Automatic inventory checking system for finished product warehouse

Abstract

The invention discloses an automatic stocktaking system for a finished product warehouse. The system comprises eight steps of task setting, path planning, stocktaking starting, information acquisition, data processing, data uploading, automatic charging and task feedback. Manual work is replaced by the inventory making robot, and by combining AGV + radar mapping positioning, category acquisition by a code scanner and counting by a point cloud analysis algorithm, errors are reduced, and efficiency is improved. Multi-frequency and multiple stocktaking modes are supported, and different scenes are adapted; path planning and scanning adapt to the warehouse environment, and safety is guaranteed; the data are automatically uploaded to the WMS and can be traced; the system is easy to maintain and expand. Unmanned automatic inventory checking is realized, the effect of reducing people and increasing efficiency is achieved, and a basis is provided for management.

Description

Technical Field

[0001] This invention belongs to the technical field of inventory systems, and particularly relates to an automatic inventory system for finished goods warehouses. Background Technology

[0002] In the daily operation of the finished goods warehouse, manual sorting is required for retailers every day. This process is prone to errors in quantity distribution due to human error, leading to discrepancies between the records and the actual inventory. To solve this problem, a physical inventory reconciliation is required after the end of each workday. The inventory reconciliation covers pallets on the shelves that have not yet been shipped out, as well as loose pallets on the ground that have been partially sorted.

[0003] Currently, inventory checks suffer from problems such as high frequency (including daily, weekly, and monthly checks), time-consuming and error-prone manual operations, and low efficiency.

[0004] At the same time, traditional inventory methods are poorly adaptable to the warehouse environment and it is difficult to flexibly adjust the operation based on physical parameters such as aisle width, the gap between the top of the goods and the shelf beams, and the distance between the top goods and the top surface.

[0005] Furthermore, the lack of standardized mechanical structures and electrical control components makes equipment maintenance and functional expansion difficult, and it also makes it impossible to interact efficiently with a warehouse management system (WMS) through information technology, thus failing to meet the finished goods warehouse's requirements for accurate inventory checks, automation, and intelligence. Summary of the Invention

[0006] The purpose of this invention is to provide an automated inventory system for finished goods warehouses, comprising the following steps:

[0007] S1. Task Setting: Inventory tasks can be set manually or automatically through the inventory system. Inventory time can be set in batches or individually. Inventory tasks cover different frequencies such as daily, weekly, and monthly inventory. The inventory scope includes pallets on the shelves that have not been shipped out and loose pallets on the ground that have been partially sorted. At the same time, the inventory mode can be selected when setting the task, such as full inventory or key inventory. Key inventory can specify a specific area or a specific category of goods.

[0008] S2. Path planning: After receiving the set inventory task, the inventory system automatically plans the inventory path based on information such as the layout of the finished goods warehouse shelves, the location of goods storage and the distribution of aisles. The path planning must take into account the physical parameters of the finished goods warehouse to ensure that the robot can pass normally in the aisles, where the aisle width must be ≥1.5m.

[0009] S3. Start Inventory Check: The scheduling system drives the inventory check robot to move along the planned path. The inventory check robot is equipped with a scanning system and uses AGV + radar mapping to perform real-time positioning and map construction of the internal environment of the finished product warehouse during the movement.

[0010] S4. Information Collection: After the inventory robot arrives at the designated storage location, the scanning system automatically scans and images the goods to obtain basic information such as the category of the goods. At the same time, point cloud scanning technology is used to scan the goods. When scanning, the spatial conditions of the goods must be considered, and there must be no objects within the height of the top surface of the goods to affect the lidar imaging.

[0011] S5. Data Processing: The backend system calls the point cloud parsing algorithm to parse the point cloud data obtained by scanning, and calculates the quantity of goods by combining it with the goods information obtained by scanning. If an anomaly occurs during the data processing, an anomaly handling measure is initiated.

[0012] S6. Data Upload: Upload the calculated goods category and quantity information to the customer's WMS through the information standard interface to complete the update of inventory data;

[0013] S7. Automatic charging: When the inventory robot's battery level is lower than the preset threshold, the scheduling system guides it to the charging station for automatic charging. After charging is completed, it continues to execute the unfinished inventory task.

[0014] S8. Task Feedback: When all inventory tasks are completed or not completed within the set time, the inventory system generates a task report. The report includes the inventory completion status, the comparison results between the inventory data and the WMS data, information on abnormal storage locations, etc., and sends the report to the designated terminal.

[0015] In a further embodiment of the present invention, in S1, when setting inventory times in batches, multiple inventory time points can be automatically generated according to preset periodic rules, such as setting a fixed time for daily inventory, a fixed date for weekly inventory, and a fixed date for monthly inventory, and the upper limit of the duration of each inventory frequency can be set.

[0016] When manually setting inventory check times, operators can input specific dates and times through the inventory check system's interactive interface. The system verifies the validity of the input time. If the input time is before the current time, a prompt message is issued and the user is asked to re-enter the information. At the same time, the interface displays the time schedule of historical inventory check tasks for reference. When selecting key inventory check targets, operators can accurately specify the inventory check targets by inputting information such as the storage location number and cargo code. The system will automatically associate relevant information for that target.

