A fully automated material handling system

Abstract

This application relates to the field of industrial automation technology, and in particular to a fully automated material handling system. Through the automated collaborative operation of AGV transport vehicles, empty basket transfer stations, and conveyors, the system achieves intelligent transfer of clean baskets. Specifically, the system constructs a three-level positioning and detection network using a first signaler at the transfer station, a second signaler on the conveyor, and a third signaler on the AGV transport vehicle. Combined with the coordinated control of the first, second, and third roller transfer units, seamless connection and precise docking are achieved between the three workstations: the transfer station, the AGV transport vehicle, and the conveyor. This design completely replaces the traditional manual loading and unloading method, shortens the time for manual transfers, improves manual transfer efficiency, matches the production rhythm requirements of high-speed production lines, and significantly reduces labor costs.

Description

Technical Field

[0001] This application relates to the field of industrial automation technology, and in particular to a fully automated material handling system. Background Technology

[0002] Currently, in industrial automated production processes, the loading and unloading of cleaning baskets still mainly relies on manual operation, which presents the following prominent problems: operators need to frequently load empty baskets, and each operation takes a long time, which is not only inefficient and labor-intensive, but also difficult to match the production rhythm of high-speed production lines; taking a certain automotive parts cleaning line as an example, each shift requires two full-time personnel to be responsible for basket transfer, which is very time-consuming and labor-intensive, becoming a key bottleneck restricting the improvement of production line efficiency.

[0003] To address the aforementioned issues, this application proposes a fully automated material handling system that uses AGV transport vehicles to automatically load empty containers, thereby improving production efficiency. Summary of the Invention

[0004] This application provides a fully automated handling system to solve the problem that the loading and unloading of cleaning baskets in the prior art requires manual operation, resulting in low production efficiency.

[0005] In a first aspect, a fully automated handling system includes: an empty basket receiving station for storing empty baskets, and equipped with a first roller conveyor and a first signal; a conveyor including: a second roller conveyor and a loading area arranged along the length of the second roller conveyor, the loading area being equipped with a second signal; and an AGV transport vehicle including: a vehicle body, drive wheels located at the bottom of the vehicle body, a third roller conveyor located at the top of the vehicle body, and a third signal; wherein the AGV transport vehicle is configured to move to the empty basket receiving station via the drive wheels, thereby aligning the third signal with the first signal and the first roller conveyor with the third roller conveyor to automatically receive empty baskets; and the AGV transport vehicle is configured to move to the loading area, thereby aligning the third signal with the second signal and the third roller conveyor with the second roller conveyor to automatically unload empty baskets into the loading area.

[0006] Furthermore, it also includes a full-basket transfer station for storing full baskets. The full-basket transfer station is equipped with a fourth roller transfer unit and a fourth signal device. The AGV transport vehicle moves to the full-basket transfer station by driving its drive wheels, so that the third signal device is connected to the fourth signal device and the first roller transfer unit is aligned with the fourth roller transfer unit, so as to automatically unload the full baskets to the full-basket transfer station.

[0007] Furthermore, it also includes a cleaning and transfer station, which is equipped with a fifth roller transport unit and a fifth signal device; the AGV transport vehicle moves to the full basket transfer station by driving wheels, so that the third signal device is connected to the fifth signal device, and the first roller transport unit is aligned with the fifth roller transport unit, so as to automatically unload the full basket to the cleaning and transfer station.

[0008] Furthermore, the AGV transport vehicle also includes an identification sensor; a QR code is provided on the AGV transport vehicle's movement route; the QR code contains the coordinate information of each connecting station, and the AGV transport vehicle adjusts the movement angle of the drive wheels according to the coordinate information so that the third roller transmission unit accurately docks with the roller transmission unit of each connecting station.

[0009] Furthermore, it also includes a standby position, which is used for AGV transport vehicles to park and charge when idle.

[0010] Furthermore, the conveyor is provided with an assembly and palletizing area and a unloading area; the assembly and palletizing area is located between the loading area and the unloading area.

[0011] Furthermore, the conveyor includes several stopping mechanisms;

[0012] At least one stop mechanism is provided at an adjacent position of the feeding area, assembly and stacking area, and unloading area.

