Double-area dynamic collaborative intelligent storage shelf management method and system
By combining a dynamic partitioning module and a collaborative scheduling engine, the problems of rigid partitioning and insufficient synchronization in intelligent warehousing systems are solved. Dynamic collaboration between fast and slow zones is achieved, replenishment and outbound efficiency is improved, the empty running rate and repetitive handling of automated guided vehicles are reduced, and real-time synchronization and consistency between accounts and physical inventory are ensured.
Patent Information
- Application Number
- CN202511039840.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-07-28
- Publication Date
- 2025-11-11
AI Technical Summary
In existing intelligent warehousing systems, the zoning strategy is rigid and difficult to adjust dynamically, resulting in low replenishment efficiency. Shortages of empty spaces in the express zone or storage locations affect outbound shipments. The lack of real-time synchronization between systems increases the cost of waiting and switching operations, and the need for manual maintenance of mapping tables can easily lead to discrepancies between accounts and physical inventory.
The system employs a dynamic partitioning module to calculate shelf area attributes in real time. Combined with a collaborative scheduling engine and task preemption mechanism, attributes are automatically switched via storage location sensors to achieve dynamic collaboration between fast and slow zones. Inventory status is synchronized via a message bus, avoiding the need for manual maintenance of mapping tables.
It enables real-time dynamic adjustment of shelf area attributes, improves replenishment and outbound efficiency, reduces the empty run rate and repeated handling of automated guided vehicles, and enhances the reliability and scalability of the system.
Smart Images
Figure CN120931202A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of intelligent warehousing system technology, specifically to an intelligent warehouse racking management method and system with dynamic collaboration between two zones. Background Technology
[0002] With the rapid development of e-commerce and manufacturing, the scale and pace of warehousing operations are constantly increasing, making intelligent warehousing systems a key means to improve logistics efficiency. Existing intelligent warehousing systems typically divide the entire warehouse into "fast zones" and "slow zones" statically according to material turnover rate or category. The warehouse management system is responsible for overall inventory planning, the warehouse control system is responsible for equipment execution scheduling, and automated equipment such as AGVs move shelves according to plan. The various subsystems largely rely on pre-set static rules or manual intervention to complete inbound, outbound, and replenishment operations. Furthermore, "regional complementarity" operations between fast and slow zones are only occasionally triggered manually or under fixed rules to meet the basic needs of high-frequency picking and low-frequency storage.
[0003] While the aforementioned solutions have achieved inventory zoning management and automated handling to some extent, several shortcomings remain: First, the zoning strategy is too rigid, making it difficult to dynamically adjust according to order fluctuations or real-time changes in goods attributes. This leads to low replenishment efficiency when fast zones are empty, or affects outbound operations when fast zone space is scarce. Second, replenishment and outbound operations often conflict; replenishment must be paused when there are no available spaces in the fast zone, and vice versa, significantly increasing operational waiting and switching costs. Third, there is a lack of real-time synchronization and coordination mechanisms between the WMS, WCS, and AGV scheduling systems, resulting in delays and gaps in data and instruction transmission, leading to high AGV empty runs and low scheduling efficiency. Fourth, the definitions and maintenance of the "fast / slow zone" attributes are inconsistent across systems, requiring additional manual maintenance of mapping tables, which can easily cause discrepancies between inventory records and actual stock, and abnormal handling. These deficiencies indicate that existing technologies cannot yet meet the needs of intelligent warehousing for dynamic coordination between two zones, efficient replenishment scheduling, and real-time data synchronization. Summary of the Invention
[0004] To address the shortcomings of existing technologies, this invention provides a dual-zone dynamic collaborative intelligent warehouse racking management method and system, which solves the problem of how to achieve system synchronization and efficiently complete replenishment and outbound operations through real-time dynamic zoning and collaborative scheduling of automated guided vehicles, automatic sensor switching, and threshold-triggered replenishment.