[0017] In a further embodiment of the present invention, in S2, when automatically planning the inventory route, the route with the shortest distance and no obstacles is selected first, while avoiding areas where goods storage and retrieval operations are in progress.

[0018] If new obstacles appear in the finished goods warehouse during the inventory process, the scheduling system will update the path planning in real time and replan a feasible path for the inventory robot.

[0019] After the route planning is completed, the planned route and the estimated time to reach each storage location are displayed on the inventory system interface. It can also display the estimated inventory time for each storage location.

[0020] For storage locations that require priority inventory checks, priority can be set in the path planning so that the robot can reach that storage location first for inventory checks.

[0021] In a further embodiment of the present invention, in S3, when the AGV+radar is building a map, the radar scans the surrounding environment in real time and acquires environmental data, transmits the data to the background for processing, and constructs a three-dimensional map of the finished goods warehouse. The map contains information such as shelf location, warehouse location distribution, and aisle location, and the map is updated regularly to reflect changes in the warehouse environment.

[0022] The inventory robot's movement speed is adjusted according to its current state: 0.3 m / s during scanning and 1-1.5 m / s during idle operation.

[0023] The robot is equipped with a safety sensor. When it detects a person or object within a preset distance in front of it, it will automatically slow down or stop moving and send an abnormal signal to the dispatch system.

[0024] The robot also has a self-diagnostic function, which checks its mechanical structure and electrical control components before starting to ensure reliability.

[0025] In a further embodiment of the present invention, in S4, the scanning system includes a barcode scanner and a point cloud scanner. The barcode scanner is used to scan the barcode or QR code on the goods to obtain the goods category information, and the point cloud scanner is used to perform an all-round scan of the goods to obtain point cloud data.

[0026] If a scan fails on the first attempt, the scanning angle and distance are automatically adjusted for multiple scans. If multiple scans still fail, the location information is recorded and the system continues to scan the next location. At the same time, the failure information is uploaded to the inventory system in real time.

[0027] During point cloud scanning, ensure that the scanning range covers the entire area of ​​the goods to avoid scanning blind spots. If any abnormalities in the placement of the goods are detected during the scanning process, such as excessive tilt angle, the relevant information will be recorded.

[0028] After the scan is completed, the system will perform a preliminary verification of the scanned data to determine whether the data is complete.

[0029] In a further embodiment of the present invention, in S5, the point cloud parsing algorithm preprocesses the acquired point cloud data to remove noise points and redundant data, and then calculates the quantity of goods through point cloud parsing, fitting and other operations.

[0030] Anomaly handling measures include issuing an early warning and marking the storage location when the discrepancy between the parsed goods category or quantity and the information recorded in the WMS exceeds a preset value, while saving the relevant scanning data and parsing results for subsequent verification;

[0031] If the point cloud data is incomplete, the inventory robot will rescan the location. The number of rescans can be preset. If the complete data cannot be obtained after multiple rescans, the location will be marked as a location for manual review.

[0032] Intermediate data logs are generated during data processing to trace each step of the data processing process.

[0033] In a further embodiment of the present invention, in S6, the information standard interface adopts encrypted transmission to ensure the security of data during transmission.

[0034] When uploading data, the integrity of the data is checked. If the check fails, the data is re-uploaded. There is a limit to the number of re-uploads. If the limit is exceeded, the upload will stop and an alarm will be issued.

[0035] After the upload is complete, WMS returns a confirmation message to the inventory system. The inventory system records the data upload time and status, and compares the uploaded data with the data stored locally.

[0036] Successfully uploaded data will be categorized and stored according to time and location for later retrieval.

[0037] In a further embodiment of the present invention, in step S7, the preset threshold can be adjusted according to actual needs, and is preferably set to 20% of the battery power.

[0038] As the inventory robot moves toward the charging station, it follows a planned charging path, maintaining a safe distance from other devices and avoiding busy areas.

[0039] During the charging process, the charging pile monitors the charging current and voltage in real time. If any abnormality occurs, charging will stop immediately and an alarm signal will be issued. At the same time, the abnormality information will be sent to the management personnel terminal.

[0040] Once charging is complete, the charging station will send a charging completion signal to the robot, and the robot will automatically disconnect from the charging station upon receiving the signal.

[0041] In a further embodiment of the present invention, the mechanical structure of the system in S1 to S8 adopts standardized components, and the connection parts of the mechanical structure are equipped with reinforcing devices to improve the stability of the overall structure.

[0042] The electrical control uses standard program blocks, which communicate with each other through standardized interfaces for function expansion and fault diagnosis. The electrical system has overload protection to prevent excessive current.

[0043] Regularly remind mechanical and electrical components to perform maintenance, and generate maintenance plans based on operating time and usage frequency.

[0044] In a further embodiment of the present invention, the system in S1 to S8 has hardware compatibility and can be connected and used with different models of barcode scanners, point cloud scanners and other devices. When connected, data interaction is achieved through a standardized interface protocol.

