AGV-based SPS box supply automatic circulation docking system and method

Abstract

The invention belongs to the technical field of logistics automation and production line supply, and particularly relates to an SPS box supply automatic circulation docking system and method based on an AGV. The automatic circulation docking system comprises at least one AGV trolley, a plurality of material stations and a control module. A goods shelf is arranged on the AGV; the material stations comprise a full box supply station, a full box carrying-out station, an empty box recycle station and an empty box carrying-out station; each material station is provided with a line side component shed, a detection module and an in-place module, and a mechanical locking mechanism is arranged at the butt joint position of the line side component shed and the AGV; the control module is used for receiving the state signals sent by the detection module and the in-place module, sending a moving instruction to the AGV trolley and sending a lifting or descending instruction to the line side component shed. According to the invention, manual dependence and labor intensity can be reduced, supply stability is improved, potential safety hazards are eliminated, and docking efficiency and precision are improved.

Description

Technical Field

[0001] This invention belongs to the field of logistics automation and production line supply technology, and particularly relates to an automatic transfer and docking system and method for SPS box supply based on AGV. Background Technology

[0002] The mechanism and system based on Automated Guided Vehicles (AGVs) realize the automatic flow and docking of SPS (Set Parts Supply) boxes. It is suitable for industries such as automobile manufacturing and electronic assembly that have high requirements for the cycle time of component supply and need to achieve lean production. It can replace traditional manual traction operations and improve the automation level and safety of SPS box supply.

[0003] In the current SPS box supply operation on the production line, the transfer of parts is generally completed by manually pulling the racks. This method has the following significant problems:

[0004] 1. High labor intensity: Workers need to participate in the entire process of rack traction, line side handling and other operations. Long-term repetitive labor can easily lead to fatigue and affect work efficiency.

[0005] 2. Poor supply stability: The pace of manual transfer is greatly affected by the condition of the personnel (such as fatigue or distraction), which can easily lead to shortages of parts, disrupt the rhythm of the production line, and increase the risk of production stoppage.

[0006] 3. Significant safety hazards: During the manual pulling of the racks, frequent movement between the production line and the material preparation area is required, inevitably creating a "human-vehicle cross-operation" scenario, which can easily lead to safety accidents such as collisions.

[0007] 4. Low docking accuracy: Manual operation makes it difficult to ensure accurate docking between the racks and the component sheds on the line, which may increase the time spent on loading and unloading components and further reduce supply efficiency.

[0008] To address the aforementioned issues, there is an urgent need for a technical solution that enables the automated transfer and docking of SPS boxes, thereby reducing reliance on manual labor, improving supply stability and security, and meeting the lean production requirements of modern production lines. Summary of the Invention

[0009] The purpose of this invention is to provide an automated transfer and docking method and system for SPS box supply based on AGV. By cooperating with the AGV trolley and the component shed on the line, the traditional manual traction method is replaced, realizing the full automation of the SPS box from material preparation, supply to empty return. This solves the problems of high labor intensity, unstable supply and safety hazards of cross-operation between people and vehicles.

[0010] The technical solution adopted by the present invention to solve this problem is as follows:

[0011] An AGV-based automated transfer and docking system for SPS container supply includes:

[0012] At least one AGV cart equipped with a shelf;

[0013] Multiple material stations, including a full-box supply station, a full-box removal station, an empty-box recycling station, and an empty-box removal station; each of the material stations is equipped with a line-side component shed, a detection module for detecting the status of boxes in the line-side component shed, and a positioning module for detecting the docking status of the AGV trolley; a mechanical locking mechanism is provided at the docking position between the line-side component shed and the AGV trolley.

[0014] The control module is used to receive status signals sent by the detection module and the positioning module of each material station, and to send movement instructions to the AGV and lifting or lowering instructions to the line-side component shed.

[0015] The AGVs connect to the line-side component sheds at the full container supply station, full container removal station, empty container recycling station, and empty container removal station respectively, completing the circulation operation between full container supply, loading and unloading, empty container recycling and return, and shelf reset.

[0016] In the above technical solution, the line-side component sheds in the full-box supply station, full-box removal station, and empty-box recycling station are equipped with inclined fixed trays and inclined lifting trays. The line-side component sheds in the empty-box removal station are equipped with inclined fixed trays. The inclined lifting trays are lifted or lowered by a lifting mechanism. Bearing rails are laid on both the inclined fixed trays and the inclined lifting trays. The higher side of the inclined fixed trays and the inclined lifting trays is the input end, and the lower side is the output end.

[0017] In the above technical solution, the shelf is a square aluminum profile frame with a cross-shaped base. The upper part of the shelf is a sloping shelf pallet with a lower front and higher back. Bearing rails are laid on the shelf pallet. The rear side of the shelf is the input end and the front side is the output end. The rear side of the shelf is equipped with an anti-tilt protection mechanism and a backflow baffle mechanism.

[0018] In the above technical solution, when the lifting mechanism drives the inclined lifting pallet to be lifted or lowered to form the same continuous slope as the inclined fixed pallet, the full or empty box can be transferred freely between the inclined fixed pallet and the inclined lifting pallet by a non-powered method; when the lifting mechanism drives the inclined lifting pallet to be lifted or lowered to form the same continuous slope as the shelf pallet, the full or empty box can be transferred freely between the online side component shelf and the shelf by a non-powered method.

[0019] In the above technical solution, when the line-side component shed docks with the AGV trolley, the mechanical locking mechanism automatically opens or locks to fix or release the connection between the line-side component shed and the AGV trolley, and the line-side component shed and the rack cooperate to complete the empty-full exchange.

[0020] In the above technical solution, a material preparation station is set up before the full container removal station. The material preparation station is equipped with a trolley detection module. The control module is configured to determine whether there is an AGV trolley at the material preparation station. If there is no AGV at the material preparation station, a trolley call command is sent repeatedly at predetermined intervals. If there is a AGV at the material preparation station, a trolley call command is sent to move the AGV trolley to the full container removal station.

[0021] In the above technical solution, the control module is configured as follows:

[0022] Upon receiving a full-box status signal from the detection module of the full-box supply station, the control module sends a first call command to the AGV, causing the AGV to move to the full-box supply station; upon receiving an arrival signal from the arrival module of the full-box supply station, the control module controls the line-side component rack of the full-box supply station to dock with the shelf of the AGV, and sends a lifting command to the line-side component rack to transfer the full box from the line-side component rack to the AGV, thus completing the full-box supply operation;

[0023] Upon receiving the empty box status signal sent by the detection module of the full box supply station, the control module sends a descent command to the part rack on the line side and simultaneously sends a second call command to the AGV, causing the AGV to move to the material preparation station to wait.