[0005] To achieve the above objectives, the present invention provides the following technical solution: a dual-zone dynamic collaborative intelligent warehouse racking management method, comprising:
[0006] S1. Set up a dynamic partitioning module. The dynamic partitioning module calculates and dynamically updates the area attributes of each shelf in real time based on the four-level material classification information and ERP sub-database data. The area attributes include fast zone and slow zone to replace the static partitioning strategy.
[0007] S2. Set up a collaborative scheduling engine. The collaborative scheduling engine dynamically selects the handling strategy based on the remaining storage space in each area and the urgency of the operation during the inbound, outbound and replenishment operations, and establishes an automated guided vehicle scheduling system by adopting a task preemption mechanism.
[0008] S3. Define the "fast zone / slow zone" attribute, establish the binding relationship between the unique packaging number of the shelf and the area attribute, and when the shelf returns to the warehouse, detect the material information through the storage location sensor and automatically switch its area attribute according to the material information;
[0009] S4. Replenishment from the slow zone to the fast zone is completed through the replenishment management process. It is only executed when the empty capacity of the fast zone exceeds the preset threshold. When the outbound task needs to be taken from the slow zone and the shelf has not been replenished, the outbound task is converted into a replenishment priority task to reduce the repeated handling of the automated guided vehicle.
[0010] S5. Real-time synchronization of inventory status and "fast zone / slow zone" attributes between the warehouse management system, warehouse control system and the automated guided vehicle scheduling system is achieved through a message bus, avoiding manual maintenance of the mapping table.
[0011] Preferably, the dynamic partitioning module performs just-in-time priority calculation on materials based on the outbound document type, prioritizing urgent materials to the fast zone to support rapid response to urgent orders.
[0012] Preferably, the handling strategy described in S2 includes:
[0013] S2.1. When the remaining capacity of the fast zone is lower than the preset lower limit, switch to the "least empty positions priority" strategy;
[0014] S2.2. When the remaining capacity of the fast zone is higher than the preset limit, switch to the "most empty slots first" strategy.
[0015] Preferably, the task preemption mechanism is as follows: when the system detects an urgent outbound task, it immediately suspends or cancels the corresponding replenishment task and prioritizes scheduling the automated guided vehicle to execute the urgent outbound task.
[0016] Preferably, the storage location sensor includes an optical sensor installed on the shelf support unit, which is used to detect the remaining materials on the shelf in real time and trigger automatic switching of area attributes.
[0017] Preferably, the dynamic partitioning module and the collaborative scheduling engine are deployed on the central control platform server of the warehouse control system, and the material information is collected and distributed through the warehouse workbench barcode scanner.
[0018] Preferably, the real-time synchronization not only synchronizes the fast / slow zone attributes, but also synchronizes the inventory freeze status and quality inspection status, ensuring consistency between the accounts and actual inventory in each system and avoiding manual maintenance of the mapping table.
[0019] A dual-zone dynamic collaborative intelligent warehouse racking management system includes:
[0020] The dynamic partitioning module is used to receive material four-level classification information and ERP sub-database data, and calculate and dynamically update the area attributes of each shelf in real time based on the material four-level classification information and ERP sub-database data combined with just-in-time priority calculation. The area attributes include fast zone and slow zone.
[0021] The collaborative scheduling engine is used to dynamically select handling strategies based on the remaining storage space in each area and the urgency of the operation during inbound, outbound and replenishment operations, and to issue automated guided vehicle scheduling instructions using a task preemption mechanism.
[0022] The attribute binding module is used to establish the binding relationship between the unique packaging number of the shelf and the area attribute, and when the shelf is returned to the warehouse, the storage location sensor installed on the shelf bearing unit detects the material information and automatically switches its area attribute according to the detection result.
[0023] The replenishment control module is used to trigger the replenishment operation from the slow zone to the fast zone only when the empty capacity of the fast zone exceeds a preset threshold. When it is detected that the outbound task needs to be taken from the slow zone and the shelf has not been replenished, the outbound task is automatically converted into a replenishment priority task to reduce the repeated handling of the automated guided vehicle.