[0045] The visual guidance system accurately locates the storage location by matching the inventory robot. When the storage location is slightly offset, the visual guidance system adjusts the robot's position and scanning angle. The visual guidance system is calibrated regularly to ensure positioning accuracy.

[0046] The system supports interaction with other management systems within the finished goods warehouse to obtain relevant information such as goods entering and leaving the warehouse, thereby improving the accuracy and comprehensiveness of inventory checks. During the interaction process, it follows the standard interface specifications of information technology to maintain a consistent data format.

[0047] The beneficial effects of this invention are:

[0048] By replacing manual inventory checks with inventory robots, and combining AGVs with radar mapping to achieve autonomous positioning, barcode scanners to obtain cargo category information, and point cloud analysis algorithms to count, the efficiency of inventory checks is greatly improved by reducing human error.

[0049] It supports multiple inventory checks, including daily, weekly, and monthly checks. Inventory check times can be set in batches or manually. Users can also choose between comprehensive or focused inventory check modes to meet the inventory check needs of different scenarios in finished goods warehouses.

[0050] The path planning takes into account physical parameters such as aisle width and the storage space conditions of goods during scanning to ensure that the operation is adapted to the warehouse environment; the robot is equipped with a safety sensing device that automatically slows down or stops when it detects an obstacle to ensure operational safety.

[0051] By connecting with WMS through the information standard interface, data can be automatically uploaded and updated; intermediate logs are generated during the data processing, abnormal storage locations are marked and scan data is saved, which facilitates subsequent traceability and verification.

[0052] The mechanical structure uses standardized components and standard program blocks for electrical control, which facilitates maintenance and expansion; it has hardware compatibility and can be connected to different models of scanning equipment; visual guidance technology assists in precise positioning and adapts to changes in the warehouse environment.

[0053] To automate inventory checks, reduce manual intervention, and achieve the goal of "reducing manpower and increasing efficiency," a report containing inventory status and data comparison results is generated upon completion of the task, providing a basis for management decisions. Attached Figure Description

[0054] Figure 1 This is a flowchart illustrating the system of the present invention. Detailed Implementation

[0055] The technical solutions of the embodiments of this application will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application are within the scope of protection of this application.

[0056] In the description of this application, it should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. For descriptive purposes, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following drawings denote similar items; therefore, once an item is defined in one drawing, it need not be further discussed in subsequent drawings.

[0057] It should be noted that the terms "first," "second," etc., used in the specification and claims of this application are used to distinguish similar objects and not to describe a specific order or sequence. It should be understood that such use of data can be interchanged where appropriate so that embodiments of this application can be implemented in orders other than those illustrated or described herein, and the objects distinguished by "first," "second," etc., are generally of the same class and are not limited in number; for example, a first object can be one or more. Furthermore, in the specification and claims, "and / or" indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0058] It should be noted that in the description of this application, the directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for describing this application and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the scope of protection of this application. The directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0059] It should be noted that, in this application, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element. Furthermore, it should be noted that the scope of the methods and apparatuses in the embodiments of this application is not limited to performing functions in the order shown or discussed, but can also include performing functions substantially simultaneously or in the reverse order, for example, performing the described methods in a different order than described, and adding, omitting, or combining various steps. Additionally, features described with reference to certain examples can be combined in other examples.

[0060] This embodiment provides an automated inventory system for finished goods warehouses, including the following steps:

[0061] S1. Task Setting: Inventory tasks can be set manually or automatically through the inventory system. Inventory time can be set in batches or individually. Inventory tasks cover different frequencies such as daily, weekly, and monthly inventory. The inventory scope includes pallets on the shelves that have not been shipped out and loose pallets on the ground that have been partially sorted. At the same time, the inventory mode can be selected when setting the task, such as full inventory or key inventory. Key inventory can specify a specific area or a specific category of goods.

[0062] Batch settings can generate fixed time points on a daily, weekly, or monthly basis, while manual settings support inputting specific times through an interactive interface and automatically verifying their validity.

[0063] Daily inventory checks can focus on high-frequency inbound and outbound areas of the day, weekly inventory checks cover key product categories across the entire warehouse, and monthly inventory checks enable full inventory verification. Key inventory checks can specify specific inventory targets through methods such as location number, product code, and area division. Specific areas can be divided by aisle or shelf, and specific product categories can be filtered by brand and specification.

[0064] S2. Path planning: After receiving the set inventory task, the inventory system automatically plans the inventory path based on information such as the layout of the finished goods warehouse shelves, the location of goods storage and the distribution of aisles. The path planning must take into account the physical parameters of the finished goods warehouse to ensure that the robot can pass normally in the aisles, where the aisle width must be ≥1.5m.

[0065] The shelving layout includes structural parameters such as the number of shelving layers and columns. The storage location of goods is synchronized with the location occupancy information in the WMS in real time.

[0066] The distribution of lanes includes lane numbers and connectivity. The planning logic prioritizes the "proximity principle" and the "no-turnaround principle" to avoid path intersections and duplication.

