WMS-independent three-dimensional warehouse stacker location self-calibration method and management system

Abstract

The invention provides a three-dimensional warehouse stacker location self-calibration method and management system independent of a WMS (World Management System), which is characterized by comprising a three-dimensional warehouse PLC (Programmable Logic Controller) goods taking module, a PLC goods placing module, a PLC data module, a PLC storage location management module, a stacker automatic control system and sample goods with induction whiskers, the goods taking and placing module is used for taking and placing goods on a three-dimensional warehouse conveying line by a stacking machine, data transmission of warehousing and carrying tasks can be independently completed through the data module without intervention of a WMS system, and the storage location management module is used for storage location distribution and storage location size calibration test processing of the three-dimensional warehouse stacking machine. Through the storage location management module, one-by-one storage location measurement and calibration can be independently completed without manual intervention, sample goods with induction whiskers are needed for storage location measurement and calibration, and the sample goods are consistent with actual stored materials in specification. The goods taking module, the goods placing module, the storage location management module and the data module are respectively connected with the stacker automatic control system. Through the system, manual one-by-one storage location measurement and calibration in the initial stage of a project can be realized. The warehousing and carrying tasks can be independently completed in the project operation stage without WMS and WCS system intervention and without manual intervention, the working efficiency is improved, and the labor cost is saved.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of intelligent storage, and relates to a WMS-independent rack storage stacker rack position self-calibration method and management system. BACKGROUND

[0002] An existing intelligent stereoscopic warehouse: the storage device connected with a conveyor, a jacking mechanism, an AGV rack, a buffer rack and the like is referred to as a docking station; and the device capable of achieving horizontal and vertical transportation of materials in the stereoscopic warehouse is referred to as a stacker.

[0003] The stacker takes and places materials from the docking station, and the docking station is provided with an indicating sensor. In the actual production process, if the WMS system is paralyzed, the materials need to be sent from the docking station to the warehouse for storage, and the operator needs to first confirm each warehouse storage position, and then informs the stacker of the target position after confirming the idle rack position, so that the stacker operates. In the case where there is no system record position, the stacker is easy to collide with the rack or the materials when it moves, which causes damage to the materials and safety accidents of the stacker. The number of docking stations of a large stereoscopic warehouse is large, and the number of stackers is large. In the case where there is no WMS system or in the initial warehouse inventory stage, the manual workload is huge. Therefore, it is very important to develop a rack stacker self-operation system which can be independently operated without manual intervention and without the intervention of the WMS system. Therefore, the WMS-independent rack stacker rack position self-calibration method and management system is proposed for the above problems. SUMMARY

[0004] In view of the defects and deficiencies of the prior art, the WMS-independent rack stacker rack position self-calibration method and management system is proposed, the concept of automatic allocation of rack position calibration is introduced, the stacker loaded with sample goods with sensing tentacles performs rack position calibration one by one through a rack position allocation table, and the ordered control of safe taking and placing of materials is realized through the condition judgment of the rack position calibration signal.

[0005] The specific technical scheme is as follows: A WMS-independent rack stacker rack position self-calibration method and management system, characterized in that: it comprises a goods taking module, a goods placing module, a data module, a rack position management module and a stacker automatic control system, the rack position management module accurately calculates a rack position allocation table and coordinates according to a stacker reference position value, the rack position management module generates the rack position table to the data management module, the data management module formulates a rack position calibration task table and sends it to the stacker automatic control system, and the stacker automatic control system measures and calibrates the rack position through the taking and placing action of each rack position.

[0006] If the stacker starts to transport materials, the rack position management module starts to calculate the coordinate value of the target rack position, and checks whether the coordinate value is consistent with the task rack position through the coordinate value. If the coordinate value is consistent, the coordinate value is confirmed and reported to the data module, otherwise an alarm is prompted.

[0007] Data module: one is used for the data interface of the stacker and the third party (such as the upper computer, the conveying line, the AGV, the goods information, etc.); the other is used for the generation of the automatic calibration test task of the stacker storage location, the formulation of the calibration task schedule, and the test calculation through the schedule.