[0024] The synchronous communication module is used to achieve real-time synchronization of inventory status and fast / slow zone attributes between the warehouse management system, warehouse control system and automated guided vehicle scheduling system via message bus, avoiding manual maintenance of the mapping table.
[0025] This invention provides a method and system for intelligent warehouse racking management with dynamic collaboration in two zones. It has the following beneficial effects:
[0026] This intelligent warehouse racking management method and system, featuring dynamic dual-zone collaboration, utilizes a dynamic zoning module combined with just-in-time priority calculation. It can acquire real-time data on four-level material classification and ERP sub-warehouses, dynamically adjusting the fast / slow zone attributes of the racking, completely breaking the rigidity of traditional static zoning. Simultaneously, relying on a collaborative scheduling engine, it flexibly selects either "most empty space priority" or "least empty space priority" handling strategies during inbound, outbound, and replenishment operations. Furthermore, it employs a task preemption mechanism to prioritize urgent outbound requests, significantly reducing the empty run rate of automated guided vehicles and the number of repeated handling operations, greatly improving warehouse operation efficiency and the speed of responding to urgent orders.
[0027] This solution establishes a strict correspondence between the unique packaging number of the shelf and the area attribute through the attribute binding module. Combined with the automatic detection and switching of shelf attributes by the storage location sensor, it ensures that the "fast zone / slow zone" definition is unified, real-time and accurate. Furthermore, relying on the synchronous communication module, the inventory status and area attributes of the warehouse management system, warehouse control system and automated guided vehicle scheduling system are synchronized in real time through the message bus. This completely eliminates data fragmentation between systems and manual mapping and maintenance, and improves system reliability and scalability. Attached Figure Description
[0028] Figure 1 This is a flowchart illustrating the process of realizing the invention;
[0029] Figure 2 For replenishment management flowchart;
[0030] Figure 3 This is a layout diagram for the fast / slow zones. Detailed Implementation
[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0032] like Figure 1-3 As shown, this embodiment of the invention provides a dual-zone dynamic collaborative intelligent warehouse racking management method, including: S1. Setting up a dynamic zoning module. The dynamic zoning module calculates and dynamically updates the zone attributes of each rack in real time based on the four-level material classification information and ERP sub-warehouse data. The zone attributes include fast zone and slow zone, replacing the static zoning strategy. The dynamic zoning module performs just-in-time priority calculation on materials in conjunction with the outbound document type, prioritizing urgent materials to the fast zone to support rapid response to urgent orders.
[0033] S2. Set up a collaborative scheduling engine. In the inbound, outbound and replenishment operations, the collaborative scheduling engine dynamically selects the handling strategy based on the remaining storage space in each area and the urgency of the operation, and establishes an automated guided vehicle scheduling system by adopting a task preemption mechanism.
[0034] The transport strategies in S2 include:
[0035] S2.1. When the remaining capacity of the fast zone is lower than the preset lower limit, switch to the "least empty positions priority" strategy.
[0036] S2.2. When the remaining capacity of the fast zone is higher than the preset limit, switch to the "most empty slots first" strategy.
[0037] The task preemption mechanism is as follows: when the system detects an urgent outbound task, it immediately suspends or cancels the corresponding replenishment task and prioritizes scheduling automated guided vehicles to execute the urgent outbound task.
[0038] The dynamic partitioning module and collaborative scheduling engine are deployed on the central control platform server of the warehouse control system. Material information is collected and distributed through the warehouse workbench barcode scanner.
[0039] The specific implementation method is as follows:
[0040] In this embodiment, the collaborative scheduling engine, as one of the core software components of the present invention, is deployed on the central control platform server of the warehouse control system. This server simultaneously hosts the dynamic partitioning module and the collaborative scheduling engine. Through linkage with terminal devices such as warehouse workbench touchscreens and PDA scanners, it receives real-time trigger information for inbound, outbound, and replenishment operations and issues handling instructions to the automated guided vehicles. The hardware configuration is as follows:
[0041] Server: Deploy the WCS central control platform, integrating a dynamic partitioning module and a collaborative scheduling engine module.
