A material whole-process dynamic management and control system and method

Abstract

The application discloses a kind of material whole-process dynamic control system and method, it is related to dynamic control technical field;Method includes: pre-setting material-bin binding table and equipment and personnel information, and real-time record material operation log;If the effective bin record quantity corresponding to the serial number of a certain material in material-bin binding table exceeds 1, then the material corresponding to the serial number of material is marked as conflict material, and conflict alarm is generated;Based on conflict alarm and equipment and personnel information, abnormal operation determination result is obtained by analysis;Actual position verification is carried out to conflict material, and the actual storage bin of conflict material is obtained;Based on abnormal operation determination result and the actual storage bin of conflict material, material-bin binding table is updated, and the updated material-bin binding table is obtained;Effectively avoid production interruption and order delay caused by bin conflict, reduce warehousing management cost, improve the reliability of inventory data and warehousing operation efficiency simultaneously.

Description

Technical Field

[0001] This invention relates to the field of dynamic control technology, and more specifically, to a dynamic control system and method for the entire process of materials. Background Technology

[0002] In the daily operations of modern manufacturing and e-commerce warehousing, a large number of materials that carry production or sales functions need to be managed with precise warehouse location to ensure efficient circulation. Key components used for assembly in manufacturing and goods awaiting fulfillment on e-commerce platforms must maintain a stable connection with a unique warehouse location throughout the entire process of warehousing, transfer, and picking. This connection is the core foundation for accurate allocation of production materials and rapid location of order goods. Once the warehouse location information becomes chaotic, it will directly interrupt the normal production or fulfillment rhythm. Currently, such warehousing scenarios generally rely on warehouse management systems combined with scanning terminals to achieve the association management of materials and storage locations. The technical principle is to use handheld scanning devices to collect information such as material serial number, target storage location code, operation type, and timestamp during each operation. This data is uploaded in real time to form a material operation log. At the same time, the system dynamically updates the material-storage location binding table based on the log content to maintain the "one item, one address" inventory status. When the system finds that the same material serial number corresponds to multiple storage locations through periodic checks of the binding table or manual spot checks, the existing technology lacks the ability to automatically analyze and process it. It can only rely on managers to work backward from the time the conflict was discovered, going through the historical operation log of the material one by one, comparing storage location change records at different time points. At the same time, it is also necessary to send personnel to the multiple storage locations involved in the conflict to conduct on-site inventory, and to manually verify the actual storage location of the materials to locate the root cause of the problem.

[0003] Such "one item in multiple locations" conflicts can have a series of impacts on warehousing operations and related businesses. In manufacturing scenarios, if critical components experience location conflicts, the system cannot provide accurate actual location information, forcing production line requisition requests to be suspended due to the inability to locate materials in a timely manner. In e-commerce warehousing scenarios, location conflicts can prevent the quick retrieval of target products during order picking. In the long run, manual log checks and physical inventory counts require significant manpower and time, significantly increasing warehousing management costs. Furthermore, human judgment is easily limited by experience, potentially leading to misjudgments of problematic processes and incorrect corrections, further compromising the accuracy of inventory data. Unreliable inventory data directly affects the rationality of procurement planning and inventory turnover efficiency, ultimately resulting in a decline in the overall supply chain's collaborative capabilities.

[0004] In view of this, the present invention proposes a dynamic management and control system and method for the entire process of materials to solve the above problems. Summary of the Invention

[0005] To overcome the aforementioned deficiencies of the prior art and achieve the above objectives, the present invention provides the following technical solution: a method for dynamic management and control of materials throughout the entire process, comprising:

[0006] Pre-set the material-warehouse location binding table and equipment and personnel information, and record material operation logs in real time;

[0007] If there are more than one valid storage location record corresponding to a material serial number in the material-storage location binding table, the material corresponding to the material serial number will be marked as a conflicting material and a conflict alarm will be generated.

[0008] Based on conflict alarms and equipment and personnel information, the abnormal operation judgment results are obtained through analysis;

[0009] Verify the actual location of conflict materials to determine their actual storage location.

[0010] Based on the abnormal operation judgment results and the actual storage location of the conflicting materials, the material-storage location binding table is updated to obtain the updated material-storage location binding table.

[0011] Furthermore, methods for obtaining abnormal operation determination results include:

[0012] Filter out all historical operation records of the conflicting materials corresponding to the material serial numbers recorded in the conflict alarm from the material operation log, and sort them in chronological order to form a sequence of operation events for the conflicting materials;

[0013] The operation event sequence includes the operation type, the storage location corresponding to each operation, the operation time, the operator ID, the operation equipment ID, the operation status, the operation remarks, and the document number associated with the operation.

[0014] The system iterates through the sequence of operation events for conflicting materials, compares the sequence with the normal business process step by step, identifies operation combinations or missing operations that do not match the normal business process, and locates abnormal operations by combining business rules to obtain the abnormal operation judgment result.

[0015] Furthermore, normal business processes include:

[0016] The inbound and shelving operation for the same material serial number takes precedence over subsequent storage location movement or outbound and shelving operations.

[0017] The storage location movement operation for the same material serial number includes the old storage location outbound and desold operation and the new storage location inbound and desold operation in sequence, and the time node of the old storage location outbound and desold operation is earlier than the time node of the new storage location inbound and desold operation.

[0018] Only one valid inbound and shelving operation record is allowed for the same material serial number within a preset time threshold, and the storage location code corresponding to the inbound and shelving operation record is unique;

[0019] All operation records must first undergo operation status verification before participating in the material-warehouse location association update;

[0020] In the operation status verification, only operation records with a successful status are considered valid records.