[0013] Furthermore, the conveyor is provided with a sliding mechanism, which includes a transverse slide rail, a longitudinal slide rail, and a connecting seat; the longitudinal slide rail is slidably connected to the transverse slide rail through the connecting seat.

[0014] Furthermore, the longitudinal slide rail is connected to a stacked robotic arm;

[0015] The stacked robotic arm moves along the X-axis via the transverse slide rail and moves up and down along the Z-axis via the longitudinal slide rail.

[0016] Furthermore, the conveyor is connected to a gripping robot arm;

[0017] The stacked robotic arm holds the empty basket and lifts it along the Z-axis to a preset position so that the gripping robotic arm can grasp the workpiece and place it in the empty basket.

[0018] The technical solutions provided in this application have the following advantages compared with the prior art:

[0019] This technical solution provides a fully automated material handling system that achieves intelligent transfer of cleaned and empty baskets through the automated collaborative operation of AGV transport vehicles, empty basket receiving stations, and conveyors. Specifically, this fully automated material handling system constructs a three-level positioning and detection network through a first signaler at the empty basket receiving station, a second signaler on the conveyor, and a third signaler on the AGV transport vehicle. Combined with the coordinated control of the first, second, and third roller transport units, it achieves seamless connection and precise docking between the three workstations: the empty basket receiving station, the AGV transport vehicle, and the conveyor. This design completely replaces the traditional manual loading and unloading method, shortens the manual transfer time per transaction, improves manual transfer efficiency, matches the production rhythm requirements of high-speed production lines, and significantly reduces labor costs. Attached Figure Description

[0020] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0021] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] One or more embodiments are illustrated by way of example with reference numerals in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Elements with the same reference numerals in the drawings are denoted as similar elements. Unless otherwise stated, the figures in the drawings are not to be limited by scale.

[0023] Figure 1 This is a schematic diagram showing the docking of various components in the fully automated handling system of this application;

[0024] Figure 2 This is a schematic diagram of the conveyor, sliding mechanism, and gripping robot of this application;

[0025] Figure 3 This is a structural schematic diagram of the empty basket docking station in this application;

[0026] Figure 4 This is a structural schematic diagram of the AGV transport vehicle used in this application;

[0027] Figure 5 This is a schematic diagram of the conveyor structure of the present application;

[0028] Figure 6 This is a schematic diagram of the sliding mechanism of this application.

[0029] Explanation of reference numerals in the attached figures:

[0030] 1. Empty basket transfer station; 12. First signal device; 2. Conveyor; 20. Second roller transfer unit; 21. Second signal device; 22. Loading area; 23. Loading buffer area; 24. Assembly and palletizing area; 241. Assembly area; 242. Palletizing area; 25. Full basket buffer area; 26. Unloading area; 27. Stop mechanism; 28. Sliding mechanism; 281. Transverse slide rail; 282. Longitudinal slide rail; 283. Connecting seat; 284. Stacking robot; 285. Clamping mechanism; 29. ​​Grabbing robot; 3. AGV transport vehicle; 32. Third roller transfer unit; 33. Third signal device; 4. Full basket transfer station; 5. Cleaning transfer station; 6. Standby position; 7. Charging station; 8. Telescopic stop. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0032] The following disclosure provides numerous different embodiments or examples for implementing various structures of this application. To simplify the disclosure, specific examples of components and arrangements are described below. These are merely examples and are not intended to limit the scope of this application. Furthermore, reference numerals and / or letters may be repeated in different examples. Such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed.

[0033] For ease of description, spatial relative terms may be used in the text to describe the relative position or movement of one element or feature relative to another element or feature, as shown in the figure. These relative terms include, for example, "inside," "outside," "middle," "outer," "below," "below," "above," "front," "back," etc. Such spatial relative terms are intended to include different orientations of the device in use or operation, other than those depicted in the figure. For example, if the device in the figure undergoes a positional flip, orientation change, or change of motion, these directional indications will change accordingly. For instance, an element described as "below other elements or features" or "below other elements or features" will subsequently be oriented "above other elements or features" or "above other elements or features." Therefore, the example term "below" can include both upper and lower orientations. The device may be otherwise oriented (rotated 90 degrees or in other directions), and the spatial relative descriptors used in the text will be interpreted accordingly.