[0024] Upon receiving an empty box status signal from the detection module of the full-box removal station, the control module sends a descent command to the line-side component shed; upon receiving a no-vehicle signal from the trolley detection module of the material preparation station, the control module sends a third trolley call command every 5 seconds; upon receiving a vehicle-available signal from the trolley detection module of the material preparation station, the control module sends a fourth trolley call command, and the AGV moves to the full-box removal station; upon receiving an arrival signal from the arrival module of the full-box removal station, the control module controls the line-side component shed of the full-box removal station to dock with the AGV's shelf, so as to transfer the full box from the AGV to the line-side component shed, completing the full-box removal operation;

[0025] Upon receiving the full container status signal from the detection module at the full container removal station, the control module sends a lifting command to the component shed on the line side and simultaneously sends a fifth release command to the AGV trolley. The AGV trolley then carries the empty shelf away from the full container removal station and heads to the empty container recycling station to recycle the empty containers.

[0026] The system receives the arrival signal sent by the arrival module of the empty container recycling station, controls the line-side component shed of the empty container recycling station to dock with the AGV trolley, and sends a lifting command to the empty container recycling station to transfer the empty container from the line-side component shed to the AGV trolley, thus completing the empty container recycling operation.

[0027] Upon receiving the empty box signal sent by the detection module of the empty box recycling station, the control module sends a sixth release command to the AGV trolley, and the AGV trolley carries the empty box away from the empty box recycling station to the empty box removal station to remove the empty box.

[0028] The system receives the arrival signal sent by the arrival module of the empty container removal station, controls the line-side component shed of the empty container removal station to dock with the AGV trolley, so as to transfer the empty container from the AGV trolley to the line-side component shed and complete the empty container removal operation.

[0029] The system receives an empty box signal from the detection module at the empty box removal station, sends a reset command to the AGV, and moves the AGV to the charging area, where it enters standby mode.

[0030] The second objective of this invention is to provide an automated transfer and docking method for SPS box supply based on AGV, comprising the following steps:

[0031] S1, Point A full container supply operation

[0032] The detection module monitors the status of boxes in the component shed on the line side of the full box supply station in real time. If the box is determined to be empty, a waiting operation signal is sent to the control module. If the box is determined to be full, a full box status signal is sent to the control module. After receiving the full box status signal, the control module sends the first call command to the AGV. The AGV starts from the standby state, travels along the set route to the full box supply station, and waits to dock with the component shed on the line side.

[0033] S2, Point A Full Container Loading Operation

[0034] After the AGV arrives at the full-box supply station, it triggers the positioning module, which sends a positioning signal to the control module. The control module then sends a lifting command to the line-side component shed at the full-box supply station. The line-side component shed at the full-box supply station is lifted, and the shelf carried by the AGV precisely aligns with the line-side component shed. The mechanical locking mechanism automatically opens, and the full-box components are moved in. The full-box components in the line-side component shed slide freely into and are transferred to the AGV's shelf without power. After the full-box is moved in, the detection module at the full-box supply station detects that the line-side component shed is empty and sends an empty-box signal to the control module. The control module sends a lowering command to the line-side component shed and simultaneously sends the first release command to the AGV. The mechanical locking mechanism locks, and the AGV carries the full-box components away from the full-box supply station to the preparation station to wait.

[0035] S3, Material preparation station loading and full box unloading operation at point B.

[0036] The AGV (Automated Guided Vehicle) carries a full box of parts along a pre-set route to the material preparation station to wait for loading. When the detection module at the full box removal station detects that the part rack on the line side is empty, the control module sends a command to lower the part rack. At the same time, the control module determines whether there is a vehicle at the material preparation station: if the material preparation station is empty, it sends a second call command every 5 seconds; if there is a vehicle at the material preparation station, the control module sends a third call command. The AGV then moves to the full box removal station and docks with its part rack on the line side. The mechanical locking mechanism at the front of the AGV unlocks, completing the removal of the full box of parts. The staff at the full box removal station then remove the full box of parts from the part rack on the line side for use on the production line. When the detection module at the full box removal station checks that the part rack on the line side is full, it sends a command to lift the part rack on the line side and simultaneously sends a second release command to the AGV. The AGV then carries the empty rack away from the full box removal station to the empty box recycling station.

[0037] S4, C, and D points return and reset operation

[0038] After the AGV arrives at the empty container recycling station, it triggers the positioning module, which sends a positioning signal to the control module. The control module then sends a lifting command to the line-side component shed of the empty container recycling station. The line-side component shed of the empty container recycling station is lifted, and the AGV docks with the line-side component shed of the empty container recycling station to collect the used empty container components. The detection module on the line-side component shed of the empty container recycling station detects that the container is empty and sends an empty container signal. The control module then sends a third release command, and the AGV carries the empty container components away from the empty container recycling station to the empty container removal station.

[0039] The AGV (Automated Guided Vehicle) carries empty boxes to the empty box removal station and docks with the side-line component shed. The empty boxes are removed without power, and the empty boxes on the AGV shelf are transferred to the side-line component shed of the empty box removal station. The staff at the empty box removal station will pick up the empty boxes and perform the order fulfillment operation. The fulfilled full boxes will then be placed into the side-line component shed of the full box supply station. When the detection module of the side-line component shed of the empty box removal station detects an empty box, it sends a reset and charging command to the AGV.

[0040] S5, AGV reset and battery swapping operation

[0041] After the AGV completes the docking at the empty container removal station, it returns to the charging area according to the set route. If the power is insufficient, it will automatically perform a battery swap. After the battery swap is completed, the AGV enters standby mode, waiting for the next call instruction from the full container supply station, thus completing a complete circulation cycle.

[0042] The third objective of this invention is to provide an AGV-based automatic transfer and docking mechanism for SPS box supply, comprising a mechanical locking mechanism in the AGV-based automatic transfer and docking system for SPS box supply. The mechanical locking mechanism is positioned at the docking position between the online side component rack and the AGV trolley. The mechanical locking mechanism includes:

[0043] Unlock trigger pillars, at least two of which are set side-by-side as input terminals for the online side component shed;

[0044] The linkage unlocking mechanism is located at the front output end of the shelf and includes an unlocking trigger component, a front lower blocking component, and a front upper blocking component.

[0045] When the AGV trolley docks with the line-side component shed, the unlock trigger component is triggered by the unlock trigger column of the line-side component shed, which causes the lower front blocking rod in the lower front blocking component to retract downwards, and the upper front blocking rod in the upper front blocking component to flip backwards, completing the unpowered transfer of empty or full containers; when the AGV moves backwards with the trolley, the unlock trigger component is detrimentalized, and the lower front blocking component and the upper front blocking component are reset.

[0046] In the above technical solution, the rack includes frame uprights, rear frame beams, front frame beams, and front frame uprights, wherein: the frame uprights serve as supporting uprights, and four frame uprights are arranged vertically; the rear frame beams and front frame beams are arranged horizontally and fixed to the frame uprights front and back; the front frame uprights are arranged in pairs, and the front frame uprights are connected to the frame uprights by horizontal aluminum profiles and are vertically perpendicular to the ground; the front frame uprights are parallel to and close to the frame uprights located on the front side.

[0047] In the above technical solution, the anti-flow baffle mechanism includes:

[0048] The rear lower backflow baffle is located at the lower rear side of the shelf. The rear lower backflow baffle is a flip-up one-way baffle. The rear lower backflow baffle is fixed on the rear crossbeam of the frame. The rear lower backflow baffle is slightly higher than the high side of the bearing track of the shelf pallet.