[0021] Furthermore, methods for traversing the operational event sequence of conflicting materials and comparing the operational event sequence with the normal business process step by step to identify operational combinations or missing operations that do not match the normal business process include:

[0022] If there are storage location movement operations for the same material serial number in the operation event sequence, and the old storage location outbound and desold operation record associated with the storage location movement operation is missing, and the new storage location inbound and desold operation record associated with the storage location movement operation already exists, and the time node corresponding to the new storage location inbound and desold operation record is earlier than the time node of other subsequent operation records of the conflicting material, then the conflicting material is determined to be a missed scan.

[0023] If there are two inbound and putaway operation records for the same material serial number in the operation event sequence, and the difference in operation time between the two inbound and putaway operation records is less than a preset time threshold, and the storage location codes corresponding to the two inbound and putaway operation records are different, and the operation status of both inbound and putaway operation records is successful, then the conflicting material is determined to be a misscan.

[0024] Furthermore, the business rules include:

[0025] The storage location movement operation for the same material serial number includes a complete record of the old storage location's outbound and desale operation and the new storage location's inbound and shelving operation, and the time node of the old storage location's outbound and desale operation is earlier than the time node of the new storage location's inbound and shelving operation.

[0026] Only one valid inbound and shelving operation record is allowed for the same material serial number within the same preset time threshold, and the corresponding storage location code of the inbound and shelving operation record is unique;

[0027] The outbound and offbound operation record for the same material serial number is later than the most recent inbound and put-away operation record or the new inbound and put-away operation record in the new storage location during the storage location relocation operation.

[0028] All operation records involved in conflict analysis have a successful operation status, and the document number associated with the operation has a matching valid document information in the business document database; the business document database is a pre-built database in the warehouse management system, used to store document information corresponding to all businesses in the entire warehouse process.

[0029] Furthermore, methods for locating abnormal operations by combining business rules include:

[0030] Filter out operation records in the operation event sequence that do not conform to any business rule to form a candidate set of abnormal operation records;

[0031] Calculate the correlation between each abnormal operation record in the candidate set and the storage location code involved in the conflict alarm. If the storage location code corresponding to the abnormal operation record belongs to the storage location code involved in the conflict alarm, the correlation is counted as 1; otherwise, it is counted as 0.

[0032] Calculate the time difference between the operation time corresponding to the abnormal operation record and the time of conflict alarm discovery;

[0033] The candidate set of abnormal operation records is prioritized with correlation as the primary weight and time difference as the secondary weight. Candidate records with a correlation of 1 have higher priority than candidate records with a correlation of 0. If the correlation is the same, the candidate records with smaller time differences have higher priority. The operation corresponding to the abnormal operation record with the highest priority is selected as the abnormal operation.

[0034] Furthermore, methods for obtaining the actual storage locations of conflict materials include:

[0035] For warehouses that have deployed RFID readers or shelf sensors, candidate storage locations for conflicting materials are identified in different ways.

[0036] If there is only one candidate storage location, and the detection results of the shelf sensor are consistent with the detection results of the corresponding RFID reader, then the corresponding storage location is determined to be the actual storage location of the conflicting materials. If there are multiple candidate storage locations, the candidate storage location with the smallest difference between the timestamp of the shelf sensor detection and the time of the conflict alarm is selected to form a candidate storage location set. If the candidate storage location set contains only one storage location, then the corresponding storage location is directly determined to be the actual storage location of the conflicting materials. If the candidate storage location set contains multiple storage locations, then the storage location with the most recent inbound and shelving operation record in the operation log of the corresponding storage location is used as the second screening condition, and the storage location that meets the second screening condition is selected from the candidate storage location set and determined to be the actual storage location of the conflicting materials.

[0037] Furthermore, for warehouses equipped with RFID readers or shelf sensors, methods for identifying candidate storage locations for conflicting materials in different ways include:

[0038] For warehouses that have deployed RFID readers, query the historical detection records of the RFID tags attached to the conflicting materials, filter out the detection records with the latest timestamps, and the storage area where the corresponding RFID reader is located is the current location area of ​​the conflicting materials; if the signal strength in the corresponding detection record is higher than the preset signal strength threshold, then it is confirmed that the conflicting materials are in the storage area covered by the corresponding RFID reader, and the candidate storage location of the conflicting materials is obtained.

[0039] For warehouses that deploy shelf sensors, each shelf sensor corresponds to a unique storage location. Weight-sensing shelf sensors will detect the weight data of the corresponding storage location in real time. If the weight data exceeds the preset empty threshold, it is determined that the corresponding storage location contains materials. Infrared-sensing shelf sensors will detect in real time whether the infrared signal of the corresponding storage location is blocked. If a continuous blocking state is detected, it is determined that the corresponding storage location contains materials, and candidate storage locations for conflicting materials are obtained.

[0040] Furthermore, methods for obtaining the updated material-location binding table include:

[0041] For missed scan scenarios, an additional record of the old warehouse location's outbound and destocked operation is automatically generated and inserted into the material operation log; and the association record between conflicting materials and old warehouse location codes in the material-warehouse location binding table is deleted;

[0042] For incorrect scanning scenarios, mark the corresponding inbound and put-away operation record as invalid in the material operation log; delete the associated record of the conflicting material and the corresponding incorrect inbound and put-away operation record in the material-location binding table, and retain the associated record of the conflicting material and the corresponding location code in the material-location binding table, and update the associated location of the conflicting material in the material-location binding table to the actual location.

[0043] The updated material-warehouse binding table has been obtained.