[0034] To address the problem that the loading and unloading of cleaning baskets in existing technologies requires manual operation, resulting in low production efficiency.

[0035] It should be noted that the cleaning basket is called an empty basket when it is not filled with workpieces, and a full basket when it is filled with workpieces.

[0036] like Figures 1 to 6 As shown, the applicant provides a fully automated handling system including: an empty basket receiving station 1, which in this embodiment is an AGV trolley for storing empty baskets, and is equipped with a first roller transmission section and a first signal device 12; a conveyor 2, including a second roller transmission section 20 and a loading area 22 arranged along the conveying direction of the second roller transmission section 20, the loading area 22 being equipped with a second signal device 21; and an AGV transport vehicle 3, including: a vehicle body; drive wheels located at the bottom of the vehicle body; and third rollers located at the top of the vehicle body. The AGV transport vehicle 3 is configured to move to the empty basket receiving station 1 via its drive wheels, so that the third signal 33 docks with the first signal 12 and the first roller transport unit aligns with the third roller transport unit 32 to automatically receive empty baskets; the AGV transport vehicle 3 is configured to move to the loading area 22, so that the third signal 33 docks with the second signal 21 and the third roller transport unit 32 aligns with the second roller transport unit 20 to automatically unload empty baskets into the loading area 22.

[0037] Among them, such as Figure 3 As shown, the empty basket transfer station 1 is used to centrally store empty baskets, and its first roller transmission unit and first signal device 12 provide the hardware foundation for subsequent automated operations.

[0038] like Figure 4As shown, the AGV transport vehicle 3, as a mobile carrier, integrates key components such as the third roller transmission unit 32, the third signal device 33, and drive wheels. It should be understood that the AGV transport vehicle 3 also has a control terminal to maintain the normal operation of the entire AGV transport vehicle, and also stores a preset program (which includes the movement route, position coordinate data, etc.), enabling the AGV transport vehicle to achieve autonomous navigation and precise positioning through the preset program.

[0039] like Figure 2 and Figure 5 As shown, conveyor 2 is the core transmission device in the material processing production line. A loading area 22 is provided along its length for loading empty baskets, thus forming a complete material processing production line. It should be understood that this conveyor 2 can be a link in the entire production line, or it can exist as an independent loading unit, preparing for subsequent work on the production line.

[0040] During operation, the AGV transport vehicle 3 receives feedback from terminal devices (such as computers or mobile phones) regarding the need for empty baskets in production, or the AGV transport vehicle 3 directly receives feedback from the production line regarding the need to load empty baskets. At this time, the control terminal inside the AGV transport vehicle 3 drives the drive wheels of the AGV transport vehicle 3 to the empty basket receiving station 1. A communication connection is established between the third signal device 33 and the first signal device 12. This communication connection can be achieved through infrared, RFID, or Bluetooth. After confirming the docking position, the AGV transport vehicle 3 approaches the empty basket receiving station 1 to achieve docking between the first roller transmission unit and the third roller transmission unit 32.

[0041] In detail, when the AGV transport vehicle 3 moves to the vicinity of the empty basket transfer station 1, the first signal device 12 and the third signal device 33 communicate and sense each other, and the control terminal inside the AGV transport vehicle drives the drive wheels to roll, so that the third roller transmission unit 32 of the AGV transport vehicle comes close to dock with the first roller transmission unit.

[0042] After the first roller transfer unit and the third roller transfer unit 32 are docked, they start synchronously, smoothly transferring the empty basket from the first roller transfer unit to the third roller transfer unit 32 on the AGV transport vehicle 3. It should be noted that the first roller transfer unit and the third roller transfer unit 32 are at the same height to facilitate the transfer of the empty basket from the empty basket receiving station 1 to the AGV transport vehicle 3.

[0043] Subsequently, the AGV transport vehicle 3 moves along the predetermined route to the loading area 22, confirms its position again via a signal device, and then approaches the loading area 22, allowing the third roller transport unit 32 and the second roller transport unit 20 to connect. The third roller transport unit 32 and the second roller transport unit 20 then work together, and the AGV transport vehicle 3 unloads the empty baskets onto the conveyor 2. This design enables the automatic transport of empty baskets by the AGV transport vehicle 3 for production line use, solving the problem of low efficiency in manual handling of empty baskets in existing technologies.