[0049] The upper rear stop block is located on the upper rear side of the shelf. The upper rear stop block is a flip-up one-way stop block. The upper rear stop block is fixed on the frame column located on the rear side and can rotate along the column. The reset spring is clamped between the upper rear stop block and the frame column for automatic reset.

[0050] In the above technical solution, the linkage unlocking mechanism includes:

[0051] The unlocking trigger assembly includes a front blocking shaft, a blocking rotating sleeve, a front unlocking lever, and a front unlocking guide wheel. The front blocking shaft is arranged laterally and parallel to the front crossbeam of the frame. Both ends of the front blocking shaft are connected to the front uprights of the frame. The blocking rotating sleeve is fitted on the outside of the front blocking shaft. One end of the front unlocking lever is connected to the blocking rotating sleeve, and the other end is connected to the front unlocking guide wheel.

[0052] The front lower blocking assembly includes a front lower blocking rod and a front blocking rod sleeve. The front lower blocking rod is arranged vertically and its lower end is connected to the front unlocking stop bar. The front blocking rod sleeve is fixed on the front crossbeam of the frame. The upper end of the front blocking rod passes through the front blocking rod sleeve and is higher than the bearing track of the shelf pallet.

[0053] The front upper blocking assembly includes a linkage stop, a return spring, an upper linkage sleeve, a front upper linkage, and a front upper blocking rod. The linkage stop is connected to the rotating sleeve of the blocking device. The upper linkage sleeve is fixed on the front frame column. The front upper linkage passes through the upper linkage sleeve and can move up and down along it. The lower end of the return spring is connected to the front upper linkage, and the upper end is connected to the front frame column. The front upper blocking rod is connected to the front upper linkage.

[0054] In the above technical solution, when the current unlocking guide wheel contacts the unlocking trigger column of the side component shed, it forces the front unlocking lever to move downward, which in turn moves the front blocking lever downward. Through the front upper connecting rod, the front upper blocking lever is moved upward, realizing the unlocking function. The box can slide out on the track. When the AGV carries the shelf backward, the return spring lifts the lower front blocking lever upward through the front upper connecting rod. The front upper blocking lever falls under gravity, which also realizes the force in the direction of the return spring's contraction, making the mechanism safer and more stable.

[0055] Combining all the above technical solutions, the advantages and positive effects of this invention are as follows:

[0056] 1. Reduce reliance on manual labor and labor intensity: By using AGV carts to carry and transfer shelves, the manual traction and line-side handling operations are completely replaced, eliminating repetitive manual labor and reducing the labor intensity of staff.

[0057] 2. Improve supply stability: The AGV trolley has a fixed travel route and uniform transfer rhythm, which is not affected by the condition of the personnel. It can avoid the problem of insufficient supply of parts due to human distraction or fatigue, and ensure the continuity of parts supply to the production line.

[0058] 3. Eliminate safety hazards: AGV automatic walking replaces manual movement, completely solving the "human-vehicle cross-operation" scenario, reducing the probability of safety accidents such as collisions, and improving the safety of the working environment.

[0059] 4. Improve docking efficiency and accuracy: The customized mechanical locking mechanism ensures accurate docking between the AGV and the parts rack. The powerless empty-full exchange method is quick and the mechanical mechanism is stable and durable, reducing docking failures and improving overall supply efficiency. Attached Figure Description

[0060] Figure 1 This is a flowchart of an AGV-based SPS box supply automatic transfer and docking method;

[0061] Figure 2 It is a map showing the locations and routes of full container supply stations, full container removal stations, empty container recycling stations, and empty container removal stations.

[0062] Figure 3 This is a schematic diagram of the docking between the line-side component shed and the AGV trolley for full container loading at the full container loading station (point B).

[0063] Figure 4 This is a schematic diagram of the docking between the line-side component shed and the AGV trolley for empty container recycling at the empty container recycling station (point C);

[0064] Figure 5 This is a schematic diagram of the docking of the full container supply station (point A) and the AGV trolley for the full container loading and unloading.

[0065] Figure 6 This is a schematic diagram showing the docking of the empty container return docking point (point D) with the empty container removal station;

[0066] Figure 7 This is a diagram of an AGV (Automated Guided Vehicle) carrying a rack. Figure 1 ;

[0067] Figure 8 This is a diagram of an AGV (Automated Guided Vehicle) carrying a rack. Figure 2 ;

[0068] Figure 9 This is a diagram of an AGV (Automated Guided Vehicle) carrying a rack. Figure 3 ;

[0069] Figure 10 This is an initial state diagram of the tilted lifting pallet inside the component shed on the centerline side of the full-box supply station;

[0070] Figure 11 yes Figure 10 Side view;

[0071] Figure 12 This is a diagram showing the lifting status of the tilted pallets inside the component shed on the centerline side of the full-box supply station;

[0072] Figure 13 yes Figure 12 Side view.

[0073] In the diagram: 101-Rack upright; 102-Rack beam; 103-Rack connecting beam; 104-Lifting support column; 105-Lifting guide rail; 106-Lifting slider; 107-Slider fixing plate; 108-Rectangular lifting pallet frame; 109-Cylinder connecting plate; 110-Cylinder connector; 111-Lifting cylinder; 112-Cylinder fixing seat; 113-Bearing with seat; 114-Tilting pallet; 115-Guide wheel; 116-Bottom limit plate; 117-Top limit plate; 501-Frame Column; 502 - Rear crossbeam of the frame; 503 - Front crossbeam of the frame; 504 - Front column of the frame; 505 - Lower rear backflow stop; 506 - Upper rear anti-reverse stop; 507 - Reset spring; 508 - Front blocking shaft; 509 - Blocker rotating sleeve; 510 - Front unlocking lever; 511 - Front unlocking reverse wheel; 512 - Front blocking rod; 513 - Front blocking rod bushing; 514 - Linkage lever; 515 - Reset spring; 516 - Upper connecting rod sleeve; 517 - Upper front connecting rod; 518 - Upper front blocking rod. Detailed Implementation

[0074] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0075] The present invention will be further described in detail below with reference to specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0076] Example 1: Automated Transfer and Docking System for SPS Box Supply Based on AGV

[0077] The automated transfer and docking system includes:

[0078] At least one AGV cart equipped with a shelf;

[0079] Multiple material stations, including a full-box supply station, a full-box removal station, an empty-box recycling station, and an empty-box removal station; each of the material stations is equipped with a line-side component shed, a detection module for detecting the status of boxes in the line-side component shed, and a positioning module for detecting the docking status of the AGV trolley; a mechanical locking mechanism is provided at the docking position between the line-side component shed and the AGV trolley.

[0080] The control module is used to receive status signals sent by the detection module and the positioning module of each material station, and to send movement instructions to the AGV and lifting or lowering instructions to the line-side component shed.

[0081] The AGVs connect to the line-side component sheds at the full container supply station, full container removal station, empty container recycling station, and empty container removal station respectively, completing the circulation operation between full container supply, loading and unloading, empty container recycling and return, and shelf reset.