[0067] The aisle width requirements are optimized to account for the stacking height of finished product boxes and the size of robots commonly found in finished product warehouses.

[0068] S3. Start Inventory Check: The scheduling system drives the inventory check robot to move along the planned path. The inventory check robot is equipped with a scanning system, and during the movement, it uses AGV + radar mapping to perform real-time positioning and map construction of the internal environment of the finished product warehouse.

[0069] The scanning system includes a barcode scanning module and a point cloud acquisition module. It generates a 3D map with centimeter-level accuracy. During robot movement, the system compares the preset map with the current environment in real time. If changes such as shelf shifts or temporary obstacles are detected, the system automatically marks them and synchronizes them to the scheduling system.

[0070] S4. Information Collection: After the inventory robot arrives at the designated storage location, the scanning system automatically scans and images the goods to obtain basic information such as the category of the goods. At the same time, point cloud scanning technology is used to scan the goods. When scanning, the spatial conditions of the goods must be considered, and there must be no objects within the height of the top surface of the goods to affect the lidar imaging.

[0071] The scanner supports both 1D and 2D barcode recognition, with a recognition distance of 0.5-2m. The clearance between the top of the goods and the shelf beams must be such that scanning is not obstructed by the beams. The distance between the top-level goods and the top surface must ensure sufficient field of view for the scanning lens.

[0072] The scanning angle is automatically adjusted during the scanning process, with a horizontal ±30° and a vertical ±20°, to adapt to finished boxes with different stacking heights.

[0073] S5. Data Processing: The backend system uses a point cloud parsing algorithm to analyze the scanned point cloud data and calculates the quantity of goods by combining it with the goods information obtained from barcode scanning. If an anomaly occurs during data processing, anomaly handling measures are activated. Point cloud parsing first removes environmental noise using a filtering algorithm, and then distinguishes different goods units using a clustering algorithm. Goods information includes single-box specifications. Calculations support counting palletized finished boxes and loose palletized finished boxes. Anomalies include missing point clouds, invalid barcodes, and quantity deviations. The anomaly handling measures employ a tiered response mechanism: minor anomalies are automatically recorded, and serious anomalies trigger real-time alerts.

[0074] S6. Data Upload: The calculated product category and quantity information is uploaded to the customer's WMS via the standard information interface to update the inventory data. The standard information interface supports protocols such as TCP / IP and HTTP. Data is formatted before upload to adapt to the WMS's data field requirements. The upload process employs a breakpoint resume mechanism; if the network is interrupted, the unfinished data will be automatically resumed after the connection is restored.

[0075] S7. Automatic Charging: When the inventory robot's battery level falls below a preset threshold, the scheduling system guides it to a charging station for automatic charging. After charging is complete, it resumes executing any unfinished inventory tasks. The preset threshold is 20% by default and can be manually adjusted. The charging interface features a foolproof design. Charging completion is achieved when the battery level is ≥90%. The robot automatically returns to the interruption point after charging is complete. Battery temperature is monitored in real-time during charging; the normal range is 0-45℃, and automatic power-off protection occurs if the temperature exceeds the limit.

[0076] S8. Task Feedback: When all inventory tasks are completed or not completed within the set time, the inventory system generates a task report. The report includes the inventory completion status, the comparison results between the inventory data and WMS data, and information on abnormal storage locations, and sends the report to the designated terminal. The task report is available in both PDF and electronic formats. The inventory completion status includes completion rate and time taken. The comparison results between the inventory data and WMS data include a list of discrepancies in storage locations and the quantities of discrepancies. The information on abnormal storage locations includes the type of abnormality and its processing status. The designated terminals include management personnel's computers and mobile apps. The system automatically archives the report for at least one year and supports retrieval by date and task number.

[0077] In this embodiment, during S1, when setting inventory times in batches, multiple inventory time points can be automatically generated according to preset periodic rules. For example, daily inventory can be performed at a fixed time each day, weekly inventory can be performed on a fixed date each week, and monthly inventory can be performed on a fixed date each month. The upper limit of the duration of each inventory frequency can also be set. When manually setting inventory times, operators can input specific dates and times through the interactive interface of the inventory system. The system verifies the validity of the input time. If the input time is before the current time, a prompt message is issued and the user is required to re-enter the information. At the same time, the interface will display the time schedule of historical inventory tasks for reference. When selecting key inventory items, the system can accurately specify the inventory items by inputting information such as the storage location number and cargo code. The system will automatically associate the relevant information of the item.

[0078] Preset periodic rules include daily inventory checks at 22:00, Fridays at 18:00, and the last day of each month at 20:00. Daily inventory checks are adapted for reconciliation scenarios after the finished goods warehouse closes for the day. The duration of each inventory check is capped, for example, no more than 3 hours for daily checks, to avoid impacting the next day's picking. The inventory system's interface supports touch and mouse operation. The system validates the input time, ensuring it is not earlier than the current time and does not conflict with other task times. It issues prompts including pop-ups and audible alarms. Historical inventory tasks are scheduled as a list of tasks from the past 30 days. Location numbers support fuzzy search. Goods codes are associated with finished goods warehouse coding rules. Relevant information for this object includes historical inventory discrepancies and recent inbound / outbound frequencies.