[0044] In one embodiment of the present invention, retractable stoppers 8 are provided at the empty basket transfer station 1 and the AGV transport vehicle 3 respectively.

[0045] like Figure 4 As shown, taking the retractable stop 8 on the AGV transport vehicle 3 as an example, the retractable stop 8 is respectively provided on both sides of the outward side of the second roller transmission section 20. The retractable stop 8 on both sides and the side wall of the AGV transport vehicle 3 enclose a space for loading the basket. When the AGV transport vehicle 3 is loaded with an empty basket, the second roller transmission section 20 does not roll, and the retractable stop 8 on both sides is in the extended state to constrain the basket within the space and prevent the basket from slipping off the AGV transport vehicle 3.

[0046] When the AGV transport vehicle 3 docks with the empty basket transfer station 1, the third signal device 33 of the AGV transport vehicle establishes a communication connection with the first signal device 12 of the transfer station. After receiving the connection signal, the control terminal inside the AGV transport vehicle 3 controls the retractable stop 8 to retract and starts the third roller transfer unit 32 to start rolling. At the same time, the control terminal of the empty basket transfer station 1 receives the connection signal through the first signal device 12, controls the retractable stop 8 on the empty basket transfer station 1 to retract, and drives the first roller transfer unit to roll, so that the empty basket on the empty basket transfer station 1 is smoothly transferred into the AGV transport vehicle 3, completing the automated transfer of the empty basket. After the transfer is completed, the respective control terminals control their respective retractable stops to extend, for example, the retractable stop 8 on the AGV transport vehicle 3 re-extends to restrain the basket and prevent the basket from falling off the AGV transport vehicle 3 during transportation.

[0047] Furthermore, in other embodiments, other types of connecting stations can be configured with retractable stop members 8 according to actual needs. The retractable stop members 8 extend and retract to position and fix the material basket, ensuring its stability during transport or temporary storage, thereby ensuring that the AGV transport vehicle 3 can smoothly transport the empty material basket to the conveyor 2.

[0048] In a specific embodiment of the present invention, the conveyor 2 is provided with a second roller transmission section 20 along the conveying direction. The transmission section is evenly arranged along the length direction of the conveyor 2, and multiple second roller transmission sections 20 together constitute a rolling surface that supports the movement of the material basket. According to different functions, the conveyor belt composed of the second roller transmission sections 20 is divided into multiple areas. In addition to the loading area 22 mentioned above, it also includes an assembly and stacking area 24 and a unloading area 26 located between the loading area 22 and the unloading area 26.

[0049] In practical applications, after the AGV transport vehicle 3 unloads the empty basket into the loading area 22, the second roller transmission unit 20 on the conveyor 2 is immediately started, driving the empty basket to move along the transmission direction until it is transported to the assembly and palletizing area 24.

[0050] In a specific embodiment of the present invention, the assembly and palletizing area 24 is further divided into an assembly area 241 and a palletizing area 242. The assembly area 241 is used to assemble workpieces into empty baskets; the palletizing area 242 is responsible for storing baskets containing workpieces. When the baskets filled with workpieces are stacked to a preset number of layers (e.g., four or five layers), the second roller conveyor 20 is activated again, transporting the stacked basket group to the unloading area 26, awaiting transfer by the AGV transport vehicle 3. Furthermore, the unloading area 26 is equipped with a second signal device 21. When the AGV transport vehicle 3 approaches, the third signal device 33 on the vehicle automatically docks with the second signal device 21 in the unloading area 26, guiding the AGV transport vehicle 3 to a precise stop. After docking, the third roller conveyor 32 on the AGV transport vehicle 3 seamlessly connects with the corresponding roller conveyor in the unloading area 26, thereby smoothly transferring the baskets filled with workpieces onto the AGV transport vehicle 3, completing the entire transfer process.

[0051] In some specific embodiments, the conveyor 2 also includes a plurality of stop mechanisms 27; at least one stop mechanism 27 is provided at adjacent positions of the loading area 22, the assembly and stacking area 24, and the unloading area 26.