[0082] This system mainly includes an AGV trolley, a line-side component rack, a detection module (detection switch), a positioning module (position limit switch), a mechanical locking mechanism, and a control module. The functions of each component are as follows:

[0083] AGV (Automated Guided Vehicle): Equipped with shelf lifting function, it can automatically move according to the route set by the control module to complete the transfer of shelves (full box supply, empty box return), and can cooperate with the mechanical locking mechanism of the side component shed to achieve precise docking.

[0084] Line-side component sheds: Located on the production line side (including work points such as point A (full box supply station), point B (full box removal station), point C (empty box recycling station), and point D (empty box removal station), etc.), these sheds are used to store SPS boxes (full or empty). They are equipped with lifting mechanisms and can work with the AGV carts' racks to complete "empty-full exchange".

[0085] Detection switch: Installed on the component rack on the line side, it can detect the "full / empty (present / absent)" status of the SPS boxes in the component rack and the shelf position in real time, and transmit the detection signal to the control module as the trigger condition for automatically sending "call command" and "release command".

[0086] Mechanical locking mechanism: Custom-installed at the docking position between the AGV trolley and the part rack on the line side. It adopts a non-powered design and can realize the unlocking and locking functions after the AGV docks with the part rack, preventing the SPS box from falling off during the transfer process and ensuring docking accuracy and operational safety.

[0087] Control module: Receives detection signals from the detection switch, sends AGV calling instructions, vehicle release instructions, and component shed lifting / lowering instructions according to preset logic, coordinates the collaborative operation of various components, and realizes full-process automated control.

[0088] Furthermore, in this embodiment, it can also be considered that the line-side component sheds in the full-box supply station, full-box removal station, and empty-box recycling station are equipped with inclined fixed trays and inclined lifting trays. The line-side component sheds in the empty-box removal station are equipped with inclined fixed trays. The inclined lifting trays are lifted or lowered by a lifting mechanism. Both the inclined fixed trays and the inclined lifting trays are equipped with bearing rails. The higher side of the inclined fixed trays and the inclined lifting trays is the input end, and the lower side is the output end.

[0089] Furthermore, in this embodiment, the shelf can be considered as a square aluminum profile frame with a cross-shaped base. The upper part of the shelf is a tilted shelf pallet with a lower front and higher rear. Bearing rails are laid on the shelf pallet. The rear side of the shelf is the input end and the front side is the output end. The rear side of the shelf is equipped with an anti-tilt protection mechanism and a backflow baffle mechanism.

[0090] Furthermore, in this embodiment, when the lifting mechanism raises or lowers the tilting pallet to form the same continuous slope as the tilting fixed pallet, the full or empty box can be transferred freely between the tilting fixed pallet and the tilting lifting pallet without power. When the lifting mechanism raises or lowers the tilting pallet to form the same continuous slope as the shelf pallet, the full or empty box can be transferred freely between the online component shelf and the shelf without power.

[0091] Furthermore, in this embodiment, when the line-side component rack docks with the AGV trolley, the mechanical locking mechanism automatically opens or locks to fix or release the connection between the line-side component rack and the AGV trolley, and the line-side component rack and the shelf cooperate to complete the empty-full exchange.

[0092] Furthermore, in this embodiment, a material preparation station can be set up before the full container removal station. The material preparation station is equipped with a trolley detection module. The control module is configured to determine whether there is an AGV trolley at the material preparation station. If there is no AGV at the material preparation station, a trolley call command is sent repeatedly at predetermined intervals. If there is an AGV at the material preparation station, a trolley call command is sent to move the AGV trolley to the full container removal station.

[0093] Furthermore, in this embodiment, the control module is configured as follows:

[0094] Upon receiving a full-box status signal from the detection module of the full-box supply station, the control module sends a first call command to the AGV, causing the AGV to move to the full-box supply station; upon receiving an arrival signal from the arrival module of the full-box supply station, the control module controls the line-side component rack of the full-box supply station to dock with the shelf of the AGV, and sends a lifting command to the line-side component rack to transfer the full box from the line-side component rack to the AGV, thus completing the full-box supply operation;

[0095] Upon receiving the empty box status signal sent by the detection module of the full box supply station, the control module sends a descent command to the part rack on the line side and simultaneously sends a second call command to the AGV, causing the AGV to move to the material preparation station to wait.

[0096] Upon receiving an empty box status signal from the detection module of the full-box removal station, the control module sends a descent command to the line-side component shed; upon receiving a no-vehicle signal from the trolley detection module of the material preparation station, the control module sends a third trolley call command every 5 seconds; upon receiving a vehicle-available signal from the trolley detection module of the material preparation station, the control module sends a fourth trolley call command, and the AGV moves to the full-box removal station; upon receiving an arrival signal from the arrival module of the full-box removal station, the control module controls the line-side component shed of the full-box removal station to dock with the AGV's shelf, so as to transfer the full box from the AGV to the line-side component shed, completing the full-box removal operation;

[0097] Upon receiving the full container status signal from the detection module at the full container removal station, the control module sends a lifting command to the component shed on the line side and simultaneously sends a fifth release command to the AGV trolley. The AGV trolley then carries the empty shelf away from the full container removal station and heads to the empty container recycling station to recycle the empty containers.

[0098] The system receives the arrival signal sent by the arrival module of the empty container recycling station, controls the line-side component shed of the empty container recycling station to dock with the AGV trolley, and sends a lifting command to the empty container recycling station to transfer the empty container from the line-side component shed to the AGV trolley, thus completing the empty container recycling operation.

[0099] Upon receiving the empty box signal sent by the detection module of the empty box recycling station, the control module sends a sixth release command to the AGV trolley, and the AGV trolley carries the empty box away from the empty box recycling station to the empty box removal station to remove the empty box.

[0100] The system receives the arrival signal sent by the arrival module of the empty container removal station, controls the line-side component shed of the empty container removal station to dock with the AGV trolley, so as to transfer the empty container from the AGV trolley to the line-side component shed and complete the empty container removal operation.

[0101] Upon receiving the empty container signal from the detection module at the empty container removal station, a reset command is sent to the AGV, causing the AGV to move to the charging area and enter standby mode.

[0102] Example 2: Automated Transfer and Docking Method for SPS Box Supply Based on AGV

[0103] The automated transfer and docking method strictly follows the document's logic of "full container supply - empty container return - shelf reset," clearly defining the signal interaction, action sequence, and manual coordination requirements for each stage, such as... Figure 1 This is a flowchart of the operational logic of this method. The purpose is to independently develop automatic material supply and signal transmission control based on the standard AGV operation in existing industrial production, eliminating the need for manual operation of buttons or sending instructions to the AGV via mobile phone. Figure 2 This is a route map showing the locations of application points for material sorting, material transfer, material supply and recycling in various areas during the actual field application of this method. Figure 3 A schematic diagram showing the material supply direction and automatic docking of the AGV trolley carrying the rack when personnel at the vehicle entrance are carrying materials on the production line platform. Figure 4 A diagram illustrating the return of empty containers after the completion of work by personnel on the vehicle export production line. Figure 5 and Figure 6 This is a diagram illustrating how workers in the SPS area take empty boxes and put them into full boxes.