[0079] In this embodiment, during S2, when automatically planning the inventory route, the system prioritizes routes with short distances and no obstacles, while avoiding areas where goods storage and retrieval operations are currently underway. If new obstacles appear in the finished goods warehouse during the inventory process, the scheduling system updates the route planning in real time and replans a feasible route for the inventory robot. After the route planning is completed, the planned route and the estimated arrival time at each storage location are displayed on the inventory system interface, along with the estimated inventory duration for each storage location. For storage locations requiring priority inventory checks, priority can be set in the route planning, allowing the robot to reach that location first for inventory checks. Areas where goods storage and retrieval operations are currently underway are avoided by obtaining real-time operation information through integration with the warehouse management system. New obstacles include temporarily stacked finished goods boxes and personnel operations. The scheduling system updates the route planning within 10 seconds. The replanned feasible route deviates from the original route by no more than 5 meters. The planned route is displayed on the inventory system interface using color-coded markings. The estimated arrival time at each storage location is accurate to the minute. The estimated inventory duration for each storage location is estimated based on historical data. Storage locations requiring priority inventory checks include, for example, finished goods boxes that have just been received.

[0080] In this embodiment, during S3, when the AGV+radar is mapping, the radar scans the surrounding environment in real time and acquires environmental data. This data is then transmitted to the backend for processing, constructing a 3D map of the finished goods warehouse. The map includes information such as shelf locations, warehouse location distribution, and aisle locations, and is updated periodically to reflect changes in the warehouse environment. The inventory robot's movement speed is adjusted according to its current state: 0.3 m / s during scanning and 1-1.5 m / s during idle operation. The robot is equipped with a safety sensor; when it detects a person or object within a preset distance, it automatically slows down or stops moving and sends an abnormal signal to the scheduling system. The robot also has a self-diagnostic function, checking its mechanical structure and electrical control components before startup to ensure reliability. The radar scanning angle is 360°, with a detection distance of 0.1-10 m. Warehouse location distribution includes warehouse location number markings. The map is updated automatically once per hour or immediately upon triggering an "environmental change" signal. The scanning speed ensures clear scanning. The idle speed improves movement efficiency. The safety sensor uses both infrared and ultrasonic detection. The preset distance ahead can be set from 0.5 to 2 meters. Automatic deceleration reduces speed to 0.1 m / s. Abnormal signals include position coordinates. The mechanical structure includes drive wheels and a scanning bracket. The electrical control system includes a motor and sensors. If a fault is detected, such as wheel jamming or sensor malfunction, an alarm will be issued immediately and a fault code will be displayed.

[0081] In this embodiment, in step S4, the scanning system includes a barcode scanner and a point cloud scanner. The barcode scanner is used to scan barcodes or QR codes on goods to obtain goods category information. The point cloud scanner is used to perform omnidirectional scanning of goods to obtain point cloud data. If a barcode scan fails on the first attempt, the scanning angle and distance are automatically adjusted for multiple scans. If multiple scans still fail, the location information is recorded and the system continues scanning the next location. Simultaneously, the failure information is uploaded to the inventory system in real time. During point cloud scanning, the system ensures that the scanning range covers the entire area of ​​the goods to avoid blind spots. If any abnormal placement of goods is detected during the scanning process, such as excessive tilt angle, relevant information is recorded. After scanning, the system performs a preliminary verification of the scanned data to determine its completeness. The barcode scanner supports both red light and laser scanning. Goods category information includes the brand, production date, and batch number of the finished product. The point cloud scanner uses line laser scanning, with a horizontal scanning range of 0-180° and a vertical scanning range of -30° to 90°. Location information includes the location number and timestamp. Failure information is uploaded to the inventory system in real time and displayed on the monitoring interface. The entire area of ​​the goods, including corners and stacking gaps, is examined. Any abnormalities in the goods' placement, such as a tilt angle greater than 15° or protruding finished boxes, are noted. Relevant information includes images and coordinates of the anomalies. Preliminary verification of the scanned data is conducted to check its completeness and clarity.

[0082] In this embodiment, in step S5, the point cloud parsing algorithm preprocesses the acquired point cloud data to remove noise points and redundant data, and then calculates the quantity of goods through point cloud parsing, fitting, and other operations. Anomaly handling measures include issuing a warning and marking the storage location when the parsed goods category or quantity deviates from the information recorded in the WMS by more than a preset value, while simultaneously saving relevant scan data and parsing results for subsequent verification. If the point cloud data is incomplete, the inventory robot is driven to rescan the storage location; the number of rescans can be preset. If multiple rescans still fail to obtain complete data, the storage location is marked as a manually verified location. Intermediate data logs are generated during data processing to trace each step of the data processing. Point cloud data preprocessing removes noise points using Gaussian filtering and simplifies redundant data using voxel filtering. Fitting is based on a standard size model of finished product boxes. Goods category deviation directly triggers a warning. The warning information is an audible and visual alarm plus a system pop-up. The storage location is marked in red on the map. Relevant scan data includes the original point cloud and scanned images. The parsing results include the calculation process log. The default number of rescans is 2, adjustable from 1 to 5. Manual verification of the storage locations generates a paper inventory list. Intermediate data logs include processing time and parameters for each step.