[0052] For example, when conveyor 2 is running, after the second roller transfer unit 20 of the loading area 22 receives the empty baskets transported by the AGV transport vehicle 3, the conveyor belt transports the empty baskets to the assembly area 241. Then, the stop mechanism 27 rises at a predetermined position to ensure the empty baskets are positioned in the assembly area 241. After assembly, once the baskets are filled with workpieces, they are transported to the stacking area 242. When the stacking area 242 is filled to, for example, four layers, the conveyor belt rolls again, transporting the four layers of baskets filled with workpieces to the unloading area 26. The stop mechanism 27 in the unloading area 26 extends to ensure the four layers of baskets filled with workpieces remain in the unloading area 26, waiting for the AGV transport vehicle 3 to pick them up. This design solves the problem of inaccurate positioning in traditional conveyor 2, and through the combination of multi-area division and the stop mechanism 27, it also avoids damage to the baskets due to collisions.

[0053] To further optimize the coordination of work in different areas of the conveyor, a feeding buffer area 23 and a full-basket buffer area 25 are added to conveyor 2.

[0054] The loading buffer area 23 is located between the loading area 22 and the assembly area 241. Its core function is to ensure the continuity of the production line assembly. After the AGV transport vehicle 3 has transported empty baskets multiple times, the loading buffer area 23 can temporarily store the empty baskets, so that the production line always has an appropriate amount of empty baskets in reserve, avoiding the interruption of workpiece assembly due to the shortage of empty baskets and ensuring smooth material turnover.

[0055] The full-basket buffer area 25 is located between the palletizing area 242 and the unloading area 26. The setting of the full-basket buffer area 25 is also based on process optimization considerations. This area is used to temporarily store baskets filled with workpieces. The number of full baskets is accumulated in advance before the arrival of the AGV transport vehicle 3, so as to ensure that the AGV transport vehicle 3 can quickly complete the loading after its arrival, improve transportation efficiency, and reduce equipment waiting time.

[0056] It should also be noted that conveyor 2 is equipped with motion detection units (such as position sensors and photoelectric switches) in different areas (e.g., loading area 22, assembly and palletizing area 24, unloading area 26, etc.) to provide real-time feedback on the completion status of the core actions in this area. The second roller conveyor 20 only starts after the motion detection unit sends a 'motion completion signal' to the conveyor control terminal, once the preset action is completed in the current area (e.g., empty basket reception in loading area 22, workpiece filling in assembly area 241). This design ensures that the second roller conveyor 20 remains stationary until the core action in the previous area is completed, avoiding work interference caused by premature basket delivery in different areas and ensuring the orderly connection of the work processes in each area.

[0057] In a specific embodiment of the present invention, the conveyor 2 is provided with a sliding mechanism 28, which is disposed between the assembly area 241 and the palletizing area 242 and is capable of sliding between the assembly area 241 and the palletizing area 242.

[0058] The sliding mechanism 28 includes a transverse slide rail 281, a longitudinal slide rail 282, and a connecting seat 283. The transverse slide rail 281 is arranged along the length of the conveyor 2 on one side. In this embodiment, the transverse slide rail 281 specifically spans the feeding buffer area 23, the assembly area 241, and the palletizing area 242, meaning it runs transversely through these three areas.

[0059] A longitudinal slide rail 282 is arranged in a direction perpendicular to the conveyor 2. The longitudinal slide rail 282 is slidably connected to the transverse slide rail 281 through a connecting seat 283.

[0060] Detailed, such as Figure 6As shown, a stacking robot 284 is connected to the end of the longitudinal slide rail 282 away from the connecting seat 283. The stacking robot 284 achieves X-axis movement via the transverse slide rail 281, which refers to movement along the length of the conveyor 2, and Z-axis lifting via the longitudinal slide rail 282, which refers to vertical movement perpendicular to the conveyor 2. The stacking robot 284 adopts a rectangular frame design, and its internal contour dimensions precisely match the outer contour of the empty basket, ensuring that the two can be tightly nested.