[0044] A dynamic management and control system for the entire process of materials includes:

[0045] The information collection module is used to pre-set the material-storage location binding table and equipment and personnel information, and to record material operation logs in real time;

[0046] The conflict alarm module is used to determine whether the number of valid storage location records corresponding to a certain material serial number in the material-storage location binding table exceeds one. If so, the material corresponding to the material serial number is marked as a conflicting material and a conflict alarm is generated.

[0047] The anomaly detection module analyzes conflict alarms and equipment and personnel information to determine the results of abnormal operations.

[0048] The storage location verification module is used to verify the actual location of conflicting materials and obtain the actual storage location of the conflicting materials.

[0049] The information update module updates the material-location binding table based on the abnormal operation judgment results and the actual storage location of the conflicting materials, resulting in an updated material-location binding table.

[0050] Compared with the prior art, the technical effects and advantages of the material dynamic management and control system and method of the present invention are as follows:

[0051] The material storage location conflict correction scheme of this invention pre-sets a material-storage location binding table and equipment and personnel information, and records material operation logs in real time. When the number of valid storage location records corresponding to a certain material serial number in the material-storage location binding table exceeds one, the material is marked as a conflicting material and a conflict alarm is generated. Based on the conflict alarm and equipment and personnel information, the historical operation records of conflicting materials are filtered from the material operation log and sorted by time to form an operation event sequence. Combined with the normal business process and business rules for comparison and analysis, abnormal operations such as missed scanning or incorrect scanning are located to obtain the abnormal operation judgment result. At the same time, the actual location of the conflicting material is verified by RFID reader or shelf sensor to determine its actual storage location. Finally, the material-storage location binding table is updated according to the abnormal operation judgment result and the actual storage location. In the case of missed scanning, the old storage location outbound and de-shelf operation record is added and the association between the conflicting material and the old storage location is deleted. In the case of incorrect scanning, the incorrect inbound and shelving operation record is marked as invalid and the association between the conflicting material and the actual storage location is retained. After the update, the log and binding table are stored synchronously, the conflict alarm status is changed to resolved and the management personnel are notified.

[0052] This invention solves the problems of low efficiency and high error rate in existing technologies that rely on manual log back-checking and physical inventory checks to handle storage location conflicts. It also addresses the issue of frequent missed and incorrect scans due to the lack of a real-time verification mechanism based on business logic. Furthermore, it resolves the problems of production line shutdowns due to material shortages, order fulfillment delays, high warehouse management costs, and poor inventory data accuracy caused by storage location conflicts. Its advantages include automating the entire process of storage location conflict detection, anomaly location, and correction, significantly shortening conflict handling time; ensuring the accuracy of correction results through dual confirmation of operational logic analysis and physical location verification; reducing manual intervention and lowering the probability of human error; effectively avoiding production interruptions and order delays caused by storage location conflicts; reducing warehouse management costs; and simultaneously improving the reliability of inventory data and warehouse operational efficiency. Attached Figure Description

[0053] Figure 1 This is a schematic diagram of a dynamic material management and control system according to an embodiment of the present invention;

[0054] Figure 2 This is a flowchart of a method for dynamic management and control of materials throughout the entire process, according to an embodiment of the present invention.

[0055] Figure 3 This is a flowchart of a method for obtaining abnormal operation determination results according to an embodiment of the present invention;

[0056] Figure 4 This is a flowchart illustrating the method for obtaining the actual storage location of materials according to an embodiment of the present invention. Detailed Implementation

[0057] The technical solutions of the embodiments of the present invention will be described in detail, clearly, and completely below with reference to the accompanying drawings. It should be particularly noted that the specific embodiments described below are only for better illustrating and explaining the technical solutions of the present invention, and are intended to enable those skilled in the art to better understand and implement the present invention, and should not be construed as limiting the scope of protection of the present invention. Without departing from the spirit and substance of the present invention, those skilled in the art can modify, adjust, or make equivalent substitutions based on the content disclosed in the present invention, and these should all be considered within the scope of protection of the present invention.

[0058] Example 1:

[0059] Please see Figure 1 As shown in the figure, this embodiment discloses a dynamic management and control system for the entire material process, including an information collection module, a conflict alarm module, an anomaly judgment module, a storage location verification module, and an information update module. Each module is connected by wired and / or wireless means to realize data transmission.

[0060] The information collection module is used to pre-set the material-warehouse binding table and equipment and personnel information, and to record material operation logs in real time.

[0061] Pre-set the material-warehouse location binding table and equipment and personnel information. Specific methods include:

[0062] The Material-Location Binding Table is a status data table used to record the association between materials and storage locations. This table includes at least the material serial number, storage location code, association status, and association update time. The association status identifies the validity of the association, specifically divided into valid and invalid states. The association update time is the timestamp of the most recent update to the association. The system is configured to automatically update the storage location code, association status, and association update time of the corresponding material serial number in the Material-Location Binding Table based on the operation record corresponding to the logistics operation in the material operation log after each inbound / outbound / location operation is completed. The material operation log is a data table of operation records collected and stored in real time by scanning terminal devices during each inbound / outbound / location operation. Its fields include at least the operation record ID, material serial number, operation type, storage location code involved in the operation, operation timestamp, operator ID, operation device ID, and operation status. The system is configured to only use an operation record indicating a successful operation as the basis for triggering an update to the Material-Location Binding Table. Based on the principle of one item, one address, under normal circumstances, the material-location binding table will only have one valid location code record associated with the same material serial number.

[0063] Equipment and personnel information is optional auxiliary analysis data. It includes at least the following fields: scanning terminal device number, operator ID, employee's location area code, and information update timestamp. The scanning terminal device number is a unique identifier for the terminal device used to perform the material scanning operation; the operator ID is a unique identifier for the personnel performing the material operation; and the employee's location area code is the warehouse area code where the operator typically works. Equipment and personnel information is initially set and updated by the warehouse management system administrator through the system configuration interface. The information update timestamp automatically records the time of each setting or update, used to assist in determining the background environment of the equipment and personnel during the operation when analyzing material operation logs.