[0042] Terminals: warehouse workbench and PDA barcode scanner, used to collect work requirements and send them to the central control platform.
[0043] Execution layer: Automated Guided Vehicles (AGVs) and warehouse location sensors.
[0044] The collaborative scheduling engine mainly includes the following functional units:
[0045] Storage location monitoring unit: Continuously acquires the number of remaining empty warehouses in each region.
[0046] Urgency assessment unit: Assess the urgency of operations based on the document type and priority of inbound, outbound, and replenishment orders.
[0047] Strategy Selection Unit: Based on the results of warehouse location monitoring and urgency assessment, dynamically selects handling strategies, including:
[0048] When the remaining capacity of the fast zone is lower than the preset lower limit, the strategy of "least empty positions priority" will be switched.
[0049] When the remaining capacity of the fast zone is higher than the preset limit, the strategy of "maximum number of empty slots" will be switched to.
[0050] Task preemption unit: When the urgency assessment unit detects an urgent outbound task, it immediately suspends or cancels the corresponding replenishment task and increases the priority of the urgent outbound task in the automated guided vehicle (AGV) scheduling queue to ensure that AGV resources respond first.
[0051] like Figure 2 The replenishment management flowchart shows an example of the software process:
[0052] Inbound scenario: Warehouse workstation scans inbound materials → Central control platform receives inbound request → Collaborative scheduling engine assesses the availability of space and urgency of operations in each area → Strategy selection unit prioritizes "most available space" → Issues handling and rotation instructions to automated guided vehicle → Inbound completed.
[0053] Outbound scenario: When an outbound task is issued from the warehouse management system to WCS, the collaborative scheduling engine evaluates it and prioritizes scheduling automated guided vehicles (AGVs) from the fast zone. If the fast zone inventory is insufficient, it automatically calls upon the slow zone inventory and triggers the pause of the corresponding replenishment task.
[0054] Replenishment Scenario: Triggered by the replenishment management process, when the available capacity in the fast zone meets the threshold condition, the collaborative scheduling engine selects the "least available storage space priority" strategy and dispatches automated guided vehicles. If there is an urgent need for replenished materials in the slow zone during the outbound process, the task preemption unit converts the outbound request to replenishment priority, reducing the number of repeated handling operations.
[0055] Through the above implementation, the collaborative scheduling engine can dynamically switch handling strategies based on real-time data in various operation scenarios, and ensure timely response for urgent outbound shipments through a task preemption mechanism, thereby significantly improving warehousing operation efficiency and reducing the empty running rate of automated guided vehicles and the number of repeated handling operations.
[0056] S3. Define "fast zone / slow zone" attributes, establish a binding relationship between the unique packaging number of the shelf and the zone attribute, and automatically switch the zone attribute based on the material information detected by the storage location sensors when the shelf is returned to the warehouse. The storage location sensors include optical sensors installed on the shelf support unit. The optical sensors are used to detect the remaining materials on the shelf in real time and trigger the automatic switching of zone attributes.
[0057] S4. Replenishment from slow zone to fast zone is completed through the replenishment management process. It is only executed when the empty capacity of fast zone exceeds the preset threshold. When the outbound task needs to be taken from slow zone and the shelf has not been replenished, the outbound task is converted into a replenishment priority task to reduce the repeated handling of automated guided vehicles.
[0058] The specific implementation method is as follows:
[0059] In this embodiment, the replenishment control module is deployed on the WCS central control platform server, working closely with the warehouse management system and the collaborative scheduling engine. It is responsible for triggering replenishment operations from slow zone to fast zone according to preset thresholds, and, when necessary, converting outbound tasks into replenishment-priority tasks to reduce redundant handling by automated guided vehicles (AGVs). The process is as follows:
[0060] Threshold configuration:
[0061] In the system management interface, warehouse administrators can set the threshold for available storage space in the fast zone. This threshold is stored in the parameter configuration table of the replenishment control module.
[0062] Triggering restocking:
[0063] WMS periodically or based on inbound / outbound early warning logic sends replenishment requests for fast-zone areas to the replenishment control module.