[0061] Multiple gripping mechanisms 285 are evenly distributed along the circumferential direction on the inner contour end face edge of the stacking robot 284. When the stacking robot 284 descends to cover the empty basket, each gripping mechanism 285 extends inward simultaneously, applying clamping force to the empty basket from multiple directions, firmly restraining the empty basket inside the robot, and completing the grasping action. When it is necessary to release the empty basket, the gripping mechanisms 285 retract in the opposite direction, releasing the restraint on the empty basket, and realizing a safe and precise unloading operation.

[0062] On the other side of conveyor 2, a gripping robot 29 is connected; a stacking robot 284 holds an empty basket and lifts it along the Z-axis to a preset position for the gripping robot 29 to grip the workpiece and place it in the empty basket. It should be noted that the preset position refers to a target stopping height of the stacking robot on the vertical Z-axis. This height is not a fixed value, but is set according to the optimal working range of the gripping robot, the workpiece size, and the actual working conditions such as the stacking layer height.

[0063] In actual operation, the stacking robot 284 operates as follows: First, it moves horizontally along the transverse slide rail 281 to above the loading buffer area 23, and then descends vertically along the Z-axis, precisely approaching the empty basket within the loading buffer area 23. Once the empty basket is embedded inside the stacking robot 284, its circumferentially arranged gripping mechanism 285 immediately extends inward, clamping the empty basket from multiple directions to achieve a stable grip. Next, the stacking robot 284 slides horizontally along the X-axis to the assembly area 241 and rises upward along the Z-axis to achieve a suitable height with the gripping robot 29, allowing the gripping robot 29 to perform the workpiece loading operation.

[0064] After the vision sensor (e.g., a camera) on the gripping robot 29 detects that the stacking robot 284 has grabbed an empty basket, it quickly grabs workpieces from the workpiece placement area next to the conveyor 2 and places them into the empty baskets one by one until the empty baskets are filled to form full baskets. At this time, the stacking robot 284 slides along the X-axis again to transport the full basket to the palletizing area 242 and returns to the loading buffer area 23, repeating the process of grabbing empty baskets, transferring, and loading until the palletizing area 242 is filled with full baskets according to the preset requirements (e.g., four layers).

[0065] Once palletizing is complete, the control center of conveyor 2 activates the second roller transfer unit 20 to sequentially transfer the four layers of full baskets to the full basket buffer area 25. Simultaneously, the control center sends a material transfer signal to the AGV transport vehicle 3. Upon receiving the signal, the AGV transport vehicle 3 moves to the unloading area 26. At this point, the second roller transfer unit 20 restarts, while the stacking robot 284 and the gripping robot 29 stop working. The second roller transfer unit 20 then transports the full basket from the full basket buffer area 25 to the unloading area 26 and controls the stop mechanism 27 to retract, facilitating docking with the AGV transport vehicle 3 and achieving automated transfer of the full baskets. The entire process requires no manual intervention, significantly improving material handling efficiency and saving labor costs and operating time.

[0066] In one embodiment of the present invention, the fully automated handling system further includes a full-basket transfer station 4, which is equipped with a fourth roller transfer unit and a fourth signal device; the structure of the full-basket transfer station 4 is consistent with that of the empty-basket transfer station 1. The AGV transport vehicle 3 can move to the full-basket transfer station 4 via its drive wheels, so that the third signal device 33 docks with the fourth signal device and aligns the first roller transfer unit with the fourth roller transfer unit, thereby automatically unloading the full basket to the full-basket transfer station 4. This design enables unmanned and rapid unloading of full baskets, significantly improving material handling efficiency.

[0067] For the subsequent processing of full baskets, this system provides two options: the AGV transport vehicle 3 can transport the full basket to the full basket transfer station 4 for temporary storage, or send it directly to the cleaning transfer station 5 for cleaning.

[0068] For example, for a material basket that needs to be cleaned, the control center or terminal device (such as a mobile phone or computer) at the end of the conveyor 2 transmits the cleaning request to the third signal device 33 in the AGV transport vehicle 3 through the signal device. When the control terminal located in the AGV transport vehicle 3 receives the cleaning request signal through the third signal device 33, it outputs an execution command to the drive wheel, so that the drive wheel drives the AGV transport vehicle 3 to move to the cleaning transfer station 5.