[0064] The material-location binding table and equipment and personnel information are collected in real time and stored in the system database during the daily operation of the warehouse management system. Among them, the material operation log and the material-location binding table are the core basic data for realizing the "one item, multiple locations" conflict detection and handling, while sensor data and equipment and personnel information serve as auxiliary data to further improve the accuracy of conflict location and error correction.

[0065] The conflict alarm module is used to determine whether the number of valid storage location records corresponding to a certain material serial number in the material-storage location binding table exceeds one. If so, the material corresponding to the material serial number is marked as a conflict material and a conflict alarm is generated.

[0066] Continuously monitor inventory data, group the material-location binding table by material serial number, and check the associated location records in each group one by one. Only the location records that are not marked as invalid, deleted or historically archived are determined to be valid location records. If the statistics show that the number of valid location records corresponding to a certain material serial number exceeds one, an "one item, multiple locations" anomaly is immediately determined, and the material corresponding to the material serial number is marked as a conflicting material. A conflict alarm is then generated, recording the material serial number of the conflicting material, the location code involved, and the discovery time, which serve as the trigger input for subsequent processing. Recording the serial number of the conflicting materials is to uniquely identify the specific materials that caused the conflict, ensuring that subsequent steps such as tracing operation logs and verifying actual locations can accurately locate the conflicting materials and avoid confusion with other materials. Recording the storage location codes involved is to clarify all storage locations that the conflicting materials were incorrectly associated with, providing specific guidance for narrowing down the scope of log tracing and verifying the actual storage location of the conflicting materials on-site or through sensors. Recording the discovery time is to pinpoint the time when the conflict initially appeared, helping to quickly filter the material operation logs before that time to investigate the cause of the anomaly, and also providing an initial reference for subsequent statistics on the timeliness of conflict handling.

[0067] After receiving a conflict alarm, the system filters out all historical operation records of the conflicting materials corresponding to the material serial numbers recorded in the conflict alarm from the material operation log, and sorts them chronologically to form an operation event sequence for the conflicting materials. The operation event sequence includes the operation type, the storage location corresponding to each operation, the operation time, the operator ID, the operation equipment ID, the operation status, the operation remarks, and the document number associated with the operation. The operation types include inbound shelving, outbound descrambling, storage location relocation, inventory confirmation, and anomaly marking. Inbound shelving is the initial entry of conflicting materials into the warehouse and binding them to an initial storage location. Outbound descrambling is the removal of conflicting materials from their current storage location and unbinding them from that location. Storage location relocation is the transfer of conflicting materials from their original location to a new location, requiring simultaneous updates to the storage location binding. Inventory confirmation is the verification of the current storage location of conflicting materials and the recording of the results. Anomaly marking is the marking of anomalies when a conflicting material's storage location is found to be questionable. Operation statuses are categorized as successful, failed, and pending confirmation, used to determine the effectiveness of the operation and eliminate interference from invalid operations in conflict analysis. Operation remarks record special circumstances such as temporary storage or urgent transfer needs during the operation to aid in understanding the background of abnormal operations. The associated document numbers include inbound order number, transfer order number, and outbound order number, used to trace the corresponding business process to confirm whether the operation conforms to the business plan. This information collectively provides a complete basis for accurately locating the cause of the conflict. The operation event sequence will be used to analyze the specific stages in which the conflict occurred.

[0068] The anomaly detection module analyzes conflict alarms and equipment and personnel information to determine the results of abnormal operations.

[0069] Please see Figure 3 As shown, the methods for analyzing and determining abnormal operation results based on conflict alarms and equipment and personnel information include:

[0070] The system iterates through the sequence of operation events for conflicting materials, identifies abnormal patterns based on the normal business process, and determines the cause of the conflict. The normal business process specifically includes: the inbound and shelving operation for the same material serial number precedes its subsequent location movement or outbound / removal operation; location movement operations for the same material serial number sequentially include an outbound / removal operation from the old location and an inbound and shelving operation from the new location, with the outbound / removal operation from the old location occurring earlier than the inbound and shelving operation from the new location; only one valid inbound and shelving operation record is allowed for the same material serial number within a preset time threshold, and the location code corresponding to this record is unique; all operation records must complete operation status verification before participating in the material-location association update; only operation records with a successful status are considered valid during operation status verification. Identifying abnormal patterns involves comparing the operation event sequence with the normal business process step-by-step to identify operation combinations that do not match the normal business process or missing operations.

[0071] Methods for traversing the sequence of operational events involving conflicting materials, identifying abnormal patterns based on normal business processes, and determining the cause of the conflict include:

[0072] If a storage location relocation operation for the same material serial number exists in the operation event sequence, and the old storage location outbound / removal operation record associated with the storage location relocation operation is missing, while the new storage location inbound / removal operation record associated with the storage location relocation operation already exists, and the time node corresponding to the new storage location inbound / removal operation record is earlier than the time node of other subsequent operation records for the conflicting material, then the conflicting material is determined to be missed during scanning. That is, during the storage location relocation operation, the operator did not complete the outbound / removal operation scan for the corresponding old storage location using the operating equipment, resulting in the missing old storage location outbound / removal operation record for the conflicting material in the material operation log. In this case, the time point of the missed scan and related operations are recorded. The time point of the missed scan is based on the operation time corresponding to the new storage location inbound / removal operation record to determine the time interval in which the missed scan should have occurred. Related operations include the new storage location inbound / removal operation associated with the corresponding storage location relocation operation, the storage location relocation operation document number for the corresponding storage location relocation operation, the old storage location code, and the old storage location outbound / removal operation.

