proceed to the next step; otherwise, prompt that the rack code is incorrect, rescan the rack code and return to the previous step. The light corresponding to the material tray waiting to be dispensed on the control rack will light up, prompting the user to remove the material tray from the lit storage position. Monitor and read the storage code of the storage location on the material rack whose storage location status has changed, and determine whether the storage code matches the storage code obtained from the material issuance analysis. If it matches, proceed to the next step; otherwise, proceed to the material issuance anomaly handling process. Increment the number of issued material trays by 1 and indicate that the single tray of material has been successfully issued; Read the unique code of the pallet corresponding to the storage location whose status has changed, and delete the read unique code from the pallet dataset of the rack storage; Determine whether all materials in the lit storage positions on the current material rack have been removed. If yes, proceed to the next step; otherwise, jump to the monitoring step and read the storage position code of the storage position whose status on the material rack has changed. Determine if the work order has been completed. If so, prompt that the work order has been completed and end the material issuance. Otherwise, proceed to the step of pushing the obtained information to the barcode scanning terminal device and prompt that the current rack has been completed, and proceed to the next rack for material issuance. The abnormal material feeding process includes: Determine whether there is a material tray at the storage location where the storage status has changed; If the storage location status has changed, the storage location code is added to the unscanned placement exception dataset, indicating that there is an unscanned placement exception, and then the unscanned placement resolution process is initiated. Otherwise, read the unique code of the associated pallet corresponding to the storage location whose storage status has changed, delete the obtained pallet's unique code from the rack storage pallet dataset, add the storage location code and the obtained pallet's unique code to the illegal retrieval dataset, indicate that there is an illegal retrieval exception, and enter the illegal retrieval exception resolution process.

2. The non-transfer material dispensing prompting method applied to an intelligent sensor-operated material rack according to claim 1, characterized in that, The process for removing items that have not been scanned includes: Receive the rack code of the current rack and read the abnormal dataset corresponding to the rack code; Determine if the unscanned tray in the abnormal dataset is empty. If it is, indicate that there is no abnormality in the rack and end the process. Otherwise, indicate that the unscanned tray should be removed and proceed to the next step. Monitor the status of each storage location on the material rack; Determine whether the unscanned tray has been removed. If yes, proceed to the next step; otherwise, return to the previous step. The message indicates that the "unscanned barcode placement" status has been removed, the color of the storage space light has been changed to the normal color, and the corresponding "unscanned barcode placement" data set has been deleted from the abnormal data set. Determine if the "unscanned barcode placed in the abnormal dataset" is empty. If yes, proceed to the next step; otherwise, return to the step of monitoring the status of each storage location on the material rack. The message indicates that the "unscanned QR code placed" status has been removed, ending the process of removing the "unscanned QR code placed" status.

3. The non-transfer material dispensing prompting method applied to an intelligent sensor-operated material rack according to claim 1, characterized in that, The illegal retrieval exception resolution process includes: Receive the rack code of the current rack and read the abnormal dataset corresponding to the rack code; Determine if the illegally retrieved data set in the abnormal data set is empty. If it is, indicate that the material rack is not abnormal and end the process. Otherwise, indicate that the illegally retrieved material tray should be returned and proceed to the next step. Receive and determine whether the unique code of the returned material tray is the unique code of the illegally taken material tray. If it is, prompt the tray to be put back on the shelf and proceed to the next step; otherwise, prompt the tray return error. Record the unique code of the material tray and start the countdown; Before the countdown ends, determine whether the storage location code of the returned material tray has been received from the storage location on the material rack. If yes, proceed to the next step; otherwise, prompt that the racking timeout has occurred and return to the step of receiving and determining whether the unique code of the returned material tray is the unique code of the illegally retrieved material tray. Record the storage location code of the storage location on the bound material rack where the returned material tray is placed, as well as the unique code of the returned material tray, and enter the valid material loading dataset to resolve the illegal retrieval anomaly corresponding to the returned material tray.

4. The non-transfer material dispensing prompting method applied to an intelligent sensor-operated material rack according to claim 3, characterized in that, The illegal retrieval exception resolution process also includes: Check again whether the illegally retrieved dataset in the abnormal dataset is empty; otherwise, proceed to the step of receiving and checking whether the unique code of the returned material tray is the unique code of the illegally retrieved material tray. If yes, proceed to the next step. Determine if there are any abnormalities on the material rack or in the storage location. If so, proceed with the corresponding abnormality handling process; otherwise, indicate that the abnormality has been resolved and end the illegal removal handling process.

5. The non-transfer material dispensing prompting method applied to an intelligent sensor-operated material rack according to claim 1, characterized in that, The step of determining whether all materials in the lit storage positions on the current material rack have been removed includes: Determine if the number of issued material trays on the current material rack is equal to the number of material trays waiting to be issued on the current material rack. If yes, it is determined that all materials in the lit storage positions on the current material rack have been removed; otherwise, it is determined that all materials in the lit storage positions on the current material rack have not been removed.

6. The non-transfer material dispensing prompting method applied to an intelligent sensor-operated material rack according to claim 5, characterized in that, The process of determining whether a work order has been completed includes: Determine if the total number of issued material trays is equal to the number of material trays required by the work order. If yes, the material issuance for the work order is considered complete; otherwise, the material issuance for the work order is considered incomplete.

7. The non-transfer material dispensing prompting method applied to an intelligent sensor-operated material rack according to claim 1, characterized in that, The method also includes: When the rack code is first received on the rack, the current rack is locked; When determining whether all materials in the lit storage positions on the current material rack have been removed, if the material trays on the current material rack have not been completely dispensed, the current material rack will remain locked; otherwise, the current material rack will be unlocked.

8. The non-transfer material dispensing prompting method applied to an intelligent sensor-operated material rack according to claim 1, characterized in that, The prompting methods include one or more of the following: voice prompts from the rack, tower lights from the rack, storage lights from the rack, voice prompts from the PDA, and text prompts on the PDA screen.

9. A non-transfer material dispensing prompting system applied to an intelligent sensor-operated material rack, the system comprising: The system includes a host computer, a material rack, and a barcode scanning terminal device. The material rack has multiple storage positions, and each storage position is equipped with a sensor for a material tray. The barcode scanning terminal device is used for selecting and inputting processing items, and is also used to scan the unique code of the material tray and the material rack code. The system host is used to receive data information from the material rack and the barcode scanning terminal device, and execute the barcode scanning and shelving prompt method for smart sensor material racks as described in any one of claims 1-6.

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