[0083] In this embodiment, in step S6, the information standard interface uses encrypted transmission to ensure data security during transmission. When uploading data, integrity is verified. If verification fails, the data is re-uploaded, with a maximum number of re-uploads. Exceeding this limit stops the upload and triggers an alarm. After uploading, the WMS returns confirmation information to the inventory system, which records the data upload time and status, and compares the uploaded data with locally stored data. Successfully uploaded data is categorized and stored according to time and location for later retrieval. Encrypted transmission uses the AES-256 encryption algorithm. Integrity verification uses MD5 checksum comparison. Data is re-uploaded 3 times by default. The maximum number of re-uploads is 5. An alarm flashes on the monitoring interface. Confirmation information includes reception time and data volume. Data upload status includes success / failure. The comparison between uploaded data and locally stored data is at the field level. Successfully uploaded data is categorized and stored by time (accurate to the minute) and sorted by location (aisle-shelf-layer number). Subsequent queries support searching and exporting by conditions such as date, location, and category.

[0084] In this embodiment, in step S7, the preset threshold can be adjusted according to actual needs, preferably set to 20% of the battery level. During the process of the inventory robot moving to the charging station, it moves along the planned charging path, maintaining a safe distance from other devices, and the charging path avoids busy areas. During charging, the charging station monitors the charging current and voltage in real time. If an abnormality occurs, charging immediately stops and an alarm signal is issued, while the abnormality information is sent to the management terminal. After charging is complete, the charging station sends a charging completion signal to the robot, which automatically leaves the charging station upon receiving the signal. The preset threshold can be adjusted from 10% to 30%. A setting of 20% of the battery level is preferred to balance battery life and charging efficiency. The charging path avoids work areas and high-traffic areas, such as sorting lanes. Abnormalities include overcurrent and overvoltage. The alarm signal is a buzzer and flashing indicator light. Abnormal information is sent to the management terminal via SMS and APP push notification. The charging completion signal is sent when the battery level is ≥90%. The robot automatically leaves the charging station by resetting its robotic arm.

[0085] In this embodiment, the mechanical structure of the system in S1 to S8 adopts standardized components, and the connection parts of the mechanical structure are equipped with reinforcing devices to improve the overall stability of the structure. The electrical control adopts standard program blocks, and the program blocks communicate with each other through standardized interfaces for function expansion and fault diagnosis. The electrical system has overload protection to prevent excessive current. Regular maintenance reminders are given for the mechanical and electrical parts, and maintenance plans are generated based on running time and usage frequency. Standardized components include modular scanning brackets and universal drive wheels. Reinforcing devices include high-strength bolts and reinforcing plates. The overall structural stability is suitable for continuous operation for 8 hours a day. The standard program blocks are modularly programmed and support function reuse. Standardized interfaces include OPC UA. Function expansion includes adding scanning modes. Fault diagnosis is performed to locate problems through program block logs. Overload protection is provided by air switches and software current limiting. Regular maintenance reminders are given every 500 hours for the mechanical parts and every 1000 hours for the electrical parts. The maintenance plan includes maintenance items, cycles, and operation guidelines.

[0086] In this embodiment, the system in S1 to S8 has hardware compatibility, enabling it to connect and be used with different models of barcode scanners, point cloud scanners, and other devices. Data interaction is achieved through standardized interface protocols during connection. Visual guidance is used to precisely locate the inventory robot. When a slight shift occurs in the inventory location, the visual guidance system adjusts the robot's position and scanning angle. The visual guidance system is periodically calibrated to ensure positioning accuracy. The system supports interaction with other management systems within the finished goods warehouse to obtain information such as goods entering and leaving the warehouse, improving the accuracy and comprehensiveness of inventory checks. During interaction, it adheres to information standard interface specifications, maintaining a consistent data format. Different models of devices connect via universal USB and Ethernet interfaces. Standardized interface protocols include TCP / IP. Visual guidance utilizes an industrial camera + AI recognition system, which is automatically calibrated once a week. Other management systems include a sorting management system and an inbound / outbound system. Information such as goods entering and leaving the warehouse includes details of outbound finished goods boxes and inbound acceptance records for the current day. Information standard interface specifications, such as using JSON data format, are existing and will not be elaborated upon in this embodiment.