[0069] The cleaning and transfer station 5 is equipped with a fifth roller transmission unit and a fifth signal device. The structure of the cleaning and transfer station 5 is the same as that of the empty basket transfer station 1. The third signal device 33 in the AGV transport vehicle 3 is connected to the fifth signal device, and the first roller transmission unit is aligned with the fifth roller transmission unit so as to automatically unload the full basket to the cleaning and transfer station 5 for cleaning.

[0070] This solution solves the problem of requiring manual intervention in the traditional cleaning process. Through the design of a dedicated cleaning transfer station 5, the cleaning process is perfectly integrated into the automated process, improving cleaning efficiency and completely avoiding secondary pollution that may be caused by manual operation.

[0071] In an embodiment of the present invention, the AGV transporter 3 further includes an identification sensor, which is, for example, a camera; a two-dimensional code is provided on the moving route of the AGV transporter 3; the two-dimensional code contains the coordinate information of each connection station, and the AGV transporter 3 adjusts the moving angle of the driving wheels according to this information so that the third roller transmission part 32 is accurately docked with the roller transmission part of each connection station.

[0072] In some other embodiments, the two-dimensional code representing the position information can also be replaced by a signaler, and the position calibration of the AGV transporter 3 is achieved by means of signal docking.

[0073] In this embodiment, during the driving process of the AGV transporter 3, the identification sensor at its bottom continuously scans the two-dimensional code marks laid on the ground. Each two-dimensional code contains the accurate coordinate information of the location, and the control system of the AGV transporter 3 adjusts the angle and speed of the driving wheels in real time according to these data. For example, when moving to a turning point near a connection station, the AGV transporter 3 scans the two-dimensional code to obtain the turning radius information, and the control terminal in the AGV transporter 3 automatically calculates the optimal steering parameters according to the preset program to adjust the rotation angle and speed of the driving wheels so as to reach the connection station that needs to be approached. This solution solves the problem of cumulative errors generated by the long-term operation of the AGV transporter 3, and improves the positioning accuracy of the AGV transporter 3 through two-dimensional code positioning.

[0074] It should be noted that in this embodiment, the two-dimensional code is a set of data representing a coordinate system, and each set of data corresponds to a position information (including angle information and distance information). This coordinate system data is pre-entered and stored in the control terminal in the AGV transporter 3, and the control terminal is preset with a program for processing and analyzing this two-dimensional code to control the AGV transporter 3 to accurately move to the required position.

[0075] In actual use, the identification sensor is a camera. When the camera scans the two-dimensional code on the ground, it first denoises, enhances, and performs edge detection on the two-dimensional code image to locate the "square frame" mark of the two-dimensional code. The control terminal uses the preset program therein to call a decoding algorithm (such as ZXing or ZBar) to parse the binary data in the two-dimensional code, and repairs possible data corruption through Reed-Solomon error correction coding. The parsed data contains the coordinates of the connection station or path instructions. The control terminal of the AGV matches this information with the preset map, combines a real-time positioning algorithm (such as SLAM or odometer feedback) to correct the position error, and finally adjusts the angle and speed of the driving wheels to achieve accurate docking with the roller transmission part of the connection station. The whole process requires no manual intervention, and the error can be controlled within millimeters, ensuring the stable operation of the fully automatic handling system.

[0076] In one embodiment of the present invention, the fully automated handling system includes a standby position 6, which is used for parking and charging docking of the AGV transport vehicle when it is idle.

[0077] When the system is idle, AGV transport vehicle 3 will automatically return to standby position 6 under the control of the control terminal according to the terminal's needs. Standby position 6 is equipped with a dedicated charging interface, which, for example, is preset to automatically connect for charging when the battery level of AGV transport vehicle 3 is below 20%. Simultaneously, the ground at standby position 6 is marked with special markers, and AGV transport vehicle 3 uses identification sensors for precise positioning, ensuring accurate parking. This solution, through intelligent scheduling and automatic charging design, solves the problems of disordered parking and charging management of AGV transport vehicle 3.

[0078] In actual use, for the safety of the AGV transport vehicle 3, a separate charging station 7 can be set up specifically for charging the AGV transport vehicle 3. After charging is completed, the AGV transport vehicle 3 can move to the standby position 6 to wait for being called.