[0073] If there are two inbound and putaway operation records for the same material serial number in the operation event sequence, and the difference in operation time between the two inbound and putaway operation records is less than a preset time threshold, and the storage location codes corresponding to the two inbound and putaway operation records are different, and the operation status of both inbound and putaway operation records is successful, then it is determined that one of the inbound and putaway operation records has a scanning object identification error. That is, when the operator performs the scanning action through the operating equipment, he mistakenly identifies the identification information of other materials as the material serial number of the conflicting material, resulting in the incorrect generation of the inbound and putaway operation record corresponding to the material serial number in the material operation log. Judgment is made using equipment and personnel information: Extract the operating equipment ID and operator ID corresponding to the two inbound and shelving operation records from the equipment and personnel information to obtain two sets of identification information. The consistency of the two sets of identification information is compared. If the operating equipment ID or operator ID corresponding to the two inbound and shelving operation records is different, the inbound and shelving operation record with the later operation time is determined to be an invalid record caused by the scanning object identification error. The reason for generating invalid records is that when the operator is scanning with the corresponding operating equipment, he / she mistakenly identifies the identification information of other materials as the material serial number of conflicting materials.

[0074] The system iterates through the sequence of operational events for conflicting materials, comparing actual operations with normal business processes to identify anomalies. This allows for the identification of abnormal operations in the analysis of "one item, multiple locations" conflicts, in conjunction with business rules. These business rules include: For the same material serial number, a warehouse location relocation operation must include a complete record of both the old warehouse location's outbound / removal operation and the new warehouse location's inbound / removal operation; the time of the old warehouse location's outbound / removal operation must be earlier than the time of the new warehouse location's inbound / removal operation; only one valid inbound / removal operation record is allowed for the same material serial number within the same preset time threshold, and the warehouse location code corresponding to this inbound / removal operation record must be unique; the preset time threshold is set based on warehousing operation efficiency standards, typically 5 minutes; and the outbound / removal operation record for the same material serial number must be later than the most recent inbound / removal operation record or the new warehouse location inbound / removal operation record in a warehouse location relocation operation. There are operation records that participated in conflict analysis, and their operation status is successful. The document number associated with the operation has a matching valid document information in the business document database. The business document database is a pre-built database in the warehouse management system, used to store document information corresponding to all business in the entire warehouse process, including inbound orders for inbound business, storage location orders for storage location movement business, and outbound orders for outbound business. Each document information contains a unique document number and corresponding business details, such as document creation time, document associated material information, document processing status, etc., so as to verify the business rationality of the operation through the document number in the operation record.

[0075] The method for locating abnormal operations includes: First, validating each operation record in the operation event sequence according to business rules, filtering out operation records that do not conform to any business rule, and forming a candidate set of abnormal operation records; calculating the correlation between each abnormal operation record in the candidate set and the storage location codes involved in the conflict alarm; the correlation is calculated based on the correspondence between the abnormal operation record and the conflict alarm in terms of storage location codes, specifically by extracting the storage location codes involved in the operation in the abnormal operation record, and simultaneously extracting the set of storage location codes involved in the conflict alarm. If the storage location code involved in the operation in the abnormal operation record belongs to the set of storage location codes involved in the conflict alarm, then the correlation of the abnormal operation record is considered. The correlation score is 1; if the storage location code involved in the operation in the abnormal operation record does not belong to the set of storage location codes involved in the conflict alarm, then the correlation score of the abnormal operation record is 0; calculate the time difference between the operation time corresponding to the abnormal operation record and the time of the conflict alarm discovery. The smaller the time difference, the higher the probability that the abnormal operation record is the direct cause of the conflict; prioritize the candidate set of abnormal operation records with correlation score as the primary weight and time difference as the secondary weight. The candidate record with correlation score of 1 has a higher priority than the candidate record with correlation score of 0. When the correlation scores are the same, the candidate record with a smaller time difference has a higher priority. Select the operation corresponding to the abnormal operation record with the highest priority as the abnormal operation most likely to cause the "one item in multiple locations" conflict.

[0076] The final output shows the result of the abnormal operation judgment, indicating whether the conflict was caused by a missed scan or an incorrect scan, as well as the log records or missing operation steps involved. The log records involved include the operation time, operation device ID, operator ID, and document number associated with the operation in the abnormal operation record. The missing operation steps include the storage location code corresponding to the missing outbound and destocking operation, the time range of the operation that should have been executed, and the document number associated with the operation.

[0077] The storage location verification module is used to verify the actual location of conflicting materials and obtain the actual storage location of the conflicting materials.

[0078] To improve error correction accuracy, rapid on-site location verification is performed on conflicting materials. Abnormal operation judgments are verified using sensor data to avoid correction deviations caused by missing or misjudged operation logs. Sensor data is collected by IoT devices deployed within the warehouse, including but not limited to RFID readers, shelf weight sensors, and shelf infrared sensors. RFID readers are deployed in the warehouse's storage areas and aisle areas, each with a unique coverage area code. The data they collect includes, but is not limited to, the detected material's RFID tag code, signal strength, detection timestamp, and the corresponding RFID reader's device number. Shelf weight sensors are deployed on the load-bearing structure of each storage location, collecting data including, but not limited to, the corresponding storage location code, real-time weight value, weight change timestamp, and sensor device number. Shelf infrared sensors are deployed at the entrance / exit ports of each storage location, collecting data including, but not limited to, the corresponding storage location code, infrared signal obstruction status, status change timestamp, and sensor device number. The sensor data collection frequency is set by the system according to warehouse management needs, typically 1-10 times per second, used to monitor the physical location changes and status of materials in real time, serving as supplementary verification evidence for material operation logs.