[0104] The specific steps of the automatic transfer and docking method are as follows:

[0105] Step 1: Full box supply at point A triggered

[0106] 1.1. Status Detection and Signal Triggering

[0107] The detection switch on the A-point side component shed monitors the status of the SPS box inside the A-point side component shed in real time: if an "empty box" is detected (i.e., there is no full box at A-point, and the operator needs to replenish the box to a full size), a "waiting for work signal" is sent to the control module, and the indicator light shows "A-point box to be replenished", prompting the operator to replenish the box to the A-point component shed; if a "full box" is detected (replenishment completed), a "call signal" is sent to the control module for 3 consecutive seconds (to avoid accidental triggering).

[0108] 1.2. AGV dispatching and operation

[0109] After receiving the "call signal", the control module automatically sends a "call instruction (target: point A)" to the AGV. The AGV starts from the standby state (such as the charging area), travels along the preset laser navigation route to point A and waits to dock with the parts shed (30m away from point A, speed 0.8m / s). When it reaches the docking position at point A, it triggers the "position limit switch" and sends a "position signal" back to the control module.

[0110] Step 2: Move the full container into the dock at point A.

[0111] 2.1. Lifting and Unlocking of Parts Shed

[0112] After the AGV arrives at point A, it triggers the positioning switch, sending a "positioning signal" to the control module. Simultaneously, the shelf carried by the AGV precisely aligns with the parts rack, and the mechanical locking mechanism automatically opens. Upon receiving the "positioning signal," the control module sends a "parts rack lifting command." The parts rack lifting mechanism at point A starts, lifting to be level with the AGV shelf, triggering the lifting limit switch, and the lifting action stops. At the same time, the mechanical locking mechanism between the AGV and the parts rack automatically unlocks due to the docking pressure (non-powered method), allowing the full box of parts to be moved in. The "full box loading" is completed by freely sliding in without power (i.e., transferring the full box from the parts rack to the AGV shelf).

[0113] 2.2. Loading and Resetting of Full Containers

[0114] The full boxes of SPS in the parts shed at point A slide into the AGV shelf without power along the inclined slide rail (8 boxes, total time 8 seconds), and the full box loading is completed; the detection switch detects that the parts shed at point A is "empty box" and sends a "loading completed signal" to the control module; the control module sends a "parts shed lowering command", and the parts shed is lowered to the low position; at the same time, a "release command" is sent to the AGV trolley, the mechanical locking mechanism automatically resets and locks, and the AGV trolley carrying the full box leaves point A along the route to the material preparation point at point B (43m away from point A) to wait.

[0115] Step 3: Waiting at the material preparation point and supplying at point B

[0116] 3.1. Material Preparation Point Waiting and Point B Status Detection: The AGV carrying a full box travels along the set route to the material preparation point to wait for loading. After the AGV arrives at the Point B material preparation point, it triggers the "Material Preparation Point In Position Switch," sending a "Material Preparation Point Available Signal" to the control module. The Point B detection switch scans in real time. When the Point B detection switch detects that the part rack on the line side is empty, it issues a part rack lowering command. The control module determines whether there is a vehicle at the material preparation point (i.e., whether the AGV has reached the correct position). If the material preparation point is empty, it sends a call command repeatedly every 5 seconds. If there is a vehicle at the material preparation point, the control module sends a call command. Simultaneously, if the production line operator has finished picking up the SPS box and detects an "empty box," it sends a "Point B Empty Box Signal" to the control module.

[0117] 3.2. AGV docking and full container unloading

[0118] The control module determines that "there is a vehicle at the material preparation point and an empty box at point B" and sends a "call command (target: point B)". The AGV travels 6m to point B, and the AGV trolley moves to point B and sends a "positioning signal". The control module sends a "parts shelf descent command". The parts shelf at point B descends to its lowest position. After the AGV trolley docks with the parts shelf on the line side, the mechanical locking mechanism in front of the AGV unlocks, and the full boxes on the AGV shelf are moved into the parts shelf at point B (8 boxes, taking 8 seconds). The full boxes are then moved out, and the workers at point B carry out the unloading operation (the full boxes in the parts shelf are used for the production line).

[0119] 3.3. Component Shed Reset and AGV Transfer

[0120] The detection switch at point B detects a "full container" and sends a "removal complete signal" to the control module. The control module then sends a "parts shelf lifting command," lifting the shelf to its highest position. Simultaneously, it sends a "release command" to the AGV, triggering the mechanical locking mechanism. The AGV carries the empty shelf along the route from point B to point C (138m from point B) to retrieve the empty container.

[0121] Step 4: Return point C to empty and reset point D.

[0122] 4.1. C-point empty container recycling

[0123] After the AGV arrives at point C, it sends a "positioning signal". Then it docks with the component rack on the side of point C, the mechanical locking mechanism unlocks, and the empty boxes automatically slide into the AGV rack (8 boxes, taking 8 seconds). The empty boxes are then collected. The detection switch at point C detects "empty box + rack in position" and sends a "return empty signal" to the control module. The control module sends a "component rack descent command", and the AGV descends to the low position. The control module then sends a "release command", and the AGV moves to point D (87m from point C).

[0124] 4.2. Empty container removal and order fulfillment at point D

[0125] After the AGV arrives at point D with an empty box, it sends a "positioning signal". The AGV docks with the parts rack at point D, and the empty box on the AGV shelf slides into the parts rack at point D without power, completing the "empty box removal". The staff at point D will pick up the empty box for order fulfillment and put the fulfilled full box into the parts rack at point A. When the detection switch at the parts rack at point D detects an "empty box", it sends a "cart reset and charging command" to the control module. At the same time, the auxiliary staff at point D loads the SPS area parts after removing the empty box and then replenishes them on the parts rack at point A, triggering the next cycle.

[0126] Step 5: AGV Reset and Battery Swap

[0127] 5.1. AGV returns to the standby area

[0128] The control module sends a "reset command" to the AGV. The AGV starts from point D, travels along the route to the charger area, and arrives at and connects to the charging interface.

[0129] 5.2. Battery Detection and Battery Swapping

[0130] AGV has a built-in power detection module:

[0131] If the battery level is ≥60%, it will directly enter standby mode and wait for the next "ride-hailing instruction" at point A;

[0132] If the battery level is less than 60%, the "battery swap command" will be automatically triggered. The AGV will then move to the charging area, where a fully charged AGV will take over the work. After the battery swap is completed, the AGV will enter standby mode. AGVs with insufficient battery level will automatically charge in the charging area.

[0133] This completes one full cycle and awaits the next "call order" at point A, ensuring a production cycle of 75 seconds per unit.