[0064] The replenishment control module reads the current number of available warehouse slots in the express zone and compares it with a preset threshold:
[0065] If the number of available warehouses exceeds the threshold, replenishment is permitted.
[0066] Otherwise, the replenishment request will be delayed until the available warehouse space meets the conditions.
[0067] Once the conditions are met, the replenishment control module submits a replenishment task to the collaborative scheduling engine, which then issues an automated guided vehicle (AGV) to perform the replenishment operation based on the handling strategy.
[0068] Outbound task conversion:
[0069] When a replenishment task is issued by the WMS, if the target shelf is in the slow zone and there are no outstanding replenishment tasks for that shelf, the replenishment control module will immediately perform one of the following actions:
[0070] 1. Suspend the original outbound process.
[0071] 2. Generate the corresponding replenishment priority task.
[0072] 3. Submit the order to the collaborative scheduling engine, and the automated guided vehicle will perform the replenishment first.
[0073] After replenishment is completed and the area attribute is updated to a fast zone, the replenishment control module notifies the WMS or collaborative scheduling engine to continue executing the original outbound operation.
[0074] Real-time effect:
[0075] By replenishing stock only when there is sufficient space in the fast zone, excessive stockpiling in the fast zone can be avoided.
[0076] By prioritizing outbound tasks over replenishment, the need for automated guided vehicles (AGVs) to make multiple round trips to the same shelf is eliminated, significantly reducing empty runs and energy consumption.
[0077] In summary, the replenishment control module works in concert with the collaborative scheduling engine to trigger replenishment strictly according to the condition that "the available capacity of the fast zone is greater than the preset threshold". When goods from the slow zone are needed for outbound operations, the replenishment is automatically converted into a priority replenishment task. This achieves an orderly connection between slow zone and fast zone replenishment and outbound operations, which greatly improves overall logistics efficiency and resource utilization.
[0078] S5. Real-time synchronization of inventory status and "fast zone / slow zone" attributes between the warehouse management system, warehouse control system, and automated guided vehicle (AGV) scheduling system is achieved via a message bus, avoiding manual maintenance of the mapping table. Real-time synchronization not only synchronizes the fast / slow zone attributes but also the inventory freeze status and quality inspection status, ensuring consistency between the records and actual inventory across all systems and eliminating the need for manual maintenance of the mapping table.
[0079] A dual-zone dynamic collaborative intelligent warehouse racking management system includes:
[0080] The dynamic zoning module receives material classification information and ERP sub-database data, and calculates and updates the area attributes of each shelf in real time based on the material classification information and ERP sub-database data combined with just-in-time priority calculation. The area attributes include fast zone and slow zone.
[0081] The collaborative scheduling engine is used to dynamically select handling strategies based on the remaining storage space in each area and the urgency of the operation during inbound, outbound and replenishment operations, and to issue automated guided vehicle scheduling instructions using a task preemption mechanism.
[0082] The attribute binding module is used to establish the binding relationship between the unique packaging number of the shelf and the area attribute. When the shelf is returned to the warehouse, the storage location sensor installed on the shelf bearing unit detects the material information and automatically switches its area attribute according to the detection result.
[0083] The replenishment control module is used to trigger replenishment operations from the slow zone to the fast zone only when the available capacity in the fast zone exceeds a preset threshold. When it is detected that an outbound task needs to be picked up from the slow zone and the shelf has not been replenished, the outbound task is automatically converted into a replenishment priority task to reduce the repeated handling of automated guided vehicles.
[0084] The synchronous communication module is used to achieve real-time synchronization of inventory status and fast / slow zone attributes between the warehouse management system, warehouse control system and automated guided vehicle scheduling system via message bus, avoiding manual maintenance of the mapping table.
[0085] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.