[0079] The anomaly detection module only identifies abnormal operations that may cause conflicts from the operational logic level, such as missed scans and incorrect scans, but it cannot directly confirm the current physical storage status of conflicting materials. In contrast, the storage location verification module can lock the real location of conflicting materials from the physical level through real-time sensing data collected by IoT devices, forming a dual confirmation mechanism of logical analysis and physical verification to ensure the accuracy of subsequent corrective operations.

[0080] Please see Figure 4 As shown, for warehouses equipped with RFID readers or shelf sensors, the system automatically identifies candidate storage locations for conflicting materials in the following manner: For warehouses equipped with RFID readers, the RFID readers scan RFID tags within their coverage area at a preset frequency, typically 1-2 times per minute. Each RFID reader corresponds to a fixed storage area, such as a specific shelf or storage zone. The system queries the historical detection records of the RFID tags attached to the conflicting materials, filters out the detection record with the latest timestamp, and identifies the storage area where the corresponding RFID reader is located as a candidate storage location for the conflicting materials, i.e., the area where the conflicting materials may currently be located. Simultaneously, the system reads the signal strength data in the corresponding detection record. If the signal strength is higher than a preset signal strength threshold, it further confirms that the conflicting materials are within the storage area covered by the RFID reader. The signal strength threshold is typically -60dBm to -40dBm, depending on the warehouse environment.

[0081] For warehouses deploying shelf sensors, each shelf sensor corresponds to a unique storage location, and the shelf sensors have either weight sensing or infrared sensing functions. Weight-sensing shelf sensors will detect the weight data of the corresponding storage location in real time. If the weight data exceeds the preset empty threshold, it is determined that the corresponding storage location contains materials. The empty threshold is set according to the standard weight of conflicting materials. Infrared-sensing shelf sensors will detect whether the infrared signal of the corresponding storage location is blocked in real time. If a continuous blocking state is detected, it is determined that the corresponding storage location contains materials and a candidate storage location is obtained. A continuous blocking state is defined as the blocking time exceeding a preset stability threshold, which is usually 10 seconds, but the specific value is set according to the warehouse environment.

[0082] Query the shelf sensor data corresponding to all storage locations involved in the conflicting materials. If there is only one candidate storage location, and the detection results of the shelf sensors are consistent with the detection results of the corresponding RFID readers, then the corresponding storage location is determined to be the actual storage location of the conflicting materials. If there are multiple candidate storage locations, then select the candidate storage location with the smallest difference between the timestamp of the shelf sensor detection and the time of the conflict alarm, forming a candidate storage location set. If the candidate storage location set contains only one storage location, then directly determine the corresponding storage location as the actual storage location of the conflicting materials. If the candidate storage location set contains multiple storage locations, then use the most recent inbound and shelving operation record in the operation log of the corresponding storage location as the second filtering condition, and select the storage location that meets the second filtering condition from the candidate storage location set to determine the actual storage location of the conflicting materials.

[0083] After confirming the actual storage location of conflicting materials using the above methods, the verified actual location of the materials is used to correct system records. Log analysis in the anomaly detection module can pinpoint the type of abnormal operation, while the actual location verification results can clearly identify the correct storage location that should be retained. Combining these two methods can accurately determine which operation records need to be supplemented or invalidated, avoiding the potential problem of incorrectly classifying operations corresponding to correct storage locations as abnormal if relying solely on log analysis. This ensures that the corrected system records are completely consistent with the physical storage status of the materials.

[0084] The information update module updates the material-location binding table based on the abnormal operation judgment results and the actual storage location of the conflicting materials, resulting in an updated material-location binding table.

[0085] Based on the abnormal operation judgment results and the actual location confirmation results, the system automatically corrects the relevant records in the database. These relevant records specifically refer to the material operation log and the material-location binding table. Correcting these two types of records eliminates "one item, multiple locations" conflicts. Specific methods include:

[0086] In the case of missed scans, when the abnormal operation judgment result is that the old warehouse location was missed in the warehouse location movement operation, the system automatically generates a supplementary old warehouse location outbound and desale operation record and inserts it into the material operation log. The rules for setting the timestamp for supplementing the old warehouse location outbound / removal operation record are as follows: Based on the operation time of the corresponding new warehouse location inbound / removal operation record for conflicting materials, the timestamp is set within a preset reasonable time interval before the operation time of the new warehouse location inbound / removal operation record. This preset reasonable time interval is set according to the standard duration of warehouse location movement operations, typically 1-3 minutes, to ensure that the time logic of the supplemented record conforms to the normal business process. Simultaneously, the operation type of the supplemented old warehouse location outbound / removal operation record is "old warehouse location outbound / removal operation"; the warehouse location is the old warehouse location code; the operation time is the supplemented timestamp; the operator ID matches the operator ID of the corresponding new warehouse location inbound / removal operation record; the operating device ID matches the operating device ID of the corresponding new warehouse location inbound / removal operation record; the operation status is "successful"; the operation remarks are "supplementing the missed old warehouse location outbound / removal operation"; and the document number associated with the operation matches the document number of the corresponding warehouse location movement operation. After the supplementary record is inserted, the system automatically updates the material-location binding table, deletes the records associated with conflicting materials and old location codes in the material-location binding table, and only retains the records associated with conflicting materials and new location codes, ensuring that conflicting materials correspond to only one location in the material-location binding table.