[0134] Example 3: AGV trolley and automatic transfer docking mechanism

[0135] The automated transfer and docking mechanism includes the mechanical locking mechanism in the AGV-based SPS box supply automated transfer and docking system of Embodiment 1 above. The mechanical locking mechanism is set at the docking position between the online side component shed and the AGV trolley. The mechanical locking mechanism includes:

[0136] Unlock trigger pillars, at least two of which are set side-by-side as input terminals for the online side component shed;

[0137] The linkage unlocking mechanism is located at the front output end of the shelf and includes an unlocking trigger component, a front lower blocking component, and a front upper blocking component.

[0138] When the AGV trolley docks with the line-side component shed, the unlock trigger component is triggered by the unlock trigger column of the line-side component shed, which causes the lower front blocking rod in the lower front blocking component to retract downwards, and the upper front blocking rod in the upper front blocking component to flip backwards, completing the unpowered transfer of empty or full containers; when the AGV moves backwards with the trolley, the unlock trigger component is detrimentalized, and the lower front blocking component and the upper front blocking component are reset.

[0139] like Figure 7-9 As shown, the shelf carrying the transfer parts boxes on top of the AGV trolley has no power supply or other detection switches. In existing manufacturing processes, most shelves need to have detection switches or a power supply, but this shelf has no power supply. The unlocking mechanism is a linkage unlocking mechanism, which has both docking trigger unlocking function and safety locking function to prevent the boxes from falling during transfer. Figure 7As shown in the image, the left side of the picture shows the back of the shelf, and the right side shows the front of the shelf. The shelf is a square aluminum profile frame with a cross-sectional base to enhance its stability and load-bearing capacity. Bearing rails are laid on top, with the back higher than the front, allowing the boxes to slide freely on the inclined rails. There are two protective devices at the back of the shelf. The lower one, near the rail, is a backflow stop mechanism to prevent the boxes from falling due to inertia during transport. However, this only stops the lower boxes and can easily cause stacked boxes to tip over. Therefore, a horizontal anti-tilt protection mechanism is made above the back for double protection.

[0140] Furthermore, in this embodiment, the shelf may include frame columns 501, rear frame beams 502, front frame beams 503, and front frame columns 504, wherein: the frame columns 501 serve as supporting columns, and the four frame columns 501 are arranged vertically; the rear frame beams 502 and the front frame beams 503 are arranged horizontally and fixed to the frame columns 501 front and rear; the front frame columns 504 are arranged in pairs, and the front frame columns 504 are connected to the frame columns 501 by horizontal aluminum profiles and are vertically perpendicular to the ground; the front frame columns 504 are parallel to and close to the frame columns 501 located on the front side.

[0141] Furthermore, in this embodiment, the anti-flow baffle mechanism may include:

[0142] The rear lower backflow baffle 505 is located at the lower rear side of the shelf. The rear lower backflow baffle 505 is a flip-up one-way baffle. The rear lower backflow baffle 505 is fixed on the rear crossbeam 502 of the frame. The rear lower backflow baffle 505 is slightly higher than the high side of the bearing track of the shelf pallet.

[0143] The upper rear anti-reverse stop 506 is located on the upper rear side of the shelf. The upper rear anti-reverse stop 506 is a flip-up one-way stop. The upper rear anti-reverse stop 506 is fixed on the frame column 501 located on the rear side and can rotate along the column. The reset spring 507 is clamped between the upper rear anti-reverse stop 506 and the frame column 501 for automatic reset.

[0144] Furthermore, in this embodiment, the linkage unlocking mechanism may include:

[0145] The unlocking trigger assembly includes a front blocking shaft 508, a blocking rotating sleeve 509, a front unlocking lever 510, and a front unlocking guide wheel 511. The front blocking shaft 508 is arranged laterally and is parallel to the front crossbeam 503 of the frame. Both ends of the front blocking shaft 508 are connected to the front uprights 504 of the frame. The blocking rotating sleeve 509 is fitted on the outside of the front blocking shaft 508. One end of the front unlocking lever 510 is connected to the blocking rotating sleeve 509, and the other end is connected to the front unlocking guide wheel 511.

[0146] The front lower blocking assembly includes a front lower blocking rod 512 and a front blocking rod sleeve 513. The front lower blocking rod 512 is arranged vertically and its lower end is connected to the front unlocking stop 510. The front blocking rod sleeve 513 is fixed on the front crossbeam 503 of the frame. The upper end of the front blocking rod 512 passes through the front blocking rod sleeve 513 and is higher than the bearing track of the shelf pallet.

[0147] The front upper blocking assembly includes a linkage stop 514, a return spring 515, an upper connecting rod sleeve 516, a front upper connecting rod 517, and a front upper blocking rod 518. The linkage stop 514 is connected to the blocking rotating sleeve 509. The upper connecting rod sleeve 516 is fixed on the front frame column 501. The front upper connecting rod 517 passes through the upper connecting rod sleeve 516 and can move up and down along it. The lower end of the return spring 515 is connected to the front upper connecting rod 517, and the upper end is connected to the front frame column 501. The front upper blocking rod 518 is connected to the front upper connecting rod 517.

[0148] When the unlocking guide wheel 511 engages with the unlocking trigger column of the side component shed, it forces the front unlocking lever 510 to move downward, which in turn moves the front blocking lever 512 downward. Through the front upper connecting rod 517, the front upper blocking lever 518 moves upward, thus unlocking the device. The box can then slide out on the track. When the AGV carries the shelf backward, the return spring 515 lifts the lower front blocking lever 512 upward through the front upper connecting rod 517, and the front upper blocking lever 518 falls due to gravity, which also realizes the force in the contraction direction of the return spring 515, making the mechanism safer and more stable.

[0149] The working principle of this embodiment: The frame column 501 serves as a supporting column. The rear crossbeam 502 and the front crossbeam of the frame are respectively fixed on the frame column 501. The front column 504 is connected to the frame column 501 via a horizontal aluminum profile and is horizontal and perpendicular to the ground. The lower rear backflow baffle 505 is fixed on the rear crossbeam 502. The upper rear backflow stop 506 is fixed on the frame column 501 and can rotate along the column. The reset spring 507 is clamped in the upper rear backflow stop 505. 6 is located between the frame column 501 and is used for automatic reset. The front blocking shaft 508 is connected to the front column 504 of the frame. The blocking rotating sleeve 509 is fitted over the front blocking shaft 508. One end of the front unlocking lever 510 is connected to the blocking rotating sleeve 509, and the other end is connected to the front unlocking guide wheel 511. The lower end of the front blocking rod 512 is connected to the front unlocking lever 510. The front blocking rod bushing 513 is fixed to the front crossbeam 503 of the frame. The upper end of the front blocking rod 512 extends from the front blocking rod shaft. The upper connecting rod sleeve 516 passes through the upper connecting rod sleeve 516 and is higher than the track. The connecting rod 514 is connected to the stopper rotating sleeve 509. The upper connecting rod sleeve 516 is fixed to the front frame column. The front upper connecting rod 517 passes through the upper connecting rod sleeve 516 and can move up and down. The lower end of the return spring 515 is connected to the front upper connecting rod 517, and the upper end is connected to the front column. The front upper stop rod 518 is connected to the front upper connecting rod 517. When the front unlocking guide wheel 511 is released from the fixed column of the line side component shed, the front unlocking stop is forced. When 510 moves downward, it causes the front stop bar 512 to move downward as well. Through the upper front connecting rod 517, the upper front stop bar 518 moves upward, thus unlocking the mechanism. The box can then slide out on the track. When the AGV carries the shelf backward, the return spring 515 lifts the lower front stop bar 512 upward through the upper front connecting rod 517. The upper front stop bar 518 falls due to gravity, which also creates a force in the contraction direction of the return spring 515, making the mechanism safer and more stable.