Claims
1. A dual-zone dynamic collaborative intelligent warehouse racking management method, characterized in that, include: S1. Set up a dynamic partitioning module. The dynamic partitioning module calculates and dynamically updates the area attributes of each shelf in real time based on the four-level material classification information and ERP sub-database data. The area attributes include fast zone and slow zone. S2. Set up a collaborative scheduling engine. The collaborative scheduling engine dynamically selects the handling strategy based on the remaining storage space in each area and the urgency of the operation during the inbound, outbound and replenishment operations, and establishes an automated guided vehicle scheduling system by adopting a task preemption mechanism. S3. Define the "fast zone / slow zone" attribute, establish the binding relationship between the unique packaging number of the shelf and the area attribute, and when the shelf returns to the warehouse, detect the material information through the storage location sensor and automatically switch its area attribute according to the material information; S4. Replenishment from the slow zone to the fast zone is completed through the replenishment management process. It is only executed when the empty capacity of the fast zone exceeds the preset threshold. When the outbound task needs to be taken from the slow zone and the shelf has not been replenished, the outbound task is converted into a replenishment priority task. S5. Real-time synchronization of inventory status and "fast zone / slow zone" attributes between the warehouse management system, the warehouse control system and the automated guided vehicle scheduling system is achieved through a message bus.
2. The intelligent warehouse racking management method with dual-zone dynamic collaboration according to claim 1, characterized in that: The dynamic partitioning module combines the outbound document type to perform on-time priority calculation on materials, and prioritizes urgent materials to the fast zone.
3. The intelligent warehouse racking management method with dual-zone dynamic collaboration according to claim 1, characterized in that: The transport strategy described in S2 includes: S2.
1. When the remaining capacity of the fast zone is lower than the preset lower limit, switch to the "least empty positions priority" strategy; S2.
2. When the remaining capacity of the fast zone is higher than the preset limit, switch to the "most empty slots first" strategy.
4. The intelligent warehouse racking management method with dual-zone dynamic collaboration according to claim 1, characterized in that: The task preemption mechanism is as follows: when the system detects an urgent outbound task, it immediately suspends or cancels the corresponding replenishment task and prioritizes scheduling the automated guided vehicle to execute the urgent outbound task.
5. The intelligent warehouse racking management method with dual-zone dynamic collaboration according to claim 1, characterized in that: The storage location sensor includes an optical sensor installed on the shelf support unit. The optical sensor is used to detect the remaining materials on the shelf in real time and trigger automatic switching of area attributes.
6. The intelligent warehouse racking management method with dual-zone dynamic collaboration according to claim 1, characterized in that: The dynamic partitioning module and the collaborative scheduling engine are deployed on the central control platform server of the warehouse control system, and the material information is collected and distributed through the warehouse workbench barcode scanner.
7. The intelligent warehouse racking management method with dual-zone dynamic collaboration according to claim 1, characterized in that: The real-time synchronization not only synchronizes the fast / slow zone attributes, but also the inventory freeze status and quality inspection status.
8. A dual-zone dynamic collaborative intelligent warehouse racking management system, characterized in that: include: The dynamic partitioning module is used to receive material four-level classification information and ERP sub-database data, and calculate and dynamically update the area attributes of each shelf in real time based on the material four-level classification information and ERP sub-database data combined with just-in-time priority calculation. The area attributes include fast zone and slow zone. The collaborative scheduling engine is used to dynamically select handling strategies based on the remaining storage space in each area and the urgency of the operation during inbound, outbound and replenishment operations, and to issue automated guided vehicle scheduling instructions using a task preemption mechanism. The attribute binding module is used to establish the binding relationship between the unique packaging number of the shelf and the area attribute, and when the shelf is returned to the warehouse, the storage location sensor installed on the shelf bearing unit detects the material information and automatically switches its area attribute according to the detection result. The replenishment control module is used to trigger a replenishment operation from the slow zone to the fast zone only when the available capacity in the fast zone exceeds a preset threshold. When it is detected that an outbound task needs to be taken from the slow zone and the shelf has not been replenished, the outbound task is automatically converted into a replenishment priority task. The synchronous communication module is used to achieve real-time synchronization of inventory status and fast / slow zone attributes between the warehouse management system, warehouse control system and automated guided vehicle scheduling system via a message bus.