[0008] The automatic control system of the stacker: the storage location management module and the data module respectively constitute the processing of the calibration measurement and the handling task of the storage location, the automatic control system of the stacker is used for executing the current handling task, controlling the taking and placing of goods, and further verifying the reliability of the storage location coordinate data through the sensor for secondary data verification; the sensor configuration will calculate and verify the data collected in real time and compare the coordinate values, and compare and confirm the data of the storage locations of a plurality of connection platforms one by one.

[0009] The taking module: whether the task type is a taking task is analyzed through data management, it is determined that the task is a taking task, the placing module will be locked and cannot be executed, the stacker is positioned to the task storage location, the sensor device starts to judge whether the storage location meets the taking condition, and the stacker executes the taking when the detection condition meets the taking, otherwise an alarm is prompted.

[0010] The placing module: whether the task type is a placing task is analyzed through data management, it is determined that the task is a placing task, the taking module will be locked and cannot be executed, the stacker is positioned to the task storage location, the sensor device starts to judge whether the storage location meets the placing condition, and the stacker executes the placing when the detection condition meets the placing, otherwise an alarm is prompted.

[0011] The present application is suitable for the initial inventory, storage location calibration and material storage management and control without WMS system in the project running stage of the intelligent stereoscopic warehouse, realizes the upgrading from manual calibration of the storage location coordinates or the intervention of the WMS system to the self-completion of the storage location coordinate calibration by the stacker, improves the work efficiency and saves the labor cost, improves the efficient information interaction between the main operation devices, avoids the occurrence of safety accidents, is especially suitable for the large stereoscopic warehouse with a plurality of connection platforms and stackers, and can realize the WMS system-free management and control operation of the complex system at a low cost. BRIEF DESCRIPTION OF DRAWINGS

[0012] The drawings described herein are used to provide further understanding of the present application, constitute a part of the present application, and the illustrative embodiments of the present application and the description thereof are used to explain the present application, and do not constitute an improper limitation on the present application. In the drawings: Figure 1 is the task execution state transition diagram of the present application; Figure 2 is the schematic diagram of the lane of the present application; Figure 3 is the system rest flow chart of the present application; Figure 4 is an automatic warehouse-in task storage location test allocation diagram of the present application; Figure 5 is an automatic warehouse-out task storage location test allocation diagram of the present application; Figure 6 is a solution comparison-automatic storage location test diagram of the present application. DETAILED DESCRIPTION

[0013] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the protection scope of the present application.

[0014] To make the features and advantages of the present patent more obvious and easy to understand, the following is a detailed description: S1: manually using a remote terminal and a third-party device or starting an automatic control system to control a stacker to stack goods from a platform; S2: the stacker filters data of the goods through a data module and analyzes the data into an execution cache task table; S3: the stacker performs secondary splitting of the cache task table and classifies the cache task table into warehouse-out tasks and warehouse-in tasks; S4: the stacker performs material verification on the task information through a data module and a material detection to determine whether the task information meets the conditions; S5: the stacker obtains a storage location table through a storage location management module, calculates a stacker task storage location coordinate according to a current position of the stacker, reports the coordinate to a data management for secondary confirmation, and issues an execution task table; S6: the stacker system issues the execution task table, and the tasks are written into a task execution area according to the task type to start executing the tasks; S7: the stacker performs comparison and calibration of a storage location table of a storage location management module according to the task storage location, confirms that the task storage location coordinate is correct, and starts moving and carrying the stacker; S8: the stacker reaches a specified coordinate for taking goods, verifies whether the goods are in place and whether the material information is consistent with the task information through a sensor device; S9: the stacker performs safety judgment through real-time data collected by a goods taking module and a sensor device, further verifies whether the storage location coordinate and the material meet the taking conditions, and if so, completes a series of actions for taking the goods, otherwise, alarms; S10: The stacker reaches the designated coordinate for goods placement, checks whether the storage location is ready through the sensor device, whether the storage location is consistent with the task storage location coordinate, and the stacker makes a safety judgment through the real-time data collected by the goods placement module and the sensor device, further checks whether the storage location coordinate and the current storage location meet the goods placement conditions, and if so, completes a series of actions for goods placement, otherwise, an alarm is given; S11: After the stacker completes all actions, timely feedback the current storage location information to the data management module, records the data and ends the task.