[0087] For incorrect scanning scenarios, when the abnormal operation judgment result is that there is an inbound and put-away operation record with incorrect scanning object identification, the corresponding inbound and put-away operation record is marked as invalid in the material operation log. The invalid status mark must include the invalidation reason and the marking time. The invalidation reason is incorrect scanning object identification, and the invalid status mark is irrevocable to ensure the traceability of the material operation log. Delete the association record between the conflicting material and the corresponding storage location code of the incorrect inbound and put-away operation record in the material-storage location binding table, and retain the association record between the conflicting material and the storage location code corresponding to the actual location confirmation result in the material-storage location binding table. Update the associated storage location of the conflicting material in the material-storage location binding table to the actual storage location.

[0088] After completing the above modifications, re-verify the number of associated storage locations for conflicting materials in the material-storage location binding table to ensure that there is only one valid storage location association record for each conflicting material. The updated material operation log and material-storage location binding table will be synchronously stored in the historical database of the warehouse management system for subsequent business traceability and auditing. The system automatically triggers a status update for the conflict alarm record, changing the status from pending to resolved, and sends a notification to relevant management personnel through the warehouse management system that the conflict has been resolved. The notification includes the serial number of the conflicting material, the storage location code involved in the conflict, the time the conflict was resolved, and the correction result.

[0089] After the above steps are completed, the traditional manual work of checking logs and inventory locations item by item, which used to take several hours, can be automatically completed by the system in minutes, significantly improving the efficiency of location and error correction. With the help of sensors and automation, not only are human error reduced, but production stoppages due to missing parts or order fulfillment delays are also effectively avoided. The application of IoT technologies such as RFID further improves the real-time accuracy and visibility of inventory data, reduces manual scanning operations, and enables real-time inventory tracking. This embodiment optimizes the warehouse error investigation process, enabling autonomous analysis of causes and correction of records the moment a conflict is detected, reducing manual intervention and downtime, and significantly improving warehouse operation efficiency and inventory data reliability.

[0090] Example 2:

[0091] Please see Figure 2 As shown, this embodiment provides a method for dynamic management and control of materials throughout the entire process, including:

[0092] Pre-set the material-warehouse location binding table and equipment and personnel information, and record material operation logs in real time;

[0093] If the number of valid storage location records corresponding to a certain material serial number in the material-storage location binding table exceeds one, the material corresponding to the material serial number will be marked as a conflicting material, and a conflict alarm will be generated.

[0094] Based on conflict alarms and equipment and personnel information, the abnormal operation judgment results are obtained through analysis;

[0095] Verify the actual location of conflict materials to determine their actual storage location.

[0096] Based on the abnormal operation judgment results and the actual storage location of the conflicting materials, the material-storage location binding table is updated to obtain the updated material-storage location binding table.

[0097] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

[0098] In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for dynamic management and control of materials throughout the entire process, characterized in that, include: Pre-set the material-warehouse location binding table and equipment and personnel information, and record material operation logs in real time; If there are more than one valid storage location record corresponding to a material serial number in the material-storage location binding table, the material corresponding to the material serial number will be marked as a conflicting material and a conflict alarm will be generated. Based on conflict alarms and equipment and personnel information, an operation event sequence for conflicting materials is constructed. The operation event sequence for conflicting materials is traversed, and the operation event sequence is compared with the normal business process step by step to identify operation combinations or missing operations that do not match the normal business process. Abnormal operations are located in combination with business rules to obtain the abnormal operation judgment result. Methods for locating abnormal operations by combining business rules include: The operation records that do not conform to any business rule in the operation event sequence are filtered out to form an abnormal operation record candidate set. The correlation between each abnormal operation record in the abnormal operation record candidate set and the storage location code involved in the conflict alarm is calculated. If the storage location code corresponding to the abnormal operation record belongs to the storage location code involved in the conflict alarm, the correlation is counted as 1, otherwise it is counted as 0. The time difference between the operation time corresponding to the abnormal operation record and the time of the conflict alarm discovery is calculated. The abnormal operation record candidate set is prioritized with correlation as the primary weight and time difference as the secondary weight. The candidate record with a correlation of 1 has a higher priority than the candidate record with a correlation of 0. If the correlation is the same, the candidate record with a smaller time difference has a higher priority. The operation corresponding to the abnormal operation record with the highest priority is selected as the abnormal operation. Verify the actual location of conflict materials to determine their actual storage location. Based on the abnormal operation judgment results and the actual storage location of the conflicting materials, the material-storage location binding table is updated to obtain the updated material-storage location binding table.

2. The method for dynamic control of materials throughout the entire process according to claim 1, characterized in that, Methods for obtaining the sequence of operational events for conflict materials include: Filter out all historical operation records of the conflicting materials corresponding to the material serial numbers recorded in the conflict alarm from the material operation log, and sort them in chronological order to form a sequence of operation events for the conflicting materials; The operation event sequence includes the operation type, the storage location corresponding to each operation, the operation time, the operator ID, the operation device ID, the operation status, the operation remarks, and the document number associated with the operation.

3. The method for dynamic control of materials throughout the entire process according to claim 2, characterized in that, Normal business processes include: The inbound and shelving operation for the same material serial number takes precedence over subsequent storage location movement or outbound and shelving operations. The storage location movement operation for the same material serial number includes the old storage location outbound and desold operation and the new storage location inbound and desold operation in sequence, and the time node of the old storage location outbound and desold operation is earlier than the time node of the new storage location inbound and desold operation. Only one valid inbound and shelving operation record is allowed for the same material serial number within a preset time threshold, and the storage location code corresponding to the inbound and shelving operation record is unique; All operation records must first undergo operation status verification before participating in the material-warehouse location association update; In the operation status verification, only operation records with a successful status are considered valid records.