[0150] Example 4: Line-side component shed

[0151] Taking the tilted lifting pallet inside the component shed on the centerline side of a full-box supply station as an example, such as Figure 10-13As shown, the side component shed is equipped with shelf uprights 101, shelf beams 102, shelf connecting beams 103, lifting support columns 104, lifting guide rails 105, lifting sliders 106, slider fixing plates 107, rectangular lifting pallet frames 108, cylinder connecting plates 109, cylinder connectors 110, lifting cylinders 111, cylinder fixing seats 112, bearings with seats 113, flipping pallets 114, guide wheels 115, bottom limiting plates 116 and top limiting plates 117. The shelf uprights 101 are connected to the shelf beams 102, and together with the shelf connecting beams 103, they form the A-zone input shelf assembly. Lifting support columns 104 are located on both sides and connected to the shelf beams 102. Lifting guide rails 105 are fixed to the lifting support columns 104. Lifting sliders 106 can slide up and down along the lifting guide rails 105 and are fixed to slider fixing plates 107. Slider fixing plates 107 are connected to rectangular lifting pallet frames 108. Cylinder connecting plates 109 are located on both sides of the rectangular lifting pallet frame 108. 09 is connected to the cylinder connector 110, which is fixed to the lifting rod of the lifting cylinder 111. The bottom end of the lifting cylinder 111 is fixed to the cylinder mounting base 112. The cylinder mounting base 112 is connected to the bottom of the shelf beam 102. The rectangular lifting pallet frame 108 is provided with a seated bearing 113 slightly to the left of the center. The seated bearing 113 is connected to the flipping pallet (tilting lifting pallet) 114. The left end of the flipping pallet 114 is provided with a guide wheel 115. In addition, the bottom limit plate 116 and the top limit plate 117 are respectively fixed to the left side of the shelf column 101.

[0152] In this embodiment, the initial position of the tilting lifting pallet is the bottom, the cylinder is in the retracted state, and the tilting lifting pallet is in a horizontal mode. When personnel are engaged in operation, after the shelf is full of goods, the AGV trolley carrying the shelf docks with the front end, and then the cylinder extends, and the inner pallet rises. Since the shaft is on the left side of the pallet, the pallet remains horizontal during the lifting process. Once it rises to the top, the left side of the pallet reaches its limit, causing the pallet to tilt and form a slope, allowing the full box to slide into the AGV trolley carrying the shelf. After the pallet is empty, it descends and resets to the initial state, and this cycle repeats.

[0153] The reason why the tilting lifting pallet is horizontal while the AGV trolley carrying rack is tilted is as follows: Since point A is the personnel placement position and the boxes are stacked in layers of 4, in order to prevent the bottom boxes from sliding away with the slope after placement, thus making it impossible to continue the operation, the rack in the placement area of ​​point A is specially made into a horizontal pallet. After personnel are placed, they can slide in sequence. When docking, in order to save energy and reduce emissions, the direction is changed when it is raised to the top, forming a slope that allows the full box to slide out without power for empty-full exchange.

[0154] The above description is merely a preferred embodiment of the present invention. It should be understood that the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. The present invention is not limited to the forms disclosed herein and should not be construed as excluding other embodiments, but can be used in various other combinations, modifications, and environments. Modifications and variations made by those skilled in the art that do not depart from the spirit and scope of the present invention should be within the protection scope of the appended claims.

Claims

1. An AGV-based automated transfer and docking system for SPS box supply, characterized in that: include: At least one AGV cart equipped with a shelf; Multiple material stations, including a full-box supply station, a full-box removal station, an empty-box recycling station, and an empty-box removal station; each of the material stations is equipped with a line-side component shed, a detection module for detecting the status of boxes in the line-side component shed, and a positioning module for detecting the docking status of the AGV trolley; a mechanical locking mechanism is provided at the docking position between the line-side component shed and the AGV trolley. The control module is used to receive status signals sent by the detection module and the positioning module of each material station, and to send movement instructions to the AGV and lifting or lowering instructions to the line-side component shed. The AGVs connect to the line-side component sheds at the full container supply station, full container removal station, empty container recycling station, and empty container removal station respectively, completing the circulation operation between full container supply, loading and unloading, empty container recycling and return, and shelf reset.

2. The AGV-based SPS box supply automatic transfer and docking system according to claim 1, characterized in that: The line-side component sheds in the full-box supply station, full-box removal station, and empty-box recycling station are equipped with inclined fixed pallets and inclined lifting pallets. The line-side component sheds in the empty-box removal station are equipped with inclined fixed pallets. The inclined lifting pallets are lifted or lowered by a lifting mechanism. Both the inclined fixed pallets and the inclined lifting pallets are equipped with bearing rails. The higher side of the inclined fixed pallets and the inclined lifting pallets is the input end, and the lower side is the output end.

3. The AGV-based SPS box supply automatic transfer and docking system according to claim 2, characterized in that: The shelf is a square aluminum profile frame with a cross-shaped base. The upper part of the shelf is a sloping pallet with a lower front and higher back. Bearing rails are laid on the pallet. The rear side of the shelf is the input end and the front side is the output end. The rear side of the shelf is equipped with an anti-tilt protection mechanism and a backflow baffle mechanism.

4. The AGV-based SPS box supply automatic transfer and docking system according to claim 3, characterized in that: When the lifting mechanism raises or lowers the tilting pallet to form the same continuous slope as the tilting fixed pallet, full or empty boxes can slide freely into or out between the tilting fixed pallet and the tilting lifting pallet without power. When the lifting mechanism raises or lowers the tilting pallet to form the same continuous slope as the shelf pallet, full or empty boxes can slide freely into or out between the online component shelf and the shelf without power.

5. The AGV-based SPS box supply automatic transfer and docking system according to claim 1, characterized in that: When the line-side component rack docks with the AGV trolley, the mechanical locking mechanism automatically opens or locks to fix or release the connection between the line-side component rack and the AGV trolley, and the line-side component rack and the rack work together to complete the empty-full exchange.

6. The AGV-based SPS box supply automatic transfer and docking system according to claim 1, characterized in that: A material preparation station is set up before the full container removal station. The material preparation station is equipped with a trolley detection module. The control module is configured to determine whether there is an AGV trolley at the material preparation station. If there is no AGV at the material preparation station, a trolley call command is sent repeatedly at predetermined intervals. If there is an AGV at the material preparation station, a trolley call command is sent to move the AGV trolley to the full container removal station.