[0079] In summary, this technical solution presents a fully automated material handling system that achieves a high degree of automation throughout the entire material handling process through the coordinated operation of the AGV transport vehicle 3, the conveyor 2, and various transfer stations. The system first employs QR code positioning, enabling the AGV transport vehicle 3 to accurately reach each transfer station. Furthermore, upon arrival at each transfer station, communication is established via signal devices to ensure accurate docking and transfer of material baskets, achieving seamless integration between different workstations.

[0080] In practical applications, this system not only significantly reduces labor costs but also improves production safety by minimizing human intervention. Its modular design gives the system excellent scalability, allowing for flexible adjustments to workstation configurations based on production needs.

[0081] In the above embodiments, the descriptions of each embodiment have different focuses. For parts that are not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0082] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0083] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0084] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0085] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0086] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. The illustrative expressions of the above terms in this specification should not be construed as necessarily referring to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. In addition, those skilled in the art can combine and integrate the different embodiments or examples described in this specification.

[0087] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. Since these modifications and variations fall within the scope of the claims and their equivalents, this application also intends to include these modifications and variations.

[0088] The above description describes specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and such modifications or substitutions should all be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A fully automated material handling system, characterized in that, include: An empty basket transfer station is used to store empty baskets and is equipped with a first roller transport unit and a first signal device; The conveyor includes: a second roller transmission section and a feeding area arranged along the length of the second roller transmission section, wherein the feeding area is provided with a second signal device; An AGV transport vehicle includes: a vehicle body, drive wheels located at the bottom of the vehicle body, a third roller transmission unit located at the top of the vehicle body, and a third signal device; The AGV transport vehicle is configured to move to the empty basket receiving station via its drive wheels, so that the third signal device is connected to the first signal device and the first roller transmission unit is aligned with the third roller transmission unit to automatically receive the empty basket; the AGV transport vehicle is configured to move to the loading area, so that the third signal device is connected to the second signal device and the third roller transmission unit is aligned with the second roller transmission unit to automatically unload the empty basket to the loading area. It also includes a full basket transfer station for storing full baskets, which is equipped with a fourth roller transfer unit and a fourth signal device; The AGV transport vehicle moves to the full basket transfer station via its drive wheels, so that the third signal device is connected to the fourth signal device and the first roller transfer unit is aligned with the fourth roller transfer unit, so as to automatically unload the full basket to the full basket transfer station. The AGV transport vehicle also includes an identification sensor; A QR code is provided along the movement route of the AGV transport vehicle; The QR code contains the coordinate information of each connecting station. The AGV transport vehicle adjusts the movement angle of the drive wheel according to the coordinate information so that the third roller transmission unit can accurately dock with the roller transmission unit of each connecting station. It also includes a standby position, which is used for AGV transport vehicles to park and connect to charging when they are idle; The conveyor is equipped with an assembly and palletizing area and a material unloading area; The assembly and palletizing area is located between the loading area and the unloading area; The conveyor includes several stopping mechanisms; At least one stop mechanism is provided at an adjacent position of the feeding area, assembly and stacking area, and unloading area.

2. The fully automated handling system according to claim 1, characterized in that: It also includes a cleaning and transfer station, which is equipped with a fifth roller transport unit and a fifth signal device; The AGV transport vehicle moves to the cleaning and transfer station via its drive wheels, aligns the third signal device with the fifth signal device, and aligns the first roller transport unit with the fifth roller transport unit to automatically unload the full basket to the cleaning and transfer station.

3. The fully automated handling system according to claim 1, characterized in that: The conveyor is equipped with a sliding mechanism, which includes a transverse slide rail, a longitudinal slide rail, and a connecting seat. The longitudinal slide rail is slidably connected to the transverse slide rail via the connecting seat.

4. The fully automated handling system according to claim 3, characterized in that: The longitudinal slide rail is connected to a stacked robotic arm; The stacked robotic arm moves along the X-axis via the transverse slide rail and moves up and down along the Z-axis via the longitudinal slide rail.

5. The fully automated handling system according to claim 4, characterized in that: The conveyor is connected to a gripping robot arm; The stacked robotic arm holds the empty basket and lifts it along the Z-axis to a preset position so that the gripping robotic arm can grasp the workpiece and place it in the empty basket.

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