[0087] The system's inventory checks cover daily, weekly, and monthly frequencies, matching the daily inventory reconciliation and periodic full-scale verification needs of the finished goods warehouse. The inventory scope includes pallets on shelves that haven't been shipped and loose pallets sorted on the ground, comprehensively covering the various forms of goods within the finished goods warehouse and preventing omissions. A full inventory check of 3000 locations can be completed in approximately 2-3 hours, significantly reducing time compared to manual inventory checks and meeting the daily rapid inventory reconciliation needs of the finished goods warehouse. By using barcode scanners to obtain product category information and combining it with point cloud analysis algorithms to calculate product quantities, the system reduces errors from manual counting. Anomaly handling measures provide timely warnings for discrepancies and retain relevant data for verification, helping to ensure consistency between records and actual inventory and resolving discrepancies caused by quantity errors during manual sorting. From task setting and path planning to scanning and data uploading, all processes are completed automatically by the system, reducing human intervention and achieving the goal of reducing manpower and increasing efficiency, meeting the requirements for improving the automation level of the finished goods warehouse through automation. The path planning system incorporates physical parameters such as aisle width ≥1.5m and considers spatial conditions including a gap >150mm between the top of the goods and the shelf beams, and a distance >500mm between the top-level goods and the top surface. This allows for stable operation in the specific environment of the finished goods warehouse. The mechanical structure utilizes standardized components and reinforcement devices, and the electrical control uses standard program blocks. The robot possesses self-diagnostic capabilities, adapting to the demands of long-term inventory operations in the finished goods warehouse and minimizing the impact of equipment malfunctions. Through a standard information interface with the WMS, automatic data upload and updates are achieved, and encrypted transmission and verification mechanisms ensure data security and integrity, improving the management efficiency of finished goods warehouse inventory data.

[0088] The embodiments of this application have been described above with reference to the accompanying drawings. Unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other. This application is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of this application without departing from the spirit and scope of the claims, and all of these forms are within the protection scope of this application.

Claims

1. An automated inventory management system for finished goods warehouses, characterized in that, Includes the following steps: S1. Task Setting: Inventory tasks can be set manually or automatically through the inventory system. Inventory time can be set in batches or individually. Inventory tasks cover different frequencies such as daily, weekly, and monthly inventory. The inventory scope includes pallets on the shelves that have not been shipped out and loose pallets on the ground that have been partially sorted. At the same time, the inventory mode can be selected when setting the task, such as full inventory or key inventory. Key inventory can specify a specific area or a specific category of goods. S2. Path planning: After receiving the set inventory task, the inventory system automatically plans the inventory path based on information such as the layout of the finished goods warehouse shelves, the location of goods storage and the distribution of aisles. The path planning must take into account the physical parameters of the finished goods warehouse to ensure that the robot can pass normally in the aisles, where the aisle width must be ≥1.5m. S3. Start Inventory Check: The scheduling system drives the inventory check robot to move along the planned path. The inventory check robot is equipped with a scanning system and uses AGV + radar mapping to perform real-time positioning and map construction of the internal environment of the finished product warehouse during the movement. S4. Information Collection: After the inventory robot arrives at the designated storage location, the scanning system automatically scans and images the goods to obtain basic information such as the category of the goods. At the same time, point cloud scanning technology is used to scan the goods. When scanning, the spatial conditions of the goods must be considered, and there must be no objects within the height of the top surface of the goods to affect the lidar imaging. S5. Data Processing: The backend system calls the point cloud parsing algorithm to parse the point cloud data obtained by scanning, and calculates the quantity of goods by combining it with the goods information obtained by scanning. If an anomaly occurs during the data processing, an anomaly handling measure is initiated. S6. Data Upload: Upload the calculated goods category and quantity information to the customer's WMS through the information standard interface to complete the update of inventory data; S7. Automatic charging: When the inventory robot's battery level is lower than the preset threshold, the scheduling system guides it to the charging station for automatic charging. After charging is completed, it continues to execute the unfinished inventory task. S8. Task Feedback: When all inventory tasks are completed or not completed within the set time, the inventory system generates a task report. The report includes the inventory completion status, the comparison results between the inventory data and the WMS data, information on abnormal storage locations, etc., and sends the report to the designated terminal.

2. The finished goods warehouse automatic inventory system according to claim 1, characterized in that, In S1, when setting inventory times in batches, multiple inventory time points can be automatically generated according to preset periodic rules. For example, daily inventory can be performed at a fixed time every day, weekly inventory can be performed on a fixed date every week, and monthly inventory can be performed on a fixed date every month. The maximum duration of each inventory frequency can also be set. When manually setting inventory check times, operators can input specific dates and times through the inventory check system's interactive interface. The system verifies the validity of the input time. If the input time is before the current time, a prompt message is issued and the user is asked to re-enter the information. At the same time, the interface displays the time schedule of historical inventory check tasks for reference. When selecting key inventory check targets, operators can accurately specify the inventory check targets by inputting information such as the storage location number and cargo code. The system will automatically associate relevant information for that target.

3. The finished goods warehouse automatic inventory system according to claim 1, characterized in that, In S2, when automatically planning inventory routes, the shortest and unobstructed routes are prioritized, while avoiding areas where goods storage and retrieval operations are in progress. If new obstacles appear in the finished goods warehouse during the inventory process, the scheduling system will update the path planning in real time and replan a feasible path for the inventory robot. After the route planning is completed, the planned route and the estimated time to reach each storage location are displayed on the inventory system interface. It can also display the estimated inventory time for each storage location. For storage locations that require priority inventory checks, priority can be set in the path planning so that the robot can reach that storage location first for inventory checks.