7. The AGV-based SPS box supply automatic transfer and docking system according to claim 6, characterized in that: The control module is configured as follows: Upon receiving a full-box status signal from the detection module of the full-box supply station, the control module sends a first call command to the AGV, causing the AGV to move to the full-box supply station; upon receiving an arrival signal from the arrival module of the full-box supply station, the control module controls the line-side component rack of the full-box supply station to dock with the shelf of the AGV, and sends a lifting command to the line-side component rack to transfer the full box from the line-side component rack to the AGV, thus completing the full-box supply operation; Upon receiving the empty box status signal sent by the detection module of the full box supply station, the control module sends a descent command to the part rack on the line side and simultaneously sends a second call command to the AGV, causing the AGV to move to the material preparation station to wait. Upon receiving an empty box status signal from the detection module of the full-box removal station, the control module sends a descent command to the line-side component shed; upon receiving a no-vehicle signal from the trolley detection module of the material preparation station, the control module sends a third trolley call command every 5 seconds; upon receiving a vehicle-available signal from the trolley detection module of the material preparation station, the control module sends a fourth trolley call command, and the AGV moves to the full-box removal station; upon receiving an arrival signal from the arrival module of the full-box removal station, the control module controls the line-side component shed of the full-box removal station to dock with the AGV's shelf, so as to transfer the full box from the AGV to the line-side component shed, completing the full-box removal operation; Upon receiving the full container status signal from the detection module at the full container removal station, the control module sends a lifting command to the component shed on the line side and simultaneously sends a fifth release command to the AGV trolley. The AGV trolley then carries the empty shelf away from the full container removal station and heads to the empty container recycling station to recycle the empty containers. The system receives the arrival signal sent by the arrival module of the empty container recycling station, controls the line-side component shed of the empty container recycling station to dock with the AGV trolley, and sends a lifting command to the empty container recycling station to transfer the empty container from the line-side component shed to the AGV trolley, thus completing the empty container recycling operation. Upon receiving the empty box signal sent by the detection module of the empty box recycling station, the control module sends a sixth release command to the AGV trolley, and the AGV trolley carries the empty box away from the empty box recycling station to the empty box removal station to remove the empty box. The system receives the arrival signal sent by the arrival module of the empty container removal station, controls the line-side component shed of the empty container removal station to dock with the AGV trolley, so as to transfer the empty container from the AGV trolley to the line-side component shed and complete the empty container removal operation. The system receives an empty box signal from the detection module at the empty box removal station, sends a reset command to the AGV, and moves the AGV to the charging area, where it enters standby mode.

8. An automatic transfer and docking method for SPS box supply in an AGV-based automatic transfer and docking system as described in any one of claims 1-7, characterized in that: Includes the following steps: S1, Point A full container supply operation The detection module monitors the status of boxes in the component shed on the line side of the full box supply station in real time. If the box is determined to be empty, a waiting operation signal is sent to the control module. If the box is determined to be full, a full box status signal is sent to the control module. After receiving the full box status signal, the control module sends the first call command to the AGV. The AGV starts from the standby state, travels along the set route to the full box supply station, and waits to dock with the component shed on the line side. S2, Point A Full Container Loading Operation After the AGV arrives at the full-box supply station, it triggers the positioning module, which sends a positioning signal to the control module. The control module then sends a lifting command to the line-side component shed at the full-box supply station. The line-side component shed at the full-box supply station is lifted, and the shelf carried by the AGV precisely aligns with the line-side component shed. The mechanical locking mechanism automatically opens, and the full-box components are moved in. The full-box components in the line-side component shed slide freely into and are transferred to the AGV's shelf without power. After the full-box is moved in, the detection module at the full-box supply station detects that the line-side component shed is empty and sends an empty-box signal to the control module. The control module sends a lowering command to the line-side component shed and simultaneously sends a first release command to the AGV. The mechanical locking mechanism locks, and the AGV carries the full-box components away from the full-box supply station to the preparation station to wait. S3, Material preparation station loading and full box unloading operation at point B. The AGV (Automated Guided Vehicle) carries a full box of parts along a pre-set route to the material preparation station to wait for loading. When the detection module at the full box removal station detects that the part rack on the line side is empty, the control module sends a command to lower the part rack. At the same time, the control module determines whether there is a vehicle at the material preparation station: if the material preparation station is empty, it sends a second call command every 5 seconds; if there is a vehicle at the material preparation station, the control module sends a third call command. The AGV then moves to the full box removal station and docks with its part rack on the line side. The mechanical locking mechanism at the front of the AGV unlocks, completing the removal of the full box of parts. The staff at the full box removal station then remove the full box of parts from the part rack on the line side for use on the production line. When the detection module at the full box removal station checks that the part rack on the line side is full, it sends a command to lift the part rack on the line side and simultaneously sends a second release command to the AGV. The AGV then carries the empty rack away from the full box removal station to the empty box recycling station. S4, C, and D points return and reset operation After the AGV arrives at the empty container recycling station, it triggers the positioning module, which sends a positioning signal to the control module. The control module then sends a lifting command to the line-side component shed of the empty container recycling station. The line-side component shed of the empty container recycling station is lifted, and the AGV docks with the line-side component shed of the empty container recycling station to collect the used empty container components. The detection module on the line-side component shed of the empty container recycling station detects that the container is empty and sends an empty container signal. The control module then sends a third release command, and the AGV carries the empty container components away from the empty container recycling station to the empty container removal station. The AGV (Automated Guided Vehicle) carries empty boxes to the empty box removal station and docks with the side-line component shed. The empty boxes are removed without power, and the empty boxes on the AGV shelf are transferred to the side-line component shed of the empty box removal station. The staff at the empty box removal station will pick up the empty boxes and perform the order fulfillment operation. The fulfilled full boxes will then be placed into the side-line component shed of the full box supply station. When the detection module of the side-line component shed of the empty box removal station detects an empty box, it sends a reset and charging command to the AGV. S5, AGV reset and battery swapping operation After the AGV completes the docking at the empty container removal station, it returns to the charging area according to the set route. If the power is insufficient, it will automatically perform a battery swap. After the battery swap is completed, the AGV enters standby mode, waiting for the next call instruction from the full container supply station, thus completing a complete circulation cycle.

9. An AGV-based automatic transfer and docking mechanism for SPS box supply, characterized in that: It includes a mechanical locking mechanism in the AGV-based SPS box supply automatic transfer and docking system as described in any one of claims 1-7, wherein the mechanical locking mechanism is disposed at the docking position between the online side component shed and the AGV trolley, and the mechanical locking mechanism includes: Unlock trigger pillars, at least two of which are set side-by-side as input terminals for the online side component shed; The linkage unlocking mechanism is located at the front output end of the shelf and includes an unlocking trigger component, a front lower blocking component, and a front upper blocking component. When the AGV trolley docks with the line-side component shed, the unlock trigger component is triggered by the unlock trigger column of the line-side component shed, which causes the lower front blocking rod in the lower front blocking component to retract downwards, and the upper front blocking rod in the upper front blocking component to flip backwards, completing the unpowered transfer of empty or full containers; when the AGV moves backwards with the trolley, the unlock trigger component is detrimentalized, and the lower front blocking component and the upper front blocking component are reset.

Images