4. The method for dynamic control of materials throughout the entire process according to claim 2, characterized in that, Methods for traversing the operational event sequence of conflicting materials and comparing the operational event sequence with the normal business process step by step to identify operational combinations or missing operations that do not match the normal business process include: If there are storage location movement operations for the same material serial number in the operation event sequence, and the old storage location outbound and desold operation record associated with the storage location movement operation is missing, and the new storage location inbound and desold operation record associated with the storage location movement operation already exists, and the time node corresponding to the new storage location inbound and desold operation record is earlier than the time node of other subsequent operation records of the conflicting material, then the conflicting material is determined to be caused by a missed scan. If there are two inbound and putaway operation records for the same material serial number in the operation event sequence, and the difference in operation time between the two inbound and putaway operation records is less than a preset time threshold, and the storage location codes corresponding to the two inbound and putaway operation records are different, and the operation status of the two inbound and putaway operation records is successful, then the conflicting material is determined to be caused by an incorrect scan.

5. The method for dynamic control of materials throughout the entire process according to claim 2, characterized in that, The business rules include: The storage location movement operation for the same material serial number includes a complete record of the old storage location's outbound and desale operation and the new storage location's inbound and shelving operation, and the time node of the old storage location's outbound and desale operation is earlier than the time node of the new storage location's inbound and shelving operation. Only one valid inbound and shelving operation record is allowed for the same material serial number within the same preset time threshold, and the corresponding storage location code of the inbound and shelving operation record is unique; The outbound and offbound operation record for the same material serial number is later than the most recent inbound and put-away operation record or the new inbound and put-away operation record in the new storage location during the storage location relocation operation. All operation records involved in conflict analysis have a successful operation status, and the document number associated with the operation has a matching valid document information in the business document database; the business document database is a pre-built database in the warehouse management system, used to store document information corresponding to all businesses in the entire warehouse process.

6. The method for dynamic control of materials throughout the entire process according to claim 1, characterized in that, Methods for obtaining the actual storage location of conflict materials include: For warehouses that have deployed RFID readers or shelf sensors, candidate storage locations for conflicting materials are identified in different ways. If there is only one candidate storage location, and the detection results of the shelf sensor are consistent with the detection results of the corresponding RFID reader, then the corresponding storage location is determined to be the actual storage location of the conflicting materials. If there are multiple candidate storage locations, the candidate storage location with the smallest difference between the timestamp of the shelf sensor detection and the time of the conflict alarm is selected to form a candidate storage location set. If the candidate storage location set contains only one storage location, then the corresponding storage location is directly determined to be the actual storage location of the conflicting materials. If the candidate storage location set contains multiple storage locations, then the storage location with the most recent inbound and shelving operation record in the operation log of the corresponding storage location is used as the second screening condition, and the storage location that meets the second screening condition is selected from the candidate storage location set and determined to be the actual storage location of the conflicting materials.

7. The method for dynamic control of materials throughout the entire process according to claim 6, characterized in that, For warehouses that have deployed RFID readers or shelf sensors, methods for identifying candidate storage locations for conflicting materials in different ways include: For warehouses that have deployed RFID readers, query the historical detection records of the RFID tags attached to the conflicting materials, filter out the detection records with the latest timestamps, and the storage area where the corresponding RFID reader is located is the current location area of ​​the conflicting materials; if the signal strength in the corresponding detection record is higher than the preset signal strength threshold, then it is confirmed that the conflicting materials are in the storage area covered by the corresponding RFID reader, and the candidate storage location of the conflicting materials is obtained. For warehouses that deploy shelf sensors, each shelf sensor corresponds to a unique storage location. Weight-sensing shelf sensors will detect the weight data of the corresponding storage location in real time. If the weight data exceeds the preset empty threshold, it is determined that the corresponding storage location contains materials. Infrared-sensing shelf sensors will detect in real time whether the infrared signal of the corresponding storage location is blocked. If a continuous blocking state is detected, it is determined that the corresponding storage location contains materials, and candidate storage locations for conflicting materials are obtained.

8. The method for dynamic control of materials throughout the entire process according to claim 4, characterized in that, Methods to obtain the updated material-location binding table include: For missed scan scenarios, an additional record of the old warehouse location's outbound and destocked operation is automatically generated and inserted into the material operation log; and the association record between conflicting materials and old warehouse location codes in the material-warehouse location binding table is deleted; For incorrect scanning scenarios, mark the corresponding inbound and put-away operation record as invalid in the material operation log; delete the associated record of the conflicting material and the corresponding incorrect inbound and put-away operation record in the material-location binding table, and retain the associated record of the conflicting material and the corresponding location code in the material-location binding table, and update the associated location of the conflicting material in the material-location binding table to the actual location. The updated material-warehouse binding table has been obtained.

9. A dynamic material management and control system for the entire process, used to implement the dynamic material management and control method for the entire process as described in any one of claims 1-8, characterized in that, include: The information collection module is used to pre-set the material-storage location binding table and equipment and personnel information, and to record material operation logs in real time; The conflict alarm module is used to determine whether the number of valid storage location records corresponding to a certain material serial number in the material-storage location binding table exceeds one. If so, the material corresponding to the material serial number is marked as a conflicting material and a conflict alarm is generated. The anomaly detection module analyzes conflict alarms and equipment and personnel information to determine the results of abnormal operations. The storage location verification module is used to verify the actual location of conflicting materials and obtain the actual storage location of the conflicting materials. The information update module updates the material-location binding table based on the abnormal operation judgment results and the actual storage location of the conflicting materials, resulting in an updated material-location binding table.

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