[0015] Based on the above design, the problem of storing and delivering materials in a complex warehouse system with multiple docking platforms and multiple stackers can be solved, and the project can be completed without manual measurement and calibration of each storage location, without the intervention of WMS, WCS data management system, and without manual intervention to complete the warehouse transportation task independently.

[0016] The above shows and describes the basic principles, main features and advantages of the present application. Those skilled in the art should understand that the present application is not limited to the above embodiments, and the above embodiments and descriptions in the specification are only to illustrate the principles of the present application. Without departing from the spirit and scope of the present application, various changes and improvements can be made to the present application, and these changes and improvements all fall within the scope of the claimed present application.

Claims

1. This invention provides a method and management system for self-calibration of storage locations of stacker cranes in automated warehouses that does not rely on a WMS (Warehouse Management System), characterized in that: The system includes a PLC picking module, a PLC placing module, a PLC data module, a PLC location management module, a stacker crane automatic control system, and sample goods with sensor tentacles. The picking and placing modules are used by the stacker crane to pick up and place goods on the automated storage and retrieval system (AS / RS) conveyor line. The data module enables independent data transmission for warehousing and handling tasks without WMS (Warehouse Management System) intervention. The location management module is used for stacker crane location allocation and location size calibration testing. It allows for independent measurement and calibration of each location without manual intervention. This calibration requires sample goods with sensor tentacles, and the sample goods must match the specifications of the actual stored materials. The picking, placing, location management, and data modules are connected to the stacker crane automatic control system. This system allows for location-by-location measurement and calibration without manual intervention during the initial project phase; and enables independent warehousing and handling tasks without WMS, WCS (Warehouse Management System), or manual intervention during project operation, improving work efficiency and saving labor costs.

2. The self-calibration method and management system for stacker crane locations in automated warehouses that does not rely on WMS, as described in claim 1, is characterized in that: The picking and placing modules include hardware and software modules. The hardware modules include inbound / outbound conveyor lines, photoelectric switch sensors, barcode scanners, laser instruments, motor drives, high-speed doors, conveyor lines, size detection, and cargo detection. The software modules include an inbound / outbound operation safety calculation module and an action flow control module. The inbound / outbound operation safety calculation module is used to ensure the safe operation of the stacker crane and the safe picking and placing of goods. The action flow control module is used to control the picking and placing actions of the stacker crane and to provide safety protection control.

3. The self-calibration method and management system for stacker crane locations in automated warehouses that does not rely on WMS, as described in claim 1, is characterized in that: The storage location management module includes a storage location allocation module and a storage area location positioning module. The storage location allocation module is used to allocate storage locations in the automated warehouse. Stacker cranes can perform picking and placing operations by addressing the storage location allocation table. The storage area location positioning module calculates the accurate location of the storage area by means of laser ranging or barcode positioning. It is used to calculate the location reference value of each storage location in the storage area, which can realize the independent measurement and calibration of each storage location without human intervention.

4. The self-calibration method and management system for stacker crane locations in automated warehouses that does not rely on WMS, as described in claim 1, is characterized in that: The data module is used for data integration with third-party systems, goods category management, and task management. The third-party data integration refers to data exchange with third-party equipment such as conveyor lines, WMS, WCS, and AGVs. The goods category management is used for material information recording. The task management module is used to manage business data such as picking tasks, outbound tasks, outbound records, historical records, and material changes, and send them to the stacker crane for operation. It can independently complete warehousing and handling tasks without the intervention of WMS or WCS data management systems.

5. A self-calibration method and management system for stacker crane locations in an automated warehouse that does not rely on a WMS, as described in claim 1, is characterized in that: The alarm notification module includes a hardware module and a software module. The hardware module includes an HMI, a computer, an audible and visual alarm, etc. The software module displays the specific alarm cause and solution through a visual interface, which facilitates the operator to quickly handle the fault. The audible and visual alarm notifies the operator of the equipment failure as soon as possible.

Images