4. The finished goods warehouse automatic inventory system according to claim 1, characterized in that, In S3, when AGV+radar is building a map, the radar scans the surrounding environment in real time and acquires environmental data. The data is then transmitted to the backend for processing to build a 3D map of the finished goods warehouse. The map includes information such as shelf locations, warehouse location distribution, and aisle locations. The map is also updated regularly to reflect changes in the warehouse environment. The inventory robot's movement speed is adjusted according to its current state: 0.3 m / s during scanning and 1-1.5 m / s during idle operation. The robot is equipped with a safety sensor. When it detects a person or object within a preset distance in front of it, it will automatically slow down or stop moving and send an abnormal signal to the dispatch system. The robot also has a self-diagnostic function, which checks its mechanical structure and electrical control components before starting to ensure reliability.

5. The finished goods warehouse automatic inventory system according to claim 1, characterized in that, In S4, the scanning system includes a barcode scanner and a point cloud scanner. The barcode scanner is used to scan the barcode or QR code on the goods to obtain the goods category information, and the point cloud scanner is used to scan the goods from all directions to obtain point cloud data. If a scan fails on the first attempt, the scanning angle and distance are automatically adjusted for multiple scans. If multiple scans still fail, the location information is recorded and the system continues to scan the next location. At the same time, the failure information is uploaded to the inventory system in real time. During point cloud scanning, ensure that the scanning range covers the entire area of ​​the goods to avoid scanning blind spots. If any abnormalities in the placement of the goods are detected during the scanning process, such as excessive tilt angle, the relevant information will be recorded. After the scan is completed, the system will perform a preliminary verification of the scanned data to determine whether the data is complete.

6. The finished goods warehouse automatic inventory system according to claim 1, characterized in that, In S5, the point cloud parsing algorithm preprocesses the acquired point cloud data to remove noise points and redundant data, and then calculates the quantity of goods through point cloud parsing, fitting and other operations. Anomaly handling measures include issuing an early warning and marking the storage location when the discrepancy between the parsed goods category or quantity and the information recorded in the WMS exceeds a preset value, while saving the relevant scanning data and parsing results for subsequent verification; If the point cloud data is incomplete, the inventory robot will rescan the location. The number of rescans can be preset. If the complete data cannot be obtained after multiple rescans, the location will be marked as a location for manual review. Intermediate data logs are generated during data processing to trace each step of the data processing process.

7. The finished goods warehouse automatic inventory system according to claim 1, characterized in that, In S6, the information standard interface uses encrypted transmission to ensure data security during transmission. When uploading data, the integrity of the data is checked. If the check fails, the data is re-uploaded. There is a limit to the number of re-uploads. If the limit is exceeded, the upload will stop and an alarm will be issued. After the upload is complete, WMS returns a confirmation message to the inventory system. The inventory system records the data upload time and status, and compares the uploaded data with the data stored locally. Successfully uploaded data will be categorized and stored according to time and location for later retrieval.

8. The finished goods warehouse automatic inventory system according to claim 1, characterized in that, In S7, the preset threshold can be adjusted according to actual needs, and is preferably set to 20% of the battery level; As the inventory robot moves toward the charging station, it follows a planned charging path, maintaining a safe distance from other devices and avoiding busy areas. During the charging process, the charging pile monitors the charging current and voltage in real time. If any abnormality occurs, charging will stop immediately and an alarm signal will be issued. At the same time, the abnormality information will be sent to the management personnel terminal. Once charging is complete, the charging station will send a charging completion signal to the robot, and the robot will automatically disconnect from the charging station upon receiving the signal.

9. The finished goods warehouse automatic inventory system according to claim 1, characterized in that, The mechanical structure of the system from S1 to S8 uses standardized components, and the connection parts of the mechanical structure are equipped with reinforcing devices to improve the overall stability of the structure. The electrical control uses standard program blocks, which communicate with each other through standardized interfaces for function expansion and fault diagnosis. The electrical system has overload protection to prevent excessive current. Regularly remind mechanical and electrical components to perform maintenance, and generate maintenance plans based on operating time and usage frequency.

10. The finished goods warehouse automatic inventory system according to claim 1, characterized in that, The S1 to S8 systems are hardware compatible and can be connected to different models of barcode scanners, dot cloud scanners and other devices. Data interaction is achieved through standardized interface protocols during connection. The visual guidance system accurately locates the storage location by matching the inventory robot. When the storage location is slightly offset, the visual guidance system adjusts the robot's position and scanning angle. The visual guidance system is calibrated regularly to ensure positioning accuracy. The system supports interaction with other management systems within the finished goods warehouse to obtain relevant information such as goods entering and leaving the warehouse, thereby improving the accuracy and comprehensiveness of inventory checks. During the interaction process, it follows the standard interface specifications of information technology to maintain a consistent data format.

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